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 combustion seals for internal combustion engines. In particular but not exclusively the invention relates to combustion seals for Wankel rotary engines.
BACKGROUND
[0002] Rotary engines can provide a number of advantages over reciprocating piston engines including reduced complexity and increased power for a given engine weight.
[0003] An example of a known rotary engine 100 of Wankel type is shown in FIG. 1 . The engine 100 has a housing 110 and an eccentric shaft 120 that provides a drive output. The eccentric shaft 120 has a shaft portion 120 ′ having a longitudinal axis and an eccentric portion projecting in a substantially radial direction from a longitudinal axis of the shaft portion 120 ′. The shaft portion 120 ′ is arranged to be generally coaxial with a stationary gear 122 that is provided in a fixed orientation with respect to the housing 110 . The stationary gear 122 is arranged to engage a rotor phasing gear 132 of a rotor 130 , the rotor 130 being rotatably coupled to the eccentric portion of the eccentric shaft 120 .
[0004] In use the rotor 130 describes a rotation-translation motion within a cavity 112 formed in the housing 110 , the cavity 112 having a trochoidal shape.
[0005] In the example of FIG. 1 the rotor phasing gear 132 is an internal gear whilst the stationary gear 122 is an external gear, the eccentric shaft 120 being arranged to rotate three times for each rotation of the rotor 130 .
[0006] FIG. 2 shows a cross-section of a portion of the rotor 130 showing corner seal elements 150 provided in cut-out portions 131 of the rotor 130 . The cut-out portions 131 are provided in each of three corners of each side face 130 A of the rotor. Coil spring elements are provided between the corner seal elements and an internal face of the cut-out portion 131 , the spring elements being arranged to urge the corner seal elements against a respective end plate (or ‘sidewall’ or ‘end face’) 112 of the housing 110 . The corner seal elements 150 are arranged to be slidable within the cut-out portions 131 .
[0007] A tip seal 160 is provided along a side of the rotor at each of three corners 130 B of the rotor 130 . Each tip seal 160 is provided in a recess 161 formed in the rotor 130 . A leaf spring element 162 is arranged to urge the tip seal 160 against the sidewall 112 of the housing 110 .
STATEMENT OF THE INVENTION
[0008] In a first aspect of the invention there is provided a corner seal assembly for a rotor of a rotary engine, the assembly comprising a pair of corner seal elements, each seal element of the pair being arranged to provide a seal between the rotor and a respective one of a pair of opposed end faces of the rotary engine, the seals being arranged to be resiliently coupled to one another whereby the seals exert substantially the same force on each one of the pair of opposed end faces.
[0009] Embodiments of the invention have the advantage that loads exerted on a side of the rotor by the action of the corner seal elements against respective end faces may be arranged to be substantially equal on opposed sides of the rotor. This has the effect that a rate of wear of an engine may be reduced. Furthermore, a smoothness of operation of the engine may be increased due to equalisation of the loads on respective end faces.
[0010] Some embodiments of the invention have the advantage that a rotor arranged to receive a corner seal module according to some embodiments of the invention may be formed in a more convenient manner. In some embodiments the rotor may be formed using a more cost effective forming process. In some embodiments the rotor may be formed with improved precision.
[0011] Preferably the assembly has a body portion arranged to be provided between the pair of seal elements.
[0012] Preferably the body portion is movable along a direction having a component normal to a plane parallel to the end faces of the engine.
[0013] In general, the end faces of the engine are substantially parallel to a plane of opposed sides of the rotor. Typically, the rotor is arranged to rotate in a plane parallel to the end faces of the engine.
[0014] The body portion may be slidably movable along said direction.
[0015] The seal elements may be resiliently coupled to one another by means of the body portion.
[0016] Preferably the seal elements are each resiliently coupled to a respective opposed end of the body portion.
[0017] Alternatively the seal elements may be directly coupled to one another by means of a seal coupling.
[0018] The seal coupling may be arranged to pass through the body portion.
[0019] Alternatively or in addition the seal coupling member may be arranged to pass through a portion of the rotor.
[0020] The seal coupling may comprise a resilient member, preferably a spring member.
[0021] The seal coupling may comprise one or more resilient members.
[0022] The seal coupling may further comprise one or more substantially incompressible and substantially inextensible members.
[0023] Preferably the assembly is arranged to be coupled to a corner of the rotor.
[0024] Preferably the assembly is arranged to be provided in a slot provided in the rotor.
[0025] The slot may have a pair of opposed ends provided with openings formed in respective opposed sides of the rotor.
[0026] The assembly may further comprise a tip seal assembly arranged to provide a seal between a tip of the rotor and a sidewall of the engine.
[0027] In a second aspect of the invention there is provided a unitary module comprising an assembly according to the first aspect of the invention, the module being arranged to be removably attachable to the rotor.
[0028] Preferably the module is arranged to be provided in the slot provided in the rotor.
[0029] The module may comprise an outer tube member arranged to be inserted into the slot provided in the rotor.
[0030] The outer tube member may be provided with an opening along at least a portion of a length thereof.
[0031] The opening may be arranged to receive a portion of the tip seal therethrough.
[0032] The tube member may be arranged to house at least a portion of the assembly therein.
[0033] This has the advantage of simplifying assembly of the rotor.
[0034] The tube member may have an opening provided along at least a portion of a length thereof. The opening may be arranged to receive a portion of the tip seal therethrough.
[0035] In a third aspect of the invention there is provided a rotary engine having a corner seal assembly according to the first aspect of the invention.
[0036] In a fourth aspect of the invention there is provided a rotary engine having a module according to the second aspect of the invention.
[0037] In a fifth aspect of the invention there is provided a method of forming a corner seal assembly for a rotor of a rotary engine, comprising: providing a pair of corner seal elements, each corner seal element of the pair being arranged to provide a seal between the rotor and a respective one of a pair of opposed end faces of the rotary engine; resiliently coupling the corner seal elements to one another whereby the seal elements may be arranged to exert substantially the same force on each one of the pair of opposed end faces of the rotary engine.
[0038] The method may further comprise the step of providing the rotor; and installing the corner seal assembly in the rotor.
[0039] The step of installing the corner seal assembly may comprise the step of forming corner seal cavities at each of three opposed corners of the rotor, the corner seal cavities each being arranged to receive a corner seal element.
[0040] The step of forming corner seal cavities may comprise the step of forming cavities arranged to pass from one side of the rotor to the other, the cavities being open at respective opposed sides of the rotor.
[0041] Thus a requirement to drill separate holes in opposed sides of the rotor may be eliminated. Alignment of openings in opposed sides of the rotor may therefore be effected substantially automatically.
[0042] Preferably the step of forming the cavities comprises the step of forming the cavities by means of a cutting operation.
[0043] The cutting operation may comprise the steps of cutting the cavity by means of one selected from amongst a laser cutting operation, a wire cutting operation and a water jet cutting operation.
[0044] The method may further comprise the step of providing the corner seal assembly in the form of a unitary module, the pair of corner seals of the corner seal assembly being resiliently coupled to one another.
[0045] The step of installing the corner seal assembly in the rotor may comprise the step of inserting the module into one of the corner seal cavities.
[0046] The step of providing the pair of corner seals in the form of a unitary module may comprise the step of applying a removable binding medium to the module to prevent separation of one or more components of the module.
[0047] The binding medium may comprise one selected from amongst a wax and a plastics material.
[0048] The step of inserting the module into one of the corner seal cavities may be followed by the step of removing the binding medium.
[0049] Alternatively the step of inserting the module into one of the corner seal cavities may be preceded by the step of removing the binding medium.
[0050] The step of removing the binding medium may comprise the step of performing at least one selected from amongst heating and chemical washing of the binding medium.
[0051] Some embodiments of the invention have the advantage that the problem of misalignment of respective recesses formed in opposed sides of a rotor within which respective corner seals are arranged to move is substantially eliminated since a single recess may be formed within which both corner seals slide. This has the advantage that a longevity of a rotary engine may be increased due to a reduction in strain on components of the engine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] Embodiments of the invention will now be described with reference to the accompanying figures in which:
[0053] FIG. 1 shows a perspective view of a portion of a prior art Wankel rotary engine;
[0054] FIG. 2 shows a cross-sectional view of a portion of a rotor of a prior art rotary engine;
[0055] FIG. 3 shows an exploded cross-sectional view of a portion of the rotor of FIG. 2 ;
[0056] FIG. 4 shows a perspective view of a portion of the rotor of FIG. 2 ;
[0057] FIG. 5 shows an exploded view of a portion of a rotor according to an embodiment of the invention;
[0058] FIG. 6 shows a further exploded view of a portion of a rotor according to an embodiment of the invention;
[0059] FIG. 7 shows an exploded view of a portion of a rotor according to an embodiment of the invention;
[0060] FIG. 8 is a cut-away view of a portion of a rotor according to an embodiment of the invention showing a single recess formed through a corner portion of the rotor; and
[0061] FIG. 9 is a perspective view of a portion of a rotor according to an embodiment of the invention showing a single recess formed through the corner portion of the rotor.
DETAILED DESCRIPTION
[0062] FIG. 5 shows a portion of a rotor 230 formed according to an embodiment of the invention using a wire cutting operation in which a single wire is employed to cut a corner seal recess (or ‘slot’) 231 in each of three corners 230 B of the rotor 230 . The corner seal recess 231 may also be referred to as a corner seal cavity 231 . Other fabrication methods are also useful such as laser cutting, moulding, casting, milling or other machining or any other suitable method.
[0063] The rotor 230 has a corner seal assembly installed therein, the corner seal assembly having a body portion 252 arranged to be provided in the recess 231 . In the embodiment of FIG. 5 the body portion has an aperture 253 provided therethrough. Resilient elements 254 (see also FIG. 6 ) having coil springs provided in cylindrical casings 254 C are provided within the aperture 253 and arranged whereby opposed corner seal elements 250 provided in the recess 231 at opposed ends of the recess and on opposite sides of the body portion 252 are resiliently coupled to one another. Thus in some embodiments the body portion 252 does not itself provide a medium through which forces between respective opposed corner seal elements 250 are transmitted.
[0064] In some embodiments the resilient elements 254 shown in FIG. 6 are provided by known cartridges for attaching watch straps to a watch body.
[0065] In some embodiments each of the resilient elements 254 of FIG. 6 are replaced by a conventional coil spring.
[0066] In some embodiments in which the body portion has an aperture 253 formed therethrough a shuttle member 255 ( FIG. 6 ) may be provided within the aperture 253 between a pair of resilient elements 254 . The shuttle member 255 is arranged to provide a medium through which forces may be transmitted between respective opposed corner seal elements 250 .
[0067] In some embodiments the body portion 252 is arranged to be slidable in the recess 231 . In some embodiments the corner seal elements 250 are coupled to the body portion 252 by means of resilient coupling elements whereby the body portion effects coupling between the corner seal elements 250 . It is to be understood that in such embodiments the body portion itself provides a medium through which forces between respective opposed corner seal elements are transmitted.
[0068] In some embodiments of the invention the corner seal elements 250 and body portion 252 are provided with recessed portions 251 B, 251 C arranged to receive a tip seal 260 and corresponding leaf spring element 262 therein. The recessed portion 251 B of the body portion 252 and recessed portion 251 C of each of the corner seal elements 250 are arranged to be aligned with one another, providing an open channel facing away from the rotor 230 . The leaf spring element 262 is arranged to be provided between the body portion 252 and the tip seal 260 .
[0069] In some embodiments the tip seal 260 is maintained in a required position within the recessed portions 251 B, 251 C by entrapment between the rotor and a sidewall of a housing of a rotary engine in which the rotor 230 is provided.
[0070] FIG. 7 shows the rotor 230 of FIG. 6 in which the corner seal elements 250 are substantially in the positions assumed when the rotor 230 is in normal use.
[0071] FIGS. 8 and 9 show the rotor 230 of FIG. 7 with the corner seal assembly removed.
[0072] In some embodiments of the invention the corner seal assembly is provided in the form of a unitary module or cartridge arranged to be slotted into the corner seal recess 231 . In some embodiments the assembly may be provided in a substantially tubular member arranged to be slotted into the corner seal recess 231 .
[0073] In some embodiments the corner seal assembly and tip seal assembly are provided in the form of a single module that is also arranged to be slotted into a corner seal recess 231 . The corner seal assembly may be provided in a substantially tubular member having a slot provided therealong through which at least a portion of a tip seal of the tip seal assembly may be arranged to pass.
[0074] The assembly may be supplied in a form in which a binder medium is arranged to maintain components of the assembly in a substantially fixed configuration with respect on one another to aid assembly. The binder medium may be a wax, a plastics material or any other suitable medium that may be removed once the assembly has been delivered to a customer. In some embodiments the binder is arranged to be removed once the assembly has been installed in a rotor.
[0075] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, means “including but not limited to”, and is not intended to (and does not) exclude other moieties, additives, components, integers or steps.
[0076] Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0077] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. | A corner seal assembly for a rotor of a rotary engine, the assembly comprising a pair of corner seal elements, each seal element of the pair being arranged to provide a seal between the rotor and a respective one of a pair of opposed end faces of the rotary engine, the seals being arranged to be resiliently coupled to one another whereby the seals exert substantially the same force on each one of the pair of opposed end faces. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to internal combustion engines, and more particularly to an engine with an offset crankshaft.
2. Brief Description of the Prior Art
The internal combustion engine is well known in the prior art. Examples of prior art references are Campbell U.S. Pat. No. 1,091,629; Pulman U.S. Pat. No. 1,201,098; Penning U.S. Pat. No. 1,317,939; Swensen U.S. Pat. No. 2,236,738; and Sanchez Great Britain Pat. No. 24,568.
Campbell U.S. Pat. No. 1,091,629 discloses a four cycle engine using two pistons in the same cylinder, connected with the crank shaft by an improved system of rods and rockarms or cranks having a small number of parts adapted to efficiently transmit the forces to which they are subjected, whereby one piston effects the suction of the charge at a relatively slow rate, and the scavenging of the cylinder, the other piston serving to compress the charge at a relatively rapid rate and execute the power stroke. The objective of this arrangement of crankshafts is to allow for driving the two pistons in opposition and provide a stroke of the pistons for every 360° revolution of the crankshaft. The power stroke is no more than 90 of rotation of the crankshaft.
Pulman U.S. Pat. No. 1,201,098 discloses an engine of the kind or class in which the working pressure is exerted between two pistons moving in opposite directions in the working cylinder, and operating a single crank. This Patent claimed the combination of two oppositely-moving pistons, a single cross-head operated by the joint action of said two pistons, and moving in the same direction as one of the pistons, and a crank driven from such cross-head and common to the two pistons, in an internal-combustion engine.
Penning U.S. Pat. No. 1,317,939 discloses a combustion engine wherein the cylinders are arranged in pairs, each cylinder having two pistons, between which the explosion occurs, the movement of the pistons being transmitted to a single crank shaft by means of rockers and connecting rods. The power stroke is no more than 180° in this engine. The object of this invention was to provide improvements more especially applicable to two cycle engines, and also various improvements in details of construction and oiling, whether of the type employing carburetors for forming the explosive charge, or of the Diesel or semi-Diesel types.
Swensen U.S. Pat. No. 2,236,738 discloses a novel power transmission mechanism whereby the reciprocating movement of the cylinder-and-piston engine will be converted into rotary motion, or conversely, rotary motion of the power-driven shaft may be converted into reciprocating movement in a cylinder-and-piston machine, such as a pump or air compressor. The power stroke is no more than 180° in this engine. That invention may be employed in connection with a single cylinder-and-piston engine or in connection with a multi-cylinder-and-piston engine. However, the preferred embodiment employed a plurality of such engines in connection with a rotary shaft having a plurality of oblique cranks set in such a way that the endwise thrust on the rotary shaft will be neutralized.
Sanchez Great Britain Pat. No. 24,568 discloses an engine of the rotary type in which the cylinders are arranged in the form of a star, such as were intended for aviation in 1914. The invention is a sleeve-valve engine. The power stroke is no more than 180° in this engine.
The present invention is distinguished over the prior art in general, and these patents in particular, by a new and useful improvement to internal combustion engines which is an engine with an offset crankshaft. When the crankshaft is rotated in a clockwise direction, the distance the piston travels from the top of the stroke (piston at maximum travel) to the bottom of the stroke (piston at the bottom of its travel) is greater than the diameter of the crankshaft rotation. The angle through which the crankshaft moves during the downstroke is greater than 180°. The engine therefore has a longer time power stroke than exhaust stroke. The intake cycle is longer in time than the exhaust cycle which improves aspiration of the engine. This concept can be applied to Otto cycle engines, Diesel engines, two stroke engines, and may be applied to compressors. When used in compressors, the intake stroke is extended which improves aspiration.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an engine with an offset crankshaft.
It is another object of this invention to provide an engine having a downstroke longer than the downstroke in a standard engine for an equal diameter crankshaft.
Another object of this invention is to provide an engine in which the crankshaft moves through an angle greater than 180° during the downstroke.
Another object of this invention is to provide an engine in which the power stroke is longer in time than the compression stroke.
Another object of this invention is to provide an engine in which the intake stroke is longer in time than the exhaust stroke.
A further object of this invention is to provide an engine having improved aspiration.
A still further object of this invention is to provide an engine that applies power through a greater rotation of the crankshaft than a standard engine
Other objects of the invention will become apparent from time to time throughout the specification and claims as hereinafter related.
The above noted objects and other objects of the invention are accomplished by a new and useful improvement to internal combustion engines which is an engine with an offset crankshaft. When the crankshaft is rotated in a clockwise direction, the distance the piston travels from the top of the stroke (piston at maximum travel) to the bottom of the stroke (piston at the bottom of its travel) is greater than the diameter of the crankshaft rotation. The angle through which the crankshaft moves during the downstroke is greater than 180°. The engine therefore has a longer time power stroke than exhaust stroke. The intake cycle is longer in time than the exhaust cycle which improves aspiration of the engine. This concept can be applied to Otto cycle engines, Diesel engines, two stroke engines, and may be applied to compressors. When used in compressors, the intake stroke is extended which improves aspiration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing the aligned relation of the piston and crankshaft in a conventional engine.
FIG. 2 is a schematic view showing the offset relation of the piston and crankshaft in accordance with the present invention.
FIG. 3 is a cross-section view of an internal combustion engine with an offset crankshaft, in accordance with the present invention, shown during the intake stroke.
FIG. 4 is a cross-section view of an internal combustion engine with an offset crankshaft, in accordance with the present invention, shown during the compression stroke.
FIG. 5 is a cross-section view of an internal combustion engine with an offset crankshaft, in accordance with the present invention, shown at the beginning of the power stroke.
FIG. 6 is a cross-section view of an internal combustion engine with an offset crankshaft, in accordance with the present invention, shown during the exhaust stroke.
FIG. 7 is a right elevation of an internal combustion engine with an offset crankshaft, as shown in FIGS. 3-6.
FIG. 8 is a graph of piston position vs. degrees of crankshaft rotation for a conventional engine with aligned piston and crankshaft and an engine with the offset relation of the piston and crankshaft in accordance with the present invention of the arrangement shown in 3-6 where both engines have equal stroke.
FIG. 9 is a graph of piston velocity vs. degrees of crankshaft rotation for a conventional engine with aligned piston and crankshaft and an engine with the offset relation of the piston and crankshaft in accordance with the present invention of the arrangement shown in FIGS. 3-6 where both engines have equal stroke.
FIG. 10 is a graph of piston acceleration vs. degrees of crankshaft rotation for a conventional engine with aligned piston and crankshaft and an engine with the offset relation of the piston and crankshaft in accordance with the present invention of the arrangement shown in FIGS. 3-6 where both engines have equal stroke.
FIG. 11 is a graph of crankshaft torque vs. degrees of crankshaft rotation for a conventional engine with aligned piston and crankshaft and an engine with the offset relation of the piston and crankshaft in accordance with the present invention of the arrangement shown in FIGS. 3-6 where both engines have equal stroke.
FIG. 12 is a graph of integrated torque vs. degrees of crankshaft rotation for a conventional engine with aligned piston and crankshaft and an engine with the offset relation of the piston and crankshaft in accordance with the present invention of the arrangement shown in FIGS. 3-6 where both engines have equal stroke.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention relates to new and useful improvements in internal combustion engines and more particularly to an engine in which the piston is substantially offset from the center line of the crankshaft.
Referring to the drawings by numerals of reference, in FIG. 1, there is shown a schematic view showing the aligned relation of a piston 10 and crankshaft in a conventional engine. In FIG. 2, there is shown a schematic view showing the offset relation of the piston 12 and crankshaft 13 in accordance with the present invention.
For a standard engine, when the crankshaft 11 is rotated, the time it takes the piston 10 to travel from the top of the stroke to the bottom of the stroke is equal to the time it takes the piston to return from the bottom of the stroke to the top of the stroke. However, in an engine with an offset crank shaft embodying the present invention, when the crankshaft 13 is rotated, the time it takes the piston 12 to travel from the top of the stroke to the bottom of the stroke is greater than the time it takes the piston to return from the bottom of the stroke to the top of the stroke. The distance the piston travels from the top of the stroke (piston at maximum travel) to the bottom of the stroke (piston at the bottom of its travel) is greater than the diameter of the crankshaft rotation The angle through which the crankshaft moves during the downstroke is greater than 180°. The engine therefore has a longer time power stroke than exhaust stroke. The intake cycle is longer in time than the exhaust cycle which improves aspiration of the engine.
In FIGS. 3-7, an engine in which the piston is substantially offset from the center line of the crankshaft is shown in more detail. Internal combustion engine 14 comprises a cylinder 15 with a piston 16 positioned for reciprocal movement therein.
The upper end of cylinder 15 includes a cylinder head portion 17 with an intake port 18 and exhaust port 19. An overhead intake valve 20 cooperates with valve seat 21 and an overhead exhaust valve 22 cooperates with valve seat 23. Overhead valves 20 and 22 are spring loaded to a closed position by springs 24 and 25. Rocker arms 26 and 27 are operated by camshaft 28 to operate valves 20 and 22 in coordination with movement of piston 16. Camshaft block 29 encloses an overhead camshaft 28 and rocker arms 26, 27. The camshaft lobes are spaced 85° or 95° apart in contrast to 90° for a standard engine to accommodate the offset crankshaft timing. The structure so far described, except for the spacing of the camshaft lobes, is conventional internal combustion engine design.
The bottom end of cylinder 15 includes a skirt portion 30 forming the cover for the crankcase 31. A crankshaft 32 is positioned for rotation inside the crankcase 31 with its center line 33 laterally offset from the center line of cylinder 15. The amount of offset is a matter of choice for the engine designer along with other factors such as dimensions of the engine, length of connecting rod, etc. In the embodiment shown, the amount of offset is approximately equal to the length of the crank arm. The portion of cylinder 15 adjacent to crankcase 31 has a slot 36 positioned to accommodate sidewise pivotal movement of connecting rod 34 during movement of piston 16 and crankshaft 32 through a full cycle of operation.
In FIG. 7, a right elevation of the engine is shown to illustrate the various connections. Crankshaft 32 has a gear 36a at its outer end connected by a timing belt 37 to gear 38 which operates camshaft 28. The operation of engine 14 is the same as that of conventional engines except for the crankshaft offset and valve timing. The piston 16 reciprocates in cylinder 15 through the conventional intake, compression, power and exhaust strokes. Rotation of crankshaft 32 operates camshaft 28 through timing belt 37 to operate the intake valve 20 and exhaust valve 22 in the proper sequence for the intake, compression, power and exhaust strokes.
This invention is conventional in structure except for the offset relation of the center line of piston 16 and the center line of crankshaft 32. Air inlet to the engine is provided through a carburetor (not shown) and an intake manifold (not shown). Exhaust gases from the engine pass through an exhaust manifold (not shown). The position of the crankshaft 32 in relation to piston -6 and connecting rod 34 is shown for the intake, compression, power and exhaust strokes in FIGS. 3-6 and the operating characteristics of the engine are shown in the graphs comprising FIGS. 8-12.
In FIG. 3, the engine 14 with offset crankshaft 32 is shown in the intake stroke. Cylinder 15 is filling with the fuel-air mixture, and the piston 16 is shown in the first downstroke or intake stroke. The connecting rod 34 and crankshaft 32 are shown offset as described above. Exhaust valve 22 is closed and intake valve 20 is open.
In FIG. 4, the engine 14 with offset crankshaft 32 is shown at the start of the compression stroke. Cylinder 15 is filled with the fuel-air mixture, and the piston 16 is shown in the first upstroke or compression stroke. The connecting rod 34 and crankshaft 32 are shown offset as described above. Both valves 20 and 22 are closed.
In FIG. 5, the engine 14 with an offset crankshaft 32 is shown with the cylinder 15 containing the fuel-air mixture at the completion of the compression stroke and start of the power stroke. When the fuel mixture is ignited by a spark from the spark plug, the piston 16 starts to move downward in the second downstroke or power stroke. The connecting rod 34 and crankshaft 32 are shown arranged for the offset position. Both valves 20 and 22 are shown in the closed position. On full movement through the power stroke, the piston reaches the position shown in FIG. 4, and exhaust valve 22 is opened in preparation for the exhaust stroke.
In FIG. 6, the engine 14 with an offset crankshaft 32 is shown with the cylinder 15 as the exhaust gases are leaving. The piston 16 is shown in the second upstroke or exhaust stroke. The connecting rod 34 and crankshaft 32 are shown arranged for the offset position. The exhaust valve 22 is shown in the open position.
For starting the engine 14, initial rotation of the crankshaft 32 is provided by a starter motor (not shown). The charge for the electrical system is maintained by a generator (not shown). Fuel is provided to the engine 14 through the carburetor, by a fuel pump (not shown). The fuel is mixed with air, and the mixture is introduced into the cylinder 15 for combustion. Any impurities which may be present in the fuel are removed by a fuel filter (not shown).
The overhead camshaft 28 is rotated through a gear 38 attached at one end which is engaged to a timing belt 37, which is also engaged to, and rotated by, a gear 36 attached at one end of the crankshaft 32. The engine 14 has an ignition system (not shown) which includes spark plugs, spark plug wires, distributor, distributor cap, points, and condenser.
Where contact of metal-to-metal surfaces occurs, sealing is provided by gaskets (not shown) of appropriate material. Shaft deflection of the crankshaft 32 is prevented by the provision of suitable bearings. The engine may be water cooled or air cooled.
OPERATION
The operation of the engine 10 with an offset crankshaft 32 should be obvious from the description of the preferred embodiment, but will be stated herein for clarity.
The operation of the engine 14 with an offset crankshaft 32 is similar to the operation of a standard engine having a four-stroke cycle, or a two-stroke cycle. Combustion occurs in the cylinder 15, in the upper portion, forcing the piston 16 to move downward. The piston downward movement moves the connecting rod 34 downward turning the crankshaft 32.
The rotation of crankshaft 32 and movement of piston 16 is seen in FIGS. 3-6. At the start of the intake stroke, the piston 16 is at the upper end of cylinder 15, as seen in FIG. 5, but with the intake valve 20 open. Piston 16 moves downward, as in FIG. 3, until it reaches the lowest position, as in FIG. 4, but with intake valve 20 still open.
At this point, both valves 20 and 22 are closed, as in FIG. 4, and the piston 16 starts the upstroke for compression and moves to the uppermost position, as in FIG. 5, which is the end of the compression stroke. Ignition then takes place, and piston 16 starts downward from the position of FIG. 5 until it reaches the position of FIG. 4. Exhaust valve 22 then opens and piston 16 moves upward, as in FIG. 6, through the exhaust stroke.
Through this rotation of crankshaft 32 and movement of piston 16, the offset relation of the crankshaft and piston results in the time for piston travel from the top of the stroke to the bottom of the stroke being greater than the time for the piston to return from the bottom of the stroke to the top of the stroke. The distance the piston travels from the top of the stroke (piston at maximum travel) to the bottom of the stroke (piston at the bottom of its travel) is greater than the diameter of the crankshaft rotation. The angle through which the crankshaft moves during the downstroke is greater than 180°. The engine therefore has a longer time power stroke than exhaust stroke. The intake cycle is longer in time than the exhaust cycle which improves aspiration of the engine.
FIGS. 8-12 graph the crankshaft rotation against piston position, torque, etc. In FIG. 8, piston position is graphed against crankshaft rotation for an engine with conventional crankshaft and for this invention where the crankshaft is offset. It is seen that the angle of movement of the crankshaft between top and bottom positions of the piston is 180° for the conventional crankshaft arrangement and 190.3° for the offset crankshaft of this invention. This allows a longer time power stroke and intake stroke and a shorter time compression stroke and exhaust stroke.
In FIG. 9, piston velocity is graphed against crankshaft rotation for an engine with conventional crankshaft and for this invention where the crankshaft is offset by the length of the crank arm. It is seen that the maximum downward velocity occurs at about 165° for the conventional crankshaft arrangement and 180° for the offset crankshaft of this invention.
In FIG. 10, piston acceleration is graphed against crankshaft rotation for an engine with conventional crankshaft and for this invention where the crankshaft is offset. It is seen that the maximum acceleration is lower for the offset crankshaft than for the conventional crankshaft during the down stroke but higher on the upstroke.
In FIG. 11, crankshaft torque is graphed against crankshaft rotation for an engine with conventional crankshaft and for this invention where the crankshaft is offset by the length of the crank arm. It is seen that the maximum torque for the offset crankshaft occurs after and is lower than the maximum torque for the conventional crankshaft
In FIG. 12, integrated crankshaft torque is graphed against crankshaft rotation for an engine with conventional crankshaft and for this invention where the crankshaft is offset by the length of the crank arm. It is seen that the maximum integrated torque for the offset crankshaft occurs after but is equal to the total integrated torque of the conventional engine, both engines having equal stroke.
While this invention has been described fully and completely with special emphasis upon a preferred embodiment, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A new and useful improvement to internal combustion engines is disclosed which is an engine with an offset crankshaft. When the crankshaft is rotated in a clockwise direction, the distance the piston travels from the top of the stroke (piston at maximum travel) to the bottom of the stroke (piston at the bottom of its travel) is greater than the diameter of the crankshaft rotation. The angle through which the crankshaft moves during the downstroke is greater than 180°. The engine therefore has a longer time power stroke than exhaust stroke. The intake cycle is longer in time than the exhaust cycle which improves aspiration of the engine. This concept can be applied to Otto cycle engines, Diesel engines, two stroke engines, and may be applied to compressors. When used in compressors, the intake stroke is extended which improves aspiration. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from German Patent Application No. 10 2009 013 412.3 dated Mar. 18, 2009, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to an apparatus on a carding machine for cotton, synthetic fibres and the like, in which there is at least one card flat bar having a card flat clothing.
[0003] It is known in a card flat bar for the card flat clothing, preferably wire hooks, to be arranged in a strip-like support layer, the clothing being attached to the card flat bar and lying opposite the clothing of a roller, for example the cylinder, and at least the regions of the card flat clothing that face the card flat bar comprising an iron material, especially of steel, with at least one magnetic means (element) being provided between the card flat bar and the regions of the card flat clothing that face the card flat bar.
[0004] The revolving card top of a carding machine is the crucial technological element for reducing the number of neps in the fibre material, for example, cotton, in its most highly opened state. In its interaction with the cylinder, the revolving card top loosens the fibre knots, it being necessary for the spacing to be as small as possible but for mutual contact between the clothings to be prevented. Contact results in unnecessary wear. Premature wear in turn results in a reduction in quality. The flexible revolving card top is also the only element which can be set to extremely narrow carding nips without significant adverse technological secondary effects.
[0005] In order reliably to manage extremely narrow carding nips, precision components are a prerequisite. The revolving card flats used simultaneously on a machine are referred to as a card flat set. The differences in dimensions from card flat to card flat in the card flat set should be as small as possible. Likewise, each individual card flat should have a high degree of evenness across the width of the machine. Because increased precision is always associated with increased cost, it is necessary to combine increased precision with optimum handling at an acceptable cost. In practice, the clothings are clipped onto the card flats using enormous forces. The clipping-on operation, which has to be made reversible for re-clothing, has an adverse effect on precision and is not possible without destruction of the clothing.
[0006] In a known apparatus (DE 10 2006 005 605 A), the card flat clothing is adhesively bonded, in a tolerance compensating manner, to a metal backing sheet and is held in the revolving card top by a planar magnetic strip. The magnetic strip itself is in turn adhesively bonded, in a tolerance compensating manner, to the card flat bar. The magnetic force absorbs the process forces during the carding process with a high degree of reliability. As a result, many of the disadvantages of the old clip-on card flat system have been eliminated. The card flat sets have a high degree of precision even without an additional grinding process. Handling during re-clothing is optimum, because the clothing can be demounted, without being destroyed, using a single movement. The new clothing can be inserted again just as quickly.
[0007] The magnetic connection is a force-based connection. If a threshold force opposite to the attractive force of the magnet is applied, the clothing strip becomes detached from the card flat bar. The threshold force is such that the normal process forces can be transmitted with a high degree of reliability. This has been demonstrated by a large number of practical tests and experiments. The “old” mounting technique using clips was an interlocking connection. That connection could be broken only by overcoming the rigidity of the component. The forces necessary for that purpose are in turn a multiple greater than the threshold force of the “new” magnetic connection.
[0008] If operating conditions that can be considered abnormal then arise in a carding machine, forces can develop which exceed the threshold force of the magnet but still lie significantly below the connection strength of the clip-on technique. Abnormal operating conditions arise when the nips used are too narrow; when the fibre/clothing combination has been incorrectly selected and therefore cylinders become clogged; when, as a result of fibres that are difficult to process, temperatures suddenly rise very rapidly and there is substantial contact between clothings; when operators do not recognise the abnormal operating conditions in good time and allow the machines to continue running, and so on. It can also happen that an unusually large or solid disruptive element, for example a trash particle, fibre knot or the like, projects at least partly beyond the circle of tips of the cylinder and thus exerts undesirable pressure on the forwardly arranged regions (front regions) of the clothing of at least one card flat bar. In summary, there are situations which occur extremely rarely (exceptional cases) but give rise to enormous adverse forces.
[0009] In normal operation, the magnet absorbs all the operating forces and provides for precision support. In an abnormal operating state, the interlocking connection safeguards against contact with the cylinder clothing.
SUMMARY OF THE INVENTION
[0010] It is an aim of the invention to create an apparatus which, in particular, provides a structurally simple way of holding the clothing element against the card flat bar in the event of an increase in pressure on the card flat clothing, especially of preventing the card flat clothing from making contact with the cylinder clothing, and allows quick replacement of the card flat clothing strip.
[0011] The invention provides a card flat bar for use in a carding machine opposite a clothed roller of said machine, having a card flat bar body having a material inlet side at which in use fibre material is received, and a card flat clothing strip which is magnetically attachable to the card flat bar body, wherein the card flat bar body includes a counter-bearing associated with said material inlet side and the card flat clothing strip comprises a counter-element arranged to co-operate, in use, with the counter-bearing in a direction towards said opposed clothed roller.
[0012] Because there is associated with the card flat bar, on the fibre material inlet side of the card flat clothing, a counter-bearing, stop or the like with which the base and/or the support member co-operate(s) in the direction towards the roller, for example carding cylinder, undesirable forces are compensated for. In this structurally simple way, in the event of an increase in pressure on the clothing, the clothing element is held against the card flat bar, that is to say contact between the card flat clothing and the cylinder clothing is reliably avoided even if there is local detachment from the magnet. The invention has the further substantial advantage that in the event of replacement the card flat clothing strip can be removed or inserted without problems, because there is no counter-bearing, stop or the like on the fibre material outlet side of the card flat clothing.
[0013] Advantageously, the clothing strip has a support layer and a base for attachment to the card flat bar, and the counter-element is the base. The counter-element may be, for example, a shoulder or the like on the base. In another embodiment, the counter-element may be the support layer. For example, the counter-element may be a shoulder or the like on the support layer. In certain embodiments the base or the support layer co-operates with the card flat bar by means of an interlocking connection. The counter-bearing may be in any suitable form. Illustrative arrangements for the counter-bearing include those in which the counter-bearing is a shaped portion of the foot of the card flat bar body, for example, an angled edge on the card flat foot, an undercut, a nose, an angled side on the card flat foot, or a groove in the card flat foot; and arrangements in which a bearing element is inserted into or attached to the foot of the card flat body, for example, a bent-over sheet metal element or the like, a screw, a bolt or the like, a resilient element, or a clip-like element. In the case of a groove, the base of the clothing , advantageously projects into the groove. Advantageously, the base projects beyond the support layer of the clothing. The counter-bearing may extend under the base or the support layer of the clothing at a spacing of about from 1 to 3 mm. Advantageously, the counter-bearing, for example the stop, is present at least partially along the longitudinal edge of the card flat foot on the fibre material inlet side. Advantageously, there is a spacing (play) between the upper side of the counter-bearing and the underside of the base or support layer. Advantageously, during normal carding conditions, the spacing (play) is smaller than the spacing between the card flat clothing and the clothing of the cylinder (carding nip).
[0014] In some embodiments, there is a counter-bearing in the region of each of the two end faces of the card flat foot (card flat heads). Advantageously, when the threshold force of the magnet is exceeded the clothing strip is supported on the counter-bearing. That prevents the clothing strip from contacting the opposed roller. For example, the base may be supported on the counter-bearing in the event of abnormal carding conditions resulting in detachment of the clothing strip. Where the counter-element is the support layer, the support layer may be supported on the counter-bearing in the event of detachment of the carding strip.
[0015] In some embodiments, magnetic means are attached to the card flat bar, for example, by means of an adhesive layer or the like, or by means of a screw connection or the like. In some embodiments, the magnetic means consists of a permanently magnetic material. It will be appreciated that, under normal carding conditions, the magnetic force is greater than other forces acting on the clothing, for example carding force, force of a rotating cleaning roller or the like. Preferably, the clothing is removable from the magnetic means. Preferably, the clothing is joined to the card flat bar by means of the magnetic means as attachment element. Preferably, the clothing is removably detachable from the magnetic means. In one preferred embodiment, the clothing, which is inserted into a substrate, for example fabric or the like, consists of wires or the like which are bent into approximately a U-shape and inserted in such a way that the crosspiece of the U-shaped wires or the like runs on the rear side of the substrate. Preferably, between the card flat bar and the card flat clothing there is a compensating layer which is able to compensate for the different spacings between the card flat bar and the card flat clothing. In certain embodiments, an adhesive layer is provided. The clothing is preferably a clothing strip.
[0016] In certain embodiments, the card flat bar comprises a neodymium magnet. In certain advantageous forms of clothing, a thin metal support is advantageously provided. Advantageously, the clothing is a flexible clothing. Preferably, the flexible clothing comprises a support and clothing tips, wires, hooks or the like. Preferably, the support is strip-shaped. In other embodiments, the clothing consists of sawtooth wire strips, for example all-steel clothing.
[0017] Advantageously, the clothing is attached to the card flat bar in the region of the foot surface. Advantageously, a plastics material, a synthetic resin, for example epoxy resin, or the like, is provided as compensating composition. Preferably, the card flat bar is an extruded profile made from a lightweight metal, for example aluminium. Preferably, the extruded profile is a hollow profile. Preferably, the card flat bar comprises a supporting member, with which are associated two end head parts (card flat heads). Preferably, the end head parts are pins made of hardened steel or the like. Preferably, a supporting element of the clothing (for example, of textile material) and the compensating layer are arranged in a recess in the foot face (supporting member). Preferably, the recess is defined by at least two lateral ribs or the like on the longitudinal sides of the supporting member of the card flat bar. In some embodiments, the underside of the clothing strip against which the backs of bent wires of the clothing are located is held by means of a magnet fixed to the card flat bar. In certain embodiments, a clothing strip is included, to which there is additionally attached, by way of a compensating adhesive layer, a metal sheet which is brought into connection with the magnet of the card flat bar. In preferred embodiments of the invention, a vertical linkage on the fibre material inlet side is supported mechanically.
[0018] Advantageously, the magnetic means comprises an elongate magnetic element, for example magnetic tape, magnetic strip, magnetic bar or the like, that runs in the longitudinal direction of the card flat bar. In some embodiments, a plurality of magnetic elements are present in the longitudinal direction of the card flat bar. Preferably, the magnetic elements are arranged spaced apart from one another. In certain embodiments, the magnetic structural elements are arranged offset with respect to one another. Preferably, the offset runs in the working direction. In certain embodiments, a base made of a magnetic material is arranged on the rear side of the card flat clothing. Advantageously, the base is a steel tape, metal sheet or the like. Advantageously, the base has, on the fibre material inlet side, shoulders, ribs or the like which are bent at an angle at the side.
[0019] In some embodiments, the card flat clothing has at least two clothing groups which are each held by a magnet. For example, there may be at least two clothing groups each having a heel zone opposite the roller clothing. In certain embodiments the card flat clothing consists of a multiplicity of all-steel clothing wires which are arranged in the axial direction with respect to the clothed roller, for example the cylinder. Preferably, the card flat clothing is held against the card flat bar by at least, one magnetic element.
[0020] In certain preferred embodiments, magnetic means is integrated into the card flat bar. Advantageously, a base made of a fine material is provided on the rear side of the card flat clothing. In one advantageous embodiment, magnetic means is formed with the card flat bar by casting. In another advantageous embodiment, the magnetic means is incorporated into the card flat bar by casting or compression moulding. Advantageously, the magnetic means is simultaneously incorporated during the manufacture of the card flat bar. In one advantageous embodiment, at least one and preferably each of the marginal regions bordering the longitudinal edges is provided with tips. Advantageously, the magnetic element is at least partly in contact with the sheet-form metal support of the clothing.
[0021] The invention also provides a card flat bar for a carding machine for cotton, synthetic fibres and the like, having a card flat clothing, wherein the card flat clothing, preferably wire hooks, which is arranged in a strip-shaped support layer, is attached to the card flat bar and at least the regions of the card flat clothing that face the card flat bar consist of an iron material, especially of steel, with at least one magnetic means being provided between the card flat bar and the regions of the card flat clothing that face the card flat bar, wherein on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the cylinder—there is associated with the card flat bar a counter-bearing, stop or the like with which the base co-operates in the direction towards the cylinder.
[0022] Further, the invention provides a flexible clothing for a card flat bar on a carding machine for cotton, synthetic fibres and the like, having a card flat clothing, wherein the card flat clothing, preferably wire hooks, which is arranged in a strip-shaped support layer, is attachable to the card flat bar and at least the regions of the card flat clothing that are arranged to face the card flat bar consist of an iron material, especially of steel, wherein on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the cylinder—there is associated with the card flat bar a counter-bearing, stop or the like with which the base co-operates in the direction towards the cylinder.
[0023] Moreover, the invention provides a carding machine having a revolving card flat assembly for cotton, synthetic fibres and the like, in which there is at least one card flat bar having a card flat clothing, wherein the card flat clothing, preferably wire hooks, which is arranged in a strip-shaped support layer, is attached to the card flat bar and lies opposite the clothing of a roller, for example the cylinder, and at least the regions of the card flat clothing that face the card flat bar are provided with at least one magnetic element wherein on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the cylinder—there is associated with the card flat bar a counter-bearing, stop or the like with which the base co-operates in the direction towards the cylinder.
[0024] The invention also provides an apparatus on a carding machine for cotton, synthetic fibres and the like, in which there is at least one card flat bar having a card flat clothing, wherein the card flat clothing, preferably wire hooks, which is arranged in a strip-like support layer, is attached to the card flat bar and lies opposite the clothing of a roller; for example the cylinder, and at least the regions of the card flat clothing that face the card flat bar consist of an iron material, especially of steel, with at least one magnetic means (element) being provided between the card flat bar and the regions of the card flat clothing that face the card flat bar, wherein on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the cylinder—there is associated with the card flat bar a counter-bearing, stop or the like with which a counter-element associated with the card flat clothing co-operates in the direction towards the cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a diagrammatic side view of a carding machine having a revolving card top with card flat bars according to a first embodiment of the invention;
[0026] FIG. 2 shows card flat bars of the revolving card top and a portion of a slideway, of a setting bend (flexible bend) having a side screen and of the cylinder, as well as showing the carding nip between the clothings of the card flat bars and the cylinder clothing;
[0027] FIG. 3 a is a side view in section through a portion of a card flat bar with a counter-bearing and with magnetic strip and clothing strip (wire hook clothing) in the assembled position;
[0028] FIG. 3 b shows the card flat bar with counter-bearing and magnetic strip in accordance with FIG. 3 a , but with a separately detached clothing strip;
[0029] FIG. 4 is a side view in section of a further card flat bar according to the invention, showing diagrammatically the installation of the clothing strip in the card flat foot of the card flat bar or the demounting of the clothing strip therefrom;
[0030] FIG. 5 shows the force application point and the angle of application with respect to the card flat clothing on the fibre material inlet side;
[0031] FIG. 6 a shows on the fibre material inlet side of a card flat bar according to FIG. 4 , a spacing between the underside of a shoulder of the base and the counter-bearing;
[0032] FIG. 6 b shows the card flat bar according to FIG. 4 with a spacing between the upper side of the base and the magnet
[0033] FIG. 7 shows an embodiment having an angled side on the counter-bearing and on the base;
[0034] FIG. 8 shows an embodiment having a screw as counter-bearing;
[0035] FIG. 9 shows an embodiment having a flexible metal sheet as counter-bearing;
[0036] FIG. 10 shows an embodiment having a counter-bearing with which the support layer of the clothing strip co-operates, and
[0037] FIG. 11 shows an embodiment having a shoulder on the supporting element which co-operates with the counter-bearing.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] With reference to FIG. 1 , a carding machine, for example a flat card TC 07 (trademark) made by Trützschler GmbH & Co. KG of Mönchengladbach, Germany, has a feed roller 1 , feed table 2 , lickers-in 3 a, 3 b, 3 c, cylinder 4 , doffer 5 , stripper roller 6 , nip rollers 7 , 8 , web guide element 9 , web funnel 10 , delivery rollers 11 , 12 , revolving card top 13 with card top guide rollers 13 a, 13 b and card flat bars 14 , can 15 and coiler 16 . The directions of rotation of the rollers are indicated by curved arrows. Reference letter M denotes the centre point (axis) of the cylinder 4 . Reference numeral 4 a denotes the clothing and reference numeral 4 b denotes the direction of rotation of the cylinder 4 . Reference letter B denotes the direction of rotation of the revolving card top 13 in the carding position and reference letter C denotes the return transport direction of the card flat bars 14 , with reference numerals 30 ′, 30 ″ denoting functional elements and reference numerals 13 a and 13 b denoting card top guide rollers. The arrow A denotes the working direction.
[0039] In accordance with FIG. 2 , on each side of the carding machine there is provided a setting bend 17 (flexible bend) which is integrated integrally into the associated side screen 19 . The setting bend 17 has a convex outer surface 17 a and an underside 17 b. On top of the setting bend 17 there is a slideway 20 , for example made of low-friction plastics material, which has a convex outer surface 20 a and a concave inner surface 20 b. The concave inner surface 20 b rests on top of the convex outer surface 17 a and is able to slide thereon in the direction of arrows D, E. Each card flat bar 14 consists of a rear part 14 a and a card flat foot 14 b. Each card flat bar 14 has, at each of its two ends, a card flat head, each of which comprises two steel pins 14 1 , 14 2 . Those portions of the steel pins 14 1 , 14 2 that extend out beyond the end faces of the card flat foot 14 b slide on the convex outer surface 20 a of the slideway 20 in the direction of the arrow B. A clothing 18 is attached to the underside of the card flat foot 14 b. Reference numeral 21 denotes the circle of tips of the card flat clothings 18 . The cylinder 4 has on its circumference a cylinder clothing 4 a, for example a sawtooth clothing. The tooth height of the sawteeth is, for example, h=2 mm. Reference numeral 22 denotes the circle of the tips of the cylinder clothing 4 a. The spacing (carding nip) between the circle of tips 21 and the circle of tips 22 is denoted by reference letter a and is, for example, 3/1000″. The spacing between the convex outer surface 20 a and the circle of tips 22 is denoted by reference letter b. The spacing between the convex outer surface 20 a and the circle of tips 21 is denoted by reference letter c. The radius of the convex outer. surface 20 a is denoted by reference letter r 3 and the radius of the circle of tips 22 is denoted by reference letter r 1 . The radii r 1 and r 3 intersect at the centre point M of the cylinder 4 . Reference numeral 19 denotes the side screen. The card flat bars 14 are extruded hollow profiles made of aluminium having an internal cavity 14 c.
[0040] FIGS. 3 a and 3 b show a first embodiment of card flat bar according to the invention. The card flat clothing 24 consists of clothing tips 18 (wire hooks) and a supporting element 25 (support layer) made of a textile material. The wire hooks 18 are approximately U-shaped and, punched through the surface 25 ′, are fixed in the supporting element 25 . The turn regions 18 ′ (see FIG. 4 ) of the wire hooks 18 project beyond the surface 25 ′. The ends of the wire hooks 18 , the clothing tips, are free. The wire hooks 18 consist of steel wire.
[0041] Two ribs 14 d, 14 e are provided laterally on the card flat foot 14 a in the longitudinal direction, so that in the region of the foot face there is a recess 14 f, by means of which the card flat clothing 24 is held, protected and embedded. In the recess 14 f there is arranged a magnetic element 29 , for example a magnetic tape, magnetic strip, magnetic bar or the like, which is attached to the foot face by means of an adhesive layer 30 . The magnetic element can also be formed on the card flat bar by casting, compression moulding or the like, for example magnetic powder with a curable resin. The magnetic element is advantageously a permanent magnet, for example a neodymium magnet. In the lower recess 14 f there is arranged the card flat clothing 24 . The card flat clothing 24 is attached to, i.e. held against, the magnetic element 29 by its region remote from the free clothing tips 18 (teeth).
[0042] In the arrangement shown in FIGS. 3 a and 3 b , the card flat clothing 24 (clothing strip) consists of wire hooks 18 and supporting element 25 . The arrangement additionally has a compensating layer 32 which enables card flat precision to be improved and the attachment surface area to be enlarged. The compensating layer 32 is advantageously an adhesive layer to which there is attached a metal sheet 33 (base) or the like, for example a steel sheet, which is in contact with the magnet 29 .
[0043] FIG. 3 a shows the card flat bar 14 and the card flat clothing 24 in the assembled state, the card flat clothing 24 being held so securely by the magnet 29 by way of the steel sheet 33 that, during operation, forces acting through the carding machine on the card flat clothing 24 hold the card flat clothing 24 against the magnet 29 . According to FIG. 3 b , the card flat clothing 24 has, for example in the event of wear, damage or the like to the clothing hooks 18 including the base 33 , been separated from the magnet 29 and removed from the recess 14 f. Separation from the magnet 29 can be effected by means of a suitable tool with which the holding force of the magnet is overcome. The separation can be effected manually even while the carding machine is running, during operation, on the return transport of the card flat bars 14 (see arrow C in FIG. 1 ). The card flat bars 14 are removable from the toothed drive belt (not shown).
[0044] In the card flat bar of FIG. 3 a , 3 b , on the fibre material inlet side ES of the clothing 18 —seen in the direction of rotation 4 a of the cylinder 4 (see FIG. 1 )—a counter-bearing 34 is present only on the rib 14 d. The counter-bearing 34 , which projects into the recess 14 f in the form of a shoulder on the rib 14 d, is formed in one piece with the rib 14 d during the extrusion of the card flat bar 14 . In this arrangement, rib 14 d and counter-bearing 34 are merged integrally in one piece. The width of the rib 14 d is denoted by reference letter d. According to FIG. 3 b , the counter-bearing 34 has a width e and a height f. The width e is about from 1 to 3 mm and projects beyond the width d. The length l (not shown) of the counter-bearing 34 corresponds to the working width of the card flat bar 14 across the cylinder 4 and can be, for example, 1000 mm, 1200 mm or 1500 mm or more. The counter-bearing 34 can be of one-part or multi-part construction in the longitudinal direction.
[0045] In the embodiment of FIG. 3 b , the supporting element 25 has a width g. The width of the adhesive layer 32 corresponds to the width g of the supporting element 25 . The width h of the sheet metal strip 33 is greater than the width g of the supporting element 25 . In that way, the edge region 33 ′ of the sheet metal strip 33 on the fibre material inlet side ES of the clothing 18 projects beyond the supporting element 25 by amount i. Reference letter K denotes the width of the magnetic element 29 .
[0046] FIG. 4 shows diagrammatically the installation of the clothing strip 24 in the card flat foot 14 b of the card flat bar 14 and the demounting of the clothing strip therefrom. Because the rib 14 e is not associated with a counter-bearing, stop or the like, the clothing strip 24 , for example having a worn or damaged clothing 18 , can —after separation of the sheet metal strip 33 from the magnetic element 29 —be rotated clockwise in the direction of arrow F out of the recess 14 f. The edge region 33 ′ of the sheet metal strip 33 that projects by amount i (see FIG. 3 b ) is rotated about the upper edge region of the counter-bearing 34 in direction F, the edge region 33 ′ at the same time being withdrawn from a groove 35 in the rib 14 d, which groove runs in the longitudinal direction l of the card flat bar 14 . A new clothing strip 24 is installed in the card flat foot 14 b of the card flat bar 14 in a corresponding way. First the edge region 33 ′ is introduced, around the upper edge region of the counter-bearing 34 , into the groove 35 , so that the clothing strip 24 is rotated anti-clockwise in the direction of arrow G until the sheet metal strip 33 adheres firmly to the magnetic element 29 . In that way, handling during installation and demounting of the clothing strip is problem-free.
[0047] By way of illustration with reference to a card top bar according to FIG. 4 , FIG. 5 shows, by the force application point 36 and the angle of application a on the fibre material inlet side ES. Reference letters AS denote the fibre material outlet side. The force that arises in any particular case can vary greatly in magnitude but the force application point 36 and the application angle a is limited. It is therefore possible to create geometric conditions which absorb the forces through an interlocking connection. FIG. 5 shows an exemplary configuration of such an interlocking connection. It will be apparent from, for example, the illustrative embodiment of FIGS. 4 and 5 that the counter-bearing provided, in accordance with the invention, presents on obstacle to removal of the clothing strip in the direction towards the roller, during use, at the position most prone to abnormal carding conditions, that is at the material inlet side of the card flat. On the other hand, the counter-bearing does not impede removal of the strip when desired (see, for example, FIG. 4 ).
[0048] Reference letter 4 b denotes the direction of rotation of the cylinder (flow of fibre material). The angle of application a represents a possible variation of the direction of application of the threshold force K. The curved arrow I indicates the direction in which in an abnormal operating state, that is to say in the event of the limit force K being exceeded, the clothing strip 24 is rotated minimally about a pivot point in the region of the rib 14 e (see FIG. 6 b ).
[0049] In accordance with FIG. 6 a , on the fibre material inlet side ES there is a spacing m between the underside of the sheet metal strip 33 serving as base and the upper side 34 ′ of the counter-bearing, 34 . FIG. 6 a represents the normal operating state. According to FIG. 6 b , on the fibre material inlet side ES there is a spacing n between the upper side 33 ′ (see FIG. 3 b ) of the sheet metal strip 33 serving as base and the underside 29 ′ (see FIG. 3 b ) of the magnetic element 29 . FIG. 6 b represents the abnormal operating state. Whereas during normal operation in accordance with FIG. 6 a there is no contact between the marginal regions 33 ′ of the sheet metal strip 33 and the counter-bearing 34 , in the abnormal operating state according to FIG. 6 b the marginal region 33 ′ of the sheet metal strip 33 is supported by, i.e. presses against, the counter-bearing 34 in direction H.
[0050] In order that handling during mounting is not appreciably limited, the interlocking connection must be designed to have some play. The spacing m in accordance with FIG. 6 a allows for play. In a case of abnormal operation in which the limit force K of the magnet 29 is overcome, the clothing strip 24 together with its metal backing sheet 33 tilts away from the planar magnetic surface 29 ′ (arrow H in FIG. 6 b ) and is supported on the counter-bearing 34 (aluminium edge) of the card flat bar.
[0051] The clearance m is significantly smaller than the spacing a (see FIG. 2 ) between the card flat clothing 18 and the cylinder clothing 4 a, so that there is no risk of contact.
[0052] In normal operation ( FIG. 6 a ), the magnet 29 absorbs all the operating forces and provides for precision support. In the abnormal operating state ( FIG. 6 b ), the interlocking connection safeguards against contact between the card flat clothing 18 and the cylinder clothing 4 a.
[0053] In another embodiment of the invention shown in
[0054] FIG. 7 , a card flat bar has an angled side on the counter-bearing 34 ′ and an angled side 33 ″ on the sheet metal strip 33 is provided, the respective angled sides being in interlocking engagement.
[0055] In a further embodiment, shown in FIG. 8 , a screw 37 passing through the rib 14 d is provided as counter-bearing. The screw 37 is removable, and the screw 37 allows a settable depth into the recess 14 f for the support of the edge region 33 ′ of the sheet metal strip 33 .
[0056] In yet another embodiment, shown in FIG. 9 , a flexible metal sheet 38 is mounted on the outside of the rib 14 d, the limb 38 ′ of which, bent over, serves as counter-bearing.
[0057] FIG. 10 shows an embodiment in which there is a counter-bearing 39 on the rib 14 d with which the support layer 25 of the clothing strip 24 co-operates.
[0058] In the embodiment of FIG. 11 , a shoulder 25 ′ is present on the supporting element 25 , which shoulder co-operates with the counter-bearing 34 . In this arrangement the turn regions 18 ′ of the clothing 18 are in contact with the magnetic element 29 .
[0059] The invention has been explained by way of illustration with reference to the embodiments shown. Further arrangements are included in the scope of protection. For example, in the region of the two end faces of the card flat foot 14 b of the card flat bars 14 there can be provided, in addition or on its own, at least one counter-bearing with which a shoulder on the base 33 and/or on the support member 25 in that region co-operates. The card flat clothing can also be semi-rigid or can be in the form of all-steel clothing, for example sawtooth clothing.
[0060] Although the foregoing invention has been described in detail by way of illustration and example for purposes of understanding, it will be obvious that changes and modifications may be practised within the scope of the appended claims. | In a card flat bar having a card flat clothing, the card flat clothing is magnetically attached to the card flat bar body and, in use, lies opposite a clothed roller. In order to hold the clothing element against the card flat bar in a structurally simple way in the event of an increase in force on the clothing, especially to prevent the card flat clothing from making contact with the cylinder clothing, and to allow quick replacement of the card flat clothing strip, on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the roller—there is associated with the card flat bar a counter-bearing, stop or the like with which a base of the clothing co-operates in the direction towards the cylinder. | 3 |
BACKGROUND OF THE INVENTION
In the manufacture of textile filaments of yarns from meltspun polymers, especially for the finer textile deniers, it is useful to wind a number of separate packages or rolls of filaments simultaneously from the same polymer extrusion source. Aside from an increase in the rate of production of textile filaments, the increased polymer usage aids in controlling the time a polymer is at high temperature spinning conditions.
For substantially the same reason, spinnerettes, or spinning orifices for spinning polymer into conditions where it forms filaments, are grouped closely together. It follows that winding of the separate groups of filaments will be done in a compact manner. Often, the same winding rotor will be used to wind a number of "packages" of yarn simultaneously--"in-line", so to speak.
In high speed spinning, particularly at speeds above 2500 meters per minute, "threading in" of two or more filament packages creates conditions which can be difficult. "Threading" is the process of capturing yarn from a spinnerette and directing it through processing conditions ultimately ending in placing the filaments on a winding arbor for takeup into package form. Threading is simplified somewhat by use of at least one and usually two means for taking yarn to a waste collection device--aspirators. One waste aspirator is usually mounted on the machine; another is mounted at the end of a flexible tube. Individual ends of textile filaments or yarn are extruded through the spinnerettes and brought down to the machine aspirator and sent to waste until all ends associated with a particular winding arbor or rotor are spinning satisfactorily. Depending upon the winding process, one or more intermediate godets or rolls may be involved, but the type of process is not relevant to this invention.
Where all ends have been "spun in" satisfactorily, the winding arbor is brought to speed. Individual ends are brought from the machine aspirator via the tube aspirator "gun" to a winding position on the arbor, the spinning end is transferred to the rotating arbor and begins the formation of a package. Obviously, all ends being spun simultaneously, the ends have to be strung quickly and efficiently, else substantial material will be lost. It is not unusual for just the slightest movement or drag against the filaments moving so closely together to cause them to intermingle with adjacent filaments and create yarn breaks or loose ends or both. Historically, at least two operators have been necessary during threading to keep the ends separated and to properly wind them within the short term allotted to startup. This invention eliminates the need for more than one operator and simplifies separation of the yarns during startup to avoid yarn breaks or loose ends.
BRIEF DESCRIPTION OF THE INVENTION
This invention involves a trap guide for use in high speed spinning of multiple ends of filaments. The trap guide of this invention involves a plate mounted to the face of a fiber melt-spinning machine, the plate having a multiplicity of finger-like rods extending outwardly from the face of the plate in an orderly sequence. The rods may be straight across or may be positioned in a downward slant or in a "V" slanted configuration. The face plate has a bracket attached extending outwardly and parallel to the finger rods and a guide rod of sufficient length to extend substantially across the face of the plate and the finger rods. The guide rod is pivotally attached to the bracket.
In operation the guide rod can be pivoted out of the way to remove or insert individual yarn ends as necessary. A fixed back guide may be located on the face of the plate to arrest rearward movement of yarn ends in a plane parallel to the machine face.
The movable or pivoting guide rod positioned in front of the fixed back guide prevents yarn ends from looping over the end of the guide rods or fingers in their downward movement from the spinning orifices to the remainder of the processing of the spinning machine.
The process involves a threading in of a multiplicity of ends of filaments in a high speed spinning operation of greater than 2500 m/min utilizing the trap guide described above, a stationary waste aspirator and removable waste filament aspirator comprising the steps of pivoting, if necessary, the guide rod from across the face of the guide plate; capturing a first group of filaments with the movable aspirator and guiding the group of filaments between a first set of finger rods; and directing the captured group to the fixed aspirator. This capturing step is repeated until all groups of the filaments have been threaded through the guide and captured by the fixed aspirator. The first group of filaments is then captured and removed from the fixed aspirator using the movable aspirator and thereafter threaded through the remaining elements of the spinning process ultimately to a winding arbor. The pivotable guide rod can be placed in position to prevent the string of filaments as necessary during the threading up process of this first and then the remaining threadlines in sequence.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a typical spin winding process in which four groups of textile yarn are being wound simultaneously on a single arbor.
FIG. 2 shows the face view of a spinning guide for separating individual ends of textile filaments.
FIG. 2A is a side view of FIG. 2.
FIG. 3 is an oblique three-dimensional view of the guide of this invention showing the front trap guide in open position.
FIG. 3A is a side view of FIG. 3 with the front trap guide in closed position.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a simplified process for manufacturing multiple ends (2, 3, 4, and 5) of yarn spun simultaneously from a spinnerette 1 are separated through the fingers of a guide 6 to separate the yarn ends as they are fed to separate packages 7, 8, 10 and 11 being formed on a rotating arbor 12.
As shown in FIGS. 2 and 2A, the guide rods or fingers 13, 14, 15, 16, 17, 18 and 20 extend perpendicularly from mounting plate 6 to a distance sufficient to segregate ends of filaments projecting downwardly from the spinnerette assembly 1. An aspirator 27 may be mounted in the machine face 28 to temporarily collect surplus or waste yarn ends during startup or a break of one or more of the yarn filaments.
FIG. 2 illustrates a preferred orientation of the guide rods. In the orientation shown, an odd number of rods extend outwardly from the face of mounting plate 6. A first rod 16 is mounted in the lower quadrant of the face and substantially halfway across the face. Remaining finger rods 13, 14, 15, 17, 18 and 20 are mounted in groups of two, each group of two being mounted about a rod diameter above and outside the preceding group. For example, rods 15 and 17 form one group. These rods are mounted above and outside first rod 16. Rods 14 and 18 form a second group. Rods 14 and 18 are mounted above and outside rods 15 and 17, respectively. In this manner, the rods are positioned to form a separate vertical path for the groups of filaments therebetween.
In FIG. 3 and FIG. 3A, the guide face 6 and separate fingers 13-20 are shown as in FIGS. 2 and 2A. A back guide rod 21 is mounted to plate 6 and provides a stop for rearward movement of the yarn groups 2-5. Bracket 23 extends forward from face 6 parallel to the guide fingers.
A pivot support 25 is mounted to bracket 23 and front guide rod 22 is pivotally mounted to support 25 by dowel 26. Tab stop 24 provides a rest for front guide rod 22 as it rotates approximately 90° clockwise from its depicted upward location. In its rotated position (FIG. 3A), rod 22 prevents yarns 2-5 from moving forward off the guide fingers.
In operation, rod 22 is rotated to its upper position (FIG. 3) and each of the groups of textile yarn 2-5 are positioned between their respective fingers -i.e., group 2 is positioned between fingers 13 and 14, group 3 between fingers 14 and 15, etc. Rod 22 may be moved from an upper position away from the finger rods to a rotated position blocking the finger rods after each group is separately threaded in. The yarn groups so captured stay positioned within the finger rods and are not permitted to stray into adjacent yarn groups where they may become entangled. In this manner a single operator may conveniently and efficiently sequentially thread in a complete spinning position in short order and without need for future assistance. | A trap guide process for high speed spinning are described in which a pivotable guide rod is utilized across the face of a multiplicity of finger-like rods. The finger-like rods are used to separate the separate ends or groups of filaments in a multiple-end spinning operation. | 1 |
RELATED APPLICATIONS
Switzerland filed June 4, 1975.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to target sight recording apparatus, for use in conjunction with telescopically sighted rifles for example.
2. Description of the Prior Art
There are numerous occasions on which it is desirable to conduct a firing practice on moving targets in particular, without at the same time having to fire live rounds. Until now, however, there have been no suitably economic means and methods of checking or determining with adequate precision whether the firearm had been accurately aimed at the target at the instant of actuation of the trigger of the firearm, or of indicating where the projectile would have struck had the weapon been loaded with live ammunition.
An object of the invention, therefore, is to provide a relatively uncomplicated and inexpensive target sighting apparatus for providing a photographic record of the target aimed at via a telescopic sight during actuation of the trigger of the firearm.
SUMMARY OF THE INVENTION
According to the invention there is provided in a firearm having a trigger and a telescopic sight through which light from a target zone can pass along the optical axis of the sight through an eyepiece to reach the eye of an observer, target sight recording apparatus comprising an optical beam splitter element rigid with the telescopic sight for diverting a fraction of the light passing through the telescopic sight along a path extending at an angle to the optical axis, a photographic camera rigid with the telescopic sight and inclined at an angle to receive the deflected light, the camera having an objective lens system, a camera shutter, a cassette for housing photographic exposure material all aligned along the optical axis of the camera and a shutter releasing device coupled to actuate the camera shutter, and means coupling the shutter release device with the trigger of the firearm so that upon operating the trigger the camera shoots the picture which at that instant the observer can view through the telescopic sight.
BRIEF DESCRIPTION OF THE DRAWINGS
Target sighting apparatus embodying the invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings in which:
FIG. 1 is a fragmentary section of the target sighting apparatus taken along the line I--I in FIG. 3;
FIG. 2 is a rear elevation of the apparatus of FIG. 1;
FIG. 3 is a section of the apparatus of FIG. 1 taken along the line III--III;
FIG. 4 shows a fragmentary side elevation of a rifle for supporting the apparatus of FIG. 1 and incorporating a release device for the apparatus; and
FIG. 5 is a fragmentary plan view of the rifle and release device of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The target sighting apparatus shown in FIGS. 1 and 2 includes a telescopic sight 10 of conventional construction and which is to be secured to a rifle. The sight 10 has an output lens 11 at one end arranged to face the target and an eyepiece 12 at the other end. Upon looking through the eyepiece 12 of the telescopic sight 10, a sight graticule 13, 14 (FIG. 2) for marking the theoretical striking point of the bullet in the target plane, is superimposed on the image of the target plane.
The body 15 of the telescopic sight 10 adjacent to the eyepiece 12 carries a removably attached clamping sleeve 20 which can be tightened around the body 15 of the sight 10 by means of a clamping device 21. The clamping sleeve 20 carries a tube 22 which together with the clamping sleeve acts as a tubular rearward extension of the telescopic sight and has an eyepiece aperture 23. An optical beam splitter element in the form of a partially transparent mirror 24 is located within the clamping sleeve 20. The plane of the mirror lies at an angle of 45° with respect to the optical axis of the telescopic sight 10. The clamping sleeve 20 and the tube 22 have respectively aligned apertures 25 and 26 through which light rays deflected by the mirror 24 pass. The aligned apertures 25 and 26 are surrounded by a tubular housing 27 secured to the tube 22 in a lightproof and rigid manner. The tubular housing 27 carries a photographic camera 28 of special design and having an optical axis which extends at right angles to that of the telescopic sight 10 and at 45° with respect to the reflecting plane of the mirror 24. The camera 28 includes an extension tube 30 and an annular lens support 29 joined to the housing 27 in lightproof manner with the aid of a screw joint 31. The lens support 29 houses a photographic objective lens system 32 having an adjustable aperture diaphragm, the adjustment of which can be varied by means of a setting ring 33 rotatably supported on the lens support 29. A self-cocking camera shutter 34 co-ordinated with the objective lens system 32 is equipped with a remote operation connection fitting 35 so that the shutter can be triggered through a Bowden cable 36. The exposure period of the shutter 34 can be selected by means of a setting ring 37 which is also rotatably carried by the lens support 29. The shutter and exposure setting rings 33 and 37 are respectively provided with setting graduations 38 and 39 which can be aligned with respective datum marks 40 and 41 on the lens support 29.
The upper end of the tubular extension 30 carries a circular plate 42 which is secured on the extension 30 by means of screws 42a (FIG. 1). The diameter of the plate 42 is at least twice the external diameter of the extension 30, and the position of the plate with respect to the extension 30 is such that the centre of the plate 42 is situated outside the tubular extension 30, see FIG. 3. A pivot pin 43 is secured to the centre of the plate 42 and thus eccentrically with respect to the optical axis of the camera 28. The pivot pin 43 is arranged to rotatably support a cassette 44 loaded with photographic exposure material. The cassette 44 has a rectangular base 45 which is slidably supported on the plate 42, the plate 42 engaging in a circular recess 46 of the cassette base 45. The plate 42 has a circular opening 47 coincident with the optical axis of the camera. The cassette base 45 has a total of four circular gates 48, 49, 50 and 51 (FIGS. 1 and 3) each of which can in turn be brought into coincidence with the opening 47 in the plate 42 when the cassette 44 is turned about the pivot pin 43. Thus each time one of the gates 48 to 51 is brought into coincidence with the opening 47, it is open for exposure whereas the other gates are simultaneously closed off in lightproof manner by the plate 45.
A block 52 secured in the plate 45 has a bore which extends radially of the pivot pin 43. The bore houses a compression coil spring 53 and a ball 54. The spring 53 biases the ball 54 against the outer surface of the plate 42. The plate 42 has four equiangularly spaced notches 55 in its outer surface for selective engagement by the ball 54 which thus acts as part of a detent mechanism for ensuring each of the gates 48 to 51 is accurately located in the exposure position in turn. It will also be appreciated that one of the four lateral sides 56, 57, 58 and 59 of the cassette 44 is positioned at right angles with respect to the optical axis of the telescopic sight 10 when the ball 54 is engaged in one of the notches 55. Each gate 48, 49, 50 and 51 incorporates a thin and narrow transparent strip 60 bearing a marking 61 (FIG. 3), e.g. in the form of a number identifying the firearm used, which is recorded on the film during the photographic exposure. The transparent strip of each gate bears another marking so that the individual exposures can be identified later on. Appropriate markings 62 corresponding to the individual exposure numbers are formed on corresponding ones of the sides 56, 57, 58 and 59 of the cassette, care being taken to ensure that the marking of the gate situated in the exposure position corresponds in each case to that on the side of the cassette facing the marksman.
Apart from the specially designed cassette base 45, which has been described, the cassette 44 is a conventional cassette for instant photographic picture material. The cassette thus contains a pack 63 of exposure material sheets which can be exposed and subsequently withdrawn from the cassette through a slot 64 (FIG. 2), the development of the photographic exposure occurring automatically in known manner. The size of each sheet of exposure material carried by the cassette 44 is so dimensioned that there is room on one and the same sheet for four target plane pictures which are exposed consecutively through four gates 48, 49, 50 and 51. The image plane is marked 65 in FIG. 1. The sheet of exposure material ready for exposure is pushed into this image plane by means of a spring (not shown) housed in the cassette. A part 66 of the cassette 44, (see FIGS. 1 and 2) is hinged to allow the insertion of the pack 63 of exposure material. A clip 67 acts to lock the hinged part 66 in a closed position.
The rifle shown in FIGS. 4 and 5 includes a releasing device 71 connected to the Bowden cable 36 already referred to and secured on a part 70 of a rifle containing the lock. The releasing device includes a housing 72 supporting a lever 74 pivotably supported on a spindle 73. The spindle 73 is coupled to the rifle lock or action, so that upon operating the lock by actuating the trigger 75, the lever 74 pivots upwardly as viewed in FIG. 4. The spindle 73 is coupled to the pivot pin of a cock of the rifle lock by means of a claw or dog coupling. On the upper side of the housing 72, a tubular connection element 76 enables the Bowden cable 36 to be secured to the rifle in axially adjustable manner. A pin 77 is slidably supported by the connector 76. The upper end of the pin 77 is intended to co-operate with the core of the Bowden cable 36. The facing end of the pin 77 is connected to a slide member 78 which engages a peg-like projection 79 in a slot 80 of the lever 74, the slot 80 extending radially with respect to the spindle 73. The lever 74 and the pin 77 are coupled to each other by the slide member 78 and its projection 79, so that the pin is longitudinally displaced during the pivoting of the lever 74. Screws 81 and 82 act to secure the releasing device 71 on the part 70 of the rifle. The releasing member 71 can be removed from the rifle by freeing the screws 81 and 82.
In operation the telescopic sight 10 is secured on a rifle and the clamping sleeve 20 is clamped fast on the cylindrical terminal portion 15 of the telescopic sight 10 in the manner illustrated in FIGS. 1 and 2, so that the optical axis of the photographic camera 28 is vertically upwardly and the cassette 44 is located at the upper end of the camera. The releasing device 71 is secured to the part 70 of the rifle containing the lock or action, in the manner illustrated in FIGS. 4 and 5, and is connected to the connecting device 35 of the camera shutter 34 by the Bowden cable 36.
Photographic exposure material 63 for instant pictures is inserted into the cassette 44. The pivotal position of the cassette 44 is such initially that the lateral side 56 of the cassette having the slot 64 and marked with a numeral "1" is turned towards the marksman. The corresponding gate 48 is thus positioned in the exposure position above the opening 47 in the plate 42, and the transparent strip 60 of this gate is marked with the numeral "1". The action of the rifle is cocked, without the rifle being loaded with a live cartridge.
The marksman lines up the rifle with a selected target, while looking through the telescopic sight 10 via the eyepiece aperture 23, from the left in FIG. 1, and takes aim at the same target with the sight graticule 13,14. About half the light rays traversing the telescopic sight in the direction from the output lens 11 to the eye 12 are allowed to pass through by the mirror 14, so that the marksman can see the sight graticule 13, 14 and the image of the target plane, while the remaining light rays are deflected towards the objective lens system of the camera 28. If the trigger of the rifle is actuated and the rifle action is thereby released, the lever 74 of the releasing device 77 is pivoted upwardly as viewed in FIG. 4. The pin 77 is thus pushed upwardly and the core of the Bowden cable 36 is actuated. The camera shutter 34 is released by means of the Bowden cable 36 and an optical image of the target plane and of the sight graticule 13,14 is formed in the image plane 65 during the period of the exposure time set by means of the ring 37. This causes an exposure of the portion of the photographic material enclosed by the gate 48 in the exposure position. The sight graticule 13,14 and the image of the target plane visible in the telescopic sight 10 at the instant of actuation of the trigger 75, are thereby recorded photographically. The numeral "1" present on the transparent strip 60 for identifying the picture in question is also photographically recorded at the same time on a marginal portion of the picture.
The marksman thereupon turns the cassette 44 through an angle of 90° around the pivot pin 43 until the ball 54 is urged by the spring 53 in the next notch 55 in the plate 42. After re-cocking the rifle lock or action, the above described cycle is repeated to produce the photographic picture of a target image plane but this time within an area on the photographic sheet defined by the gate 49. After rotation of the cassette 44 through another 90°, a third target plane image can be recorded photographically on an area of the photographic sheet defined by the gate 50. Finally after yet further rotation of the cassette 44 through another 90°, a fourth target image plane can be produced photographically on an area of the photographic sheet defined by the gate 51. The exposure material in question is then pulled out of the cassette 44 through the slot 64, the developing of the photographically exposed material taking place automatically. The four different target plane pictures, each of which bears a unique marking on a marginal portion, namely one of the numerals "1", "2", "3" and "4", are visible after developing, on one and the same sheet.
Before the start of the next series of four shots, the cassette 44 is turned through another 90°, until it reaches its initial position again, which is illustrated in FIGS. 1 to 3.
After freeing the Bowden cable 36, the clamping sleeve 20 can be removed from the telescopic sight together with the components connected to it, and the rifle can then be used for shooting with live ammunition in the usual manner. If desirable, the release device 71 can also be removed from the part 70 of the rifle containing the rifle lock or action, but this is unnecessary in many cases.
The device described offers a series of advantages, namely a relatively uncomplicated and robust structure, relatively low procurement costs, simple operation without disturbing the otherwise customary handling of the firearm, the possibility of rapid and precise checking of the target subject aimed at and "hit" in each case upon actuation of the trigger, a relatively low operating cost (expenditure on photographic exposure material) since several target plane pictures may be produced on the same sheet in each instance.
In a modification instead of the Bowden cable 36, another effective coupling, for example an electrical, a pneumatic or a hydraulic coupling, can be used between the release device 71 and the camera shutter 34. Instead the release of the camera shutter 34 can be effected by means of ultrasonic or radio waves. Instead of being arranged to house instant picture photographic material, the cassette 44 can be adapted to take a negative film pack or a rollfilm strip. Instead of a manually rotatable cassette, a cassette for rollfilm and for motorised film advance after each exposure, can be used. A kinematographic moving picture camera may be incorporated if appropriate, instead of a single or series exposure camera. It is also possible for the camera or its cassette to be constructed so as to be interchangeable. If, as shown, the cassette 44 is rotatably arranged and has several gates 48 to 51, the number of gates can be made greater of smaller than four, but of course the number of notches 55 in the plate 42 will need to be increased or decreased accordingly. Finally, it is possible to integrate the optical beam splitter element 24 into the optical system of the telescopic sight 10 rather than to house it in an extension to the telescopic sight. | A rifle having a telescopic sight has apparatus for recording the target as seen through the telescopic sight at the instant the trigger is pulled. The apparatus includes a beam splitter for directing to a camera some of the light passing through the telescopic sight. The shutter mechanism of the camera is coupled to the rifle trigger so that the camera will "shoot" the picture of the target when the trigger is pulled. The camera is of the instant-copy type so that pictures of the target can be viewed shortly after "shooting". The apparatus thus enables the ability of a rifleman to be tested without the need for firing live ammunition. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. provisional application Ser. No. 61/231,266 filed Aug. 4, 2009 and to U.S. 61/361,843 filed Jul. 6, 2010.
FIELD OF THE INVENTION
The invention has to do with provision of powered linear motion to equipment by a motor. It is known in the art to provide reciprocating linear motion powered remotely to tools such as a pump in a well. Typically, such pumps may have spring-returns, a variety of one-way valves, solenoids if powered by electricity, and generally speaking are provided at one end of an assembly comprising the motor, its reciprocation-controlling componentry, and a pump, assembled in a sequence.
Typical motors of this type have a driven shaft which operates under compression, requiring large amounts of materials to defeat buckling forces.
As well, the larger drive shaft results in greater mass, the direction of motion of which involves defeating greater inertia, and larger collision forces. Some motors have complex latch-releases or are powered in one direction opposing a spring which powers them in another direction. Still others have stall positions within the travel of their components, resulting in the potential of accidental stalls from which the motors cannot recover without being physically retrieved and serviced or pushed somehow past the stall point of travel in the reciprocating movement's path. Others suffer from blow-by and have difficulties maintaining seals to isolate working parts from harsh environments and contaminants. Most have larger numbers of moving parts, with excessive susceptibility to wear. Some require the power source to switch, others require carefully controlled pressures and volumes of motive power fluids.
A need is recognized to provide short length, small diameter linear motors driven by pressurized fluid in one-directional unswitched flow, with few moving parts, provided with useful seals and isolating small tolerance piston/cylinder arrangements from the motor's working environment.
SUMMARY OF THE INVENTION
The present invention relates to valve assemblies that can convert one directional flow of fluid power medium into mechanical reciprocating action.
This invention provides in one embodiment a motor for providing powered reciprocating linear drive motion using a pressurized power fluid flow, the motor comprising: a housing having a first end and a second end; a first chamber provided in the housing proximate the first end of the housing, the first chamber having a first piston and operative to provide motive linear power during a power stroke of the first piston; a second compression chamber provided in the housing proximate the second end of the body, the second compression chamber having a second piston and operative to provide motive linear power during a power stroke of the second piston, the second piston connected to the first piston such that a power stroke of the first piston causes an exhaust stroke of the second piston and a power stroke of the second piston causes an exhaust stroke of the first piston; the first chamber in fluid communication with the power fluid flow during a power stroke of the first piston and in fluid communication with a first exhaust port during an exhaust stroke of the first piston; and a second chamber in fluid communication with the power fluid flow during a power stroke of the second piston and in fluid communication with a second exhaust port during an exhaust stroke of the second piston; the motor in one embodiment further comprising a reversing sleeve provided between the first piston and the second piston, the reversing sleeve having a first end partially defining the first chamber and a second end partially defining the second chamber, wherein the reversing sleeve is operative to expose the first chamber to the first exhaust port during an exhaust stroke of the first piston and to block the first exhaust port during a power stroke of the first piston, and wherein the reversing sleeve is operative to expose the second chamber to the second exhaust port during an exhaust stroke of the second piston and block the second exhaust port during a power stroke of the second piston; wherein the reversing sleeve has a first reversing sleeve exhaust port, in fluid communicating with the first chamber, that substantially aligns with the first exhaust port during an exhaust stroke of the first piston and a second reversing sleeve exhaust port, in fluid communication with the second chamber, that substantially aligns with the second exhaust port during an exhaust stroke of the second piston; the sleeve further comprising a first inlet port in fluid communication with the power fluid flow and a second inlet port in fluid communication with the power fluid flow, wherein the first chamber is in fluid communication with the first inlet port during a power stroke of the first piston and the second chamber is in fluid communication with the second inlet port during a power stroke of the second piston, and where the reversing sleeve blocks the first chamber from the first inlet port during an exhaust stroke of the first piston and the reversing sleeve blocks the second chamber from the second inlet port during an exhaust stroke of the second piston, the motor in an embodiment further comprising: a reversing spool provided within the reversing sleeve and having a first end and a second end, the reversing sleeve and the reversing spool partially defining the first chamber and the second chamber; wherein when the first piston in its motion is proximate an end of a power stroke, the second piston contacts the second end of the reversing spool, forcing the reversing spool towards the first piston, and moving the reversing sleeve towards the first piston causing the reversing sleeve to place the second chamber in fluid communication with the power fluid flow and venting the first chamber to exhaust, and wherein when the second piston in its motion is proximate an end of its power stroke, the first piston contacts the first end of the reversing spool, forcing the reversing spool towards the second piston and causing the reversing sleeve to place the first chamber in fluid communication with the power fluid flow and venting the second chamber to exhaust, where the reversing spool includes a position piston to hold the reversing spool in position and a balancing pressure piston to counteract pressure forces on the reversing spool, wherein the first piston, the first chamber, a connecting rod connected between the first piston and the second piston, the second piston and the second compression chamber are all aligned in a single line and the housing and the outer housing are cylindrical, wherein the first chamber and second chamber are in fluid isolation from each other, and where in one embodiment the motor is configured for seal-less operation; yet in another embodiment the motor further comprises a first sealing ring 34 A encircling the first piston and separating the motor's environment from the first chamber and a second sealing ring 34 B encircling the second piston and separating the motor's environment from the second chamber.
The invention further comprises a method of providing reciprocating linear motion powered by one directional fluid flow, the method comprising: providing a motor having a first piston defining a first chamber, a second piston defining a second chamber, the first piston and the second piston connected with a connecting rod so that the first piston and the second piston move in unison one pulling the other, the first chamber and the second chamber positioned between the first piston and the second piston; supplying power fluid under pressure to the first chamber to drive the first piston through a power stroke and the second piston through an exhaust stroke; when the first piston reaches an end of its power stroke, supplying power fluid to the second chamber to drive the second piston through a power stroke of its own; and when the second piston has reached the end of its power stroke, again supplying power fluid to the first chamber; in one embodiment the motor energizes equipment placed down a well casing to operate or condition the well; in another, the motor is inserted in a well casing with a tubing string supplying power fluid to the motor; in another where used power fluid is exhausted from the motor into a first annulus between the tubing string and well casing; in another embodiment, a second tubing string is provided inside the tubing string and power fluid is supplied to the motor through the second tubing string, and used power fluid is exhausted to a second annulus formed between the tubing string and the second tubing string.
A further embodiment of the invention further provides a motor with a hydraulic/pneumatic valve for converting one directional flow of power medium (fluid being a liquid or gas) into mechanical reciprocating motion, the motor comprising: a first piston, acting at the same time as an attaching platform to a mechanism to be powered by the motor, defining a first compression chamber and a second piston, acting at the same time as an attaching platform to the mechanism to be powered by the motor, defining a second compression chamber, the pistons connected together with a connecting rod so that the first piston and the second piston are forced to move in conjunction; their movement being coordinated by tension on the rod; around the connecting rod, a valve comprising a reversing spool provided within a reversing sleeve and having a first end and a second end, the reversing sleeve and the reversing spool partially defining the first compression chamber and the second compression chamber; the reversing sleeve having a first end partially defining the first compression chamber and a second end partially defining the second compression chamber, operating to open the first compression chamber to the power fluid and open the second compression chamber to an exhaust vent during the first piston power stroke, and to open the second compression chamber to the power fluid and open the first compression chamber to the exhaust vent during the second piston power stroke; when the first piston is proximate an end of its power stroke, the second piston contacts the second end of the reversing spool, forcing the reversing spool towards the first piston, and moving the reversing sleeve towards the first piston causing the reversing spool to place the second valve chamber in fluid communication with the at least one power fluid supply and venting the first chamber to exhaust and forcing the reversing sleeve towards the first piston; and when the second piston is proximate an end of its power stroke, the first piston contacts the first end of the reversing spool, forcing the reversing spool towards the second piston and causing the reversing spool to place the first compression chamber in fluid communication with the at least one power fluid supply and venting the second compression chamber to exhaust and forcing the reversing sleeve towards the second piston; where the valve's reversing spool also includes a position piston to hold the reversing spool in position and a balancing pressure piston to counteract pressure forces on the reversing spool, wherein the first piston, the first compression chamber, the connecting rod connected between the first piston and the second piston, the second compression chamber and the second piston are all aligned in a line.
In yet a further embodiment, the invention provides a method of inducing a reciprocating movement to a motor's connecting rod, the method comprising: providing a valve having a first piston defining a first compression chamber, a second piston defining a second compression chamber, the first and the second piston connected with a connecting rod so that the first piston and the second piston move in unison, the first chamber and the second chamber positioned between the first and the second piston; supplying power fluid to the first chamber to drive the first piston through a power stroke and the second piston through an exhaust stroke; when the first piston reaches an end of the power stroke, supplying power fluid to the second chamber to drive the second piston through a subsequent power stroke; and when the second piston has reached the end of the subsequent discharge stroke, supplying power fluid to the first chamber.
In another embodiment, a reciprocating linear motor powered by one directional fluid flow is provided, having small external diameter, optimized for shortened overall length, with few moving parts and effective seals, low mass and thus low inertia in direction changes. The motor provides reciprocating linear powered motion for use by attached equipment such as a pump, chisel, hammer, valve, remote actuator, or other machine requiring such power.
It is to be understood that other aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description. As will be realized, the invention is capable for other and different embodiments and its several details are capable of modification in various other aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings, wherein like reference numerals indicate similar parts throughout, the several views are illustrated by way of example, and not by way of limitation.
FIG. 1 is a schematic illustration of an embodiment of a valve assembly;
FIG. 2 is a schematic illustration of the valve assembly of FIG. 1 , during a power stroke by a top piston;
FIG. 3 is a schematic illustration of the valve assembly of FIG. 1 , during a changing of direction of motion by the top piston;
FIG. 4 is a schematic illustration of the valve assembly of FIG. 1 , during a reversal of motion;
FIG. 5 is a schematic illustration of the valve assembly of FIG. 1 , during a discharge stroke by the top piston.
FIG. 6 is a schematic drawing of a valve assembly showing certain seals.
FIG. 7 is a schematic drawing of the valve assembly of FIG. 6 during a power stroke of a top piston, showing certain seals.
FIG. 8 is a schematic drawing of the valve assembly of FIG. 6 during a changing of motion by the top piston, showing certain seals.
FIG. 9 is a schematic drawing of the valve assembly of FIG. 6 during a reversal of motion, showing certain seals.
FIG. 10 is a schematic drawing of the valve assembly of FIG. 6 during a discharge stroke of the top piston, showing certain seals.
DETAILED DESCRIPTION
This invention herein provides a motor comprised of a valve assembly that can convert one directional flow of a power medium into powered reciprocating motion of power rods. The reciprocating movement of these rods can be in turn applied in a mechanism that requires such powered reciprocating motion, e.g. pumps, hammers, chisels, compactors, jacks, remotely controlled valves, actuators, remote hydraulic/pneumatic servo mechanisms and the like.
The invention contemplates in one embodiment a form of reciprocating control valve which at the limits of its stroke causes the reversal of fluid flow under pressure to a piston assembly. The invention is also concerned with the aspects of automatic and positive control and in accordance with or in response to the valve piston assembly travel, the retention of the valve in either its two operative or pressure fluid transmitting positions by providing an arrangement for valve blocking, in the nature of exposing auxiliary pistons to the system pressure by which to positively position the valve in one or the other functional position with no dead, stalled, or equilibrium position.
FIGS. 1-5 are schematic illustrations of a valve assembly in a first aspect. Pistons 7 A and 7 B with power rods 6 A and 6 B the body of which extends through the center of the motor as attaching the two pistons 7 A and 7 B in tension and not necessarily in compression, the reciprocating movement of the rods 6 A and 6 B can be attached to and utilized by a mechanism that requires such reciprocating motion, e.g. pumps, hammers, chisels, compactors, jacks, remotely controlled valves, actuators, remote hydraulic/pneumatic servo mechanisms and the like.
Valve assembly 1 can have a first end 2 , a second end 3 , an outer housing 4 , and an inner housing 5 provided within the outer housing 4 . The inner housing 5 can contain a first compression chamber 15 A and a second compression chamber 15 B, wherein the first compression chamber 15 A may be positioned adjacent the first piston 7 A, and the second compression chamber 15 B maybe positioned adjacent the second piston 7 B. The first piston 7 A and the second piston 7 B maybe connected together with a connecting rod 28 so that the first piston 7 A and second piston 7 B can be forced to move in conjunction by the connecting rod 28 . The first piston 7 A and the second piston 7 B may be provided with extrusions i.e. power rods 6 A and 6 B, respectively. The reciprocating movement of the power rods 6 A and 6 B, depending on the application, can be used to power various mechanisms or tools.
In FIGS. 1-5 , the outer housing 4 is shown with a power fluid supply conduit 9 that may run between the outer housing 4 and the inner housing 5 and supply power fluid to drive the assembly 1 . A fluid discharge conduit 11 may be provided within the outer housing 4 , but outside the inner housing 5 , a power fluid may be exhausted directly to the motor's surroundings by bents 27 A, 27 B.
Power fluid can be directed in an alternating way into the first compression chamber 15 A and the second compression chamber 15 B to drive the connecting rod of assembly 1 . To drive the first piston 7 A through a power stroke, power fluid may be directed into the first compression chamber 15 A and to drive the second piston 7 B through a power stroke, power fluid may be directed into the second chamber 15 B.
In a preferred embodiment, the connector between pistons operates moving in a linear manner concentrically through the motor's control valve system, comprised of a reversing spool 16 concentrically inside a reversing sleeve 22 , within the motor's body which also comprises an inner housing 5 and an outer housing 4 .
The annulus between inner 5 and outer 4 housings may provide fluid conduits for supply and, optionally exhaust of a power fluid flow under pressure during operation of the motor. The annulus between the inner housing 5 and the reversing sleeve 22 provides a positioning 17 and a balancing 18 piston and corresponding cylinder arrangements, with conduits 20 , 21 through the sleeve 22 to provide power fluid to those pistons, the respective conduits 20 , 21 being opened or closed, respectively, by positioning of the sleeve 22 , to provide pressurized power fluid to one side or the other of piston 18 to exert a force toward one end or the other 2 , 3 of the assembly 1 .
Several advantages of this arrangement become apparent: the direction control over fluid flow takes place between the two cylinders decreasing the length of the assembly 1 from end-to-end ( 2 to 3 ); there is no catchment, spring, mechanical détente or similar biasing means to prevent the motor from reaching a stall or equilibrium position, also reducing the parts count and complexity, as well as wear points and mass of parts in motion and thus reducing inertial changes required in each reciprocation's direction change; improving maintainability, serviceability and useful life-cycle. Further, the two main pistons 7 A and 7 B are joined by a connector which operates in tension during both power strokes, and need not be built to withstand compressive forces of the pistons' motion, thus reducing mass, inertia change, collision forces in operation and stress on material, improving motor efficiencies and life-span.
Note that the only physical contact required is between the pistons 7 A or 7 B and the reversing spool 16 . The reversing sleeve 22 is moved not by the physical contact but by the hydraulic force produced by redirecting of the hydraulic pressure through the respective movement of the reversing spool 22 . Therefore the entire process is relatively shock free since the hydraulic medium will cushion the impact. Shock forces of collision between powered pistons 7 A or 7 B with the sleeve and spool of the assembly 1 at the end of a power stroke may be absorbed by fluid reservoirs within the power fluid deployed in the balancing or position pistons' chambers eliminating dead-stop collisions and reducing shock stress changes to materials.
With only 3 moving parts (pistons 7 A, 7 B and connector; reversing sleeve 22 ; and reversing spool 16 ) assembly, disassembly, and maintenance of the motor is simplified.
A reversing spool 16 may have a position piston 17 and a balancing pressure piston 18 . The balancing pressure piston 18 can equalize forces acting on the reversing spool during the operation of the assembly 1 , exerting a force on the reversing spool 16 acting in an opposite direction to the force exerted by power fluid on either the first end 19 A or the second end 19 B of the reversing spool 16 . A first balancing pressure piston passage 20 and a second balancing pressure piston passage 21 may be provided in the reversing sleeve 22 . Based on the position of the reversing sleeve 22 , either the first balancing pressure piston passage 20 or the second balancing pressure piston passage 21 may be placed in fluid communication with power fluid supply conduit 9 to supply power fluid to one of the sides of the balancing pressure piston 18 . If the reversing sleeve 22 is positioned so that the first balancing pressure piston passage 20 is provided in fluid communication with the power fluid supply conduit 9 , the power fluid passing through the first balancing pressure piston passage 20 to the balancing pressure piston 18 exerts a force on the balancing pressure piston 18 towards the second end 3 of the assembly 1 . If the reversing sleeve 22 is positioned so that the second balancing pressure piston passage 21 is provided in fluid communication with the power fluid supply conduit 9 , the power fluid passing through the second balancing pressure piston passage 21 to the pressure balancing piston 18 exerts a force on the balancing pressure piston 18 towards the first end 2 of the assembly 1 .
Power fluid in either the first compression chamber 15 A or the second compression chamber 15 B can apply a force to first end 19 A of the reversing spool 16 or the second end 19 B of the reversing spool 16 , respectively. The balancing pressure piston 18 can exert a force on the reversing spool 16 in an opposite direction from the force exerted by the power fluid in either the first compression chamber 15 A or the second compression chamber 15 B. By adjusting the surface area of the first end 19 A and the second end 19 B of the reversing spool 16 with the surface area of the balancing pressure piston 18 , the forces placed on the reversing spool 16 can be substantially balanced, with the pressure balancing piston 18 substantially counteracting the forces placed on the reversing sleeve 16 by the power fluid in either the first compression chamber 15 A or the second chamber 15 B.
With the force exerted on either the first end 19 A of the second end 19 B of the reversing spool 16 substantially counteracted by the balancing pressure piston 18 , the reversing spool 16 may be held in place by the position piston 17 . Power fluid from the power fluid supply conduit 9 maybe routed to either side of position piston 17 to hold the reversing spool 16 in place. A first fluid supply passage 23 A maybe provided in the inner housing 5 in fluid communication with the power fluid supply conduit 9 . A second fluid supply passage 23 B maybe provided in the reversing sleeve 22 that may align with the first fluid supply passage 23 A. A first slot 24 A and a second slot 24 B maybe provided on the position piston 17 which can route power fluid from the fluid supply 9 and the fluid supply 23 B to either side of the position piston 17 , depending on the position of the reversing spool 16 . By altering the surface area of the position piston 17 , the amount of force required to shift the reversing spool 16 can be adjusted.
In this manner, the pressure balancing piston 18 can counteract the forces on the reversing spool 16 from the first compression chamber 15 A and the second compression chamber 15 B, wherein the position piston 17 can hold the reversing spool 16 in position and the motor by tailoring how much force is required to shift the reversing spool 16 .
A reversing sleeve piston 25 may be provided to shift the reversing sleeve 22 .
Referring to FIG. 1 , the assembly 1 is shown during a power stroke of the first piston 7 A and a discharge stroke of the second piston 7 B. The reversing sleeve 22 maybe initially positioned towards the second end 3 of the assembly 1 , exposing the power fluid inlet port 26 A to the first compression chamber 15 A, placing the first compression chamber 15 A in fluid communication with the power fluid supply conduit 9 , while blocking the exhaust port 27 A. At the same time, the reversing sleeve 22 can expose the second exhaust port 27 B to the second compression chamber 15 B while blocking the power fluid inlet port 26 B from the second compression chamber 15 B. With power fluid entering the first compression chamber 15 A adjacent the first piston 7 A and fluid being vented from the second chamber 15 B adjacent the second piston 7 B, the first piston 7 A may be driven through a power stroke while the second piston 7 B may be pulled along by the connecting rod 28 .
During the power stroke of the first piston 7 A, the power fluid may exert a force on the first piston 7 A as well as a first side 19 A of the reversing spool 16 and a first side 29 A of the reversing sleeve 22 . The force exerted on the first side 19 A of the reversing spool 16 by the power fluid in the first compression chamber 15 A maybe substantially counteracted by the force exerted on the reversing spool 16 by the pressure balancing piston 18 with the position piston 17 exerting a force on the reversing spool 16 towards the second end 3 of the assembly 1 and pressing the reversing spool 16 against the reversing sleeve 22 . The reversing sleeve 22 maybe pressed against a bumper 30 in the inner housing 5 .
When the first piston 7 A reaches the top of a power stroke, the reversing sleeve 22 and the reversing spool 16 may act in conjunction to reverse the direction of motion of the first piston 7 A and the second piston 7 B.
Referring to FIG. 2 , as the first piston 7 A reaches an end of the power stroke, a bottom of the second piston 7 B may come into contact with the second end 19 B of the reversing spool 16 . Because of the balancing of the forces on the reversing spool by the balancing pressure piston 18 , the second piston 7 B may only have to exert a force on the reversing spool 16 to overcome the force exerted on the reversing spool 16 towards the second piston 7 B by the position piston 17 . With the first piston 7 A overcoming the force placed on the reversing spool 16 by the position piston 17 , the reversing spool 16 maybe shifted by the second piston 7 B towards the first end 2 of the assembly 1 .
Referring to FIG. 3 , with the reversing spool 16 shifted towards the first end 2 of the assembly 1 , power fluid maybe directed to the other side of the position piston 17 which can cause the force exerted on the reversing spool 16 by the position piston 17 to act in the direction of the force exerted on the reversing spool 16 by the second piston 7 B. The shifting of the reversing spool 16 may move the first slot 32 A away from the reversing sleeve piston passage 31 and place the second slot 32 B in fluid communication with the reversing sleeve piston passage 31 which can route power fluid from the power fluid supply conduit 9 to the other side of the reversing sleeve piston 25 . The force exerted on the other side of the reversing sleeve piston 25 can drive the reversing sleeve 22 towards the first end 2 of the assembly 1 , shifting the reversing sleeve 22 , as shown in FIG. 4 .
Referring to FIG. 5 , when the reversing sleeve 22 has been shifted towards the first end 2 of the assembly 1 until the reversing sleeve 22 has been stopped by the bumper 30 A, the reversing sleeve 22 can expose the second power fluid inlet port 26 B, which allows power fluid to enter the second compression chamber 15 B, while at the same time can align the first housing exhaust port 27 A with the exhaust port 33 A which can allow fluid in the first compression chamber 15 A to be vented. With power fluid entering the second compression chamber 15 B and the first compression chamber 15 A being vented, the second piston 7 B maybe driven by the power fluid in the second compression chamber 15 B through a power stroke, while the first piston 7 A maybe pulled through a discharge stroke by the connection rod 28 .
When the second piston 7 B reaches a bottom of the power stroke, the reversing sleeve 22 and the reversing spool 16 may act in conjunction to change the direction of motion of the first piston 7 A and the piston 7 B.
It will be obvious that the stroke length can be altered to suit the characteristics required by the equipment the motor is to power. Similarly, a number of motors could be arranged in gangs to provide power in small diameter settings. While particularly well suited to be deployed downhole in a well to power a reciprocating pump with a pump chamber at either or both ends of the motor, it is apparent that the motor may be used in other settings to power other equipment. Power fluids can be any one or more of a variety of suitable fluids, including for example liquids or gases of suitable compressibility to transfer fluid flow at pressures and volumes sufficient to power the motor in operation remotely from the pressurized fluid's source.
Additionally, the invention provides that the working chambers of the pistons and cylinders of the motor may always be kept at higher pressures than the motor's environment, thus isolating the motor's moving parts within an environment provided by the power fluid, which can be significantly cleaner and qualitatively controlled than the motor's external environment. Seals, if any, between the moving components of the motor, are similarly operative in a controlled environment, with higher pressure on the same side of each seal between the motor and its environment (the motor's side) during all strokes, with any leakage essentially flushing the seals' path of motion. It is to be noted that alterations to the diameter of the connecting rod, the exposed surface areas of the sleeve and spool, and the hydraulically active surface areas of the various position and balancing pistons and chambers, the volumes of the various active chambers and relative surface areas of the pistons in the motor will permit the alteration of motor operating parameters such as stroke, power, reciprocation speed, stall and the like, and to power fluid pressure and volumes required for specific motor outputs.
Similarly, unbalanced situations may be desired, and variance of conduit size or duration of conductivity during a stroke might provide more or less power or speed to one stroke versus the stroke in the opposite direction. As well, more than one power piston might be deployed on one or both sides of the valve arrangement.
The detailed description of the valve assembly is provided to enable any person skilled in the art to make or use the present invention. Various modifications to this invention will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiment shown herein, but is to be accorded the full scope consistent with the claims, wherein reference to an element in the singular, such as by use of the article “a” or “an” is not intended to mean “one and only one” unless specifically so stated, but rather “one or more”. All structural and functional equivalents to the elements of the embodiment described throughout the disclosure that are known or later come to be known to those ordinary skill in the art are intended to be encompassed by the elements of the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. | A reciprocating linear motor powered by one directional fluid flow is provided, having small external diameter, optimized for length, with few moving parts and effective seals, low mass and thus low inertia in direction changes. The motor provides reciprocating linear powered motion for use by attached equipment such as a pump, chisel, hammer, valve, or other machine requiring such power. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for generating power from the continuous rise and fall of tides. More particularly, the invention involves the generation of power from the flow of water in an airtight duct between two reservoirs as the water in these reservoirs seeks a level of equilibrium.
2. Description of the Prior Art
Devices for utilizing the rise and fall of the tides or utilizing wave action as a means of producing energy are well-known in the prior art. For example, devices have been designed such that wave action or the rise and fall of the tides will actuate rotating or reciprocating devices and thereby impart motion to mechanical systems to perform such functions as lifting water for irrigation. Such devices commonly involve the compression of air within storage tanks or pipes for subsequent use in the production of power. Tidal motion and wave action have also frequently been used to drive electrical generators. For example, reference is made to the April 1978 "Energy From the Ocean" Report of the Subcommitte on Advanced Energy Technologies and Energy Conservation Research, Development and Demonstration of the Committee on Science and Technology for the U.S. House of Representatives which describes potential schemes as well as actual tidal power plants at Rance, France and Kislaya Guba in the Soviet Union.
U.S. Pat. No. 4,039,847 discloses an apparatus designed to harness the energy of tidal currents. Basically, this system involves the placement of movable overflow type turbines in a position where they can be driven by both the incoming flood tides and the outgoing ebb tides.
Other inventions, such as disclosed in U.S. Pat. Nos. 3,925,986 and 4,103,490, involve the use of tidal chambers wherein the rise and fall of ocean tides is utilized to create either positive air pressure or partial vacuums within said chambers. These forces are then used to operate other power mechanisms.
A problem with all these inventions is the intermittent characteristic of the wave or tidal motion being utilized. The inherently inconsistent action of these natural forces creates a problem in making the harnessed power available as a relatively steady source. The circumstance has been addressed in several ways. For example, in U.S. Pat. No. 4,098,081, the invention discloses the use of a plurality of tidal chambers which are filled in succession during the rising tide and then sequentially emptied during the falling tide, with power being generated as a result of the use of the air pressure and partial vacuums created within the tidal chambers.
In U.S. Pat. No. 3,391,903, an apparatus utilizing the siphon principle to urge water in a single direction from a reservoir of a higher level to a reservoir of a lower level is described. As long as the level of water in the first reservoir remains higher than the level in the second reservoir, the flow of water will be continuous, resulting in the availability of a constant flow for driving a turbine. However, in this device the continous flow of water is dependent upon the constant replenishing of water in the first reservoir by the action of waves splashing over its sides. Necessarily, the continuous generation of power from this device is dependent upon sufficient wave action, a condition which is not consistent or controllable.
SUMMARY OF THE INVENTION
A feature of the present invention is the capability of generating energy from the rise and fall of the tides.
Another feature of the present invention is that relatively simple apparatus involving only a few moving parts is necessary and that this apparatus is of simple construction.
Yet another feature of the present invention is that the apparatus will provide a substantially continuous flow of water, and therefore a source of substantially more continuous energy production.
The apparatus of this invention involves the use of the siphon principle to urge the flow of water between a natural reservoir such as the ocean, which is subject to level variations due to tidal flow and a second man-made reservoir or a natural reservoir appropriately modified for utilization with this invention. The two reservoirs are connected by an airtight duct, filled with water, and through which water will be drawn because of the siphon principle as the water levels in the two reservoirs seek a state of equilibrium. Affixed within the duct is an energy converter such as a turbine or a Water Low Velocity Energy Converter (WLVEC) which are driven by the flow of water from one reservoir to the other. Final conversion of the energy is accomplished through a generator which communicates with the energy converter but is situated outside the duct system.
The second or man-made reservoir is constructed to have a depth which exceeds the level of the lowest tide and a height which exceeds the level of the highest tide of the first natural reservoir. The duct openings are situated at levels in each reservoir which are constantly submerged, assuring that once the duct system is charged with water, the siphon effect will cause water to flow from one reservoir to the other as the tide level changes. As the tide comes in, the level of the first reservoir rises and exceeds the level of the second reservoir. Water is caused to flow from the first reservoir to the second reservoir as those two bodies of water seek a level of equilibrium. Conversely, when the tide moves out, the level of water in the first reservoir drops below that of the second reservoir thereby causing the water flow to reverse in the duct system and move back to the first reservoir.
A single turbine, capable of being driven by water flow from either direction, may be used. Further, additional velocity for the water flow entering the turbine may be achieved by constricting the inside diameter of the duct in the immediate areas fore and aft of the turbine.
In another aspect of the invention, two turbines may be utilized in the duct system such that one turbine receives the water flow as the tide moves in and the other as the tide moves out. A bypass channel, with appropriate valving in the vicinity of the turbines, would permit the water to flow through the active turbine, but bypass the inactive turbine and thereby decrease the system resistance to the water flow. A Water Low Velocity Energy Converter (WLVEC) or other conversion mechanism might be substituted for the turbines.
Examples of the more important features of this invention have thus been summarized rather broadly in order that the detailed description that follows may be better understood, and in order that the contribution to the art may be better appreciated.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional features and advantages of the present invention will become apparent with reference to the following detailed description of a preferred embodiment thereof in connection with the accompanying drawings wherein like reference numerals have been applied to like elements, in which:
FIG. 1 is a plan view of an embodiment of the present invention during a phase of rising tide; and
FIG. 2 is a plan view of an embodiment of the present invention during a phase of ebbing tide.
DETAILED DESCRIPTION OF THE INVENTION
Turning first to FIG. 1 there is shown an airtight duct system 10 constructed to connect a natural reservoir 12, which is subject to a change in sea level due to tidal action, and a second reservoir 14. The support structure necessary to sustain the duct system is not shown. Various means of supporting a system such as this are possible and will be apparent to those of ordinary skill in this field. The duct system has openings 16 communicating with the natural reservoir and openings 18 communicating with the second reservoir. The duct system must be constructed such that duct openings 16 and 18 are always submerged, which requires that these openings be at a level which is at least lower than the level of the lowest tide for that geographic region.
The second reservoir 14 should be constructed with a depth which is below the level of the lowest tide for the particular area in which the reservoir is constructed or situated. The total depth of the second reservoir normally need only be enough to accommodate the continuous submergence of the duct openings 18 and the differential in height between the lowest tide and highest tide for that region. However, the duct openings 18 for the second reservoir may be arranged in a well within that reservoir such that the depth for the entire second reservoir would not have to fall below the sea-level of the lowest tide of the natural reservoir.
Once the duct system 10 is properly situated such that duct openings 16 and 18 are positioned at appropriate levels, the duct system must be charged with water. Charging involves the filling of the duct system with water such that all air is expelled therefrom. Charging may be accomplished by any known means such as use of a pump to force water through the duct. A drain and recharge valve 54 may be provided in the duct system for purposes of charging. Once charged, the airtight duct system will remain water filled as long as the duct openings always remain under water. A closed system then exists, and the siphon principle will cause water to flow from one reservoir to the other whenever the water level in one exceeds the level in the other. The continuous changing of the water level of the natural reservoir due to the movement of the tides will cause water to flow through the duct system as the water level in the second reservoir seeks a condition of equilibrium with the natural reservoir. The overall size, structure and support for the duct system will be determined by assessing the amount of energy it is desired to produce in conjunction with the economics involved for the construction.
A turbine 20 is situated in the duct system in a position to receive and be driven by the flow of water between the reservoirs. The generator for final conversion of the flow energy to electrical energy is not shown but would exist outside the duct system and cooperate with the turbine by means well-known to those skilled in the art. Turbine 20 may be constructed so as to be driven by the flow of water from either direction through the duct system. Alternatively, two single direction turbines could be utilized, one to be driven by the incoming flow and the other by the outgoing flow.
The velocity of the water flow through the duct system will be directly related to the size of the "head", which is the difference in height between the levels of the two reservoirs. At various times throughout the daily cycle, the two reservoirs will quickly pass an approximate state of equilibrium. As equilibrium is approached, the flow of water through the duct system will decrease in velocity and will theoretically come to a standstill at the moment of equilibrium. The direction of the flow of water will then reverse and gradually increase in velocity as the sea level of the natural reservoir changes with respect to the second reservoir. Brief lull periods will exist in the ability of the system to generate energy during this time when the direction of flow of the water is changing. In order to extend the time when there will be a sufficient velocity of the water to drive the turbines, the duct system is provided with duct constrictions 22 and 24. By increasing the velocity of the water flow in the area of the duct system adjacent to the turbine, the brief period during which the velocity of the water would otherwise be insufficient to drive the turbine is further decreased. A shut off valve 56 may be installed in the duct system to stop all water flow during the lull periods and until an adequate head has been created to justify reactivation of the system.
As previously described, duct openings 16 and 18 are situated at levels which will be constantly submerged. While a single opening may be utilized, a tee-type opening into the main duct may be used to decrease the possibility that debris might block the system openings. This would also allow tidal currents to pull water through the openings 16 and enhance the siphon effect during an ebbing tide.
In order to further prevent the clogging of the duct system and the introduction of particles which would damage or reduce the efficiency of the turbines, or energy converting means, a baffle means may be employed. Deflection of debris may be accomplished through use of baffling screen or louvres 28 and 30 in the vicinity of duct openings 16 and 18 respectively. These elements will act to restrain and divert debris which might otherwise be sucked into the duct system. The baffles could be of any known construction, and in addition to screens, could include perforated or slotted cones circumventing the duct system openings.
Filter elements 17 and 19 are provided within the duct system relatively close to duct openings 16 and 18 respectively. Filters 17 and 19 are designed to prevent foreign matter and particles which do enter the duct system from reaching and damaging the turbines or reducing their efficiency. Drop filter 48 is also provided in the duct system as a further measure to eliminate particles from the water flow.
As noted, the duct system must necessarily be airtight and fully charged with water before the siphon principle will induce water to flow through the duct system in response to the differential water level in the two reservoirs. Drain and recharge valve 54 may be provided in the duct system to facilitate the initial charging of the system as well as to permit additional water to be added should the system lose its charge, or to drain the system.
As previously described, when a state of equilibrium is approached, and the water velocity decreases, a brief period will occur where the velocity will be insufficient to drive the turbine or energy converting means. Until the system has reversed itself and sufficient velocity achieved to again drive the turbine, no energy will be available from the system. By constricting the inside diameter of the duct in the area immediately above the turbine or turbines, the water velocity impacting on the turbine may be increased and will shorten the lull period which accompanies the shifting of the water flow direction as the reservoirs pass the state of equilibrium. As indicated, low velocity energy converting means may also be utilized in place of a turbine to further reduce the periods when energy can not be generated.
The length of time during which the water will flow from one reservoir to the other will also be affected by the size of the second reservoir. A reservoir of small area will necessarily fill quicker such that its water level will rise in closer correspondence to the rise of the ocean level. This situation would result in a small head and thus a lesser velocity of water flow through the duct system. By increasing the size of the second reservoir such that the flow of water through the duct system cannot be sufficient to achieve a rise or fall of the water level in timely correspondence with the rise and fall of the sea level in the first reservoir, a larger head, and hence an increased velocity of the water through the operating turbine, may be obtained.
The foregoing description of the invention has been directed to particular embodiments thereof, including a preferred embodiment, in accordance with the requirements of the Patent Statutes and for purposes of explanation and illustration. However, it will be apparent to those skilled in this art that modifications and changes in the apparatus may be made without departing from the scope and spirit of the invention. For example, two one way turbines may be used, one for flow in each direction, where the turbines are situated in separate portions of the duct system. This arrangement could function with or without the use of separate bypass channels and accompanying valving. These, and other modifications of the invention will be apparent to those skilled in the art. It is the applicant's intention in the following claims to cover all such equivalent modifications and variations which fall within the true spirit and scope of the invention. | An apparatus is disclosed which is capable of producing usable energy as a result of the rise and fall of ocean tides. A second reservoir is connected to a natural reservoir such as the ocean by means of a duct system wherein the duct openings in the two reservoirs are established at levels which will constantly be submerged. Upon charging the duct system with water, the siphon principle will urge the flow of water back and forth through the duct system between the two reservoirs as the water in the second reservoir seeks a level of equilibrium with that of the ocean. A turbine is mounted in the duct system and is driven by the substantially continuous flow of water back and forth through the system thereby producing a source of useable energy. | 8 |
FIELD OF THE INVENTION
Technical Field
[0001] This invention relates generally to containers for food, pharmaceuticals and other items and more particularly to such containers that are resistant to the ingress of moisture, provide for the reduction of moisture content within the package, and have a closure attached to the container with a living hinge.
BACKGROUND OF THE INVENTION
Description of Related Art
[0002] Living hinges, most commonly resin-based hinges are usually relatively thin and flexible and join two rigid or semi-rigid parts of a container together, allowing them to bend along the line of the hinge. Conveniently, living hinges are manufactured in an injection molding operation that simultaneously creates the hinge and the two package components connected to respective sides of the hinge. Living hinges are convenient, reduce the price of articles in which they are used, and have a relatively long life.
[0003] In pharmaceutical and food packaging containers, as well as other containers, it is oftentimes desirable to attach a closure element to the package being closed so that it is not displaced and to facilitate easy opening and closing of the package. Living hinges provide a convenient way to do this and are used on a wide variety of such packages.
[0004] It is also desirable in packages used for food and pharmaceuticals as well as other items that are degraded by excess moisture content in the package, to provide a package that is made from a material that provides a desiccating function, that is, a material that includes ingredients that cause the material itself to absorb water vapor and reduce the humidity within the package. Such materials are generally known and packages of the type described have been provided in the past.
[0005] The composition of moisture absorbing plastic materials has, heretofore, been inconsistent with using such material to provide a living hinge. In order to absorb useful amounts of moisture, plastics and other resins used to form containers must contain a high percentage of additives such as desiccant material. The presence of desiccant material in amounts sufficient to provide an adequate desiccating function changes the characteristics of the plastic material. The material becomes less flexible and prone to strain and flexure fatigue and ultimately breakage when repeatedly stressed as is required of materials from which living hinges are made.
[0006] Therefore, a desiccating package with a living hinge cannot be made from a single material and still provide both an adequate living hinge and an adequate desiccating function.
[0007] It is an object of this invention to provide a desiccating container having a living hinge that addresses the limitations of containers heretofore known.
SUMMARY OF THE INVENTION
[0008] Briefly stated, a self desiccating container with a living hinge includes a container body made from a resin bonded sorbent and at least one attachment feature, and a container closure having a closure portion engageable with the container body to close the body and an attachment feature compatible with the attachment feature on the container body for securing the closure to the body, and a living hinge connecting the closure portion to the attachment feature.
[0009] In accordance with another aspect of the invention, the body of the container and the container closure characterized by first and second different flex moduli, the flex modulus of the closure being greater than the flex modulus of the container.
[0010] In accordance with another aspect of the invention, the container body comprises high density polyethylene.
[0011] In accordance with another aspect of the invention, the container body comprises polypropylene.
[0012] In accordance with another aspect of the invention, the container body comprises between about 5 and about 50, preferably about 30% by weight of desiccant selected from the group consisting of gel or sieve, clay, calcium oxide, or carbon.
[0013] In accordance with another aspect of the invention, the container body and container are different colors.
[0014] In accordance with another aspect of the invention, the resin bonded sorbent comprises a resin bonded desiccant.
[0015] In accordance with another aspect of the invention, the container body comprises an oxygen scavenger.
[0016] In accordance with yet another aspect of the invention, the attachment feature on the closure comprises an annular ring.
[0017] In accordance with yet another aspect of the invention, the annular ring comprises a plurality of aperture.
[0018] In accordance with still another aspect of the invention, the attachment feature on the container body comprises a plurality of projections extendable into the plurality of apertures.
[0019] In accordance with a still further aspect of the invention, the attachment feature on the container body comprises a tapered region.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0020] The novel aspects of the invention are set forth with particularity in the appended claims. The invention itself, together with further objects and advantages thereof may be more readily understood by reference to the following detailed description of presently preferred embodiments thereof taken in conjunction with the accompanying drawing in which:
[0021] FIGS. 1 and 2 are perspective views of a container in accordance with this invention taken from different perspectives.
[0022] FIG. 3 is a perspective view showing the container body and the container closure separately.
[0023] FIGS. 4 and 5 are perspective views showing the container closure being assembled to the container body.
[0024] FIG. 6 is a perspective view showing a container body and a container closure having corresponding apertures and projections for securing the container closure to the container body.
[0025] FIGS. 7A and 7B are side elevations of a container in accordance with another embodiment of this invention made by two shot injection molding.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring now to FIG. 1 , a container in accordance with this invention is illustrated in a perspective view. The container indicated generally at 10 includes a container body 12 and a container closure 14 having a cap and an attachment feature 18 assembled on the body. A living hinge 16 is connected between the cap 24 and the attachment feature 18 . The living hinge 16 preferably has thicker portions 28 , 30 attached to the closure cap 24 and the attachment feature 18 and a thinner hinge portion between the thicker portions.
[0027] Preferably, the closure 14 , the living hinge 16 , and the attachment feature 18 are made from a resin material such as polyethylene, polypropylene, or another polymer having characteristics suitable for making a living hinge. The container body 12 is preferably made from a polymer such as high density polyethylene or polypropylene, or another polymer with a low water vapor transmission rate. A desiccant such as silica gel, a sieve, clay, calcium oxide, or carbon is incorporated in the polymer in amounts between about 5% and 50%, preferably about 30%. In place of or in addition to the desiccant, an oxygen scavenger such as an iron-based oxygen scavenger may be included. Scented resins or gels can also be included where useful in the particular application.
[0028] FIG. 3 shows the container body 12 and the closure 14 separately. The body 12 is generally cylindrical. In accordance with one embodiment of the invention, the body 12 is tapered from a slightly smaller diameter at the base 20 to a slightly larger diameter at the open end 22 . The open end of the body may have a slight outwardly extending lip 26 . The closure 14 includes a cap 24 that preferably snaps on to the open end 22 of the body 12 , perhaps engaging the lip 26 , and an annular attachment feature 18 in the form of a ring having an inside surface 19 that is preferably tapered to match the taper of the body 12 . The cap 24 and the attachment member 18 are connected by a living hinge 16 that has two thick portions 28 , 30 , connected by a thinner living hinge portion having a lesser thickness of about 0.2-0.3 mm. The thicker portions 28 , 30 are connected to the cap 24 and the attachment feature 18 , respectively. The precise form of the living hinge 16 is not limited in connection with this invention, any known living hinge construction may be used. The dimensions are solely by way of example and may vary depending upon materials and other factors.
[0029] Preferably, the closure 14 is formed from neat polymer, that is, polymer without a desiccating or oxygen absorbing additive. It is preferable that the attachment feature 18 fit snugly on the container body 12 when slid into a final position near the open end 22 . The closure 14 may be made from polyethylene or polypropylene or other polymeric materials.
[0030] FIGS. 4 and 5 show how the container closure 14 is placed on the container body 12 . As can be seen in FIG. 4 , the closure 14 is slipped over the closed end 20 of the body 12 and, as shown in FIG. 5 , slid up towards the larger open end 22 where it fits securely. Preferably, the container body 12 is tapered and the interior surface of the attachment feature 18 has a compatible taper.
[0031] FIG. 6 shows another embodiment of the invention in which the container body 30 includes a plurality of projections 32 , each of which is preferably but not necessarily tapered or triangular in cross-section spaced a short distance from a circumferential annular ring 34 disposed adjacent the upper open end 44 of the container body 30 . The corresponding container closure 40 includes a closure cap portion 42 engageable with the open upper end 44 of the container body and an attachment feature in the form of an annular band 46 having a plurality of apertures 48 formed therein spaced and sized to engage the like plurality of projections 32 on the container body 30 . In the embodiment illustrated, the apertures 48 are generally rectangular in cross section. It will be understood that there may be fewer projections than apertures. A living hinge 50 connects the container closure cap portion 42 with the attachment feature or rim 46 . The container body 30 and container closure 40 are formed from the materials mentioned in connection with the corresponding elements in FIGS. 1-5 .
[0032] While the invention may be formed in two parts as described above, in accordance with another embodiment of the invention, the container is molded as a single piece using a two-shot molding process. Referring to FIGS. 7A and 7B , the bottom portion of the container is formed by filling a portion of the mold with a plastic material of the type already described that includes a desiccant and without curing that portion or removing it from the mold, the upper portion of the container and the cap are injected into the mold cavity using a plastic material of the type already discussed without a desiccant additive. The plastic materials for the two injected components should be selected so that they are compatible, that is that they will produce a single substantially continuous body of material with additive in the lower portion, but not in the upper portion and cap. Alternatively, the cap could also include a desiccant additive leaving only the hinge portion without an additive in a three-shot molding procedure.
[0033] While the invention has been described in connection with certain presently preferred embodiments thereof, various modifications and changes will suggest themselves to those of skill in the art, and it is intended that the invention as claimed includes such modifications and changes. For example, the body can be of various shapes and sizes, such as round, oval, square, and the like. While a particular arrangement of projections and apertures has been described, other snap-fit arrangements such as a groove in the annular member rather than an aperture could also be employed.
[0034] In addition, the attachment feature on the container body and the attachment feature on the container closure may be features that can be connected together by welding, gluing or the like. While the invention is shown with projections on the container body and apertures in the annular ring, the arrangement could be reversed so that there were apertures in the container body and projections in the annular ring.
[0035] The materials could be selected so that they could be welded to one another either by heat or ultrasonics. The container body and top could also be co-extruded from different materials.
[0036] The cap itself could include tamper evident features and/or snap and lock types of closures.
[0037] The container body, the top, or both could be color coated to identify the type and capacity of desiccant and/or oxygen absorber and/or other absorbers in the container body.
[0038] Applicants have discovered that the presence of a desiccant or oxygen absorber in the container body improves the characteristics of the body, namely the warp and shrink characteristics.
[0039] While polypropylene is an effective barrier to moisture, it is not preferred for manufacturing the container body because it has high warp and shrink characteristics. The same material, when provided with a desiccant material in accordance with this invention, has greatly improved warp and shrink characteristics.
[0040] As already discussed, the container body may have a water vapor absorbing material, an oxygen-absorbing material, an odor-absorbing material, a scented material, or a combination of two or more of these.
[0041] Containers made in accordance with this invention are useful in the pharmaceutical area, to package diagnostic test strips, as packages for hearing aides, and for snack and/or candy applications, as well as any other food applications where removing moisture from the package is desirable. | A self desiccating container with a living hinge includes a container body made from a resin bonded sorbent and at least one attachment feature, and a container closure having a closure portion engageable with the container body to close the body and an attachment feature compatible with the attachment feature on the container body for securing the closure to the body, and a living hinge connecting the closure portion to the attachment feature. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 61/539,703 filed Sep. 27, 2011, titled “VIRTUAL GENERAL PURPOSE INPUT/OUTPUT FOR A MICROCONTROLLER,” which is hereby incorporated by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present disclosure relates to microcontrollers and, in particular, to general purpose input/output ports in microcontrollers.
[0004] 2. Description of the Related Art
[0005] A general purpose input/output (GPIO) port is generally understood as a parallel digital input/output port of a microcontroller. With current microcontrollers, GPIO functions are organized by ports (A, B, C, etc.), with each port having a set of registers input/output registers to control it. Furthermore, to control whether the port is used for digital input or digital output, a direction register such as a tri-state control register can be provided. Increasingly, microcontrollers are “low pin count” devices.
[0006] When, as a consequence, a large number of peripherals are multiplexed onto each pin, it is unlikely that more than one to three GPIO functions will be available on any given port, once a user allocates the pins necessary for dedicated pin functions, such as UART (universal asynchronous receiver/transmitter), SPI (serial peripheral interface), I2C (Inter-integrated circuit), etc. This means that when the user wants a coherent (atomic, i.e., the ability to read or write the set of GPIO pins with a single CPU instruction) set of GPIO pins with more than a couple of pins, they must access multiple registers to drive data out on or sample data from those pins. This leads to limitations, such as the inability to drive all GPIO pins high at the same time, or to sample all GPIO pins at the same time.
SUMMARY
[0007] These and other drawbacks in the prior art are overcome in large part by a system and method according to embodiments of the present invention.
[0008] A microcontroller according to embodiments includes a general purpose input/output (GPIO) port having a plurality of bits coupled to a plurality of external pins; a first set of registers for providing at least one of first control and data input/output functionality of the GPIO port; a second set of registers for providing at least one of second control and data input/output functionality of the GPIO port; and a multiplexer and associated select register for controlling the multiplexer to control said GPIO port through either said first or second register set.
[0009] In some embodiments, the first and second register set comprise a read register, a write register, and a direction control register. In some embodiments, the port comprises a controllable output driver having an output coupled with an external pin and an input driver having an input coupled with the external pin. In some embodiments, the first and second read register are coupled through a first multiplexer with the output of the input driver, the first and second write register are coupled through a second multiplexer with the input of the output driver, and the first and second direction control register are coupled through a third multiplexer with a control input of the output driver. In some embodiments, the microprocessor further includes a peripheral pin select unit operable to programmably assign an external pin to the second functionality of the GPIO.
[0010] An input/output configuration for a processor according to some embodiments include a first plurality of registers comprising a first general purpose input/output configuration selectively coupled to an external pin of the processor; a second plurality of registers comprising a second general purpose input/output configuration selectively coupled to the external pin; and a control register operably coupled to control switching between the first general purpose input/output configuration and the second general purpose input/output configuration. In some embodiments, the input/output configuration includes at least one multiplexer for receiving control inputs from the control register for selecting between the first general purpose input/output configuration and the second general purpose input/output configuration. In some embodiments, the first plurality of registers includes a first read register, a first write register, and a first direction control register; and the second plurality of registers includes a second read register, a second write register, and a second direction control register. In some embodiments, the at least one multiplexer includes a first multiplexer for selecting between the first direction control register and the second direction control register; and a second multiplexer for selecting between the first write register and the second write register. In some embodiments, the input/output configuration includes a controllable output driver having an output coupled with the external pin and an input driver having an input coupled with the external pin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention may be better understood, and its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference symbols in different drawings indicates similar or identical items.
[0012] FIG. 1 is a diagram illustrating an exemplary microcontroller pin configuration.
[0013] FIG. 2 is a diagram illustrating a conventional GPIO port.
[0014] FIG. 3 is a diagram illustrating a GPIO port in accordance with embodiments of the invention.
[0015] FIG. 4 is a diagram illustrating a GPIO port in accordance with embodiments of the invention.
[0016] FIG. 5 illustrates exemplary registers for use with a virtual port in accordance with embodiments.
DETAILED DESCRIPTION
[0017] The disclosure and various features and advantageous details thereof are explained more fully with reference to the exemplary, and therefore non-limiting, embodiments illustrated in the accompanying drawings and detailed in the following description. Descriptions of known programming techniques, computer software, hardware, operating platforms and protocols may be omitted so as not to unnecessarily obscure the disclosure in detail. It should be understood, however, that the detailed description and the specific examples, while indicating the preferred embodiments, are given by way of illustration only and not by way of limitation. Various substitutions, modifications, additions and/or rearrangements within the spirit and/or scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure.
[0018] As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, product, article, or apparatus that comprises a list of elements is not necessarily limited only those elements but may include other elements not expressly listed or inherent to such process, process, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
[0019] Additionally, any examples or illustrations given herein are not to be regarded in any way as restrictions on, limits to, or express definitions of, any term or terms with which they are utilized. Instead these examples or illustrations are to be regarded as being described with respect to one particular embodiment and as illustrative only. Those of ordinary skill in the art will appreciate that any term or terms with which these examples or illustrations are utilized encompass other embodiments as well as implementations and adaptations thereof which may or may not be given therewith or elsewhere in the specification and all such embodiments are intended to be included within the scope of that term or terms. Language designating such non-limiting examples and illustrations includes, but is not limited to: “for example,” “for instance,” “e.g.,” “in one embodiment,” and the like.
[0020] As will be explained in greater detail below, according to various embodiments, a user can map GPIO pins that are spread across multiple physical ports to a single software port, called a Virtual Port. That is, in some embodiments, a Virtual Port is constructed by mapping unrelated pins to a single “port.”
[0021] In some embodiments, the mapping employs a remappable pin function, such as the Peripheral Pin Select (PPS) infrastructure, available from Microchip, which provides flexible multiplexing between pins and peripherals, and also employs a dedicated set of extra GPIO registers. It then becomes possible to simultaneously drive or sample multiple GPIOs even though they do not necessarily belong to the same originally assigned port. In other applications, the same port may be used in different configurations that require extensive re-programming of that port. According to an embodiment, at least a second set of registers allows users to set two or more configurations of a GPIO port which can be switched by simply setting at least one bit of a select register.
[0022] Turning now to the drawings and, with particular attention to FIG. 1 , a diagram of an exemplary microcontroller that can be used in accordance with the teachings of the disclosure is shown. The microcontroller 100 may be embodied as a PIC18F67J94, available from Microchip Technologies, Inc., or a similar microcontroller or processor. Microcontroller 100 includes a plurality of pins, many of which are used to implement more than one function. In the example illustrated, pins with the designation “R” are remappable using a Peripheral Pin Select functions. Peripheral Pin Select allows a programmer to map the I/O of most peripherals to a selection of pins.
[0023] However, with low pin counts and increasing number of peripherals, users are often constrained in their GPIO to “leftover” pins. Even with PPS (Peripheral Pin Select), board layout may constrain pin selection on a device. If a multi-pin GPIO “port” is required to implement a protocol or control, and all of the pins are not on the same physical port (i.e.—Port A, B, etc.), then multiple instruction cycles are required to read the port, for example with a read register (PORT), write the port, for example with a write register (LAT), or switch directionality of the port, for example with a tri-state register (TRIS) on these pins. With conventional systems, it is impossible to keep cycle coherency on the GPIO port for reads and writes.
[0024] For example, shown in FIG. 2 is a conventional GPIO port 200 . Shown is I/O pin 201 , read driver 204 and read register 210 (PORT); and tri-state write driver 202 , with a write register (LAT) 208 and select register 206 (TRIS). In operation, the register 206 is used to select the input or output functioning or directionality of the port 200 .
[0025] According to an embodiment, a virtual port allows a user to allocate any possible GPIO pin to a virtual PORT. As shown in FIG. 3 , an existing GPIO port is assigned a shadow function which can be activated by merely setting a single bit switching the functionality from an original configured port to the configuration set in the register assigned to the virtual function.
[0026] More particularly, FIG. 3 illustrates an exemplary GPIO virtual port structure according to an embodiment. As shown, the port 300 includes pin 301 , drivers 302 , 304 , and read (PORT) register 210 , write (LAT) register 208 , and select (TRIS) register 206 , which function similarly to conventional ports. However, according to embodiments, the virtual port 300 includes virtual write (PBLAT) register 306 , virtual read (PBPORT) register 310 , and virtual select (TRIS) register 308 . Multiplexers 314 , 316 allow users to select between the “real” or virtual port functions. More particularly, in standard operation, the standard port configuration may be used. By selecting using the virtual pin select line(s) 318 , 313 , 320 , a user can select the virtual port function.
[0027] The additional logic requires only a minimum of real estate, thus, die cost is kept small. For example, with 40 GPIO pins and 8-pin virtual port, the additional logic requires about 1K gates. However, this requirement can be even further reduced when using an existing PPS.
[0028] Generally, the GPIO is considered as a dedicated pin function, and not treated as a peripheral. However, according to various embodiments, the GPIO is treated like any other mappable peripheral. As will be discussed in greater detail below, according to some embodiments, using a remappable pin function infrastructure, such as the PPS infrastructure, which allows for multiplexing between any or almost any pin and any or almost any peripheral, a new “GPIO peripheral” is added to the list of re-mappable peripherals. That is, with a remappable pin function such as PPS, the virtual port looks just like another peripheral device. Within this GPIO peripheral, a new set of dedicated GPIO registers functions identically to pin-based GPIO functions. In some embodiments, this additional GPIO peripheral can be placed as the lowest priority re-mappable peripheral, right above the pin-based GPIO pin functions (which are not part of the re-mappable pin function set), thereby making them behave like the pin-based GPIO pin functions (look and feel), but independent of the physical pin they are mapped to. Consequently, a group of disjointed (i.e.—spread across multiple GPIO “ports”) pins can be transformed into what looks like an atomic (i.e.—all on the same GPIO “port”) group of pins with minimal additional logic.
[0029] Turning now to FIG. 4 , a diagram 400 showing virtual GPIO in a remappable pin function environment is shown. The environment 400 includes GPIO virtual port structure 402 and peripherals 422 a - 422 n. The GPIO virtual port structure includes pin 401 , drivers 302 , 304 , and read (PORT) register 210 , write (LAT) register 208 , and select (TRIS) register 206 , which function similarly to conventional ports and as described above with reference to FIG. 3 . In addition, the virtual port 402 includes virtual write (PBLAT) register 306 , virtual read (PBPORT) register 310 , and virtual select (TRIS) register 308 . Multiplexers 414 , 416 allow users to select between the “real” or virtual port functions in a manner similar to that discussed above. By selecting the virtual pin select line(s) (not shown), a user can select the virtual port function.
[0030] In addition, in a remappable pin function environment, the multiplexers 414 , 416 receive inputs from peripherals 422 a, 422 n. In particular, in some embodiments, the output enable lines 426 a, 426 n are provided to multiplexer 414 to enable writing to the pin 401 , and output data lines 428 a . . . 428 n are provided to multiplexer 416 to write data to the pin.
[0031] According to various embodiments, a set of separate PBLAT, PBPORT and PBTRIS registers is implemented. For example, shown in FIG. 5 are 8-bit wide LAT (write) 308 , port (read) 310 , and tris (select) 306 registers for a PIC18 microcontroller. Register width would be the native data width of the architecture, so that register reads/writes are atomic.
[0032] Although the foregoing specification describes specific embodiments, numerous changes in the details of the embodiments disclosed herein and additional embodiments will be apparent to, and may be made by, persons of ordinary skill in the art having reference to this description. In this context, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of this disclosure. Accordingly, the scope of the present disclosure should be determined by the following claims and their legal equivalents. | A microcontroller includes a general purpose input/output (GPIO) port having a plurality of bits coupled to a plurality of external pins; a first set of registers for providing at least one of first control and data input/output functionality of the GPIO port; a second set of registers for providing at least one of second control and data input/output functionality of the GPIO port; and a multiplexer and associated select register for controlling the multiplexer to control said GPIO port through either said first or second register set. | 6 |
[0001] This application claims priority to Application Ser. No. 62/388,976, filed Feb. 16, 2016. All extrinsic materials identified in this application are incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The field of the invention is three-dimensional puzzles.
BACKGROUND
[0003] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided in this application is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0004] Sudoku is a puzzle where the solution requires each number to appear exactly once in each row and once in each column. A Sudoku-like puzzle can refer to any puzzle where each symbol or color must appear no more than once in each row and no more than once in each column, or no more than once on each side of a three-dimensional puzzle. From herein the term color shall be used to refer to a color, symbol or set of symbols.
[0005] One example of a Sudoku-like puzzle is Jay Horowitz's SudoKube, U.S. Pat. No. 7,644,924. It is a variant of Rubic's Cube with numbers 1 through 9 placed on the nine squares on each side of the cube, where the goal is to recreate a positioning where each number appears once on each side. It is a twisting puzzle, in which it is possible to move and reposition components of a piece while holding the rest stationary.
[0006] Another example is Uwe Meffert's Ball Sudoku Cube, which is a variant of the SudoKube where each of the 26 visible subcubes are the same color on all of theirs sides, and the goal is to have each color appear once on each side. Like SudoKube, Meffert's Ball Sudoku Cube is a twisting puzzle.
[0007] U.S. Pat. No. 646,463 describes four cubes, where each side of every cube is assigned one of four colors, and the goal is to place the four cubes in a vertical line so that every color appears once on each of the four sides. This patent describes single cubes in which different sides are assigned different colors.
[0008] There was a failed Kickstarter campaign for a product called SU-DI-KU that consisted of 9 dice, where every side of every die had a 3×3 of numbers 1 through 9. The goal was to place the dice into a 3×3 pattern so that it formed a 9×9 Sudoku. The numbers had to be upright and positioned properly for a valid solution. And the same corner of a die may have 3 separate numbers on each of its three sizes. Unless the user has the dice memorized, looking at one side of a die tells the user nothing about the neighboring sides.
[0009] In addition to the references and games mentioned above, Polycube puzzles are puzzles where Polycubes must be placed into a two-dimensional rectangle or a three-dimensional rectangular block. While there are versions that require the user to form a checkerboard pattern, none of them require the user to create a Sudoku.
[0010] An example of a multiple piece three-dimensional polycube puzzle can be seen in U.S. Pat. No. 5,868,388. This patent describes a puzzle whose goal is to create a checkerboard pattern in which the same two values alternate in every row and every column. It does not describe a Sudoku-like solution. Furthermore, the patent describes pieces that have different markings on the sides of a cube.
[0011] One famous polycube puzzle is Soma Cube, a solid dissection puzzle invented by Piet Hein. It consists of seven polycubes that need to be placed into the shape of a 3×3×3 cube. There are versions of it in which each of the cubes in the polycubes are assigned one of two colors, with the goal of solving the Soma Cube so that the resulting 3×3×3 cube has a checkerboard pattern on all sides. There are no versions of Soma in which the user needs to create a Sudoku on each side.
[0012] DBox comes with 32 cubes, and allows users to join them together and create their own dissection puzzles. The cubes come in two colors, allowing the user create a solution that has a checkerboard pattern. There is no way to form a Sudoku like solution for any shape with length three or greater.
[0013] Cirplexed by Susan McKinley Ross is a game that incorporate multi-colored 2×2 squares, where each of the 4 squares is assigned a color. The pieces are flat and two dimensional, and the game does not have the goal of creating a Sudoku solution.
[0014] These and all other extrinsic materials discussed in this application are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided in this application, the definition of that term provided in this application applies and the definition of that term in the reference does not apply.
[0015] It has yet to be appreciated that polycubes are ideal for Sudoku-like puzzles, as long as certain guidelines are followed. Because polycubes are three-dimensional they offer a wide range of possible positions, allowing for challenging Sudoku-like puzzles.
SUMMARY OF THE INVENTION
[0016] The present invention provides apparatus, systems, and methods of puzzles and games using three-dimensional figures.
[0017] In one aspect of the inventive subject matter, a puzzle made up of a set of polycubes, where each polycube of the set of polycubes has a defined shape is contemplated. Each polycube of the set of polycubes comprises a set of cubes, and each cube of the set of cubes has a unique visually identifiable attribute on all exterior sides. The set of polycubes are arranged together to create a larger polycube such that the larger polycube does not repeat any of the visually identifiable attributes on a given side.
[0018] In some embodiments, the visually identifiable attribute is at least one of a color, a shape, and a symbol. The unique visually identifiable attribute can be selected from a set of at least three unique visually identifiable attributes.
[0019] In another aspect of the inventive subject matter, a puzzle that includes a set of polycubes, where each polycube of the set of polycubes has a defined shape is contemplated. Each polycube of the set of polycubes (e.g., the constituent pieces of a Soma Cube) comprises a set of cubes, and each cube of the set of cubes is has a unique visually identifiable attribute on all exterior sides. The set of polycubes are arranged together to create a larger polycube such that the larger polycube does not repeat any of the visually identifiable attributes on any row or column of a side of the larger polycube.
[0020] In some embodiments, the unique visually identifiable attribute is selected from a set of at least three unique visually identifiable attributes. The visually identifiable attribute can be at least one of a color, a shape, and a symbol.
[0021] In some embodiments, the larger polycube is a cubic polycube. In some embodiments, each polycube of the set of polycubes is a cubic polycube, and the larger polycube is arranged as a square. In some embodiments, each cubic polycube comprises eight cubes.
[0022] In some embodiments, each cubic polycube can include four pairs of cubes, where each pair of cubes have the same unique visually identifiable attribute on all exterior sides. In these embodiments, each side of the cubic polycube comprises cubes having different unique visually identifiable attributes.
[0023] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows a T-shaped polycube.
[0025] FIG. 2 shows a Sudoku-like pattern formed by four polycubes put together.
[0026] FIG. 3 shows an exploded view of a polycube
[0027] FIG. 4 shows another T-shaped polycube.
[0028] FIG. 5 shows an exploded view of four polycubes.
[0029] FIG. 6 shows an L-shaped polycube.
[0030] FIG. 7 shows a cubic polycube.
[0031] FIG. 8 shows a variety of different polycube configurations.
[0032] FIG. 9 shows a cubic polycube comprised of the polycubes shown in FIG. 8 .
DETAILED DESCRIPTION
[0033] The following discussion provides example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0034] As used in the description in this application and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description in this application, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0035] Also, as used in this application, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.
[0036] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, and unless the context dictates the contrary, all ranges set forth in this application should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
[0037] A polycube is a solid figure formed by joining one or more equal cubes face to face, as seen in FIG. 4 . Polycubes can take on many different shapes, depending on the number of cubes within the polycube. Polycubes of the inventive subject matter can include 3, 4, 5, 6, 7, 8, or 27 cubes. This application describes a specific type of polycube that was designed for Sudoku-like puzzles.
[0038] One application of the inventive subject matter is a Sudoku-like puzzle based on polycubes that have a unique property. Each of the cubes within the polycube has a unique attribute (e.g., the same color, symbol, or sets of colors and symbols on each of its exterior sides). The cubes, e.g., cubes 101 , 102 , 103 , and 104 of polycube 100 cannot be twisted or repositioned, and the cubes of a polycube always have the same relative position to the other cubes of the same polycube.
[0039] In an embodiment of the inventive subject matter, a polycube can be rotated or flipped in three dimensions, allowing the user to position it however they like in their attempt to solve a puzzle. The set of cubes within the a polycube can include three or more visual identifiers (e.g., colors, symbols, or shapes). In these embodiments, the goal of the puzzle is to assemble the polycubes so that each visual identifier appears no more than once in each row or each column, as seen in FIG. 2 .
[0040] As seen in FIG. 3 , polycubes are assembled by using a set of cubes 301 , 302 , 303 and 304 , where each side of the cube is the same (e.g., the same color, symbol, feature, character, etc.). To create a polycube as seen in FIG. 1 , cubes 301 , 302 , 303 and 304 are connected together into a solid block or polycube, where the cubes are fixedly aligned to each other. All neighboring cubes should be fully aligned so that they are orthogonal to each other, with each cube completely covering the sides of its neighboring cubes that are closest to it.
[0041] The inventive subject matter lends itself to several puzzles that can be made using a set of Polycubes. For example, a Tetracube is a Polycube comprising four cubes. One possible shape of Tetracube is a T, as seen in FIG. 4 . If each of the four cubes in the T-shaped polycube are different colors, there are 12 distinct blocks that can be created. Four such T-shaped polycubes can be arranged as seen in FIG. 5 , and placed so that each color appears once in every row and once in every column, as seen in FIG. 2 .
[0042] Another possible shape of Tetracube is an L, as seen in FIG. 6 . If each of the four cubes in the L-shaped polycube are different colors, there are 24 distinct versions that can be created. It can be challenging to find a way to arrange those Tetracubes into a 4×4×4 arrangement where each color appears once in every row and once in every column on each of the 6 sides of the resulting cube. The remaining eight pieces can then be placed in two separate 4×4×1 arrangements where each color appears only once in every row and column (similar to a Sudoku puzzle where a number cannot be repeated in a row or column).
[0043] In one embodiment of the inventive subject matter, polycube blocks are in the shape of a cube (e.g., 2×2×2, 3×3×3, or 4×4×4). From herein we may refer to that shape as a Cubic Polycube, to differentiate it from the subcubes which are its components. A 2×2×2 Cubic Polycube having eight total cubes using four different colors is seen in FIG. 7 . The cubes of the polycube in FIG. 7 come in four different colors, with two cubes of each color. A 2×2×2 cubic polycube can be created by following these steps: (1) place one of each color in a 2×2×1 polycube, and (2) above each cube of the polycube, place the second cube that shares the same color (3) then switch each cube on the top row with the one that is diagonal to it. The resulting pattern can be seen in FIG. 7 .
[0044] Thus, when the 2×2×2 cubic polycube as seen in FIG. 7 is completed, each colored cube within the polycube is diametrically opposite its corresponding colored cube in the polycube. Every cube within the polycube in FIG. 7 has three neighboring cubes that are orthogonal to it, and 3 more cubes that are diagonal to it. There is only one cube that it doesn't share a side with, and that is its corresponding color on the diametrically opposite corner. For example, cube 702 is diametrically opposite to cube 705 , cube 703 is diametrically opposite to cube 704 , and cube 701 is diametrically opposed to cube 706 .
[0045] The resulting polycube is a 2×2×2 cubic polycube where each of the four colors appear once on every side as seen in FIG. 7 , with each side having a unique arrangement of colors. Since a cube has six sides, and each side can be rotated four different ways, the Cube allows 24 distinct ways to position the four colors. Thus, no matter how a user wants to position the four colors, this 2×2×2 cubic polycube has a side that can be rotated into a desired position.
[0046] For such a puzzle to be solvable, the colors of each cube within a polycube must be properly chosen. In general, any N×N number of cubic polycubes should use 2*N distinct colors, where N is greater than two. Divide the 2*N colors into two teams, with N colors in each team. Assign an order to each of the colors in both teams. Each of the colors in each team should be placed into two pairs. One pair should be with the color that comes after it in the ordering, and one pair should be with the color that comes before it in the ordering. Each Cubic Polycube then takes one pair from each team. As each cubic polycube in a set of N×N polycubes for this type of puzzle should be different from one another, each Cubic Polycube should take a different a different combination of pairs.
[0047] For example, if there are 16 blocks and eight colors, we can label the colors on one team 1, 2, 3, 4 and the colors on the other team A, B, C, and D. The four pairs from the first team will be (1,2), (2,3), (3,4), (4,1), and the four pairs from the second team will be (A,B), (B,C), (C,D), (D,A). The resulting colors for the Cubic Polycubes will then be AB12, AB23, AB34, AB41, BC12, BC23, BC34, BC41, CD12, CD23, CD34, CD41, DA12, DA23, DA34, and DA41.
[0048] When there are 16 cubic polycubes to be formed into a 4×4 grid having 8 colors, there is an alternate method to choose the colors of the blocks which gives the same results. The colors are grouped into four pairs, where each cube chooses only one color from each pair. If the 8 colors are labeled 1, 2, 3, 4, A, B, C, D and the pairs are (A,C), (B,D), (1,3), and (2,4) it will produce the same 16 Cubic Polycubes.
[0049] In some embodiments, the puzzle could include nine cubic polycubes and six colors, 16 cubic polycubes and 8 colors, 25 cubic polycubes and 10 colors, and 36 cubic polycubes with 12 colors. Each of the above can also be formed into three-dimensional cube puzzles by adding multiple copies of the same cubic polycubes. For example, if you take 3 complete sets of the 9 cubic polycubes, you can place the 27 cubic polycubes into a 3×3×3 box that forms a Sudoku-like pattern on every side.
[0050] Another version of the puzzle involves 9 cubic polycubes and 9 colors, where each cubic polycube is a 3×3×3 of color cubes. The cubic polycubes must be designed so that no color appears more than once on each side. There are different configuration that can assure that property, with some of them leading to harder puzzles. In the harder version of the puzzle, for each of the 9 cubic polycubes, the center cube of each of the six sides is a different color. In an easier version, every cubic polycube has the same color in the center of each of its six sides.
[0051] In another embodiment, a version of the puzzle involves 4 cubic polycubes and 6 colors, where each cubic polycubes is a 3×3×3 polycube with six distinct colors on each side, and no color appearing more than once in any row of column. There is also a three-dimensional version with 8 cubic polycubes that are 3×3×3×3 and contain 6 colors. The solution requires placing the 8 cubic polycubes into a 2×2×2 box, with each side forming a Sudoku-like pattern on the colors.
[0052] In another embodiment, a puzzle has 8 cubic polycubes with 4 colors and 4 symbols, where each cubic polycube is a 2×2×2 with the properties described above. For each cubic polycube, every color is paired with a different symbol, so that every appearance of the color on the cube will also have that symbol. Every side of every cubic polycube has all 4 colors and all 4 symbols, but each of the 8 cubes will have somewhat different pairings between the colors and symbols. For instance, if one cubic polycube has A1, B2, C3, D4, the next cubic polycube may have A1, B4, C3, D2, where 1, 2, 3, 4 represent colors and A, B, C, D represent symbols. The goal of the puzzle is to assemble the 8 Cubes into a 2×2×2, so that for all 6 sides, each color and each symbol appears only once in each row and once in each column.
[0053] The Soma Cube is a solid dissection puzzle invented by Piet Hein. The present invention allows one to make variant of the Soma Cube called “Soma Sudoku” that can be more challenging for experienced puzzle solvers. It involves giving each of the cubes in the polycubes of the Soma pieces one of 3 colors, and requiring the solved Cube to have a Sudoku-like patterns on every row and column of every side. An example of the Soma Sudoku pieces can be seen in FIG. 8 , and the solved cube can be seen in FIG. 9 . There are 240 distinct solutions of the classic Soma cube puzzle. There is only one pattern that can support a solution to the Soma Sudoku, but there are four ways to position it. Therefore, for each of the 240 Soma solutions there are 4 ways to color the 26 exterior cubes so that each of the 6 sides of the solved cube form a Sudoku-like pattern where each of the three colors appear once on every row and once on every column. There will be 9 cubes with the first color, 9 cubes with the second color, and 8 cubes of the third color. It is recommended to give the interior cube of the solved puzzle that third color, so that people can't analyze the color distribution to know the color of the interior cube.
[0054] The exterior 26 cubes of a solved Soma Cube can also be assigned 9 colors such that each color appears only once on each side. There will be 8 colors that have 3 cubes each, and one color that only appears twice. It is recommended to assign that color to the one interior cube, so that each of the 9 colors appear on an equal number of cubes.
[0055] Other dissection puzzles include Diabolical Cube, and Bruce Bedlam's Bedlam Cube. All such puzzles can be used to create new puzzles by assigning a color to each of the cubes of the polycubes of the pieces, similar to the manner described above with the Soma Cube.
[0056] Thus, specific compositions and methods of polycube games have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts in this application. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure. Moreover, in interpreting the disclosure all terms should be interpreted in the broadest possible manner consistent with the context. In particular the terms “comprises” and “comprising” should be interpreted as referring to the elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps can be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. | Polycube-based puzzles are disclosed. Three-dimensional Sudoku-like puzzles using polycubes of various sizes and dimensions, where the cubes making up each polycube have visually identifiable features on all sides such that sets of polycubes can be created to facilitate the Sudoku-like puzzle game. Polycube-based puzzles using sets of polycubes arranged in different configurations where each side of a resulting combination of a set of polycubes has no repeated visual identifier. | 0 |
This is a continuation in part of patent application Ser. No. 692,018 filed Aug. 2, 1996, now U.S. Pat. No. 5,794,695 and also Ser. No. 795,147 filed Feb. 7, 1997 now U.S. Pat. No. 5,839,509.
BACKGROUND OF THE INVENTION
This invention is directed toward apparatus and methods for gathering and preparing liquid samples for analysis, and more specifically directed toward the gathering and preparing of water samples for analysis for tritium content, where the samples are collected from underground formations penetrated by a borehole or collected at varying depths in surface canals and the like. The monitoring of liquid samples for contaminants is quite common in today's industrialized society. Such monitoring is carried out to track the efficiency of various manufacturing processes. In addition, such monitoring is employed to monitor potential hazards to humans and to the environment resulting from various manufacturing and processing operations.
Many types of nuclear manufacturing and processing facilities were built in significant numbers starting in the late 1940's and early 1950's. In the following decades, even more such facilities were built world wide as a result of the proliferation of nuclear power, nuclear weaponry, and nuclear medicine. As with most manufacturing and processing operations, nuclear facilities generate wastes which can be hazardous to the environment and to the human and animal population, and such wastes must be monitored and disposed using methods which minimize health and environmental risks.
Attention is now directed toward nuclear facilities designed for the manufacture of nuclear weapons. More particularly, attention is directed toward "fission" weapon facilities used to produce weapons based upon induced neutron "chain" reactions in certain isotopes of uranium and plutonium. Great quantities of energy are released as a result of the induced chain reaction which is often referred to as an "atomic explosion". It is well known that one precursor for such an energy release or explosion is a "critical mass" of the fission material in order to sustain the chain reaction. Weapons designers also found in the 1940's that more efficient energy releases or explosions could be obtained if the chain reaction were initiated with a burst of neutrons from a device known in the art as a "trigger".
Several techniques have been used in nuclear weapons to construct triggers which produce large neutron fluxes for relatively short periods of time. The most common trigger is based upon the reaction
H.sup.2 +H.sup.3 =He.sup.4 +n
where ##EQU1## That is, when tritium is bombarded with deuterium at a sufficient energy, a nuclear reaction occurs which yields helium, plus a neutron with approximately 14 million electron volts (MeV) of energy. Triggers based upon this "deuterium-tritium" reaction therefore produce the neutron flux desired as a trigger for fission type weapons.
Tritium is used at fission type weapons manufacturing facilities and, as might be expected, most of these manufacturing facilities produce significant amounts of tritium. Tritium is radioactive with a half life of approximately 12.33 years, and decays to ground state He 3 by the emission of a beta particle. Tritium reacts chemically as "normal" hydrogen (H 1 ). It is well known that hydrogen is easily ingested by plant life and animal life including humans. Tritium is likewise easily ingested, but tritium ingestion results in the possible chemical binding of radioactive tritium within the plant or animal organism. As an example, tritium ingested by a human would result in radioactive tritium atoms being chemically bound or "lodged" within the human. Subsequently, as the tritium decays with a half life of 12.33 years, beta particles are emitted at the sites of the bound tritium causing significant biological and cellular damage in the area of emission. It is apparent, therefore, that waste liquid, such as water which is contaminated with tritium, can be a significant health threat to humans and to the environment. Such tritium contaminated water can be found in cooling ponds and drainage canals in the vicinity of nuclear facilities such as nuclear weapons plants. Furthermore, run-off water, which migrates and percolates into the earth around nuclear facilities, can also be contaminated with tritium. This becomes an especially critical problem if these contaminated waters migrate into drinking water aquifers. The result is a potable aquifer contaminated with a beta emitting tritium with a half life of 12.33 years.
Nuclear sites are currently monitored for tritium wastes. Liquid samples such as water are collected at varying depths from cooling ponds or canals. To monitor the migration of tritium contaminated water toward the water tables, test wells are often drilled about the site, ground water is allowed to flow into each of these wells, and water samples are taken at varying depths within the well. As an example, the detection of tritium contamination in a water sample gathered near the surface usually indicates that contaminated water has not migrated to deeper aquifers. Furthermore, the combination of tritium concentration measurements made at multiple depths in multiple wells can be used to generate a three dimensional map of any tritium contamination in the ground beneath the nuclear facility. Since nuclear facilities can be quite large and cover hundreds if not thousands of acres, it should be understood that tens or even hundreds of monitor wells are required to properly monitor water movement and possible ground water contamination.
Again, examining current tritium monitoring techniques, liquid samples gathered from monitor wells, or at different depths within surface ponds or canals, must be pretreated prior to analysis for tritium. In one such pretreatment, the water is passed through a column containing a plurality of resin materials in order to remove certain cations and other materials which prohibit accurate tritium concentration measurements. This pretreatment can be performed at the sample site, but, using current technology, is preferably performed at a remote, analytical laboratory under controlled conditions. Tritium analysis is currently being performed at the remote, analytical laboratory. The time required to perform this type of analysis often takes one to two months from the time samples are received. The analysis cost per sample is also quite high. Considering that multiple sample sites such as monitor wells are needed, and that samples should be taken at varying depths at each sample site, the total cost of a monitor survey can be quite high. Furthermore, it is highly desirable to sample at a given site, such as a monitor well, as many as three to four times per day, in order to detect early, any tritium contamination so that remedial actions can be taken immediately. Although sampling at this time frequency can be done today, the current sample analysis turnaround of one to two months negated the usefulness of this method.
SUMMARY OF THE INVENTION
The invention is directed toward apparatus and methods for gathering and preparing liquid samples for analysis for elements or compounds within the liquid samples. Although applicable to a variety of liquids and to a variety of elements or compounds, the preferred embodiment of the invention is directed toward the gathering and pretreating of water samples for tritium analysis. This disclosure is further directed toward apparatus and methods for the gathering or collecting of water samples from underground formations penetrated by a borehole, or collecting water samples at varying depths in surface canals, ponds, and the like. The invention is particularly suited for monitoring water in the vicinity of nuclear manufacturing, fabrication and disposal facilities for tritium contamination of ground waters.
The sampling system includes submersible pumps and a vacuum/compressor system and valving system for operating these pumps in order to gather liquid samples at varying depths below the surface of the earth, and transporting these samples to the surface of the earth for pretreatment prior to analysis for contaminants. For purposes of discussion, it will be assumed that the liquid is water and that the contaminant is tritium.
Although the system can be used to sample only one location, one of its main advantages is that multiple locations can be sequentially sampled or "monitored" for tritium contamination. As mentioned previously, the system can be used to obtain samples from below the surface, such as water samples from subterranean wells, from cooling ponds, canals and the like. Again, for purposes of discussion, it will be assumed that the water samples are being obtained at varying depths in a plurality of well boreholes. Each well is preferably lined or "cased" with a steel, plastic or composite liner to prevent the respective boreholes from caving in. A submersible pump is positioned within each well, and water samples from each well are taken by the submersible pumps sequentially and automatically under the control of a microprocessor and timer. The valving system of each submersible pump includes a spring loaded check valve which can be set to operate at above a certain hydraulic pressure. This, in turn, allows a given pump to obtain a water sample only below a given depth corresponding to the selected hydrostatic pressure. This feature allows sampling at varying, preselected depths as will be discussed in detail is a subsequent section of this disclosure.
Samples from each pump, therefore each well, are transferred or "evacuated" to the surface for pretreating and analysis. The compressor/vacuum pump system cooperating with a valving system, which also includes flow lines, is used to transfer the samples to the surface. Specifics of the operation of the valving system will subsequently be presented in detail. At this point, it suffices to say that the vacuum/compressor system and the valving system, under the control of the microprocessor and timer, are used to control the flow of the sample water. Furthermore, these systems are also used to flow purge air and wash water within the sample in order to clean the system between sampling sequences so that the next sample will not be contaminated by the previous sample.
While the earlier disclosures include a carousel mechanism selecting one of a plurality of columns sample water is pretreated for testing for tritium. The term "pretreated" is used to delineate this step of the analysis from any "treatment" of the sample that might be required in the analysis of the sample within a tritium analyzer. This improved mechanism includes a set of similar valves cooperating with cylinder and piston devices powered by the compressor/vacuum pump system under a controller which, in turn, is under control of the system microprocessor and timer. This feature of the invention greatly increases the speed and automation of the pretreatment phase of the sampling and analysis process.
Once each collected water sample has been treated in a specific sample pretreatment column in the carousel, the sample is then passed to an analyzer for analysis by means of the valving system and its accompanying flow lines. This transfer is also under control of the system microprocessor and timer, which cooperates with the analyzer by means of communication signals. Tritium concentration is preferably measured with a chromatographic analyzer such as a Radiomatic HPLC high precision liquid chromatographic unit. Results of each sample analysis are displayed with an appropriate analog or digital meter, printed by means of a printer, or recorded on a magnetic disk or other digital recording device.
All of the previously discussed elements of the system, with the exception of the submersible pumps and some elements of the valving system and flow lines, are preferably located at the surface of the earth. The plurality of submersible pumps of the invention rapidly and automatically obtain samples and transfer these samples to the surface for pretreatment and analysis. The pumps are also automatically purged after sample transfer such that the next sample will not be contaminated by the previous sample.
The invention also provides rapid and automatic means for pretreating each sample prior to analysis by using the carousel mechanism in cooperation with the valving system and the system microprocessor and timer. This means increases the accuracy and precision of the overall analysis method, while reducing cost by eliminating the need for manual sample pretreatment. Furthermore, the samples can be pretreated on site thereby reducing the overall sampling and analysis time when compared with current methods.
The valving system (at the surface) for the submersible pumps collects the sample from any selected sample site. Furthermore, the system microprocessor and timer gets multiple samples sequentially in time. Since the entire sampling and pretreatment system is fast, efficient and automatic, each sample site can be sampled and analyzed as often as needed, even three to four times per day. This makes the system ideally suited for monitoring tritium at facilities where contamination can be sudden. As an example, using a four times per day sampling, the maximum time interval between samples is six hours. Since sample pretreating and analysis typically takes approximately thirty minutes, the maximum time that can elapse after contamination, such as a spill, is slightly more than six hours. This rapid detection capability of the invention permits rapid remedial action to be taken, especially when compared with typical one to two month sample analysis turnaround times of present, off site, commercial tritium analysis services.
In summary, the sequence of sample acquisition and sample pretreatment events, described briefly above, are controlled by the system microprocessor and timer thereby eliminating need for direct human operation. This substantially reduces the cost and increases the accuracy of sampling and pretreating compared to present human operated systems. The entire sampling, pretreatment and analysis sequence requires less than thirty minutes thereby analysis results can be obtained very rapidly when compared with present, commercial, off site tritium analysis services. The entire sampling and pretreatment system is relatively small and portable, as is the preferred analyzer. Sample analysis can therefore be obtained on site within thirty minutes compared with the typical one to two month turn-around of present, commercial, off site analysis services.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to embodiments thereof which are illustrated in the appended drawings.
FIGS. 1 to 25 show the same schematic connections for a sampling, pretreatment and analyzer and shows a progression of operative steps in the system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The two parent applications set forth a system in general terms while the 25 similar views diagram the sampling and pretreating system which cooperates with a tritium analyzer. Building on the prior disclosures, specific structural aspects are first noted in FIG. 1 and then the 25 steps in detail will be reviewed.
Going first to FIG. 1 of the drawings, it will be noted that this description of the apparatus can be extended to all the other views.
The 25 views are incorporated to make the explanation of operation easier. They show a suggested sequence of operations. More will be noted regarding operations and alternative sequences of operation in substantial detail later.
The system shown in FIG. 1 accomplishes testing as set forth in the earlier disclosures. It collects a set of samples, provides pretreatment and then tests for radiation. This is especially useful in testing ground water and other sources of water for the radioactive hydrogent, namely, tritium. The numeral 10 in FIG. 1 refers generally to the entire system. It cooperates with a first pump 11 and a second pump 12. Others are shown, and the number can be increased indefinitely. Typically, the pumps 11 and 12 are located underground in wells having a depth which is determined by the sampling requirements for the region. The pumps 11 and 12 operation in the fashion set forth in the foregoing disclosures. Those disclosures are incorporated by reference.
The pumps 11 and 12 are installed to selectively deliver a measured quantity of sample. The pumps 11 and 12 are configured and scaled so that the requisite quantity is obtained. A typical operational mode recovers about 50 cc of the water sample. For test purposes, typically only about 10 cc is required for the specific test. Again, this is a scale factor and relates to the size of the test instrument and other aspects.
Each of the pumps 11, 12 and the others which are unnumbered, is connected with two lines. The lines extend collectively to first and second manifolds 13 and 14. These manifolds, similar in construction, connect with a number of valves 15 and 16 which are replicated. FIG. 1 shows the system installed with N wells where N is a whole number integer, and the manifolds 13 and 14 include N valves on each manifold. This enables control of the system through the valves 15 and 16 on the manifolds. These valves are preferably provided with valve operators (omitted for sake of clarity) and they are opened and closed in response to a controller to be described. Indeed, FIG. 1 shows many valves in the system and each valve is provided with an operator. All the operators have been omitted for sake of clarity. The specific operation of the many valves included in FIG. 1 is timed by virtue of the control signals applied to the operators. Rather than show valve operation in a timing chart or other logic table, it is perhaps more helpful in operation by presenting this format, namely, the 25 sequential steps shown in operation. As will be understood, this is one way in which the system 10 can be operated. Equally so, it is not the only way in which the system 10 can be operated.
As will be further understood, the manifold 14 operates as a vacuum source. The manifold 14 is provided with vacuum controlled by a vacuum switch 17 which is communicated through a vacuum line 18 to the manifold 14. By the appropriate provision of vacuum through the manifold 14, a particular pump chamber 11, 12 or any of the N pumps are then filled.
The vacuum switch 17 prompts operation of the pump 20. On one side, the pump 20 provides vacuum, and the opposite side of the pump delivers air at pressure in the line 19. Just as the switch 17 triggers operation to provide vacuum, the switch 21 operates to assure delivery of air under pressure. Conveniently, a tank 22 is incorporated to accumulate air at an elevated pressure. This can speed up operation and reduce waiting time while the pump 20 builds up pressure.
The manifold 13 is the sample manifold. It is connected with a reservoir 24 which holds a measured quantity, typically 50 cc. While it can be scaled to a different size, it is provided with a control switch which measures filling to a specified level such as the suggested amount of 50 cc. In addition to that, it is connected with a pump 25. Surplus from the container 24 is delivered through a waste line 26 to a waste outlet 27.
For convenience at a different testing lab, the waste line 26 serves a dual purpose in that it connects through a branch to fill a sample container 30. The container 30 can be demounted and removed to another lab for testing for any purpose. Alternatively, the sample container 30 can be tagged with time and date of the sample and can be stored for archive purposes. In view of the fact that the tritium does decay, it is not easy to store for a long time radioactive samples if the half life of the radioactive elements in the container is relatively short. Storage in the container 30 is therefore subject to decay depending on the half life.
The sample container 32 is similar to the container 24 but smaller. It holds a requisite volume such as 10 cc. A pump 33 delivers a wash liquid from a wash liquid source 34. In addition to the container 34, there are other containers requiring mention. Briefly, the containers 35, 36 and 39 contain identified liquids. The containers 37 and 38 receive waste. The system further incorporates the counting cell 40 which will be described in greater detail. Pumps 41 and 42 are illustrated with pump 42 connected to a manifold 43. A carousel mechanism 48 better described in the disclosures incorporated by reference is also included for pretreatment.
While the foregoing describes certain of the components the operation of the many valves shown in FIG. 1 is keyed to the sequence of flow patterns deployed in the 25 views. Proceeding therefore from FIG. 1, this shows the system in a state of readiness but prior to operation. This occurs when the equipment is on and operative but has not yet been switched for starting an operational sequence. Proceeding from FIG. 1 to FIG. 2, vacuum is applied through the line 18 and triggers filling of the pump 11. Wash is delivered from the container 34 through the pump 33 to be available for a later step.
FIG. 3 shows the delivery of air through the line 18. This air, under pressure, forces the sample out of the pump 11, through the manifold 13 and into the container 24. As stated before, this container holds the sample and preferably captures a measured amount, i.e., 50 cc in this embodiment. FIG. 4 shows surplus sample is delivered to the waste container 27. FIG. 5 then shows how the sample is directed from the sample container 24 into the container 32 through the carousel 48 for any requisite pretreatment. The progression from FIG. 5 to FIG. 6 then leads to the step shown in FIG. 7 which is pumping a specified sample such as 10 ml into the sample container 30. FIG. 8 is similar to FIG. 7 and shows preparation for cleaning the sample line 13. Continuing in FIG. 9, the pump 42 is operated to fill the counting chamber 40 from the container 32. Surplus is dumped in the container 37. Ideally, there should be no surplus because the container 32 holds a measured quantity. FIG. 10 shows the counting chamber 40 with the sample in it so that radiation counts are totaled and stored for a fixed interval. In another portion of the system 10, air from the pump 20 is delivered through the manifold 13 and elsewhere to blow out the lines and clear the chambers. This helps purge any remnant materials. The purge is further assisted by delivery of a wash liquid from the wash source 34 which is delivered from it through the pump 33 and ultimately through the manifold 13, the chamber 24 and into the waste container 34. In other words, washing of these lines occurs while counting is going on at the counting cell 40.
After that wash cycle in those specified lines shown in FIG. 11, another air dry sequence occurs as illustrated in FIG. 12. Again, this can be conducted while the cell 40 holds the sample and counting continues. As will be understood, counting cannot be rushed; it requires a finite interval to measure a statistically meaningful number of counts in the chance that the water sample in the chamber 40 includes tritium. Accordingly, an air dry sequence occurs in FIG. 12 and another wash sequence is then initiated thereafter as illustrated in FIG. 13. FIG. 14 shows that the wash water is delivered to the waste container 34 after the sequence shown in FIG. 13. FIG. 14 shows the continuation of this and the next step which is permitting an interval of time so that the container 24 has time to dry. FIG. 16 shows the start of this drying sequence in which air is delivered through selected lines for air drying.
FIG. 17 shows another wash step. In this particular instance, the measured sample container 32 is washed. Previously, the container 24 had been washed. Therefore, the washing sequence illustrated in FIG. 17 is then terminated and an air drying sequence is initiated as shown in FIG. 18. All the while, counting continues of any radioactivity from the sample in the cell 40. FIG. 19 is contrasted with FIG. 18 which shows air drying; FIG. 19 shows a second wash cycle. This leads then to the operative status shown in FIG. 20 from FIG. 19. This repairs the system so that wash water is then directed through the counting cell 40 to flush out the prior sample. This occurs at the end of the counting sequence. If, for instance, five or ten minutes are required for counting, the sample is left in the cell 40 for that interval. The interval is one scale factor as are the size of the sample, the sensitivity of the test instrument and the like. When finished, the sample is washed out so that the wash water from the source 34 is delivered, under pressure, through the cell 40. FIG. 21 shows that the cell 40 has been provided with the wash water and it is then vented from that cell into the waste container 37.
After the wash water is put into the cell 40, it is then forced out as shown in FIG. 22. It is empty as illustrated in FIG. 23. This sequence is repeated with a second or alternate wash from the source 35 delivered through the cell 40. When this step of FIG. 25 is completed, the chamber 40 is then empty. When the condition of FIG. 25 is achieved, the equipment has operated one full cycle and is then returned to the state of affairs shown in FIG. 1. Then, this or some other sequence can be executed again.
Speaking in summary terms, it will be observed that two wash cycles are applied in most critical areas. Dry cycles are intermeshed between wash cycles. This provides a high level of cleanliness. This prevents a first sample from cross-contaminating second and third samples. This assures that the data from a first sample will not blur into the data for a second and following samples. This also operates to provide data for each of the samples as well as a demounted sample in the container 30 if so desired. The sample container 30 can be filled from time to time and moved to another location.
The system 10 is more readily built, maintained, operated and repaired. It includes less costly valves. Moreoveri it is constructed with the manifolds 13 and 14 which can be replicated where N is increased to a different number. Finally, the system 10 enables ready recovery of the samples with testing occurring as rapidly as possible depending on the nature and duration required for the particular test.
While the foregoing disclosure is directed toward preferred embodiments, the scope of the invention is set forth by the claims which follow. | The apparatus gathers and prepares liquid samples for analysis for elements or compounds within the liquid samples such as water samples for tritium analysis. This disclosure is further directed toward apparatus and methods for the gathering or collecting of water samples from underground formations penetrated by a borehole, or collecting water samples at varying depths in surface canals, ponds, and the like. The invention is particularly suited for monitoring water in the vicinity of nuclear manufacturing, fabrication and disposal facilities for tritium contamination of ground waters. | 4 |
FIELD OF THE INVENTION
The invention relates to chiral compounds, methods of their preparation, and to their use in optical, electrooptical, electronic, semiconducting or luminescent components or devices, and in decorative, security, cosmetic or diagnostic applications.
BACKGROUND AND PRIOR ART
Chiral liquid crystal (LC) materials are useful for many applications, for example LC displays (LCD) or polymer films with a twisted structure. Usually they consist of an LC host material containing one or more chiral dopants which induce the desired helical twist. The effectiveness of a chiral compound to induce a helically twisted molecular structure in a liquid crystal host material is described by its so-called helical twisting power (HTP). The HTP is given in first approximation, which is sufficient for most practical applications, by equation (1):
H T P = 1 p · c ( 1 )
wherein c is the concentration of the chiral compound in the host material and p is the helical pitch.
As can be seen from equation (1), a short pitch can be achieved by using a high amount of the chiral compound or by using a chiral compound with a high absolute value of the HTP. Thus, in case chiral compounds with low HTP are used, high amounts are needed to induce a short pitch. This is disadvantageous, because the chiral compounds known from prior art do often negatively affect the properties of the LC host mixture like the clearing point, dielectric anisotropy, viscosity, driving voltage or switching times, and because chiral compounds can be used only as pure enantiomers and are therefore expensive and difficult to synthesize.
Another disadvantage of prior art chiral compounds is that they often show low solubility in the LC host material, which leads to undesired crystallization at low temperatures. To overcome this disadvantage, typically two or more different chiral dopants have to be added to the host mixture. This implies higher costs and does usually also require additional effort for temperature compensation of the material, as the different dopants have to be selected such that their temperature coefficients of the twist compensate each other.
Consequently, there is a considerable demand for chiral compounds with a high HTP which are easy to synthesize, can be used in low amounts, show low temperature dependence of the twisting power e.g. for utilizing a constant reflection wavelength, show good solubility in an LC host material and do not have a negative influence on the properties of the LC host.
The invention has the aim of providing chiral compounds having these properties, and not having the above-mentioned disadvantages of prior art chiral compounds. Another aim of the invention is to extend the pool of chiral compounds available to the expert. Other aims are immediately evident to the expert from the following description.
The inventors of the present invention have found that these aims can be achieved by providing chiral compounds as claimed in this invention, which comprise a 6,6′-bisalkinyl-1,1′-bi(2-naphthol) group.
Chiral binaphthol derivatives with alkinyl groups are disclosed in JP 2002-179668 A, JP 2002-179669 A, J. Am. Chem. Soc. 2001, 123(11), 2683, Chem. Phys. Letters 1996, 253(1,2), 141, Mol. Cryst. Liq. Cryst. S&T, Section B 1995, 9, 181, and J. Chem. Soc., Chem. Commun. 1994, 3, 249. However, compounds as claimed in the present invention are not disclosed.
SUMMARY OF THE INVENTION
The invention relates to compounds of formula I
wherein
R 1 and R 2 independently of each other denote H, F, Cl, Br, I, CN, NCS, SF 5 , or straight-chain, branched or cyclic alkyl, aryl or heteroaryl having 1 to 30 C-atoms that is optionally mono- or polysubstituted by F, Cl, Br, I or CN, and in which one or more non-adjacent CH 2 groups are optionally replaced, in each case independently from one another, by —O—, —S—, —NH—, —NR 0 —, —SiR 0 R 00 —, —CO—, —COO—, —OCO—, —OCO—O—, —S—CO—, —CO—S—, —CY 1 ═CY 2 — or —C≡C— in such a manner that O and/or S atoms are not linked directly to one another, or denote -(Z 1 -A 1 ) m -R 5 or P-Sp-, R 3 and R 4 independently of each other have one of the meanings of R 1 , R 5 is H, F, Cl, Br, I, CN, NCS, SF 5 , or straight-chain or branched alkyl having 1 to 30 C-atoms that is optionally mono- or polysubstituted by F, Cl, Br, I or CN, and in which one or more non-adjacent CH 2 groups are optionally replaced, in each case independently from one another, by —O—, —S—, —NH—, —NR 0 —, —SiR 0 R 00 —, —CO—, —COO—, —OCO—, —OCO—O— —S—CO, —CO—S—, —CY 1 ═CY 2 — or —C≡C— in such a manner that O and/or S atoms are not linked directly to one another, or denotes P-Sp-, P is a polymerizable group, Sp is a spacer group or a single bond, A 1 is, in case of multiple occurrence independently of one another, an aromatic or alicyclic group, which optionally contains one or more hetero atoms selected from N, O and S, and is optionally mono- or polysubstituted by R 1 , Z 1 in case of multiple occurrence independently of one another denotes —O—, —S—, —CO—, —COO—, —OCO—, —S—CO—, —CO—S—, —O—COO—, —CO—NR 0 —, —NR 0 —CO—, —NR 0 —CO—NR 00 , —NR 0 —CO—O—, —O—CO—NR 0 —, —OCH 2 —, —CH 2 O—, —SCH 2 —, —CH 2 S—, —CF 2 O—, —OCF 2 —, —CF 2 S—, —SCF 2 —, —CH 2 CH 2 —, —(CH 2 ) 4 —, —CF 2 CH 2 —, —CH 2 CF 2 —, —CF 2 CF 2 —, —CH═N—, —N═CH—, —N═N—, —CH═CR 0 —, —CY 1 ═CY 2 —, —C≡C—, —CH═CH—COO—, —OCO—CH═CH— or a single bond, R 0 and R 00 independently of each other denote H or alkyl with 1 to 12 C-atoms, Y 1 and Y 2 independently of each other denote H, F, Cl or CN, m is 0, 1, 2, 3 or 4, n is an integer from 2 to 5,
with the proviso that, if n is 3 and all R 3 and R 4 are H, then R 1 and R 2 are not 4-cyanophenyl.
The invention further relates to an LC material comprising one or more compounds of formula I.
The invention further relates to a chiral anisotropic polymer obtained by polymerizing a compound of formula I or an LC material as described above and below, preferably in its oriented state in form of a thin film.
The invention further relates to the use of compounds, materials and polymers as described above and below in electrooptical displays, LCDs, optical films, polarizers, compensators, beam splitters, reflective films, alignment layers, colour filters, holographic elements, hot stamping foils, coloured images, decorative or security markings, LC pigments, adhesives, cosmetics, diagnostics, nonlinear optics, optical information storage, electronic devices, organic semiconductors, field effect transistors (FET), components of integrated circuitry (IC), thin film transistors (TFT), Radio Frequency Identification (RFID) tags, organic light emitting diodes (OLED), electroluminescent displays, lighting devices, photovoltaic devices, sensor devices, electrode materials, photoconductors, electrophotographic recording, lasing materials or devices, or as chiral dopants.
TERMS AND DEFINITIONS
The term “film” includes rigid or flexible, self-supporting or freestanding films with mechanical stability, as well as coatings or layers on a supporting substrate or between two substrates.
The term “liquid crystal or mesogenic material” or “liquid crystal or mesogenic compound” means materials or compounds comprising one or more rod- or board-shaped (calamitic) or disk-shaped (discotic) mesogenic groups, i.e. groups with the ability to induce liquid crystal (LC) phase behaviour. The compounds or materials comprising mesogenic groups do not necessarily have to exhibit an LC phase themselves. It is also possible that they show LC phase behaviour only in mixtures with other compounds, or when the mesogenic compounds or materials, or the mixtures thereof, are polymerized.
For the sake of simplicity, the term “liquid crystal material” is used hereinafter for both mesogenic and LC materials.
Polymerizable compounds with one polymerizable group are also referred to as “monoreactive” compounds, compounds with two polymerizable groups as “direactive” compounds, and compounds with more than two polymerizable groups as “multireactive” compounds. Compounds without a polymerizable group are also referred to as “non-reactive” compounds.
The term “reactive mesogen” (RM) means a polymerizable mesogenic or liquid crystal compound.
The binaphthyl group shown in the formulae above and below includes both the S,S- and R,R-isomer.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of formula I have several advantages
they can easily be synthesized, also on large scale of several hundred grams, with a broad range of derivatives using standard methods that are known from the literature, the starting materials, S,S-binaphthol or R,R-binaphthol, can be obtained commercially, they can be prepared enantiomerically pure as compounds of different handedness (left handed and right handed), enabling both left and right handed helices to be formed in a nematic host, they exhibit a high HTP, they exhibit a good solubility in LC mixtures, they are mesogenic or even liquid crystalline, when used as chiral dopants in an LC host material they do not negatively influence the LC phase of the host.
Especially preferred are compounds of formula I, wherein
R 1 and R 2 are identical groups, R 1 and/or R 2 are P-Sp-, wherein Sp is preferably —(CH 2 ) z — with z being an integer from 1 to 12, preferably 1 to 6, most preferably 1, R 1 and R 2 are optionally fluorinated alkyl with 1 to 12 C atoms, the compounds comprise at least one group P-Sp-, n is 2, 3, 4 or 5 and all of R 3 and R 4 denote H, n is 2, 3, 4 or 5 and one or more of R 3 and R 4 denote alkyl or alkoxy with 1 to 12 C atoms, n is 2, 3, 4 or 5 and one or more groups CR 3 R 4 denote CH-(Z 1 -A 1 ) m -R 5 , with R 5 , Z 1 , A 1 and m being as defined above, R 5 is P-Sp-, R 5 is alkyl or alkoxy with 1 to 12 C atoms that is optionally fluorinated, n is 2, 3, 4, 5 or 6, m is 1, 2 or 3.
Preferred cycloalkyl, aryl and heteroaryl groups include, without limitation, furan, pyrrol, thiophene, oxazole, thiazole, thiadiazole, imidazole, phenylene, cyclohexylene, bicyclooctylene, cyclohexenylene, pyridine, pyrimidine, pyrazine, azulene, indane, naphthalene, tetrahydronaphthalene, anthracene and phenanthrene, all of which are optionally substituted by one or more groups L, with L having one of the meanings of R 1 given in formula I.
Particular preferred cycloalkyl, aryl and heteroaryl groups are selected from 1,4-phenylene, pyridine-2,5-diyl, pyrimidine-2,5-diyl, thiophene-2,5-diyl, naphthalene-2,6-diyl, 1,2,3,4-tetrahydronaphthalene-2,6-diyl, indane-2,5-diyl, bicyclooctylene or 1,4-cyclohexylene wherein one or two non-adjacent CH 2 groups are optionally replaced by O and/or S, wherein these groups are unsubstituted, mono- or polysubstituted by L as defined above.
Preferably L is selected from F, Cl, Br, I, —CN, —NO 2 , —NCO, —NCS, —OCN, —SCN, —C(═O)NR 0 R 00 , —C(═O)X, —C(═O)R 0 , —NR 0 R 00 , —OH, —SF 5 , wherein R 0 , R 00 and X are as defined above, optionally substituted silyl, aryl with 1 to 12, preferably 1 to 6 C atoms, and straight chain or branched alkyl, alkoxy, alkylcarbonyl, alkoxycarbonyl, alkylcarbonlyoxy or alkoxycarbonyloxy with 1 to 12, preferably 1 to 6 C atoms, wherein one or more H atoms are optionally replaced by F or Cl.
More preferably L is selected from F, Cl, CN, NO 2 or straight chain or branched alkyl, alkoxy, alkylcarbonyl, alkoxycarbonyl, alkylcarbonlyoxy or alkoxycarbonyloxy with 1 to 12 C atoms, wherein the alkyl groups are optionally perfluorinated.
Most preferably L is selected from F, Cl, CN, NO 2 , CH 3 , C 2 H 5 , C(CH 3 ) 3 , CH(CH 3 ) 2 , CH 2 CH(CH 3 )C 2 H 5 , OCH 3 , OC 2 H 5 , COCH 3 , COC 2 H 5 , COOCH 3 , COOC 2 H 5 , CF 3 , OCF 3 , OCHF 2 or OC 2 F 5 , in particular F, Cl, CN, CH 3 , C 2 H 5 , C(CH 3 ) 3 , CH(CH 3 ) 2 , OCH 3 , COCH 3 or OCF 3 , most preferably F, Cl, CH 3 , C(CH 3 ) 3 , OCH 3 or COCH 3 .
Some preferred groups -(Z 1 -A 1 ) m - are listed below. For reasons of simplicity, Phe in these groups is 1,4-phenylene, PheL is 1,4-phenylene that is substituted with 1 to 4 groups L as defined in formula I, Cyc is 1,4-cyclohexylene and Z has one of the meanings of Z 1 in formula I. The list is comprising the following subformulae as well as their mirror images
-PheL-
II-1
-PheL-Z-Phe-
II-2
-PheL-Z-PheL-
II-3
-Phe-Z-Cyc-
II-4
-PheL-Z-Cyc-
II-5
Z is preferably —O—, —COO—, —OCO—, —CH═CH—, —C≡C—, —CH═CH—COO—, —OCO—CH═CH—, —CH 2 CH 2 — or a single bond.
Very preferably the group -(Z 1 -A 1 ) m - is selected from the following formulae and their mirror images
wherein L and Z are as defined above and r is 0, 1, 2, 3 or 4, preferably 0, 1 or 2.
A group
wherein r is different from 0 is preferably denotin
furthermore
with L having each independently one of the meanings given above. Very preferred compounds of formula I comprise at least two groups
wherein r is 1 or at least one group
wherein r is 2.
An alkyl or alkoxy radical, i.e. where the terminal CH 2 group is replaced by —O—, can be straight-chain or branched. It is preferably straight-chain, has 2, 3, 4, 5, 6, 7 or 8 carbon atoms and accordingly is preferably ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, ethoxy, propoxy, butoxy, pentoxy, hexoxy, heptoxy, or octoxy, furthermore methyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, nonoxy, decoxy, undecoxy, dodecoxy, tridecoxy or tetradecoxy, for example.
Oxaalkyl, i.e. where one CH 2 group is replaced by —O—, is preferably straight-chain 2-oxapropyl (=methoxymethyl), 2-(=ethoxymethyl) or 3-oxabutyl (=2-methoxyethyl), 2-, 3-, or 4-oxapentyl, 2-, 3-, 4-, or 5-oxahexyl, 2-, 3-, 4-, 5-, or 6-oxaheptyl, 2-, 3-, 4-, 5-, 6- or 7-oxaoctyl, 2-, 3-, 4-, 5-, 6-, 7- or 8-oxanonyl or 2-, 3-, 4-, 5-, 6-, 7-, 8- or 9-oxadecyl, for example.
An alkyl group wherein one or more CH 2 groups are replaced by —CH═CH— can be straight-chain or branched. It is preferably straight-chain, has 2 to 10 C atoms and accordingly is preferably vinyl, prop-1-, or prop-2-enyl, but-1-, 2- or but-3-enyl, pent-1-, 2-, 3- or pent-4-enyl, hex-1-, 2-, 3-, 4- or hex-5-enyl, hept-1-, 2-, 3-, 4-, 5- or hept-6-enyl, oct-1-, 2-, 3-, 4-, 5-, 6- or oct-7-enyl, non-1-, 2-, 3-, 4-, 5-, 6-, 7- or non-8-enyl, dec-1-, 2-, 3-, 4-, 5-, 6-, 7-, 8- or dec-9-enyl.
Especially preferred alkenyl groups are C 2 -C 7 -1E-alkenyl, C 4 -C 7 -3E-alkenyl, C 5 -C 7 -4-alkenyl, C 6 -C 7 -6-alkenyl and C 7 -6-alkenyl, in particular C 2 -C 7 -1E-alkenyl, C 4 -C 7 -3E-alkenyl and C 5 -C 7 -4-alkenyl. Examples for particularly preferred alkenyl groups are vinyl, 1E-propenyl, 1E-butenyl, 1E-pentenyl, 1E-hexenyl, 1E-heptenyl, 3-butenyl, 3E-pentenyl, 3E-hexenyl, 3E-heptenyl, 4-pentenyl, 4Z-hexenyl, 4E-hexenyl, 4Z-heptenyl, 5-hexenyl, 6-heptenyl and the like. Groups having up to 5 C atoms are generally preferred.
In an alkyl group wherein one CH 2 group is replaced by —O— and one by —CO—, these radicals are preferably neighboured. Accordingly these radicals together form a carbonyloxy group —CO—O— or an oxycarbonyl group —O—CO—. Preferably this group is straight-chain and has 2 to 6 C atoms. It is accordingly preferably acetyloxy, propionyloxy, butyryloxy, pentanoyloxy, hexanoyloxy, acetyloxymethyl, propionyloxymethyl, butyryloxymethyl, pentanoyloxymethyl, 2-acetyloxyethyl, 2-propionyloxyethyl, 2-butyryloxyethyl, 3-acetyloxypropyl, 3-propionyloxypropyl, 4-acetyloxybutyl, methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, butoxycarbonyl, pentoxycarbonyl, methoxycarbonylmethyl, ethoxycarbonylmethyl, propoxycarbonylmethyl, butoxycarbonylmethyl, 2-(methoxycarbonyl)ethyl, 2-(ethoxycarbonyl)ethyl, 2-(propoxycarbonyl)ethyl, 3-(methoxycarbonyl)propyl, 3-(ethoxycarbonyl)propyl, 4-(methoxycarbonyl)-butyl.
An alkyl group wherein two or more CH 2 groups are replaced by —O— and/or —COO— can be straight-chain or branched. It is preferably straight-chain and has 3 to 12 C atoms. Accordingly it is preferably bis-carboxy-methyl, 2,2-bis-carboxy-ethyl, 3,3-bis-carboxy-propyl, 4,4-bis-carboxy-butyl, 5,5-bis-carboxy-pentyl, 6,6-bis-carboxy-hexyl, 7,7-bis-carboxy-heptyl, 8,8-bis-carboxy-octyl, 9,9-bis-carboxy-nonyl, 10,10-bis-carboxy-decyl, bis-(methoxycarbonyl)-methyl, 2,2-bis(methoxycarbonyl)-ethyl, 3,3-bis-(methoxycarbonyl)-propyl, 4,4-bis(methoxycarbonyl)-butyl, 5,5-bis-(methoxycarbonyl)-pentyl, 6,6-bis(methoxycarbonyl)-hexyl, 7,7-bis-(methoxycarbonyl)-heptyl, 8,8-bis(methoxycarbonyl)-octyl, bis-(ethoxycarbonyl)-methyl, 2,2-bis(ethoxycarbonyl)-ethyl, 3,3-bis-(ethoxycarbonyl)-propyl, 4,4-bis(ethoxycarbonyl)-butyl, 5,5-bis-(ethoxycarbonyl)-hexyl.
An alkyl or alkenyl group that is monosubstituted by CN or CF 3 is preferably straight-chain. The substitution by CN or CF 3 can be in any desired position.
An alkyl or alkenyl group that is at least monosubstituted by halogen is preferably straight-chain. Halogen is preferably F or Cl, in case of multiple substitution preferably F. The resulting groups include also perfluorinated groups. In case of monosubstitution the F or Cl substituent can be in any desired position, but is preferably in ω-position. Examples for especially preferred straight-chain groups with a terminal F substituent are fluormethyl, 2-fluorethyl, 3-fluorpropyl, 4-fluorbutyl, 5-fluorpentyl, 6-fluorhexyl and 7-fluorheptyl. Other positions of F are, however, not excluded.
Halogen is preferably F or Cl.
The polymerizable group P is a group that is capable of participating in a polymerization reaction, like radicalic or ionic chain polymerization, polyaddition or polycondensation, or capable of being grafted, for example by condensation or addition, to a polymer backbone in a polymeranaloguous reaction. Especially preferred are polymerizable groups for chain polymerization reactions, like radicalic, cationic or anionic polymerization. Very preferred are polymerizable groups comprising a C—C double or triple bond, and polymerizable groups capable of polymerization by a ring-opening reaction, like oxetanes or epoxides.
Very preferably the polymerizable group P is selected from CH 2 ═CW 1 —COO—, CH 2 ═CW 1 —CO—,
CH 2 ═CW 2 —(O) k1 —, CH 3 —CH═CH—O—, (CH 2 ═CH) 2 CH—OCO—, (CH 2 ═CH—CH 2 ) 2 CH—OCO—, (CH 2 ═CH) 2 CH—O—, (CH 2 ═CH—CH 2 ) 2 N—, (CH 2 ═CH—CH 2 ) 2 N—CO—, HO—CW 2 W 3 —, HS—CW 2 W 3 —, HW 2 N—, HO—CW 2 W 3 —NH—, CH 2 ═CW 1 —CO—NH—, CH 2 ═CH—(COO) k1 -Phe-(O) k2 —, CH 2 ═CH—(CO) k1 -Phe-(O) k2 —, Phe-CH═CH—, HOOC—, OCN—, and W 4 W 5 W 6 Si—, with W 1 being H, F, Cl, CN, CF 3 , phenyl or alkyl with 1 to 5 C-atoms, in particular H, C 1 or CH 3 , W 2 and W 3 being independently of each other H or alkyl with 1 to 5 C-atoms, in particular H, methyl, ethyl or n-propyl, W 4 , W 5 and W 6 being independently of each other Cl, oxaalkyl or oxacarbonylalkyl with 1 to 5 C-atoms, W 7 and W 8 being independently of each other H, Cl or alkyl with 1 to 5 C-atoms, Phe being 1,4-phenylene that is optionally substituted by one or more groups L as defined above, and k 1 and k 2 being independently of each other 0 or 1.
Especially preferred groups P are CH 2 ═CH—COO—, CH 2 ═C(CH 3 )—COO—, CH 2 ═CH—, CH 2 ═CH—O—, (CH 2 ═CH) 2 CH—OCO—, (CH 2 ═CH) 2 CH—O—,
Especially preferably Pg is a vinyl group, an acrylate group, a methacrylate group, an oxetane group or an epoxy group, especially preferably an acrylate or methacrylate group.
Very preferred are acrylate and oxetane groups. Oxetanes produce less shrinkage upon polymerization (cross-linking), which results in less stress development within films, leading to higher retention of ordering and fewer defects. Oxetane cross-linking also requires a cationic initiator, which unlike a free radical initiator is inert to oxygen.
As spacer group all groups can be used that are known for this purpose to the skilled in the art. The spacer group Sp is preferably of formula Sp′-X′, such that -Sp-C≡C— is -Sp′-X—C≡C—, -Sp-A 1/2 - is -Sp-X-A 1/2 - and P-Sp is P-Sp′-X′-, wherein
Sp′ is alkylene with 1 to 20 C atoms, preferably 1 to 12 C-atoms, which is optionally mono- or polysubstituted by F, Cl, Br, I or CN, and wherein one or more non-adjacent CH 2 groups are optionally replaced, in each case independently from one another, by —O—, —S—, —NH—, —NR 0 —, —SiR 0 R 00 —, —CO—, —COO—, —OCO—, —OCO—O—, —S—CO—, —CO—S—, —NR 0 —CO—O—, —O—CO—NR 0 —, —NR 0 —CO—NR 0 —, —CH═CH— or —C≡C— in such a manner that O and/or S atoms are not linked directly to one another, X′ is —O—, —S—, —CO—, —COO—, —OCO—, —O—COO—, —CO—NR 0 —, —NR 0 —CO—, —NR 0 —CO—NR 0 —, —OCH 2 —, —CH 2 O—, —SCH 2 —, —CH 2 S—, —CF 2 O—, —OCF 2 —, —CF 2 S—, —SCF 2 —, —CF 2 CH 2 —, —CH 2 CF 2 —, —CF 2 CF 2 —, —CH═N—, —N═CH—, —N═N—, —CH═CR 0 —, —CY 1 ═CY 2 —, —C≡C—, —CH═CH—COO—, —OCO—CH═CH— or a single bond, R 0 and R 00 are independently of each other H or alkyl with 1 to 12 C-atoms, and Y 1 and Y 2 are independently of each other H, F, Cl or CN. X′ is preferably —O—, —S—CO—, —COO—, —OCO—, —O—COO—, —CO—NR 0 —, —NR 0 —CO—, —NR 0 —CO—NR 0 — or a single bond.
Typical groups Sp′ are, for example, —(CH 2 ) p —, —(CH 2 CH 2 O) q —CH 2 CH 2 —, —CH 2 CH 2 —S—CH 2 CH 2 — or —CH 2 CH 2 —NH—CH 2 CH 2 — or —(SiR 0 R 0 O—O) p —, with p being an integer from 2 to 12, q being an integer from 1 to 3 and R 0 and R 00 having the meanings given above.
Preferred groups Sp′ are ethylene, propylene, butylene, pentylene, hexylene, heptylene, octylene, nonylene, decylene, undecylene, dodecylene, octadecylene, ethyleneoxyethylene, methyleneoxybutylene, ethylene-thioethylene, ethylene-N-methyl-iminoethylene, 1-methylalkylene, ethenylene, propenylene and butenylene for example.
Further preferred are compounds with one or two groups P-Sp- wherein Sp is a single bond. In case of compounds with two groups P-Sp, each of the two polymerizable groups P and the two spacer groups Sp can be identical or different.
Particularly preferred compounds of formula I are those of the following formulae
wherein
R′ and R″ have one of the meanings of R 1 in formula I, R′″ is P-Sp, preferably P—CH 2 —, or has one of the meanings of R 1 in formula I, R″″ is P-Sp or has one of the meanings of R 1 in formula I, Z has one of the meanings of Z 1 in formula I, A has one of the meanings of A 1 in formula I.
Especially preferred are compounds of the following subformulae
wherein R′, P and Sp′ are as defined above, and “alkyl” is n-alkyl with 1 to 12 C atoms, preferably methyl, ethyl, propyl, butyl, pentyl or hexyl.
The compounds of formula I can be synthesized according to or in analogy to methods which are known per se and which are described in the literature and in standard works of organic chemistry such as, for example, Houben-Weyl, Methoden der organischen Chemie, Thieme-Verlag, Stuttgart. Preferably the compounds are synthesized according or in analogy to the methods shown in the examples.
According to a preferred method, Binaphthol is reacted with bromine in a suitable organic solvent, preferably dichloromethane, at low temperatures, preferably −70° C. The intermediate 6,6′-dibromo-[1,1′]binaphthalenyl-2,2′-diol is reacted with an alkyl ditosylate and potassium carbonate in a suitable organic solvent, preferably NMP. The resulting ring closed intermediate is reacted with an aromatic acetylene compound in the presence of a base, preferably triethylamine, and a catalytic amount of a copper salt, preferably copper iodide, and a palladium catalyst, preferably bis(triphenylphosphine)dichloride, to form a desired product with high HTP. This is also depicted in the Schemes shown in the examples. The method to prepare a compound of formula I is another aspect of the invention.
The compounds of formula I can be used in LC mixtures for LCDs exhibiting a twisted structure like, for example, twisted or supertwisted nematic (TN, STN) displays with multiplex or active matrix addressing, or in cholesteic displays like surface stabilized or polymer stabilized cholesteric texture displays (SSCT, PSCT) as described in WO 92/19695, WO 93/23496, U.S. Pat. No. 5,453,863 or U.S. Pat. No. 5,493,430, for LCDs with variable pitch, like multi-domain LCDs as described in WO 98/57223, multicolour cholesteric displays as described in U.S. Pat. No. 5,668,614, or displays comprising a chiral LC medium operating in the isotropic or blue phase as described in WO 02/93244.
The inventive compounds of formula I are also suitable for use in thermochromic or photochromic LC media, which change their colour upon temperature change or photoirradiation, respectively.
Thus, another aspect of the invention is an LC mixture comprising at least one chiral compound of formula I. Yet another aspect of the invention are cholesteric LCDs comprising cholesteric LC media containing at least one chiral compound of formula I.
The compounds of formula I have a good solubility in LC host mixtures, and can be added as dopants to LC hosts in high amounts without significantly affecting the phase behaviour and electrooptical properties of the mixture. Undesired spontaneous crystallization at low temperatures is thereby reduced and the operating temperature range of the mixture can be broadened. Furthermore, they can be used for the preparation of highly twisted LC media even if they have a low HTP, because the dopant concentration can be increased to yield low pitch values (i.e. high twist) without affecting the mixture properties. The use of a second dopant, which is often added to avoid crystallization, can thus be avoided. As the chiral compounds of formula I exhibit high HTP values, an LC mixture with high helical twist, i.e. a low pitch, can be prepared by adding these compounds in very small amounts.
Such an LC mixture comprises preferably 0.1 to 30%, in particular 1 to 25% and very particularly preferably 2 to 15% by weight of chiral compounds of formula I. Preferably it comprises 1 to 3 chiral compounds of formula I.
In a preferred embodiment of the invention the LC mixture is consisting of 2 to 25, preferably 3 to 15 compounds, at least one of which is a chiral compound of formula I. The other compounds are preferably low molecular weight LC compounds selected from nematic or nematogenic substances, for example from the known classes of the azoxybenzenes, benzylidene-anilines, biphenyls, terphenyls, phenyl or cyclohexyl benzoates, phenyl or cyclohexyl esters of cyclohehexanecarboxylic acid, phenyl or cyclohexyl esters of cyclohexylbenzoic acid, phenyl or cyclohexyl esters of cyclohexylcyclohexanecarboxylic acid, cyclohexylphenyl esters of benzoic acid, of cyclohexanecarboxylic acid and of cyclohexylcyclohexanecarboxylic acid, phenylcyclohexanes, cyclohexylbiphenyls, phenylcyclohexylcyclohexanes, cyclohexylcyclohexanes, cyclohexylcyclohexenes, cyclohexylcyclohexylcyclohexenes, 1,4-biscyclohexylbenzenes, 4,4′-bis-cyclohexylbiphenyls, phenyl- or cyclohexylpyrimidines, phenyl- or cyclohexylpyridines, phenyl- or cyclohexylpyridazines, phenyl- or cyclohexyldioxanes, phenyl- or cyclohexyl-1,3-dithianes, 1,2-diphenyl-ethanes, 1,2-dicyclohexylethanes, 1-phenyl-2-cyclohexylethanes, 1-cyclohexyl-2-(4-phenylcyclohexyl)ethanes, 1-cyclohexyl-2-biphenyl-ethanes, 1-phenyl2-cyclohexylphenylethanes, optionally halogenated stilbenes, benzyl phenyl ether, tolanes, substituted cinnamic acids and further classes of nematic or nematogenic substances. The 1,4-phenylene groups in these compounds may also be laterally mono- or difluorinated. The LC mixture is preferably based on achiral compounds of this type.
The most important compounds that can be used as components of the LC mixture can be characterized by the following formula
R′-L′-G′-E-R″
wherein L′ and E, which may be identical or different, are in each case, independently from one another, a bivalent radical from the group formed by -Phe-, -Cyc-, -Phe-Phe-, -Phe-Cyc-, -Cyc-Cyc-, -Pyr-, -Dio-, —B-Phe- and —B-Cyc- and their mirror images, where Phe is unsubstituted or fluorine-substituted 1,4-phenylene, Cyc is trans-1,4-cyclohexylene or 1,4-cyclohexenylene, Pyr is pyrimidine-2,5-diyl or pyridine-2,5-diyl, Dio is 1,3-dioxane-2,5-diyl abd B is 2-(trans-1,4-cyclohexyl)ethyl, pyrimidine-2,5-diyl, pyridine-2,5-diyl or 1,3-dioxane-2,5-diyl.
G′ in these compounds is selected from the following bivalent groups —CH═CH—, —N(O)N—, —CH═CY—, —CH═N(O)—, —C≡C—, —CH 2 —CH 2 —, —CO—O—, —CH 2 —O—, —CO—S—, —CH 2 —S—, —CH═N—, —COO-Phe-COO— or a single bond, with Y being halogen, preferably chlorine, or —CN.
R′ and R″ are, in each case, independently of one another, alkyl, alkenyl, alkoxy, alkenyloxy, alkanoyloxy, alkoxycarbonyl or alkoxycarbonyloxy with 1 to 18, preferably 3 to 12 C atoms, or alternatively one of R′ and R″ is F, CF 3 , OCF 3 , Cl, NCS or CN.
In most of these compounds R′ and R″ are, in each case, independently of each another, alkyl, alkenyl or alkoxy with different chain length, wherein the sum of C atoms in nematic media generally is between 2 and 9, preferably between 2 and 7.
Many of these compounds or mixtures thereof are commercially available. All of these compounds are either known or can be prepared by methods which are known per se, as described in the literature (for example in the standard works such as Houben-Weyl, Methoden der Organischen Chemie [Methods of Organic Chemistry], Georg-Thieme-Verlag, Stuttgart), to be precise under reaction conditions which are known and suitable for said reactions. Use may also be made here of variants which are known per se, but are not mentioned here.
A preferred use of the compounds of formula I is the preparation of polymerizable LC mixtures, anisotropic polymer gels and anisotropic polymer films, in particular polymer films that exhibit a helically twisted molecular structure with uniform planar orientation, i.e. wherein the helical axis is oriented perpendicular to the plane of the film, like oriented cholesteric films.
Anisotropic polymer gels and displays comprising them are disclosed for example in DE 195 04 224 and GB 2 279 659.
Oriented cholesteric polymer films can be used for example as broadband reflective polarizers, colour filters, security markings, or for the preparation of LC pigments.
Thus, another aspect of the invention is a polymerizable LC material comprising one or more compounds of formula I and one or more further compounds, which can also be polymerizable and/or LC compounds.
The polymerizable LC material is preferably a mixture of two or more compounds, at least one of which is polymerizable or crosslinkable compound. Polymerizable compounds with one polymerizable group are hereinafter also referred to as “monoreactive”. Crosslinkable compounds, i.e. having two or more polymerizable groups, are hereinafter also referred to as “di- or multireactive”.
The polymerizable mesogenic or LC compounds are preferably monomers, very preferably calamitic monomers. These materials typically have good optical properties, like reduced chromaticity, and can be easily and quickly aligned into the desired orientation, which is especially important for the industrial production of polymer films at large scale. It is also possible that the polymerizable material comprises one or more discotic monomers.
The polymerizable materials as described above and below are another aspect of the invention.
Polymerizable mesogenic mono-, di- and multireactive compounds suitable for the present invention can be prepared by methods which are known per se and which are described in standard works of organic chemistry like for example Houben-Weyl, Methoden der organischen Chemie, Thieme-Verlag, Stuttgart.
Suitable polymerizable mesogenic or LC compounds for use as monomer or comonomer in a polymerizable LC mixture are disclosed for example in WO 93/22397, EP 0 261 712, DE 195 04 224, WO 95/22586, WO 97/00600, U.S. Pat. No. 5,518,652, U.S. Pat. No. 5,750,051, U.S. Pat. No. 5,770,107 and U.S. Pat. No. 6,514,578.
Examples of suitable and preferred polymerizable mesogenic or LC compounds (reactive mesogens) are shown in the following list.
wherein
P 0 is, in case of multiple occurrence independently of one another, a polymerizable group, preferably an acryl, methacryl, oxetane, epoxy, vinyl, vinyloxy, propenyl ether or styrene group, r is 0, 1, 2, 3 or 4, x and y are independently of each other 0 or identical or different integers from 1 to 12, z is 0 or 1, with z being 0 if the adjacent x or y is 0, A 0 is, in case of multiple occurrence independently of one another, 1,4-phenylene that is optionally substituted with 1, 2, 3 or 4 groups L, or trans-1,4-cyclohexylene, u and v are independently of each other 0 or 1, Z 0 is, in case of multiple occurrence independently of one another, —COO—, —OCO—, —CH 2 CH 2 —, —C═C—, —CH═CH—, —CH═CH—COO—, —OCO—CH═CH— or a single bond, R 0 is alkyl, alkoxy, thioalkyl, alkylcarbonyl, alkoxycarbonyl, alkylcarbonyloxy or alkoxycarbonyloxy with 1 or more, preferably 1 to 15 C atoms which is optionally fluorinated, or is Y 0 or P—(CH 2 ) y —(O) z —, Y 0 is F, Cl, CN, NO 2 , OCH 3 , OCN, SCN, SF 5 , optionally fluorinated alkylcarbonyl, alkoxycarbonyl, alkylcarbonyloxy or alkoxycarbonyloxy with 1 to 4 C atoms, or mono- oligo- or polyfluorinated alkyl or alkoxy with 1 to 4 C atoms, R 01,02 are independently of each other H, R 0 or Y 0 , R* is a chiral alkyl or alkoxy group with 4 or more, preferably 4 to 12 C atoms, like 2-methylbutyl, 2-methyloctyl, 2-methylbutoxy or 2-methyloctoxy, Ch is a chiral group selected from cholesteryl, estradiol, or terpenoid radicals like menthyl or citronellyl, L is, in case of multiple occurrence independently of one another, H, F, Cl, CN or optionally halogenated alkyl, alkoxy, alkylcarbonyl, alkoxycarbonyl, alkylcarbonyloxy or alkoxycarbonyloxy with 1 to 5 C atoms,
and wherein the benzene rings can additionally be substituted with one or more identical or different groups L.
In addition to compounds of formula I, the polymerizable material may further comprise one or more polymerizable or unpolymerizable chiral compounds.
Suitable unpolymerizable chiral compounds are for example standard chiral dopants like R- or S-811, R- or S-1011, R- or S-2011, R- or S-3011, R- or S-4011, R- or S-5011, or CB 15 (all available from Merck KGaA, Darmstadt, Germany), sorbitols as described in WO 98/00428, hydrobenzoins as described in GB 2,328,207, chiral binaphthols as described in WO 02/94805, chiral binaphthol acetals as described in WO 02/34739, chiral TADDOLs as described in WO 02/06265, or chiral compounds having fluorinated linkage groups as described in WO 02/06196 or WO 02/06195. Suitable polymerizable chiral compounds are for example those listed above, or the polymerizable chiral material Paliocolor® LC756 (from BASF AG, Ludwigshafen, Germany).
The general preparation of polymer LC films according to this invention is known to the ordinary expert and described in the literature. Typically a polymerizable LC material is coated or otherwise applied onto a substrate where it aligns into uniform orientation, and polymerized in situ in its LC phase at a selected temperature for example by exposure to heat or actinic radiation, preferably by photo-polymerization, very preferably by UV-photopolymerization, to fix the alignment of the LC molecules. If necessary, uniform alignment can promoted by additional means like shearing or annealing the LC material, surface treatment of the substrate, or adding surfactants to the LC material.
As substrate for example glass or quarz sheets or plastic films can be used. It is also possible to put a second substrate on top of the coated material prior to and/or during and/or after polymerization. The substrates can be removed after polymerization or not. When using two substrates in case of curing by actinic radiation, at least one substrate has to be transmissive for the actinic radiation used for the polymerisation. Isotropic or birefringent substrates can be used. In case the substrate is not removed from the polymerized film after polymerisation, preferably isotropic substrates are used.
Suitable and preferred plastic substrates are for example films of polyester such as polyethyleneterephthalate (PET) or polyethylenenaphthalate (PEN), polyvinylalcohol (PVA), polycarbonate (PC) or triacetylcellulose (TAC), very preferably PET or TAC films. As birefringent substrates for example uniaxially stretched plastics film can be used. PET films are commercially available for example from DuPont Teijin Films under the trade name Melinex®).
The polymerizable material can be applied onto the substrate by conventional coating techniques like spin-coating or blade coating. It can also be applied to the substrate by conventional printing techniques which are known to the expert, like for example screen printing, offset printing, reel-to-reel printing, letter press printing, gravure printing, rotogravure printing, flexographic printing, intaglio printing, pad printing, heat-seal printing, ink-jet printing or printing by means of a stamp or printing plate.
It is also possible to dissolve the polymerizable material in a suitable solvent. This solution is then coated or printed onto the substrate, for example by spin-coating or printing or other known techniques, and the solvent is evaporated off before polymerization. In many cases it is suitable to heat the mixture in order to facilitate the evaporation of the solvent. As solvents for example standard organic solvents can be used. The solvents can be selected for example from ketones such as acetone, methyl ethyl ketone, methyl propyl ketone or cyclohexanone; acetates such as methyl, ethyl or butyl acetate or methyl acetoacetate; alcohols such as methanol, ethanol or isopropyl alcohol; aromatic solvents such as toluene or xylene; halogenated hydrocarbons such as di- or trichloromethane; glycols or their esters such as PGMEA (propyl glycol monomethyl ether acetate), γ-butyrolactone, and the like. It is also possible to use binary, ternary or higher mixtures of the above solvents.
Initial alignment (e.g. planar alignment) of the polymerizable LC material can be achieved for example by rubbing treatment of the substrate, by shearing the material during or after coating, by annealing the material before polymerization, by application of an alignment layer, by applying a magnetic or electric field to the coated material, or by the addition of surface-active compounds to the material. Reviews of alignment techniques are given for example by 1. Sage in “Thermotropic Liquid Crystals”, edited by G. W. Gray, John Wiley & Sons, 1987, pages 75-77; and by T. Uchida and H. Seki in “Liquid Crystals—Applications and Uses Vol. 3”, edited by B. Bahadur, World Scientific Publishing, Singapore 1992, pages 1-63. A review of alignment materials and techniques is given by J. Cognard, Mol. Cryst. Liq. Cryst. 78, Supplement 1 (1981), pages 1-77.
Especially preferred is a polymerizable material comprising one or more surfactants that promote a specific surface alignment of the LC molecules. Suitable surfactants are described for example in J. Cognard, Mol. Cryst. Liq. Cryst. 78, Supplement 1, 1-77 (1981). Preferred aligning agents for planar alignment are for example non-ionic surfactants, preferably fluorocarbon surfactants such as the commercially available Fluorad FC-171® (from 3M Co.) or Zonyl FSN® (from DuPont), multiblock surfactants as described in GB 2 383 040 or polymerizable surfactants as described in EP 1 256 617.
It is also possible to apply an alignment layer onto the substrate and provide the polymerizable material onto this alignment layer. Suitable alignment layers are known in the art, like for example rubbed polyimide or alignment layers prepared by photoalignment as described in U.S. Pat. No. 5,602,661, U.S. Pat. No. 5,389,698 or U.S. Pat. No. 6,717,644.
It is also possible to induce or improve alignment by annealing the polymerizable LC material at elevated temperature, preferably at its polymerization temperature, prior to polymerization.
Polymerization is achieved for example by exposing the polymerizable material to heat or actinic radiation. Actinic radiation means irradiation with light, like UV light, IR light or visible light, irradiation with X-rays or gamma rays or irradiation with high energy particles, such as ions or electrons. Preferably polymerization is carried out by UV irradiation. As a source for actinic radiation for example a single UV lamp or a set of UV lamps can be used. When using a high lamp power the curing time can be reduced. Another possible source for actinic radiation is a laser, like for example a UV, IR or visible laser.
Polymerization is preferably carried out in the presence of an initiator absorbing at the wavelength of the actinic radiation. For example, when polymerizing by means of UV light, a photoinitiator can be used that decomposes under UV irradiation to produce free radicals or ions that start the polymerization reaction. For polymerizing acrylate or methacrylate groups preferably a radical photoinitiator is used. For polymerizing vinyl, epoxide or oxetane groups preferably a cationic photoinitiator is used. It is also possible to use a thermal polymerization initiator that decomposes when heated to produce free radicals or ions that start the polymerization. Typical radicalic photoinitiators are for example the commercially available Irgacure® or Darocure® (Ciba Geigy AG, Basel, Switzerland). A typical cationic photoinitiator is for example UVI 6974 (Union Carbide).
The polymerizable material may also comprise one or more stabilizers or inhibitors to prevent undesired spontaneous polymerization, like for example the commercially available Irganox® (Ciba Geigy AG, Basel, Switzerland).
The curing time depends, inter alia, on the reactivity of the polymerizable material, the thickness of the coated layer, the type of polymerization initiator and the power of the UV lamp. The curing time is preferably ≦5 minutes, very preferably ≦3 minutes, most preferably ≦1 minute. For mass production short curing times of ≦30 seconds are preferred.
Preferably polymerization is carried out in an inert gas atmosphere like nitrogen or argon.
The polymerizable material may also comprise one or more dyes having an absorption maximum adjusted to the wavelength of the radiation used for polymerization, in particular UV dyes like e.g. 4,4″-azoxy anisole or Tinuvin® dyes (from Ciba AG, Basel, Switzerland).
In another preferred embodiment the polymerizable material comprises one or more monoreactive polymerizable non-mesogenic compounds, preferably in an amount of 0 to 50%, very preferably 0 to 20%. Typical examples are alkylacrylates or alkylmethacrylates.
In another preferred embodiment the polymerizable material comprises one or more di- or multireactive polymerizable non-mesogenic compounds, preferably in an amount of 0 to 50%, very preferably 0 to 20%, alternatively or in addition to the di- or multireactive polymerizable mesogenic compounds. Typical examples of direactive non-mesogenic compounds are alkyldiacrylates or alkyldimethacrylates with alkyl groups of 1 to 20 C atoms. Typical examples of multireactive non-mesogenic compounds are trimethylpropanetrimethacrylate or pentaeryth ritoltetraacrylate.
It is also possible to add one or more chain transfer agents to the polymerizable material in order to modify the physical properties of the polymer film. Especially preferred are thiol compounds, for example monofunctional thiols like dodecane thiol or multifunctional thiols like trimethylpropane tri(3-mercaptopropionate). Very preferred are mesogenic or LC thiols as disclosed for example in WO 96/12209, WO 96/25470 or U.S. Pat. No. 6,420,001. By using chain transfer agents the length of the free polymer chains and/or the length of the polymer chains between two crosslinks in the polymer film can be controlled. When the amount of the chain transfer agent is increased, the polymer chain length in the polymer film decreases.
The polymerizable material may also comprise a polymeric binder or one or more monomers capable of forming a polymeric binder, and/or one or more dispersion auxiliaries. Suitable binders and dispersion auxiliaries are disclosed for example in WO 96/02597. Preferably, however, the polymerizable material does not contain a binder or dispersion auxiliary.
The polymerizable material can additionally comprise one or more additional components like for example catalysts, sensitizers, stabilizers, inhibitors, chain-transfer agents, co-reacting monomers, surface-active compounds, lubricating agents, wetting agents, dispersing agents, hydrophobing agents, adhesive agents, flow improvers, defoaming agents, deaerators, diluents, reactive diluents, auxiliaries, colourants, dyes or pigments.
The thickness of a polymer film according to the present invention is preferably from 0.3 to 5 microns, very preferably from 0.5 to 3 microns, most preferably from 0.7 to 1.5 microns. For use as alignment layer, thin films with a thickness of 0.05 to 1, preferably 0.1 to 0.4 microns are preferred.
The polymer film of the present invention can be used as retardation or compensation film for example in LCDs to improve the contrast and brightness at large viewing angles and reduce the chromaticity. It can be used outside the switchable LC cell of the LCD or between the substrates, usually glass substrates, forming the switchable LC cell and containing the switchable LC medium (incell application).
The polymer film of the present invention can also be used as alignment layer for LC materials. For example, it can be used in an LCD to induce or improve alignment of the switchable LC medium, or to align a subsequent layer of polymerizable LC material coated thereon. In this way, stacks of polymerized LC films can be prepared.
In particular, the chiral compounds, mixtures, polymers and polymer films according to the present invention can be used in reflective polarizers as disclosed in GB 2 315 072 or WO 97/35219, negative C plate retarders as disclosed in WO 01/20394 or WO 2004/013666, biaxial negative C plate retarders as disclosed in WO 2003/054111, alignment layers as disclosed in EP 1 376 163, birefringent markings or images for decorative or security use as disclosed in GB 2 315 760, WO 02/85642, EP 1 295 929 or EP 1 381 022.
The polymer film of the present invention can be used in conventional LC displays, for example displays with vertical alignment like the DAP (deformation of aligned phases), ECB (electrically controlled birefringence), CSH (colour super homeotropic), VA (vertically aligned), VAN or VAC (vertically aligned nematic or cholesteric), MVA (multi-domain vertically aligned) or PVA (patterned vertically aligned) mode; displays with bend or hybrid alignment like the OCB (optically compensated bend cell or optically compensated birefringence), R—OCB (reflective OCB), HAN (hybrid aligned nematic) or pi-cell (π-cell) mode; displays with twisted alignment like the TN (twisted nematic), HTN (highly twisted nematic), STN (super twisted nematic), AMD-TN (active matrix driven TN) mode; displays of the IPS (in plane switching) mode, or displays with switching in an optically isotropic phase or in the blue phase, as described for example in WO 02/93244.
Especially preferred are TN, STN, VA and IPS displays, in particular those of the active-matrix type. Further preferred are transflective displays.
In the foregoing and the following, all temperatures are given in degrees Celsius, and all percentages are by weight, unless stated otherwise. The following abbreviations are used to illustrate the LC phase behaviour: C, K=crystalline; N=nematic; S=smectic; N*, Ch=chiral nematic or cholesteric; I=isotropic. The numbers between these symbols indicate the phase transition temperatures in degree Celsius. Furthermore, mp is the melting point and cp is the clearing point (in ° C.).
Unless stated otherwise, the precentages of components of a polymerizable mixture as given above and below refer to the total amount of solids in the mixture polymerizable mixture, i.e. not including solvents.
The HTP of a chiral dopant in an LC host material is given as HTP=(p·c) −1 (in μm −1 ), wherein p is the pitch of the molecular helix (in μm) and c is the concentration (in wt. %) of the chiral compound in the host (a concentration of 1% by weight for example corresponds to c=0.01). Unless stated otherwise, specific HTP values given above and below relate to a dopant concentration of 1% in the LC host mixture MLC-6260 (Merck KGaA, Darmstadt, Germany) at 20° C.
The examples below shall illustrate the invention without limiting it. The corresponding S,S- or R,R-isomers of all binaphthyl compounds shown in the examples can also be prepared according or in analogy to the methods described.
EXAMPLE 1
Compound (1) is prepared according to reaction scheme 1 below.
Step 1: S-(−)-6,6′-Dibromo-[1,1′]binaphthalenyl-2,2′-diol
Bromine (10.2 ml, 200.0 mmol) is added dropwise to a solution of S-(−)-1,1′-bi-2-naphthol (30.0 g, 104.8 mmol) dissolved in dichloromethane (400 ml) at −70° C. under an atmosphere of nitrogen. The mixture is allowed to warm to room temperature, whereupon sodium bisulphite is added to destroy excess bromine. The solution is washed with brine, removed, dried over sodium sulphate and evaporated to dryness. The resulting crude product is recrystallised from a mixture of toluene and petrol to yield white crystals of the desired product. 1 H NMR shows expected signals.
Step 2: S-(−)-6,6′-Dibromo-[1,1′]binaphthalenyl-2,2′-dioxypropane
S-(−)-6,6′-Dibromo-[1,1′]binaphthalenyl-2,2′-diol (10.0 g, 22.5 mmol), potassium carbonate (8.7 g, 62.6 mmol) and propane di-tosylate (8.7 g, 22.5 mmol) are stirred at 80° C. in NMP. After 16 hours the mixture is poured into ether and washed with water. The ethereal layer is removed, dried over sodium sulphate and evaporated to dryness. The resulting crude solid is purified by flash column chromatography using petrol/ethyl acetate (4/1) as eluant to yield white crystal of the desired product. 1 H NMR shows expected signals.
Step 3: S-(−)-6,6′-bis[1-ethynyl-4-pentylbenzene]binaphthalenyl-2,2′-dioxypropane
S-(−)-6,6′-Dibromo-[1,1′]binaphthalenyl-2,2′-dioxypropane (1.0 g, 2.1 mmol), 1-ethyneyl-4-pentylbenzene (0.7 g, 4.1 mmol), triethylamine (5 mol), tetrahydrofuran (10 ml) and a catalytic amount of palladium bis(triphenylphosphine)dichloride and copper (1) iodide are stirred under reflux for 20 hours. The mixture is poured into dichloromethane, washed with water, dried over sodium sulphate and evaporated to dryness to leave a brown solid. Purification is achieved by flash column chromatography using dichloromethane/petrol as eluant to give upon evaporation of the appropriate fractions a white solid of the desired product. 1 H and 13 C NMR show expected signals. Optical microscopy shows a transition of K-47-I.
The helical twisting power (HTP) is extrapolated by dissolving 5 weight % of the compound in BL087 (from Merck Chemicals Ltd, UK). The HTP is 48, with a right handed twist sense.
EXAMPLE 2
Compound (2) is prepared according to reaction scheme 2 below.
Step 1: Add bromine (2 equiv) to binaphthol in dichloromethane at −70° C., allow to warm to room temperature. Remove excess bromine by washing with sodium bisulphite and water, then dry. Recrystallise from toluene/petrol.
Step 2: Ring closure is achieved by stirring 1,2-dibromoethane (2.9 equiv), potassium carbonate (6 equiv.) and a catalytic amount of sodium iodide under reflux in acetone.
Step 3: Cross-coupling with acetylene compound is achieved under typical Sonogashira cross-coupling conditions, using triethylamine as a base, a catalytic amount of palladium tetrakistriphenylphoshine and copper (1) iodide in tetrahydrofuran as solvent.
EXAMPLE 3
Compound (3) is prepared according to reaction scheme 3 below.
Step 1: Add bromine (2 equiv) to binaphthol in dichloromethane at −70° C., allow to warm to room temperature. Remove excess bromine by washing with sodium bisulphite and water, then dry. Recrystallise from toluene/petrol.
Step 2: Ring closure is achieved by Mitsunobu conditions, triphenylphosphine (2.3 equiv.), diisopropylazodicarboxylate (2.7 equiv.) in tetrahydrofuran at room temperature.
Step 3: Cross-coupling with acetylene compound is achieved under typical Sonogashira cross-coupling conditions, using triethylamine as a base, a catalytic amount of palladium tetrakistriphenylphoshine and copper (1) iodide in tetrahydrofuran as solvent.
EXAMPLE 4
Compound (4) is prepared according to reaction scheme 4 below.
Step 1: Add bromine (2 equiv) to binaphthol in dichloromethane at −70° C., allow to warm to room temperature. Remove excess bromine by washing with sodium bisulphite and water, then dry. Recrystallise from toluene/petrol.
Step 2: Ring closure is achieved by etherification conditions, potassium carbonate, dimethyl formamide (90° C.) with 1,3-dibromo compound.
Step 3: Cross-coupling with acetylene compound is achieved under typical Sonogashira cross-coupling conditions, using triethylamine as a base, a catalytic amount of palladium tetrakistriphenylphoshine and copper (1) iodide in tetrahydrofuran as solvent.
EXAMPLE 5
Compound (5) is prepared as described below.
(S)-6,6′-Dibromo-1,1′-binaphthalenyl-2,2′-diol
(S)-1,1′-Binaphthalenyl-2,2′-diol (40.00 g, 139.70 mmol) is dissolved in DCM (400 ml) and stirred under nitrogen at −70° C. Bromine (13.6 ml, 265.4 mmol) is added very slowly, ensuring the temperature remained at −70° C. on complete addition the reaction is allowed to slowly return to r.t. overnight. On completion the excess bromine is destroyed by addition of 50 ml of 10% solution of sodium bisulphite. Two layers form and the organic is separated, washed with brine, dried (sodium sulphate) and excess solvents removed in vacuo. The resulting solid is recrystallised from toluene/petrol to yield a white solid, which is dried without heating (55.2 g, 124.3 mmol, 89%). M.p. 79° C. 1 H NMR and 13 C NMR give expected signals. GCMS shows the (M/z) 444 ([M] + .
(S)-9,14-Dibromodinaphtho[2,1-d: 1′,2′-f][1,3]dioxepine
(S)-6,6′-Dibromo-1,1′-binaphthalenyl-2,2′-diol (5.00 g, 11.26 mmol) is dissolved in acetone (60 ml), potassium carbonate (9.80 g, 70.93 mmol) and sodium iodide (0.10 g, 0.67 mmol) are added and the resulting solution stirred at 70° C. Dibromomethane (5.68 ml, 32.65 mmol) in acetone (20 ml) is added slowly and the reaction stirred overnight. On completion the reaction is diluted with diethyl ether and poured onto water. The layers are separated and the aqueous phase extracted with diethyl ether (×2). Combined organic phases are washed with water (×2), dried over magnesium sulphate and excess solvents removed in vacuo to yield the product as a cream solid. The crude product is purified by FlashMaster column chromatography (SiO 2 , 10% EtOAc/petrol) and a front running impurity is removed. The product is further purified by recrystallisation from the minimum amount of DCM in hot petrol the yield the product as off-white crystals (2.29 g). The product is further purified by preparative HPLC (100 ml/min, 30% water in acetonitrile running up to 100% acetonitrile after 8 minutes) to yield a white solid (0.99 g, 2.17 mmol, 19%).
M.p. 215° C. 1 H NMR and 13 C NMR give expected signals. GCMS shows the (M/z) 456 ([M] +HTP= 49 (5% concentration in BLO87, give a right handed twist).
(S)-10,15-Dibromo-4,5-dihydrodinaphtho[2,1-e:1′,2′-g][1,4]dioxocine
(S)-6,6′-Dibromo-1,1′-binaphthalenyl-2,2′-diol (27.18 g, 61.20 mmol) is dissolved in NMP (150 ml), potassium carbonate (10.15 g, 73.44 mmol) is added and the resulting solution stirred at 80° C. Ethylene glycol di-p-tosylate (22.67 g, 61.20 mmol) in NMP (100 ml) is added slowly and the reaction stirred overnight. On completion the reaction is diluted with diethyl ether and poured onto water. Layers are separated and extracted once with diethyl ether. Combined organic phases are washed with water (×4), dried over magnesium sulphate and excess solvents removed in vacuo to yield the product as a brown solid. The solid is purified by column chromatography (SiO 2 , 100% petrol, running up to 20% ethyl acetate/petrol) to yield compound 12 as white crystals (25.00 g, 53.19 mmol, 87%). M.p. 116° C. 1 H NMR and 13 C NMR give expected signals. GCMS shows the (M/z) 470 ([M] + . HTP 47 (5% concentration in BLO87, give a right handed twist).
(S)-2,7-Dibromo-13,14-dihydro-12H-dinaphtho[2,1-f:1′,2′-h][1,5]-dioxonine
(S)-6,6′-Dibromo-1,1′-binaphthalenyl-2,2′-diol (90% content, 53.27 g, 107.94 mmol) is dissolved in NMP (150 ml), potassium carbonate (49.80 g, 129.53 mmol) is added and the resulting solution stirred at 80° C. Propane di-p-tosylate (41.50 g, 107.94 mmol) in NMP (400 ml) is added slowly and the reaction stirred overnight. On completion the reaction is diluted with diethyl ether and poured onto water. The layers are separated and the aqueous phase is extracted with diethyl ether (×2). Combined organic phases are washed with water (×3), dried over magnesium sulphate and excess solvents removed in vacuo to yield the product as a cream solid. The solid is purified by column chromatography (SiO 2 , 100% petrol, running up to 20% ethyl acetate/petrol) to yield white crystals (32.64 g, 67.44 mmol, 63%). M.p. 179° C. 1 H NMR and 13 C NMR give expected signals. GCMS shows the (M/z) 484([M] + . HTP=44 (5% concentration in BLO87, give a right handed twist).
(S)-2,7-Dibromo-12,13,14,15-tetrahydrodinaphtho[2,1-b:1′,2′-d][1,6]dioxecine
(S)-6,6′-Dibromo-1,1′-binaphthalenyl-2,2′-diol (5.00 g, 11.26 mmol) is dissolved in NMP (40 ml), potassium carbonate (1.87 g, 13.51 mmol) is added and the resulting solution stirred at 80° C. 1,4-butanediol dimethanesulfonate (2.77 g, 11.26 mmol) in NMP (40 ml) is added slowly and the reaction stirred overnight, after which NMP (80 ml) and potassium carbonate (1.87 g, 13.51 mmol) are added to dissolve a gel that had formed. On completion the reaction is diluted with diethyl ether and poured onto water. Layers are separated and extracted with diethyl ether (×2). Combined organic phases are washed with water (×3), dried over sodium sulphate and excess solvents removed in vacuo to yield the product as a cream solid. The solid is purified by column chromatography (SiO 2 , 50% toluene/petrol) to yield compound 14 as an off-white solid (3.20 g, 6.42 mmol, 57%).
M.p. 109° C. 1 H NMR and 13 C NMR give expected signals. GCMS shows the (M/z) 498 ([M] + . HTP=37 (7% concentration in BLO87, give a right handed twist).
(S)-9,14-bis((4-pentylphenyl)ethynyl)dinaphtho[2,1-d:1′,2′-f][1,3]dioxepine
(S)-9,14-Dibromodinaphtho[2,1-d:1′,2′-f][1,3]dioxepine (0.65 g, 1.43 mmol) is stirred under nitrogen in triethylamine (3 ml) and THF (5 ml). A catalytic amount of PdCl 2 (PPh 3 ) 2 and CuI is added and the reaction stirred at 80° C. 1-ethynyl-4-pentyl benzene (0.52 g, 2.99 mmol) in THF (5 ml) is added very slowly over 3 hours and the reaction stirred for 72 hours with addition of extra 1-ethynyl-4-pentyl benzene (1.00 ml, 5.81 mmol) in THF, triethylamine, PdCl 2 (PPh 3 ) 2 and CuI over this time. On completion the solution is diluted with DCM and poured onto water. Layers are separated and extracted with DCM (×2); organics are combined and washed with brine (×2) and dried over sodium sulphate. Excess solvents are removed in vacuo to yield a brown solid, which is purified using FlashMaster column chromatography (SiO 2 , 20% DCM/petrol), which removed the brown colour. The product is further purified using FlashMaster column chromatography (C18 reverse phase, 100% acetonitrile, running up to 10% DCM/acetonitrile) to yield compound 15 as a white solid (0.41 g, 0.64 mmol, 45%).
M.p. 167° C. 1 H NMR and 13 C NMR give expected signals. HTP=57 (5% concentration in BLO87, give a right handed twist)
EXAMPLE 6
Compound (6) is prepared as described below.
(S)-10,15-bis((4-pentylphenyl)ethynyl)-4,5-dihydrodinaphtho[2,1-e:1′,2′-g][1,4]dioxocine
(S)-10,15-Dibromo-4,5-dihydrodinaphtho[2,1-e:1′,2′-g][1,4]dioxocine (2.00 g, 4.25 mmol) is stirred under nitrogen in triethylamine (3 ml) and THF (5 ml). A catalytic amount of PdCl 2 (PPh 3 ) 2 and CuI is added and the reaction stirred at 80° C. 1-ethynyl-4-pentyl benzene (1.47 g, 8.51 mmol) in THF (5 ml) is added very slowly over 3 hours and the reaction stirred for 72 hours with addition of extra 1-ethynyl-4-pentyl benzene (2×0.50 g, 5.81 mmol) in THF and triethylamine over this time. On completion the solution is diluted with DCM and poured onto water. Layers are separated and extracted with DCM (×2); organics are combined and washed with water (×2) and dried over sodium sulphate. Excess solvents are removed in vacuo to yield a brown solid, which is purified by using an SP Flash Purification System (SiO 2 , 2% ethyl acetate/n-hexane, running up to 20% ethyl acetate/n-hexane), which removed the brown colour. The product is further purified using the same system (C18 reverse phase, 50% acetonitrile/water, running up to 100% acetonitrile) to yield an off-white solid (0.07 g, 0.1 mmol, 3%).
M.p. 161° C. 1 H NMR and 13 C NMR give expected signals. HTP=52 (5% concentration in BLO87, give a right handed twist)
EXAMPLE 7
Compound (7) is prepared as described below.
(S)-2,7-bis((4-pentylphenyl)ethynyl)-13,14-dihydro-12H-dinaphtho[2,1-f:1′,2′-h][1,5]dioxonine
(S)-2,7-Dibromo-13,14-dihydro-12H-dinaphtho[2,1-f:1′,2′-h][1,5]dioxonine (1.00 g, 2.07 mmol) is stirred under nitrogen in triethylamine (3 ml) and THF (5 ml). A catalytic amount of PdCl 2 (PPh 3 ) 2 and CuI is added and the reaction stirred at 80° C. 1-ethynyl-4-pentyl benzene (0.71 ml, 4.13 mmol) in THF (5 ml) is added very slowly over 3 hours and the reaction stirred for 20 hours. On completion the solution is diluted in DCM and poured onto water. Layers are separated and extracted with DCM (×2), organics are combined and washed with water (×2), dried over sodium sulphate and excess solvents removed in vacuo to yield a brown solid, which is purified by FlashMaster column chromatography (SiO 2 , 10% DCM/petrol, running up to 40% DCM/petrol). The columned product shows an impurity at 12 minutes by HPLC and is further purified by preparative HPLC (100 ml/minute, 20% water in acetonitrile, running up to 100% acetonitrile after ten minutes) to yield compound 17 as a white solid (0.62 g, 0.93 mmol, 45%).
M.p. 47° C. 1 H NMR and 13 C NMR give expected signals. HTP=48 (5% concentration in BLO87, give a right handed twist)
EXAMPLE 8
Compound (8) is prepared as described below.
(S)-5,5′-(4,5-dihydrodinaphtho[2,1-e:1′,2′-g][1,4]-dioxocine-10,15-diyl)dipent-4-yn-1-ol
(S)-10,15-Dibromo-4,5-dihydrodinaphtho[2,1-e:1′,2′-g][1,4]dioxocine (2.00 g, 4.25 mmol) is stirred under nitrogen in triethylamine (6 ml) and THF (10 ml). A catalytic amount of PdCl 2 (PPh 3 ) 2 and CuI is added and the reaction stirred at 80° C. 4-Pentyn-1-ol (0.75 g, 8.93 mmol) in THF (10 ml) is added very slowly over 3 hours and the reaction stirred for 48 hours with addition of additional THF and triethylamine as the solvent evaporated and 4-Pentyn-1-ol (1.00 ml, 11.89 mmol), PdCl 2 (PPh 3 ) 2 and CuI to ensure completion of reaction. Over time the solution darkens to a brown colour. On completion the solution is diluted in DCM and poured onto water. Layers are separated and extracted with DCM (×2), organics are combined and washed with brine (×2), dried over sodium sulphate and excess solvents removed in vacuo to yield a yellow/brown oil, which is purified by FlashMaster column chromatography (SiO 2 , 100% DCM, running up to 60% DCM/ethyl acetate) to yield both the mono- and di-substituted products. The product is purified by FlashMaster column chromatography (SiO 2 , 40% ethyl acetate in petrol, running up to 100% ethyl acetate before running through with propanol) to yield a cream oil (0.77 g, 1.62 mmol, 38%).
3-Chloro-propionic Acid 3-(4-chlorocarbonyl-phenoxy)-propyl Ester
HPBA-3-chloropropionate (5.00 g, 17.44 mmol) is dissolved in DCM (160 ml). NMP (0.5 ml, 5.04 mmol) is added and the materials are stirred under nitrogen until complete dissolution had occurred. Thionyl chloride (2.49 g, 20.93 mmol) is added and the reaction stirred under nitrogen overnight at 35° C. On completion the reaction turns clear yellow and excess solvents are removed in vacuo to yield a dark yellow oil (6.02 g, 19.73 mmol, 113% (contained NMP)).
1 H NMR and FT-IR give expected signals.
EXAMPLE 9
Compound (9) is prepared as described below.
(S)-6,6′-(4,5-dihydrodinaphtho[2,1-e:1′,2′-g][1,4]dioxocine-10,15-diyl)bis(Pent-4-yne-5,1-diyl)bis(4-(3-(acryloyloxy)propoxy)benzoate)
(S)-5,5′-(4,5-Dihydrodinaphtho[2,1-e:1′,2′-g][1,4]dioxocine-10,15-diyl)dipent-4-yn-1-ol (0.77 g, 1.62 mmol) and 3-Chloro-propionic acid 3-(4-chlorocarbonyl-phenoxy)-propyl ester (1.18 g, 3.39 mmol (88% content)) are dissolved in DCM (60 ml) and stirred under nitrogen. Triethylamine (1.96 ml, 19.39 mmol) is added slowly with evolution of white HCl gas and the reaction heated to 35° C. and stirred for overnight. On completion the reaction mixture is cooled to r.t., diluted with DCM and poured onto water. Layers are separated and extracted with DCM (×2) before the organic phases are combined and washed with brine (×3) and dried over sodium sulphate. Excess solvents are removed in vacuo to yield the product as a brown oil (1.36 g), 28% pure by HPLC. The crude product is purified by FlashMaster column chromatography (SiO 2 , 20% ethyl acetate/petrol), however; all materials come off together, but the brown colour is removed so the fractions are recombined. The product is purified again by preparative HPLC (80 ml/minute, 50% water in acetonitrile for five minutes, running up to 100% acetonitrile after fifteen minutes) to yield an off-white solid (0.29 g, 0.31 mmol, 19%).
M.p. 33° C. 1 H NMR and 13 C NMR give expected signals. HTP=15 (10% concentration in BLO87, give a right handed twist). | The invention relates to chiral compounds, methods of their preparation, and to their use in optical, electrooptical, electronic, semiconducting or luminescent components or devices, and in decorative, security, cosmetic or diagnostic applications. | 2 |
BACKGROUND OF THE INVENTION
The term "complement" refers to a complex group of proteins in body fluids that, working together with antibodies or other factors, play an important role as mediators of immune, allergic, immunochemical and/or immunopathological reactions. The reactions in which complement participates take place in blood serum or in other body fluids, and hence are considered to be humoral reactions.
With regard to human blood, there are at present more than 11 proteins in the complement system. These complement proteins are designated by the letter C and by number: C1, C2, C3 and so on up to C9. The complement protein C1 is actually an assembly of subunits designated C1q, C1r and C1s. The numbers assigned to the complement proteins reflect the sequence in which they become active, with the exception of complement protein C4, which reacts after C1 and before C2. The numerical assignments for the proteins in the complement system were made before the reaction sequence was fully understood. A more detailed discussion of the complement system and its role in the body processes can be found in, for example, Bull. World Health Org., 39, 935-938 (1968); Ann. Rev. Medicine, 19, 1-24 (1968); The Johns Hopkins Med. J., 128, 57-74 (1971); Harvey Lectures, 66, 75-104 (1972); The New England Journal of Medicine, 287, 452-454; 489-495; 545-549; 592-596; 642-646 (1972); Scientific American, 229, (No. 5), 54-66 (1973); Federation Proceedings, 32, 134-137 (1973); Medical World News, Oct. 11, 1974, pp. 53-66; J. Allergy Clin. Immunol., 53, 298-302 (1974); Cold Spring Harbor Conf. Cell Proliferation 2/Proteases Biol. Control/229-241 (1975); Ann. Review of Biochemistry, 44, 697 (1975); Complement in Clinical Medicine, Disease-a-Month, (1975); Complement, Scope, December 1975; Annals of Internal Medicine, 84, 580-593 (1976); "Complement: Mechanisms and Functions", Prentice-Hall, Englewood Cliffs, N.J. (1976); Essays Med. Biochem., 2, 1-35 (1976); Hospital Practice, 12, 33-43 (1977); Perturbation of Complement in Disease, Chap. 15 in Biological Amplification Systems in Immunology (Ed. Day and Good), Plenum, New York and London (1977); Am. J. Clin. Pathology, 68, 647-659 (1977).
The complement system can be considered to consist of three sub-systems: (1) a recognition unit (C1q) which enables it to combine with antibody molecules that have detected a foreign invader; (2) an activation unit (C1r, C1s, C2, C4, C3) which prepares a site on the neighboring membrane; and (3) an attack unit (C5, C6, C7, C8 and C9) which creates a "hole" in the membrane. The membrane attack unit is non-specific; it destroys invaders only because it is generated in their neighborhood. In order to minimize damage to the host's own cells, its activity must be limited in time. This limitation is accomplished partly by the spontaneous decay of activated complement and partly by interference by inhibitors and destructive enzymes. The control of complement, however, is not perfect, and there are times when damage is done to the host's cells. Immunity is, therefore, a double-edged sword.
Activation of the complement system also accelerates blood clotting. This action comes about by way of the complement-mediated release of a clotting factor from platelets. The biologically active complement fragments and complexes can become involved in reactions that damage the host's cells, and these pathogenic reactions can result in the development of immune-complex diseases. For example, in some forms of nephritis, complement damages the basal membrane of the kidney, resulting in the escape of protein from the blood into the urine. The disease disseminated lupus erythematosus belongs in this category; its symptoms include nephritis, visceral lesions and skin eruptions. The treatment of diphtheria or tetanus with the injection of large amounts of antitoxin sometimes results in serum sickness, an immune-complex disease. Rheumatoid arthritis also involves immune complexes. Like disseminated lupus erythematosus, it is an autoimmune disease in which the disease symptoms are caused by pathological effects of the immune system in the host's tissues. In summary, the complement system has been shown to be involved with inflammation, coagulation, fibrinolysis, antibody-antigen reactions and other metabolic processes.
In the presence of antibody-antigen complexes the complement proteins are involved in a series of reactions which may lead to irreversible membrane damage if they occur in the vicinity of biological membranes. Thus, while complement constitutes a part of the body's defense mechanism against infection it also results in inflammation and tissue damage in the immunopathological process. The nature of certain of the complement proteins, suggestions regarding the mode of complement binding to biological membranes and the manner in which complement effects membrane damage are discussed in Annual Review in Biochemistry, 38, 389 (1969); Journal of Immunology, 119, 1-8, 1195, 1358-1364, 1482 (1977).
A variety of substances have been disclosed as inhibiting the complement system, i.e., as complement inhibitors. For example, the compounds 3,3'-ureylenebis[6-(2-amino-8-hydroxy-6-sulfo-1-naphthylazo)benzenesulfonic acid], tetrasodium salt (chlorazol fast pink), heparin and a sulphated dextran have been reported to have an anticomplementary effect, British Journal of Experimental Pathology, 33, 327-339 (1952). German Pat. No. 2,254,893 or South African Pat. No. 727,923 discloses certain 1-(diphenylmethyl)-4-(3-phenylallyl)piperazines useful as complement inhibitors. Other chemical compounds having complement inhibiting activity are disclosed in, for example, Journal of Medicinal Chemistry, 12, 415-419; 902-905; 1049-1052; 1053-1056 (1969); Canadian Journal of Biochemistry, 47, 547-552 (1969); The Journal of Immunology, 104, 279-288 (1970); The Journal of Immunology, 106, 241-245 (1971); The Journal of Immunology, 111, 1061-1066 (1973); Biochim. Biophys. Acta, 317, 539-548 (1973); Life Sciences, 13, 351-362 (1973); Journal of Immunology, 113, 584 (1974); Immunology, 26, 819-829 (1974); Journal of Medicinal Chemistry, 17, 1160-1167 (1974); Biochim. Biophys. Res. Comm., 67, 225-263 (1975); Ann. N.Y. Acad. Sci., 256, 441-450 (1975); Journal of Medicinal Chemistry, 19, 634-639, 1079 (1976); Journal of Immunology, 118, 466 (1977); Arch. Int. Pharmacodyn., 226, 281-285 (1977); Biochem. Pharmacol. 26, 325-329 (1977); Journal Pharm. Sci., 66, 1367-1377 (1977); Chem. Pharm. Bull., 25, 1202-1208 (1977); Biochim. Biophys. Acta, 484, 417-422 (1977) and Journal Clin. Microbiology, 5, 278-284 (1977).
It has been reported that the known complement inhibitors epsilon-aminocaproic acid and tranexamic acid have been used with success in the treatment of hereditary angio-neurotic edema, a disease state resulting from an inherited deficiency or lack of function of the serum inhibitor of the activated first component of complement (C1 inhibitor), The New England Journal of Medicine, 286, 808-812 (1972), 287, 452-454 (1972); Ann. Intern. Med., 84, 580-593 (1976); J. Allergy and Clin. Immunology, 60, 38-40 (1977).
It has also been reported that the drug pentosan-polysulfoester has an anticomplementary activity on human serum, both in vitro and in vivo, as judged by the reduction in total hemolytic complement activity; Pathologie Biologie, 25, 33-36, 25 (2), 105-108, 25 (3), 179-184 (1977).
SUMMARY OF THE INVENTION
This invention is concerned with compounds having complement inhibiting activity of the general formula I: ##STR1## wherein X is SO 3 A; wherein A is a pharmaceutically acceptable salt cation; and R is selected from the group consisting of OX, ##STR2##
Specific compounds of the above formula I which are of interest as complement inhibitors are listed below. In this instance, these compounds are given both by their full name according to Chemical Abstracts nomenclature and then by an abbreviated nomenclature which is used throughout the balance of the specification and claims.
O-α-D-galactopyranosyl(1→6)-α-D-glucopyranose [gal 1α,6 glc] octakis (H-sulfate), octasalt with trimethylamine
O-α-D-galactopyranosyl(1→6)-α-D-glucopyranose [gal 1α,6 glc] octakis (H-sulfate), octasodium salt
O-β-D-galactopyranosyl(1→6)-O-α-D-galactopyranosyl(1.fwdarw.6)-α-D-glucopyranose [gal 1β,6 gal 1α,6 glc] undecakis (H-sulfate), undecasalt with trimethylamine
O-β-D-galactopyranosyl(1→6)-O-α-D-galactopyranosyl(1.fwdarw.6)-α-D-glucopyranose [gal 1β,6 gal 1α,6 glc] undecakis (H-sulfate), undecasodium salt
O-α-D-galactopyranosyl(1→6)-O-β-D-glucopyranosyl(1.fwdarw.6)-O-α-D-galactopyranosyl(1→6)-α-D-glucopyranose [gal 1α,6 glc 1β,6 gal 1α,6 glc] tetradecakis (H-sulfate), tetradecasalt with trimethylamine
O-α-D-galactopyranosyl(1→6)-O-β-D-glucopyranosyl(1.fwdarw.6)-O-α-D-galactopyranosyl(1→6)-α-D-glucopyranose [gal 1α,6 glc 1β,6 gal 1α,6 glc] tetradecakis (H-sulfate), tetradecasodium salt
O-α-D-glucopyranosyl(1→4)-O-β-D-glucopyranosyl(1→6)-O-α-D-galactopyranosyl(1→6)-D-glucopyranose [glc 1α,4 glc 1β,6 gal 1α,6 glc] tetradecakis (H-sulfate), tetradecasalt with trimethylamine
O-α-D-glucopyranosyl(1→4)-O-β-D-glucopyranosyl(1→6)-O-α-D-galactopyranosyl(1→6)-D-glucopyranose [glc 1α,4 glc 1β,6 gal 1α,6 glc] tetradecakis (H-sulfate), tetradecasodium salt
O-β-D-glucopyranosyl(1→4)-O-β-D-glucopyranosyl(1→6)-O-α-D-galactopyrranosyl(1→6)-α-D-glucopyranose [glc 1β,4 glc 1β,6 gal 1α,6 glc] tetradecakis (H-sulfate), tetradecasalt with trimethylamine
O-β-D-glucopyranosyl(1→4)-O-β-D-glucopyranosyl(1→6)-O-α-D-galactopyranosyl(1→6)-α-D-glucopyranose [glc 1β,4 glc 1β,6 gal 1α,6 glc] tetradecakis (H-sulfate), tetradecasodium salt
O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1→4)-O-β-D-glucopyranosyl(1→6)-O-α-D-galactopyranosyl(1.fwdarw.6)-α-D-glucopyranose [(glc 1α,4) 2 glc 1β,6 gal 1α,6 glc] heptadecakis(H-sulfate), heptadecasalt with trimethylamine
O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1→4)-O-β-D-glucopyranosyl(1→6)-O-α-D-galactopyranosyl(1.fwdarw.6)-α-D-glucopyranose [(glc 1α,4) 2 glc 1β,6 gal 1α,6 glc] heptadecakis(H-sulfate), heptadecasodium salt
O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1.fwdarw.4)-O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1.fwdarw.4)-O-β-D-glucopyranosyl(1→6)-O-α-D-galactopyranosyl(1→6)-D-glucopyranose [(glc 1α,4) 6 glc 1β,6 gal 1α,6 glc] nonacosakis (H-sulfate), non-acosasalt with trimethylamine
O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1.fwdarw.4)-O-α-D-glucopyranosyl(1→4)-O-α-D-glucopyranosyl(1.fwdarw.4)-O-β-D-glucopyranosyl(1→6)-O-α-D-galactopyranosyl(1→6)-D-glucopyranose [(glc 1α,4) 6 glc 1β,6 gal 1α,6 glc] nonacosakis (H-sulfate), non-acosasodium salt
This invention is also concerned with a method of inhibiting the complement system in a body fluid, such as blood serum, which comprises subjecting body fluid complement to the action of an effective complement inhibiting amount of a compound as described hereinabove. The method of use aspect of this invention is further concerned with a method of inhibiting the complement system in a warm-blooded animal which comprises administering to said animal an effective complement inhibiting amount of a compound as described hereinabove. Body fluid can include blood, plasma, serum, synovial fluid, cerebrospinal fluid, or pathological accumulcations of fluid such as pleural effusion, etc.
The compounds of the present invention find utility as complement inhibitors in body fluids and as such may be used to ameliorate or prevent those pathological reactions requiring the function of complement and in the therapeutic treatment of warm-blooded animals having immunologic diseases such as rheumatoid arthritis, systemic lupus erythematosus, certain kinds of glomerulonephritis, certain kinds of auto-allergic hemolytic anemia, certain kinds of platelet disorders and certain kinds of vasculitis. The instant compounds may also be used in the therapeutic treatment of warm-blooded animals having non-immunologic diseases such as paroxysmal nocturnal hemoglobinurea, hereditary antioneurotic edema (treated with Suramin Sodium, etc.) and inflammatory states induced by the action of bacterial of lysosomal enzymes on the appropriate complement components as for example, inflammation following coronary occlusion. They may also be useful in the treatment of transplant rejection and as blood culture and transport mediums.
DESCRIPTION OF THE INVENTION
The compounds of the present invention may be prepared according to the following flowchart. ##STR3##
In accordance with the above flowchart gal 1α,6 glc (A) is dissolved in pyridine containing anhydrous calcium sulfate with warming. Trityl chloride is added and the mixture is heated producing trityl gal 1α,6 glc (B). Further treatment with acetic anhydride and extraction into methylene chloride produces trityl peracetyl gal 1α,6 glc (C).
The compound (D) where R and R' are selected from the following grouped pairs, ##STR4## is converted to the corresponding compound (E) where X is COCH 3 by conventional methods. Compound (E) is then brominated using hydrobromic acid in glacial acetic acid and extracting in methylene chloride to give the bromo polyacetyl sugar (F).
Compound (F) and (C) are then reacted with silver trifluorosulfonate in nitromethane containing calcium sulfate under anhydrous conditions and at reduced temperature. The product is extracted in methylene chloride treated with acetic anhydride in pyridine and subjected to conventional purification by chromatography to give (G) where X is COCH 3 .
The polyacetates (G) are then reduced to the sugars (H) by reaction in a 6:2:3 mixture of methanol, water and triethylamine for a period of several hours. The product (H) is extracted from methanol and ether.
The sugars (H) are converted to the poly (H-sulfate) poly salts with trimethylamine (J) where X is SO 3 H.N(CH 3 ) 3 , by treatment with trimethylamine sulfur trioxide in dimethylformamide with heat for several hours. The product (J) is extracted from ethanol.
The product (J) is converted to the poly (H-sulfate) poly alkali metal salt (K) by treatment with an alkali metal acetate or alkali hydroxide in trimethylamine. The product (K) is precipitated by ethanol.
The compounds of the present invention may be administered internally, e.g., orally, intra-articularly or parenterally, e.g., intra-articular, to a warm-blooded animal to inhibit complement in the body fluid of the animal, such inhibition being useful in the amelioration or prevention of those reactions dependent uon the function of complement, such as inflammatory process and cell membrane damage induced by antigen-antibody complexes. The range of doses may be employed depending on the mode of administration, the condition being treated and the particular compound being used. For example, for intravenous or subcutaneous use from about 5 to about 50 mg/kg/day, or every six hours for more rapidly excreted salts, may be used. For intra-articular use for large joints such as the knee, from about 2 to about 20 mg/joint per week may be used, with proportionally smaller doses for smaller joints. The dosage range is to be adjusted to provide optimum therapeutic response in the warm-blooded animal being treated. In general, the amount of compound administered can vary over a wide range to provide from about 5 mg/kg to about 100 mg/kg of body weight of animal per day. The usual daily dose for a 70 kg subject may vary from about 350 mg to about 3.5 g. Unit doses of the acid or salt can contain from about 0.5 mg to about 500 mg.
While in general the sodium salts of the acids of the invention are suitable for parenteral use, other salts may also be prepared, such as those of primary amines, e.g., ethylamine; secondary amines, e.g., diethylamine or diethanolamine; tertiary amines, e.g., pyridine or triethylamine or 2-dimethylaminomethyldibenzofuran; aliphatic diamines, e.g., decamethylenediamine; and aromatic diamines, can be prepared. Some of these are soluble in water, others are soluble in saline solution, and still others are insoluble and can be used for purposes of preparing suspensions for injection. Furthermore, as well as the sodium salt, those of the alkali metals, such as potassium and lithium; of ammonia; and of the alkaline earth metals, such as calcium or magnesium, may be employed. It will be apparent, therefore, that these salts embrace, in general, derivatives of salt-forming cations.
The compounds of the present invention may also be administered topically in the form of ointments, creams, lotions and the like, suitable for the treatment of complement dependent dermatological disorders.
Moreover, the compounds of the present invention may be administered in the form of dental pastes, ointments, buccal tablets and other compositions suitable for application periodontally for the treatment of periodontitis and related diseases of the oral cavity.
In therapeutic use, the compounds of this invention may be administered in the form of conventional pharmaceutical compositions. Such compositions may be formulated so as to be suitable for oral or parenteral administration. The active ingredient may be combined in admixture with a pharmaceutically acceptable carrier, which carrier may take a wide variety of forms depending on the form of preparation desired for administration, i.e., oral or parenteral. The compounds can be used in compositions such as tablets. Here, the principal active ingredient is mixed with conventional tabletting ingredients such as corn starch, lactose, sucrose, sorbitol, talc, stearic acid, magnesium stearate, dicalcium phosphate, gums, or similar materials as non-toxic pharmaceutically acceptable diluents or carriers. The tablets or pills of the novel compositions can be laminated or otherwise compounded to provide a dosage form affording the advantage of prolonged or delayed action or predetermined successive action of the enclosed medication. For example, the tablet or pill can comprise an inner dosage and an outer dosage component, the latter being in the form of an envelope over the former. The two components can be separated by an enteric layer which serves to resist disintegration in the stomach and permits the inner component to pass intact into the duodenum or to be delayed in release. A variety of materials can be used for such enteric layers or coatings, such materials including a number of polymeric acids or mixtures of polymeric acids with such materials as shellac, shellac and cetyl alcohol, cellulose acetate and the like. A particularly advantageous enteric coating comprises a styrene maleic acid copolymer together with known materials contributing to the enteric properties of the coating. The tablet or pill may be colored through the use of an appropriate non-toxic dye, so as to provide a pleasing appearance.
The liquid forms in which the novel compositions of the present invention may be incorporated for administration include suitable flavored emulsions with edible oils, such as, cottonseed oil, sesame oil, coconut oil, peanut oil, and the like, as well as elixirs and similar pharmaceutical vehicles. Sterile suspensions or solutions can be prepared for parenteral use. Isotonic preparations containing suitable preservatives are also desirable for injection use.
The term dosage form, as described herein, refers to physically discrete units suitable for unitary dosage for warm-blooded animal subjects, each unit containing a predetermined quantity of active component calculated to produce the desired therapeutic effect in association with the required pharmaceutical diluent, carrier or vehicle. The specification for the novel dosage forms of this invention are indicated by characteristics of the active component and the particular therapeutic effect to be achieved or the limitations inherent in the art of compounding such an active component for therapeutic use in warm-blooded animals as disclosed in this specification. Examples of suitable oral dosage forms in accord with this invention are tablets, capsules, pills, powder packets, granules, wafers, cachets, teaspoonfuls, dropperfuls, ampules, vials, segregated multiples of any of the foregoing and other forms as herein described.
The complement inhibiting activity of the compounds of this invention has been demonstrated by one or more of the following identified tests: (i) Test Code 026 (Cl inhibitor)--This test measures the ability of activated human C1 to destroy fluid phase human C2 in the presence of C4 and appropriate dilutions of the test compound. An active inhibitor protects C2 from C1 and C4; (ii) Test Code 035 (C3-C9 inhibitor)--This test determines the ability of the late components of human complement (C3-C9) to lyse EAC 142 in the presence of appropriate dilutions of the test compound. An active inhibitor protects EAC 142 from lysis by human C3-C9; (iii) Test Code 036 (C-Shunt inhibitor)--In this test human erythrocytes rendered fragile are lysed in autologous serum via the shunt pathway activated by cobra venom factor in the presence of appropriate dilutions of the test compound. Inhibition of the shunt pathway results in failure of lysis; (iv) Forssman Vasculitis Test--Here, the well known complement dependent lesion, Forssman vasculitis, is produced in guinea pigs by intradermal injection of rabbit anti-Forssman antiserum. The lesion is measured in terms of diameter, edema and hemorrhage and the extent to which a combined index of these is inhibited by prior intraperitoneal injection of the test compound at 200 mg/kg is then reported, unless otherwise stated; (v) Forssman Shock Test--Lethal shock is produced in guinea pigs by an i.v. injection of anti-Forssman antiserum and the harmonic mean death time of treated guinea pigs is compared with that of the simultaneous controls; (vi) Complement Level Reduction Test--In this test, the above dosed guinea pigs, or others are bled for serum and the complmenet level is determined in undiluted serum by the capillary tube method of U.S. Pat. No. 3,876,376 and compared to undosed control guinea pigs; (vii) Cap 50 Test--Here, appropriate amounts of the test compound are added to a pool of guinea pig serum in vitro, after which the undiluted serum capillary tube assay referred to above is run. The concentration of compound inhibiting 50% is reported.
With reference to Table I, guinea pigs weighing about 300 g were dosed intravenously (i.v.) or intraperitoneally (i.p.) with 200 mg/kg of the test compound dissolved in saline and adjusted to pH 7-8. One hour after dosing, the guinea pigs were decapitated, blood was collected and the serum separated. The serum was tested for whole complement using the capillary tube assay. Percent inhibition was calculated by comparison with simultaneous controls. The results appear in Table I together with resulrs of tests code 026,035, 036, Cap 50, % inhibition. Table I shows that the compounds of the invention possess highly significant in vitro and in vivo complement inhibiting activity in warm-blooded animals. Results obtained are listed in Table I.
Table I__________________________________________________________________________Biological Activities In vivo Activity (Guinea Pig) Shunt % Inhibition Cl C-Late Inhibition Intraperitoneal 026* 035* 036* Time (Min.)Compound Wells Wells Wells Cap 50 30 60 120__________________________________________________________________________ ##STR5## +8** N N 407 ##STR6## +9 N N 279 ##STR7## +9 N N <100 -30 -17 -56 (5/5) ##STR8## +9 +1 +5 110 ##STR9## +9 +1 +6 93 -44 -55 -80 ##STR10## +9 +1 +5 187 ##STR11## `+10 +1 +6 112 -54 -45 -39 ##STR12## +9 N +4 247 ##STR13## +9 N N 86 -25 -34 -60 ##STR14## +9 +1 N 152 ##STR15## +9 +2 +6 116 ##STR16## +10 +1 +5 420 ##STR17## +9 +3 +5 193__________________________________________________________________________ *Tests identified by code herein **Activity in wells, a serial dilution assay; higher well number indicate higher activity. The serial dilutions are twofold-
DETAILED DESCRIPTION OF THE INVENTION
The following examples describe in detail the preparation and formulation of representative compounds of the present invention.
EXAMPLE 1
Gal 1α,6 glc octakis (H-sulfate), octasalt with trimethylamine
A 1.44 g. portion of gal 1α,6 glc and 5.5 g. of trimethylamine sulfur trioxide are added to 75 ml. of dimethylformamide and heated at 65°-70° C. for 20 hours. The crystals are recovered, triturated repeatedly with dimethylformamide and then with acetone, then filtered, washed with ether and dried, giving the desired product as a colorless granular solid.
EXAMPLE 2
Gal 1α,6 glc octakis (H-sulfate), octasodium salt
A 3.0 g. portion of gal 1α,6 glc octakis (H-sulfate), octasalt with trimethylamine is dissolved in 10 ml. of water. A 10 ml. portion of 30% aqueous sodium acetate solution is added and the mixture is filtered. The filtrate is allowed to stand for about 10 minutes and then absolute ethanol is added, producing a gum. The gum is collected and triturated with absolute ethanol producing a granular solid. This solid is washed four times with absolute ethanol and twice with anhydrous ether. The solid is redissolved in 10 ml. of water, 10 ml. of 30% sodium acetate solution is added and the process is repeated, giving the desired product as a colorless granular solid.
EXAMPLE 3
Gal 1β,6 gal 1α,6 glc undecaacetate
A 51.3 g. portion of gal 1α,6 glc (dried at 78° C. for 20 hours over phosphorous pentoxide) and 25 g. of anhydrous calcium sulfate are added to 750 ml. of pyridine and the mixture is warmed. When partially dissolved at 60°-70° C., 46.1 g. of trityl chloride is added and the mixture is heated at 90° C. on a steam bath for 3 hours. The mixture is cooled to 45° C. and the liquid is recovered by decantation. To this liquid is added 150 ml. of acetic anhydride, the mixture is allowed to stand at room temperature for 18 hours and then poured into 21/2 liters of ice and water with vigorous mechanical stirring. Stirring is continued for 2 hours and then the mixture is filtered. The gummy white solid is collected, washed with water, air dried and then dissolved in methylene chloride. This solution is dried over magnesium sulfate, filtered and evaporated to a gum. This gum is dissolved in about 400 ml. of methanol and poured into 3000 ml. of water with stirring. The white solid is collected and dried, giving 110.8 g. of trityl peracetyl gal 1α,6 glc.
A 3.84 g. portion of silver triflate is added to 100 ml. of nitromethane containing 10 g. of anhydrous calcium sulfate and stirred at room temperature for 5 minutes. The mixture is cooled in an ice bath and 8.8 g. of trityl peracetyl gal 1α,6 glc is added. The mixture is stirred and then 6.16 g. of acetobromogalactose is added with vigorous stirring at 0° C. for one hour. The mixture is warmed on a steam bath for 2 minutes, cooled, diluted with methylene chloride and filtered. The filtrate is washed with water and then saturated sodium bicarbonate solution and dried over anhydrous sodium sulfate. Evaporation of the solvent in vacuo gives a pale cream colored glassy solid. This solid is dissolved in 50 ml. of pyridine and 40 ml. of acetic anhydride is added. The mixture is stirred overnight at room temperature, poured into ice water and the resulting precipitate is collected and washed with water. This solid is dissolved in 250 ml. of methylene chloride and dried over anhydrous sodium sulfate. Evaporation of the solvent in vacuo gives a pale cream colored glass. This solid is passed through a silica gel chromatographic column using the system ethyl acetate:hexane (60:40). The first two fractions give the desired product.
EXAMPLE 4
Gal 1β,6 gal 1α,6 glc
A 2.4 g. portion of gal 1β,6 gal 1α,6 glc undecaacetate is dissolved in 55 ml. of a mixture of methanol, water and triethylamine [6:2:3]. The clear solution is stirred at room temperature for 22 hours and then evaporated to dryness in vacuo. The residue is dissolved in 50 ml. of water and treated with a small amount of Amberlite® IR-120 (H + form) and charcoal and then filtered through celite. The filtrate is evaporated to dryness in vacuo giving the desired product as a colorless glass.
EXAMPLE 5
Gal 1β,6 gal 1α,6 glc undecakis (H-sulfate), undecasalt with trimethylamine
A 4.95 g. portion of trimethylamine sulfur trioxide is dissolved in 25 ml. of dimethylformamide by warming to 70° C. A 1.1 g. portion of gal 1β,6 gal 1α,6 glc is added and the solution is stirred at 70° C. for 20 hours. The mixture is cooled to room temperature. The gum is collected and triturated with absolute ethanol giving a granular solid which is collected, washed with absolute ethanol and then anhydrous ether and dried in vacuo giving the desired product as a colorless product.
EXAMPLE 6
Gal 1β,6 gal 1α,6 glc undecakis (H-sulfate), undecasodium salt
A 1.8 g. portion of gal 1β,6 gal 1α,6 glc undecakis (H-sulfate), undecasalt with trimethylamine is dissolved in 5 ml. of water. A 10 ml. portion of 30% aqueous sodium acetate solution is added and the mixture is swirled and allowed to stand for 15-20 minutes. A 75 ml. portion of absolute ethanol is added and the mixture is stirred vigorously. The resulting gum is collected and triturated repeatedly with absolute ethanol. The resulting granular solid is recovered, washed with absolute ethanol and then anhydrous ether and dried in vacuo, giving the desired product as an off-white granular solid.
EXAMPLE 7
Gal 1α,6 glc 1β,6 gal 1α,6 glc, tetradecaacetate
A 50 ml. portion of 30-32% hydrobromic acid in glacial acetic acid is cooled in an ice bath and a solution of 10.0 g. of gal 1α,6 glc octaacetate in 80 ml. of chloroform is added with shaking. The mixture is allowed to stand in the ice bath for 2 hours with occasional swirling and then poured into crushed ice with vigorous swirling. The mixture is extracted with 100 ml. of chloroform and the aqueous layer is washed twice with 75 l. portions of chloroform. The chloroform extracts are combined and washed with ice-cold water until neutral. The organic layer is dried over anhydrous calcium chloride and evaporated to dryness in vacuo giving gal 1α,6 glc heptaacetyl bromide as a pale yellow glass.
A 5.0 g. portion of anhydrous calcium sulfate and 995 mg. of silver perchlorate are added to 50 ml. of nitromethane and the mixture is cooled in an ice bath for 10 minutes. A 3.52 g. portion of trityl peracetyl gal 1α,6 glc is added with stirring followed by the rapid addition of 3.36 g. of gal 1α,6 glc heptaacetyl bromide with vigorous stirring. for 10 minutes. The mixture is warmed on a steam bath for 5 minutes, cooled to room temperature, diluted with 150 ml. of methylene chloride and filtered. The filtrate is washed with water and then with saturated aqueous sodium bicarbonate solution. The organic extract is dried over anhydrous sodium sulfate and evaporated in vacuo to a yellow paste. This paste is dissolved in 20 ml. of a 1:1 mixture of pyridine and acetic anhydride and stirred at room temperature overnight. It is then poured dropwise with stirring into ice-water. The resulting gum is recovered, dissolved in a small volume of ethanol and poured dropwise with stirring into ice-water. The resulting brown solid is collected, washed with cold water and air dried. This solid is dissolved in small volume of methylene chloride and appllied to a 100 g. silica gel column prepared in hexane. Elution is started with hexane and then gradually changed to hexane containing ethyl acetate. The product is eluted in the fractions of 25-40% ethylacetate in hexane which are pooled and evaporated to dryness in vacuo. This product is further purified by chromatography on thick silica layer plates, eluting with ethyl acetate:hexane (60:40). The band with the desired product is removed from the plates and extracted into ethyl acetate. The silica is removed by filtration and the ethyl acetate extract is evaporated to dryness in vacuo giving the desired product.
EXAMPLE 8
Gal 1α,6 glc 1β,6 gal 1α,6 glc
A 2.0 g. portion of gal 160 ,6 glc 1β,6 gal 1α,6 glc tetradecaacetate is dissolved in 55 ml. of a mixture of methanol anol, water and triethylamine (6:2:3) and reacted as described in Example 4, giving the desired product as a colorless glass.
EXAMPLE 9
Gal 1α,6 gls 1β,6 gal 1α,6 glc tetradecakis (H-sulfate), tetradecasalt with trimethylamine
A 4.5 g portion of trimethylamine sulfur trioxide is dissolved in 25 ml. of dimethylformamide with stirring at 70° C. A 1.0 g. portion of gal 1α,6 glc 1β,6 gal 1α,6 glc is added and the reaction proceeds as described in Example 5, giving the desired product as a pale brown granular solid.
EXAMPLE 10
Gal 1α,6 glc 1β,6 gal 1α,6 glc tetradecakis (H-sulfate), tetradecasodium salt
A 3.4 g. portion of gal 1α,6 glc 1β, 6 gal 1α, 6 glc tetradecakis (H-sulfate), tetradecasalt with trimethylamine is dissolved in 10 ml. of water. A 10 ml. portion of 30% aqueous sodium acetate solution is added and the reaction proceeds as described in Example 6, giving the desired product as a pale brown granular solid.
EXAMPLE 11
Glc 1α,4 glc 1β, 6 gal 1α, 6 glc tetradecaacetate
A suspension of 50 g. of anhydrous sodium acetate in 500 ml. of acetic anhydride is heated to boiling and 100 g. of glc 1α, 4 glc monohydrate is added slowly and portionwise to maintain boiling. The mixture is boiled vigorously, cooled to about 150° C. and poured into 2 liters of vigorously stirred ice and water. The mixture of gum and solid is separated by decantation and fresh ice and water are added. After standing for 4 hours the solid is collected, dissolved in 500 ml. of methylene chloride, washed once with water, once with saturated sodium bicarbonate solution, twice with water, dried over sodium sulfate, filtered through diatomaceeous earth, washed with methylene chloride and evaporated to a gum. This gum is recrystallized several times from ethanol, giving glc 1α,4 glc octaacetate as a white solid.
A 1.5 g. portion of glc 1α,4 glc octaacetate is added to 7.5 ml. of 30-32% hydrobromic acid in glacial acetic acid cooled to 0°-5° C. in an ice bath. The solution is stored at 0°-5° C. for 21/2 hours, then 30 ml. of methylene chloride are added. The mixture is washed with ice water until neutral to Congo Red paper, dried over sodium sulfate, filtered and evaporated to a solid which is glc 1α,4 glc heptaacetyl bromide.
A 622 mg. portion of silver perchlorate is dissolved in 10 ml. of nitromethane with warming. A 250 mg. portion of anhydrous calcium sulfate is added and the mixture is cooled to 0°-5° C. An 880 mg. portion of trityl peracetyl gal 1α,6 glc is added, followed by 860 mg. of glc 1α,4 glc heptaacetyl bromide. The mixture is warmed slightly to complete the reaction then filtered and washed with nitromethane. The combined filtrate and washings is washed with cold saturated sodium bicarbonate solution, then twice with cold water, dried over sodium sulfate, filtered and evaporated to a gum. Ether is added to the gum and the mixture is evaporated giving a yellow glass. This glass is dissolved in 10 ml. of pyridine and 5 ml. of acetic anhydride is added. After standing at room temperature for 18 hours the mixture is poured into ice-water giving a white solid which is collected, washed several times with water and air dried. Chromatography of this solid as described in Example 7 gives a band containing the product which is eluted with acetone, filtered and evaporated to a glass. This glas is dissolved in ether, filtered and then evaporated giving the desired product as a colorless glass.
EXAMPLE 12
Glc 1α,4 glc 1β,6 gal 1α,6 glc
A 1.0 g. portion of glc 1α,4 glc 1β,6 gal 1α,6 glc tetradecaacetate is dissolved in a solution of 2 parts methanol, one part water and one part triethylamine. The procedure of Example 4 is followed, giving the desired product as a glass.
EXAMPLE 13
Glc 1α,4 glc 1β,6 gal 1α,6 glc tetradecakis (H-sulfate), tetradecasalt with trimethylamine
A 200 mg. portion iof glc 1α,4 glc 1β, 6 gal 1α,6 glc is dissolved in 5 ml. of dimethylformamide and 1.4 g. of trimethylamine sulfur trioxide is added. The procedure of Example 5 is followed giving the desired product as a glass.
EXAMPLE 14
Glc 1α,4 glc 1β,6 gal 1α,6 glc tetradecakis (H-sulfate), tetradecasodium salt
A 500 mg. portion of glc 1α,4 glc 1β,6 gal 1α,6 glc tetradecakis (H-sulfate), tetradecasodium salt with trimethylamine is added to 4 ml. of water and the mixture is filtered. To the filtrate is added 2 ml. of 30% aqueous sodium acetate solution and the procedure of Example 6 is followed, giving the desired product as a white solid.
EXAMPLE 15
Glc 1β,4 glc 1β,6 gal 1β,6 glc tetradecaacetate
Glc 1β,4 glc is converted to its octaacetate form by conventional methods as disclosed in Methods of Carbohydrate Chemistry 1, 334. A 20 g. portion of this octaacetate is dissolved in 200 ml. of methylene chloride and the solution is cooled to 0° C. An 80 ml. portion of 32% hydrobromic acid in glacial acetic acid is added and the mixture is allowed to stand in an ice bath for 2 hours. The mixture is then poured into crushed ice and diluted with 200 ml. of methylene chloride. The organic layer is separated, washed repeatedly with ice water until neutral, dried over anhydrous sodium sulfate and evaporated in vacuo, giving glc 1β,4 glc heptaacetate bromide as a white solid.
A 1.92 g. portion of silver tritylate and 10 g. of anhydrous calcium sulfate are added to 100 ml. of nitromethane. The mixture is stirred for 5 minutes, then cooled in an ice bath and 4.4 g. of trityl peracetyl gal 1α,6 glc is added. A 5.25 g. portion of glc 1β,4 glc heptaacetate bromide is added with vigorous stirring and the mixture is stirred in an ice bath for one hour. The mixture is diluted with 125 ml. of methylene chloride and filtered through diatomaceous earth. The filtrate is washed with water and then with saturated aqueous sodium bicarbonate solution. The organic layer is separated, dried over anhydrous sodium sulfate and evaporated in vacuo to a light brown glass.
This glass is dissolved in 50 ml. of pyridine and 30 ml. of acetic anhydride is added. The mixture is stirred at room temperature for 20 hours and then poured in a thin stream into ice water with vigorous stirring. The precipitate which forms is collected, washed with cold water and dried. This solid is subjected to chromatography on silica gel plates using ethyl acetate:hexane (60:40) giving the desired product.
EXAMPLE 16
Glc 1β,4 glc 1β,6 gal 1α,6 glc
A 1.6 g. portion of glc 1β,4 glc 1β,6 gal 1α,6 glc tetradecaacetate is dissolved in 22 ml. of a mixture of triethylamine, water and methanol (3:2:6). The mixture is treated as described in Example 4, giving the desired product as an off-white glass.
EXAMPLE 17
Glc 1β,4 glc 1β,6 gal 1α,6 glc tetradecakis (H-sulfate), tetradecasalt with trimethylamine
A 4.1 g. portion of trimethylamine sulfur trioxide is dissolved in 15 ml. of dimethylformamide by warming to 70° C. An 800 mg. portion of glc 1β,4 glc 1β,6 gal 1α,6 glc is added and the procedure of Example 5 is followed giving the desired product as a colorless granular solid.
EXAMPLE 18
Glc 1β,4 glc 1β,6 gal 1α,6 glc tetradecakis (H-sulfate), tetradecasodium salt
A 2.0 g. portion of glc 1β,4 glc 1β,6 gal 1α,6 glc tetradecakis (H-sulfate), tetradecasalt with trimethylamine is dissolved in 10 ml. of water. A 10 ml. portion of 30% aqueous sodium acetate solution is added and the reaction proceeds as described in Example 6, giving the desired product as a light brown powder.
EXAMPLE 19
(Glc 1α,4)2glc 1β,6 gal 1α,6 glc heptadecaacetate
A mixture of 5 g. of anhydrous sodium acetate and 50 ml. of acetic anhydride is heated to vigorous boiling. A 10 g. portion of glc 1α,4 glc 1α,4 glc is added in small portions. The mixture is boiled vigorously for a few minutes, cooled to 50°-60° C. and then poured in a thin stream into crushed ice with vigorous stirring. The oil which separates is redissolved in ethanol and then poured over crushed ice. The colorless precipitate which forms is collected, washed with ice-cold water, dried and crystallized from ethanol-water giving glc 1α,4 glc 1α,4 glc hendecaacetate as colorless crystals.
A 75 ml. portion of 30-32% hydrobromic acid in glacial acetic acid is cooled in an ice bath. A solution of 15.0 g. of glc 1α,4 glc 1α,4 glc hendecaacetate in 125 ml. of chloroform is added with swirling and the mixture is allowed to stand in the ice bath for 2 hours with occasional swirling. The mixture is poured onto crushed ice and diluted with 200 ml. of methylene chloride. The organic layer is washed with ice-cold water until neutral, dried over anhydrous calcium chloride and evaporated in vacuo to a colorless glass, which is glc 1α,4 glc 1α,4 glc decaacetate bromide.
A 995 mg. portion of silver perchlorate and 5.0 g. of anhydrous calcium sulfate are added to 50 ml. of nitromethane. The mixture is stirred for 5 minutes, then cooled in an ice bath and 3.52 g. of trityl peracetyl gal 1α,6 glc is added. A 3.91 g. portion of glc 1α,4 glc 1α,4 glc decaacetate bromide is added with vigorous stirring and the mixture is stirred in an ice bath for 10 minutes, then warmed on a steam bath for 5 minutes, cooled to room temperature, diluted with 150 ml. of methylene chloride and filtered. The filtrate is washed with water and then with saturated aqueous sodium bicarbonate solution. The organic extract is separated, dried over anhydrous sodium sulfate and evaporated in vacuo to a pale yellow glass. This glass is dissolved in 25 ml. of pyridine and 10 ml. of acetic anhydride is added. The mixture is allowed to stand at room temperature overnight and then poured into crushed ice. The precipitate is collected, washed with water, dried and chromatographed on a silica gel column, eluting with ethyl acetate:hexane (1:1) giving the desired product.
EXAMPLE 20
(Glc 1α,4)2 glc 1β,6 gal 1α,6 glc
A solution of 1.8 g. of glc 1α,4 glc 1α,4 glc 1β,6 gal 1α,6 glc heptadecaacetate in 55 ml. of a mixture of methanol, water and triethylamine (6:2:3) is reacted as described in Example 4, to give the desired product as a colorless glass.
EXAMPLE 21
(Glc 1α,4)2 glc 1β,6 gal 1α,6 glc heptadecakis (H-sulfate) heptadecasalt with trimethylamine
A 3.5 g. portion of trimethylamine sulfur trioxide is dissolved in 25 ml. of dimethylformamide with warming to 70° C. An 828 mg. portion of glc 1α,4 glc 1α,4 glc 1β,6 gal 1α,6 glc is added and the procedure of Example 5 is followed, giving the desired product as a pale brown granular solid.
EXAMPLE 22
(Glc 1α,4)2 glc 1β,6 gal 1α,6 glc heptadecakis (H-sulfate) heptadecasodium salt
A reaction mixture comprising 2.45 g. of glc 1α,4 glc 1α,4 glc 1β,6 gal 1α,6 glc tetradecakis (H-sulfate) heptadecasalt with trimethylamine, 10 ml. of water and 10 ml. of 30% aqueous sodium acetate solution is treated as described in Example 6, giving the desired product as a pale brown granular solid.
EXAMPLE 23
(Glc 1α,4)6 glc 1β,6 gal 1α,6 glc nonacosaacetate
(Glc 1α,4)6 glc is converted to its polyacetate form by conventional methods as described in Methods in Carbohydrate Chemistry 1, 334. A 10 g. portion of this polyacetate is dissolved with warming in 15 ml. of glacial acetic acid. To this is added 100 ml. of cold (0°-5° C.) 32% hydrobromic acid in glacial acetic acid. The mixture is stirred for 21/2 hours in an ice bath, then diluted with 100 ml. of methylene chloride and washed with ice-water until neutral to Congo Red paper. The solution is dried over magnesium sulfate, filtered and evaporated to a white glass which is (glc 1α,4) 6 glc polyacetate bromide.
A 2.72 g. portion of trityl peracetyl gal 1α,6 glc which has been previously dried, is dissolved in 50 ml. of dry nitromethane. A 3 g. portion of anhydrous calcium sulfate and 1.2 g. of silver trifluorosulfonate are added. The mixture is cooled with stirring in an ice bath and 10 g. of (glc 1α,4) 6 glc polyacetate bromide in 50 ml. of dry nitromethane is added. The mixture is stirred at 0°-5° C. for one hour, filtered and the filter cake is washed with nitromethane. The filtrate is diluted with 100 ml. of methylene chloride, washed with cold saturated aqueous sodium bicarbonate solution, then twice with water, dried over magnesium sulfate, filtered and evaporated to a glass. This glass is dissolved in 10 ml. of pyridine and 3 ml of acetic anhydride is added. The mixture is allowed to stand 48 hours at room temperature, then poured into ice water giving a tam solid which is washed with water, dissolved in methylene chloride, dried over magnesium sulfate, filtered and evaporated leaving a gum. This gum is subjected to conventional chromatographic separation. The recovered product is dissolved in methylene chloride, filtered through diatomaceous earth, reevaporated and dried in vacuo over phosphorous pentoxide giving the desired product.
EXAMPLE 24
(Glc 1α,4)6 glc 1β,6 gal 1α,6 glc
A 1.0 g. portion of (glc 1α,4)6 glc 1β,6 gal 1α,6 glc nonacosaacetate is dissolved by swirling at room temperature in 16 ml. of a mixture of methanol, water and triethylamine (6:2:3). The solution is allowed to stand for 18 hours and then is concentrated in vacuo at 50° C. The residue is dissolved in 5 ml. of water. A small amount of charcoal is added and the mixture is swirled, filtered through diatomaceous earth, evaporated at 50° C. to a gum and dried in vacuo over phosphorous pentoxide. This material is dissolved in 2 ml. of water and filtered through diatomaceous earth. To the filtrate is added 5 ml. of methanol and then ether. The solvent is decanted from the resulting precipitate and the gum is triturated twice with fresh ether. The solid is then dried at 110° C. in vacuo over phosphorous pentoxide. This solid is dissolved in a small amount of methanol and ether is added giving a gum. The solvents are decanted, fresh ether is added and the solid is collected and dried overnight over phosphorous pentoxide in vacuo giving the desired product.
EXAMPLE 25
(Glc 1α,4) 6 glc 1β,6 gal 1α,6 glc nonacosakis (H-sulfate) nonacosasalt with trimethylamine
A 100 mg. portion of (glc 1α,4) 6 glc 1β,6 gal 1α,6 glc is added to 1 ml. of dimethylformamide. A 327 mg. portion of trimethylamine sulfur trioxide is added and the procedure of Example 5 is followed giving the desired product as a white solid.
EXAMPLE 26
(Glc 1α,4) 6 glc 1β,6 gal 1α,6 glc nonacosakis (H-sulfate) nonacosasodium salt
A 200 mg. portion of (glc 1α,4) 6 glc 1β,6 gal 1α,6 glc nonacosakis (H-sulfate), nonacosasalt with trimethylamine is dissolved in 1-2 ml. of water and then filtered. A 1.0 ml. portion of 30% aqueous sodium acetate solution is added to the filtrate and the procedure of Example 6 is followed, giving the desired product as a white solid.
EXAMPLE 27
______________________________________Preparation of Compressed TabletIngredient mg/Tablet______________________________________Active Compound 0.5-500Dibasic Calcium Phosphate N.F. qsStarch USP 40Modified Starch 10Magnesium Stearate USP 1-5______________________________________
EXAMPLE 28
______________________________________Preparation of Compressed Tablet - Sustained ActionIngredient mg/Tablet______________________________________Active Compound as Aluminum 0.5-500 (as acidLake*, Micronized equivalent)Dibasic Calcium Phosphate N.F. qsAlginic Acid 20Starch USP 35Magnesium Stearate USP 1-10______________________________________ *Complement inhibitor plus aluminum sulfate yields aluminum complement inhibitor. Complement inhibitor content in aluminum lake ranges from 5-30%.
EXAMPLE 29
______________________________________Preparation of Hard Shell CapsuleIngredient mg/Capsule______________________________________Active Compound 0.5-500Lactose, Spray Dried qsMagnesium Stearate 1-10______________________________________
EXAMPLE 30
______________________________________Preparation of Oral Liquid (Syrup)Ingredient % W/V______________________________________Active Compound 0.05-5Liquid Sugar 75.0Methyl Paraben USP 0.18Propyl Paraben USP 0.02Flavoring Agent qsPurified Water qs ad 100.0______________________________________
EXAMPLE 31
______________________________________Preparation of Oral Liquid (Elixir)Ingredient % W/V______________________________________Active Compound 0.05-5Alcohol USP 12.5Glycerin USP 45.0Syrup USP 20.0Flavoring Agent qsPurified Water qs ad 100.0______________________________________
EXAMPLE 32
______________________________________Preparation of Oral Suspension (Syrup)Ingredient % W/V______________________________________Active Compound as Aluminum 0.05-5Lake, Micronized (acid equivalent)Polysorbate 80 USP 0.1Magnesium Aluminum Silicate,Colloidal 0.3Flavoring Agent qsMethyl Paraben USP 0.18Propyl Paraben USP 0.02Liquid Sugar 75.0Purified Water qs ad 100.0______________________________________
EXAMPLE 33
______________________________________Preparation of Injectable SolutionIngredient % W/V______________________________________Active Compound 0.05-5Benzyl Alcohol N.F. 0.9Water for Injection 100.0______________________________________
EXAMPLE 34
______________________________________Preparation of Injectable OilIngredient % W/V______________________________________Active Compound 0.05-5Benzyl Alcohol 1.5Sesame Oil qs ad 100.0______________________________________
EXAMPLE 35
______________________________________Preparation of Intra-Articular ProductIngredient Amount______________________________________Active Compound 2-20 mgNaCl (physiological saline) 0.9%Benzyl Alcohol 0.9%Sodium Carboxymethylcellulose 1-5%pH adjusted to 5.0-7.5Water for Injection qs ad 100%______________________________________
EXAMPLE 36
______________________________________Preparation of Injectable Depo SuspensionIngredient % W/V______________________________________Active Compound 0.05-5 (acid equivalent)Polysorbate 80 USP 0.2Polyethylene Glycol 4000 USP 3.0Sodium Chloride USP 0.8Benzyl Alcohol N.F. 0.9HCl to pH 6-8 qsWater for Injection qs ad 100.0______________________________________
EXAMPLE 37
______________________________________Preparation of Dental PasteIngredient % W/W______________________________________Active Compound 0.05-5Zinc Oxide 15Polyethylene Glycol 4000 USP 50Distilled Water qs 100______________________________________
EXAMPLE 38
______________________________________Preparation of Dental OintmentIngredient % W/W______________________________________Active Compound 0.05-5Petrolatum, White USP qs 100______________________________________
EXAMPLE 39
______________________________________Preparation of Dental CreamIngredient % W/W______________________________________Active Compound 0.05-5Mineral Oil 50Beeswax 15Sorbitan Monostearate 2Polyoxyethylene 20 SorbitanMonostearate 3Methyl Paraben USP 0.18Propyl Paraben USP 0.02Distilled Water qs 100______________________________________
EXAMPLE 40
______________________________________Preparation of Topical CreamIngredient % W/W______________________________________Active Compound 0.05--5Sodium Lauryl Sulfate 1Propylene Glycol 12Stearyl Alcohol 25Petrolatum, White USP 25Methyl Paraben USP 0.18Propyl Paraben USP 0.02Purified Water qs 100______________________________________
EXAMPLE 41
______________________________________Preparation of Topical OintmentIngredient % W/W______________________________________Active Compound 0.05-5Cholesterol 3Stearyl Alcohol 3White Wax 8Petrolatum, White USP qs 100______________________________________
EXAMPLE 42
______________________________________Preparation of Spray Lotion (non-Aerosol)Ingredient % W/W______________________________________Active Compound 0.05--5Isopropyl Myristate 20Alcohol (Denatured) qs 100______________________________________
EXAMPLE 43
______________________________________Preparation of Buccal TabletIngredient g/Tablet______________________________________Active Ingredient 0.003256 × Sugar 0.29060Acacia 0.01453Soluble Starch 0.01453F. D. & C. Yellow No. 6 Dye 0.00049Magnesium Stearate 0.00160 0.32500______________________________________
The final tablet will weigh about 325 mg. and may be compressed into buccal tablets in flat faced or any other tooling shape convenient for buccal administration.
EXAMPLE 44
______________________________________Preparation of LozengeIngredient g/Lozenge______________________________________Active Ingredient 0.0140Kompact® Sugar (Sucrest Co.) 0.71386 × Sugar 0.4802Sorbitol (USP Crystalline) 0.1038Flavor 0.0840Magnesium Stearate 0.0021Dye qsStearic Acid 0.0021 1.4000______________________________________
The ingredients are compressed into 5/8" flat based lozenge tooling. Other shapes may also be utilized | O-α-D (and O-β-D) multi-galactopyranosyl (and glucopyranosyl) 1→4 (and 1→6) galactopyranosyl 1→6-α-D-glucopyranose sulfate salts which are useful as complement inhibitors. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to the radiographic arts. It finds particular application in conjunction with x-ray tubes for computerized tomographic (CT) scanners and will be described with particular reference thereto. However, it is to be appreciated that the present invention may also be amenable to x-ray tubes for other applications.
CT scanners have commonly included a floor-mounted frame assembly which remains stationary during a scan. An x-ray tube is mounted to a rotatable frame assembly which rotates around a patient receiving examination region during the scan. Radiation from the x-ray tube traverses the patient receiving region and impinges upon an array of radiation detectors. Using the position of the x-ray tube during each sampling, a tomographic image of one or more slices through the patient is reconstructed.
The x-ray tube assembly typically comprises a lead lined housing containing a vacuum envelope or x-ray insert which holds a rotating anode and a stationary cathode. Cooling oil is flowed between the x-ray insert and the housing. In large, high performance x-ray tubes, the x-ray insert may be a metal shell or frame with a beryllium window mounted or brazed thereon for allowing the transmission of x-rays from the x-ray insert. Likewise, the housing defines an x-ray output window that is in alignment with the beryllium window of the x-ray insert such that x-rays may pass directly through the beryllium window and the x-ray output window.
During x-ray generation, electrons are emitted from a heated filament in the cathode and accelerated to a focal spot area on the anode. Upon striking the anode, some portion of the electrons, or secondary electrons, are bounced to the surrounding frame and converted into heat. The beryllium window receives the highest intensity of the secondary electron heating because the window is closer to the focal spot on the anode. The heat is undesirable and is commonly termed waste heat. One of the persistent problems in CT scanners and other radiographic apparatus is dissipating the waste heat created while generating x-rays.
In order to remove the waste heat, a cooling oil is often circulated through the housing and around the x-ray insert forming a cooling jacket around the x-ray insert. For example, oil may be drawn through an output aperture located at one end of the housing, circulated through a radiator or heat exchanger and returned to an inlet aperture in the opposite end of the housing. The returned cooled fluid flows axially through the housing toward the outlet aperture, absorbing heat from the x-ray insert.
Removing waste heat in this manner is not always completely effective. More specifically, waste heat removal by merely forcing coolant to flow between the x-ray insert and the housing is particularly ineffective around the x-ray output window. The beryllium window and its environs, being the recipient of the secondary electrons and heat from the closely adjacent focal spot, is preferentially heated. Further, the beryllium window protrudes out from the frame and generally disrupts the flow of coolant around the window preventing optimal cooling. Additionally, the configuration of the x-ray output window on the housing disrupts coolant flow and, by its proximity to the beryllium window, limits the amount of coolant capable of passing over the beryllium window.
When the window is not sufficiently cooled, the heat can damage the braze joint between the beryllium window and the x-ray insert causing the x-ray tube to fail. Further, the coolant adjacent to the beryllium window may boil and leave a carbon residue on the beryllium window. Such a coating is undesirable as it may degrade the quality of the x-ray image.
The present invention provides a new and improved cooling system and technique for overcoming the above-reference drawbacks and others.
SUMMARY OF THE INVENTION
The present invention relates to the use of a cold-plate on the x-ray window of an x-ray insert to provide for the removal of undesirable waste heat from an x-ray tube.
In accordance with one aspect of the present invention, a CT scanner comprises an x-ray tube assembly mounted on a rotating frame portion. The x-ray tube assembly includes a housing, an x-ray tube operatively mounted within the housing, and a cooling fluid reservoir defined between the x-ray tube and the housing. The cooling fluid reservoir includes an inlet aperture through the housing and an outlet aperture through the housing. The CT scanner also comprises an x-ray window mounted on the x-ray tube, a cooling fluid circulation line, and a cooling fluid return line. The circulation line is in fluid communication with the inlet aperture of the cooling fluid reservoir and with a heat exchanger. The return line is in fluid communication with the heat exchanger and the outlet aperture of the cooling fluid reservoir. The CT scanner additionally comprises a pump and a cold-plate mounted on the x-ray tube around the x-ray window. The pump circulates the cooling fluid through the heat exchanger, the suction and return lines, and the x-ray tube housing assembly.
In accordance with another aspect of the present invention, an x-ray tube assembly comprises a housing, an x-ray tube, and a cold-plate. The housing has an x-ray window and defines a housing cavity therein. The x-ray tube includes a vacuum envelope which holds an anode and a cathode. The vacuum envelope has an x-ray translucent window adjacent the anode. The x-ray tube is mounted in the housing cavity spaced from the housing to define a cooling fluid reservoir therebetween and the x-ray translucent window is aligned with the x-ray window. The cold-plate is operatively mounted on the x-ray translucent window.
In accordance with another aspect of the present invention, an x-ray tube comprises a cold plate and a vacuum envelope having an anode and a cathode with an x-ray window mounted thereon adjacent the anode. The cold plate includes an elongated shell and a plurality of heat transfer elements positioned therein. The shell is operatively mounted around the x-ray window and circumferentially oriented relative to the vacuum envelope. The shell includes an inlet defined in a first end, an outlet defined in an opposite end, and an expansion section disposed therebetween.
In accordance with another aspect of the present invention, a method of cooling an x-ray tube is provided. A first portion of a cooling fluid is circulated over an x-ray tube to remove heat. A second portion of the cooling fluid forced around an x-ray translucent window disposed on the x-ray tube removes heat from the window. The cooling fluid is cooled and recirculated around the window and over the x-ray tube.
The advantages of the present invention include the ability to prevent or reduce the risk of thermal damage to the joint between the beryllium window and the x-ray insert.
Another advantage resides in reducing or preventing failure of the x-ray tube due to overheating.
Another advantage of the present invention resides in reducing or preventing carbon build-up on the beryllium window due to overheating of the cooling fluid.
Another advantage of the present invention resides in maintaining the dielectric characteristics of the cooling fluid to decrease the possibilities of high-voltage instabilities.
Still other advantages and benefits of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating a preferred embodiment and are not to be construed as limiting the invention.
FIG. 1 is a diagrammatic illustration of a CT scanner in accordance with the present invention;
FIG. 2 is a diagrammatic cross-sectional illustration of the x-ray tube assembly of FIG. 1;
FIG. 3 is a perspective view of the cold-plate with a portion of a shell removed to show corrugated fins; and
FIG. 4 is a diagrammatic illustration of a cooling system according to an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a CT scanner includes a floor mounted or stationary frame portion A whose position remains fixed during data collection. An x-ray tube B is mounted on a rotating frame C rotatably mounted within the stationary frame portion A. Heat generated by the x-ray tube B is transferred to a heat exchanger D by a cooling fluid, such as oil, water, refrigerant gas, other fluids and combinations thereof.
The stationary frame portion A includes a bore 10 that defines a patient receiving examination region 12 . An array of radiation detectors 14 are disposed concentrically around the patient receiving region 12 . The stationary frame A with the rotating frame C can be canted or tipped to scan slices at selectable angles. A control console 16 contains an image reconstructing processor 18 for reconstructing an image representation of output signals from the detector array 14 , performing image enhancements, and the like. A video monitor 20 converts the reconstructed image representation into a human readable display. The console 16 also includes appropriate digital recording memory media for archiving the image representations. Various control functions, such as initiating a scan, selecting among different types of scans, calibrating the system, and the like are also performed at the control console 16 .
With further reference to FIG. 2, the x-ray tube B includes a housing 22 having an x-ray permeable window 24 directed toward the patient receiving region 12 and an x-ray insert 26 mounted in the housing 22 . The x-ray insert 26 can be made of glass, ceramic or metal. A rotary anode 28 is rotatably mounted in the x-ray insert 26 by bearings and a cathode 30 is mounted adjacent the rotary anode 28 . Electrons from the cathode 30 are propelled by high voltage against the rotating anode 28 causing the emission of x-rays and a large amount of heat. The x-ray insert 26 includes a beryllium or other low Z metal window 32 mounted adjacent the cathode 30 and the x-ray permeable window 24 of the housing 22 . The beryllium window 32 passes x-rays generated by the cathode 30 and the anode 28 out of the x-ray insert 26 through the x-ray permeable window 24 and into the patient receiving area 12 . The beryllium window 32 is attached to the x-ray insert 26 by bending, brazing, or by any other suitable manner. Electrical leads for supplying current to the cathode 30 and leads for biasing the cathode 30 to a large, negative potential difference relative to the anode 28 pass through the envelope in a cathode well 34 .
Once the x-rays pass through the x-ray permeable window 24 and across the patient receiving region 12 , appropriate x-ray collimators focus the radiation into one or more planar beams which span the examination region 12 in a fan or cone pattern, as is conventional in the art. Other equipment associated with the x-ray tube B, such as a high voltage power supply 36 and a pump 38 , are also mounted on the rotating frame C.
During operation of the x-ray tube B, the temperature of the beryllium window 32 tends to rise quickly. The rapid increase of the window temperature is caused not only by thermal radiation from the hot anode 28 inside the x-ray insert 26 , but also by the kinetic energy from the secondary electrons impinging on the beryllium window 32 and its neighboring x-ray insert area. The dissimilar coefficients of thermal expansion of the beryllium window 32 , the insert 26 , and the bonding materials used to mount the window 32 to the x-ray insert 26 tend to create mechanical stresses that escalate as the temperature increases. Excessive window temperature is potentially dangerous for cracking the window joint, which can destroy the vacuum within the insert and cause failure of the x-ray tube B. A high window temperature can also overheat the cooling fluid near an outer surface of the window 32 , deteriorating the dielectric characteristics of the cooling fluid, and increasing possibilities of high-voltage instabilities. Overheated cooling fluid near the window 32 is also detrimental because it could be carbonized and form particles. Electrically conductive carbon particles floating inside the x-ray tube B can deteriorate the stability of the fluid and cause arcing. This effect may decrease the quality of the x-ray image produced by the CT scanner.
With additional reference to FIG. 3, a cold-plate 40 is integrated onto the beryllium 32 window for removing excess heat. The cold-plate 40 comprises a plurality of corrugated fins 42 , a shell 44 , an inlet 46 , and an outlet 48 . The corrugated fins 42 of thermally conductive material, such as beryllium or aluminum, are built on the rim area of the beryllium window 32 and its neighboring x-ray insert area. The shell 44 encloses the fins 42 and defines a fluid channel in a circumferential direction around the x-ray insert. The inlet 46 , and the outlet 48 are oriented to direct flow along the longitudinal direction of the window 32 . To reduce the pressure drop across the cold-plate 40 , the inlet 46 contains a smooth expansion section 50 and the outlet 48 is wide open. When cooling fluid is provided to the cold-plate 40 , the cooling fluid discharges through the outlet 48 and mixes with cooling fluid inside the x-ray tube housing 22 . The shell 44 can be made of aluminum. Therefore, this aluminum shell can be also used as an x-ray filtration plate by setting its thickness as the required filtration thickness.
Alternatively, the cold-plate cover 40 can be made of titanium instead of aluminum. The advantage of using titanium is that this alloy has excellent x-ray transparent features. Further, the cover 40 can also be made of thermally conductive and x-ray transmissible plastics.
To cool the x-ray tube B, heated cooling fluid is circulated from the x-ray tube housing 22 through a first cooling fluid duct to the heat exchanger D on the rotatable frame C. Circulation of the cooling fluid is effected by the fluid pump 36 . Cooled cooling oil exiting from the heat exchanger D is returned to the housing 22 via a second cooling fluid duct. The cooling fluid enters the housing 22 through an inlet aperture 52 . The cooling fluid flows through the x-ray tube B absorbing heat created during x-ray generation. The fluid exits the housing 22 through an outlet aperture 54 into the first cooling fluid duct and recirculates back to the heat exchanger D.
Cooling fluid flowing to the inlet 52 of the x-ray tube B is distributed into two streams. A first stream of the fluid goes generally into the housing 22 , whereas a second stream flows through a tube 56 to the cold-plate 40 . The tube 56 fluidly connects to the inlet 46 of the cold-plate 40 and can be made of plastic or any other non-metallic material. Thus, the tube 56 provides cooling fluid directly to the beryllium window 32 via the cold-plate 40 . The fluid exiting the tube 56 into the cold-plate 40 flows perpendicularly relative to the general flow of cooling fluid through the housing 22 around the cold-plate 40 . The inlet 52 and outlet 54 of the x-ray tube housing 22 are at a first end of the housing 22 , and separated by a first flow divider 54 .
A second flow divider 58 is installed in the middle section of the housing 22 along an axial plane of the x-ray insert 26 and perpendicular to the direction of the inlet 52 of the housing 22 . The second flow divider 58 is used for forcing the fluid to flow through the housing 22 in two passes. More specifically, the second flow divider 58 divides the housing 22 into a beryllium window cavity and an opposing cavity. The cavities are fluidly connected at the cathode side of the housing 22 . The upper half of the x-ray insert 26 , the upper half of the housing 22 , and the second flow divider 58 generally define the beryllium window cavity. The lower half of the x-ray insert 26 , the lower half of the housing 22 , and the second flow divider 58 generally define the opposing cavity.
In operation, cooling fluid supplied from the heat exchanger D enters the inlet 52 of the x-ray tube housing 22 . The cooling fluid is divided into first and second streams. The first stream enters generally into the x-ray housing 22 into the beryllium window cavity to cool the top half of the x-ray insert 26 . The second stream flows to the cold-plate 36 through a tube 56 fluidly connecting the flow inlet 52 of the housing 22 and the inlet 46 of the cold-plate 40 . The cooling fluid directed into the cold-plate 40 engages in vigorous heat transfer inside the cold-plate 40 while washing through the cold-plate 40 . The cooling fluid exits the cold-plate 40 and mixes with the fluid flowing in the beryllium window cavity. The joined cooling fluid flows continuously towards the cathode end of the housing 22 before making a one-hundred-eighty degree turn over the second flow divider 58 . The cooling fluid then flows into the opposing cavity and back to the outlet 54 of the housing 22 while cooling the bottom half of the x-ray insert 26 . Cooling fluid exits the outlet 54 of the housing 22 and goes to the heat exchanger D to release the heat that it has absorbed from inside the x-ray tube housing 22 .
To integrate the cold-plate 40 to the beryllium window 32 , corrugated fins 42 are built around the rim area of the window 32 and the x-ray insert area neighboring the window 32 . A shell 44 is brazed on the x-ray insert 26 thereby covering the window 32 and the fins 42 to form the cold-plate 40 . A high volume of cooling fluid is driven into the cold-plate 40 to enhance the heat transfer from the fins 42 and the window 32 . The cooling fluid to the cold-plate can be regulated and supplied through a flow director that may be placed at the inlet 52 to the x-ray housing 22 .
With reference to FIG. 4, in an alternate embodiment of the present invention, a second and independent cooling loop is used to provide cooling fluid to the cold-plate 40 . Cool cooling fluid is provided from a second heat exchanger E to the cold-plate 40 through a conduit 60 . While flowing through the cold-plate 40 , the cooling fluid removes heat from the beryllium window 32 and the area on the x-ray insert 26 surrounding the beryllium window 32 . The heated cooling fluid discharges from the cold-plate 40 into a return conduit 62 and is circulated back to the heat exchanger E by a second pump 64 . The first heat exchanger D continues to cool heated cooling fluid exiting the housing 22 of the x-ray tube B and provide cooled cooling fluid for circulation through the housing 22 by the pump 38 .
The cooling fluid exiting the cold-plate 40 no longer merges with the cooling fluid flowing through the housing 22 . Further, the cooling fluid flowing through the cold-plate 40 is not in fluid communication with the cooling fluid flowing through the x-ray housing. As a result, it is possible to introduce a non-dielectric and water-based fluid to cool the cold-plate 40 . Use of such a cooling fluid will enhance the heat transfer of the cold-plate 40 while keeping the beryllium window 32 clean.
The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they are within the scope of the appended claims or the equivalents thereof. | A CT scanner comprises an x-ray window mounted on an x-ray tube, a cooling fluid circulation line, and a cooling fluid return line. A cold-plate is operatively mounted on the x-ray tube around the x-ray window. The cold plate includes an elongated shell and corrugated fins for rapidly removing heat from the x-ray window. The circulation line is in fluid communication with an inlet of the cold-plate, a cooling fluid reservoir defined between the x-ray tube and a surrounding housing, and a heat exchanger. The return line is in fluid communication with an outlet of the cold-plate, the cooling fluid reservoir, and the heat exchanger. A pump circulates the cooling fluid through the heat exchanger, the suction and return lines, the cold-plate, and the x-ray tube housing. | 7 |
Background of the Invention
1. Field of the Invention
This invention relates to a nonvolatile semiconductor memory using nonvolatile transistors and more particularly to a nonvolatile semiconductor memory in which data can be electrically programmed. 2. Description of the Related Art
A nonvolatile semiconductor memory in which data can be electrically programmed is well known in the art as an electrically erasable and programmable read only memory (E 2 PROM). Memory cells used for constituting the E 2 PROM can be formed with various types of constructions, and the memory cells are generally formed with a construction in which a floating gate is partly overlapped with a drain diffusion layer with a thin insulation film disposed therebetween.
FIG. 1 is a cross sectional view of a conventional memory cell with the above construction. In FIG. 1, 50 denotes a P-type semiconductor substrate. N-type diffusion layers 51, 52 and 53 are separately formed in the surface area of the substrate 50, and a channel region 54 is provided between the diffusion layers 51 and 52. A floating gate 56 formed of polysilicon is disposed over the channel region 54 with a relatively thick insulation film 55 disposed therebetween. The floating gate 56 is also formed over the diffusion layer 52 with a thin film portion 57 thinner than the insulation film 55 disposed therebetween. Further, a control gate 59 formed of polysilicon is disposed over the floating gate 56 with a relatively thick insulation film 58 disposed therebetween.
A channel region 60 is provided between the diffusion layers 52 and 53, and a select gate 62 formed of polysilicon is disposed over the channel region 60 with a relatively thick insulation film 61 disposed therebetween.
With the above construction, the diffusion layer 51 is connected to a source line S and the diffusion layer 53 is connected to a bit line BL. Further, the control gate 59 and select gate 62 are respectively connected to control gate line CG and select gate line SG.
FIG. 2 is a circuit diagram of an equivalent circuit of the element shown in FIG. 1. In FIG. 2, a transistor Q11 is a floating gate type MOS transistor having the diffusion layers as the source and drain thereof and constituting a memory cell transistor for storing data. Further, a transistor Q12 is an ordinary type MOS transistor having the diffusion layers 52 and 53 as the source and drain thereof and constituting a selection transistor for selecting the memory cell transistor Q11. The MOS transistors Q11 and Q12 are serially connected between the source line S and the bit line BL.
The memory cell with the above construction has a data erasing mode, data programming mode and data readout mode. FIG. 3 shows voltages applied to the source line S, control gate line CG, select gate line SG and bit line BL in the respective operation modes. In this case, three types of power sources of ground voltage GND, V CC and V PP are used in an integrated circuit containing an E 2 PROM, and in an ordinary case, GND is 0V, V CC is +5V and V PP is +20V. In general, the voltage V PP is not supplied as an exterior power source voltage, but is obtained by stepping up the voltage V CC in the integrated circuit.
The data erasing mode is also called an electron injection mode in which the threshold voltage Vth of the memory cell transistor Q11 is raised by injecting electrons into the floating gate 56 of the transistor Q11. In this case, voltages of 0V, +20V, +20V and 0V are respectively applied to the bit line BL, select gate line SG, control gate line CG and source line S. When a voltage of +20V is applied to the select gate line SG, the selection transistor Q12 is turned on and the diffusion layer 52 is set to 0V by the voltage of the bit line BL. At this time, the floating gate 56 is held at a high potential by the voltage applied to the control gate line CG. Therefore, an intense electric field is applied across the thin film portion 57 of the insulation film 52 lying between the floating gate 56 and diffusion layer 52 so that a tunnel current may flow from the diffusion layer 52 towards the floating gate 56, thus injecting electrons into the floating gate 56. As a result, the threshold voltage Vth of the memory cell transistor Q11 is raised to approx. 8V, for example.
The data programming mode is also called an electron emitting mode in which the threshold voltage Vth of the memory cell transistor Q11 is lowered by emitting electrons injected into the floating gate 56 of the transistor Q11. In this case, voltages of +20V, +20V and 0V are respectively applied to the bit line BL, select gate line SG and control gate line CG, and the source line S is applied with a voltage of +5V or set in the electrically floating state. When a voltage of +20V is applied to the select gate line SG, the selection transistor Q12 is turned on and the diffusion layer 52 is set to +20V by the voltage of the bit line BL. Therefore, an intense electric field is applied across the thin film portion 57 in a direction opposite to that set in the case of the erasing mode so that a tunnel current may flow from the floating gate 56 towards the diffusion layer 52, thereby emitting electrons from the floating gate 56. As a result, the threshold voltage Vth of the memory cell transistor Q11 is lowered and set to approx. -5V, for example.
In the data readout mode, voltages of +1V, +5V, 0V and 0V are respectively applied to the bit line BL, select gate line SG, control gate line CG and source line S. When a voltage of 5V is applied to the select gate line SG, the selection transistor Q12 is turned on and the diffusion layer 52 is set to +1V by the voltage of the bit line BL. At this time, if electrons are previously injected into the floating gate 56 and the threshold voltage Vth is raised, then the memory cell transistor Q11 is not turned on. Therefore, no current flows between the bit line BL and source line S, thereby keeping the voltage of the bit line BL at +1V. In contrast, if electrons are previously emitted from the floating gate 56 and the threshold voltage Vth is lowered, the memory cell transistor Q11 is turned on. Therefore, a current flows between the bit line BL and source line S, causing the bit line BL to be set to 0V which is equal to the voltage of the source line S. That is, in the data readout mode, the voltage of the bit line BL is set to a voltage of 1V or 0V depending on the data storing state of the selected memory cell transistor Q11. Then, data detection of logic value "1" or "0" is effected by amplifying the voltage of the bit line BL by means of a sense circuit (not shown) connected to the bit line BL.
A problem occurring in this case is to amplify a potential difference between 1V and 0V on the bit line BL by means of a sense circuit. That is, in the sense circuit, it is necessary to determine the level by amplifying a potential difference which is as low as 1V.
Now, the reason why the voltage of the bit line BL must be suppressed to approx. 1V in the readout mode instead of setting the same to +5V which is the normal power source voltage is explained. If a voltage of the bit line BL is set to +5V in the readout mode, the potential of the diffusion layer 52 is also set to 5V. Then, an electric field between the voltage of 0V of the control gate line CG and the voltage of +5V of the diffusion layer 52 is applied across the thin film portion 57 via the floating gate 56. That is, the electric field is applied to the thin film portion 57 in the same direction as in the case of the programming mode (electron emitting mode) and the different point is that the intensity of the electric field is weaker than in the case of the programming mode. Therefore, if the memory cell transistor is kept in the programming mode for a long period of time, electrons which have been previously injected will be gradually emitted by the tunnel effect. As a result, the threshold voltage Vth is gradually lowered and a logically erroneous operation may be caused when a certain length of time has passed. Such a phenomenon is called a soft write (weak write) phenomenon, and the resistance to the soft write phenomenon relating to the length of sustaining time thereof is called a read retention characteristic (data holding characteristic in the readout mode).
The soft write phenomenon is explained with reference to FIG. 4. FIG. 4 is a characteristic diagram showing the relation between the threshold voltage Vth of a memory cell transistor in which electrons are injected into the floating gate and total time t BL in which a voltage is applied to the bit line with a voltage V BL of the bit line set as a parameter. As is clearly seen from FIG. 4, in order to prevent electrons from being emitted from the floating gate or suppress the electron emission to a minimum, it is necessary to set the bit line voltage V BL as low as possible. Therefore, in order to suppress occurrence of the soft error phenomenon, the bit line voltage in the readout mode may be set to a low level. However, if the voltage is lowered, a voltage difference between the bit line voltage set when an electron injected cell is selected and that set when an electron emitted cell is selected becomes smaller, reducing the voltage margin at the time of determining the logic level of "1" or "0" by means of the sense circuit. For this reason, in the prior art, a voltage of approx. +1V is applied to the bit line in the data readout mode to take the sufficiently effective measure for the read retention characteristic, and at the same time, the sense circuit is formed with a high performance to cope with the problem that the voltage margin becomes small, and thus a severe load is imposed on the sense circuit itself.
As described above, in the prior art, an extremely heavy load is imposed on the sense circuit and various problems as described below have occurred. The first problem is that the construction of the sense circuit becomes complicated and the chip area may be increased in the case of forming the circuit in the integrated form. Increase in the chip area causes rise in the manufacturing cost. The second problem is that the operable power source voltage margin in the readout mode becomes small and particularly the operation on a low voltage becomes unstable. The third problem is that it becomes necessary to use a constant voltage source for supplying an intermediate voltage of +1V to the bit line. If a circuit for producing the intermediate voltage is contained in the sense circuit, the current consumption increases, thereby making it difficult to attain low power consumption. The fourth problem is that the access time will become longer as the sense circuit becomes complex in construction.
As described above, the conventional nonvolatile semiconductor memory has problems that the chip area increases, the low voltage operation becomes unstable, it is difficult to attain the low power consumption and the access time becomes longer.
SUMMARY OF THE INVENTION
An object of this invention is to provide a non-volatile semiconductor memory which can attain a low voltage operation and low power consumption and permits peripheral circuits including a sense circuit to be formed simple in construction and operated at a high speed.
According to this invention, there is provided a nonvolatile semiconductor memory comprising a semiconductor substrate of a first conductivity type; source and drain diffusion layers formed in the substrate; a channel region provided between the source and drain diffusion layers; a first insulation film continuously formed on the channel region and the drain diffusion layer adjacent to the channel region; a floating gate layer formed on the first insulation film; a second insulation film formed on the floating gate layer and having a thin film portion which is formed thinner than the first insulation film; and a control gate layer formed on the second insulation film.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a cross sectional view showing the element structure of the conventional memory cell;
FIG. 2 is a diagram showing an equivalent circuit of the element shown in FIG. 1;
FIG. 3 shows voltages in the various operation modes of the memory cell shown in FIG. 1;
FIG. 4 is a characteristic diagram showing the relation between the threshold voltage of the memory cell transistor shown in FIG. 1 and the total time in which a voltage is applied to the bit line;
FIG. 5 is a cross sectional view showing the element structure of a memory cell used in a nonvolatile semiconductor memory according to a preferred embodiment of the present invention;
FIG. 6 is a pattern plan view of the memory cell shown in FIG. 5;
FIG. 7 is a diagram showing an equivalent circuit of the element shown in FIG. 5;
FIG. 8 is a diagram showing voltages in the various operation modes of the memory cell shown in FIG. 5;
FIG. 9 is a circuit diagram showing the schematic construction of a readout-side circuit of a nonvolatile semiconductor memory of a preferred embodiment of the present invention using the memory cell shown in FIG. 5;
FIG. 10 shows another schematic construction of the above readout-side circuit;
FIG. 11 shows still another schematic construction of the above circuit;
FIG. 12 is a timing chart of the circuit shown in FIG. 10;
FIG. 13 is a circuit diagram showing the schematic construction of a readout-side circuit of a nonvolatile semiconductor memory of a preferred embodiment of the present invention using the memory cell shown in FIG. 5; and
FIG. 14 is a circuit diagram showing the construction of a memory cell array portion of a memory of a preferred embodiment of the present invention using a large number of memory cells having the same construction as the memory cell shown in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, a preferred embodiment of this invention is explained with reference to the accompanying drawings. FIG. 5 is a cross sectional view showing the element structure of a memory cell used in a nonvolatile semiconductor memory according to the prepared embodiment and FIG. 6 is a pattern plan view thereof. 10 denotes a P-type silicon semiconductor substrate. N-type diffusion layers 11, 12 and 13 are in the surface area of the substrate 10, and a channel region 14 is provided between the diffusion layers 11 and 12. An insulation film 15 of a silicon oxide film, for example, is continuously formed to a thickness of 400 Å on the channel region 14 and the diffusion layer 12 adjacent to the region 14. A floating gate 16 of polysilicon is on the insulation film 15. Further, an insulation film 17 of a silicon oxide film which has an approx. 400 Å thickness in a large portion thereof is disposed on the floating gate 16, and a thin film portion 18 having a film thickness of approx. 150 Å is in part of the insulation film 17 or in position corresponding to the diffusion layer 12. Further, a control gate 19 of polysilicon is disposed on the insulation film 17.
A channel region 20 is provided between the diffusion layers 12 and 13. A select gate 22 of polysilicon is formed over the channel region 20 with an insulation film 21 disposed therebetween. The insulation film 21 is of a silicon oxide film with a film thickness of approx. 400 Å, for example.
The diffusion layers 11 and 13 are respectively connected to a source line S and a bit line BL, and the control gate 19 and select gate 22 are respectively connected to a control gate line CG and a select gate line SG.
The memory cell shown in FIGS. 5 and 6 is constructed by two series-connected MOS transistors Q1 and Q2 as shown by the equivalent circuit of FIG. 7. The transistor Q1 is a floating gate type transistor having the diffusion layers 11 and 12 as the source and drain thereof and constitutes a memory cell transistor for storing data. The other transistor Q2 is an ordinary type MOS transistor having the diffusion layers 12 and 13 as the source and drain thereof and constitutes a selection transistor for selecting the memory cell transistor Q1.
Like the conventional memory cell, the memory cell with the above construction has three different operation modes, that is, electron injection, electron emission and readout modes. FIG. 8 shows voltages applied to the source line S, control gate line CG, select gate line SG and bit line BL in the respective operation modes, and the operation in each operation mode is explained below.
In the electron injection mode, voltages of +20V, +20V and 0V are respectively applied to the bit line BL, select gate line SG and control gate line CG, and the source line S is set in the electrically floating state (indicated by FL in FIG. 8). When a voltage of +20V is applied to the select gate line SG, the selection transistor Q2 is turned on and a voltage of +20V of the bit line BL is transmitted to the diffusion layer 12. At this time, a voltage of 0V of the control gate line CG is applied to the control gate 19. In this case, the potential of the floating gate 16 is determined by dividing a voltage of +20V of the diffusion layer 12 according to the capacitance ratio of a capacitance between the control gate 19 and floating gate 16 to a capacitance between the floating gate 16 and diffusion layer 12. The potential of the floating gate 16 is lower than 20V but is sufficiently higher than 0V. Therefore, an intense electric field is applied between the control gate 19 and floating gate 16 via the thin film portion 18 of the insulation film 17 so that a tunnel current may flow from the floating gate 16 towards the control gate 19, thus injecting electrons into the floating gate 16. As a result, the threshold voltage Vth of the memory cell transistor Q1 is raised.
In the case of electron emitting mode, voltages of 0V, +20V, +20V and 0V are respectively applied to the bit line BL, select gate line SG, control gate line CG and source line S. When a voltage of +20V is applied to the select gate line SG, the selection transistor Q2 is turned on and a voltage of 0V of the bit line BL is transmitted to the diffusion layer 12. At this time, the potential of the floating gate 16 is determined by dividing a voltage of the control gate 19 according to the capacitance ratio of a capacitance between the control gate 19 and floating gate 16 to a capacitance between the floating gate 16 and diffusion layer 12. The potential of the floating gate 16 is higher than 0V but is sufficiently lower than +20V. Therefore, in this case, an intense electric field is applied between the control gate 19 and floating gate 16 via the thin film portion 18 of the insulation film 17 in a direction opposite to that set in the case of the electron injection mode so that a tunnel current may flow from the control gate 19 towards the floating gate 16, thereby causing electrons to be emitted from the floating gate 16. As a result, the threshold voltage Vth of the memory cell transistor Q1 is lowered.
In the data readout mode, voltages of +5V, +5V and 0V are respectively applied to the bit line BL, select gate line SG and source line S, and the control gate line CG is set in the electrically floating state (FL). When a voltage of 5V is applied to the select gate line SG, the selection transistor Q2 is turned on and a voltage of +5V of the bit line BL is transmitted to the diffusion layer 12. At this time, if electrons are previously injected into the floating gate 1 and the threshold voltage Vth is raised, then the memory cell transistor Q1 is not turned on. Therefore, no current flows in the transistors Q1 and Q2, thereby keeping the voltage of the bit line BL at +5V.
In contrast, if electrons are previously emitted from the floating gate 16 and the threshold voltage Vth is lowered, the value of the threshold voltage Vth may be negative. At this time, the memory cell transistor Q1 is turned on. Therefore, a current flows from the bit line BL to the source line S through the transistors Q1 and Q2, causing a voltage of the bit line BL to be lowered to the voltage of 0V of the source line S. Then, in the data readout mode, data determination of logic value "1" or "0" is effected by amplifying the voltage of the bit line BL by means of a sense circuit (not shown) connected to the bit line BL.
It should be noted here that an ordinary power source voltage of +5V can be applied to the bit line BL as it is. Further, even if a voltage of +5V is applied to the bit line BL, occurrence of the soft error phenomenon can be suppressed and the read retention characteristic can be significantly improved. This is because the control gate 19 is set in the electrically floating state in the readout mode and no electric field is applied across the thin film portion 18 of the gate insulation film 17 disposed between the floating gate 16 and control gate 19 so that injection and emission of electrons due to the tunnel effect will not occur.
Next, a nonvolatile semiconductor memory of this invention using the memory cell with the construction shown in FIG. 5 is explained. FIG. 9 is a circuit diagram showing the schematic construction of a readout-side circuit of the nonvolatile semiconductor memory of this invention using the memory cell of FIG. 5. For clarifying the explanation, only one memory cell 30 which is constructed by the memory cell transistor Q1 and selection transistor Q2 is shown in FIG. 9. A resistor 31 acting as a load is connected between an ordinary readout power source Vcc of +5V and the bit line BL, and an input terminal of a sense circuit (sense amplifier circuit) 32 is connected to the bit line BL.
In the circuit of FIG. 9, the potential of the bit line BL is fully swung or changed between 5V and 0V when the data readout operation is effected in the electron injected and emitted states of the memory cell 30. That is, when a voltage of +5V is applied to the select gate line SG and the transistor Q2 is turned on, the transistor Q1 is turned off if electrons are previously injected into the transistor Q1, thereby permitting the potential of the bit line BL to be kept at 5V. In contrast, if electrons have been emitted from the transistor Q1, the transistor Q1 is turned on, thereby setting the potential of the bit line BL to 0V. Then, the potential of the bit line BL is detected by the sense circuit 32 and output as data.
At this time, even if the level of the power source voltage Vcc is lowered, the potential of the bit line BL will be substantially fully swung between Vcc and 0V. Therefore, a sufficiently large operation margin can be attained even in the low voltage operation in which the operation is effected with the level of the power source voltage Vcc lowered. Further, since an intermediate voltage of +1V which is required in the prior art is not necessary, it is not necessary to form a circuit for creating such an intermediate voltage and the current consumption can be reduced.
FIG. 10 is a circuit diagram showing the schematic construction of another readout-side circuit of the memory of a preferred embodiment of the invention using the memory cell of FIG. 5. In this memory, a P-channel MOS transistor 33 is used instead of the resistor 31 as the load circuit of the bit line BL. A ground voltage of 0V is applied to the gate of the transistor 33 to normally set the transistor 33 in the conductive state. In this way, it is possible to use a MOS transistor as the load circuit of the bit line BL.
FIG. 11 is a circuit diagram showing the schematic construction of still another readout-side circuit of the memory of this invention using the memory cell of FIG. 5. In this circuit, a clock signal φp is supplied instead of the ground voltage to the gate of the P-channel MOS transistor 33 which is used as the load circuit of the bit line BL and the transistor 33 is turned on when required. Further, the select gate line SG of the selection transistor Q2 in the memory cell 30 is connected to an output terminal of a decoder circuit 34 acting as a combination circuit for supplying a selection signal in response to an input address. The operation of the decoder circuit 34 is also controlled by the clock signal φp.
In the circuit of FIG. 11, the clock signal φp is set to "0" level in the precharging period as shown in the timing chart of FIG. 12 so as to turn on the transistor 33. As a result, the potential of the bit line BL is precharged to Vcc. In the next logically enabling period (in which φp="1"), the transistor 33 is turned off to complete the operation of precharging the bit line BL. Further, in this period, the decoder circuit 34 becomes operative and sets the select gate line SG to 5V or 0V in response to the input address. When the select gate is set to a voltage of 5V, the selection transistor Q2 in the memory cell 30 is turned on to select the memory cell 30.
FIG. 13 is a circuit diagram representing the sense circuit 32 available in each of the circuits of FIGS. 10 and 11 together with the memory cell 30. In this case, a load circuit 35 connected between the power source terminal Vcc and bit line BL corresponds to the resistor 31 in FIG. 9, and the P-channel MOS transistor 33 in FIGS. 10 and 11.
In other words, since the potential of the bit line BL is fully swung between 5V and 0V when any type of load is connected between the power source terminal Vcc and bit line BL, it is not necessary to use a sense circuit with a complicated structure which has been required in the prior art for amplifying a small potential difference. For example, as shown in FIG. 13, it is possible to use a simple inverter 36 constituted by MOS transistors as the sense circuit. Therefore, the sense circuit can be simplified and the access time can be shortened.
FIG. 14 shows the construction of a memory cell array of a memory of this invention using a large number of memory cells having the same construction as shown in FIG. 5. In this memory cell array, (n+1) groups each of which includes eight memory cells each constituted by two MOS transistors Q1 and Q2 are arranged in a lateral direction and a preset number of memory cells 30 are arranged in a vertical direction. Row address decoding signals ADRi, ADRi-1, ADRi-2, ADRi-3, --- output from a row address decoder (not shown) are supplied to the respective select gate lines SG of the memory cells 30. Further, a voltage of a program line PL is applied to the respective control gate lines CG of the memory cells 30 via respective depletion type MOS transistors Q3. The program line PL is applied with a voltage of 0V and +20V in the data erasing mode and programming mode, respectively and set into the electrically floating state in the data reading mode.
The eight bit lines BL of each group are selected by eight column selection MOS transistors Q4. The gates of the eight column selection MOS transistors Q4 are commonly connected to a corresponding one of column select lines CSL and the conduction states of the transistors Q4 are controlled by column address decoding signals ADC0 to ADCn output from a column address decoder (not shown). Data read out and supplied to the eight bit lines BL selected by the eight column selection MOS transistors Q4 of one group are sensed by means of eight inverters 36-1 to 36-8. In FIG. 14, 35-1 to 35-8 denote load circuits which correspond to the resistor 31 in FIG. 9, and the P-channel MOS transistor 33 of FIGS. 10 and 11.
As described above, according to this invention, it is possible to provide a nonvolatile semiconductor memory which can attain a low voltage operation and low power consumption, simplify the construction of peripheral circuits such as sense circuits and enhance the operation speed thereof.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices, shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A nonvolatile semiconductor memory is a programmable and erasable nonvolatile semiconductor memory including a semiconductor substrate of a first conductivity type, source and drain diffusion layers in the semiconductor substrate, and a channel region between the source and drain diffusion layers. A first insulation film is continuously on the channel region and the drain diffusion layer adjacent to the channel region, and a floating gate layer is on the first insulation film. Further, a second insulation film having a thin film portion which is thinner than the first insulation film is on the floating gate layer, and a control gate layer is on the second insulation film. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a radiator for a vehicle engine, and more particularly to a radiator for a water-cooled engine used in a motorcycle.
Generally, under a high temperature condition immediately after stopping the engine, when the radiator cap is removed from the filler neck of the radiator, the high temperature cooling medium or the vapor thereof is ejected from the cooling medium supply port of the filler neck due to the increased pressure within the radiator, followed by a great possibility of an operator being burned on the hand or other area.
For preventing a radiator cap disclosed in this, Japanese Utility Model Application Publication No. 46-7707, has been proposed. That radiator cap is provided with a valve for permitting the cooling medium supply port to communicate with the open air, and a release mechanism for releasing the radiator cap from the filler neck and opening said valve. In the case of this radiator cap, however, when removing it, the operator may directly touch said release mechanism while still hot. As the result, the operator runs the risk of being burned. Further more, since the radiator cap can be readily removed by anybody, there is the danger that it may be stolen by a miscreant particularly in case of a motorcycle whose radiator is in an exposed position.
SUMMARY OF THE INVENTION
The object of the invention is to provide a radiator having a safe and reliable cap which can be removed only by an unlocking operation performed with a the key followed by the valve release.
The radiator according to the invention comprises a radiator cap having valve means for permitting the radiator interior to communicate with the exterior, locking means for locking the radiator cap to the mouth portion of the radiator, and a key for positively opening the valve means at the time of unlocking the locking means.
Since, in the foregoing construction, the radiator cap can be removed from the radiator only by the key operation, there is no risk that the radiator cap will be stolen. Further more, while the valve means is positively opened by the key operation, yet the operator only indirectly touches the radiator cap through the key.
As a result, there is no fear of the operator being burned on the hand or any other place.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view illustrating the front part of a motorcycle provided with a radiator according to the invention;
FIG. 2 is a longitudinal sectional view illustrating a radiator cap mounted on the radiator;
FIG. 3 is a cross sectional view taken along the line 3--3 of FIG. 2;
FIG. 4 is a longitudinal sectional view taken along the line 4--4 of FIG. 3;
FIG. 5 is an exploded view illustrating the slider and radiator cap body of FIG. 2; and
FIG. 6 is a longitudinal sectional view illustrating partially a modification of the radiator according to the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
A motorcycle 10 illustrated in FIG. 1 comprises a water-cooled engine 11 fixed to a frame 12, and radiator 13 for cooling the engine 11. The radiator 13 is fixed to a down tube 14 of the frame 12, and permits the circulation of cooling medium such as water through a feed pipe 15, the engine 11 and a return pipe 16 in the order mentioned.
Referring to FIGS. 2 to 5, the radiator 13 according to the invention, as known, comprises a radiator body 13a having a chamber 17 for receiving the cooling medium. The radiator body has at its upper part a mouth portion or filler neck 18 forming a supply port for supplementarily supplying the cooling medium into the chamber 17 as required. The filler neck 18 has a tubular portion 19 integrally projecting upwardly of the radiator body 13a and a cylindrical member 20 welded to the tubular portion. The cylindrical member 20 has at its lower end an inwardly curved portion 21 forming a lower seat 22 and at its upper end an outwardly curved portion 23 forming a top seat 24. The outwardly curved portion 23 is formed with a pair of first notches 25 (See FIGS. 2 and 3) opposed to each other diametrically of the cylindrical member 20 and a second notch 26 (See FIGS. 3 and 4) angularly spaced from the first notches. Further, the cylindrical member 20 has an overflow pipe 27 communicating with the open air. The overflow pipe 27 extends in a direction in which it goes away from the filler neck 18, that is, extends downwardly along the down tube 14, and is opened at its lower end (See FIG. 1).
The radiator 13 has a radiator cap 28 removably attachable to the filler neck 18 in order to close the supply port. The cap 28 includes a cap body 29, a substantially circular cap plate 30 fixed by bolts 31 to the upper side of the cap body 29, and an annular ornamental member 32 semicircularly convexed in cross section which is welded to the upper side of the cap plate 30. The outer peripheral portion 33 of the cap plate 30 is bent downward and is formed at its lower end with a pair of tabs 34 bent inward in a manner diametrically opposed to each other. These tabs are fitted into the notches 25 when the radiator cap 28 is about to be fitted over the filler neck 18. To the underside of the cap body 29 is fixed a disk spring 35 having at the underside of its outer peripheral portion a seal member 36 formed of a suitable flexible material such as plastic. The disk spring 35 is so designed as to press the seal member 36 airtightly against the top seat 24 when the cap 28 is fitted over the filler neck 18.
The cap body 29 and the cap plate 30 are formed, respectively, with concentric holes constituting an interconnected cylindrical hole 37. Into the cylindrical hole 37 is fitted a known key cylinder 38 in such a manner that it is axially slidable by a prescribed amount and yet nonrotatable about its axis. The key cylinder 38 has a key hole 39 conformed with a key 40, for example, for a main switch of the engine, and a locking pin 41 rockable by the key 40 about the center axis of the cylinder 38. The outer peripheral wall of the key cylinder is formed with an annular groove 42 in which is set an O-ring 43.
The radiator cap 28 is provided with a pressure valve for preventing the interior pressure of the radiator chamber from exceeding a specified valve (which is greater than the atmospheric pressure) and a vacuum valve for preventing the interior pressure of the radiator chamber from being reduced to a value below a specified negative pressure. Explaining this in detail by reference to FIG. 2, an inverted cup-shaped member 44 whose lower edge portion is bent outward is fixed to the lower end of the key cylinder 38. Over the inverted cup-shaped member is loosely fitted a holding member 45, to the lower end of which is welded a circular plate 46. To the underside of the plate 46 is fixed by an eyelet 48 a seal member 47 formed of an appropriate flexible material such as plastic. The plate 46 and the seal member 47 constitute a pressure valve body 49. The pressure valve body is urged downward by a pressure valve spring 50, and when the radiator cap is fitted, is airtightly pressed against the lower seat 22. Into the hole through the eyelet 48 is loosely inserted a rod 51 having a flange 52 at its upper end. To the lower end of the rod 51 is riveted a vacuum valve body 53 consisting of a dish spring, said vacuum valve body being always urged against the seal member 47 by a vacuum valve spring 54 disposed between the flange 52 and the plate 46. To the inverted inner bottom of the inverted cup-shaped member 44 is fixed a pressing member 55 in such a manner that it is opposed to the upper end of the rod 51. Between the inverted cup-shaped member 44 and the plate 46 is disposed a compression spring 56, which acts to urge the inverted cup-shaped member 44 upwardly so that the key cylinder 38 is in an upwardly raised position when the radiator cap is fitted.
In the upper part of the cap body 29 is formed a recess 57, the side wall portions 58a, 58b of which form a guide extending substantially diametrically of the cap body. In the recess 57 is disposed a slider 59 having guide walls 60a, 60b slidably engaging the side wall portions 58a, 58b, so that the slider 59 can be moved from a solid line-indicated position to a chain line-indicated position of FIG. 3 and vice versa. On one end of the slider 59 is integrally formed a locking lug 61 movable from a locking position (indicated by solid lines of FIG. 4) at which it engages the second notch 26 of the outwardly curved portion 23 of the filler neck 18 to a release position (indicated by chain lines of FIG. 4) at which it disengages from the second notch 26 and vice versa. That portion of the slider 59 which faces the locking pin 41 of the key cylinder 38 is formed with an escapement depression 62 whose depth is slightly greater than the thickness of the locking pin 41, and a trapezoid notch 63 whose both sides form cam surfaces 64a, 64b. The locking pin 41 is situated within the escapement depression 62 or trapezoid notch 63 in accordance with the axially moved position of the key cylinder 38. In the bottom of the recess 57 of the cap body 29 is formed a sectorial depression 65 which is located below the trapezoid notch 63. The sectorial depression 65 has stop surfaces 66a, 66b for limiting the rocking movement of the locking pin 41, and its depth is smaller than the thickness of the locking pin 41.
Under the condition in which the radiator cap 28 is removed from the filler neck 18 of the radiator 13, the slider 59 is in the chain line-indicated position of FIG. 3 to keep the locking lug 61 at the chain line-indicated release position of FIG. 4. When the radiator cap 28 is fitted over the filler neck 18 of the radiator 13, the cap tabs 34 are first inserted from above into the first notches 25 of the outwardly curved portion 23 to cause the disk spring 35 and the seal member 36 to abut against the top seat 24. Simultaneous with this abutment, the pressure valve body 49 is pressed against the lower seat 22 by the spring 50 while the key cylinder 38 is relatively pushed upward by the compression spring 56 so as to cause the locking pin 41 to escape from the trapezoid notch 63 and enter the escapement depression 62. The upward movement of the key cylinder 38 may be limited by engagement of the locking pin 41 with the cap plate 30, or may be limited by other stop means.
When the radiator cap 28 is rotated, the tabs are pressed against the lower edge of the outer periphery of the outwardly curved portion 23 by the biasing force of the disk spring 35 so as to prevent the cap 28 from coming away upwardly from the filler neck 18. Rotation of the cap 28 is performed until the locking lug 61 of the slider 59 is aligned with the second notch 26 of the outwardly curved portion 23. Aligning of the lug 61 with the notch 26 may be carried out through indicating the alignment position by placing, for example, an arrow mark on the cap 28, or may be carried out through separately providing stop means.
When the key 40 is inserted into the key hole 39 and is pushed downward to push the key cylinder 38 down against the biasing force of the compression spring 56, the locking pin 41 moves from the escapement depression 62 into the trapezoid notch 63 and then into the sectorial depression 65, and simultaneously the pressing member 55 pushes the rod 51 down to open the vacuum valve. When, under this condition, the key 40 is rotated counter-clockwise (FIG. 3), the locking pin 41 is brought into engagement with the cam surface 64b of the trapezoid notch 63 to move the slider 59 up to the solid line-indicated position of FIG. 3. At this time, the locking lug 61 enters the second notch 26 of the outwardly curved portion 23 to prevent the radiator cap 28 from being rotated any further this position being shown by (the solid line-indicated position of FIG. 4). The stop surface 66b of the sectorial depression 65 prevents the locking pin 41 from being rotated to far. When the key 40 is drawn out, the key cylinder 38 is pushed upward by the spring 56 to cause the locking pin 41 to be brought back into the escapement depression 62.
If, when performing the locking operation, the key 40 is rotated without depressing the key cylinder 38, the locking pin 41 will be idly rotated within the escapement depression 62 to causing no movement of the slider 59.
If while the cap 28 is fitted to the filter neck, the interior pressure of the radiator chamber 17 exceeds its specified limit, the pressure valve body 49 is pushed upward against the biasing force of the pressure valve spring 50 to cause the interior pressure of the radiator chamber to escape into the overflow pipe 27. Further more, when the interior pressure of the radiator chamber 17 exceeds its specified negative pressure limit, for example, due to the radiator being cooled, the vacuum valve body 53 is lowered against the biasing force of the vacuum valve spring 54 to cause the cooling medium to be introduced into the radiator chamber through the overflow pipe.
When it is desired that the radiator cap 28 be removed, the key 40 is first inserted into the key hole 39 and then the key cylinder 38 is depressed. This causes the pressing member 55 to push the rod 51 of the vacuum downward to cause the interior pressure of the radiator chamber 17 to escape into the overflow pipe 27. Subsequently, when the locking pin 41 is rotated by the key 40, the slider 59 is moved up to the chain line-indicated position of FIG. 3 to cause the locking lug 61 to be brought to the release position (indicated by the chain lines of FIG. 4). This causes the radiator cap 28 to be rendered rotatable so as to be removed from the filler neck 18. The stop surface 66a imposes a limitation upon the clockwise rotation movement of the locking pin 41.
Unless, when performing the unlocking operation, the key cylinder 38 is depressed, the locking pin 41 is idly rotatable within the escapement depression 62, failing to complete the unlocking operation. Where, accordingly, it is desired that the locking lug 61 to be brought to the release position, it is unavoidably necessary to depress the key cylinder 38 (this depression is followed by the release of the vacuum valve).
In FIG. 6, the same parts and sections as those of the preceding embodiment are denoted by the same reference numerals. An overflow pipe 127 of this modification is connected to a pipe 71 extending up to the bottom of a reserve tank 70 communicating with the open air through an outlet 72. In this construction, the vapor of the cooling medium coming from the radiator 13 is liquefied within the reserve tank 70 and stored therein. When the interior pressure of the radiator becomes negative, the cooling medium thus liquefied is returned to the radiator interior through the overflow pipe 127. Therefore, the amount of cooling medium consumed is decreased, hence supplemental addition to the cooling medium is not required to any great extent. | The radiator comprises a radiator cap for closing a cooling medium supply port, valve means for permitting the interior of a radiator body to communicate with the open air, locking means operatively associated with the valve means and for locking the radiator cap to the radiator body, and a key for actuating the locking means, whereby the valve means is opened simultaneously with the time when the locking means has been unlocked by the key. | 1 |
FIELD OF THE INVENTION
The present disclosure pertains to methods for increasing production of metal values from sulfidic ores in smelting operations.
BACKGROUND OF THE INVENTION
Smelting is a common method for recovering the desired metal value from sulfidic ores. During the smelting process, the sulfur in the ore is oxidized, resulting in an exothermic reaction, whereby the heat generated is sufficient to melt the metal without the need for an external heat source. Typically, a carbonaceous reducing agent, such as coke, is employed in the reaction.
Reverberatory smelters, sometimes called “copolas” are commonly used. The fuel and metal ore charge are usually fed separately. In the first step, two liquids are formed: one is an oxide slag containing the impurities, and the other is a sulfide “matte” containing the valuable metal sulfide and some impurities. Fuel is burned at one end of the furnace, and the heat melts the dry sulfide concentrate (usually after partial roasting) which is fed through the openings in the roof of the furnace. The slag floats on the top of the heavier “matte” and is removed or rejected. The sulfide matte then is forwarded to a converter.
Metal production during the smelting operation is limited by the upper temperature limitations of the smelting furnace. Due to the exothermic nature of the pyrometallurgical reduction, adding additional metal sulfide has the same effect as adding more fuel. In order to increase production, smelters can benefit from smelting ores with increased surface moisture since the moisture will evaporate, reducing the temperature of the upper furnace, and thereby allowing more ore to be fed to the furnace, resulting in an increase in metal production.
While adding moisture to a sulfidic ore prior to smelting provides benefit, the amount of moisture added is limited due to problems that may be associated with increasing ore moisture content, such as caking and clogging of conveyor belts and other conventional ore transport means.
SUMMARY OF THE INVENTION
The present invention involves improvement of metal value yield in smelting processes of the type in which a sulfide containing metal ore is smelted. An aqueous solution or dispersion comprising a surfactant is brought into contact with the ore. In this manner, higher moisture content ores can enter the smelter, allowing for an increase in the amount of ore processed per given time period, and therefore an increase in metal production.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
In accordance with one exemplary embodiment, an aqueous solution or dispersion comprising a surfactant is applied to the sulfidic ore prior to entry into the smelter. Preferably, the surfactant may be applied in the form of an aqueous foam.
With respect to foam formation, air is preferred for use as the foam forming gas. Details of the foam forming process are not critical to the invention. Generally, foam may be produced as stated in U.S. Pat. No. 4,700,200 (Cole), the disclosure of which is incorporated herein. Typically, the aqueous based surfactant is mixed with air at a ratio of about one gallon liquid with from about 1-100, preferably 1-10, scf air. The air and liquid may combine at a point immediately upstream from the mixing chamber. The mixing chamber may be a packed column, venturi, or static mixer. The purpose of the mixing chamber is to induce the air in liquid dispersion that is defined as a “foam”. Acceptable foam properties include expansion ratios (volume foam:volume liquid) on the order of about 10-100. Average bubble size is on the order of about 200 microns or less. Exemplary feed rates would range from about 0.1-1.0 pounds of active surfactant per ton of metal sulfide.
Exemplary surfactants that can be used include the anionic surfactants and non-ionic surfactants. Preferably, the non-ionic surfactants have an HLB of between about 10-15. Blends of the aforementioned surfactants can also be mentioned.
Suitable anionic surfactants include sulfates and sulfonates such as alkyl aryl sulfonic acids, alkyl sulfonic acids, alkenyl sulfonic acids, sulfonated alkyls, sulfonated alkyl ethers, sulfonated alkenyls, sulfated fatty esters, and the sulfosuccinates.
The term anionic surfactants should be broadly construed to include the anionic detergents such as the long chain alpha olefin sulfonates, water soluble salts of alkenyl sulfonic acid, such as the sodium salt of C 14 -C 18 alpha olefin sulfonates, water soluble alkyl aryl sulfonic acid salts, such as sodium alkylnaphthalene sulfonate and sodium alkyl benzene sulfonate and water soluble salts of lauryl sulfate.
Particularly preferred anionic surfactants are esters represented by the formula
wherein R is an aliphatic carbon chain containing at least one sulfonic group and R 1 and R 2 may be the same or different, but are chosen from alkyl groups having from 3 to about 18 carbon atoms. Most preferred are the succinic acid esters such as the dioctylester of sodium sulphosuccinic acid.
Exemplary non-ionic surfactants include alkyl phenols, such as the polyalkylene alkyl phenols; polyalkoxylated alkyl phenols; polyoxyalkylene polymers and block copolymers, glycol esters, glycol ethers including diethylene glycol esters, and diethylene glycol ethers, and polyalkylene glycols.
Specific non-ionic surfactants that may be mentioned include polyethylene nonyl phenol, polyethoxylated nonyl phenol, polyoxyethylene polymers and polyoxypropylene polymers, (EO) ethylene oxide (PO) propylene oxide polymers, polyethylene oxide octyl phenol ether, polyoxyethylene glycol dioleate, propylene glycol, and diethylene glycol ethers such as the “carbitol” series and diglymes.
Exemplary compounds falling within the classification of diethylene glycol ether compounds include diethylene glycol monobutyl ether, diethylene glycol monobutyl ether acetate, diethylene glycol monoethyl ether acetate, diethylene glycol monoethyl ether, diethylene glycol dibutyl ether, diethylene glycol monohexyl ether, diethylene glycol monomethyl ether, and diethylene glycol monomethyl ether acetate. Additionally, diglyme (diethylene glycol dimethyl ether), ethyl diglyme (diethylene glycol diethyl ether), and tetraglyme (tetraethylene glycol dimethyl ether may also be mentioned.
Accordingly, the diethylene glycol ether compounds may be defined as having the formula:
R 3 —(O-Et-O-Et-O) n —R 4 (II)
wherein R 3 and R 4 are independently selected from the group consisting of C 1 -C 8 lower alkyl, acyl and hydrogen; n is equal to 1 or 2. Of these, diethyleneglycol monobutyl ether (sometimes referred to as butyl carbitol) is preferred.
Preferably, the foam or other carrier containing the surfactant or surfactant blend is fed to the sulfidic ore in an amount of about 0.01 to about 5.0 pounds of active surfactant(s) per ton of metal sulfide. More preferably, from about 0.01 to 1.0 pounds of surfactant(s) is fed per ton of metal sulfide.
Any sulfidic ore that is to be smelted may benefit from the invention. For example, the surfactant treatment may be applied to sulfidic ores such as Au, Fe, Ag, Ni, Cu, Zn, Pb, and Mo ores.
Field Trial
At one zinc smelting operation, ZnS ore was treated with a foamed surfactant formulation comprising on all actives bases
45 wt % sodium dioctyl sulfosuccinate 9.65 wt % propylene glycol 25.70 wt % diethylene glycol monobutyl ether remainder water.
Typically, the ZnS ore fed to the smelter had a moisture content of about 10% as received. Normally, when the ore was sprayed with water to increase the moisture content to about 12.0 wt %, flow and plugging problems were encountered. When the above surfactant blend was foamed onto the ore, moisture contents of from 12.0 to about 14.0 wt % could be processed without significant hopper blockage, transport or plugging problems.
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention. | A process for improving recovery of metal values in a smelting operation of the type wherein sulfidic ores are pyrometallurgically reduced. The process includes adding an anionic or non-ionic surfactant and blends thereof to the ore. | 2 |
BACKGROUND
This invention pertains generally to pressure molding of fluid materials and particularly using light energy to cure such materials. It also pertains to molds fabricated from self curing optically clear materials so that fluid materials cured with light energy may be used in conjunction with such molds.
Various types of dental restorative materials that use light energy to change from a plastic state to a fused or “cured” state are used in dentistry. These materials may either be placed incrementally in the tooth and cured in layers or fabricated in the laboratory on a model made from an impression taken in the patient's mouth.
In the first instance where the curing takes place in the patient's mouth, control becomes a problem. Such control incorporates ability to maintain a dry field, to completely cover all the prepared tooth surface (close the margins), maintain a homogeneous material layer without incorporating spaces which have no restorative material, proper contact, contour size, shape, occlusal harmony and depth of cure to name a few. The advantages are that it is quick, has a reasonable success rate and is of moderate expense. It satisfies the patient's desire for an aesthetic restoration.
In the second instance the indirect method which requires a model made from an impression allows for complete control over the size, shape, contour, contact, shade and occlusal harmony to name a few. The disadvantages are that the model is completely dependant upon an accurate impression, an accurate stone model (no bubble, cracks, etc.), requires more time for fabrication and is much more costly.
In both instances, shrinkage of the material must be taken into consideration. In each case the material does not cure at the surface (an oxygen inhibited layer). In the first instance complete curing by tempering is not possible while in the second instance heat tempering (200-250 degrees F. for 15 minutes) gives the laboratory fabricated restoration more strength.
Laboratory fabricated composite resin inlays and/or crowns are usually assembled in an incremental fashion by placing small amounts of the appropriate colored composite in or on the stone die and light curing it followed by an additional increment until the proper configuration is accomplished. Notwithstanding the care with which the material may be placed, there is always a difference in the cure and coverage of the material in the incremental method. In addition clear modeling resins are used to prevent the instruments from sticking to the resin and ensure one layer sticks to the other. All manufacturers advise using only small amounts of the fluid as it has the tendency of reducing the strength of the cured material. This method is cured from the inside out. The light source is unidirectional and as a consequence the shrinkage is away from the margins and die surface. It requires that a separating material be placed on or in the model such that the partially cured material may be removed without breaking or mutilating the die. It is not desirable to remove the restoration prior to completion in this method as it never reseats accurately. Consequently the thickness of the restoration cannot be verified prior to curing. Spacer thickness creates a problem when the restoration is to be placed in the mouth and cured. The American Dental Association has specifications regarding cement thickness for all types of restorations. The spacer thickness cannot be controlled to a degree such that there is a reproducible specified space between the restoration and the tooth.
An additional problem with the above method is that to generate occlusal harmony, the finished product must be ground and fitted to the die. This has the problem of possible fracture or changing of the die. The laboratory technician must be extremely careful in the fabrication. Also if the shade of the restoration has to be changed, the die then becomes used again where fracture can be a problem.
Many patents have been granted whereby the materials used for the fabrication laboratory restorations are subjected to various methods to strengthen them. Vacuum, pressure under nitrogen or water, and heat are just some of them. Those methods have been used singularly or in combination. In most instances they have met the test inventors' intentions.
SUMMARY OF THE INVENTION
The invention provides for a system where a viscous material such as a dental composite is heated by various means and is injected into a mold of optically clear self curing material such as silicone or polyvinylsiloxane. This mold is contained in an optically clear glass or other such optically clear retention device that is keyed to allow for the sections of the mold to come together such that there is not rotation or gap between the sections. This will allow that no distortion of the finished product will occur. The outer surface of the retention device is formed in the manner of a focusing lens that will direct the curing light energy directly upon the material contained within the mold. The shape of the retention device can be of any shape from a sphere to any parabolic shape or configuration with the intention of the invention, such that when light energy is in use, it will focus on the mold with the greatest intensity. This will enhance the rate at which the material is cured and for the material to be cured from the outside inward. This will allow for complete curing to the surface and prevent the “oxygen inhibited layer” from forming. By using intermittent light pulses of an appropriate duration and wavelength, the composite shrinks at a prescribed rate.
The shrinkage of the material is compensated by feeder tubes filled with composite and fabricated of a material that is impervious to the light energy and thus is not cured when the light is focused on the material being molded. The feeder tubes are under pressure of at least 50-150 lbs. per square inch. This will allow for the material in the tubes to be forced into the main mold as the curing takes place and compensates for the shrinkage that is inherent to the material
The mold and the retention device along with the material within the mold and feeder tubes is heated to a temperature that will maximize the reduction in viscosity for each material used in the process. This heat is maintained prior to being placed within the pressure chamber.
Once the initial light curing has taken place, the restoration is removed from the clear mold and is placed in an oven under vacuum and heated to a temperature of 200-250 degrees F. for approximately 15 minutes. This process removes any volatile molecules and strengthens the finished restoration.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings illustrate the invention. In such drawings:
FIG. 1 is a perspective view of the separated parts of the mold retention device with the wax pattern and sprue and sprue reservoir placed between the upper and lower halves of the retention device.
FIG. 2 shows the placement of the wax pattern and the sprue and sprue reservoir in the correct position prior to closing the upper and lower halves.
FIG. 3 is a perspective view showing the upper and lower halves of the retention device with the wax pattern, sprue and sprue reservoir in the closed position.
FIG. 4 is a perspective view showing the placement of the mold material through an opening opposite the sprue reservoir as shown in FIG. 3 .
FIG. 5 is a perspective view of the separation of the retention device subsequent to the hardening of the mold material around the wax pattern, sprue and sprue reservoir as shown in FIGS. 2 and 3 .
FIG. 6 is a perspective view of the mold without the surrounding retention device and showing the components as in FIG. 2 .
FIG. 7 is a perspective view of the separation of the mold as in FIG. 6 with a sharp instrument-such that the mold is separated in two equal parts.
FIG. 8 is an exploded perspective view showing the mold separated in two equal parts so that the components as shown in FIG. 2 may be removed.
FIG. 9 is a perspective view of the two halves of the mold placed together showing the void where the mold components as shown in FIG. 2 have been removed.
FIG. 10 is a perspective view showing the placement of the composite material in the sprue reservoir end of the mold as shown in FIG. 9 .
FIG. 11 is a perspective view showing the separation of the mold with an instrument subsequent to the curing of the composite material within the mold.
FIG. 12 is an exploded perspective view showing the cured composite being removed from the mold.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates the device embodying the present invention. The illustrated device is comprised of an optical glass or other optical material of such configuration that the retention device ( 1 ) and ( 2 ) are fabricated in a way that there is a male and female section of equal dimension that come together so there is no gap or rotation at the mated surfaces. There are openings 1801 from one another such that a sprue reservoir ( 5 ) is attached to a sprue ( 3 ) of an appropriate material (polyethelene, etc.) so that the sprue reservoir ( 5 ) may slide along the sprue ( 3 ) to allow for maximum placement of a wax pattern ( 4 ) equidistant from openings ( 10 ) and ( 11 ). The openings ( 10 and 11 ) are of such shape that when the sections ( 1 and 2 ) are in contact with one another, the sprue reservoir ( 5 ) and the sprue ( 3 ) connected to the wax pattern ( 4 ) are held in a rigid position ( FIG. 3 ) at opening ( 10 ). The interior area of the mated sections ( 1 and 2 ) of the retention device is spherical in shape such that each half is a duplicate of the other. There is a dimple ( 12 and 13 ) placed in each half of the retention device ( 1 and 2 ) so that when the mold that will be made in the retention device may be seated without any confusion.
When the parts ( 1 and 5 ) as shown in FIG. 1 are placed together as shown in FIGS. 2 and 3 , and secured, opening ( 11 ) is available for placement of the mold material ( 6 ) that may be poured or injected into the opening so that it may completely fill the area surrounding the wax pattern ( 4 ) that is held by the sprue ( 3 ) and the sprue reservoir ( 5 ). This material is a clear self setting either polyvinylsiloxane or silicone but not limited to such materials. Upon setting of the mold material, the retention device ( 1 and 2 ) is separated and the hardened mold material ( 7 ) is removed. The mold is cut into two separate equal parts and the wax pattern ( 4 ), the sprue ( 3 ) and the sprue reservoir ( 5 ) are removed as shown in FIGS. 7 and 8 .
Fib. 9 shows the mold with the duplicate space left when the was pattern ( 4 ) was removed from the mold. FIG. 10 shows the placement of the composite material. In this instance being poured into the opening made by the sprue reservoir ( 5 ). Other methods may be employed, namely, placing paste-like materials in each half of the mold ( 7 ) curing each half then placing the mold in the retention device, placing the sprue reservoir into the mold and then injecting composite into the space between the upper and lower mold sections and then curing to form one homogeneous finished restoration. Many methods of fabrication and curing using the above invention may be employed including a single shade material, strengthening inserts of various types including ceramics or glass fibers (but not limited to such materials) in keeping with the intention of the invention.
FIG. 11 shows the appropriately cured composite within the mold ( 7 ) ready to be removed. This is done by separating the retention device ( 1 and 2 ), opening the mold ( 7 ) and removing the cured restoration ( 9 ). To insure that the cured restoration is of the proper dimension, any excess composite material that was placed prior to both halves being mated together with the retention device exited through a trough ( 14 ) made from the impression of the sprue ( 3 ). Any type of overflow device may be incorporated prior to the mold ( 7 ) being made. Once the mold ( 7 ) is cut in two in FIG. 7 , a trough surrounding the impression of the wax pattern ( 4 ) may be cut into one or both halves of the mold ( 7 ). This will help to insure the complete seating of mold ( 7 ) sections and the accuracy of the finished restoration.
In this invention all of the problems of the previous methods have been overcome. We use a wax pattern that fulfills the size; shape, contact, contour and occlusal harmony. This pattern is fabricated from a wax that suffers no loss of dimensional shape, is strong, can be removed from the die without alteration to check for thickness, the wax can be thickened or thinned very easily and does not adhere to the die such that removal from the die might cause the die to be broken. In addition the wax pattern can be modified such that shades of composites can be added to cusp tips or colors to fossa by removing wax in certain areas that will be filled after the initial cure.
The die spacer is a silicone spray that is blown into or on the die such that there is no loss of the size and shape of such die as can occur with other separating materials that are needed in all the other methods, if they are to be removed easily. Working with wax is and has been a mainstay of the dental laboratory dental profession. To work with it only requires a heated instrument and sharp carving instruments. This invention uses the wax in a liquid form from a dispensing device such as a dropper and is of such nature that most of the occlusal harmony is accomplished merely by closing the opposing model on the semi-solid wax. This method allows for rapid fabrication, checking for thickness and addition car deletion of material.
Once the pattern is fabricated, and has feeder tubes attached, it is surrounded by an optically self curing liquid (silicone or polyvinylsiloxane) to form a mold within a retention device. Upon curing, the mold is cut in an appropriate manner. The wax pattern is then removed and composite is pre-heated and injected into both halves of the mold with the proper color scheme. The feeder tubes which are fabricated of a material which is impervious to light energy are filled with appropriate shades of composite and the entire mold and retention device is heated to a temperature that will take advantage of the lowest viscosity of the material within the mold without causing any chemical or setting prior to the curing of the material.
After the mold and heating device are heated to the appropriate temperature. the entire mold and retention device is placed in a pressure apparatus that pressurizes the heated material to a minimum of 50-150 lbs. per sq. inch. The pressurized apparatus is then placed in a light curing device that uses intermittent light energy that cures from the surface inward. This inward curing method allows for “Directed Shrinkage” such that as the material shrinks toward the surface of the mold the pressurized material from the feeder tubes makes up any shrinkage thus allowing for a precision fit that can be duplicated over and over. This is in direct contrast to the methods where small increments are placed as the curing is unidirectional toward the light thus causing the material to shrink toward the greatest mass and away from the margins.
Following the curing of the material, it is removed from the mold, the sprues are removed and the restoration is placed in a tempering oven under vacuum at approximately 200-250 degrees F. for fifteen minutes. It is then placed on the die to check for fit and occlusal interferences. With the preceding method any adjustments are minimal. Since the wax pattern has a very smooth surface, the resulting restoration requires only buffing and no major polishing. There is complete curing to the surface without any “oxygen inhibited layer”. Should the shade of the restoration be inadequate, small additions to the surface can be made without any major grinding and/or polishing. If a major color change is indicated, a new restoration can be made within minutes. An added attraction is that the lab or dentist can hold onto the mold and should the restoration fracture or come loose and is lost, a new one can be made without any other new impression and model or wax pattern.
A major advantage to the above system, is that the system is clear and the operator can see if there are any voids within the mold. While the present materials are very strong, reinforcing materials add much more strength to the material. The ideal material is various glass or ceramic fibers. It chemically bonds to the resins and is optically compatible with the shades of the material. If the glass or ceramic fibers should come to the surface, they can be polished away. This does not in any way create a defect in the restoration as the material does not wick and does not stretch. Plasma treated polyethylene or kevlar does not have a chemical compatibility with the resins of the composite. The present invention allows for any such compatible inserts of any configuration to be inserted with ease. The fact that the restoration is cured in one continuous process allows for the elimination of stresses and voids.
While but a limited number of embodiments to the present invention have been here described, it will be apparent that many variations may be made therein, without departing from the spirit of the invention defined in the following claims: | The method of making a dental device or the like which involves starting with a pattern of the device to be made, closely surrounding that pattern with a settable material to form a unit with the pattern, separating the unit and removing the pattern therefrom, filling the thus produced space with settable material of the type desired for the ultimate device, setting that material and removing the set material constituting the device to be made, and in particular utilizing a retention device to enclose the settable materials and other contents. The process is particularly useful when the device is to be made of a light-sensitive material, in which case the retention device and the first-used settable material are light-transmissive and the retention device preferably focuses light on the material to be set. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. application Ser. No. 09/493,381, filed Jan. 28, 2000, which is incorporated herein in its entirety.
STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to natural lighting systems for roofs, and more particularly, to a light transmitting panel connectable within a metal roofing system.
[0006] 2. Description of the Related Art
[0007] For many years commercial buildings have utilized sheet metal roofs. Recently it has become more common and popular to utilize sheet metal roofs on residential homes, shops, patios and the like. Typically, the standing seam metal roof utilizes metal sheets having lateral upturned edges. The panels are laid side by side with the lateral edges of one panel contiguous with the upstanding edge of adjacent panels. The panels are joined together by a cap piece or by folding over the upstanding edge to tightly hold the panels together. The roofs are sloped so that water runs down the trough formed between the upstanding edges of each panel.
[0008] The above referenced roofing systems may take many forms such as, but not limited to, trapezoidal, 90-degree modular, architectural, and industrial. Metal roofs may have minor ribs, stiffener ribs, or no ribs of all and may be a screw down roofing system. All of these roofing systems are similar in the requirement of attaching the panels at adjacent edges or side rails.
[0009] It is very often desirable with metal roofing systems to have additional natural lighting whereby sunlight is permitted to enter the structure through the roof. Heretofore, this natural lighting was provided by installing domed skylights of either the curb or curbless variety. Unfortunately, skylights can be expensive and create water leakage. One of the causes of water leakage is due to the restricted flow path of water between the domed skylight and the standing seam, whereby the water level rises such as to penetrate the roof at the panel junctions. Additional problems arise with domed skylights when freezing temperatures are encountered. Ice and/or snow may collect between the skylight and the dome, and as the ice melts it is blocked by ice dams resulting in the level of water rising and penetrating the panel seam.
[0010] Curbed skylights include a “curb” which is a raised structure formed around the opening in the roof upon which the transparent material is attached. The curb raises the seal between the curb and the transparent material above the point of water flowing down the roof. However, curbs are expensive to construct and to install. If not installed correctly leaks will develop around the curb and roof junction resulting in expensive repair. Additionally, installing curbed skylights requires cutting a hole in the existing roof which is performed at the job site increasing the cost of the skylight.
[0011] Curbless skylights have been utilized and by definition do not require a raised frame. However, the prior art skylights typically utilize flashing, mechanical fasteners, and or sealing rings to install and to alleviate water leakage. Although curbless skylights do provide benefits over curbed skylights they often increase the weight of the panel with framing, increase the likelihood of water leakage and increase the cost of the metal roofing.
[0012] In addition, OSHA requires that skylights be less than twelve inches square or metal grate is required to be placed over the skylight. This so called OSHA 252 bag test is instituted to prevent people, in particular, workers from falling through the skylight when it is stepped or sat on. In order to meet these requirements the skylights and light transmitting panels in the prior art required a combination of fasteners, clips, clips, and fasteners, flanges, etc. in order to secure the transparent or semi-transparent material to the sheet metal surfaces. The differences in the respective linear coefficients of expansion of the various materials of construction resulted in systems that would inherently fail over time. The failures resulted from movement of the various materials in various directions due to the heating and cooling affect that occurs every day. With materials often moving in opposite directions fatigue occurs causing cracks, leaks and the inability to meet OSHA and UL testing requirements as discussed below.
[0013] During the heating and cooling cycle of a typical day, the metal roof and its components expand and contract. For example, it is not an unusual occurrence in a normal pitched roof to expand and contract as much as 6″ over a 100 linear feet. As a result of this and other effects, UL 90 requires that a panel withstand a 90 mph wind created uplift without loss of containment. In order to achieve this, again the prior art systems employed very elaborate clip and/or conventional fasteners. However, due to the vastly different linear expansion coefficients of the fasteners, metal panels, clips, and metal panels and light transmitting panels, loss of containment or component failure would occur as noted above over time.
[0014] It would be a benefit therefor, to have a light transmitting panel adapted for connection in a metal roofing system that did not comprise the use of clips, fasteners and the like to secure the light transmitting panel to the metal panel while at the same time meeting OSHA 252 bag test and UL 90 requirements. It would be a further benefit to have a light transmitting panel which has side rails adapted for connecting with metal roofing panels. It would be a still further benefit to have a light transmitting panel prefabricated for installation on site in a metal roofing system in the same manner as standard metal roofing panels. It would be a still further benefit to have a light transmitting panel having substantially the same strength characteristics as adjacent metal panels.
BRIEF SUMMARY OF THE INVENTION
[0015] It is thus an object of this invention to provide a light transmitting panel for use in metal roofing systems for allowing ambient light to enter a structure and which meets UL 90 and OSHA 252 bag test specifications without the use of conventional fasteners or clips.
[0016] It is a further object of this invention to provide a light transmitting panel which is inexpensive and may be constructed off site.
[0017] It is a still further object of this invention to provide a light transmitting panel which is readily connectable in a metal roofing system in the same manner as standard metal roofing panels.
[0018] Accordingly, a light transmitting panel of the type for connecting within a metal roofing system is provided. The light transmitting panel includes a translucent panel, a metal panel and a linear coefficient buffer therebetween.
[0019] The linear coefficient buffer is adapted to connect the translucent panel and the metal panel in such a was as to allow the translucent panel and metal panel to expand and contract according to its individual linear coefficient relative to the other without loosing containment.
[0020] The linear coefficient buffer may comprise any material which allows the light transmitting panel to expand and contract along the metal panel and vice versa, without loss of containment or seal therebetween. In a preferred embodiment, the linear coefficient buffer comprises and may be selected from the group consisting of adhesives, adhesive gaskets, adhesive foam and adhesive rubber. In a most preferred embodiment the linear coefficient buffer is a SIKA 452 adhesive, manufactured by SIKA Industries. In order to allow for the expansion and contraction of the materials the linear coefficient buffer thickness will be generally in the range of about 0.1 mil.-20 mil., and more specifically in the range of 2 mil.-10 mil. in thickness. While we have disclosed that certain adhesives, gaskets, and other materials may comprise the buffer, one skilled in the art will understand that any material capable of adhering to the translucent panel and the metal panel so as to allow the respective panels to move according to their respective linear coefficients without resulting in a loss of containment so that if they can do that, then they fall within the scope of the linear coefficient buffers according to the present invention.
[0021] The light transmitting panel may further comprise a pair of side rails on both the metal panel and light transmitting panel. The side rails may form a 90° angle, a trapezoid shape or any other shape. In this embodiment, the light transmitting panel side rails are disposed adjacent to the metal panel side rails in the metal roofing system.
[0022] The light transmitting panel may comprise material such as, but not limited to, fiberglass, polycarbonates, and acrylic so as to allow ambient or exterior light to enter a structure through the light transmitting panel. It is not required for the translucent material to be transparent. The translucent section may be planar, substantially planar, or have a domed section formed therein. The translucent section has a planar section running approximate the lateral or longitudinal sides which may turn into an angled portion extending from the planar portion. The angle of departure between the angled portion and the planar portion is chosen so as to match the configuration of the side rail of the particular metal roofing system in which it is to be installed.
[0023] The side rails are chosen to match the roofing system in which the light transmitting panel is to be installed. The side rails may be obtained from cutting the middle section out of an existing metal panel. The side rails may be individually turned to match particular roofing systems. Typically the side rails will have at least one horizontal portion and an angled portion extending therefrom. The adhesion surface of the horizontal portion, and the angled portion if desired, should be cleaned to remove foreign material, protective coatings and metal oxides before the adhesive is applied to join the side rails with the translucent material.
[0024] Once the translucent material is formed to match the side rails chosen for the installation a chemical adhesive or bonding material is applied to either or both the translucent material and the adhesion surface of the side rails. A neutral cure 100 percent silicon adhesive is desired because of its ability to bond many combinations of material with a chemical degradation and its strength. The side rails and translucent material are then compressed at the contact point and the adhesive is allowed to cure. Once the adhesive has cured the light transmitting panel will have substantially the same configuration and strength characteristics of the metal roofing panels for a particular installation. In particular, the light transmitting panel will have properties which allow it to be installed in a metal roofing system in a manner so as not to require metal grating to be installed in conjunction. The light transmitting panel may then be shipped to the site to be installed and will not require any additional equipment or additional expertise of the on-site personnel for installation.
[0025] Once on site the light transmitting panel may be installed in the same manner as the metal roofing panels utilized in the construction. The adjacent side rails may be connected by rolling, folding, or caps and additionally may include screws or other types of mechanical fasteners. Light transmitting panels may be installed adjacent to other light transmitting panels and/or metal roofing panels.
[0026] The foregoing has outlined the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0027] [0027]FIG. 1 is a perspective view of a light transmitting panel of the present invention.
[0028] [0028]FIG. 2 is a front, planar view of the light transmitting panel of the present invention in connection with adjacent panels.
[0029] [0029]FIG. 3 is a front, planar view of an alternative connection of the light transmitting panel of the present invention and an adjacent panel.
[0030] [0030]FIG. 4 is a perspective view of another configuration of the light transmitting panel of the present invention.
[0031] [0031]FIG. 5 is a perspective view of another embodiment of a light transmitting panel of the present invention.
[0032] [0032]FIG. 6 is a perspective view of an embodiment of the light transmitting panel.
[0033] [0033]FIG. 7 is a perspective view of an embodiment of the light transmitting panel.
[0034] [0034]FIG. 8 is a perspective view of an embodiment of the light transmitting panel.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0036] [0036]FIG. 1 is a perspective view of a light transmitting panel of the present invention, generally designated by the numeral 10 . Light transmitting panel 10 includes a translucent section 12 , first side rail 14 , second side rail 16 , and a chemical adhesive 18 .
[0037] Translucent section 12 in the embodiment shown is constructed of fiberglass and permits the passage of light exterior of the structure, such as sun light, to be transmitted into a structure on which it is installed. Translucent section 12 may be constructed of material such as, but not limited to, fiberglass, polycarbonates, and acrylic either singularly or in combination. Translucent section 12 , is constructed of material so as to substantially match the characteristics of the metal panels utilized in the roofing system. It is desired that translucent section 12 have strength characteristics which alleviate requirements of metal grating. As shown, and in the present embodiment, light transmitting panel 12 is constructed so as to withstand at least 200 pounds per square foot of pressure so as not to require metal grating pursuant to OSHA regulations.
[0038] Translucent section 12 includes a planar section 20 , and may have a first and second lateral, angled portion 22 , 24 . As shown in FIG. 1, lateral portions 22 , 24 are angled approximately perpendicular to planar section 20 to form a 90-degree modular system. Translucent section 12 may be formed to fit and match any metal roofing design configuration.
[0039] Side or locking rails 14 , 16 are constructed of metal of the same type as the roofing system in which the present invention is to be installed. Side rails 14 , 16 are formed by taking a metal panel section of the design type chosen for a roof and cutting the side rails from the metal panel. As shown in FIG. 1, side rails 14 and 16 are adapted for incorporation in metal roofing systems in which the roofing panels have male and female side rails 14 , 16 which are interconnected by rolling or folding, and possibly caps or mechanical fasteners. However, the present invention is adaptable to many shapes, and forms of side rails 14 , 16 , three examples of which are shown in FIGS. 1 through 4.
[0040] As shown in FIG. 1, first side rail 14 is a female side rail having a first horizontal portion 26 and a first angled portion 28 which extends substantially perpendicular and upward from first horizontal portion 26 . Second side rail 16 is a male side rail also having a first portion 26 and first angled portion 28 which extends substantially perpendicular and upward from first horizontal portion 26 . Both side rails 14 and 16 have a top locking section 30 . In the female side rails, top locking section 30 of side rail 14 extends in the same direction as first horizontal portion 26 and is substantially parallel to first portion 26 . In the male side rails, top locking section 30 of side rail 16 extends in the opposite direction as first portion 26 and is substantially parallel to first portion 26 . As shown in FIG. 1, side rails 14 and 16 are adapted for connecting to adjacent light transmitting panels 10 or adjacent metal roofing panels 32 (FIG. 2) by rolling or folding and therefor include tongues 34 . One or both tongues 14 may be deleted still allowing a rolled connection via locking section 30 . Additionally, at least first horizontal portion 26 and possibly first angled portion 28 have an adhesion surface 36 for connecting translucent section 12 such that section 12 is located below side rails 14 and 16 . However, as shown in FIGS. 5 and 6, translucent section 12 may be adhered atop side rails 14 and 16 .
[0041] Side rails 14 and 16 are connected to translucent section 12 by an adhesive or bonding agent to form light transmitting panel 10 . Examples of adhesives or bonding agents are UNI-WELD, a two-part epoxy from Kent Industries, and adhesives from Dynatron Bondo Adhesives. In particular, it is desired to utilize a neutral 100 percent silicone adhesive.
[0042] To connect side rails 14 and 16 to translucent section 12 adhesion surface 36 and the surface of a portion of first planar section 20 adjacent to lateral angled portion 22 and lateral angled portion 22 should be cleaned to remove any foreign materials, protective coatings such as terne, and metal oxides. An adhesive or bonding agent 18 is applied to adhesion surface 36 and/or translucent section 12 and side rails 14 and 16 are placed in position whereby horizontal portions 26 are disposed upon a portion of planar section 20 and first angled portion 28 is disposed upon first lateral portion 22 of translucent section 12 . Side rails 14 and 16 and translucent section 12 are compressed together and adhesive 18 is allowed to cure to form light transmitting panel 10 .
[0043] [0043]FIG. 2 is a front, planar view of light transmitting panel 10 of the present invention in connection with adjacent metal roofing panels 32 . As shown, adjacent side rails 14 and 16 are positioned so that a male side rail 16 overlaps a female side rail 14 . To connect panels 10 and panels 32 or panels 10 to adjacent panels 10 (not shown) by folding tongues 34 in the direction of the arrows. It should be recognized that tongue 34 is not necessary.
[0044] [0044]FIG. 3 is a front, planar view of an alternative connection of light transmitting panel 10 of the present invention and an adjacent metal roofing panel 32 . FIG. 3 demonstrates the connection of adjacent roofing panels 10 and 32 utilizing a cap 38 . Metal roofing panel 32 utilizes a female side rail 14 as does light transmitting panel 10 . Each panel 32 and 10 are placed side by side in a manner such that side rails 14 are adjacent and top locking sections 30 extend away from each other. A cap 38 is slid onto both side rails 14 along top locking sections 30 or cap 38 is placed atop locking sections 30 and crimped thereon. Although not shown this connection may be made between adjacent light transmitting panels 10 in the same manner.
[0045] [0045]FIG. 4 is a perspective view of another configuration of light transmitting panel 10 of the present invention shown in a trapezoidal configuration. In the trapezoidal configuration translucent section 12 has a first angled portion 22 which extends upwardly from planar portion 20 at an angle to match the angle that first angled portion 28 of side rails 14 and 16 extends from first horizontal portion 26 of side rails 14 and 16 . In this embodiment translucent material 12 is connected to side rails 14 and 16 in the same manner as described above. Additionally, light transmitting panel 10 as shown in FIG. 4 may be connected to adjacent light transmitting panels 10 and/or metal roofing panels as shown in FIG. 2.
[0046] [0046]FIG. 5 is a perspective view of another embodiment of light transmitting panel 10 of the present invention. Light transmitting panel 10 includes a translucent section 12 , first side rail 14 , second side rail 16 , and a chemical adhesive 18 .
[0047] Translucent section 12 in the embodiment shown is constructed of fiberglass and permits the passage of light exterior of the structure, such as sun light, to be transmitted into a structure on which it is installed. Translucent section 12 may be constructed of material such as, but not limited to, fiberglass, polycarbonates, and acrylic either singularly or in combination. Translucent section 12 , is constructed of material so as to substantially match the characteristics of the metal panels utilized in the roofing system. It is desired that translucent section 12 have strength characteristics which alleviate requirements of metal grating.
[0048] Translucent section 12 includes a planar section 20 , and may have a first and second lateral, angled portion 22 , 24 . As shown in FIG. 1, lateral portions 22 , 24 are angled approximately perpendicular to planar section 20 to form a 90-degree modular system. Translucent section 12 may be formed to fit and match any metal roofing design configuration.
[0049] Side or locking rails 14 , 16 are constructed of metal of the same type as the roofing system in which the present invention is to be installed. Side rails 14 , 16 are formed by taking a metal panel section of the design type chosen for a roof and cutting the side rails from the metal panel.
[0050] Although not shown, it is contemplated to connect a cap or seal atop or about translucent section 12 so as to aid in the prevention of water entry through the connection between section 12 and side rails 14 , 16 . It should also realized that the embodiment as disclosed applies to all forms of
[0051] Use of light transmitting panel 10 is now described with reference to FIGS. 1 through 5. A metal roofing panel (not shown) is taken and the panel is cut so as to provide two side rails 14 and 16 . Side rails 14 and 16 may be of any configuration so as to match the roofing system in which light transmitting panel 10 is to be installed. Additionally, side rails 14 and 16 may be turned individually to match the side rails of the roofing installation in which to be installed. A translucent section 12 formed of material such as, but not limited to, fiberglass, polycarbonates, and acrylic is formed so as to have a planar section 20 and may have an adjacent lateral angled section 22 . Translucent section 12 is formed so that lateral angled portions 22 are angled from planar section 20 to match the angle between first horizontal section 26 and first angled portion 28 of side rails 14 , 16 . Adhesion surface 36 of side rails 14 , 16 should be cleaned as well as the contacting surface of translucent material 12 . An adhesive or bonding agent 18 is applied to adhesion surface 36 and/or translucent section 12 . Side rails 14 and 16 are placed in contact with translucent material 12 such that horizontal portions 26 and planar sections 20 and angled portions 28 and lateral angled portions 22 are aligned. Compression is applied to side rails 14 , 16 and translucent section 12 and adhesive 18 is allowed to cure. Once adhesive 12 is cured light transmitting panel 10 is completed and may be shipped for installation in a metal roof system. Light transmitting panel 10 may be installed in any system in which side rails 14 , 16 are adapted, whether it be by rolling, folding, caps, and/or mechanical fasteners for connection with adjacent metal roofing panels.
[0052] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. For example, many configurations of metal roofing panels exist to which the light transmitting panel of the present invention may be adapted, many translucent materials are available for use in the light transmitting panel, and additionally it is contemplated that mechanical fasteners such as screws and nuts and bolts may be used for additional security between adjacent metal roofing panels and light transmitting panels, and adhesion of the light transmitting panels along a single portion or section of the side rails.
[0053] The invention will be further described by the following example. This example is not intended to be limiting, in any way, the invention being defined by the appended claims.
EXAMPLE
[0054] A light transmitting panel assembly according to the present invention was constructed for testing under UL 90 test requirements. A five (5) panel assemble was created wherein one of the panels included a light transmitting panel. The panels were nominally ten feet (10′) in length and two feet (2′) wide. The panel which comprised the light transmitting panel assembly included a metal panel including one cut-out nominally 17″×53″ and two cut-outs that nominally 17″×24″. A translucent fiberglass panel nominally 8 oz./ft 2 (˜0.045″ thick) was overlaid onto the metal panel so as to cover the cut-outs. A SIKA 252 adhesive was used as the linear coefficient buffer and was disposed between the metal panel and translucent fiberglass panel to a thickness of 2.5 mil. A neutral cure silicone (Silpruf manufactured by Bayer Corporation) was used as an addition adhesive/buffer on the light transmitting panel edges as a secondary seal and to prevent the infusion of air or water under the panel in the event of a void in the SIKA adhesive. The five (5) panel assembly including the light transmitting panel assembly was testing according to ASTM specification UL 90. After the testing, the light transmitting panel assembly was inspected and no break down or fatigue of the component parts was observed.
[0055] The foregoing disclosure and description of the preferred embodiment are illustrative and explanatory thereof, and various changes in the components, circuit elements, circuit configurations, and signal connections, as well as in the details of the illustrated circuitry and construction and method of operation may be made without departing from the spirit and scope of the invention. | A light transmitting panel of the type for connecting within a metal roofing system is provided. The light transmitting panel includes a translucent panel, a metal panel and a linear coefficient buffer therebetween to allow the respective panels to expand and contract with respect to the other without loss of containment or seal. The light transmitting panel is formed so as to substantially match the configuration and the strength characteristics of the roofing system into which it is installed. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 07/933,408 filed Aug. 21, 1992, now U.S. Pat. No. 5,346,905, which is a continuation-in-part of commonly assigned U.S. Ser. No. 07/754,610, filed 4 Sep. 1991, now U.S. Pat. No. 5,268,376.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to 1H-imidazo[4,5-c]quinoline compounds. In other aspects, this invention relates to 1H-imidazo[4,5-c]quinolin-4-amines, intermediates for the preparation of such compounds, pharmaceutical compositions containing such compounds, and pharmacological methods of using such compounds.
2. Description of the Related Art
The first reliable report of the 1H-imidazo[4,5-c]quinoline ring system, Backman et al., J. Org. Chem. 15, 1278-1284 (1950), describes the synthesis of 1-(6-methoxy-8-quinolinyl)-2-methyl-1H-imidazo[4,5-c]quinoline for possible use as an antimalarial agent. Subsequently, syntheses of various substituted 1H-imidazo[4,5-c]quinolines have been reported. For example, Jain et al., J. Med. Chem. 11, pp. 87-92 (1968), has synthesized the compound 1-[2-(4-piperidyl)ethyl]-1H-imidazo[4,5-c]quinoline as a possible anticonvulsant and cardiovascular agent. Also, Baranov et al., Chem. Abs. 85, 94362 (1976), has reported several 2-oxoimidazo[4,5-c]quinolines, and Berenyi et al., J. Heterocyclic Chem. 18, 1537-1540 (1981), has reported certain 2-oxoimidazo[4,5-c]quinolines.
Certain antiviral 1H-imidazo[4,5-c]quinolin4-amines are described in U.S. Pat. No. 4,689,338 (Gerster). These compounds are substituted on the 1-position by alkyl, hydroxyalkyl, acyloxyalkyl, benzyl, phenylethyl or substituted phenylethyl, and at the 2-position with hydrogen, alkyl, benzyl, or substituted benzyl, phenylethyl or phenyl. Furthermore, these compounds are known to induce interferon biosynthesis. Other antiviral 1H-imidazo[4,5-c]quinolin-4-amines, substituted on the 1-position by alkenyl substituents, are described in U.S. Pat. No. 4,929,624 (Gerster).
U.S. Pat. No. 4,698,348 (Gerster) discloses 1H-imidazo[4,5-c]quinolines that are active as bronchodilators, such as 4-substituted 1H-imidazo[4,5-c]quinolines wherein the 4-substituent is, inter alia, hydrogen, chloro, alkylamino, or dialkylamino, and the 2-substituent is, inter alia, hydroxyalkyl, aminoalkyl, or alkanamidoalkyl. Said patent also discloses 3-amino and 3-nitro quinoline intermediates substituted at the 4-position by hydroxyalkylamino or cyclohexylmethylamino, and 1H-imidazo[4,5-c]quinoline N-oxide intermediates substituted at the 2-position with, inter alia, hydroxyalkyl, aminoalkyl, or alkanamidoalkyl.
DETAILED DESCRIPTION OF THE INVENTION
This invention provides compounds of Formula I: ##STR1## wherein R' 1 is hydrogen or a carbon-carbon bond, with the proviso that when R' 1 is hydrogen R 1 is alkoxy of one to about four carbon atoms, hydroxyalkoxy of one to about four carbon atoms, 1-alkynyl of two to about ten carbon atoms, tetrahydropyranyl, alkoxyalkyl wherein the alkoxy moiety contains one to about four carbon atoms and the alkyl moiety contains one to about four carbon atoms, 2-, 3-, or 4-pyridyl, and with the further proviso that when R' 1 is a carbon-carbon bond R' 1 and R 1 together form a tetrahydrofuranyl group optionally substituted with one or more substituents independently selected from the group consisting of hydroxy and hydroxyalkyl of one to about four carbon atoms;
R 2 is selected from the group consisting of hydrogen, alkyl of one to about four carbon atoms, phenyl, and substituted phenyl wherein the substituent is selected from the group consisting of alkyl of one to about four carbon atoms, alkoxy of one to about four carbon atoms, and halogen; and
R is selected from the group consisting of hydrogen, straight chain or branched chain alkoxy containing one to about four carbon atoms, halogen, and straight chain or branched chain alkyl containing one to about four carbon atoms;
or a pharmaceutically acceptable acid addition salt thereof.
This invention provides intermediate compounds of the formula ##STR2## wherein R is as defined above, Y is --NO 2 or --NH 2 , and R 4 is alkoxyalkyl wherein the alkoxy moiety contains one to about four carbon atoms and the alkyl moiety contains one to about four carbon atoms.
This invention also provides intermediate compounds of the formula ##STR3## wherein Y and R are as defined above and R 5 is 2-, 3-, or 4-pyridyl.
This invention provides intermediate compounds of the formula ##STR4## wherein R, R 2 , and R 4 are as defined above.
This invention provides intermediate compounds of the formula ##STR5## wherein R, R 2 , and R 4 are as defined above.
Further this invention provides compounds of the formula ##STR6## wherein R, R 2 , and R 5 are as defined above.
This invention also provides intermediate compounds of the formula ##STR7## wherein R and R 2 are as defined above and R 6 is alkanoyloxyalkoxy methyl or aroyloxyalkoxy methyl wherein the alkyl group contains one to about four carbon atoms, or tetrahydrofuranyl substituted by one or more substituents independently selected from the group consisting of alkanoyloxy, aroyloxy, and alkanoyloxyalkyl and aroyloxyalkyl wherein the alkyl group contains one to about four carbon atoms.
R 1 of Formula I is preferably alkoxyalkyl or 4-pyridyl.
Other substituents in compounds of Formula I that contain an alkyl radical (e.g., R when R is alkoxy or alkyl) preferably contain two carbon atoms or, more preferably, one carbon atom in each alkyl radical.
It is preferred that R of Formula I be hydrogen.
Preferred compounds of Formula I include: 1-ethoxymethyl-1H-imidazo[4,5-c]quinolin-4-amine; 1-(2-propynyl)-1H-imidazo[4,5-c]quinolin-4-amine; 1-[(tetrahydro-2H-pyran-2-yl)methyl]-1H-imidazo[4,5-c]-quinolin-4-amine; and 1-(2-pyridylmethyl)-1H-imidazo[4,5-c]quinolin-4-amine.
Most preferred compounds of Formula I include 1-(2-methoxypropyl)-2-methyl-1H-imidazo[4,5-c]quinolin-4-amine, 1-(2-methoxyethyl)-2-methyl-1H-imidazo[4,5-c]quinolin-4-amine, and 1-(4-pyridylmethyl)-1H-imidazo[4,5-c]-quinolin-4-amine.
Compounds of Formula I can be prepared by alkylating the 1-position of a 1H-imidazo[4,5-c]-quinolin-4-amine with an alkylating agent of the formula (R' 1 )(R 1 )HC-X wherein R' 1 and R 1 are as defined above and X is chloro or bromo, in a polar solvent in the presence of sodium hydride. In instances wherein R 1 comprises a hydroxyl group, the hydroxyl group can be protected for the alkylation step and subsequently deprotected. Suitable protecting groups include alkanoyloxy (e.g., acetoxy) or aroyloxy (e.g., benzoyloxy or p-toloyloxy). Reactions for placement and removal of such groups are well known to those skilled in the art and disclosed, e.g., in U.S. Pat. No. 4,689,338 (Gerster), Examples 115-123. 1H-Imidazo[4,5-c]quinolin-4-amines are disclosed in commonly assigned copending application Ser. No. 07/484,761 (incorporated herein by reference to the extent relevant to the preparation of such compounds) and can be prepared as set forth in Scheme I below: ##STR8##
In Scheme I, R and R 2 are as defined above and R E is a substituent capable of being subjected to an elimination or like reaction to afford a 1H-imidazo[4,5-c]quinolin-4-amine. R E can be any substituent that can be removed. Examples of general classes of R E include groups that will yield a stable cation upon treatment with aqueous acid (e.g. tertiary substituents, meaning for the purposes of the instant specification and claims any substituent wherein the carbon atom bonded to the 1-nitrogen is fully substituted with electron-donating groups, for example hydroxy, alkoxy, acyloxy, halogen, alkyl, phenyl, and the like) and substituents from which the 1H-imidazo[4,5-c]quinolin-4-amine can be eliminated (e.g. 2-hydroxyalkyl groups). Such R E substituents include 1,1-dimethylethyl (i.e., t-butyl), 1,1-dimethyl-2-hydroxyethyl, 2-hydroxy-1-phenyl-1-methylethyl, 1,1-dimethyl-2-hydroxypropyl, and the like.
Many quinolines of Formula III are known compounds (see, for example, U.S. Pat. No. 3,700,674 and references cited therein). Those that are not known can be prepared by known methods, for example, from 4-hydroxy-3-nitroquinolines as illustrated in step (1) of Scheme I. Step (1) can be conducted by reacting the 4-hydroxy-3-nitroquinoline of Formula II with 1-2 moles of phosphorus oxychloride per mole of the 4-hydroxy-3-nitroquinoline of Formula II. The reaction can be conducted in N,N-dimethylformamide and can be accompanied by heating. In step (2) a 3-nitro-4-chloroquinoline of Formula III is reacted by heating with a compound of the formula R E NH 2 , wherein R E is as defined above, in a suitable solvent such as dichloromethane, water, or tetrahydrofuran, and optionally in the presence of a tertiary amine catalyst such as triethylamine to provide a quinoline of Formula IV.
Steps (1) and (2) can be combined such that the 3-nitro-4-chloroquinoline need not be isolated prior to reaction with R E NH 2 . Such a reaction is exemplified in Example 134 and Example 188 (Step A) of U.S. Pat. No. 4,689,338, the disclosure of which is incorporated herein by reference.
A compound of Formula IV is reduced in step (3) preferably using a catalyst such as platinum on charcoal, to provide a compound of Formula V. The reduction can be carried out conveniently on a Paar apparatus in an inert solvent such as toluene or a lower alkanol.
In step (4) an intermediate compound of Formula V is reacted with (i) a 1,1-dialkoxyalkyl alkanoate such as diethoxymethyl acetate, or (ii) a carboxylic acid that will introduce the desired R 2 group, or (iii) a trialkyl ortho ester of the formula R 2 C(Oalkyl) 3 , wherein "alkyl" is an alkyl group containing 1 to about 4 carbon atoms, or (iv) a combination of such a carboxylic acid with such a trialkyl ortho ester to provide a compound of Formula VI. The reaction can be carried out by heating, e.g., at about 130° C., in the presence of an acid, preferably an alkanoic acid having one more carbon atom than R 2 .
Step (5) provides an intermediate of Formula VII. First, the hydroxy group, if one is present in R E , is protected with, for example, an alkanoyloxy group such as acetoxy, or with benzoyloxy. Such protecting groups and reactions for their placement and removal are well known to those skilled in the art. See, for example, U.S. Pat. No. 4,689,338, Examples 115 to 123. The resulting protected compound is then oxidized with a conventional oxidizing agent that is capable of forming N-oxides. Suitable oxidizing agents include peroxyacids and hydrogen peroxide. Heating is generally employed to accelerate the rate of reaction.
In step (6) an N-oxide of Formula VII is first heated in the presence of a suitable chlorinating agent such as phosphorus oxychloride to provide an intermediate of Formula VIII. Phosphorus oxychloride can be used in combination with a solvent (e.g., dichloromethane) inert to conventional chlorinating agents, optionally in the presence of a catalytic amount of N,N-dimethylformamide. The second part of step (6) involves removal of the protecting group, if one is present, by methods well known to those skilled in the art.
In step (7) the 4-chloro group is replaced by a 4-amino group to provide a compound of Formula IX. The intermediate of Formula VIII can be heated, e.g., at 125° to 175° C. under pressure for 6-24 hours in a sealed reactor in the presence of either ammonium hydroxide or a solution of ammonia in an alkanol, (e.g., 15% ammonia in methanol). In step (8), a compound of Formula IX is heated in the presence of aqueous acid to effect the deamination of the R E group, thus providing a 1H-imidazo[4,5-c]- quinolin-4-amine of Formula X. Preferred conditions for the reaction include brief (e.g., 30 minute) reflux in dilute (e.g. 4N) aqueous hydrochloric acid.
Another method of preparing compounds of Formula I involves the reactions shown in Scheme II below. ##STR9##
Step 1 of Scheme II involves reacting a compound of Formula III in an inert solvent with an amine of the formula R 1 CH 2 NH 2 to provide a compound of Formula XI. The reaction of step 1 can be carried out in the presence of a tertiary amine catalyst (such as triethylamine).
Step 2 involves: (i) reduction of the nitro group of the compound of Formula XI as described above in connection with step (3) of Scheme I; (ii) reaction of the resulting 3-amino compound with a carboxylic acid or an equivalent thereof as described above in connection with step (4) of Scheme I in order to provide a cyclized imidazo[4,5-c]quinoline; and (iii) oxidizing the quinoline nitrogen as described above in connection with step (5) of Scheme I to provide the N-oxide of Formula XII.
A 1H-imidazo[4,5-c]quinolin-4-amine is prepared in step (3) of the Scheme II. Step (3) involves (i) reacting a compound of Formula XII with an acylating agent; (ii) reacting the product with an aminating agent; and (iii) isolating the compound of Formula I. Part (i) of step (3) involves reacting an N-oxide with an acylating agent. Suitable acylating agents include alkyl- or aryl- sulfonyl chlorides (e.g., benzenesulfonyl chloride, methanesulfonyl chloride, p-toluenesulfonyl chloride). Arylsulfonyl chlorides are preferred. p-Toluenesulfonyl chloride is most preferred. Part (ii) of step (3) involves reacting the product of part (i) with an excess of an aminating agent. Suitable aminating agents include ammonia (e.g., in the form of ammonium hydroxide) and ammonium salts (e.g., ammonium carbonate, ammonium bicarbonate, and ammonium phosphate). Ammonium hydroxide is preferred. The reaction of step (3) is preferably carried out by dissolving the N-oxide of Formula XII in an inert solvent such as methylene chloride, adding the aminating agent to the solution, and then adding the acylating agent. Preferred conditions involve cooling to about 0° C. to about 5° C. during the addition of the acylating agent. Heating or cooling can be used to control the rate of the reaction.
Compounds of Formula XIX, a subgenus of Formula I, can be prepared according to the general method disclosed in U.S. Pat. No. 4,988,815 (Andre et al.), incorporated herein by reference), as shown below in Scheme III, wherein R and R 2 are as defined above and R 7 is 1-alkynyl of two to about ten carbon atoms, tetrahydropyranyl alkoxyalkyl wherein the alkoxy moiety contains one to about four carbon atoms and the alkyl moiety contains one to about four carbon atoms, 2-, 3-, or 4-pyridyl. ##STR10##
The unsubstituted compound of Formula XIII, 4-hydroxy-2(1H)-quinolinone, is a known, commercially available compound, and other compounds of Formula XIII can be prepared therefrom by methods known to those skilled in the art. For example, Chem. Ber., 1927, 60, 1108 (Kohler), discloses the preparation of 7-chloro-4-hydroxy-2(1H)-quinolinone.
In step (1) a compound of Formula XIII is nitrated at the 3-position using conventional nitration methods. It is known to those skilled in the art, however, that nitration is not necessarily selective. For example, depending on the particular R substituent in a compound of Formula XIII and the particular conditions employed, nitration might occur on the benzo ring of a compound of Formula XIII. Those skilled in the art, however, are able to select appropriate conditions that will afford a compound of Formula XIV. Suitable conditions involve mild heating (e.g., at about 40° C.) with acetic acid as the solvent. The unsubstituted compound of Formula XIV, 4-hydroxy-3-nitro-2(1H)quinoline is known and the preparation thereof is disclosed in Chem, Ber., 1918, 51, 1500 (Gabriel), the disclosure of which is incorporated herein by reference.
In step (2) the nitrated compound of Formula XIV is chlorinated with a suitable chlorinating agent such as phosphorus pentachloride or phosphorus oxychloride to provide the dichloride product of Formula XV. The reaction can be carried out in an inert solvent or if appropriate in neat chlorinating agent. Mild heating serves to accelerate the rate of reaction. The unsubstituted compound of Formula XV, 2,4-chloro-3-nitroquinoline, is known and the preparation thereof is disclosed in Gabriel cited above.
The product of Formula XV can be isolated if desired, but steps (2) and (3) can be carried out without isolation of the compound of Formula XV. Such a process involves carrying out the reaction of step (2), careful hydrolysis of unreacted chlorinating agent at a relatively low temperature (e.g., below about 35° C.), separating the organic layer, removing the product of Formula XV from the remaining aqueous layer, by extraction with an organic solvent, and using the combined organic extracts as described below in connection with step (3).
In step (3), a compound of Formula XV is substituted at the 4-position by reaction with an excess of a compound of the formula R 7 CH 2 NH 2 , wherein R 7 is as defined above. It is sometimes necessary to use gentle heating (e.g., 50° C.). This reaction proceeds selectively, affording only the 4-substituted product and no detectable amount of the 2-substituted compound. The reaction is run in a solvent comprising a base such as triethylamine or pyridine. When step (3) is run independent of step (2), the reaction can be carried out in a neat basic solvent such as triethylamine. Gentle heating (e.g., at about 70° C.) is preferred.
In step (4), a compound of Formula XVI is reduced to afford a compound of Formula XVII. This reduction can be carried out by conventional methods such as by electrochemical reduction, by reaction with metals such as zinc, tin, or iron in acid, and by other conventional single step or multi-step methods known to those skilled in the art. Suitable reduction conditions include conventional homogeneous or preferably heterogeneous catalytic hydrogenation conditions. A compound of Formula XVI is suspended or dissolved in a solvent such as ethanol, ethyl acetate, methanol, isopropyl alcohol, or mixtures thereof with acetic acid, in the presence of a suitable heterogeneous hydrogenation catalyst such as a platinum or rhodium on alumina, palladium on carbon, platinum on carbon, or the like under hydrogen pressure (e.g., 1-5 atm) in a steel bomb. Isopropyl alcohol is the preferred solvent.
In step (5), a compound of Formula XVII is reacted with an orthoester or an orthoformate of the formula R 2 C(O-Alkyl) 3 or a carboxylic acid of the formula R 2 CO 2 H or a mixture thereof, as described above in connection with step (4) of Scheme I.
In step (6), a compound of Formula XVIII is reacted with ammonia as described above in connection with step (7) of Scheme I to afford a compound of Formula XIX.
Compounds of Formula I can be isolated by the conventional means disclosed in U.S. Pat. No. 4,689,338 (Gerster), such as, for example, removal of the solvent and recrystallization from an appropriate solvent (e.g., N,N-dimethylformamide) or solvent mixture, or by dissolution in an appropriate solvent (such as methanol) and re-precipitation by addition of a second solvent in which the compound is insoluble.
A compound of Formula I can be used as an antiviral agent itself or it can be used in the form of a pharmaceutically acceptable acid-addition salt such as a hydrochloride, dihydrogen sulfate, trihydrogen phosphate, hydrogen nitrate, methanesulfonate or a salt of another pharmaceutically acceptable acid. A pharmaceutically acceptable acid-addition salt of a compound of Formula I can be prepared, generally by reaction of the compound with an equimolar amount of a relatively strong acid, preferably an inorganic acid such as hydrochloric, sulfuric, or phosphoric acid, or an organic acid such as methanesulfonic acid, in a polar solvent. Isolation of the salt is facilitated by the addition of a solvent, such as diethyl ether, in which the salt is insoluble.
A compound of the invention can be formulated for the various routes of administration in a pharmaceutically acceptable vehicle, such as water or polyethylene glycol, along with suitable adjuvants, excipients, and the like. Particular formulations will be easily selected by those skilled in the art. Suitable formulations for topical application include creams, ointments and like formulations known to those skilled in the art. Formulations generally contain less than 10% by weight of a compound of Formula I, preferably about 0.1% to 5% by weight of a compound of, Formula I.
The compounds of Formula I exhibit antiviral activity in mammals. They can therefore be used to control viral infections. For example, a compound of Formula I can be used as an agent to control infections in mammals caused by Type II Herpes simplex virus. Compounds of Formula I can also be used to treat a herpes infection by oral, topical, or intraperitoneal administration.
A number of compounds of Formula I were tested and found to induce biosynthesis of interferon in human cells. The test methods and results are set forth below. These results suggest that at least certain compounds of the invention might be useful in treating other diseases such as rheumatoid arthritis, warts, eczema, Hepatitis B, psoriasis, multiple sclerosis, essential thrombocythemia, cancer such as basal cell carcinoma, and other neoplastic diseases.
In the following Examples, all reactions were run with stirring under an atmosphere of dry nitrogen unless otherwise indicated. The particular materials and amounts thereof recited in the Example, as well as other conditions and details, should not be construed to unduly limit the invention.
EXAMPLE 1
1-Ethoxymethyl-1H-imidazo[4,5-c]quinolin-4-amine
A 0.48 g (0,012 mole) portion of 60% sodium hydride was added to a suspension of 2.0 g (0.011 mole) of 1H-imidazo[4,5-c]quinolin-4-amine in 20 mL of dimethylformamide. The resulting mixture was stirred for about 45 minutes until a solution was obtained. A 1.07 g (0.011 mole) portion of chloromethyl ethyl ether was added to the solution. A precipitate formed immediately. The reaction mixture was stirred at room temperature for one hour. The precipitate was collected, slurried with water then dried to give 1.4 g of a solid which was identified as the 1-isomer by nuclear magnetic resonance spectroscopy. This solid was recrystallized from 150 mL of ethanol to provide 0.86 g of 1-ethoxymethyl-1H-imidazo[4,5-c]quinolin-4-amine, m.p. 255°-261° C. Analysis: Calculated for C 13 H 14 H 4 O: % C, 64.4; % H, 5.8; % N, 23.1; Found: % C, 64.2; % H 5.8, % N 22.8.
EXAMPLE 2
1-(2-Propynyl)-1H-imidazo[4,5-]quinolin-4-amine
Using the general method of Example 1, 2.1 g of 1H-imidazo[4,5-c]quinolin-4-amine was reacted with 1.7 g of propargyl bromide to provide 0.4 g of 1-(2-propynyl)-1H-imidazo[4,5-c]quinolin-4-amine, m.p. 220°-222° C. The structure was confirmed by nuclear magnetic resonance spectroscopy. Analysis: Calculated for C 13 H 10 N 4 : % C, 70.3; % H, 4.5; % N, 25.2; Found: % C, 70.5; % H, 4.6; % N, 25.4.
EXAMPLE 3
1-[(Tetrahydro-2H-pyran-2-yl)methyl]-1H-imidazo[4,5-c]quinolin-4-amine
Using the general method of Example 1, 3.0 g of 1H-imidazo[4,5-c]quinolin-4-amine was reacted with 2-bromomethyltetrahydropyran to provide about 2.5 g of a mixture of the 1 and 3 isomers. The mixture was slurried with about 30 mL of refluxing ethyl acetate then cooled in an ice bath. The resulting precipitate was collected and dried to provide 0.6 g of 1-[(tetrahydro-2H-pyran-2-yl)methyl]-1H-imidazo[4,5-c]quinolin-4-amine, m.p. 206°-210° C. The structure was confirmed by nuclear magnetic resonance spectroscopy. Analysis: Calculated for C 16 H 18 N 4 O: % C, 68.1; % H, 6.4; % N, 19.8; Found: % C, 67.8; % H, 6.4; % N, 19.6.
EXAMPLE 4
1-[(2-Acetoxyethoxy)methyl]-1H-imidazo[4,5-c]quinolin-4-amine
Using the general method of Example 1, 5.0 g of 1H-imidazo[4,5-c]quinolin-4-amine was reacted with (2-acetoxyethoxy)methyl bromide (prepared according to the method of Robins et al., Can. J. Chem. 60, 547 (1982)) to provide 5.3 g of a yellow solid. The solid was slurried with ethyl acetate to provide 2.3 g of a light yellow solid which was identified as the 1-isomer by nuclear magnetic resonance spectroscopy.
EXAMPLE 5
1-[(2-Hydroxyethoxy)methyl]-1H-imidazo[4,5-c]quinolin-4-amine
A 2.1 g portion of 1-[(2-acetoxyethoxy)methyl]-1H-imidazo[4,5-c]quinolin-4-amine was combined with 25 mL of 15% ammonia in methanol and stirred at room temperature for about 16 hours. The resulting precipitate was collected, rinsed with ether and dried to provide 1.1 g of a solid. This solid was recrystallized from 50 mL of ethanol to provide 0.8 g of 1-[(2-hydroxyethoxy)]methyl-1H-imidazo[4,5-c]quinolin-4-amine as a yellow crystalline solid, m.p. 210°-212° C. Analysis: Calculated for C 13 H 14 N 4 O 2 : % C, 60.4; % H, 5.5; % N, 21.7; Found: % C, 60.3; % H, 5.5; % N, 21.5.
EXAMPLE 6
1-(2-Deoxy-3,5-di-O-p-toluoyl-D-erythropentofuranoxyl)-1H-imidazo[4,5-c]quinolin-4-amine
A 0.34 g (0.011 mole) portion of 60% sodium hydride was added to a suspension of 1.7 g (0.009 mole) of 1H-imidazo[4,5-c]quinolin-4-amine in 65 mL of methylene chloride. The reaction mixture was then diluted with 65 mL of acetonitrile and stirred at room temperature for 2 hours. 3.6 g (0.009 mole) of 2-deoxy-3,5-di-O-p-toluoyl-D-erythropentosyl chloride (prepared according to the method of Bhat, pp. 521-22 from Volume 1, Synthetic Procedures in Nucleic Acid Chemistry, Zorbach and Tipson (1968)) was added to the reaction mixture and stirring at room temperature was continued for about 16 hours. The reaction mixture was filtered to remove a small amount of insoluble material. The filtrate was evaporated to provide a residue which was purified by silica gel chromatography using ethyl acetate as the eluent to provide 1.4 g of the 3-isomer and 2.0 g of the 1-isomer. The structural assignments were confirmed by nuclear magnetic resonance spectroscopy.
EXAMPLE 7
1-(2-Deoxy-β-D-erythro-pentofuranoxyl)-1H-imidazo[4,5-c]quinolin-4-amine
A 2.2 g portion of 1-(2-deoxy-3,5-di-O-p-toluoyl-D-erythro-pentofuranoxyl)-1H-imidazo[4,5-c]-quinolin-4-amine was dissolved in about 150 mL of 15% ammonia in methanol and stirred at room temperature for about 48 hours. The volume of the reaction was reduced to about 50 mL and the precipitate collected to provide 0.56 g of a solid. The filtrate was evaporated and the residue was slurried with ether then filtered to provide 0.55 g of a solid. The two solids were combined then recrystallized from ethanol to provide 0.8 g of 1-(2-deoxy-β-D-erythro-pentofuranosyl)-1H-imidazo[4,5-c]quinolin-4-amine, m.p. 232°-237° C. Analysis: Calculated for C 15 H 16 N 4 O 3 : % C, 60.0; % H, 5.4; % N, 18.7; Found: % C, 59.7; % H, 5.4; % N, 18.3.
EXAMPLE 8
N-(2-Methoxyethyl)-3-nitro-4-quinolinamine
A mixture containing 16 mL (0.22 mole) of thionyl chloride and 18 mL of dimethylformamide was added to a suspension of 38 g (0.2 moles) of 4-hydroxy-3-nitroquinoline in 500 mL of dichloromethane. The resulting mixture was heated at reflux for 2 hours and then allowed to cool to room temperature. A 20 mL (0.23 mole) portion of methoxyethylamine was combined with 30 mL of triethylamine and the combination was slowly added with vigorous stirring to the reaction mixture. A vigorous heat of reaction was observed and the mixture was allowed to reflux until the heat of reaction dissipated. The reaction mixture was concentrated under vacuum to provide a residue which was then slurried with dilute hydrochloric acid. The slurry was filtered and the filtrate was made basic with ammonium hydroxide. The resulting precipitate was collected, rinsed with water and air dried to provide 37.4 g of a yellow solid. A sample of this material was recrystallized from ethanol-dichloromethane to provide N-(2-methoxyethyl)-3-nitro-4-quinolinamine as a yellow solid, m.p. 113°-115° C. Analysis: Calculated for C 12 H 13 N 3 O 3 : % C, 58.3; % H, 5.3; % N, 17.0; Found: % C, 58.0; % H, 5.3; % N, 16.8.
EXAMPLE 9
1-(2-Methoxyethyl)-2-methyl-1H-imidazo[4,5-c]quinoline
A mixture containing 12.5 g of N-(2-methoxyethyl)-3-nitro-4-quinolinamine, 0.6 g of 5% platinum on carbon, 10 g of magnesium sulfate and 380 mL of ethyl acetate was hydrogenated in a Parr apparatus at an initial pressure of about 53 psi. After the hydrogenation was complete, the reaction mixture was filtered. The filtrate was evaporated under vacuum to provide the diamine intermediate as a clear amber oil. The oil was taken up in 150 mL of glacial acetic acid and the resulting solution was refluxed for one and a half hours before being evaporated under vacuum. The resulting residue was dissolved in water. The solution was made strongly basic with aqueous sodium hydroxide then extracted several times with ethyl acetate. The extracts were combined, dried over magnesium sulfate and evaporated. The residue was slurried with ether/hexane then filtered to provide 9.5 g of crude product. A 0.5 g sample was recrystallized to provide pure 1-(2-methoxyethyl)-2-methyl-1H-imidazo[4,5-c]quinoline, m.p. 128°-130° C. Analysis: Calculated for C 14 H 15 N 3 O: % C, 9.7, % H, 6.3; % N, 17.4; Found: % C, 69.8; % H, 6.3; % N, 7.4.
EXAMPLE 10
1-(2-Methoxyethyl)-2-methyl-1H-imidazo[4,5-c]quinolin-4-amine
A 6.3 mL (0.03 mole) portion of 32% peracetic acid was added to a solution of 7.0 g (0.029 mole) of 1-(2-methoxyethyl)-2-methyl-1H-imidazo[4,5-c]quinoline in 100 mL of ethyl acetate. The solution was heated at reflux for 30 minutes and then allowed to cool to room temperature. The resulting precipitate was collected, rinsed with a small amount of ethyl acetate and dried to provide 7.7 g of the N-oxide as a solid. The N-oxide was dissolved in 125 mL of dichloromethane then mixed with 40 mL of concentrated ammonium hydroxide. The resulting heterogeneous mixture was stirred vigorously and cooled to 4° C. A 5.7 g (0.03 mole) portion of p-toluenesulfonyl chloride was dissolved in 25 mL of dichloromethane and added dropwise to the mixture. The rate of addition was controlled such that the reaction mixture was maintained at a temperature of 4°-9° C. After the addition was completed the reaction mixture was allowed to stir at room temperature for one hour. The dichloromethane was removed under vacuum. The aqueous mixture was diluted further with water and the solid was collected, washed with water and dried to provide 6.1 g of crude product as a tan solid. The tan solid was recrystallized from methanol/dichloromethane to provide 3.0 g of 1-(2-methoxyethyl) -2-methyl-1H-imidazo[4,5-c]quinolin-4-amine as a colorless crystalline solid, m.p. 230°-233° C. Analysis: Calculated for C 14 H 16 H 16 N 4 O: % C, 65.6; % H, 6.3; % N, 21.9; Found: % C, 65.5; % H, 6.1; % N, 21.7.
EXAMPLE 11
2-Chloro-3-nitro-N-(2-pyridylmethyl)-4-quinolinamine
A 8.2 g portion of 2,4-dichloro-3-nitroquinoline was dissolved in 85 mL of dimethylformamide. 2-(Aminomethyl)pyridine (2.5 mL) was added dropwise followed by the addition of 4.7 mL of triethylamine. The reaction mixture was stirred for 15 minutes then an additional 1.0 mL of 2-(aminomethyl)pyridine was added. The reaction mixture was stirred at room temperature for about an hour and then on a steam bath for about 45 minutes. The reaction mixture was diluted with 150 mL of water. The resulting precipitate was collected and dried to provide 7.3 g of a yellow brown solid. The solid was slurried with about 75 mL of refluxing hexane then filtered while hot to give 4.5 g of a solid. A 200 mg sample was recrystallized from about 15 mL of ethanol to provide pure 2-chloro-3-nitro-N-(2-pyridylmethyl)-4-quinolinamine, m.p. 179°-182° C. Analysis: Calculated for C 15 ClH 11 N 4 O 2 : % C, 57.2; % H, 3.5; % N, 17.8; Found: % C, 57.4; % H, 3.6; % N, 17.7.
EXAMPLE 12
2-Chloro-N 4 -(2-pyridylmethyl)-3,4-quinolinediamine
A mixture containing 5.8 g of 2-chloro-3-nitro-N-(2-pyridylmethyl)-4-quinolinamine, 5.8 g of magnesium sulfate, 0.6 g of 5% platinum on carbon and 300 mL of ethyl acetate was hydrogenated on a Parr apparatus. After the hydrogenation was complete, the reaction mixture was filtered and the filtrate evaporated to provide 4.6 g of a solid. A sample was recrystallized from ethyl acetate/hexane to provide pure 2-chloro-N 4 -(2-pyridylmethyl)-3,4-quinolinediamine m.p. 98°-102° C. Analysis: Calculated for C 15 ClH 13 N 4 : % C, 63.3; % H, 4.6; % N, 19.7; Found % C, 63.5; % H, 4.7; % N, 19.8.
EXAMPLE 13
4-Chloro-1-(2-pyridylmethyl)-1H-imidazo[4,5-c]quinoline
A 1.6 mL portion diethoxymethyl acetate was added to a solution of 2.3 g of 4-Chloro-N 4 -(2-pyridylmethyl)-3,4-quinolinediamine in 15 mL of warm xylene. The reaction mixture was heated on a steam bath for 90 minutes then diluted with hexane. The precipitate was collected and dried to provide 2.3 g of a solid. A 300 mg sample was recrystallized from 10 mL of ethanol to provide pure 4-chloro-1-(2-pyridylmethyl)-1H-imidazo[4,5-c]quinoline, m.p. 217°-220° C. Analysis: Calculated for C 16 ClH 11 N 4 : % C, 65.2; % H, 3.8; % N, 19.0; Found: % C, 65.0; % H, 3.7; % N, 18.8.
EXAMPLE 14
1-(2-Pyridylmethyl)-1H-imidazo[4,5-c]quinolin-4-amine
A mixture of 2.4 g of 4-chloro-1-(2-pyridylmethyl)-1H-imidazo[4,5-c]quinoline and 50 mL of 15% ammonia in methanol was placed in a bomb and heated at 150° C. for 6 hours. After cooling, the reaction mixture was filtered. The solid was slurried with aqueous sodium bicarbonate, collected and dried to provide 1.9 g of crude product. The crude product was recrystallized from 350 mL of ethanol to provide 1.25 g of a solid, m.p. 278°-284° C. The mother liquor was concentrated to a volume of 50 mL to provide a second crop of 0.32 g, m.p. 275°-281° C. The two crops were combined for analysis. Analysis: Calculated for C 16 H 13 N 5 : % C, 69.8; % H, 4.8; % N, 25.4; Found % C, 69.7; % H, 4.8; % N, 25.2.
EXAMPLE 15
2-Chloro-3-nitro-N-(4-pyridylmethyl)-4-quinolinamine
Using the general method of Example 11, 6.8 g of 2,4-dichloro-3-nitroquinoline was reacted with 4-(aminomethyl)pyridine to provide 7.8 g of crude 2-chloro-3-nitro-N-(4-pyridylmethyl)-4-quinolinamine. This material was used without further purification.
EXAMPLE 16
2-Chloro-N 4 -(4-pyridylmethyl)-3,4-quinolinediamine
Using the general method of Example 12, 5.0 g of 2-chloro-3-nitro-N-(4-pyridylmethyl)-4-quinolinamine was hydrogenated to provide 2.9 g of crude 2-chloro-N 4 -(4-pyridylmethyl)-3,4-quinolinediamine. This material was used without further purification.
EXAMPLE 17
4-Chloro-1-(4-pyridylmethyl)-1H-imidazo[4,5-c]quinoline
A mixture containing 2.9 g of 2-chloro-N 4 -(4-pyridylmethyl)-3,4-quinolinediamine and 3 mL of diethoxymethyl acetate was heated on a steam bath for about 45 minutes. The reaction suspension was dissolved in cold dilute aqueous hydrochloric acid. The solution was made basic with ammonium hydroxide. The resulting oily solid was taken up in ethyl acetate and purified by silica gel chromatography using first ethyl acetate then 5% methanol in ethyl acetate as the eluent to provide 0.9 g of a solid. A 100 mg portion was recrystallized from 5 mL of ethanol to provide 4-chloro-1-(4-pyridylmethyl)-1H-imidazo[4,5-c]quinoline, m.p. >300° C. Analysis: Calculated for C 16 ClH 11 N 4 : % C, 65.2; % H, 3.8; % N, 19.0; Found: % C, 64.8; % H, 3.9; % N, 18.5.
EXAMPLE 18
1-(4-Pyridylmethyl)-1H-imidazo[4,5-c]quinolin-4-amine
Using the general method of Example 14, 0.8 g of 4-chloro-1-(4-pyridylmethyl)-1H-imidazo[4,5c]quinoline was aminated to provide 0.25 g of 1-(4-pyridylmethyl)-1H-imidazo[4,5-c]quinolin-4-amine, m.p. >300° C. Analysis: Calculated for C 16 H 13 N 5 : % C, 69.8; % H, 4.8; % N, 25.4; Found: % C, 70.2; % H, 4.9; % N, 25.5.
EXAMPLE 19
Part A
1-[(3-Nitro-4-quinolinyl)amino]-2-propanol
A mixture containing 16 mL (0.22 mole) of thionyl chloride in 18 mL of dimethylformamide was added with stirring to a suspension of 38 g (0.2 mole) of 4-hydroxy-3-nitroguinoline. The resulting mixture was heated at reflux for 3 hours then cooled to -15° C. in a dry ice bath. A solution containing 18 mL (0.23 mole) of 1-amino-2-propanol and 30 mL (0.23 mole) triethylamine in 100 mL of methylene chloride was added dropwise with vigorous stirring to the chilled reaction mixture. After the addition was complete, the reaction mixture was heated at reflux for about 30 minutes. The reaction mixture was concentrated under vacuum to provide a yellow precipitate which was collected, rinsed with water and a small amount of ethanol and dried to provide 45 g of a yellow crystalline solid. A 1 g portion was recrystallized to provide 1-[(3-nitro-4-guinolinyl)amino]-2-propanol as a yellow crystalline solid, m.p. 209° -210° C. The structure was confirmed by nuclear magnetic resonance spectroscopy.
Part B
α,2-Dimethyl-1H-imidazo[4,5-c]quinoline-1-ethanol
Using the general method of Example 9, 44.2 g of 1-[(3-nitro-4-quinolinyl)amino]-2-propanol was hydrogenated to provide the intermediate diamine as a brown oil. Using the general method of Example 9, 17 g of the crude diamine was reacted with glacial acetic acid to provide 6.3 g of crude product. A sample was recrystallized from ether to provide α,2-dimethyl-1H-imidazo[4,5-c]quinoline-1-ethanol as a blue tinged solid, m.p. 176°-177° C. The structure was confirmed by nuclear magnetic resonance spectroscopy.
Part C
1-(2-Methoxypropyl)-2-methyl-1H-imidazo[4,5-c]quinoline
Sodium hydride (1 g of 60% ) was added to a suspension of 5 g (0.021 mole) of α,2-dimethyl-1H-imidazo[4,5-c]quinoline-1-ethanol in 100 mL of tetrahydrofuran. The resulting mixture was stirred for an hour. Methyl iodide (1.55 mL; 0.025 mole) was added and the reaction mixture was stirred for an hour. The reaction mixture was diluted with water then extracted three times with ethyl acetate. The ethyl acetate extracts were combined, dried over magnesium sulfate then concentrated under vacuum to provide 4.9 g of crude product as a brown oil. The oil was refluxed for one hour with 250 mL of hexane then filtered. The filtrate was cooled and the resulting precipitate was collected and dried to provide 2.4 g of a sticky light yellow powder. A sample was recrystallized from ether to provide 1-(2-methoxypropyl)-2-methyl-1H-imidazo[4,5c]quinoline as a white crystalline solid, m.p. 55°-57° C. The structure was confirmed by nuclear magnetic resonance spectroscopy.
EXAMPLE 20
1-(2-Methoxypropyl)-2-methyl-1H-imidazo[4,5-c]quinoline 5N Oxide
Using the general method of Example 10, 2.4 g of 1-(2-methoxypropyl)-2-methyl-1H-imidazo[4,5c]quinoline was oxidized using peracetic acid to provide 2.65 g of the crude N oxide as a yellow solid. A 100 mg sample was recrystallized from ethyl acetate to provide 1-(2-methoxypropyl)-2-methyl-1H-imidazo[4,5-c]quinoline 5N oxide as a solid, m.p. 146°-149° C. The structure was confirmed by nuclear magnetic resonance spectroscopy.
EXAMPLE 21
1-(2-Methoxypropyl)-2-methyl-1H-imidazo[4,5-c]quinolin-4-amine
Using the general method of Example 10, 2.55 g of 1-(2-methoxypropyl)-2-methyl-1H-imidazo[4,5c]quinoline 5N oxide was aminated to provide 2.5 g of crude product as a light orange powder. The powder was recrystallized from ethyl acetate to provide 1.46 g of 1-(2-methoxypropyl)-2-methyl-1H-imidazo[4,5-c]quinolin-4-amine as a white crystalline solid, m.p. 196°-197° C. Analysis: Calculated for C 15 H 18 N 4 O: % C, 66.6; % H, 6.7; % N, 20.7; Found: % C, 66.4; % H, 6.7; % N, 20.6.
Compounds of the invention were tested according to the test methods set forth below.
ANTIVIRAL ACTIVITY AND INTERFERON INDUCTION IN GUINEA PIGS
The test methods described below demonstrate the ability of compounds of the invention to reduce the number and severity of lesions developed by guinea pigs infected with Type II Herpes simplex virus and to induce the biosynthesis of interferon in guinea pigs.
Female Hartley guinea pigs weighing 200 to 250 g are anesthetized with methoxyflurane (available under the tradename METAFANE™ from Pitman-Moore, Inc., Washington Crossing, N.J.), after which the vaginal area is swabbed with a dry cotton swab. The guinea pigs are then infected intravaginally with a cotton swab saturated with Herpes simplex virus Type II strain 333 (1×10 5 plaque forming units/mL). Guinea pigs are assigned to groups of 7 animals; one group for each treatment and one to serve as a control (vehicle treated). The compounds of the invention are formulated in water containing 5% Tween 80 (a polyoxyethylene sorbitan monooleate available from Aldrich Chemical Company, Inc., Milwaukee, Wis.). The guinea pigs are treated orally once daily for four consecutive days starting 24 hours after infection.
Antiviral Activity
Antiviral activity is evaluated by comparing lesion development in compound-treated versus vehicle-treated guinea pigs. External lesions are scored 4, 7, 8 and 9 days after infection using the following scale: 0--no lesion, 1--redness and swelling, 2--a few small vesicles, 3--several large vesicles, 4--large ulcers with necrosis and 5--paralysis. The maximum lesion score of each guinea pig is used to calculate the percentage lesion inhibition. The percentage lesion inhibition is calculated as follows: ##EQU1## Interferon Induction
Twenty-four hours after the initial dose of test compound has been administered, blood is obtained from 3 guinea pigs from each treatment group by cardiac puncture of methoxyflurane anesthetized animals. Blood is pooled and allowed to clot at room temperature. After low speed centrifugation, serum is collected and stored at -70° C. until analysis.
Interferon levels in the guinea pig serum are determined in a standard microtiter assay using transformed guinea pig cells (ATCC CRL 1405). The interferon assay is done in 96 well microtiter plates. Confluent monolayers of transformed guinea pig cells are treated with dilutions of guinea pig serum made with medium 199 (GIBCO, Grand Island, N.Y.). The cell and serum dilutions are incubated at 37° C. overnight. The following day, the medium and serum are removed and about 10 plaque forming units of Mengovirus are added to each well. Controls consist of wells that receive no guinea pig serum (virus positive control) and wells that receive no virus (virus negative control). Cells and virus are incubated for 2 to 3 days at 37° C. before quantifying for viral cytopathic effect. The viral cytopathic effect is quantified by staining with 0.05% crystal violet followed by spectrophotometric absorbance measurements. The titer of interferon in serum is expressed as units/mL and is the reciprocal of the highest dilution that protects cells from virus.
Results are shown in the table below.
______________________________________Antiviral Activity and Interferon Induction in Guinea PigsCompound of Dose % Lesion ReferenceExample mg/kg Inhibition Units/mL______________________________________1 2 55% not determined2 2 57% 60014 2 20% not determined18 2 0% not determined18 5 88% >12,800______________________________________
These results show that the tested compounds of the invention inhibit Herpes simplex virus type II lesions in guinea pigs. Those compounds tested were also shown to induce interferon biosynthesis in guinea pigs.
INTERFERON-α INDUCTION IN HUMAN CELLS
The test methods described below demonstrate the ability of compounds of the invention to induce the biosynthesis of interferon-α in human cells.
An in vitro human blood cell system was used to assess interferon-α induction by compounds of the invention. Activity is based on the measurement of interferon secreted into culture medium. Interferon is measured by bioassay.
Blood Cell Preparation for Culture
Whole blood is collected by venipuncture into EDTA vacutainer tubes. Peripheral blood mononuclear cells (PBM's) are prepared by LeucoPREP™ Brand Cell Separation Tubes (available from Becton Dickinson) and cultured in RPMI 1640 medium (available from GIBCO, Grand Island, N.Y.) containing 25 mM HEPES 4-(2-hydroxyethylpiperazine-N'-2-ethanesulfonic acid and L-glutamine (1% penicillin-streptomycin solution added) with 10% autologous serum added. Alternatively, whole blood diluted 1:10 with RPMI 1640 medium supplemented with 25 mM HEPES and L-glutamine with 1% penicillin-streptomycin solution added can be used. 200 μL portions of diluted whole blood or of PBM in medium are added to 96 well (flat bottom) MicroTest™III tissue culture plates.
Compound Preparation
The compounds are solubilized in water, ethanol, or dimethyl sulfoxide then diluted with distilled water, 0.01N sodium hydroxide or 0.01N hydrochloric acid. (The choice of solvent will depend on the chemical characteristics of the compound being tested.)
Incubation
The solution of test compound is added (in a volume less than or equal to 50 μL) to the wells containing 200 μL of PBM in medium or diluted whole blood. Solvent and/or medium is added to control wells (i.e., wells with no test compound) and also as needed to adjust the final volume of each well to 250 μL. The plates are covered with plastic lids, vortexed gently and then incubated for 24 hours at 37° C. with a 5% carbon dioxide atmosphere.
Separation
Following incubation, the plates are covered with PARAFILM™ and then centrifuged at 1000 rpm for 15 minutes at 4° C. in a Damon IEC Model CRU-5000 centrifuge. Medium (about 175 μL) is removed from 4 to 8 wells and pooled into 2 mL sterile freezing vials. Samples are maintained at -70° C. until analysis.
Interferon Analysis/Calculation
Interferon is determined by bioassay using A549 human lung carcinoma cells challenged with encephalomyocarditis. The details of the bioassay method are described by G. L. Brennan and L. H. Kronenberg in "Automated Bioassay of Interferons in Micro-test Plates" Biotechniques, June/July; 78, 1983., incorporated herein by reference. Briefly stated the method is as follows: interferon dilutions and A549 cells are incubated at 37° C. for 12 to 24 hours. The incubated cells are infected with an inoculum of encephalomyocarditis virus. The infected cells are incubated for an additional period at 37° C. before quantifying for viral cytopathic effect. The viral cytopathic effect is quantified by staining followed by spectrophotometric absorbance measurements. Results are expressed as α interferon reference units/mL based on the value obtained for NIH HU IF-L standard. The interferon was identified as essentially all interferon alpha by testing in checkerboard neutralization assays against rabbit anti-human interferon (beta) and goat anti-human interferon (alpha) using A549 cell monolayers challenged with encephalomyocarditis virus. Results are shown in the table below wherein the absence of an entry indicates that the compound was not tested at the particular dose concentration. Results designated as "<" a certain number indicate that interferon was not detectable in amounts above the lower sensitivity level of the assay.
__________________________________________________________________________Interferon - Induction in Human CellsReference Units/mLDose Concentration (μg/mL)Compound of Example 0.01 0.05 0.10 0.50 1.0 2.5 5.0 10 Cell Type__________________________________________________________________________1 * * * * 210 * 630 360 whole blood2 * * * 21 * 190 110 * whole blood3 * * * 110 * 140 64 * whole blood5 * * * * 1.8 * 84 190 whole blood7 * * <1.8 <1.8 <1.8 * 84 * PBM10 <4 24 3300 1600 490 * 490 * PBM14 <1 <1 <1 <1 570 * 430 * PBM18 <1 <1 <1 430 330 * 430 * PBM21 <4.5 160 830 830 830 * 710 * PBM__________________________________________________________________________ *not determined
These results show that the tested compounds of the invention induce interferon biosynthesis at detectable levels in human whole blood and/or PBM cells over a wide range of dose concentrations. | 1-substituted 1H-imidazo[4,5-c]quinolin-4-amines, active as immunomodulators and antiviral agents. Also, intermediates in the preparation of such compounds, pharmaceutical compositions, and pharmacological methods of use. | 2 |
PRIORITY CLAIM
This application claims the benefit of U.S. Provisional Application No. 61/694,248 filed on Aug. 28, 2012.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention generally relates to the formation of polymeric fibers from biorenewable materials.
2. Description of the Relevant Art
The vast majority of commercially produced synthetic polymers used for fiber applications are made entirely from non-renewable, petroleum-based feedstocks. By substituting these source materials with biorenewable alternatives, the dependence on finite resources is reduced; harnessing solar energy through agriculture to transform carbon dioxide into useful monomers may be a more environmentally friendly option. Because annual worldwide production of nonwoven fibers (or “nonwovens”) is in the billions of kilograms, incorporating even small amounts of biorenewable materials in these products could significantly impact the allocation of non-renewable resources. Two important examples of commercially available polymers containing biorenewable materials from which fibers can be formed are poly(lactide) (PLA) and poly(trimethylene terephthalate). However, these and other preformed synthetic polymers still require heating to temperatures above their melting or glass transition temperature, and/or solvent to reduce their viscosities for processing into functional fiber products. Polymeric fibers made at least in part from biorenewable feedstocks and processed without applied heat or solvent would likely be “greener” than conventional, petroleum-derived fibers formed using heat and/or solvent.
SUMMARY OF THE INVENTION
In an embodiment, a composition for use in forming fibers, comprising a monomer derived from a biorenewable source, a polymer, a cross-linker, and a photoinitiator. The monomer may be any monomer derived from a biological source.
In an embodiment, a method of forming fibers includes placing a fiber foil ring composition in a fiber producing device, the fiber forming composition comprising a monomer derived from a biorenewable source, a polymer, a cross-linker and a photoinitiator; ejecting at least a portion of the fiber forming composition through an opening of the fiber forming device; and subject the ejected fiber forming composition to light at wavelengths sufficient to activate the photoinitiator.
The fiber producing device may be an electrospinning device, a melt blowing device, or a centrifugal spinning device. The fiber forming composition includes at least 10% by weight of a monomer derived from a biorenewable source. In some embodiments, the polymer comprises an acrylate. In some embodiments, the monomer derived from a biorenewable source comprises acrylated epoxidized soybean oil.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the present invention will become apparent to those skilled in the art with the benefit of the following detailed description of embodiments and upon reference to the accompanying drawings in which:
FIG. 1 depicts a schematic diagram of an electrospinning apparatus;
FIG. 2 depicts an NMR spectrum of acrylated epoxidized soybean oil;
FIG. 3 shows SEM micrographs of fibers composed of, by mass, 51% AESO, 29% DPPA, 14% PETT, and 6% Irgacure® 2100;
FIG. 4 shows SEM micrographs of fibers composed of, by mass, 60% AESO, 22% DPPA, 12% PETT, and 6% Irgacure® 2100;
FIG. 5 shows SEM micrographs of fibers composed of, by mass, 70% AESO, 14% DPPA, 10% PETT, and 6% Irgacure® 2100;
FIG. 6 shows SEM micrographs of fibers composed of, by mass, 80% AESO, 6% DPPA, 8% PETT, and 6% Irgacure® 2100;
FIG. 7 shows SEM micrographs of fibers composed of, by mass, 87% AESO, 7% PETT, and 6% Irgacure® 2100;
FIG. 8A depicts a representative micrograph of fibers produced from the composition of Table 1;
FIG. 8B depicts a diameter distribution of fibers produced from the composition of Table 1,
FIG. 8C depicts a representative SEM micrograph of the fibers produced from the composition of Table 1 after toluene soaking;
FIG. 8D depicts a representative SEM of fibers made when DPPA is omitted entirely from the composition of Table 1;
FIG. 9A depicts the conversion of chemical groups at short irradiation times; and
FIG. 9B depicts the conversion of chemical groups at radiation times of up to 150 s.
While the invention may be 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. The drawings may not be to scale. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but to the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It is to be understood the present invention is not limited to particular devices or methods, which may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include singular and plural referents unless the content clearly dictates otherwise. Furthermore, the word “may” is used throughout this application in a permissive sense (i.e., having the potential to, being able to), not in a mandatory sense (i.e., must). The term “include,” and derivations thereof, mean “including, but not limited to.” The term “coupled” means directly or indirectly connected.
This general method for the manufacture of nonwoven fibers does not use applied heat or volatile chemical solvents. A mixture of a monomer or mixture of monomers with at least one monomer being derived from a biorenewable source is ejected from a fiber producing device and photopolymerized in-situ to produce solid cross-linked fibers. The liquid composition used to make fibers was substantially nonvolatile, since all its substituents possessed very high boiling points. In one embodiment, electrospinning is used to form the fibers. Electrospinning is a fiber formation technique that uses a strong electric field to draw a fluid into a thin jet. Other techniques that may be sued to form the fibers include melt blowing (e.g., hot air jets) or centrifugal spinning. In principle, the general method of photopolymerizing liquid monomers during fiber formation is applicable to any of these processes. This approach is different than other reports where fibers are formed from preformed polymers (via melt or solution based spinning techniques) and are subsequently photocrosslinked.
Vegetable oils are one biorenewable source to which many useful chemical functionalities have been introduced to make useful alternatives to petroleum-based monomers. In the present work, the process of simultaneous photopolymerization and fiber formation is made even greener by incorporating a commercially available, biorenewable, monomer. Examples of monomers derived from a biorenewable source include, but are not limited to acrylated vegetable oil or thiol functionalized vegetable oil. For example, acrylated epoxidized soybean oil (AESO) may be used to form commercially useful fibers in place of petroleum based monomers.
Acrylated vegetables oils may be manufactured from vegetable oils composed of triglycerides, using known processes (see, for example, Lu et al. Polymer 2005, 46, (1), 71-80). In the process described by Lu et al., secondary alkenes present in the vegetable oil are converted to pendant acrylate groups. For example, AESO is generally acrylated as shown in order to increase the molecule's reactivity, making it a more useful monomer in radiation-cure applications. AESO can be a suitable replacement for petroleum-derived multifunctional acrylates in many applications. For example, compositions containing AESO have been explored by others as biobased alternatives to conventional sheet molding compound resins, thermosetting foams, membrane surface modifiers, UV curable inks and coatings, and solar cell electrode binders. AESO can be a suitable replacement for petroleum-derived multifunctional acrylates in many applications. For example, compositions containing AESO have been explored by others as biobased alternatives to conventional sheet molding compound resins, thermosetting foams, membrane surface modifiers, UV curable inks and coatings, and solar cell electrode binders.
In an embodiment, fibers may be formed containing over 50 wt. % AESO using electrospinning, melt-blowing or centrifugal spinning Materials used to make the fibers other than AESO included an acrylate compound, a crosslinker, and a photoinitiator.
An acrylate compound includes one or more ethylenic substituents. Acrylate compounds include, but are not limited to, C 1 -C 20 alkyl acrylates, C 1 -C 20 alkyl methacrylates, C 2 -C 20 alkenyl acrylates, C 2 -C 20 alkenyl methacrylates, C 5 -C 8 cycloalkyl acrylates, C 5 -C 8 cycloalkyl methacrylates, phenyl acrylates, phenyl methacrylates, phenyl(C 1 -C 9 )alkyl acrylates, phenyl(C 1 -C 9 )alkyl methacrylates, substituted phenyl (C 1 -C 9 )alkyl acrylates, substituted phenyl(C 1 -C 9 )alkyl methacrylates, phenoxy(C 1 -C 9 )alkyl acrylates, phenoxy(C 1 -C 9 )alkyl methacrylates, substituted phenoxy(C 1 -C 9 )alkyl acrylates, substituted phenoxy(C 1 -C 9 )alkyl methacrylates, C 1 -C 4 alkoxy(C 2 -C 4 )alkyl acrylates, C 1 -C 4 alkoxy (C 2 -C 4 )alkyl methacrylates, C 1 -C 4 alkoxy(C 1 -C 4 )alkoxy(C 2 -C 4 )alkyl acrylates, C 1 -C 4 alkoxy(C 1 -C 4 )alkoxy(C 2 -C 4 )alkyl methacrylates, C 2 -C 4 oxiranyl acrylates, C 2 -C 4 oxiranyl methacrylates, copolymerizable di-, tri- or tetra-acrylate monomers, copolymerizable di-, tri-, or tetra-methacrylate monomers.
Examples of such monomers include methyl methacrylate, ethyl methacrylate, propyl methacrylate, isopropyl methacrylate, butyl methacrylate, isobutyl methacrylate, hexyl methacrylate, 2-ethylhexyl methacrylate, nonyl methacrylate, lauryl methacrylate, stearyl methacrylate, isodecyl methacrylate, ethyl acrylate, methyl acrylate, propyl acrylate, isopropyl acrylate, butyl acrylate, isobutyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, nonyl acrylate, lauryl acrylate, stearyl acrylate, isodecyl acrylate, ethylene methacrylate, propylene methacrylate, isopropylene methacrylate, butane methacrylate, isobutylene methacrylate, hexene methacrylate, 2-ethylhexene methacrylate, nonene methacrylate, isodecene methacrylate, ethylene acrylate, propylene acrylate, isopropylene, hexene acrylate, 2-ethylhexene acrylate, nonene acrylate, isodecene acrylate, cyclopentyl methacrylate, 4-methyl cyclohexyl acrylate, benzyl methacrylate, o-bromobenzyl methacrylate, phenyl methacrylate, nonylphenyl methacrylate, benzyl acrylate, o-bromobenzyl phenyl acrylate, nonylphenyl acrylate, phenethyl methacrylate, phenoxy methacrylate, phenylpropyl methacrylate, nonylphenylethyl methacrylate, phenethyl acrylate, phenoxy acrylate, phenylpropyl acrylate, nonylphenylethyl acrylate, 2-ethoxyethoxymethyl acrylate, ethoxyethoxyethyl methacrylate, 2-ethoxyethoxymethyl acrylate, ethoxyethoxyethyl acrylate (SR-256), glycidyl methacrylate, glycidyl acrylate, 2,3-epoxybutyl methacrylate, 2,3-epoxybutyl acrylate, 3,4-epoxybutyl acrylate, 3,4-epoxybutyl methacrylate, 2,3-epoxypropyl methacrylate, 2,3-epoxypropyl acrylate 2-methoxyethyl methacrylate, 2-ethoxyethyl methacrylate, 2-butoxyethyl methacrylate, 2-methoxyethyl acrylate, 2-ethoxyethyl acrylate, 2-butoxyethyl acrylate, tetrahydrofurfuryl acrylate, tetrahydrofurfuryl methacrylate, ethoxylated bisphenol-A-dimethacrylate, ethylene glycol diacrylate, 1,2-propane diol diacrylate, 1,3-propane diol diacrylate, 1,2-propane diol dimethacrylate, 1,3-propane diol dimethacrylate, 1,4-butane diol diacrylate, 1,3-butane diol dimethacrylate, 1,4-butane diol dimethacrylate, 1,5 pentane diol diacrylate, 2,5-dimethyl-1,6-hexane diol dimethacrylate, diethylene glycol diacrylate, polyethylene glycol (400) diacrylate (SR-344), diethylene glycol dimethacrylate (SR-231), trimethylolpropane trimethacrylate, tetraethylene glycol diacrylate (SR-306), tetraethylene glycol dimethacrylate, dipropylene glycol dimethacrylate, trimethylolpropane triacrylate (SR-351), glycerol triacrylate, glycerol trimethacrylate, pentaerythritol triacrylate, pentaerythritol dimethacrylate, pentaerythritol tetracrylate, pentaerythritol tetramethacrylate, dipentaerythritol pentaacrylate (SR-399), ethoxylated 4 bisphenol A dimethacrylate (SR-540), ethoxylated 2 bisphenol A dimethacrylate (SR-348), tris (2 hydroxyethyl) isocyanurate triacrylate (SR-368), ethoxylated 4 bisphenol A diacrylate (SR-601), ethoxylated 10 bisphenol A dimethacrylate (SR-480), ethoxylated 3 trimethylopropane triacrylate (SR-454), ethoxylated 4 pentaerithritol tetraacrylate (SR-494), tridecyl acrylate (SR-489), 3-(trimethoxysilyl) propyl methacrylate (PMATMS), 3-glycidoxypropyltrimethoxysilane (GMPTMS), neopentyl glycol diacrylate (SR-247), isobornyl methacrylate (SR-243), tripropylene glycol diacrylate (SR-306), aromatic monoacrylate (CN-131), vinyl containing monomers such as vinyl acetate and 1-vinyl-2 pyrrolidone, epoxy acrylates such as CN 104 and CN 120 which are commercially available from Sartomer Company, and various urethane acrylates such as CN-962, CN-964, CN-980, and CN-965 all commercially available from Sartomer Company.
Other monomers that may be present include, but are not limited to, vinyl ethers, norbornenes or thiol compounds.
Photoinitiators that may be used include α-hydroxy ketones, α-diketones, acylphosphine oxides, bis-acylphosphine oxides or mixtures thereof. Examples of photoinitiators that may be used include, but are not limited to: phenyl bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, commercially available from Ciba Additives in Tarrytown, N.Y. under the trade name of Irgacure 819; a mixture of phenyl bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide and 1-hydroxycyclohexylphenyl ketone, commercially available from Ciba Additives under the trade name of Irgacure 184; a mixture of phenyl bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide and 2,4,6-trimethylbenzoylphenylphosphinic acid ethyl ester, commercially available from Ciba Additives under the trade name of Irgacure 2100; 2-hydroxy-2-methyl-1-phenylpropane-1-one commercially available from Ciba Additives under the trade name of Darocur 1173; and benzophenone.
Crosslinkers may be acrylate monomers having two or more ethylenic substituents. Examples of suitable acrylate crosslinkers include, but are not limited to: ethoxylated bisphenol-A-dimethacrylate, ethylene glycol diacrylate, 1,2-propane diol diacrylate, 1,3-propane diol diacrylate, 1,2-propane diol dimethacrylate, 1,3-propane diol dimethacrylate, 1,4-butane diol diacrylate, 1,3-butane diol dimethacrylate, 1,4-butane diol dimethacrylate, 1,5 pentane diol diacrylate, 2,5-dimethyl-1,6-hexane diol dimethacrylate, diethylene glycol diacrylate, polyethylene glycol (400) diacrylate (SR-344), diethylene glycol dimethacrylate (SR-231), trimethylolpropane trimethacrylate, tetraethylene glycol diacrylate (SR-306), tetraethylene glycol dimethacrylate, dipropylene glycol dimethacrylate, trimethylolpropane triacrylate (SR-351), glycerol triacrylate, glycerol trimethacrylate, pentaerythritol triacrylate, pentaerythritol dimethacrylate, pentaerythritol tetracrylate, pentaerythritol tetramethacrylate, dipentaerythritol pentaacrylate (SR-399), ethoxylated 4 bisphenol A dimethacrylate (SR-540), ethoxylated 2 bisphenol A dimethacrylate (SR-348), tris (2 hydroxyethyl) isocyanurate triacrylate (SR-368), ethoxylated 4 bisphenol A diacrylate (SR-601), ethoxylated 10 bisphenol A dimethacrylate (SR-480), ethoxylated 3 trimethylopropane triacrylate (SR-454), and ethoxylated 4 pentaerithritol tetraacrylate (SR-494).
In an embodiment, a composition includes AESO, an acrylate polymer (e.g., dipentarythritol pentaacrylate (DPPA)), a crosslinker (e.g., pentaerythritol tetrakis(3-mercaptopropionate) (PETT)), and a photoinitiator (e.g., Irgacure® 2100). AESO used in this embodiment has, on average, a molecular weight of 1138 g/mol and 2.7 acrylate groups per molecule. DPPA has 5 acrylate groups per average molecule and PETT has 4 thiol groups per molecule. We targeted a thiol to -ene ratio, r, of between 0.18 and 0.30 to ensure proper -ene photoconversion during fiber production.
The average -ene functionality, f ene , represents the average number of acrylate groups per -ene monomer in fiber precursor compositions containing both AESO and DPPA and is defined as
f ene =f AESO m AESO +f DPPA (1 −m AESO ). (1)
f AESO and f DPPA are the number of acrylate groups on an AESO or DPPA monomer, respectively. m AESO is the mole fraction of total -ene groups in the composition contributed by the AESO monomers.
Materials
Acrylated epoxidized soybean oil (AESO, Sigma Aldrich), pentaerythritol tetrakis(3-mercaptopropionate) (PETT, Sigma Aldrich), dipentaerythritol pentaacrylate (DPPA, Sartomer), and Irgacure® 2100 (BASF Corporation) were used as received to make photocurable monomer mixtures. We used Irgacure® 2100, a liquid photoinitiator formulation based on bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide, because its light absorption spectra overlaps with the emission spectra of our light source and it mixes easily with the other materials. Nuclear magnetic resonance (NMR) spectroscopy indicated that AESO contains 2.7 average acrylate groups per molecule, and the average molecular weight was 1138 g/mol. On average, DPPA has 5 acrylate groups per molecule and a molecular weight of 524.51 g/mol; PETT has 4 thiol groups per molecule and a molecular weight of 488.66 g/mol.
Electrospinning Methods and Conditions
Precise quantities of monomers and photoinitiator were placed in a vial and mixed by 3 minutes of stirring followed by 5 minutes of shaking by a vibratory mixer. Then the mixture was placed under vacuum (10 torr) to remove air bubbles. The sample was loaded into an opaque syringe, which was then fitted with a blunt tip, 0.8 mm inner diameter needle. Exposure of the sample to ultraviolet room light was minimized in each of these steps to limit ambient curing.
A schematic diagram of the electrospinning apparatus is shown in FIG. 1 . For the experiments, the grounded collector was positioned 7.6 cm from the needle tip, from which monomers were fed at a rate of 10 mL/h. 10 kV of positive DC charge was applied to the needle tip, creating an electric field of sufficient strength to drive a jet of solution towards the grounded collector. The broadband light source, fitted with a collimating lens, was positioned about 2.5 cm from the liquid jet and angled so that it illuminated both the collected fibers and the liquid jet near the collector. At this distance, the light intensity was measured by a radiometer to be 490 mW/cm 2 .
Scanning Electron Microscopy (SEM)
Fiber quality and the diameter distribution was measured by SEM. Fibers were cut from the photocured mat and affixed to carbon tape placed on the top of an SEM sample post. The post was then sputter-coated from an Au/Pd target to deposit a charge dissipation layer on the fiber surface. The sample was then loaded into a Hitachi S-4500 SEM operated with 10-15 kV accelerating voltage, a working distance of 14-17 mm, and a secondary electron detector. Subsequent analysis of the images using ImageJ gave the distribution of fiber diameters.
Real Time Infrared Spectroscopy (RTIR)
Infrared spectra of monomer mixtures during photo-exposure were measured using a Nicolet 6700 FT-IR spectrometer with a KBr beamsplitter and a MCT-A detector (Thermo Fisher Scientific, Waltham, Mass.). A horizontal transmission accessory (Harrick Scientific Products, Inc., Pleasantville, N.Y.) enabled measurement of supported liquid films. A polished germanium crystal disc was placed in the beam path close to the detector as a longpass filter. This prevented the broadband light used to cure the film from altering the recorded spectra. The spectrometer and horizontal transmission accessory were continuously purged with dry, CO 2 free air. Background scans and sample spectra were taken following 20 minutes of purging after loading the as-received NaCl crystal or sample into the spectrometer, respectively. Spectra were recorded every 0.1 s as an average of 2 scans with 8 cm −1 resolution. Data collection and calculation of peak areas were performed using the instrument's Omnic software.
Samples were prepared by spin coating a monomer mixture on a polished, 25 mm diameter, 4 mm thick NaCl crystal (International Crystal Laboratories, Garfield, N.J.) at 2500 RPM for 1 minute. The sample was then loaded into the spectrometer. When the liquid monomer mixtures were irradiated by UV light, absorption peaks corresponding to acrylate (1652-1582 cm −1 ) and thiol (2599-2540 cm −1 ) quickly decreased in size. To account for any changes in sample thickness during the experiment, the area under acrylate and thiol peaks, for any given irradiation time, were self-referenced to a photochemically stable one (hydroxyl, 3643-3203 cm −1 ). Conversion of acrylate or thiol groups at a given irradiation time is the decrease in self-referenced peak area from the initial self-referenced peak area, A t −A 0 , relative to the initial self-referenced peak area, A 0 (i.e. Conversion=(A t −A 0 )/A 0 ).
Characterization of AESO by Nuclear Magnetic Resonance (NMR)
The NMR spectrum of acrylated epoxidized soybean oil (Sigma Aldrich, AESO) was recorded on a Varian 400 MHz DirectDrive NMR using CDCl 3 (0.05 v/v % tetramethylsilane, Cambridge Isotope Laboratories) as solvent. The spectrum is shown in FIG. 2 , using SpinWorks v. 3.1.8.1 for data analysis. The area under peaks corresponding to acrylate groups was compared quantitatively to two other well-defined peaks to determine the average number of acrylate groups per AESO molecule as 2.7.
Refined soybean oil is composed almost entirely of triglyceride molecules of varying fatty acid length and degree of unsaturation. Their average molecular weight is 871 g/mol and their average number of secondary alkenes is 4.6. Therefore, the molecular weight of an AESO molecule with 2.7 acrylate groups per molecule is 1138 g/mol, if all unsaturated carbons were epoxidized in the intermediate step of AESO manufacture.
Estimation of Biobased Carbon Content in Fibers
The amount of biobased carbon was calculated on the basis of fiber composition. The only source of biobased carbon is AESO, which has 56.3 biobased carbons and 8.1 non-biobased carbons per molecule, on average. The exact composition of Irgacure® 2100, which makes up 6 wt. % of the fibers, is not known. For our estimations we assumed Irgacure® 2100 had the structure of one of its known constituents, bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide.
The biobased carbon content of fibers is high because the carbon density of AESO is very high relative to other fiber components. For example, we estimate that fibers containing 51 wt. % AESO (the “good fibers” composition described in Table 1 and shown in FIG. 3 ) have 49% biobased carbon and the fibers containing 87 wt. % AESO (the “no DPPA” composition described in Table 1 and shown in FIG. 7 have 72% biobased carbon.
FIG. 3 shows SEM micrographs of fibers composed of, by mass, 51% AESO, 29% DPPA, 14% PETT, and 6% Irgacure® 2100. r=0.28 and f ene =4.3. An estimated 49% of the carbon in these fibers is biobased.
FIG. 4 shows SEM micrographs of fibers composed of, by mass, 60% AESO, 22% DPPA, 12% PETT, and 6% Irgacure® 2100. r=0.28 and f ene =4.1. An estimated 53% of the carbon in these fibers is biobased.
FIG. 5 shows SEM micrographs of fibers composed of, by mass, 70% AESO, 14% DPPA, 10% PETT, and 6% Irgacure® 2100. r=0.28 and f ene =3.7. An estimated 59% of the carbon in these fibers is biobased.
FIG. 6 shows SEM micrographs of fibers composed of, by mass, 80% AESO, 6% DPPA, 8% PETT, and 6% Irgacure® 2100. r=0.28 and f ene =3.2. An estimated 65% of the carbon in these fibers is biobased.
FIG. 7 shows SEM micrographs of fibers composed of, by mass, 87% AESO, 7% PETT, and 6% Irgacure® 2100. r=0.28 and f ene =2.7. An estimated 72% of the carbon in these fibers is biobased.
Discussion
A composition that could be reproducibly electrospun and photocured into solid fibers is described in Table 1 and referred to throughout the text as “good fibers”. In this monomer mixture an estimated 49% of the carbon is biobased. A representative micrograph of these fibers taken by scanning electron microscopy (SEM) is shown in FIG. 8A . The fibers have a smooth surface without wrinkles or beads, and relatively few fused junctions where fibers have become attached to one another prior to being completely cured. The diameter distribution of these fibers was taken from 236 diameter measurements, and is shown in FIG. 8B . The mean fiber diameter is 30 μm, with a standard deviation of 7 μm.
TABLE 1
Summary of compositions used in FIGS. 2 and 3.
Composition
Name and
% composition, by mass
Representative
Irgacure ®
f
ane
SEM
AESO
DPPA
PETT
2100
r
(Eq. S1)
good fibers,
51
29
14
6
0.28
4.3
FIG. 2a
no PETT
59
34
0
6
0
4.3
no DPPA,
87
0
7
6
0.28
2.7
FIG. 2d
The thermochemical stability of the fibers containing 51% AESO was explored by soaking fibers in hot toluene. The as-spun fiber mats were placed in 75° C. toluene, removed after 5 hours, and then dried under vacuum. Toluene readily dissolves all of the substituents used to make the fibers, but not the final cross-linked fibers. A representative SEM micrograph of the fibers after toluene soaking is shown in FIG. 8C . The fibers retain their shape, and no new features such as wrinkling or cracking develop on the surface.
Fibers with higher biorenewable content than the composition in FIG. 8A were also made. These compositions retained r=0.28 and the same photoinitiator content as above, but higher AESO content, and lower DPPA and PETT content. However, fibers made from the compositions with higher biorenewable content appeared to have more defects, and less overall fibers were made in a given electrospinning run. The compositions that did not make as many fibers exhibited some fibers were not fully cured when they reached the collector, at which point the fluid coalesced. This could be easily remedied by implementing a more intense light source. A representative SEM micrograph of fibers made when DPPA is omitted entirely from the composition is shown in FIG. 8D (i.e., -ene component is 100% AESO). This composition is described in Table 1 and referred to in the text as “no DPPA”, and contains about 72% biobased carbon. The surface of many of these fibers is not smooth and contains small defects. Additionally, more fused fiber junctions are present. These features in FIG. 8D are phenomenologically consistent with a slower rate of photocuring compared to compositions used to generate the highest quality fibers shown in FIG. 8A .
To gain greater insight into the factors influencing photocuring speed and fiber formation, real-time Fourier transform infrared spectroscopy (RTIR) was performed on three different monomer compositions. The results showing conversion of chemical groups at short irradiation times (<5 s) are shown in FIG. 9A . This timescale is useful for fiber formation because the fluid jet can break into droplets if it is not photocured extremely quickly. Additionally, RTIR data extending to 150 s are shown in FIG. 9B . The mixtures are described in terms of composition and reaction stoichiometry in Table 1 and listed according to the data labels used in the legend of FIG. 9 .
The data representing the “good fibers” composition is described first. The photoconversion of thiol and -ene groups increases rapidly in the early stages of irradiation, and the photo-conversions of thiol and -ene groups in this composition proceed at nearly identical rates. At any given irradiation time the conversion of -enes is no more than 4% higher than that of thiol groups. Note that since the monomer composition contains a 3.5 fold excess of -ene groups relative to thiols, this means that acrylates are homopolymerizing at a faster rate than they are reacting with thiol groups.
To demonstrate the necessity of thiol-ene chemistry for this application, the photoconversion of -ene groups for a mixture that omits PETT was measured, called “no PETT”, yet has the same f ene . and photoinitiator content as the “good fibers” composition. Without a thiol component, the polymerization is oxygen inhibited and the photoconversion rate is greatly suppressed.
The photoconversion kinetics of the “no DPPA” composition were also measured, which retains the same r and photoinitiator content as the “good fibers” composition. The photoconversion of the “no DPPA” composition is actually as fast as that of the “good fibers” composition for the first 0.7 s of irradiation, and for any given time after that the conversion of the “no DPPA” composition is higher than the “good fibers” composition. Initially, this may appear incompatible with our previous observation that higher quality fibers are made with a composition containing both AESO and DPPA as -ene components than a composition that omits DPPA entirely (see FIGS. 2 a and 2 d ). However, since f ene is considerably lower for the “no DPPA” composition, any prediction of the gel point will undoubtedly be higher, and the irradiation time needed to form a gel will be correspondingly longer.
To quantitatively estimate the impact of f ene on the irradiation time necessary to photo-crosslink the fiber precursors, t α , the gelation theory of Bowman and coworkers [Reddy, S. K.; Okay, O.; Bowman, C. N. Macromolecules 2006, 39, (25), 8832-8843] was applied to the RTIR data for the “good fibers” and “no DPPA” compositions. Their predictive expressions for the critical conversion to reach a gel, p α , in thiol-acrylate polymerizations (Eq. 38 in Bowman) are simplified by neglecting termination and cyclization effects and setting the conversion of -ene groups equal to the conversion of thiol groups, as justified by the data in FIG. 3 . p α then found by solving
2 r ( f _ ene - 1 ) k pCC k CT p α + ( f SH - 1 ) ( f _ ene - 1 ) ( 1 + 1 r k pCC k CT ) p α 2 = 1 ( 2 )
Here,
k pCC k CT = 1.5
is the ratio of propagation to chain transfer kinetic parameters for thiol-acrylate systems 33 and f SH is the number of thiol groups per PETT monomer. Eq. 2 predicts p α =2.7% for the “good fibers” composition and p α =5.0% for the “no DPPA” composition. Using these values of p α to extract t α from RTIR data by interpolation yields t α =61 ms for the “good fibers” composition and t α =132 ms for the “no DPPA” composition. While higher conversions than the values of p α predicted by Eq. 2 are undoubtedly necessary to lower the sol fraction and obtain high quality fibers, the RTIR data suggests that the “no DPPA” composition cures about twice as slow as the “good fibers” composition and is indeed consistent with the latter yielding higher quality fibers.
In summary, chemically stable fibers containing over 50 wt. % of AESO, with an average diameter of 30 μm, can be made by photopolymerizing a monomer composition during the fiber formation process. It is estimated that fibers with 51 wt. % AESO have about 49% biobased carbon. This process can be viewed as replacing the thermal energy needed for melt processing with light energy. It is worth noting that, while the amount of thermal energy needed to render a given thermoplastic processable is related to thermodynamic constants such as the heat of melting, opportunity exists to improve the energy efficiency of this photocuring-based process. By precisely tuning the light source emission spectra to the photoinitiator absorption spectra, and photocuring many monomer jets in the same irradiation area, this process could be made more energy efficient.
In this patent, certain U.S. patents, U.S. patent applications, and other materials (e.g., articles) have been incorporated by reference. The text of such U.S. patents, U.S. patent applications, and other materials is, however, only incorporated by reference to the extent that no conflict exists between such text and the other statements and drawings set forth herein. In the event of such conflict, then any such conflicting text in such incorporated by reference U.S. patents, U.S. patent applications, and other materials is specifically not incorporated by reference in this patent.
Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as examples of embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims. | Fibers can be formed from monomers derived from a biorenewable source. In an embodiment, a fiber forming composition that includes a monomer or mixture of monomers with at least one monomer being derived from a biorenewable source in placed in a fiber producing device. At least a portion of the fiber forming composition is ejected through an opening of the fiber forming device. The ejected fiber forming composition is subjected to light at wavelengths sufficient to activate a reaction which causes solidification of the fiber as the fibers are ejected from the fiber producing device. | 3 |
RELATED APPLICATION DATA
This application is a continuation of U.S. patent application Ser. No. 11/382,453, filed May 9, 2006. The Ser. No. 11/382,453 application is a continuation of U.S. patent application Ser. No. 10/002,954, filed Oct. 23, 2001 (now U.S. Pat. No. 7,042,470), which is a continuation-in-part of U.S. patent application Ser. No. 09/800,093, titled “Geo-Referencing of Aerial Imagery Using Embedded Image Identifiers and Cross-Referenced Data Sets,” filed Mar. 5, 2001 (published as US 2002-0124171 A1). The Ser. No. 10/002,954 application also claims the benefit of U.S. Provisional Application Nos. 60/284,163, filed Apr. 16, 2001, titled “Watermark Systems and Methods,” and 60/284,776, filed Apr. 18, 2001, titled “Using Embedded Identifiers with Images.” Each of these patent documents is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to image management and processing, and is particularly illustrated in the context of management of satellite and other aerial imagery.
BACKGROUND AND SUMMARY OF THE INVENTION
Acquisition of aerial imagery traces its history back to the Wright brothers, and is now commonly performed from satellite and space shuttle platforms, in addition to aircraft.
While the earliest aerial imagery relied on conventional film technology, a variety of electronic sensors are now more commonly used. Some collect image data corresponding to specific visible, UV or IR frequency spectra (e.g., the MultiSpectral Scanner and Thematic Mapper used by the Landsat satellites). Others use wide band sensors. Still others use radar or laser systems (sometimes stereo) to sense topological features in 3 dimensions. Some satellites can even collect ribbon imagery (e.g., a raster-like, 1-dimensional terrestrial representation, which is pieced together with other such adjacent ribbons).
The quality of the imagery has also constantly improved. Some satellite systems are now capable of acquiring image and topological data having a resolution of less than a meter. Aircraft imagery, collected from lower altitudes, provides still greater resolution.
Such imagery can be used to develop maps or models, such as Digital Elevation Models (DEM) and others. DEM, essentially, is an “elevation map” of the earth (or part thereof). One popular DEM is maintained by the U.S. Geological Survey and details terrain elevations at regularly spaced intervals over most of the U.S. More sophisticated DEM databases are maintained for more demanding applications, and can consider details such as the earth's pseudo pear shape, in addition to more localized features. Resolution of sophisticated DEMs can get well below one meter cross-wise, and down to centimeters or less in actual elevation. DEMs—with their elevation data—are sometimes supplemented by albedo maps (sometimes termed texture maps, or reflectance maps) that detail, e.g., a grey scale value for each pixel in the image, conveying a photographic-like representation of an area.
(There is a large body of patent literature that illustrates DEM systems and technology. For example: U.S. Pat. No. 5,608,405 details a method of generating a Digital Elevation Model from the interference pattern resulting from two co-registered synthetic aperture radar images. U.S. Pat. No. 5,926,581 discloses a technique for generating a Digital Elevation Model from two images of ground terrain, by reference to common features in the two images, and registration-mapping functions that relate the images to a ground plane reference system. U.S. Pat. Nos. 5,974,423, 6,023,278 and 6,177,943 disclose techniques by which a Digital Elevation Model can be transformed into polygonal models, thereby reducing storage requirements, and facilitating display in certain graphics display systems. U.S. Pat. Nos. 5,995,681 and 5,550,937 detail methods for real-time updating of a Digital Elevation Model (or a reference image based thereon), and are particularly suited for applications in which the terrain being mapped is not static but is subject, e.g., to movement or destruction of mapped features. The disclosed arrangement iteratively cross-correlates new image data with the reference image, automatically adjusting the geometry model associated with the image sensor, thereby accurately co-registering the new image relative to the reference image. Areas of discrepancy can be quickly identified, and the DEM/reference image can be updated accordingly. U.S. Pat. No. 6,150,972 details how interferometric synthetic aperture radar data can be used to generate a Digital Elevation Model. Each of these patents is hereby incorporated by reference.).
From systems such as the foregoing, and others, a huge quantity of aerial imagery is constantly being collected. Management and coordination of the resulting large data sets is a growing problem. Integrating the imagery with related, often adjacent, imagery, and efficiently updating “stale” imagery is also a problem.
In accordance with one aspect of the present invention, digital watermarking technology is employed to help track such imagery, and can also provide audit trail, serialization, anti-copying, and other benefits.
In accordance with another aspect of the invention, data imagery, including images having unique features, is pieced together using embedded data or data indexed via embedded data. In accordance with still another aspect of the present invention, a so-called “geovector” is carried by or indexed with a digital watermark.
The foregoing and additional features and advantages of the present invention will be more readily apparent from the following detailed description with reference to the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates imagery, which is segmented into image patches.
FIGS. 2 a and 2 b illustrate a correlation of image patches.
FIG. 3 is a flow diagram illustrating an image management method according to one aspect of the present invention.
FIG. 4 is a flow diagram illustrating a method of embedding a geovector in image data.
FIG. 5 is a flow diagram illustrating a method of decoding an embedded watermark to access a database.
DETAILED DESCRIPTION
For expository convenience, the following section focuses on satellite and aerial “imagery” to illustrate the principles of the invention. The principles of the invention, however, are equally applicable to other forms of aerial surveillance data and other topographic/mapping information. Accordingly, the term “image” should be used to encompass all such other data sets, and the term “pixel” should be construed to encompass component data from such other data sets.
When new aerial imagery is received, it is generally necessary to identify the precise piece of earth to which it corresponds. This operation, termed “georeferencing” or “geocoding,” can be a convoluted art and science.
In many systems, the georeferencing begins with a master reference system (e.g., latitude and longitude) that takes into account the earth's known deformities from a sphere. Onto this reference system the position of the depicted region is inferred, e.g., by consideration of the satellite's position and orientation (ephemeris data), optical attributes of the satellite's imaging system (e.g., resolution, magnification, etc.), and models of the dispersion/refraction introduced by the earth's atmosphere.
In applications where precise accuracy is required, the foregoing, “ephemeris,” position determination is refined by comparing features in the image with the placement of known features on the earth's surface (e.g., buildings and other man-placed objects, geological features, etc.) and compensating the georeference determination accordingly. Thus, for example, if the actual latitude and longitude of a building is known (e.g., by measurement from a ground survey—“ground truth”), and the corresponding latitude and longitude of that building as indicated in the georeferenced satellite imagery is different, the reference system applied to the satellite data can be altered to achieve a match. (Commonly, three or more such ground truth points are used so as to assure accurate correction.)
Ground-truthing is a tedious undertaking. While computer methods can be used to facilitate the process, the best ground truth correction of imagery generally requires some human involvement. This is impractical for many applications.
As shown in FIG. 1 , aerial imagery can be segmented into area sets (e.g., image “patches”). These patches can be pieced together (or “composited”) in a quilt-like manner to form a master map. (A “master” map is used generally herein to represent a map or other area representation, typically which will include a plurality of image patches. Image patches are defined broadly and may include image segments, photographs, separate images, etc.). An image patch may include imagery representing an area, such as a 1×1 meter area, a 1×1 kilometer area, etc. Often, an image patch is combined with adjacent patches, which were gathered on different dates. For example, an image taken last week (e.g., Patch C in FIG. 1 ) may be quilted together with image patches taken today (e.g., Patch B), or a year ago (e.g., Patch A), to form a larger area map. Also, patches may be replaced over time to reflect new area developments or movements. (Of course, a master map need not be physically pieced together, but may instead be electronically maintained by a computer database, which correlates the patches or stores information, e.g., coordinates, patch locations, etc.).
Similarly, image patches can be pieced together with other images taken from different aerial platforms (e.g., satellites, airplanes, unmanned aircraft, etc.) or taken with different imagery characteristics. (Imagery characteristics may include resolution, angle, scale, rotation, skew, time, azimuth, device characteristics, altitude, attitude, physical conditions such as cloud cover and magnification, etc.)
Images typically undergo auto-correlation processes to reconcile differences between adjacent patches, prior to being composited (or arranged) with other patches. A variety of known mathematical techniques can be utilized in this operation, including dot product computation, transforming to spatial frequency domain, convolution, etc. In a lay sense, the correlation can be imagined as sliding one map over the other or matching pieces in a puzzle-like fashion until the best registration between the two image patches is obtained.
Now consider a geo-referencing example. A new satellite image is acquired corresponding to part of a region represented by a master map. The particular terrain depicted by the satellite image can be inferred from ephemeris and other factors, as noted above. By such techniques, the location of the depicted image on the earth's surface (e.g., the latitude and longitude of a point at the center of the image) may be determined within an error of, say 5-500 meters. This is a gross geo-referencing operation.
Next a fine geo-referencing operation is automatically performed, as follows. An excerpt of a master map is retrieved from a database—large enough to encompass the new image and its possible placement error (e.g., an area centered on the same latitude/longitude, but extending 250 meters further at each edge). A projective image is formed from this master DEM/map excerpt, considering, e.g., the satellite's position and atmospheric effects, thereby simulating how the master map would look to the satellite, taking into account—where possible—the particular data represented by the satellite image, e.g., the frequency bands imaged, etc. (An albedo map may be back-projected on the 3D DEM data in some arrangements to augment the realism of the projective image.).
The projective image formed from the master DEM/map excerpt differs somewhat from the image actually acquired by the satellite. This difference is due, in part, to the error in the gross geo-referencing. (Other differences may arise, e.g., by physical changes in the region depicted since the master DEM/map was compiled.).
The projective image is next automatically correlated with the satellite image. From the correlation operation, the center-to-center offset between the excerpt of the master DEM/map, and the satellite image, is determined. The satellite image can thereby be accurately placed in the context of the master map. Depending on system parameters, a fine placement accuracy of, e.g., between 5 cm and 5 meters (i.e., sub-pixel accuracy) may be achieved.
(In some embodiments, affine transformations can be applied to the image data to further enhance the correlation. E.g., particular geological or other features in the two data sets can be identified, and the satellite data (e.g., map or image) can then be affine-transformed so that these features correctly register.).
With the satellite image thus finely geo-referenced to the master DEM/map, it can be transformed (e.g., resampled) as necessary to correspond to the (typically rectilinear) reference system used in the master map, and then used to refine the data represented in the map. Buildings or other features newly depicted in the satellite image, for example, can be newly represented in the master map. The master map can be similarly updated to account for erosion and other topological changes revealed by the new satellite image.
In one embodiment, the finely geo-referenced satellite data is segmented into region or area sets, e.g., rectangular patches corresponding to terrain 1000 meters on a side, and each patch is given its own weighting factor, etc. In a system with 10 meter resolution (i.e., a pixel size of 10 m 2 , the patch thus comprises an array of 100×100 pixels. (In some embodiments, the fine geo-referencing is done following the segmentation of the image, with each patch separately correlated with a corresponding area in the master map.) Each patch may take the form of a separate data file.
When the new satellite data is added to update the master map, old data may be discarded so that it no longer influences the map. Consider an area that is imaged monthly by a satellite. Several months' worth of image data may be composited to yield the master map (e.g., so cloud cover that obscured a region in the latest fly-over does not leave part of the map undefined). As each component image data gets older, it may be given less and less weight, until it no longer forms any part of the master map. (Other component data, in contrast, may be retained for much longer periods of time. Map information collected by ground surveys or other forms of “ground truth” information may fall into this category.).
The master map may be physically maintained in different ways. In one exemplary arrangement, a database stores the ten sets of data (e.g., acquired from different sources, or at different times) for each 1000×1000 meter patch. When interrogated to produce a map or other data, the database recalls the 10 data sets for each patch, and combines them on the fly according to associated weighting factors and other criteria (e.g., viewing angle) to yield a net representation for that patch. This composite patch is then combined (e.g., graphically stitched) with other adjoining, similarly formed composite patches, to yield a data set representing the desired area.
In another embodiment, the component sets of image data are not separately maintained. Rather, each new set of image data is used to update a stored map. If the new image data is of high quality (e.g., good atmospheric seeing conditions, and acquired with a high resolution imaging device), then the new data may be combined with the existing map with a 20/80 weighting (i.e., the existing map is given a weight four-times that of the new data). If the new image data is of low quality, it may be combined with the existing map with a 5/95 weighting. The revised map is then stored, and the new data needn't thereafter be tracked.
(The foregoing examples are simplifications, but serve to illustrate a range of approaches.)
The former arrangement—with the component data stored—is preferred for many applications, since the database can be queried to yield different information. For example, the database can be queried to generate a synthesized image of terrain, as it would look at a particular time of day, imaged in a specified IR frequency band, from a specified vantage point.
It will be recognized that a key requirement—especially of the former arrangement—is a sophisticated data management system. For each data set representing a component 1000×1000 meter patch stored in the database, a large quantity of ancillary data (meta data) must be tracked. Among this meta data may be a weighting factor (e.g., based on seeing conditions and sensor attributes), an acquisition date and time (from which an age-based weighting factor may be determined), the ID of the sensor/satellite that acquired that data, ephemeris data from the time of acquisition, the frequency band imaged, the geo-referenced position of the patch (e.g., latitude/longitude), etc., etc. (Much of this data may be common to all patches from a single image.).
Classically, each component source of data to the system (here referred to as an “image” for expository convenience) is associated with a unique identifier. Tapes and data files, for example, may have headers in which this identifier is stored. The header may also include all of the meta data that is to be associated with that file. Or the identifier can identify a particular database record at which the corresponding meta data is stored. Or hybrid approaches can be used (e.g., the header can include a file identifier that identifies a data base record, but also includes data specifying the date/time of data acquisition).
In the final analysis, any form of very reliable image identification may suffice for use in such a system. The header approach just discussed is straightforward. Preferable, however, is to embed one or more identifiers directly into the image data itself (i.e., “in band” steganographic encoding using digital watermarking). A well-designed watermarking name-space can in fact become a supra-structure over several essentially independent serial numbering systems already in use across a range of satellite sources. Moreover, rudimentary georeferencing information can actually be embedded within the watermark name-space.
For example, on initial acquisition, an initial digital watermark can be applied to satellite imagery detailing the ephemeris based gross georeferencing. Once the image has been finely georeferenced, the existing watermark can either be overlaid or overwritten with a new watermark containing the georeferencing information (e.g., “center lat: N34.4324352, long: W87.2883134; rot from N/S: 3.232; x2.343, y2.340, dx0.123, dy493, etc.”). These numbers essentially encode georeferencing information including projective and atmospheric distortions, such that when this image is corrected, high accuracy should be achieved.
The assignee's U.S. Pat. No. 6,122,403, and pending U.S. patent application Ser. No. 09/503,881 (now U.S. Pat. No. 6,614,914), detail suitable digital watermarking techniques in which values of pixels, e.g., in a 100×100 pixel patch, can be slightly altered so as to convey a plural-bit payload, without impairing use of the pixel data for its intended purpose. (This patent and patent application are hereby incorporated by reference.). The payload may be on the order of 50-250 bits, depending on the particular form of encoding (e.g., convolution, turbo, or BCH coding can be employed to provide some error-correcting capability), and the number of bits per pixel. Larger payloads can be conveyed through larger image patches. (Larger payloads can also be conveyed by encoding the information is a less robust fashion, or by making the encoding more relatively visible.). The watermark payload can convey an image identifier, and may convey other meta data as well. In some systems, the component image files are tagged both by digital watermark identifiers and also by conventional out-of-band techniques, such as header data, thereby affording data redundancy. Of course, there are many watermarking techniques known to those skilled in the art, and such may be suitably interchanged with the above-cited patent documents.
Watermarking may be performed in stages, at different times. For example, an identifier can be watermarked into an image relatively early in the process, and other information (such as finely geo-referenced latitude/longitude) can be watermarked later. A single watermark can be used, with different payload bits written at different times. (In watermark systems employing pseudo-random data or noise (PN), e.g., to randomize some aspect of the payload's encoding, the same PN data can be used at both times, with different payload bits encoded at the different times.)
Alternatively, different watermarks can be applied to convey different data. The watermarks can be of the same general type (e.g., PN based, but using different PN data). Or different forms of watermark can be used (e.g., one that encodes by adding an overlay signal to a representation of the image in the pixel domain, another that encodes by slightly altering DCT coefficients corresponding to the image in a spatial frequency domain, and another that encodes by slightly altering wavelet coefficients corresponding to the image. Of course, other watermarking techniques may be used as suitable replacements for those discussed above.).
In some multiple-watermarking approaches, a first watermark is applied before the satellite image is segmented into patches. A later watermark can be applied after segmentation. (The former watermark is typically designed so as to be detectable from even small excerpts of the original image.)
A watermark can be even applied by the imaging instrument. In some embodiments, the image is acquired through an LCD optical shutter, or other programmable optical device, that imparts an inconspicuous patterning to the image as it is captured. (One particular optical technique for watermark encoding is detailed in U.S. Pat. No. 5,930,369, which is hereby incorporated by reference.). Or the watermarking can be effected by systems in the satellite (or other aerial platform) that process the acquired data prior to transmission to a ground station. In some systems, the image data is compressed for transmission—discarding information that is not important. The compression algorithm can discard information in a manner calculated so that the remaining data is thereby encoded with a watermark.
The ground station receiving the satellite transmission can likewise apply a watermark to the image data. So can each subsequent system through which the data passes.
As indicated, the watermark(s) can identify the imaging system, the date/time of data acquisition, satellite ephemeris data, the identity of intervening systems through which the data passed, etc. One or more watermarks can stamp the image with unique identifiers used in subsequent management of the image data, or in management of meta data associated with the image.
A watermark can also serve a function akin to a hyperlink, e.g., as detailed in U.S. patent application Ser. No. 09/571,422 (now U.S. Pat. No. 6,947,571), which is hereby incorporated by reference. For example, a user terminal can permit an operator to right-click on a region of interest in a displayed image. In response, the system can respond with a menu of options—one of which is Link Through Watermark(s). If the user selects this option, a watermark detection function is invoked that decodes a watermark payload from the displayed image (or from a portion of the image in which the operator clicked). Using data from the decoded watermark payload, the terminal interrogates a database for a corresponding record. That record can return to the terminal certain stored information relating to the displayed image. For example, the database can present on the terminal screen a listing of hyperlinks leading to other images depicting the same area. By clicking on such a link, the corresponding image is displayed. Or the database can present, on the user terminal screen, the meta-data associated with the image.
In some embodiments, watermarks in component images may carry-through into the master DEM/map representation. If an excerpt of the master DEM/map is displayed, the user may invoke the Link Through Watermark(s) function. Corresponding options may be presented. For example, the user may be given the option of viewing each of the component images/data sets that contributed to the portion of the master map being viewed.
(It will be recognized that a variety of user interface techniques other than right-clicking, and selecting from a menu of options thereby displayed, can be employed. That interface is illustrative only.)
In some embodiments, a watermark can be applied to each DEM/map from the master database as it is retrieved and output to the user. The watermark can indicate (i.e., by direct encoding, or by pointing to a database record) certain data related to the compiled data set, such as the date/time of creation, the ID of the person who queried the database, the component datasets used in preparing the output data, the database used in compiling the output data, etc. Thereafter, if this output data is printed, or stored for later use, the watermark persists, permitting this information to be later ascertained.
Correlating Images with Watermarks
With reference to FIGS. 2 a and 2 b , watermarks can assist in correction or correlating imagery characteristics (e.g., such as scale, rotation, resolution, skew, time-matching, etc.). For example, an embedded watermark payload may indicate the angle of the imaging device (e.g., optical camera, imaging sensor, etc.), the height to the imaging device, the relative position (e.g., skew, rotation, etc.) of the device with respect to a target area, and the resolution of the device and image. (Such measurements can be provided from sensing and positioning equipment on board or in communication with the aerial platform. Such characteristics may be alternatively determined by the georeferencing techniques discussed above. Of course, other imagery characteristic determining techniques may be suitably interchanged with the present invention.). Returning to FIGS. 2 a and 2 b , imagery characteristics provide information to help manipulate patches A and B ( FIG. 2 a ) into a standardized or compatible format ( FIG. 2 b ). Information pertaining to the imaging characteristics can be used to improve and expedite the auto-correlation processes discussed above. In addition, once the imaging characteristics are known, straightforward processing can manipulate an image patch to conform to adjacent patches (or to the map itself). For example, some or all of the patches in a master map are mathematically manipulated to achieve the same scale, orientation, and/or resolution.
With respect to a watermark payload, the imaging characteristics can be directly encoded as the watermark payload. Alternatively, an index (or identifier) associated with a set of these characteristics may be encoded in the payload. To illustrate, a numerical code or index represents a set possible imagery characteristics (or a subset of such). The imagery characteristics are stored in a data base record. The code or index, once extracted from a watermark, is used to interrogate a database to obtain the corresponding data record. (As an alternative, a payload signifies a predetermined set of values, e.g., a payload of 1237 signifies a predetermined scale, rotation, skew, etc. Or the index relates to a predetermined range of characteristics. For example, the range may specify that the scale is in a particular range, or that the resolution falls within a range, etc.). A watermark payload size and complexity can be reduced with a database/index system.
Embedding imagery characteristic in the form of a digital watermark assists in downstream processing and handling of an image. An automated-quilting process can be employed to match patches according to the georeferencing and/or imagery characteristics provided by a digital watermark. These georeferencing and/or imagery characteristics can also serve to preserve the historic information about the image and depicted area. Individual patches can also be watermarked to include coordinates or master map locators. With reference to FIG. 1 , patch E may include coordinates or a plurality of coordinates that identify its master map location, coordinates for corners or edges (e.g., either physical geo-coordinates or coordinates relative to its master map location), or its relationship with adjacent patches. Such a locator can be added once a master map is composited (e.g., by watermarking the master map). Alternatively, such locators can be embedded before quilting, such as when imagery is collected or processed.
A time-tag (or stamp) may also be embedded in imagery. The time-tag can be used to categorize images based on time (e.g., hour, minutes, date, etc.), and to help identify stale or outdated imagery. The time-tag may optionally include a plurality of fields, such as time-taken, time processed, time integrating in a master map, etc. Such time-tagging methods improve management of images. (In one embodiment, an automated process searches a master map database, looking for stale or outdated patches, based on predetermined criteria. Once found the stale image patch is preferably removed and an updated image patch is inserted in its place.).
FIG. 3 illustrates a flow diagram of an inventive method according to one embodiment of the present invention. Image data is received into a system or process. The image data is embedded with image characteristics (step S 10 ). Alternatively, the image is embedded with an identifier (index) for database interrogation. The embedded image data is then correlated or manipulated to conform to adjacent patches or to map requirements (step S 11 ). In this regard, the correlation may either render adjacent patches to have approximate (e.g., similar or in a range of) imagery characteristics, or to have nearly identical imagery characteristics. Or the correlation may group neighboring patches into a set. A map is then generated or constructed (S 12 ). (A map can be quilted together to include many image patches. The digital watermark identifiers are used to correlate the image.).
Geo-Locators and Digital Watermarks
Digital watermarking is now disclosed as a central element in a digital asset management system, particularly for photograph assets (including “digital images”). Copyright labeling, active copyright communications, marketing links, etc., have been explored in the watermark art. This section discloses how digital watermarking (and related database linking properties) and georeferenced photography inter-relate. In one embodiment, digital watermarking is used as a platform to simplify and transform georeferenced photography.
Within the universe of subject matter for photography is what is broadly referred to as “remote sensing.” For this discussion, remote sensing is defined to include all types of photography, which somehow images the Earth's surface or its landscape. Of course, while remote sensing may be facilitated with aerial platforms, such is not required. Add to the remote sensing class, all photography, which somehow has an innate connection to a location on the Earth—referred herein as “georeferenced photography.” In the final analysis, virtually all photographs, one way or another, have innate geographic properties. (Even purely synthetic images are created by an author located “somewhere.”). Most photographs, including swept-scan satellite imagery and radar, also including vacation snaps at, e.g., Niagara Falls, can be described as having innate, if not explicit, geographic properties. “Time” can also be included as an identifying property. (To simplify the discussion, the terms photograph, image, and photography are used interchangeably hereafter. Such terms may include remote sensing, georeferenced photography, image, imagery, photos, electronic images or imagery and/or aerial photo, etc., etc.).
Virtually all images can be referenced by a dimensional location vector (e.g., a “geovector”) relative to the Earth's coordinate system. In a first embodiment, the geovector is presented as a six (6) element vector, including:
Latitude; Longitude; Height/Altitude (e.g., as compared to a mean-sea level sphere with an arbitrary time origin); Time (including date); Cardinal Direction; and Azimuth.
The cardinal direction and azimuth elements can be used to determine a viewpoint depicted in a photograph (e.g., the azimuthal direction of a viewpoint for a given geo-position.). In a modification, cardinal direction and azimuth indicate the vantage point of the imaging sensor. In still another modification, azimuth and cardinal direction are used to represent other directional indicators. Of course, the cardinal direction can be used to orient an image depicted in the photograph. (Although the term “geovector” is introduced in connection with a six (6) dimensional vector, the present invention is not so limited. Indeed, a geovector is defined broadly herein to include information conveying location and/or directional specifying data, regardless of vector size.).
In a modification to the first embodiment, a geovector includes “6+1” elements. The extra “+ 1 ” dimension can be multi-dimensional in nature, generally representing “sensor geometry.” Sensor geometry is defined broadly herein to include a coherent set of optical (or electrical) sampling functions, e.g., corresponding to each pixel (or pixel block) and/or a microdensity region of a photograph. Of course, there is a variety of other types of sensor geometry, each associated with various rules on how the geometry is defined and how it affects the referencing parameters (e.g., latitude, longitude, height, etc.). A common form of sensor geometry is a rectangular fan or pyramid centered on a camera's aperture, which can be used as a stand-in for many others forms. Of course, there are many other geometry forms known to one of ordinary skill in the art, which are suitably interchangeable with the present invention.
The march of technological progress is transitioning more photography from the “innate” category to the “explicit” category through the use of global positioning system (GPS) technology and/or local wireless technologies. GPS can be used to determine a physical location (e.g., including properties of a geovector). As will be appreciated by those skilled in the art, GPS is a satellite-based radio navigation system capable of providing continuous position, velocity, and time information. GPS receiver units receive positioning signals from a constellation of satellites deployed in various orbits about earth (e.g., 12-hour orbits). The satellites continuously emit electronic GPS signals (or telemetry) for reception by ground, airborne, or watercraft receiver units. By receiving GPS signals from a plurality of satellites, a properly configured receiver unit can accurately determine its position in at least three dimensions (e.g., longitude, latitude, and altitude/height). Some GPS systems also provide compass-like functionality, in which cardinal direction and azimuth are determined. (Alternative methods can be used to determine a geovector. For example, many terrestrial-based stations emit navigational beacons that can be used to determine geo-location and relational-direction. Wireless systems may also be used to triangulate signals emitted from a mobile device. Such signals are collected at multiple receiving locations and based on the relative reception time and/or strength a geo-location is determined for the mobile device. Similarly, a mobile device can triangulate its position based on received beacons.).
The georeferencing techniques discussed above and in the incorporated by reference patents and applications can also be used to determine geovector information corresponding to a location depicted in a photograph. (E.g., a GPS or wireless system can provide geovector information. Or geovector information can be obtained from an image capture device, among the other techniques discussed.). In one embodiment, geovector data is obtained via an online (e.g., internet or network) database. A user simply enters in a street address or map-grid location, and the database returns corresponding geovector data (e.g., longitude, latitude, height, etc.). Or the geovector information is obtained from a user or agency based on human or computer analysis of an image. Artisans know other ways to determine and obtain geovector information. Of course, such other known techniques are suitably interchangeable with the present invention.
Beginning with the area of remote sensing, and extending to all photography with an innate geovector, digital watermarking is extended to embrace this fundamental set of information inherent in each and every photograph. Just as a “copyright” is fundamentally a part of every photograph, so too is a “geovector” a fundamental part of every photograph, and digital watermarking can expressly convey this geovector information.
Once obtained, a geovector is either contained in the embedded watermark information itself, or contained in a database to which the watermark represents a pointer, or both (see FIG. 4 ). Indeed, the geovector can be included in a watermark message or payload. In one embodiment, a watermark embedder performs error correction coding of a watermark's binary message (e.g., representing the geovector), and then combines the binary message with a carrier signal to create a component of a watermark signal. There are several error correction coding schemes that may be employed. Some examples include BCH, convolution, Reed Solomon, and turbo codes. These forms of error correction coding are sometimes used in communication applications where data is encoded in a carrier signal that transfers the encoded data from one place to another. In the digital watermarking application discussed here, raw bit data can be encoded in a fundamental carrier signal. It then combines the watermark signal with a host signal (e.g., a photograph). Further discussion for embedding messages can be found in assignee's U.S. patent application Ser. No. 09/503,881 (now U.S. Pat. No. 6,614,914), mentioned above. Artisans know other embedding techniques that are suitably interchangeable with the present invention.
A watermark embedded within a photograph may serve as (or carry) a database index or pointer. For example, the watermark includes an index, which once decoded, is used to interrogate a database (see FIG. 5 ). The database preferably contains data records including geovector information. The watermark index is used to identify a corresponding data record for the respective photograph (e.g., the photograph in which the watermark is embedded within). Of course, the database may be local or may be remotely accessed. In one embodiment, the watermark includes data corresponding to a URL or IP address, which is used to access a website. See Assignee's U.S. patent application Ser. No. 09/571,422 (now U.S. Pat. No. 6,947,571), mentioned above, for a further discussion of watermark-based linking. (The data may directly include the URL or may be used to access the URL.). A database associated with the website may be interrogated to retrieve the corresponding geovector information for a photograph. (In another embodiment, a watermarking reading device defaults to a URL or to an IP address, or queries a default database, upon detection of a watermark in a photograph.).
In yet another embodiment, geovector information is redundantly provided in header structures and watermark payloads.
Standardization efforts are currently underway, which are extending the idea of the geovector well beyond the examples presented above. See, for example, the Open GIS Consortium, an international consortium seeking to foster collaborative development of the OpenGIS Specifications to support full integration of geospatial data and geoprocessing resources into mainstream computing (http://www.opengis.org). (Of course, there are other known groups and companies focusing on geospatial and geographic information and services efforts. The “digital earth” concept is also known.). Such proposed standards have straightforward coordinate systems at their core.
We have determined that the standardization proposals lend themselves to conveying georeferencing in several different formats, including conveying information with digital watermarks, classic header structures, and pointer-to-elements in an associated database. Upon closer examination, however, we believe that our inventive digital watermarking techniques provide enhanced benefits when compared to these other techniques.
In today's world, where photography is rapidly becoming digital, a method of securely attaching identifying information (e.g., geovector information) to a corresponding photograph is needed. Digitally watermarking photographs provides a solution for the attachment problem. As discussed, a watermark may provide geovector information (or access to such information). A photograph many even be redundantly embedded with multiple copies of a watermark, further ensuring robust attachment of information to the photograph. Contrast our digital watermarking procedure with a procedure, which appends geovector information via headers. Whereas headers may be able to provide geovector information, they have a higher chance of separation from the underlying data—defeating a secure attachment feature.
Some of our inventive digital watermarking techniques involve a step of identifying a photograph (e.g., digitally watermarking a photograph with a binary identifier or a geovector) and, if using an index or identifier, storing information related to the index in some database or across a group of distributed databases. Adding a dimension of geovector information to the management of photographs results in a database or set of coordinated databases, which represent a searchable platform suitable for geographically based queries. The implications of such are tremendous. For example, a fisherman may search the database(s) for a photograph of a favorite fishing hole in Wyoming, based on a search criteria for a given time period, a range of time periods or by geo-location. The applications are endless—expanding far beyond dispelling fish stories. Friends of the fisherman may decode a watermark geovector or index embedded within the fisherman's watermarked photographs (e.g., by a compliant watermark reading device) to determine whether an area depicted in a photograph corresponds to a trout farm or to a high mountain lake—allowing “fish stories” to be verified. This information is readily available via a geovector associated with the image. The fisherman can maintain a photo-journal of his fishing trips, knowing that the embedded watermarks provide sufficient information to help retrace his steps and travels. To aid this endeavor, digital cameras are envisioned to be equipped with watermark embedding software and geovector gathering modules such as GPS units. Or the geovector information can be added when images are stored in a database or processed after the fishing excursion.
Digitally watermarking photographs helps to provide a collision-free serial numbering system for identifying imagery, owners, and attributes.
There are additional benefits in creating a georeferenced system of images using digital watermarks. A classic notion in most standardizations across all industries is a notion of a “stamp” or “seal” or a similar concept of indicating that some object has successfully completed its appointed rounds. Call it branding, call it formality, or call it a soft form of “authenticity;” the historical momentum behind such a branding concept is huge. In one embodiment, to ensure that a given image is properly georeferenced (under a chosen standard), digitally watermarking the given image is a final step representing a formalized “seal of approval.” The digital watermark itself becomes the seal. In one embodiment, a watermark identifier is obtained from an online repository, which issues and tracks authentic identifiers. The repository can be queried to determine the date and time of issue. Or the identifier can be linked to a seal or company logo. Software and/or hardware is configured to routinely read embedded digital watermarks and display an appropriate brand logo, seal, or certification. The “seal” itself then becomes a functional element of a standardization process, serving many functions including permanent attachment to standardized and dynamic metadata (e.g., a geovector).
Photographs by their very nature can be inter-processed, merged, split, cut up, etc., and so forth, as described in the prior art. This tendency is especially applicable to various geo-referenced imagery applications where some data sets are merged and viewed as derivative images. (See assignee's U.S. patent application Ser. No. 09/858,336, titled “Image Management System and Methods Using Digital Watermarks,” filed May 15, 2001, and published as US 2002-0124024 A1, which is hereby incorporated by reference.). Tracking image pieces is a daunting task. We have found that digital watermarks, in many such applications, are a good way of coordinating and keeping track of highly diverse image components. For example, an image is redundantly embedded with multiple copies of a watermark including a geovector for the image. When the image is cut up (or merged, etc.), each image piece preferably retains at least one of the redundantly embedded watermarks. The watermark is then decoded to identify the respective image piece, even when the piece is merged or combined with other image pieces.
A geovector may also provide sufficient information for stitching together map quilts, as discussed above, particularly if boundary or corner coordinates are provided. Instead of focusing on imagery characteristics, the map is quilted together based on the embedded geovector information.
The present invention includes many applications beyond identifying and associating data with photographs. Now consider embedding a digital watermark in a particular region of a map or photograph (e.g., corresponding to a location for a fire hydrant, tree, road, building, lake, stream, forest, manhole, water or gas line, park bench, geographical area, stadium, hospital, school, fence line, boarder, depot, church, store, airport, etc., etc.). These region-specific watermarks preferably include unique watermark payloads. A watermark payload conveys geovector information (or map coordinates) corresponding to its particular region of interest. (E.g., a geovector corresponding to a fire hydrant reveals the hydrant's location in latitude/longitude, etc. coordinates.). Now consider a modification in which, instead of uniquely watermarking individual map or photograph regions, a digital watermark is redundantly embedded throughout the map or photograph. In this modification, geovector information is conveyed via the redundant watermark payload for all fire hydrants's depicted on the map or photograph. Alternatively, instead of a payload conveying such geovector information, the payload comprises an index, which is used to interrogate a database to retrieve geovector information. (It should be appreciated that a fire hydrant is used for explanatory purposes only. Of course, other regions, structures, roads, land areas, bodies of water, buildings, etc. can be similarly watermarked.).
In another embodiment, a utility company watermarks a map or photograph to include geovector information corresponding to specific depicted objects, such as power stations, transformers and even transmission lines. Such information assists in locating areas for repair or inspection. Additional information can be stored in a database according to its geovector. For example, a power line's capacity, age, maintenance record, or rating can be associated in a database according to the line's geovector. Commonly assigned U.S. patent application Ser. No. 09/833,013, titled “Digitally Watermarked Maps and Signs and Related Navigational Tools,” filed Apr. 10, 2001, published as US 2002-0147910 A1, hereby incorporated by reference, discloses various techniques for watermarking and reading maps. Such principles can be applied here as well. In another embodiment, a city, municipal, state or government agency digitally watermarks geovector location information on its maps and charts, corresponding to streets, country areas, buildings, manholes, airports, ports, water systems, parks, etc.
In another embodiment, school age children carry bracelets, book bags, tags, ID cards, shoelaces, or necklaces, etc., each watermarked with geovector information identifying their home, parents work address or school location. When lost, the preschooler presents her bracelet (or other object) to a police officer, school official, or automated kiosk. The embedded watermark is decoded to reveal the geovector information. The child's home or school, or a map route, can be identified from such.
Tags or collars for domestic animals or livestock can be geo-watermarked to assist in recovery when lost.
In still another embodiment, documents are embedded with geovector information. Consider embedding geovector data on a deed or property listing. Additional information regarding the property (e.g., title history, tax information, community information, recording information, photographs, etc.) is obtained via the geovector data link. For example, the additional information can be stored in (or referenced by) a database. The geovector data or other pointer serves as the index for the database.
Geovector information can also assist in notarizing (or authenticating) a document. Data is embedded in the document, which may indicate the document time (e.g., date and time) and location of creation (or execution). Upon presentment to a compliant watermark-reading device, the embedded data is extracted and read for verification.
In yet another embodiment, geovector information is the common factor, which binds information together. For example, information is stored according to its geovector information (e.g., according to creation geo-location, subject matter geo-location, ancillary relationship to a geo-location, etc.). Database searching for information is carried out via the geovector data. To illustrate, the database is searched for all information pertaining to a specific geo-vector (e.g., the Washington Monument). All data (or a subset of the data) pertaining to the geovector (e.g., the Washington Monument) is returned to the user. The data can include reports, web pages, maps, video and audio clips, pictures, statistical data, tourist information, other data, musings, related sonnets, governments information, just to name a few types of data.
These are just a few embodiments and examples employing digital watermarking of geovector data. There are many other applications, which fall within the scope of the present invention.
CONCLUSION
The foregoing are just exemplary implementations of the present invention. It will be recognized that there are a great number of variations on these basic themes. The foregoing illustrates but a few applications of the detailed technology. There are many others.
For example, digital watermarks can be applied to any data set (e.g., a satellite image, or a map generated from the master database) for forensic tracking purposes. This is particularly useful where several copies of the same data set are distributed through different channels (e.g., provided to different users). Each can be “serialized” with a different identifier, and a record can be kept of which numbered data set was provided to which distribution channel. Thereafter, if one of the data sets appears in an unexpected context, it can be tracked back to the distribution channel from which it originated.
Some watermarks used in the foregoing embodiments can be “fragile.” That is, they can be designed to be lost, or to degrade predictably, when the data set into which it is embedded is processed in some manner. Thus, for example, a fragile watermark may be designed so that if an image is JPEG compressed and then decompressed, the watermark is lost. Or if the image is printed, and subsequently scanned back into digital form, the watermark is corrupted in a foreseeable way. (Fragile watermark technology is disclosed, e.g., in application Ser. Nos. 09/234,780, 09/433,104 (now U.S. Pat. No. 6,636,615), 09/498,223 (now U.S. Pat. No. 6,574,350), 60/198,138, 09/562,516, 09/567,405, 09/625,577 (now U.S. Pat. No. 6,788,800), 09/645,779 (now U.S. Pat. No. 6,714,683), and 60/232,163. Each of these patent applications is hereby incorporated by reference.) By such arrangements it is possible to infer how a data set has been processed by the attributes of a fragile watermark embedded in the original data set.
Certain “watermark removal” tools can be built to alleviate visibility or processing problems in cases where unacceptable impact of a digital watermark is identified. This can either be a generic tool or one highly specialized to the particular application at hand (perhaps employing secret data associated with that application). In another embodiment, a “remove watermark before analyzing this scene” function is included within analysis software such that 99% of image analysts wouldn't know or care about the watermarking on/off/on/off functionality as a function of use/transport.
As will be apparent, the technology detailed herein may be employed in reconnaissance and remote sensing systems, as well as in applications such as guidance of piloted or remotely piloted vehicles. Once identified from a map or photograph, geovector data can be uploaded to such vehicles.
To provide a comprehensive disclosure without unduly lengthening this specification, applicants incorporate by reference, in their entireties, the disclosures of the above-cited patents and applications. The particular combinations of elements and features in the above-detailed embodiments are exemplary only; the interchanging and substitution of these teachings with other teachings in this application and the incorporated-by-reference patents/applications are expressly contemplated.
It should be understood that the technology detailed herein can be applied in the applications detailed in the cited DEM patents, as well as in other mapping and image (or audio or video or other content) asset management contexts. (Likewise, the technologies detailed in the cited patents can be advantageously used in embodiments according to the present invention.)
While a geovector is described above to include, e.g., “6+1” dimensions, the present invention is not so limited. Indeed, a geovector can include more or less vector elements, depending on the referencing precision required. (To illustrate, altitude may be immaterial when other geovector coordinates are provided. Or a camera sensor geometry (e.g., “+1”) element may not be needed to uniquely identify a location or to account for sensor geometry. Alternatively, a map identifier or locator can be included to achieve similar functionality instead of a geovector. In other cases, where only rough referencing information is needed, providing only longitude and latitude coordinates may be sufficient. Of course, in the event that geospatial or geography information and services standards are formalized and/or updated, the geovector can be formatted to include the reference locators described in that standard. Similarly, instead of a geovector, geo-coordinates or other location information can be provided via a watermark or watermark index.).
There are many embodiments discussed herein which may benefit from the inclusion of two different watermarks. For example, a first watermark may include information regarding (or pointing to) geovector information, while a second watermark includes a database identifier or location. The second watermark may alternatively include (or point toward) information pertaining to events, people or animals identified in the photograph, occasions, groups, institutions, copyright ownership, etc. Or the embodiment may include both a robust geovector watermark and a copy-tamper fragile watermark.
While particular reference was made to Digital Elevation Models and albedo maps, the same principles are likewise applicable to other forms of maps, e.g., vegetative, population, area, thermal, etc., etc.
While one of the illustrated embodiments correlated incoming imagery with a projective image based on the master DEM/map, in other embodiments a reference other than the master DEM/map may be used. For example, a projection based just on part of the historical data from which the DEM/map was compiled can be used (e.g., one or more component data sets that are regarded as having the highest accuracy, such as based directly on ground truths).
Although not belabored, artisans will understand that the systems described above can be implemented using a variety of hardware and software systems. One embodiment employs a computer or workstation with a large disk library, and capable database software (such as is available from Microsoft, Oracle, etc.). The registration, watermarking, and other operations can be performed in accordance with software instructions stored in the disk library or on other storage media, and executed by a processor in the computer as needed. (Alternatively, dedicated hardware, or programmable logic circuits, can be employed for such operations.).
Certain of the techniques detailed above find far application beyond the context in which they are illustrated. For example, equipping an imaging instrument with an optical shutter that imparts a watermark to an image finds application in digital cinema (e.g., in watermarking a theatrical movie with information indicating the theatre's geo-location, date, time, and/or auditorium of screening).
The various section headings in this application are provided for the reader's convenience and provide no substantive limitations. The features found in one section may be readily combined with those features in another section.
In view of the wide variety of embodiments to which the principles and features discussed above can be applied, it should be apparent that the detailed embodiments are illustrative only and should not be taken as limiting the scope of the invention. Rather, we claim as our invention all such modifications as may come within the scope and spirit of the following claims and equivalents thereof. | The present invention relates generally to generating travel-logs or geographical representation of encountered media. One claim recites a method including obtaining a plurality of imagery, wherein each item of imagery from the plurality of imagery comprises steganographic encoding, the steganographic encoding altering data representing the imagery, the steganographic encoding comprising multi-bit data, and wherein the presence of the multi-bit data is imperceptible to a human observer of the imagery absent machine-detection; detecting the multi-bit data from the plurality of imagery, wherein the multi-bit data is associated with geolocation metadata; and providing a geographic path associated with the plurality of imagery based at least in part on the geolocation metadata. The geographic path is provided for display to a user relative to a graphical map. Of course, other different claims are provided as well. | 6 |
This United States utility patent application claims priority on and the benefit of provisional application 61/378,026 filed Aug. 30, 2010, the entire contents of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a radiant floor heating system having channels for receiving tubing wherein a layer having rapid planar heat dissipation and reduced pass-through heat dissipation is provided.
2. Description of the Related Art
One common home heating method includes the use of forced-air furnaces. While these systems work well for their intended purposes, their use is not without some limitations. Forced-air systems work by distributing heated air into desired rooms. The heat has a tendency to quickly rise towards the ceiling, which is inefficient. Rooms, particularly those with tile or slate flooring, may feel cold. Rooms with hard wood flooring may also feel cold. Homeowners and occupants may have reduced enjoyment of rooms with these types of flooring during the winter months when their home is heated with a forced air system.
In contrast, many homes can be constructed with radiant in-floor heating. Benefits of the in-floor heating in the winter months are well known, and include the comfortable use and enjoyment of rooms with natural flooring or other types of solid flooring. This is traditionally accomplished by locating tubing in the floor when pouring the concrete sub-floor. One drawback of this type of installation is that any punctures or leaks in the tubing can be difficult and costly to fix. Also, this type of installation is only practical for a new construction. It is not practical to install this type of system when remodeling a home. Several inches of concrete may be necessary, and the room may not be able to accommodate the required thickness of the concrete. Also, use of several inches of concrete is impractical for use in all levels but the bottom level of a home due to the weight of the concrete. A further drawback of recessing the tubing in concrete is the built-in inefficiency of allowing some heat pass to the ground below the concrete. This is due to the lack of insulation below the concrete.
A product having the name Warmboard exists utilizing panel type sub-flooring. Caulk or another type of adhesive is necessary to hold the tubes in place. It can be difficult to remove adhesively secured tubes if they are in need of repair or replacement. Further, the caulk and adhesive can interfere with the transfer of heat from the fluid within the tube to the floor.
Another system in use utilizes a tube mounted to the underside of a sub-floor between the joists. Insulation is then placed below the tube and between the joists so that the heat dissipated from the tube rises through the sub-floor instead of into the room below. It is impractical to install this type of system during a remodeling job when the room below the room where the heating system is being installed is a finished room. This is because the finished ceiling will impair access to the joists.
U.S. Pat. No. 4,326,366 to Werner is entitled Support Plate for Guiding Heating Pipes of a Floor or Wall Heating System. Looking particularly to FIG. 3 of the Werner patent, it is seen that this patent discloses a heat conducting layer, and a recess that forms part of a circle.
U.S. Pat. No. 4,646,814 to Fennesz discloses a system for tempering a room. This system has duct for allowing air to pass through the system.
U.S. Pat. No. 5,788,152 to Alsberg shows a floor heating system. The system has panels overlaid with a heat conducting surface embossed with a matching groove pattern. The panels have structural characteristics of a subflooring panel. FIG. 3 shows a modular panel.
U.S. Pat. No. 5,957,378 to Fiedrich is entitled Radiant Floor and Wall Hydronic Heating Systems. This patent shows a plate for holding a tube in intimate thermal contact so that the plate is heated by conduction. The plate has a radiating surface that radiates the heat to an area. U.S. Pat. No. 6,220,523 also to Fiedrich is entitled For Radiant Floor, Wall and Ceiling Hydronic Heating and/or Cooling Systems Using Metal Plates that are Heated or Cooled by Attached Tubing that is Fed Hot or Cold Water, Techniques of Improving Performance and Avoiding Condensation when Cooling. A thermal barrier is provided between the panels and the finished floor to prevent “hot spots”. U.S. Pat. No. 6,330,980 further to Fiedrich in entitled Dry Installation of a Radiant Floor or Wall Hydronic Heating System, Metal Radiating Plates that Attach to the Edges of Side-By-Side Boards and Provide Metal Slots for Holding Hot Water Tubing. The metal plate is shown to be in two separate pieces that are attached to edges of spaced apart boards. The metal plates combine to hold the tubing.
U.S. Pat. No. 6,283,382 to Fitzemeyer shows a radiant heating system pipe mounting plate. The plate is disclosed to be a flat sheet with a groove in the upper surface. A pipe is retained in the groove by a ridge running the length of the groove so that the pipe can be snapped into the groove. A top is also shown for making a flat surface.
U.S. Pat. No. 6,533,185 and pending application with publication number 2003/0218075 to Muir shows a thermal heating board comprising a nonstructural board with a recess. A pipe can be located within the recess. A film or metal can also be provided.
U.S. Pat. No. 6,805,298 to Corbett, entitled Modular Cementitous Thermal Panels for Radiant Heating, shows panels made of Portland cement or other curable cement.
U.S. Pat. No. 7,021,372 to Pickard shows a heat tubing receptacle for tightly gripping the heat tubing. Sheet metal heat transfer plates may be attached to the tubing receptacle.
Pending application with publication number 2004/0040693 to Fiedrich shows forming a metal sheet in a unitary fashion by folding it longitudinally to provide protuberances of double thickness for holding tubing. Pending application with publication number 2006/0144578 also to Fiedrich shows modular panels having special purpose bus tracks for routing tubing.
One drawback generally of using tubes to conduct a heated medium such as fluid below a finished floor is that the flooring can have hot spots directly above the tubing, termed hot stripping, and cooler spots between two runs of tube.
To overcome this deficiency, some of the inventions in the above patents utilize sheets, plates or foils of metal such as aluminum to conduct the heat over a wider area. Yet, the metal, being conductive in all directions, is still susceptible to heat stripping. Heat stripping occurs as the heat rises to the floor faster than it is conducted to the outer reaches of area between tubes. Hence, the heat may be full transferred to the floor in a limited area.
None of the above-patents show structures or methods to rapidly deploy heat over a larger area.
GrafTech Internatinal produces a product called Grafihx Flexible Heat Transfer Plates which appear to be sheets of graphite which is available in rolls and sheets.
United States Published Application 2006/0272796 to Asmussen et al. is titled Flexible Graphite Flooring Heat Spreader. It shows a heat spreader having a layer of flexible graphite material.
United States Published Application 2009/0101306 to Reis et al. is titled Heat Exchanger System. It shows a heat exchanger system, especially for a room, including a thermal element comprising a surface; a heat spreader comprising at least one sheet of compressed particles of exfoliated graphite having a density of at least about 0.6 g/cc and a thickness of less than about 10 mm, and further comprising a first side and a second side, wherein the heat spreader is positioned relative to the thermal element such that the heat spreader is at least partially wrapped around the thermal element so that the first side of the heat spreader is in a thermal transfer relationship with a portion of the thermal element surface.
While each of these last three references may work well for their intended purposes, the each nevertheless can be improved upon.
For example, none of these references show a thermal transfer element having a protective layer on top of the graphite layer. In this regard, the graphite layer in these references may be subject to damage during the installation process.
Further, none of these references show the use of a metallic layer on top of the graphite layer to draw the heat or cold from the graphite layer and transfer it to the floor above the thermal transfer layer.
Still further, none of these references show the use of an insulative layer directly below the graphite layer to mitigate thermal loss below the graphite layer.
Thus there exists a need for a radiant floor heating system and methods of use that solves these and other problems.
SUMMARY OF THE INVENTION
The present invention in some embodiments can utilize a board for retaining a tube within a region. The board (or boards) and region can have many configurations. A transfer layer having a graphite layer can be applied and/or bonded to the board. A metal or non-metal layer can be bonded to the graphite layer as part of the transfer layer. The present invention takes advantage of the principles of heat transfer to produce a more effective and efficient system and methods of use.
According to one advantage of the present invention, the graphite layer rapidly distributes the heat away from the pipe containing the heated fluid to maximize heat transfer.
According to another advantage of the present invention, the floor is more evenly heated. This results because the graphite can move the heat away from the pipe faster than the metal layer can conduct it to the flooring. This results in a larger area on the floor with a higher initial temperature differential between the aluminum (wider area rapidly heated) and the floor (fixed area), thereby reducing heat stripping.
According to another advantage of the present invention, heat loss to the surrounding environment is reduced, as the graphite layer is highly conductive along its plane and somewhat insulative by comparison in a direction perpendicular to the planar direction. The metal layer acts as a thermal collector to conduct the heat to the floor faster than the heat is conducted to the underside of the graphite, resulting in reduced heat loss.
Because of the increase in efficiency, the floor can warm faster which results in lower overall energy requirements to accomplish the heat transfer. Hence, the system is subject to reduced operational expenses.
According to another advantage of the present invention, the metal layer protects the graphite layer, which can be more fragile than the metal layer.
In another embodiment, a non-metal layer can be bonded or applied over the graphite layer to protect the graphite layer during installation of the flooring.
In yet another embodiment, an insulative layer can be applied directly below the graphite layer to mitigate thermal loss away from the finished flooring.
Other advantages, benefits, and features of the present invention will become apparent to those skilled in the art upon reading the detailed description of the invention and studying the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is top view of a background system.
FIG. 2 is a side view of a preferred embodiment of the present invention.
FIG. 3 is a top view of a preferred embodiment showing increased heat transfer.
FIG. 4 is an exploded view showing several layers of a preferred thermal transfer element.
FIG. 4A is an exploded view showing several layers of an alternative thermal transfer element.
FIG. 5 is a view showing s transfer element, an insulating layer and a thermal element that is embedded in concrete.
FIG. 6 is a perspective view of an alternative embodiment of the present invention.
FIG. 7 is a perspective view of an alternative embodiment of the present invention having side by side panels with a thermal transfer unit above the panels.
FIG. 8 is a perspective view of an alternative embodiment of the present invention having side by side panels with a thermal transfer unit below the panels.
FIG. 9 is a perspective view of an alternative embodiment of the present invention showing a transfer element wrapping thermal elements below a panel.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
While the invention will be described in connection with one or more preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
Turning now to FIG. 1 , it is seen that in the prior art, heat stripping can be problematic. Heat stripping is encountered when the thermal transfer occurs vertically to the floor faster than the thermal energy can radiate laterally away from the thermal elements resulting in uneven heating or cooling across the floor.
Turning now to FIGS. 2 and 3 , it is seen that a preferred embodiment of the present invention is illustrated. A board or panel 10 having a top 11 and a bottom 12 is provided. The board 10 further has a channel 13 formed therein for receiving one or more thermal elements 20 and 20 A, respectively. It is understood that while a pipe or tube is illustrated, that a wire or other thermal element can be provided without departing from the broad aspects of the present invention.
It is appreciated that while one configuration of a board and channel is illustrated, that the present invention is in no way limited to such a configuration.
A transfer element 25 is further provided for being in close proximity to the thermal element 20 . In one preferred embodiment, the transfer element 25 has a graphite layer 30 and a metal layer 40 . As seen in FIG. 4A , a bonding layer 35 can be between the graphite layer 30 and metal layer 40 , and an adhesive layer 45 can be provided for bonding the graphite layer to a substrate such as a panel 10 . The adhesive layer 45 can optionally have a peel-off backing.
The graphite layer 30 can have a preferred thickness of between 0.005 inches and 1.000 inch, and preferably is about 0.010 inch thick, and can be formed in one of many manufacturing processes. It is preferred but not necessary that the graphite is pure in nature without binders or fillers. The graphite layer preferably has a thermo-conductivity in the range of between 5 to 400 W/MK, and more preferably about 250 W/MK. It is understood that the graphite layer can alternatively be a mixture of graphite with either metals or non-metals. The graphite layer 30 is preferably highly thermally conductive in the planar direction. The planar direction is along the plane of the graphite. Due to the thermal properties of the graphite layer 30 , it has a relatively low thermal conductivity perpendicular to the planar direction. In use, the graphite layer spreads heat rapidly in the planar direction, and is insulative perpendicular to the planar direction. The graphite layer 30 can be continuously formed within the channel, or slitted and pressed into the channel. It is appreciated that the graphite layer can be formed in a multitude of ways relative the board, and the present invention is not limited to any such configuration.
The metal layer 40 can be bonded to, adhered to, pressed into or otherwise be adjacent to the graphite layer 30 . It is preferred in one embodiment that bonding layer 35 continuously bond the metal layer 40 to the graphite layer 30 . The metal layer can be a foil, a sheet, a plate or any other physical size. One preferred metal layer is aluminum. The aluminum can have a have a preferred thickness of between 0.0001 inches and 0.5 inch, and preferably is about 0.005 inch thick, and can be formed in one of many manufacturing processes. However, it is appreciated that other metals or even other non-metallic materials having high conductivity through the plane of the material may be used without departing from the broad aspects of the present invention. In this regard, the metal layer 40 can more broadly be called a through-plane conductive layer.
In use, the graphite rapidly dissipates heat (or coolness) from the pipe and radiates it out from the pipe in the planar direction. The graphite layer 40 effectively conducts the heat so fast that heat stripping is greatly reduced. The metal layer 40 acts as a thermal collector to conduct the heat to the floor. Since the graphite layer widely distributed the heat, the entire surface area of the metal layer has a more uniform temperature differential between the graphite layer and the floor. It is also appreciated that the metal layer 40 acts as a thermal collector to transfer the heat to the floor faster than the heat could be conducted through the graphite layer to the underside of the graphite layer.
The metal layer 40 can provide structural support to the system, and also prevents tearing or ripping of the graphite layer 30 . The graphite layer can be particularly susceptible to tearing or ripping at the channels. The metal layer 40 accepts the majority of the wear and tear due to inserting the piping into the channels.
Turning now to FIG. 4 , it is seen that an alternative embodiment is illustrated. In this regard, a graphite layer 30 is provided and bonded to a non-metal layer 40 A. Layer 40 A can be a protective layer that protects the integrity of the graphite layer 30 during installation. For example, the protective layer 40 A may allow an installer to walk on the transfer element without causing the transfer element to tear, rip or flake. Also, the protective layer 40 A can maintain the integrity of the graphite layer 30 during the installation of the heat elements. It is preferred that the protective layer 40 A have a preferred thickness of between 0.0001 inches and 0.5 inch, and preferably is about 0.005 inch thick, and can be formed in one of many manufacturing processes. One preferred protective layer is Mylar plastic. However, other materials may be used without departing from the broad aspects of the present invention.
It is understood that multiple layers (thermal, protective and/or through-plane conductive) may be used without departing from the broad aspects of the present invention.
Looking now at FIG. 5 , it is seen that an additional preferred embodiment is illustrated. In this embodiment, several thermal elements 120 are embedded within concrete 110 . A transfer layer having a graphite layer 130 is provided directly underlying the concrete 110 . The transfer layer allows thermal energy to radiate across the plane of the graphite 130 . An insulating layer 140 is provided and is preferably directly underneath the graphite layer 130 . The insulative layer 140 can be made of foam, fiberglass, polystyrene or other suitable material. The insulative layer 140 prevents the thermal energy from dissipating to the ground below. In this regard, the thermal energy is encouraged to pass through and spread evenly within the concrete layer 110 .
Looking now at FIG. 6 , it is seen that another preferred embodiment is illustrated. A panel 210 is provided having a top 211 and a bottom 212 . A channel or region 213 is provided within the panel 210 . The channel is preferably open to the top 212 , and passes more than ½ way but not all the way through the panel 210 . The channel 213 is sized to receive a thermal element 220 . A transfer element 230 is also provided. The transfer element 230 has a graphite layer 232 and a cover 231 . The cover 231 can be a protective layer or a through-plane conductive layer. It is appreciated that a through-plane conductive layer can also function as a protective layer allowing an installer to move about without damaging the graphite layer 232 .
Panel 210 is preferably an insulative panel having an R-value above that of a typical subfloor panel (1.5 is a typical R-value for a sub-floor). In this regard, the panel preferably has an R-value above 1.5 per inch of thickness of the panel. The panel 210 can be installed directly on a sub-floor 240 .
Turning now to FIG. 7 , it is seen that yet another embodiment is illustrated. This embodiment is similar to previous embodiments, but shows the use of two panels 320 and 330 to define a gap 335 for retaining a heat element 350 . A subfloor 310 is provided and the panels can be applied to the subfloor leaving a gap of an appropriate size to retain a thermal element. A transfer element 340 is provided to transfer the thermal energy from the thermal element. The panels 320 and 330 can be insulative panels.
Now looking at FIG. 8 , it is seen that an additional embodiment is provided. In this embodiment, a subfloor 410 is provided. A transfer layer 420 is applied directly to the subfloor 410 . The transfer layer has a graphite layer and may optionally have a protective layer over the graphite layer. Panels 430 and 440 are placed over the transfer layer. The panels preferably do not have enhanced insulative properties in this embodiment, wherein the thermal energy can readily pass through the panels.
It is also appreciated that the graphite layer and metal layer can be installed under the floor (for example between floor joists) without departing from the broad aspects of the present invention. Looking now at FIG. 9 , it is seen that yet another embodiment is illustrated. A panel 510 is provided which can be a subfloor spanning between floor joists. Heat elements 520 and 525 can be provided and wrapped in a transfer element 530 . The transfer element can then be secured to the underside of the panel 510 to spread thermal energy across the panel 510 .
While several embodiments are illustrated above in relation to heating or cooling floors, it is understood that the principles of the present invention can likewise be applied to walls and ceilings without departing from the broad aspects of the present invention.
Thus it is apparent that there has been provided, in accordance with the invention, a radiant floor heating system and methods of use that fully satisfies the objects, aims and advantages as set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. | The present invention in some embodiments can utilize a board for retaining a tube within a region. The board (or boards) and region can have many configurations. A transfer layer having a graphite layer can be applied and/or bonded to the board. A metal or non-metal layer can be bonded to the graphite layer as part of the transfer layer. The present invention takes advantage of the principles of heat transfer to produce a more effective and efficient system and methods of use. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §120 to U.S. application Ser. No. 10/039,904 filed Oct. 23, 2001, and under 35 U.S.C. §119(e) to Provisional Patent Application Serial No. 60/242,797 filed Oct. 23, 2000; the disclosures of which are incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made in part with United States Government Support under Contract Number #DACA88-99-C-0006, SBIR Topic #A98-087 awarded by the Department of the Army. Therefore, the U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] Seismic events often cause dynamic responses in structures sufficient to permanently damage or destroy the primary load-bearing members. Extensive research into the dynamic response of building structures has revealed that modest applications of ancillary damping can dramatically reduce deflections and stresses due to seismic excitation. This ancillary damping may be provided by either yielding and hysteretic energy dissipation in primary structural elements or the inclusion of devices specifically designed to absorb energy while remaining within the elastic range of the primary structure. These latter devices offer the great advantage of minimizing damage to curtain walls, interior structures, and other building systems. In some cases these auxiliary dampers are sacrificial and need replacement after extreme events, while in other cases they may sustain many extreme load cycles without significant maintenance. If effective ancillary damping mechanisms can be developed, in retrofit applications, for multi-storied steel frame buildings, then seismic upgrades of numerous buildings can be significantly expedited.
[0004] A wide variety of passive damping schemes have been marketed and implemented with varying degrees of success. These damping devices assume many forms characterized by a wide range of complexity and cost as outlined below; friction dampers, hysteretic (yielding) dampers, lead extrusion dampers, shape memory alloy devices, viscoelastic (rubber or rubber/metal hybrid) isolators, magnetostrictive or magnetorheological devices, tuned mass dampers, and tuned liquid/liquid column dampers. Aside from the tuned mass and/or liquid dampers, the basic damper configuration typically spans a building frame bay, either via a diagonal strut or a chevron brace arrangement. The key design parameters for any of the damper types include maximum force capacity and damper stroke (peak-to-peak in a load cycle). The different damper technologies exhibit hysteresis curves, bounded by these load and stroke parameters, whose shape depends upon the physical characteristics of the damper, and, in the case of viscous dampers, the velocity of the building motion. The required damper stroke is determined by the building displacement limits set either by the appropriate building code or by the builder's assessment of the acceptable damage threshold. In the US, building shear displacement angles (measured as the horizontal displacement of an upper story: the height between the upper story and the story beneath it) of 1:200 are generally considered to be limiting cases, while in Japan, shear displacement angles of 1:100 are tolerated.
[0005] One successful example of the damping devices outlined above has been the line of fluid viscous dampers by Taylor Devices, Inc. of North Tonawanda, N.Y. These fluid viscous dampers are essentially superscale versions of automotive shock absorbers, with load capacities ranging from 10 kips to 2000 kips, and strokes of up to 120 inches. While providing effective damping forces out of phase with the excitation, the fluid viscous dampers are relatively complex and costly and may not provide the desired design flexibility and longevity.
[0006] A recent development in hysteretic dampers fabricated from low strength steel and concrete by Nippon Steel has shown good performance with a minimum of complexity and cost. This damper mechanism has been used in several new-build projects in Japan. One implementation of this damper brace is a welded steel box of approximately 55 cm by 65 cm filled with concrete enclosing a low strength steel brace having a cruciform shape. Braces have been fabricated having a free length of just over 20 meters and weighing approximately 34 tons. The weight of the concrete-filled steel sleeve is very high and renders retrofit application of the damping brace difficult, if not impossible. The cost of this damping method is driven upward by the proprietary nature of the very low yield strength steel (100 Mpa/14.5 ksi) used in the strut.
[0007] The technology options for seismic energy absorbers currently available include: the Nippon Steel hysteretic strut brace and sleeve combination, yielding plate dampers, and viscous dampers such as the Taylor Devices line. While there are several other technologies that have some promise (lead extrusion, shape memory alloy, magnetorestrictive), these are not currently available on a commodity basis.
BRIEF SUMMARY OF THE INVENTION
[0008] A lightweight hysteretic damper is useful for framed buildings to reduce seismic response levels. A seismic brace incorporates a low-strength aluminum multi-armed strut that plastically deforms during a seismic event, damping a building's response because of the hysteresis in the strut material stress-strain curve. This strut is surrounded by a collar providing high bending stiffness, but no extensional stiffness, to prevent a low energy buckling failure of the brace in compression. The collar is composed of an outer sleeve of composite materials or metal construction, and spacers to provide the requisite load transfer from the strut which is free floating within the collar. Substantial improvements in weight-specific energy absorption and cost as compared to extant damper concepts are possible.
[0009] The hysteretic seismic damper employing a yielding central strut surrounded by a buckling suppression collar is utilized mounted along one or more diagonals of a building frame, and reduces structure seismic response by absorbing strain energy (providing extra damping). In order to maximize this damping energy absorption, the brace remains stable in both tension and compression load cycles to a significant level of plastic strain. When under significant compressive strain, the tangent modulus of the structural material is much lower than its initial modulus, introducing the requirement for a very rigid collar to prevent strut/brace buckling. Composite materials provide an opportunity to create such a collar at minimum weight and cost while metals employ known manufacturing methods.
[0010] In one embodiment utilizing a cruciform strut, the aluminum strut is surrounded by four hollow quarter-rounds of metal or composite construction, each of which contains both longitudinal and shear stiffness that in the aggregate is sufficient to prevent strut buckling up to its compressive yield strength. The quarter rounds are attached to one another and contained about the aluminum strut by a sleeve providing reinforcement mostly in the hoop/bias direction. For field assembly, the collar is assembled around the strut with the sleeve bonded to the spacers in the field using a room-temperature-curing adhesive. Factory assembly is an alternative although this field assembly embodiment is particularly well suited to retrofit applications.
[0011] In another embodiment, the aluminum strut is surrounded by four lightweight quarter-rounds, each of which is sufficient to transfer radial stresses to an outer sleeve. The four quarter-rounds may be attached to one another and are contained about the aluminum strut by a reinforced sleeve that contains both longitudinal and shear stiffness sufficient to prevent strut buckling up to its compressive yield strength. The sleeve is bonded to the spacers with an adhesive. This concept is optimized for initial installation applications since it can be constructed at greater lengths than the previous embodiment. Other aspects, features, and advantages of the present invention are disclosed in the detailed description that follows.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0012] The invention will be understood from the following detailed description in conjunction with the drawings, of which:
[0013] [0013]FIG. 1 is a diagram illustrating placement of braces according to the invention;
[0014] [0014]FIG. 2 is a desirable load deflection curve;
[0015] [0015]FIG. 3A is an illustration of a brace cross section with a multi-arm strut according to the invention;
[0016] [0016]FIG. 3B is an illustration of a brace cross section with a solid strut;
[0017] [0017]FIG. 4A is an illustration of a foam spacer according to the invention;
[0018] [0018]FIG. 4B is an illustration of a hollow rigid spacer according to the invention;
[0019] [0019]FIG. 5 is a detail of construction of an implementation of a brace according to the invention;
[0020] [0020]FIG. 6 is a view of a completed brace according to the invention;
[0021] [0021]FIG. 7 is an illustration of a cross section of a brace with a clamshell outer sleeve according to the invention; and
[0022] [0022]FIG. 8 is a detail of construction of a brace with a helical split sleeve according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] [0023]FIG. 1 illustrates a structure 16 incorporating a seismic brace 10 according to the present invention. The brace spans a building frame bay 18 , via either a diagonal strut 20 or a chevron brace 22 arrangement. The key design parameters for the braces include maximum force capacity and damper stroke (peak-to-peak in a load cycle). The braces return hysteresis curves bounded by these load and stroke parameters, such as shown in FIG. 2. Forces of 10,000 pounds or more move the brace up to 0.2 inches in this particular example. The shape of the hysteresis curves depends upon the physical characteristics of the brace. The goal of the brace is to absorb building response energy associated with a seismic event. The strut material is required to be driven substantially into the yield regime without failure at a yield stress that allows significant energy absorption in a package of tractable size. The brace material must further accommodate the expected number of load cycles without significant fatigue damage.
[0024] The specific loading and weight requirements for any particular application depend upon the frame bay proportions (H, W), the maximum allowed angle limit (typically 1:200) and the specific seismic event. The disclosed seismic brace withstands a yield load from 12-48 kips in one prototype implementation, but may easily be designed to achieve much larger load capacity.
[0025] A feasible and cost-effective hysteretic seismic brace meets these requirements by exercising in cyclic fashion a low strength aluminum strut surrounded by a buckling suppression collar. The collar is implementable utilizing combinations of metal, composite and lightweight materials. The seismic brace is composed of a central yielding strut that can be manufactured in a variety of multi-armed shapes. The central strut is surrounded by filler or spacer material contained by an outer sleeve. The filler and sleeve suppress buckling of the brace when the strut is stressed in compression. In many implementations, the central strut is made of annealed low-strength aluminum.
[0026] The basic configurations of the seismic braces according to the invention are shown in FIGS. 3A and 3B. Brace implementations using a cruciform or other multi-armed strut and a solid strut configuration are illustrated. All of the struts, whether of cruciform or cylindrical configuration, are fabricated from annealed aluminum with a yield strength between 7 to 15 ksi. Several nearly pure aluminums, 1100 and 1060 series, show yield strengths in this range. In addition, several of the 2000, 3000, 5000, and 6000 series aluminum alloys have sufficiently low yield strengths but exhibit too much age-hardening to be considered. For many implementations, 1100-O annealed aluminum is preferable.
[0027] [0027]FIG. 3A illustrates a circularly symmetric multi-armed strut 50 with a lightweight spacer 52 filling the space between the legs of the strut 50 . The strut 50 and spacer 52 are circumscribed by an outer sleeve 54 . An optional slip agent (not shown), such as a mold release agent, silicone or Teflon™ film is employed between strut 50 and spacer 52 to permit the hysteretic action of the strut to be unencumbered by the longitudinal stiffness of the spacer 52 and sleeve 54 . The desirability of such slip or release agents will be determined in each particular application case. For some applications, the natural lubricity of the constituent members may be sufficient to fulfill the stiffness-isolation function. For illustration purposes the multi-armed strut is shown as a cruciform shape, although shapes such as a tribach, star and I-section can be used. These shapes provide an axisymmetric (about the longitudinal axis) stiffness, with the tribach (three-armed) cross-section providing significant advantages in assembling end fittings.
[0028] For the multi-armed strut 50 , the basic alloy and temper may be varied to “tune” the load capacity. Annealed aluminum alloys serve as the central yielding strut 50 in this brace assembly 56 , Non-aging alloy compositions are necessary, since the service life of the seismic brace is expected to be very long (e.g. 20-50 years). In particular, 1100-O annealed aluminum is well adapted to serve as the brace strut 50 . For the multi-armed strut 50 1100-O annealed aluminum shows a material yield strength of approximately 10 ksi, and strain to failure well beyond 1%. The multi-armed strut 50 may be manufactured using extrusion or be welded from strip material.
[0029] While the 1100-O annealed aluminum exhibits the hysteretic properties needed, the resultant strut 50 must be reinforced to provide sufficient stiffening to suppress brace buckling at a reasonable weight and cost. A reinforcing outer collar (described below) is well suited to provide the stiffening. A sleeve 54 and spacer 52 together form the collar accomplishing the suppression of brace buckling.
[0030] The spacers 52 and sleeve 54 accomplish the buckling resistance as a system. When the spacer 52 serves primarily a stress transfer function, the sleeve 54 supplies the buckling suppression rigidity. When the spacer 52 performs more of the buckling suppression, the sleeve 54 may provide less of the buckling suppression rigidity, although the full function sleeves may still be used.
[0031] In a first implementation, shown in FIG. 4A, structural foam of approximately 20 lb/ft 3 density (or less) is used as the spacer 70 between the arms of the multi-armed strut 50 . The spacer 70 requires that all of the anti-buckling rigidity be supplied by the outermost sleeve 54 . An adhesive bonds the spacers 70 to the outer sleeve 54 and an optional slip agent may buffer the strut 50 and the spacer 70 preventing the application of any longitudinal restraint by the collar. The function of the foam spacers 70 is to provide a normal force restraint, effectively centering the aluminum multi-armed strut 50 within the outer sleeve 54 , and preventing any high frequency flange buckling which might be possible without deforming the sleeve 54 . This implementation is an economical configuration most amenable to factory assembly. The fully-assembled brace 56 using the foam spacer 70 is best suited to new-build applications.
[0032] A range of structural foams and pseudo concrete materials can be used in spacer 70 to provide relatively low weight at an attractive cost. The tradeoffs among these materials are related to cost, density, and performance. Compression strengths of the order a few hundred psi are sufficient for the spacer 70 , so that polymer foams of greater than 10-15 pounds per cubic foot (pcf) provide good service. In this range, there are many possible choices, ranging from homogeneous foams to syntactics. Phenolic resins and foams have the desirable characteristic of being essentially fireproof, emitting no toxins when subjected to flame.
[0033] Other choices for structural foams include polyurethane or PVC foams, epoxy based syntactic foams, or pseudo-concrete materials incorporating polymer matrices filled with inexpensive components such as fly ash, vermiculite, and pearlite. These materials are suitable for applications in which cost is a more important consideration than weight. The polymer foams are all quite expensive in the densities contemplated, but provide a 2×-3× weight advantage over the pseudo concretes (and 6×-10× as compared to regular concrete). A low initial cost fabrication method for spacer 70 is to cut the foam shapes on a shaper table, at the cost of some wasted foam. Large-scale production of the foam spacers 70 uses net-shape casting, with relatively high initial tooling cost but lower recurring cost.
[0034] The foam spacers 70 require a sleeve 54 that provides the anti-buckling function. The reinforcing sleeve 54 for the foam spacers 70 is a continuous cylinder with a suitable combination of longitudinal and off axis reinforcement. This sleeve can be fabricated from metal or composite material. Since the outer sleeve 54 is a continuous cylinder running approximately the entire length of the brace (in many cases approximately nine meters—30 ft.—or greater) that must be intimately bonded to the spacers 70 and not bonded to the multi-armed strut 50 , assembly is done in a factory-bonding fixture.
[0035] A metallic outer sleeve may be fabricated from rolled steel or aluminum sheet material of suitable alloys and provided with a fastening of the longitudinal edges of said sleeve via welding or other mechanical fastening means.
[0036] A composite outer sleeve 54 may be fabricated using a variety of methods including filament winding, roll wrapping and pultrusion. One manufacturing method for a brace using the foam spacers 70 is illustrated in FIG. 5. The spaces in the angles of the multi-armed strut 122 are filled with the stiff polymer foam (not shown) which is bonded to an outer sleeve 120 and not the strut 122 . The sleeve 120 is most conveniently constructed of fabric 121 such as graphite fabric, filament wound or roll-wrapped using the aluminum strut 122 and foam spacers as a mandrel. After wrapping, glass fiber 124 is over wrapped around the sleeve 120 and the wrapped sleeve is impregnated with resin (the resin bonds the sleeve to the foam spacer, but not to the strut, in the process). The finished assembly is then oven-cured. The completed brace is illustrated in FIG. 6 where the strut 126 is shown prepared for mounting to structural joint adapters, and the cured sleeve 128 extends to nearly the entire length of the brace. This implementation has a cost advantage because the structural parts are simple to fabricate. This implementation is adapted to factory assembly especially in larger sizes and does not readily allow assembly at the construction site. The cost/performance tradeoffs of selecting materials and manufacturing methods for a composite sleeve are the classic ones common to most fiber-reinforced composite applications as are known in the art.
[0037] In another spacer implementation illustrated in FIG. 4B, the spacers 53 are hollow structures having sufficient bending and shear rigidity to suppress buckling of the strut 50 under the intended yielding load. The outermost sleeve 54 for the hollow spacer is only required to hold the entire assembly together, providing shear and hoop rigidity from one to the other of the hollow spacers 53 . However, the high rigidity buckling suppression sleeve described above can also be used with spacer 53 .
[0038] The hollow spacer 53 consists of walls 60 and an enclosed space 62 . The walls 60 of the spacer 53 can be made of a fiber-reinforced composite material or a metal such as steel or aluminum alloys, or a hybrid construction comprising both metallic and composite elements. The composite hollow spacers 53 are easily fabricated via pultrusion or any variety of winding process. The winding approaches are applicable especially for initial production, having relatively low non-recurring tooling cost but moderate recurring cost. Pultrusion is more applicable to large-scale production, due to its extremely low recurring cost, married to relatively high initial tooling cost. Pultruded composite spacers 53 contain a reinforcement that provides a large measure of bending rigidity to stiffen the aluminum strut 50 during the compression portion of a load cycle. Because of the reinforcement requirement, the circular arc portion 64 of the cross section is composed largely of longitudinal fibers. The right-angle portion 66 of the cross section contains a balanced fabric reinforcement to provide a combination of longitudinal, transverse, and shear stiffness.
[0039] The material and fabrication tradeoffs for the hollow reinforced composite spacers 53 are quite similar to those for the outer sleeve used with the foam spacer 70 discussed above. In one embodiment, spacer mandrels are used as the foundation for fabricating the hollow composite spacers 53 . Care must be taken to assure the mandrels will release the spacers 53 . In this fabrication process, glass fabric was first wrapped around the released mandrels and longitudinal graphite fibers were added on the outermost curved surface 64 . These graphite fibers were in turn sandwiched by another layer of glass cloth, effectively capturing the graphite reinforcement. Vinyl Ester resin was then impregnated into the dry hybrid composite wrapped around the aluminum mandrel. Once the reinforcement was completely wetted, the whole assembly was wrapped in shrink tape and cured in the oven at 250 F. for 3 hours.
[0040] An advantage to the use of hollow spacers 53 is that for some sleeve implementations, the individual parts of the brace 56 can be carried to an installation site separately and assembled at the installation site using, for instance, a room-temperature-curing construction grade adhesive between spacer 53 and sleeve 54 . Field assembly renders brace 56 especially amenable to retrofit installations, where the size and weight of components represent a significant barrier to installation. While the sleeves described above in conjunction with foam spacer 70 may be used in conjunction with spacer 60 , these are not as readily amenable to on-site assembly.
[0041] [0041]FIGS. 7 and 8 illustrate two embodiments for an outer sleeve 54 that is amenable to on-site assembly. The first embodiment, a split clamshell, is shown in FIG. 7. The individual clamshell halves 86 are extruded or pultruded with lugs 88 on the long edges. These lugs 88 are secured by a fastening mechanism such as a formed sheet metal clamp 90 that is hammered over the pair of lugs 88 from the two halves of the clamshell, a bolt pattern disposed along the clamshell flanges, or other fastening mechanism. FIG. 7 also illustrates the bonded region 92 and the unbonded regions 94 of the brace.
[0042] A second embodiment shown in FIG. 8 utilizes hollow spacers 102 that are placed within the angles of the multi-armed strut 100 coated with a suitable release agent so as to slide with respect to the strut 100 . A spirally split “barber pole”-type sleeve 104 is snapped over the strut/quadrant spacer assembly 100 / 102 . After the spiral sleeve 104 shown is installed, a second spiral sleeve piece (not shown) is installed in the interstitial areas to provide complete coverage to the brace assembly 100 / 102 . The sleeves 104 are bonded to the outer circumference of the hollow spacer assemblies 102 with a construction-grade adhesive.
[0043] The outer sleeve of the clamshell 86 or split spiral 104 type can be economically fabricated using simple tooling. These sleeves hold the quadrant pieces 102 tight against the aluminum strut 100 , and provide a stiff shear interface and hoop rigidity between these pieces across the outstanding radial edges of the aluminum strut 100 . The sleeves need not provide significant added bending rigidity. The individual piece parts comprising the brace can be carried to the installation site separately and assembled on-site with room-temperature-curing construction grade adhesive (between spacer and sleeve).
[0044] The alternate configuration of the brace shown in FIG. 3B illustrates a brace 40 with a solid center hysteretic bar strut 42 surrounded by an optional relatively uniform lightweight spacer 44 fabricated of material such as may be used in spacer 70 . The outer surface of the spacer 44 is sheathed by an outer sleeve 46 . The sleeve 46 for this brace 40 may be any sleeve applicable to spacer 70 described above. The shape of this brace and strut configuration may be varied as the building requirements dictate. An optional slip agent (not shown) may be employed between strut 42 and spacer 44 to permit the hysteretic action of the strut to be unencumbered by the stiffness of the sleeve 46 .
[0045] A strut 42 having a circular cross section is desirable from the point of view of symmetry and ease of fabrication, but it is limited in its effective energy absorption capacity. When either filled or surrounded by a sheathing material of considerable hoop/radial integrity, a transverse stress is developed by Poisson effects that increases the yield stress/load by perhaps 15% as compared to the unconstrained value. This behavior may reduce the effectiveness of the solid core strut 42 . The brace of FIG. 3B can, however, have significant value as a seismic brace for light construction, or locations where space in the curtain wall is at a severe premium. This is the simplest configuration to fabricate, and will be less expensive to build and install than any of the multi-armed embodiments described above.
[0046] For composite sleeves used with the solid strut 42 , a greater thickness of composite or other high rigidity material is required in the sleeve 46 to stabilize the buckling failure mode with the simple rod brace 40 than will be true for the multi-armed strut configurations above.
[0047] The method of attaching the brace to the building structure of interest is critical to the effectiveness of the seismic brace. When the central strut is working properly, it is by definition yielding, and the secondary modulus for most structural metals suitable for yielding struts will be quite low. This situation demands that measures be taken which prevent local buckling of the strut, especially any flanges near the end of the strut. Any end fitting must satisfy the strength and grip interface requirements and allow the sleeve to be installed or manufactured easily onto the brace without interference from plates or other fitting details. Extremely stiff support for the aluminum strut is required to within a very small distance of the outer sleeve 54 surrounding the multi-armed strut.
[0048] Finite element analysis showed that the seismic brace can provide good and stable energy absorption at relatively light weight. The buckling safety factor for the multi-armed aluminum strut was much higher than that for the solid strut. Additionally, the end fittings used to attach the braces to a structure must be designed to transfer the load into the brace.
[0049] Laboratory testing on a specific configuration of prototype braces with foam spacers 70 showed that peak load capacity of the multi-armed strut can exceed +/−12,000 pounds, while the yield load is approximately 8,000-10,000 lb. The test for hollow spacers 53 yielded results similar to that observed for foam spacers 70 , indicating that the split sleeve brace configuration is equally able to support the compression portion of the load cycle, as compared to the stiff sleeve/foam spacer embodiment. The tests on round bars, with composite stiffening sleeve showed that this embodiment does not tolerate as much yielding displacement as the multi-armed strut brace. The basic result of this prototype testing is that the seismic brace implementations provide good and stable energy absorption at relatively light weight.
[0050] The multi-armed brace with both spacer implementations was shown to possess excellent damping characteristics, and a basic robustness to the required load cycling. The described seismic braces provide good and stable energy absorption at relatively light weight. Refined end fittings to attach the braces to the structures are important to maintain the brace performance.
[0051] A stiff sleeve/foam spacer configuration with a composite sleeve showed peak compression load values essentially equaling or exceeding the peak tension values. This result indicates that the composite sleeves at least performed their main requirement of eliminating the very low strength buckling failure mode. Reviewing the load-displacement curves for the tests show further that in all cases good energy absorption was achieved in the cyclic hysteresis curves.
[0052] Having described preferred embodiments of the invention it will now become apparent to those of ordinary skill in the art that other embodiments incorporating these concepts may be used. Accordingly, it is submitted that the invention should not be limited by the described embodiments but rather should only be limited by the spirit and scope of the appended claims. | An energy absorbing seismic brace for both retrofit and new construction. The brace comprises a central strut of either multi-legged or homogeneous section fabricated from low strength aluminum, whose characteristics maximize the seismic energy absorption for a building installation. This central strut absorbs energy at high weight-specific levels by virtue of the hysteresis in its load-deflection relationship. In order to eliminate the possibility of buckling of the energy absorbing strut when it passes through the compression portion of a load cycle, it is surrounded by a system of spacers and an external sleeve providing very high bending rigidity at low weight. The spacers may be fabricated from low-density foams, pseudo-concrete, fibrous composites, or metals, depending upon the application. The outer sleeve may also be fabricated from a variety of materials, depending upon whether the embodiment calls for the principal bending rigidity to be provided by the spacers or sleeve. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. application Ser. No. 12/684,161, filed Jan. 8, 2010 now U.S. Pat. No. 8,087,491, which is allowed, the entire contents of which are hereby incorporated by reference.
The invention relates generally to noise suppression techniques, and more particularly to systems and methods that provide improved sound attenuation properties. More particularly, the invention relates to silencers for ducts, including inlet and exhaust ducts, of a gas turbine.
BACKGROUND OF THE INVENTION
The environmental noise caused by airplanes, automobiles, and other modern machinery can often be an annoyance. To maintain noise below acceptable levels, noise suppression techniques are often employed. Noise suppression has, therefore, become a technology with a wide variety of industrial and residential applications. Noise suppression devices are often applied in heating, ventilation and air conditioning (HVAC) systems, industrial machinery and complexes, transportation vehicles, and any machinery that may tend to produce unacceptably high levels of noise.
In gas turbines, parallel baffle silencers are mounted in the inlet and exhaust ducts to achieve required acoustic performance. A certain duct length for inlet and exhaust is required to accommodate these silencers. The overall pressure loss in this arrangement from the face of silencer to an end of an elbow is the sum of frictional, entry and exit losses of the silencer and turning losses in the elbow. Two stages of silencers may be used in the elbow. A first stage may be used to attenuate low and mid range frequencies. The second stage may be provided to attenuate high frequencies. Alternatively, only one stage may be used in the exhaust duct to attenuate some frequencies. The use of parallel baffle silencers results in longer inlet and exhaust ducts. The overall pressure in the inlet and exhaust ducts tends to be high.
BRIEF DESCRIPTION OF THE INVENTION
According to one embodiment of the invention, a silencer for a gas turbine comprises a first duct portion; a second duct portion connected to the first duct portion, the first and second duct portions forming an elbow region at the connection; and a plurality of elbow shaped vanes provided in the elbow region, wherein the plurality of elbow shaped vanes have equal lengths and are spaced equally apart.
According to another embodiment of the invention, a silencer for a gas turbine comprises a first duct portion; a second duct portion connected to the first duct portion, the first and second duct portions forming an elbow region at the connection; and a plurality of parallel L-shaped shaped baffles provided in the elbow region, wherein the plurality of L-shaped baffles have equal lengths and are spaced equally apart.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically depicts a plan view of an exhaust duct for a gas turbine according to the prior art;
FIG. 2 schematically depicts a side view of the exhaust duct of FIG. 1 ;
FIG. 3 schematically depicts a perspective view of an exhaust duct according to an embodiment of the invention;
FIG. 4 schematically depicts a side view of the exhaust duct of FIG. 3 ;
FIG. 5 schematically depicts a plan view of the exhaust duct of FIG. 3 ;
FIG. 6 schematically depicts a perspective view of an exhaust duct according to another embodiment of the invention;
FIG. 7 schematically depicts a plan view of an exhaust duct according to the prior art;
FIG. 8 schematically depicts a side view of an exhaust duct according to another embodiment of the invention;
FIG. 9 schematically depicts a plan view of an exhaust duct according to another embodiment of the invention;
FIG. 10 schematically depicts a side view of the exhaust duct of FIG. 9 ;
FIG. 11 schematically depicts silencer baffles in a duct according to the prior art;
FIG. 12 schematically depicts a perspective view of a duct elbow including silencer vanes according to another embodiment of the invention;
FIG. 13 schematically depicts a perspective view of a duct elbow including silencer vanes according to another embodiment of the invention; and
FIG. 14 schematically depicts a perspective view of a duct elbow including L-type silencer baffles according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , an exhaust duct 2 according to the prior art includes an exhaust duct inlet 4 and an exhaust chimney 10 . A transition 6 is provided between the exhaust duct inlet 4 and the exhaust chimney 10 . Parallel silencer baffles 8 are provided after the transition 6 and prior to the exhaust chimney 10 .
As shown in FIG. 2 , the exhaust duct 2 has the general shape of an elbow. The exhaust duct 2 includes a generally horizontal portion and a generally vertical portion. The generally horizontal portion includes the inlet 4 , the transition 6 , and the parallel silencer baffles 8 . The vertical portion comprises the exhaust chimney 10 .
The overall pressure loss in the exhaust duct 2 of the prior art from the exhaust duct inlet 4 to the outlet of the exhaust chimney 10 is the sum of frictional, entry and exit losses of the parallel silencer baffles 8 and turning losses in the elbow.
Referring to FIGS. 3-5 , an exhaust duct 12 in accordance with an embodiment of the invention includes an exhaust duct inlet 14 followed by an inlet transition 16 . A plurality of silencer guide vanes 18 are provided in the elbow of the exhaust duct 12 . The silencer vanes 18 are followed by an outlet transition 20 and an exhaust chimney 22 . The exhaust duct 12 includes side walls 24 . The side walls 24 may have slots 19 through which the silencer guide vanes 18 are inserted into the exhaust duct 12 .
Referring to FIG. 4 , the exhaust duct 12 according to this embodiment of the invention has a reduced duct surface area and duct length (i.e. footprint) from the point A at the end of the end of the inlet transition 16 to the point B at the end of the outlet transition 20 than the duct surface area and the duct length from the point A to the point B of the exhaust duct 2 shown according to the prior art in FIG. 2 .
As shown in FIGS. 3-5 , the exhaust duct 12 includes fewer silencer guide vanes 18 in contrast to the number of parallel silencer baffles 8 of the prior art exhaust duct 2 of FIG. 1 . For example, the exhaust duct 12 according to this embodiment may have six silencer guide vanes 18 whereas the prior art exhaust duct 2 may have seven parallel silencer baffles 8 . The silencer guides vanes 18 of FIGS. 3-5 provide an open area and a blockage which is equal to the open area and blockage of the exhaust duct 2 of the prior art shown in FIGS. 1 and 2 . However, the exhaust duct 12 of the embodiment of FIGS. 3-5 provides the open area and blockage with a duct surface area and duct length that is less than the prior art, as discussed above.
As shown in detail in FIG. 3 , each silencer vane 18 comprises sheet material 25 , 29 that encloses sound attenuating material 31 . The sheet material 25 , 29 may be, for example, sheet metal. The sound attenuating material 31 may be, for example, fiberglass or foam. The surface of the sheet 25 in contact with the flow in the duct 12 may comprise perforations 27 . Although two sheets are shown, it should be appreciated that each silencer vane may be formed of a single sheet.
Referring to FIG. 4 , each silencer vane 18 is generally elbow or L-shaped. The silencer vanes 18 each have equal lengths, i.e. the distance from the front edge of the vane in the horizontal duct to the back edge of the vane in the vertical duct. The silencer vanes 18 are spaced so as to provide an equal flow gap between the silencer vanes 18 . The silencer vanes 18 may also be placed about a line of symmetry 23 such that each silencer vane 18 has equal extension in the horizontal and vertical ducts. It should be appreciated however that the silencer vanes 18 may be configured to have unequal extension into the horizontal and vertical ducts.
The provision of equal length and equally spaced silencer vanes provides uniform attenuation of sound compared to vanes of unequal lengths. The equal length and equally spaced silencer vanes also reduce turning losses, i.e. pressure drops, in the elbow compared to vanes of unequal length. Providing equal length and equally spaced silencer vanes reduces the amount of sound attenuating material compared to vanes of unequal length.
Referring to FIG. 6 , according to another embodiment of the invention, an exhaust duct 12 may comprise an inlet 14 and an exhaust chimney 22 that are configured as circular ducts.
Referring to FIG. 7 , an exhaust duct 26 according to the prior art comprises an exhaust duct inlet 28 and an inlet transition 30 following the inlet 28 . A plurality of first parallel silencer baffles 32 are provided after the inlet transition to dampen or silence, low frequencies in the exhaust duct. A plurality of second parallel silencer baffles 34 are provided after the first silencer baffles 32 to dampen or silence high frequencies in the exhaust duct 26 . The second silencer baffles 34 are followed by an exhaust chimney 36 .
Referring to FIG. 8 , an exhaust duct 38 according to another embodiment of the invention includes an exhaust duct inlet 40 followed by an inlet transition 42 . As shown in FIGS. 7 and 8 , the inlet transition 42 according to this embodiment of the invention shown in FIG. 8 may have the same length as the inlet transition 30 of the exhaust duct 26 of the prior art shown in FIG. 7 . The inlet transition 42 according to this embodiment of the invention may be followed by a horizontal stage 44 which is followed by the plurality of silencer guide vanes 46 . The silencer guide vanes 46 are followed by an outlet transition 48 which is followed by an exhaust chimney 50 . As shown in FIG. 8 , the exhaust duct 38 has a shorter overall duct length compared to the prior art duct 26 shown in FIG. 7
The horizontal stage 44 may be provided to attenuate high frequency noise. The horizontal stage 44 may be provided in the horizontal duct with the vane type silencers 46 in the elbow in situations in which very stringent requirements on sound levels are required. The horizontal stage provides the benefit of relocating the first stage from the horizontal duct to the elbow, thereby providing reduction in pressure loss (gain in power output) and duct cost savings.
Referring to FIGS. 9 and 10 , an exhaust duct 52 according to another embodiment of the invention includes an exhaust duct inlet 54 followed by an inlet transition 56 . A plurality of parallel elbow or L-shaped silencer baffles 58 follow the inlet transition 56 . An outlet transition 60 is provided after the silencer baffles 58 and followed by an exhaust chimney 62 . As shown in FIG. 9 , the parallel elbow or L-shaped silencer baffles 58 extend in the horizontal duct of the elbow to a position below and beyond the exhaust chimney 62 . The configuration of parallel elbow or L-shaped silencer baffles 58 shown in FIGS. 9 and 10 maintains the same gap-velocity across the silencer as the embodiment shown in FIGS. 3-5 . As shown in FIGS. 9 and 10 , the exhaust duct 52 according to this embodiment also provides a reduction in duct surface area and the duct length from the points A to B than in the prior art arrangement shown in FIGS. 1 and 2 .
Referring to FIG. 11 , an inlet or outlet duct 64 according to the prior art includes a plurality of parallel silencer baffles 66 . As shown in FIG. 12 , an inlet duct 70 according to an embodiment of the invention includes an inlet duct elbow 68 having a plurality of silencer guide vanes 72 provided in the elbow 68 . The silencer guide vanes 72 may have the same length as the parallel silencer baffles 66 of the prior art duct 64 shown in FIG. 11 . By providing the silencer guide vanes 72 in the elbow 68 , the duct length may be reduced. In addition, the silencer guide vanes 72 provide guided flow in the inlet duct elbow 68 and reduce the pressure loss due to the combination of silencer and elbow losses. The silencer vanes 72 also block the direct line of sight of sound waves and provide higher sound attenuation and insertion loss.
Referring to FIG. 13 , an exhaust duct elbow 74 according to an embodiment of the invention comprises an exhaust duct 76 and a plurality of silencer guide vanes 78 provided in an elbow of the exhaust duct.
The inlet and exhaust ducts 70 , 74 of FIGS. 12 and 13 may be used in all up and forward inlet and exhaust ducts in the gas turbine cycle.
Referring to FIG. 14 , a duct 82 includes a duct elbow 80 having a plurality of L-type inverted silencer baffles 84 . The baffles 84 have equal lengths and may extend an equal distance into the first, horizontal portion of the duct and the second, vertical portion of the duct.
The embodiments described herein provide a reduction in the pressure drop and provide improved acoustic performance. The embodiments described herein also provide cost savings in steel liner material of the ducts and savings on insulation of the ducts. Furthermore, the embodiments described herein reduce associated support structure, such as bolts, spacebars, and stiffeners.
The silencer vane configurations disclosed herein provide reduction in the length of inlet and exhaust ducts and associated support structure. The silencer configurations as disclosed herein reduce pressure losses in the inlet and exhaust ducts, thereby increasing plant output. Only one stage of silencers in the duct is sufficient to provide required acoustic performance for a wide range of frequencies.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A silencer for a gas turbine includes a first duct portion; a second duct portion connected to the first duct portion, the first and second duct portions forming an elbow region at the connection; and a plurality of elbow shaped vanes provided in the elbow region. The plurality of elbow shaped vanes have equal lengths and are spaced equally apart. | 5 |
This application claims the benefit of U.S. Provisional Application No. 60/294,362, filed May 30, 2001, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention is directed to the synthesis of γ-hydroxy-4-[[2-oxazolyl]alkyl]-α-[(cyclo)alkyl- or aryl- or heteroaryl-substituted methyl]-2-[[(un)substituted alkyl]aminocarbonyl]-1-piperazinepentanamides which are HIV protease inhibitors. The present invention also includes the preparation of intermediates useful in the synthesis of the piperazinepentanamide HIV protease inhibitors.
BACKGROUND OF THE INVENTION
The HIV retrovirus is the causative agent for AIDS. The HIV-1 retrovirus primarily uses the CD4 receptor (a 58 kDa transmembrane protein) to gain entry into cells, through high-affinity interactions between the viral envelope glycoprotein (gp 120) and a specific region of the CD4 molecule found in T-lymphocytes and CD4 (+) T-helper cells (Lasky L. A. et al., Cell 1987, 50: 975-985). HIV infection is characterized by an asymptomatic period immediately following infection that is devoid of clinical manifestations in the patient. Progressive HIV-induced destruction of the immune system then leads to increased susceptibility to opportunistic infections, which eventually produces a syndrome called AIDS-related complex (ARC) characterized by symptoms such as persistent generalized lymphadenopathy, fever, and weight loss, followed itself by full blown AIDS.
As in the case of several other retroviruses, HIV encodes the production of a protease which carries out post-translational cleavage of precursor polypeptides in a process necessary for the formation of infectious virions (S. Crawford et al., J. Virol . 1985, 53: 899). These gene products include pol—which encodes the virion RNA-dependent DNA polymerase (reverse transcriptase), an endonuclease, and HIV protease—and gag—which encodes the core-proteins of the virion. (H. Toh et al., EMBO J . 1985, 4: 1267; L. H. Pearl et al., Nature 1987, 329-351; M. D. Power et al., Science 1986, 231: 1567).
A number of synthetic anti-viral agents targeted to various stages in the replication cycle of HIV have been disclosed. These agents include inhibitors of HIV cellular fusion (Turpin et al., Expert Opinion on Therapeutic Patents 2000, 10: 1899-1909), reverse transcriptase inhibitors (e.g., didanosine, zidovudine (AZT), and efavirenz), integrase inhibitors (Neamati, Expert Opinion on Investigational Drugs 2000, 10: 281-296), and protease inhibitors (e.g., indinavir, ritonavir, and saquinavir). Protease inhibitors inhibit the formation of infectious virions by interfering with the processing of viral polyprotein precursors. Processing of these precursor proteins requires the action of virus-encoded proteases which are essential for replication (Kohl, N. E. et al., Proc. Natl. Acad. Sci. USA 1988, 85: 4686).
A substantial and persistent problem in the treatment of AIDS has been the ability of the HIV virus to develop resistance to the therapeutic agents employed to treat the disease. Resistance to HIV-1 protease inhibitors has been associated with 25 or more amino acid substitutions in both the protease and the cleavage sites. Many of these viral variants are resistant to all of the HIV protease inhibitors currently in clinical use. See Condra et al., Drug Resistance Updates 1998, 1: 1-7; Condra et al., Nature 1995, 374: 569-571; Condra et al., J. Virol . 1996, 70:8270-8276; Patrick et al., Antiviral Ther . 1996, Suppl. 1: 17-18; and Tisdale et al., Antimicrob. Agents Chemother . 1995, 39: 1704-1710.
Certain γ-hydroxy-4-[[2-oxazolyl]alkyl]-α-[substituted methyl]-2-[[fluoroalkyl)amino]carbonyl]-1-piperazinepentanamides are HIV protease inhibitors which are much more potent against HIV viral mutants than protease inhibitors presently in clinical use. The synthesis of these compounds is a complicated, multi-step process having a relatively low overall yield. The synthesis of these compounds can be represented by Scheme A as follows, wherein A10 represents the desired piperazinepentaneamide HIV protease inhibitor:
A*=absent, CH 2 , or O;
R 1 *=aryl or heteroaryl, wherein aryl is optionally substituted with one or more of halogen, hydroxy, cyano, alkyl, fluoroalkyl, alkoxy, fluoroalkoxy, S-alkyl, amino, or heteroaryl; and heteroaryl is optionally substituted with one or more of halogen, hydroxy, cyano, alkyl, fluoroalkyl, alkoxy, fluoroalkoxy, S-alkyl, amino, aryl, or heteroaryl.
R 2 *, R 3 *=H or alkyl; or
R 2 * and R 3 * together with the carbon to which they are attached form cycloalkyl;
R 6 *=monofluoroalkyl or polyfluoroalkyl;
R 7* =alkyl, cycloalkyl, aryl or heteroaryl, wherein aryl is optionally substituted with one or more of halogen, OH, alkyl, alkenyl, alkynyl, fluoroalkyl, alkoxy, or heteroaryl; and heteroaryl is optionally substituted with one or more of halogen, OH, alkyl, alkenyl, alkynyl, fluoroalkyl, alkoxy, or aryl;
R 8 *, R 9 *=H, OH, alkyl, fluoroalkyl, or alkoxy; or
R 8 * and R 9 * together with the carbons to which they are attached form a fused benzene ring.
WO 01/38332 presents a specific example of Scheme A in Example 85, which describes the preparation of (αR,γS,2S)-N-[(3S,4S)-3,4-dihydro-3-hydroxy-2H-1-benzopyran-4-yl]-γ-hydroxy-4-[1-[5-(5-methoxy-3-pyridinyl)-2-oxazolyl]-1-methylethyl]-α-(phenylmethyl)-2-[[(2,2,2-trifluoroethyl)amino]carbonyl]-1-piperazinepentanamide (hereinafter alternatively referred to as Compound 26).
The preparation of the ketoamines of formula R 1* —C(═O)CH 2 NH 2 employed in Scheme A to make Compound A6 can be represented by Scheme B as follows:
WO 01/38332 contains a specific example of Scheme B in Example 85, which describes the preparation of 3-aminomethylcarbonyl-5-methoxypyridine in Steps B and C.
There is a need for improvements in one or more steps of Scheme A and Scheme B in order to prepare this class of piperazinepentaneamide HIV protease inhibitors more efficiently and more conveniently.
SUMMARY OF THE INVENTION
The present invention provides for improvements in the process for preparing γ-hydroxy-4-[[2-oxazolyl]alkyl]-α-[(cyclo)alkyl- or aryl- or heteroaryl-substituted methyl]-2-[[(un)substituted alkyl]aminocarbonyl]-1-piperazinepentanamides. The present invention includes an improved process for making a 4-[[2-oxazolyl]alkyl]-2-[[(un)substituted alkyl]aminocarbonyl]piperazine by treating a ketoamide precursor with fuming sulfuric acid in the presence of polyphosphoric acid. The present invention also includes a process for enhancing the optical purity of 4-[[2-oxazolyl]alkyl]-2-[[(un)substituted alkyl]aminocarbonyl]-piperazines via the formation 2-naphthalenesulfonic acid crystal salts thereof. The present invention further includes a method for purifying 2-naphthalenesulfonic acid.
The foregoing embodiments as well as other embodiments, aspects and features of the present invention are either further described in or will be apparent from the ensuing description, examples, and appended claims.
DETAILED DESCRIPTION OF THE INVENTION
The present invention includes a process for preparing a piperazine of Formula (II):
which comprises:
(A) treating a ketoamide of Formula (I):
with fuming sulfuric acid in the presence of polyphosphoric acid to obtain the piperazine II; wherein
stereocenter a is either in the R configuration or in the S configuration;
G is a nitrogen-protecting group;
R 1 is:
heterocycle, or substituted heterocycle;
wherein each Q is independently hydrogen, cyano, C 1 -C 4 alkyl, or —O—C 1 -C 4 alkyl;
heterocycle in R 1 is:
substituted heterocycle in R 1 is a heterocycle as defined above with one or more substituents (e.g., from 1 to 4 substituents, or from 1 to 3 substituents; or is di-substituted; or is mono-substituted) independently selected from cyano, C 1 -C 4 alkyl, —O—C 1 -C 4 alkyl, S—(C 1 -C 4 alkyl), NR a R b , thiazolyl, oxazolyl, imidazolyl, pyrazolyl, triazolyl, pyrrolyl, isoxazolyl, and isothiazolyl;
R 2 and R 3 are each independently hydrogen, C 1 -C 6 alkyl, or aryl, wherein the alkyl group is optionally substituted with one or more substituents (e.g., from 1 to 6, or from 1 to 5, or from 1 to 4, or from 1 to 3 substituents; or is di-substituted; or is mono-substituted) each of which is independently halogen, —O—C 1 -C 6 alkyl, or —O—C 1 -C 6 haloalkyl; and wherein the aryl group is optionally substituted with one or more substituents each of which is independently halogen, —C 1 -C 6 alkyl, —C 1 -C 6 haloalkyl, —O—C 1 -C 6 alkyl, or —O—C 1 -C 6 haloalkyl; or
R 2 and R 3 together with the carbon to which they are attached form C 3 -C 8 cycloalkyl which is optionally substituted with one or more substituents (e.g., from 1 to 6, or from 1 to 5, or from 1 to 4, or from 1 to 3 substituents; or is di-substituted; or is mono-substituted) each of which is independently halogen, —C 1 -C 6 alkyl, —C 1 -C 6 haloalkyl, —O—C 1 -C 6 alkyl, —O—C 1 -C 6 haloalkyl, or —C 1 -C 6 alkyl substituted with —O—C 1 -C 6 alkyl;
R 6 is —H or C 1 -C 6 alkyl optionally substituted with one or more substituents (e.g., from 1 to 6, or from 1 to 5, or from 1 to 4, or from 1 to 3 substituents; or is di-substituted; or is mono-substituted) each of which is independently
(1) halogen,
(2) —O—C 1 -C 6 alkyl,
(3) —O—C 1 -C 6 haloalkyl,
(4) —C 1 -C 6 alkyl substituted with —C 1 -C 6 alkyl,
(5) —N(R c ) 2 ,
(6) —CO 2 R c ,
(7) —N(R c )(SO 2 R c ),
(8) —C(═O)R c , or
(9) —C(═O)—N(R c ) 2 ;
R a and R b are each independently —H or —C 1 -C 4 alkyl; or alternatively R a and R b together with the nitrogen to which they are attached form C 1 -C 6 azacycloalkyl;
each R c is independently —H or —C 1 -C 4 alkyl; and
t is an integer equal to zero, 1 or 2.
In the definition of stereocenter a in the above process, it is to be understood that stereocenter a is either wholly or substantially in the R or the S configuration. The term “substantially” means that the ketoamide I reactant generally has at least about a 20% enantiomeric excess (ee) of the desired configuration over the other, typically has at least about a 40% ee, and more typically has at least an 80% ee of one configuration over the other at stereocenter a . Ketoamide I often has a 90% to 99% ee, or even has 100% ee, of one configuration over the other. In one embodiment of the process, ketoamide I is in the S configuration at stereocenter a ; i.e., ketoamide I is wholly or substantially in the S configuration.
In an embodiment of the process of the invention, R 1 is as originally defined, except that R a and R b are each independently —H or —C 1 -C 4 alkyl. In other embodiments, R 1 is as originally defined, except that R a and R b are both —H; or R a and R b are each a —C 1 -C 4 alkyl; or R a and R b are each independently —H, methyl, or ethyl; or R a and R b together with the nitrogen to which they are attached form azetidinyl, pyrrolidinyl, or piperidinyl.
In another embodiment of the process of the invention, R 1 in ketoamide I and piperazine II is
heterocycle, or substituted heterocycle;
wherein each Q is independently hydrogen, cyano, C 1 -C 4 alkyl, or —O—C 1 -C 4 alkyl; heterocycle is
substituted heterocycle is heterocycle as defined above having from 1 to 3 substituents independently selected from C 1 -C 4 alkyl, —O—C 1 -C 4 alkyl, —S—CH 3 , —N(CH 3 ) 2 , thiazolyl, and oxazolyl; and
t is an integer equal to zero, 1 or 2.
In another embodiment, R 1 is:
heterocycle, or substituted heterocycle;
wherein each Q is independently hydrogen, C 1 -C 4 alkyl, or —O—C 1 -C 4 alkyl;
heterocycle is
substituted heterocycle is heterocycle as defined above having from 1 to 3 substituents independently selected from C 1 -C 4 alkyl, —O—C 1 -C 4 alkyl, —S—CH 3 , and —N(CH 3 ) 2 ; and
t is an integer equal to zero, 1 or 2.
In still another embodiment of the process, R 1 is pyridyl which is unsubstituted or substituted with 1 or 2 substituents independently selected from optionally substituted with C 1 -C 4 alkyl or —O—C 1 -C 4 alkyl. In an aspect of this embodiment, R 1 is pyridyl which is unsubstituted or substituted with methyl or methoxy. In another aspect of this embodiment, R 1 is:
In an embodiment of the process of the invention, R 2 and R 3 in ketoamide I and piperazine II are each independently hydrogen or C 1 -C 4 alkyl; or R 2 and R 3 together with the carbon to which they are attached form C 1 -C 6 cycloalkyl. In another embodiment, R 2 and R 3 are either both —H or both methyl.
In an embodiment of the process of the invention, R 6 is as originally defined, except that each R c is —H. In other embodiments, R 6 is as originally defined, except that each R c is a —C 1 -C 4 alkyl; or each R c is independently —H, methyl, or ethyl; or each R c is methyl.
In another embodiment, R 6 is C 1 -C 6 alkyl optionally substituted with one or more halogens each of which is independently fluoro, chloro, or bromo. In another embodiment, R 6 is C 1 -C 4 alkyl or C 1 -C 4 fluoroalkyl. In still another embodiment, R 6 is
In an aspect of the preceding embodiment, R 6 is
In the process of the invention, G is a nitrogen-protecting group. The choice of the nitrogen-protecting group is not critical. G can be, for example, any of the amino nitrogen protective groups described in T. W. Greene, Protective Groups in Organic Synthesis , John Wiley & Sons, 1981, pp. 218-287 and in T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis , 2d edition, John Wiley & Sons, 1991, pp. 309-405. Suitable G groups include: (1) (C 1 -C 8 alkyl)oxycarbonyl, (2) allyloxycarbonyl, (3) benzyloxycarbonyl wherein benzyl is optionally substituted with from 1 to 3 substituents each of which is independently halogen, C 1 -C 4 alkyl or —O—C 1 -C 4 alkyl, (4) p-nitrobenzyloxycarbonyl, (5) phenyloxycarbonyl wherein phenyl is optionally substituted with from 1 to 3 substituents each of which is independently C 1 -C 4 alkyl or —O—C 1 -C 4 alkyl, and (6) methylcarbonyl wherein the methyl is optionally substituted with from 1 to 3 substituents each of which is independently chloro or fluoro. In one embodiment, G is butyloxycarbonyl, t-amyloxycarbonyl, diisopropylmethyloxycarbonyl, allyloxycarbonyl, benzyloxycarbonyl, phenyloxycarbonyl, p-methoxybenzylcarbonyl, 2,4,6-trimethylbenzyloxycarbonyl, 3,5-dimethoxybenzyloxycarbonyl, p-nitrobenzyloxycarbonyl, 2,4-dichlorobenzyloxycarbonyl, or trifluoroacetyl. In an aspect of this embodiment, G is allyloxycarbonyl.
In the process of the invention, any amount of fuming sulfuric acid can be employed in Step A which results in the formation of at least some of Compound II. Of course, the maximum conversion of Compound I and maximum yield of Compound II is normally desired, and relative proportions of reactants and reagents suitable for this purpose are typically employed. In one embodiment, the fuming sulfuric acid (alternatively referred to herein as “oleum”) is employed in an amount in the range of from about 5 to about 20 equivalents per equivalent of ketoamide I. In another embodiment, the fuming sulfuric acid is employed in an amount of from about 7 to about 11 equivalents per equivalent of ketoamide I. It is preferred to use the fuming sulfuric acid as the solvent for the reaction, although an inert co-solvent (e.g., an aliphatic hydrocarbon or an aromatic hydrocarbon) can be employed. Fuming sulfuric acid is commercially available in 15%, 20%, 30% and 60% grades. These grades can be used directly in Step A.
The oleum cyclization of ketoamide I in Step A is conducted in the presence of polyphosphoric acid. The cyclization of I with oleum alone can occur with significant racemization of stereocenter a , leading to a piperazine II product with lower optical purity. It has been found that the presence of polyphosphoric acid can significantly minimize racemization during oleum cyclization, resulting in a piperazine II with little or no degradation in optical purity. Polyphosphoric acid is suitably employed in Step A in an amount in the range of from about 0.5 to about 10 equivalents per equivalent of ketoamide I, and is typically employed in an amount of from about 2 to about 4 equivalents per equivalent of ketoamide I. In one embodiment, the ratio of equivalents of fuming sulfuric acid to equivalents of polyphosphoric acid is in the range from about 1:1 to about 30:1. In still another embodiment, the ratio of equivalents of fuming sulfuric acid to equivalents of polyphosphoric acid is in the range from about 2:1 to about 4:1. In still another embodiment, neat polyphosphoric acid is employed in Step A.
In an aspect of Step A, fuming sulfuric acid is employed in an amount in the range of from about 5 to about 20 equivalents and the polyphosphoric acid is employed in an amount in the range of from about 0.5 to about 10 equivalents per equivalent of ketoamide I. In another aspect, fuming sulfuric acid is employed in an amount in the range of from about 7 to about 11 equivalents and the polyphosphoric acid is employed in an amount in the range of from about 2 to about 4 equivalents per equivalent of ketoamide I.
Step A is suitably conducted at a temperature in the range of from about 0 to about 80° C. and is typically conducted at a temperature in the range of from about 25 to about 60° C. (e.g., from about 30 to about 50° C.).
In a suitable procedure for conducting Step A, liquid oleum is charged to the reaction vessel and cooled (e.g., to a temperature in the range of from about 5 to about 15° C.), after which polyphosphoric acid is slowly poured into the cooled oleum, followed by addition of ketoamide I while keeping the mixture cool (e.g., below about 25° C.). Upon completion of the ketoamide I addition, the mixture is heated to and maintained at a suitable reaction temperature until the reaction is complete or, alternatively, a desired amount of conversion is achieved. The reaction can be quenched by addition of water. The piperazine II can be recovered by conventional techniques, such as, for example, by adding an organic solvent to form an organic phase containing piperazine II and an aqueous phase, separating the phases, and recovering piperazine II from the organic phase (e.g., by concentrating and/or cooling the solution to precipitate piperazine II).
In still another aspect of Step A, the ketoamide I is employed as the sulfate salt (e.g., the bis-sulfate salt). The addition of the sulfate salt to the oleum has been found to be less exothermic than the addition of the corresponding free base. The use of the sulfate salt has also been found to avoid or minimize the formation of gummy solids that have been observed with the free base.
The ketoamide I reactant employed in Step A can be prepared, for example, by Scheme C as follows, wherein a , R 1 , R 2 , R 3 , and R 6 are each as originally defined above with respect to process of the invention comprising Step A or as set forth in any of the foregoing embodiments or aspects of Step A:
The present invention includes a process for preparing a Boc aminoketone of formula C4 which comprises:
deprotonating Weinreb amide C3 by treatment with a Grignard of formula (C 1 -C 4 alkyl)MgX wherein X is Cl or Br; and
reacting the deprotonated Weinreb amide with Grignard C2 of formula R 1 —MgX to obtain the Boc aminoketone C4.
In this process, R 1 in C2 and C4 is as originally defined above or as defined in any of the embodiments or aspects set forth for Step A. Both steps of this process are conducted in inert solvents such as dialkyl ethers (e.g., ethyl ether) and cyclic ethers and diethers (e.g., THF). In one embodiment, from about 0.9 to about 1.1 equivalents of (C 1 -C 4 alkyl)MgX is employed per equivalent of C3 and from about 0.9 to about 1.1 equivalents of R 1 —MgX is employed per equivalent of C3. The deprotonation step is typically conducted at a relatively low temperature; e.g., from about −10 to about 15° C. The reaction of the deprotonated Weinreb amide with R 1 —MgX is typically conducted by adding R 1 —MgX to the deprotonated Weinreb amide at a low temperature (e.g., from about −20 to about 0° C.), followed by warming the reaction mixture to a suitable reaction temperature (e.g., from about 20 to about 30° C.) and maintaining at reaction temperature until the reaction is complete. As an alternative to this process, the Weinreb amide C3 can be reacted directly with two equivalents of R 1 —MgX to give C4. Deprotonation of the Weinreb amide prior to reaction with R 1 —MgX can reduce costs, because the deprotonation can be achieved with one equivalent of a relatively inexpensive (C 1 -C 4 alkyl)MgX such as isopropylMgCl, so that only one equivalent of the typically more expensive R 1 —MgX is required to obtain C4. The process of the invention has also been found to result in a product C4 with improved purity compared to the product obtained by direct reaction of R 1 —MgX with C3.
The present invention also includes a process for preparing Compound 16:
which comprises:
(aa) treating ketoamide 15:
with fuming sulfuric acid in the presence of polyphosphoric acid to obtain Compound 16.
Embodiments of this process include the process as just described additionally incorporating one or more of the following features:
the fuming sulfuric acid is employed in an amount in the range of from about 5 to about 20 equivalents (or from about 7 to about 11 equivalents) and the polyphosphoric acid is employed in an amount in the range of from about 0.5 to about 10 equivalents (of from about 2 to about 4 equivalents) per equivalent of ketoamide 15;
the ratio of equivalents of fuming sulfuric acid to equivalents of polyphosphoric acid is in the range from about 1:1 to about 30:1 or from about 2:1 to about 4:1;
the acid treatment of ketoamide 15 is conducted at a temperature in the range of from about 0 to about 80° C. or from about 25 to about 60° C. (e.g., from about 30 to about 50° C.); or
the bis-sulfate salt of ketoamide 15 is employed in the process.
The present invention also includes a process for preparing a compound of Formula (IV):
which comprises:
(A) treating a ketoamide of Formula (I):
with fuming sulfuric acid in the presence of polyphosphoric acid to obtain a piperazine II:
(B) reacting the piperazine II with an epoxide of Formula (III):
to obtain a compound of Formula (IV); wherein
stereocenter a , G, R 1 , R 2 , R 3 , and R 6 are each as originally defined above in the discussion of Step A or as defined in any of the embodiments of Step A set forth above;
A is absent, CH 2 , CHOH, O, or S;
R 7 is C 1 -C 6 alkyl, C 1 -C 6 cycloalkyl, aryl, or heteroaryl; wherein the alkyl or cycloalkyl is optionally substituted with one or more substituents (e.g., from 1 to 6, or from 1 to 5, or from 1 to 4, or from 1 to 3 substituents; or is di-substituted; or is mono-substituted) each of which is independently halogen, hydroxy, —C 1 -C 6 haloalkyl, —O—C 1 -C 6 alkyl, or —O—C 1 -C 6 haloalkyl; and wherein aryl or heteroaryl is optionally substituted with one or more substituents (e.g., from 1 to 5, or from 1 to 4, or from 1 to 3 substituents; or is di-substituted; or is mono-substituted) each of which is independently halogen, hydroxy, —C 1 -C 6 haloalkyl, —O—C 1 -C 6 alkyl, —O—C 1 -C 6 haloalkyl, C 2 -C 6 alkenyl, or C 2 -C 6 alkynyl; and
R 8 and R 9 are each independently —H, —C 1 -C 6 alkyl, —C 1 -C 6 haloalkyl, —C 1 -C 6 cycloalkyl, or aryl, wherein the aryl is optionally substituted with one or more substituents (e.g., from 1 to 5, or from 1 to 4, or from 1 to 3 substituents; or is di-substituted; or is mono-substituted) each of which is independently halogen, —OH, —C 1 -C 6 alkyl, —C 1 -C 6 haloalkyl, —O—C 1 -C 6 alkyl, or —O—C 1 -C 6 haloalkyl; or alternatively
R 8 and R 9 together with the carbons to which each is attached form a fused benzene ring which is optionally substituted with one or more substituents (e.g., from 1 to 4 or from 1 to 3 substituents; or is di-substituted; or is mono-substituted) each of which is independently halogen, —OH, —C 1 -C 6 alkyl, —C 1 -C 6 haloalkyl, —O—C 1 -C 6 alkyl, or —O—C 1 -C 6 haloalkyl.
Step A of this process has already been described in detail above. Step B involves the coupling of the epoxide III with the piperazine II with the opening of the epoxide ring to give Compound IV. It is to be understood that any embodiment or aspect of Step A set forth above can be employed with any embodiment or aspect of Step B as described below.
In an embodiment of the process, A in Compounds III and IV is absent, CH 2 , or O.
In another embodiment of the process, R 7 in Compounds III and IV is C 1 -C 6 alkyl, C 1 -C 6 cycloalkyl, phenyl, substituted phenyl, heteroaryl, or substituted heteroaryl, wherein heteroaryl is selected from pyridyl, pyrazinyl, pyrimidinyl, thiophenyl, thiazolyl, pyridofuranyl, pyrimidofuranyl, pyridothienyl, pyridazothienyl, pyridooxazolyl, pyridazooxazolyl, pyrimidooxazolyl, pyridothiazolyl, and pyridazothiazolyl; and wherein substituted phenyl or substituted heteroaryl is substituted with one or more substituents (e.g., substituted with from 1 to 3 substituents, or substituted with 1 or 2 substituents), and each of the substituents on substituted phenyl or substituted heteroaryl is independently halogen, hydroxy, C 1 -C 6 alkyl, C 1 -C 6 fluoroalkyl, or —O—C 1 -C 6 alkyl.
In another embodiment, R 7 in Compounds III and IV is
each Z is independently hydrogen, halogen, cyano, C 1 -C 6 alkyl, or C 1 -C 6 alkoxy; and
q is an integer from 0 to 2.
In still another embodiment, R 7 in Compounds III and IV is
In still another embodiment, R 7 in Compounds III and IV is
In another embodiment of the process, R 8 and R 9 are each independently —H, —C 1 -C 4 alkyl, —C 1 -C 4 fluoroalkyl, —C 1 -C 6 cycloalkyl, or phenyl, wherein the phenyl is optionally substituted with one or more substituents (e.g., substituted with from 1 to 3 substituents, or substituted with 1 or 2 substituents) each of which is independently halogen, —C 1 -C 4 alkyl, —C 1 -C 4 fluoroalkyl, —O—C 1 -C 4 alkyl, or —O—C 1 -C 4 fluoroalkyl; or alternatively R 8 and R 9 together with the carbons to which each is attached form a fused benzene ring which is optionally substituted with one or more substituents (e.g., substituted with from 1 to 3 substituents, or substituted with 1 or 2 substituents) each of which is independently halogen, —C 1 -C 4 alkyl, —C 1 -C 4 fluoroalkyl, —O—C 1 -C 4 alkyl, or —O—C 1 -C 4 fluoroalkyl.
In another embodiment of the process, R 8 and R 9 are each independently —H, —C 1 -C 4 alkyl, —C 1 -C 4 fluoroalkyl, or phenyl; or alternatively R 8 and R 9 together with the carbons to which each is attached form a fused benzene ring which is optionally substituted with one or more substituents (e.g., substituted with from 1 to 3 substituents, or substituted with 1 or 2 substituents) each of which is independently halogen, —C 1 -C 4 alkyl, —C 1 -C 4 fluoroalkyl, —O—C 1 -C 4 alkyl, or —O—C 1 -C 4 fluoroalkyl.
In another embodiment of the process, Compound III (and the corresponding moiety in Compound IV) is:
wherein R 7 and R 8 are each as originally defined or as defined in any of the preceding embodiments; each Y is independently —H, halogen, —C 1 -C 4 alkyl, —C 1 -C 4 fluoroalkyl, or —O—C 1 -C 4 alkyl; and p is an integer equal to zero, 1 or 2.
In still another embodiment of the process, Compound III is:
the corresponding moiety in Compound IV is:
respectively.
Step B is suitably conducted in a solvent. The solvent employed in the coupling reaction can be any organic compound which under the reaction conditions employed is in the liquid phase, is chemically inert, and will dissolve, suspend, and/or disperse the reactants. Suitable solvents include hydrocarbons, ethers, alcohols, nitrites, and esters. In one embodiment, the solvent is selected from the group consisting of C 3 -C 10 linear and branched alkanes, C 1 -C 10 linear and branched halogenated alkanes, C 5 -C 10 cycloalkanes, C 6 -C 14 aromatic hydrocarbons, dialkyl ethers wherein each alkyl is independently a C 1 -C 6 alkyl, C 1 -C 6 linear and branched alkanes substituted with two —O—C 1 -C 6 alkyl groups (which are the same or different), C 4 -C 8 cyclic ethers and diethers, C 6 -C 8 aromatic ethers, C 1 -C 6 alkyl esters of C 1 -C 6 alkylcarboxylic acids, C 1 -C 10 alkyl alcohols, C 2 -C 6 aliphatic nitriles, and C 7 -C 10 aromatic nitriles. Exemplary solvents include carbon tetrachloride, chloroform, methylene chloride, 1,2-dichloroethane (DCE), 1,1,2-trichloroethane (TCE), 1,1,2,2-tetrachloroethane, cyclohexane, toluene, o- and m- and p-xylene, ethylbenzene, ethyl ether, MTBE, THF, dioxane, 1,2-dimethoxyethane (DME), anisole, phenetole, methyl acetate, ethyl acetate, ethanol, n- and iso-propanol, tert-butyl alcohol, tert-amyl alcohol, acetonitrile, propionitrile, benzonitrile, and p-tolunitrile.
In another embodiment, the solvent employed in Step B is a C 1 -C 6 alkyl alcohol. In an aspect of this embodiment, the alcohol is methanol, ethanol, isopropanol, t-butyl alcohol, or t-amyl alcohol.
Step B is suitably conducted at a temperature in the range of from about room temperature up to the reflux temperature of the chosen solvent. In one embodiment, the reaction is conducted at a temperature in the range of from about 20 to about 100° C. In other embodiments, the temperature is in the range of from about 30 to about 95° C., or is in the range of from about 40 to about 95° C. (e.g., from about 45 to about 65° C.).
Piperazine II and epoxide m can be employed in any proportion which will result in the formation of at least some of Compound IV. Typically, however, the reactants are employed in proportions which will optimize conversion of at least one of the reactants. In one embodiment, the amount of piperazine II employed in Step B is at least about 0.5 equivalent per equivalent of epoxide III, and is typically in the range of from about 1 to about 5 (e.g., from about 1 to about 3) equivalents per equivalent of epoxide III. In another embodiment, piperazine H is employed in an amount of from about 1 to about 2 (e.g., from about 1 to about 1.5) equivalents per equivalent of epoxide III. In an aspect of the preceding embodiment, piperazine II is employed in an amount of from about 1 to about 1.1 equivalents per equivalent of epoxide III.
The solvent, piperazine II, and epoxide III can be charged to the Step B reaction vessel concurrently or sequentially in any order. In a suitable procedure, the piperazine II is dissolved in the chosen solvent, followed by addition of epoxide III. The mixture is then stirred at a suitable reaction temperature until the reaction is complete or, alternatively, until the desired or optimum degree of conversion is obtained.
Product IV can be recovered via conventional techniques, such as by treating a solution of IV with silica gel and/or activated carbon to remove impurities, filtering the solution, concentrating and cooling the filtrate to precipitate IV and separating IV by filtration.
Epoxides of Formula (III) for use in Step B can be prepared via the methods (or routine modifications thereof) described in U.S. Pat. No. 5,728,840.
The present invention also includes a process which comprises Steps A and B as heretofore described, and which further comprises:
(C) treating Compound IV with acid to obtain a compound of Formula (V):
Step C is an acid deprotection step which affords Compound V, wherein stereocenter a , A, R 1 , R 2 , R 3 , R 6 , R 7 , R 8 , and R 9 are as originally defined above in the discussion of Steps A and B or as defined in any of the embodiments of Steps A and B as set forth above. Compounds of Formula (V) are inhibitors of HIV protease, and certain classes of the compounds encompassed by Formula (V) (e.g., those in which R 6 =fluoroalkyl such as 2,2,2-trifluoroethyl) are inhibitors of mutant forms of HIV protease which are resistant to conventional protease inhibitors such as indinavir. Compounds representative of the classes of compounds of Formula (V) capable of inhibiting mutant protease have exhibited IC 50 values below 1 nM against the wild-type enzyme and below 5 nM against the mutant enzymes Q-60, K-60, and V-18 in the assay for inhibition of microbial expressed HIV protease described in International Publication No. WO 01/05230. These compounds have also exhibited CIC 95 values below 50 nM against the wild-type viral construct and CIC 95 values below 125 nM against the viral constructs Q60, K-60, and V-18 in the cell spread assay described in WO 01/05230. These compounds are generally much more potent in both of these assays than indinavir. Further description of these compounds can be found in WO 01/38332.
In Step C, Compound IV is dissolved in a suitable solvent and brought into contact with the acid. Suitable solvents include polar organic solvents which are chemically inert under the conditions employed in Step C, such as alcohols and ethers. In one embodiment, the solvent is a dialkyl ether wherein each alkyl is independently a C 1 -C 6 alkyl, C 1 -C 6 linear or branched alkane substituted with two —O—C 1 -C 6 alkyls (which are the same or different), a C 4 -C 8 cyclic ether and diether, or a C 1 -C 6 alkyl alcohol. In an aspect of this embodiment, the solvent is a C 1 -C 6 alkyl alcohol (e.g., methanol).
The acid is suitably a strong acid such as trifluoroacetic acid or HCl. The acid can be introduced directly into a solution of Compound IV (e.g., bubbling gaseous HCl into the solution) or can be charged in the form of a solution, such as an aqueous solution or a solution in suitable organic solvent such as an alcohol (e.g., methanol) or an ether (e.g., THF). The acid treatment is generally conducted at a relatively low temperature (e.g., suitably less than about 20° C. and more suitably less than about 10° C.). Typically at least about 1 equivalent of acid is employed in Step C per equivalent of Compound IV, and an excess amount of the acid is typically employed. In a suitable procedure, a solution of the acid is added slowly (e.g., dropwise) to a solution of Compound IV while maintaining the solution at a relatively low temperature, in order to avoid a rapid accumulation of heat. Once the reaction is complete or the desired degree of conversion has been obtained, the reaction mixture can be quenched with base and product V recovered by conventional means.
The present invention also includes a process for preparing Compound 25:
which comprises:
(aa) treating ketoamide 15:
with fuming sulfuric acid in the presence of polyphosphoric acid to obtain piperazine 16:
(bb) reacting piperazine 16 with epoxide 24:
to obtain compound 25.
Embodiments of this process include the process as just described incorporating one or more of the following features:
the fuming sulfuric acid is employed in Step (aa) in an amount in the range of from about 5 to about 20 equivalents (or from about 7 to about 11 equivalents) and the polyphosphoric acid is employed in an amount in the range of from about 0.5 to about 10 equivalents (of from about 2 to about 4 equivalents) per equivalent of ketoamide 15;
the ratio of equivalents of fuming sulfuric acid to equivalents of polyphosphoric acid in Step (aa) is in the range from about 1:1 to about 30:1 or from about 2:1 to about 4:1;
the acid treatment of ketoamide 15 is conducted at a temperature in the range of from about 0 to about 80° C. or from about 25 to about 60° C. (e.g., from about 30 to about 50° C.);
the bis-sulfate salt of ketoamide 15 is employed in Step (aa);
Step (bb) is conducted in a solvent selected from the group consisting of dialkyl ethers wherein each alkyl is independently a C 1 -C 6 alkyl, C 1 -C 6 linear and branched alkanes substituted with two —O—C 1 -C 6 alkyl groups (which are the same or different), C 4 -C 8 cyclic ethers and diethers, C 6 -C 8 aromatic ethers, C 1 -C 6 alkyl esters of C 1 -C 6 alkylcarboxylic acids, C 1 -C 10 alkyl alcohols, C 2 -C 6 aliphatic nitriles, and C 7 -C 10 aromatic nitriles;
Step (bb) is conducted in a solvent which is a C 1 -C 6 alkyl alcohol;
in Step (bb) piperazine 16 is employed in an amount in the range of from about 1 to about 3 equivalents (e.g., from about 1 to about 1.5 equivalents) per equivalent of Compound 24; or
the reaction in Step (bb) is conducted at a temperature in the range of from about 40 to about 95° C. (e.g., from about 45 to about 65° C.).
The present invention further includes a process for preparing Compound 26:
which comprises Steps (aa) and (bb) as set forth above and further comprises:
(cc) treating Compound 25 with acid to obtain Compound 26.
Embodiments of this process include the process as just described incorporating one or more of the following features:
the acid in Step (cc) is an aqueous solution of HCl;
the acid in Step (cc) is a solution of HCl in a C 1 -C 6 alkyl alcohol (e.g., ethanol);
Step (cc) is conducted at a temperature of less than about 10° C. (e.g., in the range of from about −10 to about 10° C.); or
the acid is employed in an amount of at least about 1 equivalent per equivalent of Compound 25.
Other embodiments of the present invention include the process for preparing Compound 26 via Steps (aa), (bb) and (cc), as originally defined above, additionally incorporating any one or more of the embodiments set forth above for any one or more of Steps (aa), (bb), and (cc).
The present invention also includes a process for enhancing the optical purity of a piperazine of Formula (II):
which comprises:
(X) forming a solution comprising piperazine II containing a minor portion of undesired optical isomer, 2-naphthalenesulfonic acid, and solvent; and
(Y) crystallizing from the solution a crystalline 2-naphthalenesulfonic acid salt of II having enhanced optical purity;
wherein stereocenter a , R 1 , R 2 , R 3 and R 6 are each as originally defined above in Step A or as defined in any embodiments of Step A set forth above.
A “minor portion” in Step X means that undesired optical isomer is present in an amount less than the desired optical isomer. Typically undesired optical isomer is present in an amount of no more than about 15 wt. %, and more typically is present in an amount of less than about 10 wt. %, or even less than about 5 wt. %. Undesired optical isomer includes any isomer(s) of piperazine II which have the undesired configuration at stereocenter a . For example, if the optical purity of piperazine II with stereocenter a in the S configuration is to be enhanced, then the undesired material includes isomer(s) of piperazine II having stereocenter a in the R configuration, irrespective of the occurrence of other chiral centers in the isomer.
The term “enhanced optical purity” means that the crystallized 2-naphthalenesulfonic acid (alternatively referred to herein as “2-NSA”) salt of II contains a greater proportion of the desired configuration at stereocenter a than the piperazine II starting material.
In an embodiment of this process, R 1 in piperaine II is pyridyl which is unsubstituted or substituted with 1 or 2 substituents each of which is independently C 1 -C 4 alkyl or —O—C 1 -C 4 alkyl; R 2 and R 3 are either both —H or both methyl; and R 6 is C 1 -C 4 alkyl or C 1 -C 4 fluoroalkyl.
The solvent employed in the process can be any organic substance which is chemically inert under the conditions employed in Step X and Step Y and which can dissolve piperazine II and optical isomers thereof and 2-NSA. A suitable class of solvents is the nitriles, including the C 2 -C 6 aliphatic nitriles. A preferred solvent is acetonitrile. In one embodiment, water is employed as a co-solvent with the nitrile solvent. Water co-solvent has been found to promote formation of the solution in Step X. In an aspect of the preceding embodiment, the solvent is acetonitrile and the volume ratio of acetonitrile to water employed in Step X is suitably in the range of from about 1.5:1 to about 10:1, and is typically in the range of from about 2:1 to about 5:1.
In another embodiment of the process, the solvent is acetonitrile and the piperazine II is suitably employed in Step X in an amount in the range of from about 0.01 to about 0.2 grams per mL of acetonitrile, is typically employed in an amount in the range of from about 0.02 to 0.1 g/mL, and is often employed in an amount in the range of from about 0.05 to about 0.07 g/mL.
The 2-NSA can be employed in the process in any proportion with respect to piperazine II which will lead to the formation of a crystalline salt having enhanced optical purity. In one embodiment, the 2-NSA is employed in Step X in an amount in the range of from about 2.5 to about 3.5 equivalents per equivalent of II. In another embodiment, 2-NSA is employed in an amount in the range of from about 2.8 to about 3.0 equivalents per equivalent of II.
In an embodiment of the process, forming the solution in Step X comprises heating a mixture comprising piperazine II containing a minor portion of undesired optical isomer, 2-naphthalenesulfonic acid, and solvent to a temperature sufficient to effect dissolution. In an aspect of this embodiment, the solvent is a nitrile (e.g., acetonitrile), water is employed as a co-solvent, and the mixture is heated to a temperature in the range of from about 30 to about 100° C. (e.g., from about 40 to about 80° C. or from about 50 to about 60° C.). (It is noted that if the reflux temperature of the mixture is below the desired or required dissolution temperature, then a higher than ambient pressure can be applied to achieve the desired temperature.)
Crystallizing the 2-NSA salt of piperazine II in Step Y can be accomplished by cooling, or by concentrating (e.g., by evaporative removal of solvent using heat and/or vacuum), or by both cooling and concentrating (concurrently or sequentially in either order) the solution resulting from Step X. In one embodiment, crystallizing Step Y comprises seeding the solution of Step X with crystalline 2-naphthalenesulfonate salt of II, aging the seeded solution, and then either (i) cooling or concentrating or (ii) cooling and concentrating (concurrently or sequentially in either order) the solution to obtain the crystalline 2-naphthalenesulfonic acid salt of II having enhanced optical purity.
As used herein with respect to a crystallization process, the term “aging” and variants thereof (e.g., “aged”) mean allowing the components of the solution (e.g., 2-NSA, piperazine H, and the crystal salt thereof) to stay in contact for a time and under conditions effective for completion or optimization of the crystallization. The term “aging” and its variants can also refer herein to allowing the reactants of a given reaction to stay in contact for a time and under conditions effective for completion of the reaction. The proper meaning of “aging” is clear from the context in which it is used.
Another embodiment of the process comprising Steps X and Y as originally defined above is the process wherein piperazine II is a piperazine of Formula (II′):
Any one or more of the embodiments of the process set forth above for piperazine II can be incorporated into this embodiment, and each such incorporation represents an additional aspect of this embodiment.
The present invention further includes a process which comprises Step A as originally defined and described above, which further comprises:
(X) forming a solution comprising the piperazine II product of Step A containing a minor portion of undesired optical isomer, 2-naphthalenesulfonic acid, and solvent; and
(Y) crystallizing from the solution a crystalline 2-naphthalenesulfonic acid salt of II having enhanced optical purity.
Embodiments of this process include the process as just defined incorporating one or more of the embodiments, aspects or features of any one or more of Steps A, X and Y as heretofore described.
The present invention also includes a process for preparing Compound IV which comprises Steps A and B as set forth above and further comprises:
(X) forming a solution comprising the piperazine II product of Step A containing a minor portion of undesired optical isomer, 2-naphthalenesulfonic acid, and solvent; and
(Y) crystallizing from the solution a crystalline 2-naphthalenesulfonic acid salt of II having enhanced optical purity; and
(Z) treating the crystallized salt of II with base (e.g., NaOH) to break the salt and afford Compound II as free base for use in Step B.
Additional embodiments of this process include the process as just described additionally incorporating one or more of the embodiments, aspects, or features of any one or more of Steps A, B, X and Y as defined and described above.
The present invention also includes a process for enhancing the optical purity of Compound 16:
which comprises:
(xx) forming a solution comprising Compound 16 containing a minor portion of its optical isomer, 2-naphthalenesulfonic acid, acetonitrile, and water;
(yy) crystallizing from the solution a crystalline tris-2-naphthalenesulfonate salt of 16 having enhanced optical purity.
In an embodiment of this process, forming the solution in Step (xx) comprises heating a mixture comprising Compound 16 containing a minor portion of its optical isomer, 2-naphthalenesulfonic acid, acetonitrile, and water to a temperature sufficient to effect dissolution; and crystallizing Step (yy) comprises (i) cooling or concentrating or (ii) cooling and concentrating (concurrently or sequentially in either order) the solution to obtain crystalline tris-2-naphthalenesulfonate salt of 16 with enhanced optical purity. In an aspect of the preceding embodiment, Step (yy) comprises seeding the heated solution of Step (xx) with crystalline tris-naphthalene sulfonate salt of 16, aging the seeded solution at elevated temperature (e.g., a temperature in the range of from about 40 to about 80° C.), and then either (i) cooling or concentrating or (ii) cooling and concentrating (concurrently or sequentially in either order) the solution to obtain crystalline tris-2-naphthalenesulfonate salt of 16 with enhanced optical purity.
Additional embodiments of this process include the process as originally described or as described in the preceding embodiment incorporating one or more of the following features:
the volume ratio of acetonitrile to water employed in Step (xx) is in the range of from about 1.5:1 to about 10:1, or from about 2:1 to about 5:1;
Compound 16 is employed in Step (xx) in an amount in the range of from about 0.01 to about 0.2 grams per mL of acetonitrile, or from about 0.05 to about 0.07 g/mL of acetonitrile;
2-naphthalenesulfonic acid is employed in Step (xx) in an amount in the range of from about 2.5 to about 3.5 equivalents per equivalent of 16, or from about 2.8 to about 3.0 equivalents per equivalent of 16; or
the solution in Step (xx) is formed by heating the mixture to a temperature in the range of from about 30 to about 100° C., or from about 40 to about 80° C., or from about 50 to about 60° C.
The present invention also includes a process which comprises Step (aa) as originally defined and described above, which further comprises:
(xx) forming a solution comprising the Compound 16 product of Step (aa) containing a minor portion of its optical isomer, 2-naphthalenesulfonic acid, acetonitrile, and water;
(yy) crystallizing from the solution a crystalline tris-2-naphthalenesulfonate salt of 16 having enhanced optical purity.
Embodiments of this process include the process as just defined incorporating one or more of the embodiments, aspects or features of any one or more of Steps (aa), (xx) and (yy) as heretofore described.
The present invention also includes a 2-naphthalenesulfonic acid salt of a piperazine of Formula IIa or IIb:
wherein R 1 , R 2 , R 3 , and R 6 are each as originally defined above in Step A or as defined in any of the embodiments, aspects or features of Step A as set forth above.
In one embodiment, the salt is a salt of a piperazine of Formula (IIa), wherein
R 1 is pyridyl which is unsubstituted or substituted with 1 or 2 substituents independently selected from optionally substituted with C 1 -C 4 alkyl or —O—C 1 -C 4 alkyl;
R 2 and R 3 are either both —H or both methyl; and
R 6 is C 1 -C 4 alkyl or C 1 -C 4 fluoroalkyl.
In an aspect of the foregoing embodiment, the salt is a tris-(2-naphthalenesulfonic acid) salt of the piperazine of Formula (IIa). In another aspect of the foregoing embodiment, the salt is a tris-(2-naphthalenesulfonic acid) salt of Compound 16:
The present invention also includes a process for preparing Compound 25 which comprises Steps (aa) and (bb) as set forth above and further comprises:
(xx) forming a solution comprising Compound 16 as obtained from Step (aa) and containing a minor portion of its optical isomer, 2-naphthalenesulfonic acid, acetonitrile, and water;
(yy) crystallizing from the solution a crystalline tris-2-naphthalenesulfonate salt of 16 having enhanced optical purity; and
(zz) treating the crystallized salt of 16 with base (e.g., NaOH) to break the salt and afford Compound 16 as free base for use in Step (bb).
Additional embodiments of this process include the process as just described additionally incorporating one or more of the embodiments, aspects, or features of any one or more of Steps (aa), (bb), (xx), or (yy) as defined and described above.
The present invention also includes a process for purifying 2-naphthalenesulfonic acid, which comprises
(L) heating a mixture comprising crude 2-naphthalenesulfonic acid, acetonitrile, and toluene to a temperature sufficient to dissolve the crude acid and form a system comprising an upper layer containing the major portion of 2-naphthalenesulfonic acid and a lower layer;
(M) separating the upper layer from the lower layer; and
(N) crystallizing purified 2-naphthalenesulfonic acid from the separated upper layer.
The term “crude 2-naphthalenesulfonic acid” refers to 2-NSA which comprises in addition to 2-NSA per se at least one of 1-NSA, sulfuric acid, a naphthalene sulfone, or naphthalene. These impurity components suitably represent a minor amount (i.e., a total of less than 50 wt. %) of the crude 2-NSA, and typically represent less than about 35 wt. % of the crude 2-NSA. Relatively pure 2-NSA (not commercially available) is preferred for use in the processes described above for enhancing the optical purity of piperazine II and piperazine 16. The process comprising Steps L, M and N can provide 2-NSA with a suitable level of purity.
The volume ratio of acetonitrile to toluene in Step L is suitably in the range of from about 1:1 to about 1:8, is typically in the range of from about 1:2 to about 1:6, and is more typically in the range of from about 1:2 to about 1:4.
The amount of crude 2-naphthalenesufonic acid can vary from an amount providing a very dilute to an amount providing a highly concentrated solution. In one embodiment, the crude 2-NSA is suitably present in Step L in an amount in the range of from about 0.1 to about 1 g per mL of acetonitrile. In another embodiment, crude 2-NSA is present in Step L in an amount in the range of from about 0.2 to about 0.8 g per mL of acetonitrile. In still another embodiment, crude 2-NSA is present in an amount in the range of from about 0.4 to about 0.6 g per mL of acetonitrile.
The temperature required in Step L to dissolve the crude acid depends upon the relative proportion of the solvent (acetonitrile and toluene) employed, higher temperatures being required to form a highly concentrated solution. The temperature is suitably in the range of from about 40 to about 100° C., and is typically in the range of from about 50 to about 90° C. (e.g., from about 70 to about 90° C.).
Water can be added to the mixture of Step L in order to promote separation of the layers. Typically no more than about 5 wt. % of water with respect to crude 2-NSA is employed for this purpose, and more typically no more than about 2.5 wt. %
Crystallization in Step N can be achieved by conventional methods such as cooling the solution, or concentrating the solution (e.g., by evaporative removal of solvent using heat and/or vacuum), or cooling and concentrating (concurrently or sequentially in either order) the solution. In one embodiment, crystallizing in Step N comprises seeding the cooled and/or concentrated upper layer with 2-naphthalenesulfonic acid crystals to obtain purified crystalline 2-naphthalenesulfonic acid.
In another embodiment, crystallizing in Step N comprises adding a minor portion of water to the hot top layer, and then (i) cooling or concentrating or (ii) cooling and concentrating (concurrently or sequentially in either order) the layer to form purified crystals of 2-NSA. The amount of water added to the hot top layer is suitably no more than about 10 wt. %, and typically is no more than about 5 wt. % (e.g., from about 1 to about 5 wt. %) of the crude 2-NSA.
In still another embodiment, crystallizing in Step N comprises adding water to the hot top layer and cooling the layer to form an organic upper phase and an aqueous lower phase containing the major portion of 2-naphthalenesulfonic acid, separating and solvent switching the aqueous phase with acetonitrile, adding toluene and heating to form a clear solution, and then (i) cooling or concentrating or (ii) cooling and concentrating (concurrently or sequentially in either order) the switched solution to form purified crystals of 2-naphthalenesulfonic acid. The amount of water added to the hot top layer is suitably at least about 50 wt. %, and typically is at least about 75 wt. % (e.g., from about 75 to about 95 wt. %) of the crude 2-NSA.
If desired, further purification of the crystallized 2-NSA can be achieved by recrystallization of the isolated Step N crystals from acetonitrile.
Still other embodiments of the present invention include any of the processes as originally defined and described above and any embodiments or aspects thereof as heretofore defined, further comprising isolating (which may be alternatively referred to as recovering) the compound of interest from the reaction or crystallization medium (e.g., Compound IV or Compound 25, or piperazine II or piperazine 16).
If desired, the progress of the reaction in any of the above-described chemical reactions can be followed by monitoring the disappearance of a reactant (e.g., piperazine I or epoxide III in Step B) and/or the appearance of the product (e.g., Compound IV in Step B) using TLC, HPLC, NMR or GC.
As used herein, the term “C 1 -C 6 alkyl” means linear or branched chain alkyl groups having from 1 to 6 carbon atoms and includes all of the hexyl alkyl and pentyl alkyl isomers as well as n-, iso-, sec- and t-butyl, n- and isopropyl, ethyl and methyl. “C 1 -C 4 alkyl” means n-, iso-, sec- and t-butyl, n- and isopropyl, ethyl and methyl.
The term “—O—C 1 -C 6 alkyl” refers to an alkoxy group wherein the alkyl is C 1 to C 6 alkyl as defined above. “—O—C 1 -C 4 alkyl” has an analogous meaning; i.e., it is an alkoxy group selected from methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, tert-butoxy, and sec-butoxy.
The term “halogen” (which may alternatively be referred to as “halo”) refers to fluorine, chlorine, bromine and iodine (alternatively, fluoro, chloro, bromo, and iodo).
The term “C 1 -C 6 haloalkyl” means a C 1 to C 6 linear or branched alkyl group as defined above with one or more halogen substituents. The term “C 1 -C 4 haloalkyl” has an analogous meaning.
The term “—O—C 1 -C 6 haloalkyl” means an alkoxy group as defined above with one or more halogen substituents on the alkyl moiety. The term “—O—C 1 -C 4 haloalkyl” has an analogous meaning.
The term “C 1 -C 6 fluoroalkyl” means a C 1 -C 6 alkyl group as defined above with one or more fluorine substituents. The term “C 1 -C 4 fluoroalkyl” has an analogous meaning. Representative examples of suitable fluoroalkyls include the series (CH 2 ) 0-3 CF 3 (i.e., trifluoromethyl, 2,2,2-trifluoroethyl, 3,3,3-trifluoro-n-propyl, etc.), 1-fluoroethyl, 2-fluoroethyl, 2,2-difluoroethyl, 3,3,3-trifluoroisopropyl, 1,1,1,3,3,3-hexafluoroisopropyl, and perfluorohexyl:
The term “—O—C 1 -C 6 fluoroalkyl” means an —O—C 1 -C 6 alkyl group as defined above wherein the alkyl moiety has one or more fluorine substituents. The term “—O—C 1 -C 4 fluoroalkyl” has an analogous meaning. Representative examples include the series O(CH 2 ) 0-3 CF 3 (i.e., trifluoromethoxy, 2,2,2-trifluoroethoxy, 3,3,3-trifluoro-n-propoxy, etc.), and 1,1,1,3,3,3-hexafluoroisopropoxy.
The term “C 3 -C 8 cycloalkyl” refers to a cyclic ring selected from cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, and cyclooctyl. “C 1 -C 6 cycloalkyl” has an analogous meaning.
The term “C 3 -C 6 azacycloalkyl” refers to a saturated cyclic ring containing a ring nitrogen and from 3 to 6 ring carbons. The term includes azetidinyl, pyrrolidinyl, piperidinyl, and hexahydroazepinyl.
The term “aryl” refers herein to phenyl or naphthyl.
The term “heteroaryl” refers to (i) a 5- or 6-membered aromatic ring consisting of carbon atoms and from 1 to 3 heteroatoms selected from N, S, and O or (ii) an 8- to 10-membered bicyclic ring system consisting of carbon atoms and from 1 to 3 heteroatoms selected from N, S, and O, wherein at least one of the rings in the bicyclic system is an aromatic ring. The heteroaryl ring may be attached at any heteroatom or carbon atom, provided that attachment results in the creation of a stable structure.
The term “substituted” (e.g., as in “substituted heterocycle”) includes mono- and poly-substitution by a named substituent or substituents to the extent such single and multiple substitution (including multiple substitution at the same site) is chemically allowed.
The symbol “” in front of an open bond in the structural formula of a group marks the point of attachment of the group to the rest of the molecule.
Combinations of substituents and/or variables are permitted only to the extent such combinations result in chemically stable compounds under the process conditions described herein.
Abbreviations used herein include the following:
ACN=acetonitrile
AIDS=acquired immune deficiency syndrome
Alloc or alloc=allyloxycarbonyl
ARC=AIDS related complex
BOC or Boc=t-butyloxycarbonyl
DMF=dimethylformamide
DSC=differential scanning calorimetry
EDC=1-ethyl-3-(3-dimethylaminopropyl)carbodiimide
Et=ethyl
HIV=human immunodeficiency virus
HOBT or HOBt=1-hydroxy benzotriazole hydrate
HPLC=high performance liquid chromatography
IPAc=isopropyl acetate
IPA=isopropyl alcohol
KF=Karl Fisher titration for water
LC=liquid chromatography
LHMDS=lithium hexamethyldisilazide
Me=methyl
MeOH=methanol
MSA=methanesulfonic acid
MTBE=methyl tert-butyl ether
NCS=N-chlorosuccinimide
NMR=nuclear magnetic resonance
NSA=naphthalenesuflonic acid
OTf=triflate
PPA=polyphosphoric acid
i-Pr=isopropyl
TBDC=di t-butyl dicarbonate
TEA=triethylamine
TGA=thermogravimetric analysis
THF=tetrahydrofuran
XRPD=x-ray powder diffraction
The following examples serve only to illustrate the invention and its practice. The examples are not to be construed as limitations on the scope or spirit of the invention.
EXAMPLE 1
3-Methoxy-5-bromopyridine (2)
Material
MW (g/mol)
Amount
mmol
Dibromopyridine 1, 98%
236.89
48.34 g
200
Bromomethoxypyridine 2
188.02
25 wt % NaOMe/MeOH
54.02
56 mL
240
(d = 0.945)
DMF
48 mL
20% Sodium chloride
420 mL
Methyl-t-butyl ether
300 mL
Water
120 mL
To a 500 mL flask equipped with condenser for distillation was charged 48.34 g dibromopyridine (200 mmol), 56 mL of 25 wt % NaOMe/CH 3 OH (240 mmol) and 48 mL DMF. The mixture was heated to 90° C. A clear solution formed, which then turned cloudy. The mixture was aged 4 h at 90° C. and 3 h at 100° C. HPLC assay showed that the reaction was complete (<0.1 A % of 1). Some solvent was distilled out continuously during the age to maintain the internal temperature. The mixture was cooled to 18° C. and 60 mL water and 60 mL 20% NaCl were added. After 1 min, 300 mL MTBE was added. The mixture was agitated for 5 min and was transferred to a separatory funnel. After settling, the bottom aqueous layer was cut and the organic was washed with 3×120 mL 20% NaCl, then 60 mL water. The assay yield of bromomethoxypyridine 2 was 88% as determined by HPLC. 1 H NMR (CDCl 3 , 500 Hz): δ 8.30 (s, 1H), 8.25 (d, J=2.3 Hz, 1H), 7.37-7.38 (m, 1H), 3.87 (s, 3H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Solvents:
60% CH 3 CN, 40% 0.1% H 3 PO 4
Flow:
1.0 mL/min
Sample volume:
10 μL
Wavelength:
210 nm
Retention times:
The tarry impurity
2.1 min
Dimethoxypyridine
2.4 min
DMF
2.7 min
Bromomethoxypyridine 2
4.9 min
Dibromopyridine 1
6.2 min
EXAMPLE 2
3-Methoxy-5-(t-butyloxycarbonylaminomethylcarbonyl)-pyridine (5)
Material
MW (g/mol)
Amount
moles
Bromomethoxypyridine 2
188.02
18.9
BOC-Aminoketone 5
266.29
iso-Propylmagnesium chloride/THF
17.6 L
35.2
Weinreb amide 4, 96.3 wt %
218.26
3.44 Kg
15.19
Tetrahydrofuran
114 L
Isopropyl acetate
92 L
n-Heptane
45 L
37% Hydrochloric acid
3.48 Kg
35.2
Water
82 L
A solution of 2 in MTBE was concentrated in a 100 L flask to 23 L by vacuum distillation at <40° C. About 91 L of dry THF was added slowly during distillation to solvent switch to THF and to dry the solution. The final THF solution (23 L, 18.9 mol 2) was charged into a 50 L flask, and the flask was degassed and then placed under a nitrogen atmosphere. After cooling over an ice bath, 10.4 L 2M iso-PrMgCl/THF was added over 21 min at <24° C. to afford a cloudy mixture. The mixture was aged 2 h at 20-30° C. at which point HPLC assay showed 2 at 1.0 A %. The reaction mixture after 1 h age was a clear, dark brown solution. The Grignard solution 3 was held 3 h more before its use.
In another 100 L flask, 3.44 kg Weinreb amide (15.19 mol) was mixed with 23 L dry THF. The cloudy solution was degassed and placed under an inert nitrogen atmosphere. The solution was cooled to −21° C. to give a slurry to which was added 7.2 L 2M i-PrMgCl/THF over 30 min at <−10° C. A nearly clear gray solution formed, to which the Grignard solution 3 was added over 30 minutes at <−11+ C. The gummy precipitate that formed in the Grignard solution was not soluble in THF and was not transferred. The mixture was warmed to 24° C. over 1 h and the resulting dark red solution was aged 15 h at 15-24° C. HPLC assay showed that the reaction complete (<1 A % Weinreb amide 4). The dark reddish-brown mixture was cooled to 9° C., and 23 L dilute aqueous HCl (prepared using 3.48 kg of 37 wt % HCl) was added with vigorous agitation at <35° C. The mixture was agitated for 5 min, transferred to an 100 L extractor, allowed to settle, and the bottom aqueous layer (pH 7-8) was cut. The organic layer was transferred back to the 100 L flask where it was batch concentrated to 55 L at <40° C. and flushed with 90 L of IPAc to solvent switch. The final solution concentrate (˜55 L) was cooled to room temperature and diluted with 23 L water. The mixture was transferred to a 100 L extractor, allowed to settle, and the aqueous layer was cut. The organic layer was washed with 2×23 L and 1×16 water. The organic layer was batch concentrated at <35° C. in a 72 L flask. The final concentration to 13 L was done at <60° C. The mixture was then heated to 64° C. to form a clear solution, then cooled to 58° C. at which point 3 g of seed crystals of 5 were added. A slurry formed at 55° C. The slurry was cooled to 25° C., 39 L of n-heptane was added over 40 min, and the slurry was aged 15 h at room temperature and then 2 h at 0-5° C. The solids were filtered, rinsed with 8 L 3:1 n-heptane/IPAc and dried in a vacuum oven at 50° C. to afford 3.61 Kg of 5 as a yellowish crystalline solid (87% yield based on 4, 99.7 A % and 97.3 wt % purity).
1 H NMR (CDCl 3 , 500 Hz): δ 8.77 (s, 1H), 8.53 (d, J=2.8 Hz, 1H), 7.70-7.71 (m, 1H), 5.49 (broad s, 1H), 4.48 (d, J=4.1 Hz, 2H), 3.93 (s, 3H), 1.49 (s, 9H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Solvents:
60% CH 3 CN, 40% 0.1% H 3 PO 4
Flow:
1.0 mL/min
Sample volume:
10 μL
Wavelength:
210 nm
Retention times:
Methoxypyridine
2.2 min
Dimethoxypyridine
2.4 min
Weinreb amide 4
3.4 min
BOC-aminoketone 5
3.9 min
IPAc
4.1 min
Bromomethoxypyridine 2
4.9 min
Impurity
6.2 min
EXAMPLE 3
3-Methoxy-5-(aminomethylcarbonyl)pyridine HCl salt
Material
MW (g/mol)
Amount
moles
BOC-Aminoketone 5
266.29
2.19 Kg
8.22
5N HCl
4.93 L
24.6
5N NaOH
2.47 L
12.3
To a 22 L round bottomed flask equipped with an overhead stirrer, thermocouple probe and nitrogen line was charged 4.93 L 5N HCl. The acid solution was warmed to 40° C. over a steam bath, after which 2.19 Kg of solid BOC-aminoketone 5 was added in portions over 20 min. After the addition, the reaction solution was aged 1.3 h at 40° C. Ice was then added to the bath to cool the batch to 15° C. and 2.47 L 5N NaOH was added over 50 min to neutralize the excess HCl. The resulting solution was cooled over salt/ice bath.
1 H NMR (D 2 O, 500 Hz): δ 8.96 (s, 1H), 8.73 (d, J=2.5 Hz, 1H), 8.52˜8.53 (m, 1H), 4.77 (s, 2H), 4.07 (s, 3H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Gradient:
min
CH 3 CN/0.1% H 3 PO 4
0
5/95
12
90/10
13
5/95
Flow:
1.0 mL/min
Sample volume:
5 μL
Wavelength:
210 nm
Retention times:
Aminoketone 6
2.1 min
BOC-aminoketone 5
8.2 min
EXAMPLE 4
4-(tert-butyloxycarbonyl)-2-(S)-((2,2,2-trifluoroethyl)aminocarbonyl) piperazine
Pyrazine 2-carboxylic acid (1204 g) was suspended in DMF (4.8 L, 4 mL/g acid). 2,2,2-trifluoroethylamine.HCl (TFEA.HCl) (1200 g), 1-hydroxybenzotriazole (HOBT) (60 g) and triethylamine (TEA) (1410 mL) were then added sequentially (exotherm upon addition of TEA, flask cooled with ice bath and temperature kept below 35° C.). The reaction was cooled to 15° C. and 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide.HCl (EDC.HCl) (1940 g) was added portionwise over 15-30 min. The reaction temperature was kept below 35° C. When the reaction appeared complete (approx. two hours, <5% pyrazine 2-carboxylic acid by LC assay), the reaction mixture (yellow/white slurry) was diluted with 10% K 2 CO 3 in water (24 L, 20 mL/g acid) and the reaction slurry was kept below 35° C. The slurry was cooled to 10° C., aged for two hours and filtered (mother liquor assay=3-4 mg/mL). The wet cake was washed with deionized water (12 L, 10 mL/g acid) and dried under vacuum (22″ Hg) at 40° C. with a nitrogen purge. Theoretical yield of 1816 g . Actual yield 1533 g (84%).
1 H NMR: (CD 3 CN, 400 MHz): δ 9.29 (d, J=1.5 Hz, 1H), 8.82 (d, J=2.5 Hz, 1H), 8.63 (dd, J=2.6, 1.4 Hz, 1H), 8.40 (bs, 1H), 4.14 (dq, J=9.4, 6.8 Hz, 2H). HPLC Assay conditions: Waters Xterra RP8 column, elution with acetonitrile and 5 mM K phosphate adjusted to pH=8, detection at 220 nm.
Pyrazine amide (60.2 g 0.268 mol, not corrected for water content) was suspended in absolute ethanol (550 mL) in a 1.0 L autoclave hydrogenation vessel and cooled to 15° C. Wet 20% Pd(OH) 2 /C 11.0 g (20 wt %, 50 wt % wet) was added and reaction was purged with N 2 three times. H 2 (5 psig) was introduced with stirring and the temperature maintained at 15° C. for 60 minutes. The temperature was then increased to 60° C. and the hydrogen pressure increased to 40 psig and the reaction mixture stirred for 18 additional hours. The reaction was considered complete when conversion is >99% by LC assay. The reaction mixture was filtered through Solka-Floc and the catalyst solids were washed with ethanol 2×110 mL. Assay of the combined filtrate and washes gave 53.5 g of racemic piperazine amide (Yield=86%)
1H NMR (CD3CN, 400 MHz): δ 7.58 (bs, 1H), 3.90 (dq, J=9.5, 6.7 Hz, 2H), 3.24 (dd, J=7.9, 5.5 Hz, 1H), 2.96 (dd, J=12.1, 3.6 Hz, 1H), 2.84-2.78 (m, 1H), 2.77-2.67 (m, 3H), 2.66-2.56 (m, 1H), 1.90 (s, 2H). HPLC Assay conditions: YMC Basic column, elution with acetonitrile and 0.1% aqueous H 3 PO 4 , detection at 210 nm.
The pip amide ethanol filtrate (116.37 g containing 10.3 g of racemic pip amide by LC assay) was concentrated in vacuo to a final volume of 40.2 mL (3.9 mL per gram of pip amide) and the slurry is diluted with 82.4 mL (8 mL per gram pip amide) of acetonitrile (ACN) and stirred until homogenous. Separately (S)-camphorsulfonic acid (S)-CSA) (19.26 g, MW=232.30, 1.7 eq) was dissolved in 185 mL of ACN (18 mL per gram of pip amide). The water content of the two solutions was then determined by Karl Fisher titration. The CSA solution was added to the pip amide solution giving a small exotherm to approx. 31-32° C. Water (11.02 mL, 1.118 mL per gram of pip amide minus the total water content of the two solutions) was then added, such that the acetonitrile:ethanol:water ratio was 26:2.9:1.1 (v/v/v). Solids began to form after 15-30 min. The solution/slurry was heated to 72° C. to completely dissolve all solids. The yellow solution was recooled to 62° C. and seeded with a slurry of 10.3 mg of pip amide salt in 1 mL of acetonitrile. After a two hour age at 62° C. the slurry was allowed to cool to room temperature overnight (crystallization was complete when loss to mother liquors was <21 mg pip amide/mL by LC assay. The slurry was filtered then washed with 2×30 mL of ACN:EtOH:H 2 O [(26:2.9:1.1), (v:v:v)] solution. The wet cake (˜13 g, white solid) was dried at 40° C. in a vacuum oven (24 in Hg, nitrogen sweep) to give 11.16 g of product (yield=33%). Assay method (Pip Amide) as above. Chiral assay gives an enantiomeric excess (ee) of 98.0%.
1H NMR (CD 3 OD, 400 MHz): d4.84 (bs, 5H), 4.64 (dd, J=12.0, 3.6 Hz, 1H), 4.13-3.94 (m, 3H), 3.77 (m, 2H), 3.66 (m, 1H), 3.54-3.43 (m, 2H), 3.28(d, J=14.7 Hz, 2H), 2.82 (d, 14.7 Hz, 2H), 2.55 (m, 2H), 2.36 (m, 2H), 2.12-1.998 (m, 4H), 1.92 (d, J=18.4 Hz, 2H), 1.72 (m, 2H), 1.45 (m, 2H), 1.09 (s, 6H), 0.87 (s, 6H). Enantiomeric excess determined by chiral HPLC of the mono BOC piperazine amide. HPLC assay conditions: Chiral AGP column, elution with acetonitrile and 10 mM Kphospate, pH=6.5, detection at 210 nm.
To a 12 L flask was charged (S)-pip amide salt (412.87 g) having an ee of less than 98%, 7.43 L of ACN and 825 mL of 190 proof EtOH. The slurry was heated to 75° C., aged for 1 hr at 75° C. (during heating the slurry thickened considerably), then allowed to cool to 25° C. overnight. The slurry was filtered and washed with EtOH (190 proof):ACN (10:90) (2×800 mL, 2 mL/g). The white solid was dried in a vacuum oven at 24 in Hg, 40° C. with a nitrogen sweep to give 400 g of product with an ee of 99%. Assays (normal and chiral) were performed as described above in the prior steps.
Bis (S)-CSA piperazine amide salt (20 g) was suspended in a mixture of 113 mL of isopropyl acetate (IPAc) and 57 mL of acetonitrile. Triethylamine (8.26 mL, 2 eq) was added and the mixture stirred until homogenous. A solution of di t-butyl dicarbonate (TBDC) (6.46 g, 1.0 eq) in a mixture of 20 mL isopropyl acetate and 10 mL of acetonitrile (ACN) was then added over 10 minutes. After aging for two hours the solution was assayed as necessary by LC (Pip Amide Assay, see above) until the reaction was complete (i.e., less than 5% starting material). When the reaction was complete, 100 mL of water and 135 mL of isopropyl acetate were added, the resulting layers were separated and the organic layer was concentrated to 28 mL. The residue was then diluted with 28 mL of isopropyl alcohol and reconcentrated to 28 mL. This was repeated two additional times. The yield of BOC pip amide was 87% with a mono:bis BOC ratio of 95:5, as determined by HPLC.
1 H NMR (CDCl 3 , 400 MHz): δ=7.39 (app t, J=6.3 Hz, 1H), 3.96 (dd, J=3.5, 13.4 Hz, 1H), 3.88 (m, 2H), 3.67 (d, J=11.5Hz, 1H), 3.39 (dd, J=3.8, 8.6 Hz, 1H), 3.13 (dd, J=8.6, 13.3 Hz, 1H), 3.02 (br, 1H), 2.91 (m, 1H), 2.77 (m, 1H), 1.43 (s, 9H). 13 C NMR (CDCl 3 ,) δ=171.43, 154.41, 123.89 (q, J=78.5 Hz), 80.16, 57.65, 43.63, 45.6 (br), 44.0 (br), 40.20 (q, J=34.7 Hz), 28.19. HPLC Assay conditions: YMC Basic column, elution with acetonitrile and 0.1% aqueous H 3 PO 4 , detection at 210 nm.
EXAMPLE 5
Boc Alloc Piperazine 12
Material
MW (g/mol)
Amount
moles
Boc piperazine 11
311.3
15 Kg
16.1
(34% soln. in IPA)
Toluene (flush)
38 L
Toluene (solvent)
33 L
Water
32.2 L
NaHCO 3
84
1.8 Kg
21.4
Allyl Chloroformate
120.5
2.2 Kg
18.5
NaCl
360 grams
To a 100 L batch concentrator equipped with condenser for distillation was charged 15 Kg of Boc piperazine 11 (34% soln.) and 38 L toluene. The solution was distilled under vacuum (40 C, 20 mm Hg) to solvent switch EPA for toluene. Expected distillate is 37 Kg or 44 L of mixed solvent. The vessel was then set for reaction and 33 L toluene (solvent), 25 L water, and 1.8 Kg NaHCO 3 were added. The batch was cooled to 15 C and with vigorous mixing allyl chloroformate (18.5 L) was added by addition funnel at a rate to maintain batch temperature between 15-20° C. The reaction was mildly exothermic and reached about 20° C. by the end of the addition and remained at about that temperature for the duration of the reaction. When the reaction was complete as determined by HPLC, the agitation was stopped and the layers separated. The organic layer was washed with a solution of 360 grams NaCl in 7.2 L water.
1 H NMR (CDCl 3 , 400 MHz) 5.95 (m, 1H), 5.35 (d, 1H), 5.28 (d, 1H), 4.75 (s, 1H), 4.68 (d, 1H), 4.53 (d, 1H), 3.90 (m, 3H), 3.20 (dd, 1H), 3.00 (m, 1H), 1.45 (s, 9H).
EXAMPLE 6
Alloc Piperazine 13
Material
MW (g/mol)
Amount
moles
Boc alloc piperazine 12
395.4
approx. 34 kg
16.1
solution
Conc. HCl
3.2 L
38.4
Water
38 L
THF
54 L
Na 2 CO 3
106
3.4 Kg
32.1
NaCl
4.9 Kg
Concentrated HCl (3.2 L) was added to a vigorously stirred solution of boc alloc piperazine 12 in toluene and the mixture was heated to 40° C. When the reaction was complete (in 1-2 hours as determined by HPLC), the reaction mixture was cooled to room temperature, and then water (33 L) was added. The batch was then cooled to 15° C. and THF (27 L) was added while maintaining the temperature at below 20° C. Na 2 CO 3 (3.4 Kg) was then added in portions as it dissolved, followed by addition of NaCl (4.9 kg) to separate the organic from the aqueous layer. The organic layer was saved and the water layer was extracted a second time with THF (27 L).
1 H NMR (CDCl 3 , 400 MHz) 7.28 (s, 1H), 4.00 (dd, 1H), 3.97 (m, 2H), 4.70 (s, 1H), 3.40 (dd, 1H), 3.20 (dd, 1H), 3.05 (s, 1H), 2.93 (d, 1H), 2.81 (t, 1H), 1.80 (s, 1H), 1.43 (s, 9H).
EXAMPLE 7
Piperazine Acid 14
Material
MW (g/mol)
Amount
moles
Alloc piperazine 13
295.26
4.31 Kg
14.6
2-bromo-2-methyl-
167.0
2.92 Kg
17.5
propionic acid
triethylamine
101.19
8.14 L
58.4
Solka-floc
3 Kg
Silver oxide
232
1.87 Kg
8.06
Toluene
44 L
6N HCl
38.4 L
2N HCl
39 L
To a 100 L batch concentrator equipped with a condenser for distillation was charged alloc piperazine 13 (4.31 Kg, approximately a 7% solution in THF). The solution was distilled under vacuum to solvent switch THF for toluene while azeotroping residual water, after which a 100 L round bottomed flask was charged with the toluene solution and diluted with further toluene to a 10% solution. 2-bromo-2-methylpropionic acid (2.92 Kg) was then added, and the mixture was stirred until all material went into solution. Triethylamine (8.14 L) was then added followed by Solka-floc (2.97 Kg). The mixture was cooled while stirring with an ice water bath to 10° C., and then silver oxide was added in portions while maintaining the exothermic reaction at less than 40° C. After completion of the reaction (approximately one hour, as determined by HPLC), the reaction mixture was cooled with an ice bath and 6N HCl (38.4 L) was added in portions while maintaining the exothermic reaction at less than 50° C. The mixture was stirred for about ten minutes and filtered through a bed of Solka-floc. The filter cake was washed with 2N HCl (3×13 L). Further product was obtained from the combined filtrate and washings by cooling and separating the layers, adjusting the pH of the separated aqueous layer to 2 with aqueous NaOH, washing the layer with MTBE, separating the layers, adjusting the pH of the aqueous layer to 10 with aqueous NaOH, washing the layer with IPAc, separating the layers and adjusting the pH of the aqueous layer to 6 with 2N HCl, adding NaCl, and extracting the aqueous layer with THF.
1 H NMR (CDCl 3 , 400 MHz): δ 9.02 (broad s, 1H), 6.98 (broad s, 1H), 5.90-6.00 (m, 1H), 5.24-5.28 (m, 2H), 5.65 (broad s, 1H), 4.16 (broad s, 1H), 2.90-2.93 (m, 1H), 2.55-2.57 (m, 1H), 2.40-2.41 (m, 1H), 1.59-1.61 (m, 1H).
EXAMPLE 8
4-[1-[5-(5-methoxy-3-pyridinyl)-carbonylmethylaminocarbonyl]-1-methylethyl]-2(S)-
[(2,2,2-trifluoroethyl)aminocarbonyl]-1-[allyloxycarbonyl]piperazine, bis sulfate 15
Material
MW (g/mol)
Amount
moles
Aminoketone solution 6
8.22
Piperazine Acid 14
381.35
3.13 Kg
8.22
Tetrahydrofuran
15 L
Dimethylformamide
12.5 L
HOBt
135.13
1.22 Kg
9.04
EDC
191.71
1.73 Kg
9.04
Diisopropylethylamine
129.25
4.29 L
24.6
Ethyl Acetate
25 L
Sat'd NaHCO 3
12.5 L
Water
13 L
Isopropyl Acetate
100 L
Sulfuric Acid (96 wt %, d = 1.84)
98.08
0.786 L
14.2
MTBE
42 L
A 100 L round bottomed flask was fitted with a batch concentrator and 16.75 Kg solution (18.7 wt %, 8.22 mol) of piperazine acid 14 in THF was charged and batch concentrated. The solution was flushed with 2×7.5 L THF to dryness and was concentrated to a minimum volume. DMF (12.5 L) was added and residual THF was distilled at <25° C. HOBT hydrate (1.22 Kg) was added and allowed to dissolve. The batch was cooled to 17° C., and then 1.73 Kg EDC was added over 10 min. The resulting solution was aged 2 h at 21° C. The solution was cooled over a salt/ice bath to 0° C. and aminoketone hydrochloride 6 solution at 4° C. was added rapidly, followed by a 0.4 L water rinse. Following an exotherm to 16° C. and cooling over 20 min to 10° C., 4.29 L Hunig's base was added rapidly. With continued cooling over ice, the reaction mixture was aged 2.5 h. The mixture was diluted with 25 L EtOAc, 12.5 L sat'd NaHCO 3 and 6.3 L water and was cooled and aged 30 min to form a slurry. The precipitated HOBT was filtered on a filter pot and the cake was rinsed with a mixture of 8 L water and 1 L EtOAc. The filtrate was pumped into a 100 L extractor, cooled to 7° C. and acidified to pH 5 with 3.1 L 5N HCl. The aqueous layer was allowed to settle 30 min and was separated and extracted with 13 L EtOAc (0.4% product loss to aqueous layer). The combined organic layer was washed with 12 L sat'd NaHCO 3 (0.2% loss) and then with 12 L water (0.1% loss). The washed organic layer was weighed and assayed to contain 3.7 Kg ketoamide 15 (86% yield). This solution was batch concentrated to a minimal volume in a 100 L round bottomed flask, flushed with 3×10 L IPAc to dry and solvent switched, filtered through a glass funnel and adjusted to 19 L in IPAc. The solution was diluted with 19 L MTBE.
A 22 L round bottomed flask was charged with 19 L MTBE and cooled over a salt/ice bath to 5° C. H 2 SO 4 (0.786 L, 2 eq vs. ketoamide) was added over 20 min (exotherm to 13° C.). The 100 L round bottomed flask containing the ketoamide solution was fitted with a 5 L addition funnel, H 2 SO 4 /MTBE was pumped in portions to the funnel and added over 2 h. The slurry is filtered over a large filter pot, rinsed with 6 L 2:1 MTBE/IPAc and dried under nitrogen, then 2 days in a vacuum oven (40° C.) to afford 5.41 Kg bis-sulfate salt in 84% yield (67.8 wt % free base, 93.5 A %).
1 H NMR of free base (CDCl 3 , 500 Hz): δ 8.80 (s, 1H), 8.52 -8.53 (m, 1H), 8.37 (broad s, 0.6H), 7.90 (Broad s, 0.4H), 7.70-7.71 (m, 1H), 6.70 (broad s, 1H), 5.94 (broad s, 1H), 5.27-5.41 (m, 2H), 4.87 (broad s, 1H), 4.82 (s, 1H), 4.67 (d, J=4.5 Hz, 2H), 4.57 (d, J=18.3 Hz, 1H), 4.05-4.14 (m, 2H), 3.92 (s, 3H), 3.66 (d, J=11.2 Hz, 1H), 3.20-3.30 (m, 1H), 2.90 (d, J=10.8 Hz, 1H), 2.45 (d, J=9.3 Hz, 1H), 2.35-2.37 (m, 1H), 1.28 (s, 6H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Gradient:
min
CH 3 CN/0.1% H 3 PO 4
0
5/95
12
90/10
13
5/95
Flow:
1.0 mL/min
Sample volume:
5 μL
Wavelength:
210 nm
Retention times:
HOBT
4.8 min
Pyrazine dimer
5.6 min
Piperazine acid 14
5.9 min
EtOAc
6.3 min
Ketoamide 15
8.2 min
HOBT adduct
11.1 min
EXAMPLE 9
4-[1-[5-(5-methoxy-3-pyridinyl)-2-oxazolyl]-1-methylethyl]-2(S)-[(2,2,2-
trifluoroethyl)aminocarbonyl]-piperazine 16
Material
MW (g/mol)
Amount
moles
Ketoamide 15 (67.8 wt % free base)
529.51
3.57 Kg
6.74
Polyphosphoric Acid
342.04*
7.67 Kg
22.4
30% Oleum (26-29%)
8.95 Kg
Water
32 L
50% NaOH
30 L
IPAc
53 L
Brine
16 L
*Estimated based on P 4 O 10 equivalent.
To a 72 L round bottomed flask equipped with an overhead stirrer, thermocouple probe and nitrogen line was charged 8.95 L of 30% fuming sulfuric acid (oleum). The liquid was cooled over dry ice/acetone bath. When the temperature dropped to 9° C., crystallization of SO 3 was observed with concomitant exotherm to 11° C. Neat PPA (7.67 Kg viscous liquid) was then poured into the oleum over 1 h, avoiding the walls of glassware. A mild exotherm (−5° C.) was observed during addition. Ketoamide bis-sulfate salt 15 (5.26 Kg dusty powder) was added via funnel over 75 min at <20° C. to form a thick mixture with some undissolved ketoamide salt. The bath was drained and the mixture was heated over steam bath to 40-45° C. and aged 7 h to afford a homogeneous brown liquid. Reaction was complete as determined by HPLC assay. The reaction mixture was cooled over dry ice acetone bath to 3° C. and 22 L water was added slowly from an addition funnel to quench the reaction mixture, keeping the internal temperature <23° C. The solution was neutralized partially with 20 L 50% NaOH (<33° C.) and pumped into a 100 L Buchi reactor along with a 10 L water rinse, where it was adjusted to pH 1.7 with more 50% NaOH, diluted with 25 L IPAc, and then adjusted to pH 9.3 with 50% NaOH. The internal temperature was allowed to rise to 37° C. toward the end of addition to keep the salts solubilized. The two phases were separated and collected in polyjugs. Aqeuous loss was 0.2%. The Buchi vessel was thoroughly rinsed with water to remove gummy residues. The combined organic layer was washed with 16 L brine (0.04% loss) and 2 L water (0.2% loss). Assay yield was 2.44 Kg (85%) of title product 16 (90.4 A %, 95.1% ee).
1 H NMR (CDCl 3 , 500 Hz): δ 8.63 (broad s, 1H), 8.50 (s, 1H), 8.28 (s, 1H), 7.36-7.37 (m, 1H), 7.34 (s, 1H), 3.91-4.00 (m, 2H), 3.94 (s, 3H), 3.78-3.79 (m, 1H), 3.02-3.11 (m, 4H), 2.88-2.91 (m, 1H), 2.65-2.73 (m, 2H), 1.60 (s, 3H), 1.59 (s, 3H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Gradient:
min
CH 3 CN/0.1% H 3 PO 4
0
5/95
12
90/10
13
5/95
Flow:
1.0 mL/min
Sample volume:
5 μL
Wavelength:
210 nm
Retention times:
Ketomaide 15
5.3 min
Biarylpiperazine 16
5.6 min
EXAMPLE 10
Tris-naphthalenesulfonic acid salt of 16
Part A — Purification of 2-Naphthalenesulfonic acid
Run 1 —
Material
MW (g/mol)
Amount
mmoles
2-NSA 17 (76 wt % and 88A %)
208.24
200 g
730
2-NSA 17 seed
0.30 g
Acetonitrile
800 mL
Water
10 mL
Toluene
950 mL
The impurities present in the crude 2-NSA 17 included 1-NSA, naphthalene, two isomers of naphthalenesulfone, and sulfuric acid. The crude 2-NSA 17 (200 g) was mixed with 400 mL CH 3 CN, 10 mL water and 800 mL toluene and heated to 78-80° C. to dissolve the solids. The two layers were allowed to settle and the lower black layer (about 100 mL) was cut at 80° C. The top layer was cooled and seeded at 40° C. (100 mg seed). A slurry formed at −33° C. The slurry was cooled to 6° C., rinsed with 150 mL toluene and air dried in the funnel to afford 169 g of acid 17. In the black cut, most of 1-naphthalenesulfonic acid and sulfuric acid were rejected. In the mother liquor most of naphthalene and isomers of naphthalenesulfone are rejected. The purity of the filtered crystals was ˜98.6 A %.
The crystals were mixed with 340 mL CH 3 CN and heated to 50° C. to form a clear, gray solution, which was cooled and seeded at 40° C. (200 mg seed). A slurry formed at ˜26° C. This was cooled to 5° C., filtered and rinsed with 100 mL CH 3 CN to afford after drying in a vacuum oven at 60° C., 76.8 g solid (99.8 A %, 94.3 wt. % with 8% water, 48% recovery based on 76 wt % pure crude acid).
1 H NMR of 17 (DMSO-d6, δ) 8.17 (s, 1H), 7.98˜7.96 (m, 1H), 7.91˜7.90 (m, 1H), 7.88˜7.86 (m, 1H), 7.73˜7.71 (m, 1H), 7.53˜7.51 (m, 2H), 6.98 (broad, 3H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Solvents:
50% CH 3 CN, 50% 0.1% H 3 PO 4
Flow:
1.0 mL/min
Sample volume:
10 μL
Wavelength:
210 nm
Retention times:
NSA isomer
2.7 min
2-NSA 17
3.1 min
Toluene
10.4 min
Naphthalene
13.5 min
Sulfone impurity #1
25.5 min
Sulfone impurity #2
29.2 min
Run 2—
Crude 2-NSA 17 (40 g; from Rutgers Organic Corp.; 88 A % and 76.6 wt. % pure) was mixed with 80 mL of acetonitrile and 320 mL of toluene. The mixture was heated to about 80-82° C. to dissolve all of the solid. The mixture was maintained at temperature and allowed to settle and form two layers. The bottom black layer (13.3 g containing about 13.6% of the acid) was cut. Water (2 mL) was added to the top layer, the mixture agitated and then allowed to cool to room temperature resulting in the formation of a slurry which was aged at room temperature overnight. The slurry was filtered and rinsed with toluene (50 mL) to afford a gray solid, which was vacuum dried at 60° C. to give 27.55 g of solid (98.1 A % and 90.0 wt. % pure). Recovery was 80.8%. 6.5% of the acid was lost in the mother liquor.
Run 3—
Crude 2-NSA 17 (40 g; from Rutgers Organic Corp.; 88 A % and 76.6 wt. % pure) was mixed with 80 mL of acetonitrile and 240 mL of toluene. The mixture was heated to about 80-82° C. to dissolve all of the solid. The mixture was maintained at temperature and allowed to settle and form two layers. The bottom black layer (13.73 g containing about 14.6% of the acid) was cut. Water (30 mL) was added to the top layer, the mixture agitated and then allowed to cool to room temperature and to settle which resulted in the formation of 2 layers. The top layer most of the organic impurities was cut (0.4 wt. % of the acid was lost). The bottom layer was concentrated to about 60 mL by vacuum distillation at less than 50° C. Acetonitrile (570 mL) was then slowly added to remove the water by continuous distillation. The final volume was about 60 mL. Tolume (20 mL) was added and the mixture heated to 60° C. providing a clear solution, which was then cooled to 45° C. and seeded with 2-NSA seed crystals which resulted in the formation of a slurry which was cooled to about 0-5° C. and aged for 30 minutes. The slurry was then filtered and rinsed with toluene (30 mL) to afford an off-white solid. After vacuum drying at 60° C., a solid acid was obtained (20.9 g, HPLC: 99.5 A % and 96.7 wt. % pure). Recovery was 66%. 21.5% of the acid was lost in the mother liquor.
Part B - Preparation of the Tris-NSA salt of 16
Material
MW (g/mol)
Amount
moles
Biarylpiperazine 16*
427.42
2321
g
5.43
Seed of tris-salt 18
1052.14
12
g
2-Naphthalenesulfonic acid 17**
208.24
3683
g
16.29
Acetonitrile
130
L
Water
8.9
L
*15.3 wt % solution in CH 3 CN, 94.8 ee %
**92.1 wt % and 99.8 A %
2-Naphthalenesulfonic acid 17 (92.1 wt % pure) was dissolved in 21 L of CH 3 CN and 8.82 L water at 65° C. A clear solution of biarylpiperazine 16 in CH 3 CN (15.17 kg, 2.321 kg free base 6) was added over 1 min along with 1 L CH 3 CN rinse. The mixture was still a clear solution (57° C.). After seeding (12 g), a slurry formed gradually. The slurry was aged 1h at 50-60° C. The slurry was vacuum distilled at 30-45° C. and 94 L CH 3 CN was added slowly to reduce the water content in order to lower the solubility of the tris-NSA salt 18. Samples were taken during distillation to monitor the change:
Volume of
Free base in
KF value of
Sample
CH 3 CN added
ee % of salt
supernatant
supernatant
#1
72 L
99.9%
3.25 g/L
6.8%
#2
84 L
99.8%
2.53 g/L
4.6%
#3
94 L
98.2%
1.48 g/L
3.5%
The volume was adjusted to ˜49 L. The slurry was cooled to 25° C. and was aged overnight. The solids were filtered, rinsed with 12 L CH 3 CN and dried in a vacuum oven at 60° C. to afford 5.29 kg crystalline solid 18 (99.5 A %, 41.2 wt %, 98.1 ee %, 94% recovery or 97% after ee % correction.) Loss in the mother liquor was 2.6%.
1 H NMR of 18 (DMSO-d6, with two drops of D2O, δ) 9.27 (t, 1H, J=6.3 Hz), 8.65 (d, 1H, J=1.6 Hz), 8.42 (d, 1H, J=1.7 Hz), 8.13 (d, 3H, J=0.8 Hz), 7.96˜7.94 (m, 3H), 7.91˜7.89 (m, 5H), 7.88˜7.85 (m, 3H), 7.72˜7.69 (m, 3H), 7.53˜7.51 (m, 6H), 4.03˜3.97 (m, 3H), 3.93 (s, 3H), 3.33˜3.24 (m, 2H), 3.02˜2.96 (m, 2H), 2.50 ˜2.45 (m, 2H), 1.56 (s, 6H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Solvents:
60% CH 3 CN, 40% 0.1% H 3 PO 4
Flow:
1.0 mL/min
Sample volume:
10 μL
Wavelength:
210 nm
Retention times:
Biarylpiperazine 16
2.1 min
2-NSA 17
3.1 min
EXAMPLE 11
Acetonide 21
Material
MW (g/mol)
Amount
mmoles
Aminochromanol 20
165.19
100.00
605
Acetonide 21
337.41
Triethylamine (d = 0.726)
101.19
98 mL
703
Hydrocinnamoyl chloride*
168.82
93 mL
622
2-Methoxypropene (d = 0.753)
72.11
232 mL
2.42
Methanesulfonic acid (d = 1.481)
96.10
4.0 mL
62
THF
2000 mL
IPAc
3000 mL
5% Sodium bicarbonate
1800 mL
Cyclohexane
3850 mL
Water
900 mL
*98%, d = 1.13
To a mixture of aminochromanol 20 (100.0 g, 95% ee, 605 mmol), TEA (89 mL, 635 mmol), and 1800 mL dry THF at room temperature was added a solution of hydrocinnamoyl chloride (93 mL, 622 mmol, 1.03 eq) in THF (200 mL) over 40 min, allowing the temperature to drift up to 45° C. At the end of the addition, a slurry was generated which was aged at 45° C. for 30 min then cooled to 30° C. 2-Methoxypropene (232 mL, 4.0 eq) was added, followed by 4.0 mL methanesulfonic acid (0.10 eq). The mixture was aged at 35˜38° C. for 1 h. The flask was fitted with a condenser, and the slurry was warmed to 40° C., aged for 2 h, heated to 60° C. and aged at 60° C. under N 2 for 2˜4 h until HPLC showed <0.1 A % amide remaining. The reaction was quenched with 9 mL triethylamine. The mixture was concentrated to about 2 L by vacuum distillation at <60° C. IPAc (3 L) was added slowly to replace THF. The final volume was 2.4 L. The mixture was cooled to room temperature and 900 mL of 5% NaHCO 3 were added to dissolve all solids. After settling, the aqueous layer was cut and the organic layer was washed with 900 mL 5% NaHCO 3 and then 900 mL water. The organic layer was concentrated to 2.5 L by vacuum distillation at <85° C., and cyclohexane (3.6 L) was added slowly during distillation to solvent switch. Some solids formed during distillation. When the mixture was heated to 70˜75° C., most of the solids dissolved. At the end of distillation all solid was dissolved by heating to 75˜80° C. The clear solution was cooled slowly to RT over 2.5 h during which slurry formed. This was aged 30 min at room temperature and 30 min at 0˜5° C. The slurry was filtered and the solids were rinsed with 250 mL cyclohexane. After vacuum oven drying at 50° C., 184.16 g (98.7 A %, 98.1 wt % pure) of acetonide 21 was obtained. There was 6.4% loss in the mother liquor. The yield after purity correction was 88%.
1 H NMR (CDCl 3 , 300 MHz) 7.25 (m, 7H), 6.82 (m, 2H), 4.70 (d, 1H), 4.33 (m, 1H), 4.08 (d, 1H), 3.92 (s, 1H), 3.11 (m, 2H), 2.92 (m, 1H), 2.68 (m, 1H), 1.61 (s, 3H), 1.23 (s, 3H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Solvents:
60% CH 3 CN, 40% 0.1% H 3 PO 4
Flow:
1.0 mL/min
Sample volume:
10 μL
Wavelength:
210 nm
Retention times:
Aminochromanol 20
2.1 min
Hydroxyamide
3.9 min
IPAc
4.1 min
Acetonide 21
7.7 min
Ester impurity
11.1 min
EXAMPLE 12
Olefin 22
Material
MW (g/mol)
Amount
mmoles
Acetonide 21 (99.6 wt. %)
337.41
50.00 g
148
Olefin 22
377.48
Allylbromide
120.98
18.60 g
154
1.38M LHMDS in THF (d = 0.89)
109 g
169
Citric acid
192.13 g/mol
8.63 g
44.9
Tetrahydrofuran
343 mL
Isopropyl acetate
1100 mL
0.3M Sulfuric acid
180 mL
5% Sodium bicarbonate
180 mL
Water
180 mL
Acetonide 21 (50.00 g, 148 mol) was dissolved in 283 mL THF (KF=116 μg/mL). The solution was degassed and was placed under N 2 . The solution was cooled to −46 to −44° C. and 18.60 g (1.04 eq) allylbromide was added. LHMDS/THF (107 g) was charged over 45 min at −46 to −44° C. After a 60 min age at this temperature, a sample was taken (quenched into 2 vol cold EPA) for HPLC assay, which showed 0.68 A % acetonide 21 remaining (99.3% conversion). More LHMDS/THF (2.14 g) was added, and the mixture was aged for 30 min more. HPLC showed 0.22 A % acetonide 21 (99.8% conversion). The reaction was quenched by adding cold citric acid solution in THF (8.63 g/60 mL THF). A slurry formed. The slurry was warmed from −32° C. to 16° C. over 1 h. The batch was vacuum distilled to ˜400 mL at <40° C. and was flushed with 1100 mL IPAc to solvent switch to IPAc. The final volume was 450 mL. To the slurry was charged 180 mL 0.3 M H 2 SO 4 (d=1.016 g/mL) at 20-25° C. All solids dissolved. After settling, the aqueous layer was cut and the organic layer was washed with 180 mL water and then 180 mL 5% NaHCO 3 . The organic layer was diluted to 500 mL with IPAc. By HPLC the solution yield of olefin 22 was 98%. The concentration of olefin 22 was about 0.3 M. The solution was used in Example 13 without further purification.
1 H NMR (CDCl 3 , 300 MHz) indicated a 5:1 mixture of rotamers: 7.30 (m, 5H), 7.05 (m, 1H), 6.80 (m, 1H), 6.4 (m, 1H), 5.85 (m, 1H), 5.15 (m, 1H), 4.98 (m, 1H), 4.40 (m, 1H), 4.25 (m, 2H), 3.38 (dd, 1H), 3.19 (m, 1H), 2.80 (m, 1H), 2.42 (m, 1H), 1.70 (s, 3H), 1.23 (s, 3H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Solvents:
60% CH 3 CN, 40% 0.1% H 3 PO 4
Flow:
1.0 mL/min
Sample volume:
10 μL
Wavelength:
210 nm
Retention times:
IPAc
4.1 min
Allylbromide
5.2 min
Acetone eliminated
6.0 min
impurity
Acetone adduct
7.2 min
Acetonide 21
7.7 min
Olefin 22
12.6 min
Epi-olefin
12.9 min
EXAMPLE 13
Iodohydrin 23
Material
MW (g/mol)
Amount
mmoles
Olefin 22
377.48
˜148
Iodohydrin 23
521.39
NCS
133.53
33.60 g
252
57% NaI
149.89
64.22 g
244
20% Na thiosulfate pentahydrate
248.18
165 mL
IPAc
˜50 mL
5% Sodium bicarbonate
220 mL
Water
220 mL
To the solution of olefin 22 (500 mL, ˜148 mmol) in IPAc was charged 220 mL water and 220 mL 5% NaHCO 3 . The mixture was cooled to 3-4° C. NCS (33.60 g, 252 mmol, 1.7 eq) was added, then 57% NaI solution (64.22 g, 244 mmol, 1.65 eq) was added over 40 min at 4-7° C. The resulting brown solution was allowed to warm to 20° C. over 2 h and then was warmed to 30° C. over 15 min. The mixture was aged at 30° C. for 4 h. The conversion to iodohydrin was 98.6% after warming to 20° C. and 99.9% after 4 h age at 30° C. The batch was cooled to room temperature and then quenched with fast addition of 165 mL 20% Na 2 S 2 O 3 .5H 2 O (d=1.17 g/mL). After agitating for 2 min, the color of reaction mixture changed to orange from brown. The mixture was settled and the aqueous layer (650 mL) was cut. The organic layer (520 mL) was assayed and solution yield of iodohydrin was 83%. The solution was used in Example 14 without further purification.
1 H NMR (CDCl 3 , 300 MHz) indicated a 5:2 mixture of rotamers: 7.30 (m, 5H), 7.05 (m, 1H), 6.82 (m, 1H), 6.60 (m, 1H), 5.92 (d, 0.3H), 5.58 (d, 0.7H), 4.45 (m, 2H), 4.20 (m, 2H), 3.63 (m, 1H), 3.44 (m, 2H), 3.20 (m, 2H), 2.82 (m, 2H), 2.40 (d, 1H), 2.00 (m, 1H), 1.72 (s, 3H), 1.49 (d, 2H), 1.29 (s, 3H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Solvents:
60% CH 3 CN, 40% 0.1% H 3 PO 4
Flow:
1.0 mL/min
Sample volume:
10 μL
Wavelength:
210 nm
Retention times:
IPAc
4.1 min
Iodohydrin 23
9.3 min
Olefin 22
12.6 min
EXAMPLE 14
Epoxide 24
Material
MW (g/mol)
Amount
mmoles
Iodohydrin 23
521.39
<148
Epoxide 24
393.48
25% NaOMe in MeOH
54.02
44.8 g
207
IPAc
500 mL
IPA
450 mL
10% Sodium sulfate decahydrate
340 mL
Water
170 mL
The solution of iodohydrin 23 in IPAc (520 mL, <148 mmol) was vacuum distilled at <35° C. IPAc (500 mL) was added slowly while the volume of solution was maintained at 500 mL. KF of the solution was <1400 μg/mL after the distillation. After azeotropic drying, the organic solution was cooled to 14-16° C. Then 44.8 g 25% NaOMe in methanol was added (small endotherm). The mixture was aged at 15° C. for 45 min. Sampling after 30 min age at 14-16° C. showed >99.7% conversion to epoxide. The reaction was quenched at 15-20° C. by adding 170 mL water. The mixture was agitated 2 min and settled 10 min. The aqueous layer was cut. The clear, dark brown organic layer was washed by 2×170 mL 10% Na 2 SO 4 -10H 2 O (d=1.04 g/mL). The pH of the first wash aqueous solution was 7 and was 6.5 for the second wash. The loss of epoxide in these two washes was <0.1%. The organic layer showed a lower 99.3% conversion to epoxide, due to some reverse reaction to iodohydrin. The organic layer was vacuum distilled to 220 mL and then flushed with 400 mL EPA at <45° C. A slurry was generated during this solvent switch. The slurry was heated rapidly to 80° C. to dissolve all solid. The dark solution was cooled slowly to 60˜65° C. and was aged at this temperature to obtain a thin slurry. The slurry was cooled to room temperature over 1 h and was cooled to 0˜5° C. for 3 h. The slurry was filtered and the cake was displacement-rinsed with 50 mL cold EPA. By HPLC there was 2.4% epoxide lost in mother liquor and rinse (160 mL). The cake was vacuum oven dried overnight at 40° C. with a nitrogen sweep to afford 48.02 g of epoxide 24 (99.4A % and 98.5 wt % pure). The yield was 81% from acetonide 21.
1 H NMR (CDCl 3 , 300 MHz) indicated a 5:2 mixture of rotamers: 7.30 (m, 5H), 7.10 (m, 1H), 6.82 (m, 1H), 6.50 (m, 1H), 5.89 (d, 0.3H), 5.40 (d, 0.7H), 4.40 (m, 2H), 4.15 (m, 2H), 3.40 (m, 2H), 3.00 (m, 1H), 2.85 (m, 2H), 2.50 (dd, 0.7H), 2.40 (dd, 0.3H), 2.20 (m, 1H), 1.72 (s, 3H), 1.49 (d, 1H), 1.29 (s, 3H).
HPLC Assay:
Column:
Zorbax RX-C8 (4.6 mm × 250 mm)
Solvents:
60% CH 3 CN, 40% 0.1% H 3 PO 4
Flow:
1.0 mL/min
Sample volume:
10 μL
Wavelength:
210 nm
Retention times:
IPAc
4.1 min
Epoxide 24
8.0 min
Iodohydrin 23
9.3 min
EXAMPLE 15
Biarylpiperazine tris-NSA salt (300.00 g, GMP) was slurried in MeOH (940 mL) and KOH in MeOH (860 mL, 1.0N). The slurry was allowed to stir for 4 h. MeOH was distilled off at 35 Torr with an internal temperature of 5° C. After ˜800 mL was distilled off, the slurry became too thick to stir and toluene (1800 mL) was added. A total of 3600 mL of toluene was used to flush the slurry (mother liquors were checked for the presence of naphthalenesulfonic acid). The slurry was then filtered, rinsing 2×360 mL toluene. The filtrates were assayed by HPLC and found to contain 123.1 g biarylpiperazine. The filtrate was then concentrated and diluted with 480 mL t-amyl alcohol. It was concentrated again and then flushed with 450 mL t-amyl alcohol. It was assayed and found to contain 115.1 g biarylpiperazine. Epoxide 24 (107.00 g, 1.01 eq.) was added, and the mixture was stirred at 55° C. (internal temperature) for 90 h. The mixture was diluted with IPAc (1720 mL) and assayed for the coupled acetonide product 25 by HPLC (found 185.00 g (84% yield). Silica gel (370.0 g) and Darco G-60 activated carbon (46.25 g) were added and the mixture was heated at 50° C. for 1 hour. It was filtered through Solka Floc and rinsed with 925 mL 5% MeOH/IPAc (4×). The initial filtrate and first rinse were assayed and were found to contain a total of 146.03 g. Rinses 3 and 4 contained 24.69 g and 7.52 g, respectively. The filtrate, first and second rinses were combined. A portion of this containing ˜100 g was chromatographed (16 cm column, 2.00 kg silica) using 0 to 6% MeOH/IPAc. Clean fractions were combined and concentrated.
1 H NMR (CD 3 OD, 500 Hz): δ 8.48 (s, 1H), 8.23 (d, J=2.3 Hz, 1H), 7.64-7.65 (m, 1H), 7.63 (s, 1H), 7.20-7.32 (m, 5H), 7.01 (t, J=7.5 Hz, 1H), 6.68 (d, J=8.3 Hz, 1H), 6.45 (t, J=6.5 Hz, 1H), 6.35 (d, J=7.7 Hz, 1H), 5.67 (d, J=3.9 Hz, 1H), 4.45 (d, J=2.3 Hz, 1H), 4.32-4.35 (m, 1H), 4.18 (d, J=3.0 Hz, 1H), 3.93-4.00 (m, 1H), 3H), 3.95 (s, 3H), 3.77-3.85 (m, 2H), 3.43-3.48 (m, 1H), 3.27 (t, J=5.1 Hz, 1H), 3.03 (d, J=4.4 Hz, 1H), 2.73-2.83 (m, 2H), 2.55 (t, J=8.3 Hz, 1H), 2.34-2.43 (m, 3H), 1.93-1.98 (m, 1H), 1.66 (s, 3H), 1.52 (s, 6H), 1.14(s, 3H). LC-MS (M + +1) (EI) 821.5.
EXAMPLE 16
Compound 25 penultimate prepared in Example 15 (97.5 g) was dissolved in 225 mL MeOH and cooled to −10° C. 5.02N HCl in methanol (245 mL) was added dropwise over 30 min, keeping the temperature below 0° C. It was then transferred to a 0° C. bath. After stirring for 13 h, it was assayed and found to be greater than 98.5% complete. 5N NaOH (250 mL) was added, keeping the temperature below 0° C. After addition was complete the pH was checked and found to be 9. IPAc (1.0L) and water (200 mL) were added and the layers were shaken to dissolve a brown oil that formed during the quench. The layers were cut and the aqueous layer was assayed and found to contain 0.19 g of Compound 26. The organic layer was washed with 200 mL brine. The organic layer was assayed and found to contain 85.95 g of Compound 26 free base (92.7%). The brine layer was found to contain 0.05 g of Compound 26. Activated carbon (17.99 g) was added and the mixture was stirred at 50° C. for 1 h. After cooling to room temperature the slurry was filtered through solka-floc and the cake washed with IPAc, 3×180 mL. The filtrate and washes were combined and assayed which showed 80.54 g of Compound 26 free base. The combined filtrate and washes were then concentrated to a yellow foamy solid.
1 H NMR (CD 3 OD, 500 Hz): δ 8.49 (s, 1H), 8.22 (d, J=1.6Hz, 1H), 7.66-7.67 (m, 1H), 7.20-7.25 (m, 4H), 7.14-7.17 (m, 1H), 7.06-7.10 (m, 2H), 6.80 (t, J=7.6 Hz, 1H), 6.71 (d, J=8.0 Hz, 1H), 5.13 (d, J=3.8 Hz, 1H), 4.04-4.06 (m, 2H), 3.92-3.98 (m, 1H), 3.94 (s, 3H), 3.78-3.82 (m, 1H), 3.72-3.77 (m, 2H), 3.06-3.10 (m, 1H), 2.96-3.03 (m, 2H), 2.88-2.94 (m, 1H), 2.85 (d, J=11.2 Hz, 1H), 2.70-2.77 (m, 2H), 2.63-2.67 (m, 1H), 2.44-2.50 (m, 1H), 2.34-2.44 (m, 4H), 2.00-2.04 (m, 1H), 1.60 (s, 3H), 1.59 (s, 3H), 1.35-1.38 (m, 1H). LC-MS (M + +1) (EI) 781.5.
While the foregoing specification teaches the principles of the present invention, with examples provided for the purpose of illustration, the practice of the invention encompasses all of the usual variations, adaptations and/or modifications that come within the scope of the following claims. | A process for preparing γ-hydroxy-4-[[2-oxazolyl]alkyl]-α-[(cyclo)alkyl- or aryl- or heteroaryl-substituted methyl]-2-[[(un)substituted alkyl]aminocarbonyl]-1-piperazinepentanamides is disclosed. The piperazinepentanamides are useful as HIV protease inhibitors. A process for making a 4-[[2-oxazolyl]alkyl]-2-[[(un)substituted alkyl]aminocarbonyl]piperazine by treating a ketoamide precursor with fuming sulfuric acid in the presence of polyphosphoric acid is also disclosed. In addition, a process for enhancing the optical purity of 4-[[2-oxazolyl]alkyl]-2-[[(un)substituted alkyl]aminocarbonyl]-piperazines via the formation 2-naphthalenesulfonic acid crystal salts thereof is disclosed, as well as a method for purifying 2-naphthalenesulfonic acid. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a Continuation in Part of Ser. No. 08/394,900, filed Feb. 27, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to automated embroidery operations. More specifically, the present invention relates to an embroidery hoop and the bracket for mounting an embroidery hoop on the hoop guide of an embroidery machine.
2. Description of the Prior Art
Embroidery commonly enhances the decorative appearance of a wide range of items. Typically, the embroidering is imparted on a workpiece by automated embroidery machines. The workpiece is mounted on any number of hoops, each hoop in turn being mounted on an automatically controlled hoop guide, also known as the X-Y driver, of an embroidery machine. The hoop guide moves the hoop relative to the needle of the embroidery machine as the needle introduces stitching to the workpiece. To ensure an accurate embroidery design, especially during mass production, the hoop must attach securely and precisely to the hoop guide. Unfortunately, repeated mounting and removing of the hoop wears the hoop attachment bracket, degrading the resolution of the stitching imparted on the fabric. For this reason, there is a need for an embroidery hoop attachment bracket which provides for secure and precise mounting of the embroidery hoop to the automatically controlled hoop guide of an embroidery machine by reducing wear on the hoop attachment bracket.
U.S. Pat. No. 5,291,843, issued Mar. 8, 1994, to Masayaki Hori, describes an attachment structure, shown in FIGS. 1 and 2, for detachably attaching an embroidery hoop to the automatically controlled hoop guide of an embroidery machine. A hoop 10 for holding a workpiece and hoop attachment bracket 12 are shown in FIG. 1. A hoop guide bracket 14 designed to matingly receive the hoop attachment bracket 12 is seen in FIG. 2. The hoop guide attachment bracket 14 is mounted to an automatically controlled hoop guide (not shown). The '843 attachment structure, including both the hoop attachment bracket 12 and the hoop guide attachment bracket 14, removably attaches the hoop 10 to the hoop guide such that the hoop can be moved by the hoop guide in a horizontal plane in synchronism with the reciprocating motion of the sewing needle of a sewing machine (not shown).
When the hoop attachment bracket 12 is removably attached to the hoop guide-attachment bracket 14, each of the two engagement pins 16 extending from the hoop attachment bracket 12 is closely received in a tight friction fit by a corresponding U-shaped slot 18 in the upturned flange portion 33 of the hoop guide attachment bracket 14. A spring clip 24 of the hoop guide attachment bracket 14 is articulated back such that the projection member 20 of the hoop attachment bracket 12 clears a knuckle portion 22 of the spring member 24. Once the hoop 10 is seated, the spring member 24 is released, biasing the projection member 20 and the hoop 10 downwardly. The spring member 24 and the engagement pins 16 act to maintain the hoop 10 stationary relative to the hoop guide.
During large-scale embroidery operations, thousands of hoops 10 are mounted and dismounted from the hoop guide. Unfortunately, repeated embroidery hoop installation results in excessive wear on the engagement pins 16 and their respective slots 18. As the engagement pins 16 and their respective slots 18 wear, the slots 18 no longer receive the engagement pins 16 in a tight friction fit as play develops between the engagement pins 16 and their respective slots 18. The resultant play causes the hoop 10 to move or wobble relative to the hoop guide, thereby dramatically effecting the resolution of the embroidery designs imparted on the workpiece. As a result, manufacturers must repair or replace hoops 10 or hoop attachment brackets 12 often.
Several other types of embroidery hoop attachment brackets are described in the patent literature. For example, U.S. Pat. No. 4,411,208, issued Oct. 25, 1983, to Koji Nishida et al., describes an embroidery frame for automatic embroidery machine. The apparatus includes a frame with a horizontal tang for an attachment. The tang is received in a slot in the machine and secured by threaded fasteners threadingly clamping the tang therein.
U.S. Pat. No. 5,101,746, issued Apr. 17, 1992, to Ricky J. Frye, describes a work holder for sewing machines. The device includes a frame with an attachment including two parallel posts extending outwardly, each having an annular groove distally disposed. Each post is received in a cylindrical bore of the machine. Radial, cylindrical chambers extend from the bores. Spring-loaded balls in the chambers are biased toward the bore and engage with the groove when the posts are inserted therein.
U.S. Pat. No. 5,261,340, issued Nov. 16, 1993, to Ralph F. Conley, Jr. et al., describes a detachable template clamp having a removable sewing template. The apparatus includes a template with an attachment including two parallel throughbores. The machine has an adaptor which traps the frame adaptor against guide rails. The machine adaptor has two posts extending toward the guide rails that are received in the frame adaptor throughbores.
U.S. Pat. No. 5,353,725, issued Oct. 11, 1994, to Hisato Sakakibara, describes front and rear embroidery frame mounting members. The apparatus includes a front and a rear attachment. The machine has a rear attachment including a flattened, C-shaped member having a vertically disposed slot. The frame has a horizontal flange with a vertical pin extending therefrom that is received by the machine attachment. The machine has a front attachment including a vertical pin. The frame has an attachment including a horizontal flange having a vertical throughbore for receiving the vertical pin.
Japanese Patent No. 1,033,262, published Feb. 3, 1989, issued to Aisin Seiki KK, in the abstract describes a machine including a fixed magnet. The frame includes a metal plate. The frame may be selectably fixed to the machine by magnetic adhesion. A problem encountered with the '262 machine is that the magnet can be easily dislodged if the frame is bumped during embroidery. Also, when heavier objects are embroidered, the frame tends to disengage from the machine.
None of the above references, taken alone or in combination, are seen as teaching or suggesting the presently claimed embroidery hoop attachment assembly.
SUMMARY OF THE INVENTION
The present invention overcomes the limitations of the above described inventions by providing a hoop attachment assembly for accurately and securely mounting an embroidery hoop to an automatically controlled hoop guide of an embroidery machine. The hoop attachment assembly includes a hoop attachment bracket which is mounted to the embroidery hoop. At least two resilient pins are attached to the hoop attachment bracket and are spaced apart to receive the hoop guide attachment bracket. The two resilient pins cooperatively squeeze and retain the hoop guide attachment bracket when the hoop attachment assembly is attached to the hoop guide attachment bracket.
In accordance with another aspect of the invention, a locking means is provided to inhibit vertical movement of the hoop attachment assembly relative to the hoop guide attachment bracket when the hoop attachment assembly is attached to the hoop guide attachment bracket.
In accordance with a further aspect of the invention, the hoop attachment bracket may include an aperture extending therethrough. The aperture is positioned in registry with a detent in the hoop guide attachment bracket. The first end of the aperture is positioned proximate to the front face of the hoop attachment bracket, and the second end of the aperture is threaded for receipt of a screw.
In accordance with still another aspect of the invention, the locking means may include a locking ball positioned in the aperture at the first end, a set screw positioned in the aperture at the second end, and biasing means for biasing the locking ball. The locking ball engages the detent of the hoop guide attachment bracket when the hoop attachment assembly is attached to the hoop guide attachment bracket. The set screw engages the threading at the second end of the aperture and permits adjustment of said locking ball relative to the hoop guide attachment bracket. The biasing means biases, i.e. forces, the locking ball into engagement with the detent when the hoop attachment assembly is attached to the hoop guide attachment bracket.
In accordance with another aspect of the invention, the hoop attachment bracket may be in the shape of a rectangular parallelpiped having a longitudinal axis, a top face, a bottom face, a front face, and a first end and a second end. The top face, the bottom face, and the front face extend in a direction parallel to the longitudinal axis between the first end and the second end.
In accordance with a further aspect of the invention, the hoop attachment bracket may be attached to a flat peripheral portion of the embroidery hoop in a manner such that the bottom face lies flush against the flat peripheral portion of the embroidery hoop.
In accordance with in another aspect of the invention, the hoop attachment bracket may include a first cut-away portion extending between the first end and the second end of the hoop attachment bracket to accommodate a raised edge at the periphery of the flat peripheral portion of the embroidery hoop. The first cut-away portion is formed by cutting away a corner of the parallelpiped at which the bottom face and the front face would otherwise join.
In accordance will still another aspect of the invention, the hoop attachment bracket may include a slot extending parallel to the front face. The slot includes a first side distal from the front face and a second side proximal the front face. The two pins extend from at least the first side to the front face.
In accordance with a further aspect of the invention, a portion of the hoop attachment bracket between the first side of the slot and the front face may be cut away to form a second cut-away portion. The second cut-away portion is in the shape of a rectangle when viewed facing the front face. Each of the two pins are positioned at opposing ends of the second cut-away portion.
In accordance with a still another aspect of the invention, a portion of the hooped attachment bracket between a plane, coincident with the first side of the slot, and the front face may be cut away to form a third cut-away portion. The third cut-away portion extends from the top face to intersect the bottom of the slot and the second cut-away portion at substantially the middle of the second cut-away portion. The third cut-away portion accommodates the spring clip of the hoop guide attachment bracket when the hoop attachment assembly is attached to the hoop guide attachment bracket.
In accordance with one aspect of the invention, the hoop attachment bracket may include a plurality of openings extending at least from the first side of the slot to the front face of the hoop attachment bracket. Each of the plurality of openings receives a first end of a respective one of the pins and is dimensioned to allow clearance between the side walls of the openings and the first end of a respective one of the pins. Thus, the side walls of each of the openings prevent over-deflection of a respective one of the pins when the hoop attachment assembly is attached to the hoop guide attachment bracket.
In consideration of the above, an object of the invention is to provide a embroidery hoop attachment bracket that assures secure mounting of an embroidery hoop on an embroidery machine.
Another object of the invention is to provide a embroidery hoop attachment bracket that is wear resistant.
A further object of the invention is to provide a embroidery hoop attachment bracket requiring minimum clearance for mounting onto an embroidery machine.
An additional object of the invention is to provide a embroidery hoop attachment including means for urging the frame mount to remain on the hoop guide attachment bracket.
Yet a further object of the invention is to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an top front perspective view of a prior art hoop.
FIG. 2 is a top rear perspective view of a prior art hoop guide attachment bracket.
FIG. 3 is a front elevational view of the present invention.
FIG. 4 is a side elevational view of the present invention, drawn to an enlarged scale.
FIG. 5 is a partial, bottom plan view of the instant hoop attachment.
FIG. 6 is a top plan view of another embodiment of the invention including biased engagement means.
FIG. 7 is a front elevational view of a second embodiment of the present invention.
Similar reference characters denote corresponding features of the invention consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 3-5, an embroidery hoop attachment assembly 110 for attaching an embroidery hoop to a hoop guide of an embroidery machine is shown mounted on an embroidery hoop 112. The embroidery hoop 112 is the subject of a pending application (Ser. No. 08/394,900, filed Feb. 27, 1995) by the present inventor which is incorporated herein by reference. Alternatively, embroidery hoop attachment assembly 110 may be used with any well known embroidery hoop.
Continuing to refer to FIGS. 3-5, the embroidery hoop attachment assembly 110 includes a hoop attachment bracket 114. The hoop attachment bracket 114 is formed in the shape of a rectangular parallelpiped having a longitudinal axis 116, a top face 118, a bottom face 120, a front face 122, a rear face 123, and a first end 124 and a second end 126. The top face 118, the bottom face 120, the front face 122 and the rear face 123 extend in a direction parallel to the longitudinal axis between the first end 124 and the second end 126.
The hoop attachment bracket 114 is attached to a flat peripheral portion 128 of the embroidery hoop in a manner such that the bottom face 120 lies flush against the flat peripheral portion 128 of the embroidery hoop. The hoop attachment bracket 114 includes a first cut-away portion 130 extending between the first end 124 and the second end 126 of the hoop attachment bracket 114 to accommodate a raised edge 132 at the periphery of the flat peripheral portion 128 of the embroidery hoop 112. The first cut-away portion 130 is formed by cutting away a corner of the parallelpiped at which the bottom face 120 and the front face 118 would otherwise join. Two parallel apertures 134, seen in FIG. 5, extend through the hoop attachment bracket 114 perpendicular to the longitudinal axis 116 and accommodate rivets 136 for fastening the hoop attachment bracket 114 to the embroidery hoop 112. Alternatively, any well known fastening means may be used to fasten the hoop attachment bracket 114 to the embroidery hoop 112.
Referring to FIG. 4, the hoop attachment bracket 114 includes a slot 138 extending parallel to the front face 122. The slot include a first side 140 distal from the front face 122 and a second side 142 proximal the front face 122. The slot also includes a bottom 143.
Referring to FIG. 3, a portion of the hoop attachment bracket 114 between the first side 140 of the slot 138 and the front face 122 is cut away to form a second cut-away portion 144. The second cut-away portion 144 is in the shape of a rectangle when viewed facing the front face 122.
Continuing to refer to FIG. 3, a portion of the hoop attachment bracket 114 between a plane 146, coincident with the first side 140 of the slot 138, and the front face 122 may be cut away to form a third cut-away portion 148. The third cut-away portion 148 extends from the top face 118 to intersect the bottom 143 of the slot 138 and the second cut-away portion 144 at substantially the middle of the second cut-away portion 144.
Referring again to FIGS. 3-5, the hoop attachment assembly 110 includes four flexible, resilient pins 150 which extend perpendicularly to the longitudinal axis 116 from the rear face 123 to the front face 122 of the hoop attachment bracket 114. Each of the pins 150 is positioned a respective corner of the of the second cut away portion 144. The pins 150 are preferably of nylon construction. However, the pins 150 may be formed from any flexible, resilient material which would allow the resilient pins to bend or deflect transverse to their longitudinal axis.
Each of the pins 150 include a first section 152 and a second section 154. A first plurality of openings 156 extends from the rear face 123 to the first side 140 of the slot 138 to receive the second section 154 of the pins 150 in a tight friction fit. The first section 152 of each of the pins 150 is thus free to bend or deflect transverse to its transverse axis, while the second section 154 of the pin 150 is held rigidly in place by the hoop attachment bracket 114. A second plurality of openings 158, each in registry with a corresponding opening of the first plurality of openings 156, extend from the first side 140 of the slot 138 to the front face 122 of the hoop attachment bracket 114. Each opening of the second plurality of openings 158 receives the first section 152 of a respective one the pins 150. Each of the second plurality of openings 158 is dimensioned to allow clearance between the first section 152 of a respective one of the pins 150 and the hoop attachment bracket 114. Thus, the hoop attachment bracket 114 acts as a collar by preventing over-deflection of the first section 152 of each of the pins 150. Preferably, the clearance between the hoop attachment bracket 114, at each opening of the second plurality of openings 158, and each of the pins 150 is less than 0.002 of an inch (0.005 mm).
Referring to FIG. 7, a second embodiment of the hoop attachment bracket 112 is shown. Preferably, the hoop attachment bracket 112 is constructed of a die-cast metal block with the slot, openings, apertures, and cut-away portions being machined out of the die-cast metal block. More preferably, the entire hoop attachment 112 may be formed through the injection molding of plastic, or a similar material, with spring brackets 300 replacing the pins 150 and being formed integral with to the hoop attachment bracket 114.
The hoop attachment assembly 110 is designed to allow removable attachment of the embroidery hoop 112 to an automatically controlled hoop guide of an embroidery machine. The hoop attachment assembly receives a hoop guide attachment bracket, such as the bracket 14 shown in FIG. 2 and discussed above. The operation of the present invention, discussed in the context of the particular hoop guide attachment bracket 12 shown in FIG. 2, is for illustrative purposes only. One skilled in the art will appreciate that the hoop attachment assembly 110 can easily be configured to allow removable attachment of an embroidery hoop to the hoop guide attachment bracket of any well known embroidery machine.
Referring to FIGS. 2-5, in operation the hoop attachment bracket 114 is aligned above the hoop guide attachment bracket 14. The second-cut away portion 144 receives the upturned flange projection 33. Each of the first sections of the pins 150 flex and cooperatively squeeze the side edges 46 of the upturned flange projection 33, thereby retaining the hoop guide attachment bracket 14 within the second cut-away portion 114 of the hoop attachment bracket 114. The third cut-away portion 148 accommodates the spring clip 24 of the hoop guide attachment bracket 14 such that no portion of the spring clip 24 engages the hoop attachment assembly 110. Thus, spring clip 24 may be removed from the hoop guide attachment bracket 14 as it is no longer necessary to ensure the hoop attachment bracket 114 remains attached to the hoop guide attachment bracket 14.
One skilled in the art will appreciate that only two pins 150, positioned at opposite sides of the second cut-away portion 144, are necessary to retain the upturned flange projection 33 of the hoop guide attachment bracket 14 within the second cut-away portion 144.
Preferably, the distance between pins 150, shown by line A on FIG. 3, is less than the distance between the two side edges 46 of the upturned flange portion 14. Even more preferably, the distance between the pins 150 is 0.005 of inch (0.013 mm) or less than the distance between the two side edges 46 of the upturned flange portion 14.
The hoop attachment assembly 110 reduces wear on the hoop attachment bracket 114 and the hoop guide attachment bracket 14 by eliminating metal to metal contact between the brackets. Contact between the brackets is maintained primarily through the pins 150. Thus, a secure and precise mounting of the embroidery hoop 112 to the automatically controlled hoop guide is ensured even through repeated use of the embroidery machine.
Referring to FIG. 6, a second embodiment of the hoop attachment assembly 110 is shown. Locking means 160 is a detent or spring-operated ball to inhibit vertical movement of the hoop attachment assembly 110 relative to the hoop guide attachment bracket 14 when the hoop attachment assembly is attached to the hoop guide attachment bracket 14. The hoop attachment bracket 114 includes a second aperture 162 extending completely therethrough. The second aperture 162 is positioned in registry with a detent (not shown) in the hoop guide attachment bracket 14. A first end 164 of the second aperture 162 is positioned at the front face 122 of the hoop attachment bracket 114 and a second end 166 of the second aperture 160 is threaded for receipt of a set screw 168. A locking ball 170 of the detent 160 is positioned within the second aperture 162 at the first end 164. The set screw 168 engages the threading within the second aperture 160 at the second end 166. The locking ball 170 engages the hoop guide attachment bracket 14 when the hoop attachment assembly 110 is attached to the hoop guide attachment bracket 14. The set screw 168 permits adjustment of the locking ball 170 relative to the second aperture 162. A spring 172 biases the locking ball 170 into engagement with the hoop guide attachment bracket 14 when the hoop attachment assembly 110 is attached to the hoop guide attachment bracket 14.
The present invention is not intended to be limited to the embodiments described above, but to encompass any and all embodiments within the scope of the following claims. | A hoop attachment assembly for accurately and securely mounting an embroidery hoop frame to an automatically controlled hoop guide of an embroidery machine. The hoop attachment assembly includes a hoop attachment bracket which is mounted to the embroidery hoop. At least two resilient pins are attached to the hoop attachment bracket and are spaced apart to receive the hoop guide attachment bracket. The two resilient pins cooperatively squeeze and retain the hoop guide attachment bracket when the hoop attachment assembly is attached to the hoop guide attachment bracket. | 3 |
U.S. GOVERNMENT SUPPORT
The invention described and claimed herein resulted from work supported by U.S. government grants from the National Institutes of Health. The Government has certain right in the invention.
This application is a continuation of application Ser. No. 08/064,356 filed May 18, 1993 now abandoned, which is a continuation of Ser. No. 07/471,106 filed Jan. 25, 1990 now abandoned.
BACKGROUND
1. Field of the Invention
This invention relates in general to hearing testing of a human being. In particular, the invention relates to recording of distortion product emissions (DPEs) of human ears. Still more particularly, the invention relates to apparatus and methods for recording DPE audiograms and input/output functions and to the minimization of random noise in the presence of DPE.
2. Description of the Prior Art
Otoacoustic Emissions (OAEs), first described in 1978, represent acoustic energy presumed to be generated by stimulus-induced, motile activity of the outer hair cells of the Organ of Corti in the Cochlea of the inner ear of a human being and other mammals. It is believed that mechanical feedback of such outer hair cells into basilar membrane motion and their related cochlear-efferent endings are part of a biomechanical gain system that is responsible for the sharp tuning and high sensitivity associated with normal hearing.
Otoacoustic emissions (OAEs) may be classified generally as spontaneous emissions and "evoked" or stimulated emissions. Stimulated emissions can be further separated into three subclasses consisting of transiently evoked emissions (TEEs), stimulus-frequency emissions (SFEs), and distortion-product emissions (DPEs). Each type of stimulus [i.e., clicks (TEEs) or low-level, continuous pure tones (SFEs) or continuous, simultaneously applied, two-tone stimuli (DPEs)] generates evoked emissions. TEEs and SFEs have an appreciable latent or delayed time period with respect to stimulus onset. DPEs, have a nonlatent or instantaneous onset. Based on the response-latency distinction, it is believed that separate subcellular components of the outer hair cell support the generation of delayed versus instantaneous evoked OAEs. For example, the stimulus-induced movements of the stereocilia bundle likely generate the nonlatent DPEs, while the motile activity of the lateral regions of the hair-cell membrane likely produces the latent TEEs and SFEs.
D. T. Kemp proposed that a transient OAE could be a diagnostic tool in the examination of impaired hearing. Kemp, Stimulated Acoustic Emissions from within the Human Auditory System, J. Acoust. Soc. Am., Vol 64, No. 5, pp 1386-1391, November 1978. After Kemp's discoveries became known to the art of hearing research, a number of researchers investigated the status of stimulated OAEs in people with normal hearing and with hearing impairments.
Early studies established that emissions are present in essentially all normally hearing individuals and that such emissions are reduced or eliminated in regions of sensorineural hearing loss. Moreover, it became apparent that, of the three types of stimulated emissions, SFEs could not be simply applied in practical settings, because they require the utilization of complex methods of analysis in order to separate them from the eliciting stimulus.
Of the remaining evoked-emission types, that is TEEs and DPEs, TEEs have received, by far, the most attention as potential clinical measures of cochlear function. The development of transiently evoked otoacoustic emissions (TEEs) has, in fact, reached an advanced level in that a computer-based commercial device is currently available to the audiologist: D. T. Kemp, et al., Acoustic Emission Cochleography--Practical Aspects, Scand Audial Suppl. 25, pp. 71-95, 1986; Peter Bray and David Kemp, An Advanced Cochlear echo Technique Suitable for Infant Screening, British Journal of Audiology, 1987, No. 21, pp. 191-204.
The form of a TEE from a given ear is subject to the invariable influence of fixed-frequency emissions that are unique to that ear. In the presence of idiosyncratic frequencies, including the spontaneous and stimulus-frequency otoacoustic emissions, as well as the TEEs themselves, cochlear function, at specific frequencies (e.g., audiometric-test frequencies), cannot be uniquely assessed. Consequently, TEE testing appears most useful as a screening device for estimating the absence or presence of reasonably normal hearing.
In contrast to the significant attention that TEEs have received as potential clinical indicators of outer hair-cell cochlea function, DPEs have not been extensively investigated as the basis of an objective test of hearing impairment.
3. Identification of Objects of the Invention
In view of the inherent problems of using TEEs and SFEs for hearing testing, it is a general object of the invention to provide method and apparatus for using DPEs as the basis of an objective hearing test, both for normal and hearing-impaired ears.
It is another object of this invention to provide a method and apparatus by which an ear may be tested, using DPEs, for hearing capability at any frequency between approximately one and eight kHz. In other words, it is an object of this invention to provide a method and apparatus for creating a DPE audiogram for a human being.
It is another object of this invention to provide a method and apparatus by which an objective measure of the hearing capability at a particular frequency varies as a function of stimulus level, so as to permit a complete evaluation of cochlear function at both threshold and suprathreshold levels of stimulation. In other words, it is an object of the invention to provide a method and apparatus for creating a DPE input/output function for a human being.
It is another object of this invention to provide a method and apparatus by which DPEs may be used to evaluate remaining outer hair-cell function in hearing impared human beings having a hearing loss up to 45-55 dB HL.
It is another object of this invention to provide noise reduction method and apparatus for reducing the noise signal which contaminates the measurement of the DPE, thereby providing a system which may be used in a noisy environment such as a doctor's clinic or other hearing screening facility.
SUMMARY OF THE INVENTION
To produce DPEs, two related pure tones are simultaneously presented to the ear. Such tones usually, (but not necessarily required) are of equal amplitude. The non-linear response to such tones, believed to occur in the cochlea of the inner ear, generate a lower amplitude tone in the ear. Such tone, believed to be produced by biomechanical elements of the cochlea, is at a frequency lower than the frequency f 1 or f 2 of the two input tones. Such DPE tone is at a frequency of 2f 1 -f 2 , but its amplitude is considerably lower than the amplitude of the two input tones at frequencies f 1 and f 2 .
This invention includes providing first and second tones of respective frequencies f 1 and f 2 to the ear canal of the outer ear. Such tones are provided to an eartip via earphones driven by a signal generator. Such eartip includes at least one microphone for sensing not only the two input tones at frequencies f 1 and f 2 , but also the DPE tone at frequency 2f 1 -f 2 . The microphone electrical signal output is amplified and then applied to a spectrum analyzer which produces, a signal output representative of the level of each frequency in the spectrum of frequencies of such microphone electrical signal output.
According to one aspect of the invention, a programmed digital computer controls the generation of the input tones and the recording of levels of the various frequencies received from the microphone electrical signal output of the spectrum analyzer. Over a frequency range such as 1 kHz to 8 kHz, input tones are generated and responses recorded by the frequency analyzer. A DPE audiogram is graphically presented by one of a plurality of ways, e.g. on graph paper, on a CRT screen, or in tabular form. Such DPE audiogram may graphically be presented on x-y axes with the response frequency of the DPE tone, 2f 1 -f 2 , plotted as the geometric mean of such two frequencies along the x-axis of the graph. The level of each such frequency, presented in decibels, is plotted along the y-axis of the graph. The response of normal ears may be superimposed on such graph to give the hearing clinician an objective view of the DPE amplitude versus frequency response of the patient being tested as compared to a person of normal hearing. The apparatus and method for DPE audiogram testing is advantageous over traditional hearing tests in that the procedure is completely objective, that is, it does not require a patient to respond as to whether or not a test tone has been "heard" by such patient.
According to another aspect of the invention a programmed digital computer controls the generation of the input tone at particular input frequencies f 1 , f 2 . The input tones, having equal amplitudes, are varied in amplitude over a predetermined range, e.g., 25 to 85 db SPL. For each input amplitude, the DPE response amplitude at frequency 2f 1 -f 2 is recorded after measurement by the frequency analyzer described above. An input/output response for the particular DPE frequency response, usually represented as the geometric mean of f 1 and f 2 , is graphically plotted, either on graph paper or on a CRT screen, or is displayed in tabular form. The input amplitude in db SPL in plotted along the x-axis; the DPE amplitude is plotted along the y-axis. The "noise floor" as measured by the frequency analyzer may also be presented on the graphical display, along with a "band" of output responses which have been determined to be "normal" as a function of input amplitude. The advantage of this DPE procedure over other kinds of stimulated emission testing, is that DPEs have a reasonably wide dynamic range, in terms of growth of response amplitude as a function of stimulus level, thereby permitting evaluation of cochlear function at both "threshold" and suprathreshold levels of stimulation.
According to another feature of the invention, methods and apparatuses are provided for reducing the level of background noise sensed in DPE detection. A first method and apparatus, called phase-locked DPE extraction, initiates averaging of the DPE signal from the ear canal only when such DPE signal is at a particular phase. This method assures that all of the DPE signal is added to the averaged waveform, but background noise is significantly reduced.
According to another feature of the invention, a method and apparatus for reducing the level of background sensed in DPE detection includes providing two microphones in the eartip by which tones in the ear canal are sensed. The output of the first microphone includes signals representative of the DPE tone as well as patient-induced noise, such as coughing. The output of the second microphone is adjusted such that signals of the DPE tone are not present, yet signals representative of patient induced noise are produced. When applied to the plus and minus inputs of a differential amplifier, the output of such amplifier includes the DPE signal, with a "body" or noise signal significantly reduced due to the subtraction of the two signals.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advantages and features of the invention will become more apparent by reference to the drawings which are appended hereto and wherein like numerals indicate like parts and wherein an illustrative embodiment of the invention is shown, of which:
FIG. 1 is a prior art illustration of a cross-section through a human ear showing outer, middle and inner ear parts with the cochlea of the inner ear responding to tones transmitted to the middle ear, generating nerve signals via the cochlear nerve;
FIG. 2 is a prior art illustration of a cross-section through one portion of the cochlea, showing the placement of the Organ of Corti along the spiral of the cochlea;
FIG. 3A is a schematic diagram of the cochlea depicted as unrolled, with a tone entering the oval window and stapes and traveling via the scala vestibuli and back via the scala tympani, while vibrating the scala media with its Basilar membrane and the Organ of Corti;
FIG. 3B is a schematic diagram illustrating tones T f1 and T f2 being applied to the ear drum membrane, where they enter the organ of Corti as a traveling wave, which produces a Distortion Product Emission tone of frequency 2f 1 -f 2 which is transmitted by the middle ear ossicles to the ear drum membrane, which vibrates like a speaker diaphram to transduce the DPE into acoustic energy in the ear canal;
FIG. 3C is an illustration showing the relative frequencies and amplitudes of the stimulating tones and the DPE tone which is generated by the cochlea;
FIG. 4 is a more detailed illustration of a cross-section of the Organ of Corti of the cochlea, in which may be seen the outer hair cells and the inner hair cells with nerve fibers connected thereto;
FIG. 5 is a system diagram of the apparatus necessary to produce DPE audiograms and input/output displays for assessing the hearing of a patient;
FIGS. 6A, B, C and D illustrate outputs of each DPE signal from the spectrum analyzer (6A) which are stored in computer memory (6B) and then are plotted as a DPE audiogram (6C) or as a DPE input/output display (6D).
FIG. 7A is a traditional audiogram for a hearing impared person, while FIG. 7B is a DPE audiogram according to the invention of such person; FIGS. 7C-7F are DPE input/output functions for such person;
FIGS. 8A and 8B illustrate two embodiments of the phase-locked averaging feature of the invention by which the noise floor of the DPE signal is reduced; and
FIG. 9 schematically illustrates a two-microphone embodiment of the apparatus by which body noises such as coughs and the like may be minimized during the measurement of the DPE signal.
DESCRIPTION OF THE INVENTION
This invention relates to apparatus and methods for measuring Distortion Product Emission (DPE) tones which are generated in the ear in what is believed to be a non-linear bio-mechanical feedback mechanism of the cochlea of an ear. By inducing such DPE tones, analyzing the level of such tones with respect to input tones, minimizing the noise associated with such tones, and presenting recorded tones in audiogram and input/output displays, hearing of a human being can be objectively assessed.
In order to introduce the basis for the apparatus and method of the invention, FIGS. 1, 2, 3A, 3B and 4 illustrate the physiology of the hearing process of a human being.
FIG. 1 shows a partial cross-section through a human ear with the outer, middle and inner sections of the ear illustrated. The ear canal is a passage in the outer ear which terminates with an ear drum membrane. Sound in the form of air pressure vibrations of multiple frequencies and amplitudes cause the ear drum membrane to vibrate.
Disposed in the middle ear cavity, are ossicles, small boney structures which oscillate in response to the oscillations of the drum membrane. As shown in FIG. 3A the stapes ossicle terminates at the oval window of the cochlea of the inner portion of the ear.
The cochlea (see FIGS. 1, 2, 3A, 4) is a spiral or snail like structure of the inner ear. It is a bio-mechanical organ for transforming oscillations of the stapes and the fluid of the cochlea into nerve impulses for recognition by the brain. FIG. 2 shows a cross-section through a portion of the cochlea. FIG. 3A shows a schematic diagram of an "unrolled" cochlea illustrating a sound wave entering the oval window and causing the scala media to oscillate as the sound pressure traverses the scala vestibuli and the scala tympani. As illustrated in FIG. 2, the Organ of Corti is disposed on the basilar membrane of the scala media. Accordingly, vibrations or oscillations of the scala media in response to air pressure vibrations via the outer ear canal and the vibration of the ear drum membrane, cause the Organ of Corti to vibrate. As illustrated in FIG. 4, the Organ of Corti has inner and outer hair cells disposed along the entire spiral length of the cochlea. Each inner hair cell includes nerve fibers which lead to the brain.
FIG. 3B illustrates the Distortion Product Emission phenomenon. When two audio tones are applied to the outer ear canal, such tones are simultaneously applied to the cochlea as traveling waves. Such tones, one of lower frequency f 1 , the other of higher frequency f 2 , are preferably applied with equal amplitude, or f 1 10-15 dB larger than f 2 , and of a frequency ratio f 2 /f 1 of about 1.21. Under such conditions a healthy human cochlea 10 generates a lower frequency, lower amplitude tone which is sensed by the ear drum 12. FIG. 3B schematically illustrates that such tone in a human being is at a frequency of 2f 1 -f 2 .
It has been discovered, as a result of tests in both normal and hearing impared ears with a number of human beings, that DPEs can form the basis of an objective hearing test. DPE testing has several advantages over the use of Transiently Evoked Emission (TEE) testing. In particular, because of the continuous, short-latency nature of the DPE, essentially any frequency, between approximately 1 and 8 kHz, can be intentionally tested. Such frequency specificity indicates that a DPE "audiogram", objectively produced, can be a substitute for, or an adjunct to a conventional audiogram, where the patient subjectively responds to tones at different frequencies and amplitudes or levels.
Moreover, it has been discovered that compared to other stimulated-emission types of responses of the human ear, the reasonably wide dynamic range of DPEs, in terms of increase of response amplitude as a function of stimulus level, permits evaluation of cochlear function at both threshold and suprathreshold levels of stimulation. This latter feature allows the use of DPEs to evaluate remaining outer hair-cell cochlear function in the ears of patients demonstrating a hearing loss up to 45-55 dB HL. In contrast, TEEs cannot typically be measured in individuals with hearing losses greater then 20-30 dBHL.
To produce DPEs, two related pure tones (e.g., f 2 /f 1 =1.21 or 1.22) are simultaneously presented to the ear. The nonlinear audio response, that is distorted primarily in frequency, is believed to be generated by active, biomechanical elements of the cochlea. In particular, these nonlinear elements react to the two-tone signal so that DPEs of additional, different frequencies are created. In human ears, the predominant DPE is generated at the frequency value defined by the simple algebraic expression 2f 1 -f 2 . The testing for DPEs differs from the examination of TEEs in that the emissions are extracted by spectral averaging of the ear-canal signal. The spectral analysis includes emissions not only at the distortion-product frequency, but also at the frequencies of the two stimulating or primary tones, at f 1 and f 2 .
FIG. 5 illustrates, by means of a system diagram, the application of equi-level tones to the ear canal 16 of a human ear 14. A foam eartip 20 is placed in the ear canal 16. Two air ways 22, 24 are connected respectively between earphones 26 and 28 and eartip 20. The earphones or speakers 26, 28 are preferably model ER-2 speakers of Etymotic Research Corporation. Such earphones have reasonably flat responses from about 200 Hz to about 10 kHz.
The ear tip 20 also includes at least one microphone 30 which is a low-noise, miniature-microphone. Such microphone 30 is preferably model ER-10 13 of the above-mentioned Etymotic Research Corporation. It is specially designed to record low amplitude audio emissions from the human ear canal.
As illustrated in FIG. 5, a digital computer 50 preferably a Digital Equipment Computer 11/23 (but any suitable microprocessor such as an IBM PC, or equivalent may be used), is programed to step through a plurality of predetermined frequency pairs at predetermined levels or amplitudes. As mentioned above, because of the physiology of the human ear, a frequency ratio of f 2 /f 1 is preferably about 1.21 or 1.22. The preferred levels of such frequency tones will be discussed below in conjunction with the generation of input/output plots.
Under control of the stored program 48 in computer 50, a control signal is sent to signal generator 40 via an IEEE instrumentation bus 44 and lead 42. Signal generator 40 is preferably a dual channel HP3326A synthesizer which produces, on command from computer 50, two equal level sinusoidal electrical signals on leads 32 and 34. Attenuators 36 and 38 advantageously may be placed in leads 32 and 34 between earphones 26, 28 and signal generator 50, to provide a means to precisely control the level of the primary tones, T f1 and T f2 applied to earphones 26 and 28 and via eartip 20 to ear canal 16. (Such attenuators preferably are Wavetek 5P programmable attentuators.)
The microphone 30 of eartip 20 is connected to pre-amplifier 54 via lead 52. Pre-amplifier 54 is preferably an Etymotic Research model ER-10-72. The DPE tone T 2f1-f2 as well as tones T f1 and T f2 from the ear canal 16 are amplified by preamplifier 54 and then applied to measuring amplifier 58, a Bruel and Kjaer model 2610. Next, such tones are applied to frequency spectrum analyzer 62, preferably a Hewlett Packard model 3561A, where the amplitude level of each tone signal is determined in decibels SPL. Such levels, as well as the frequencies of the input tones, f 1 and f 2 , and the DPE tone 2f 1 -f 2 are applied to computer 50 memory 46 via lead 64 and IEEE instrumentation bus 65. Note: (IEEE signals are digital.)
FIGS. 6A and 6B schematically illustrate the storage of the tone levels of tones T 2f1-f1 , T f1 and T f2 . The level of the noise floor is also stored.
It has been determined that the primary cochlear frequency position that contributes to the generation of the DPE at 2f 1 -f 2 is the frequency region near the geometric mean of frequencies f 1 and f 2 . The geometric mean of two frequencies f 1 and f 2 is (f 1 ×f 2 ) 1/2 . Accordingly, the levels of DPE frequencies 2f 1 -f 2 are stored in memory and plotted as described below as a function of the geometric mean frequency, f geo =(f 1 ×f 2 ) 1/2 .
According to this invention, DPE activity of a human being is specified in terms of two response measures. In the first form, illustrated at FIG. 6C, the frequency extent of cochlear function is expressed in terms of DPE amplitude as a function of stimulation frequency. Such a graphical display is called a DPE "audiogram". To obtain an objective DPE audiogram, DPEs are recorded, using the apparatus of FIG. 5, in 100 Hz steps, at three primary tone levels of 65, 75, and 85 dB SPL. The frequency ratio of the f 1 and f 2 tones are adjusted to be about 1.22 or 1.21, i.e., f 2 /f 1 =1.21 or 1.22.
The second measure of DPE activity is shown at FIG. 6D which indicates the response/growth or input/output (I/O) aspects of DPE activity. To determine the dynamic range of the distortion-generation process, the I/O functions are determined over a 60 dB range of stimulus levels, (i.e., from 25 to 85 dB SPL). Such functions are preferably acquired at 11 discrete test frequencies, distributed in regular, 1/4 octave intervals, from 1-8 kHz. The display of FIG. 6D is for one particular test frequency and shows the level response of the DPE tone as a function of increasing input tone amplitude. From the various I/O curves at the various test frequencies, information concerning the function of an ear under test can be determined. Specifically, an ear's outer hair cells at either threshold or suprathreshold sound levels can be determined.
One of ordinary skill in the digital programing art can rapidly prepare a stored program 48 and data arrangement for memory 46 to automatically collect the data for an audiogram like that of FIG. 6C and Input/Output response like that of FIG. 6D. The source code program used in a laboratory setting during the creation of this invention is attached hereto as appendix A. Such program is written in Fortran language. As indicated above, such program controls a DEC mini-computer, but the ultimate commercial version of the system of FIG. 5 will likely include a dedicated microcomputer with a stored program similar to that of Appendix A for collecting data for DPE audiograms and I/O functions.
Returning now to a more detailed explanation of the DPE audiogram of FIG. 6C, the amplitude vs. frequency bands 80, 82 represent the ±one standard deviation of a database of human DPE response as a function of DPE frequency (geometric mean of f 1 and f 2 ). Such bands were determined from "audiograms" of 44 ears displaying normal aural-acoustic immittance and hearing sensitivity. In FIG. 6D, bands 84 and 86 represent I/O ±one standard deviation bands at a particular frequency of such database. The noise floor of FIG. 6D represents the noise floor illustrated in FIG. 6A as recorded for the various input levels of tones T f1 and T f2 . The bands 88, 90 of FIG. 6C represent ±one standard deviation of the noise floor.
One advantage of DPE testing is that DPE emissions have the capability of accurately delimiting the boundary between normal and abnormal function. This property is illustrated best in patients exhibiting the effects of noise damage in which discrete notches and sharp reductions in high-frequency hearing commonly occur. FIGS. 7A through 7F are test results of a patient with noise-induced hearing loss due to the excessive use of recreational firearms. The standard audiograms, for each ear, are shown at FIG. 7A At FIG. 7B, the corresponding DPE "audiograms," in response to 75-dB SPL primaries, are shown. A comparison of the DPE audiogram of FIG. 7B with that of a standard audiogram of FIG. 7A indicates that the frequency pattern of the reduction in DPE amplitudes follows very closely the details of the hearing loss depicted by standard audiometrics. That is, the function for the more damaged left ear (triangular and square symbols) declined to the level of the noise floor at a frequency that was lower than that at which the curve for the better-hearing right ear (circular symbols) descended to these levels. In addition, the finer-frequency steps of the DPE "audiogram" demonstrate that the emissions for the right ear also returned to the average range of amplitudes, at a frequency that was lower in value than that at which the responses recorded from the poorer-hearing left ear reached normal emission levels.
FIGS. 7C through 7F represent several I/O functions selected to show the outcome of the discrete-frequency, I/O testing, between 1 and 6 kHz. For example, as expected from the behavioral threshold estimated for 1.5 kHz (i.e., by interpolating between 1 and 2 kHz on the behavioral audiogram), DPE magnitudes for the right ear are within normal limits. In contrast, the left ear exhibited an estimated hearing loss between 10 and 55 dB SPL. At 1.5 kHz, DPEs were essentially nonexistent. Thus, the observed asymmetry in the frequency extent of DPE I/O activity supported the asymmetry noted in the hearing for the two ears, around 1-2 kHz. By 6 kHz, (FIG. 7F) the behavioral measures (FIG. 7A) indicate that the right ear has slightly better hearing than the left. Similarly, the DPE I/O curves for 6 kHz (FIG. 7F) support the behavioral observation in that the detection "thresholds" for the left ear are about 5 dB poorer than the comparable measures for the right ear. In general, DPEs track hearing loss due to noise exposure accurately. This is believed to be so because excessive sound injures the outer hair cells preferentially, especially in the beginning stages. It is believed that DPEs selectively test outer hair-cell functioning.
Returning to FIG. 5, both DPE audiograms and I/O functions may be graphically displayed by means of a plotter 68 under control of digital computer 50. The plotter used in the laboratory embodiment of the invention was an HP 7470A plotter, but of course, a wide variety of commercial plotters could be used as would be known to one of ordinary skill in the data processing art. Likewise printer 70, under control of computer 50 serves to provide a print-out of DPE audiograms or I/O functions. Such DPE audiograms or I/O functions may also advantageously be displayed on a CRT or the like (not illustrated).
Turning now to FIG. 8A, an illustration of the phase-locked averaging of the DPE signals is shown which is performed in order to reduce the noise level or "floor" shown at FIG. 6A. A signal generator 40 as shown in FIG. 5 is provided to generate signals S f1 and S f2 on leads 32, 34. The master clock of signal generator 40 (Hewlett Packard 3326A) is connected to the master clock of single channel signal generator 40'. Signal generator 40' is set to the DPE frequency 2f 1 -f 2 . Connection of the master clocks of signal generators 40 and 40' insures that there is no phase drift among any of the three signals, i.e., S f1 , S f2 , S 2f1-f2 , because all clocks are synchronized.
Signal generator 40' produces a square wave output on lead 43 such that its positive going pulse is synchronized with the positive going sine wave of frequency 2f 1 -f 2 . Such square wave of frequency 2f 1 -f 2 is applied to the trigger input of spectrum analyzer 62. A time average is determined by real-time spectrum analyzer 62 each time it is triggered by the positive going zero crossing signal on lead 43. Accordingly, the time average of the DPE signal is initiated for each sample of the DPE signal at the same phase of such DPE signal. Such procedure assures that all of the DPE signal is added to the averaged waveform, but noise signals of different frequencies than that of the DPE signal will be out of phase from sample to sample. Accordingly, the noise signal, dissimilar in phase, is substantially reduced during the averaging process.
Once the time averaged waveform has been collected, spectrum analyzer 62 uses standard Fourier-transform techniques to determine the level of the DPE signal, and of course the noise floor for frequencies other than that of the DPE signal. Using the method and apparatus of FIG. 8A to augment that of FIG. 5, background noise is reduced by approximately 15 dB below that observed without the phase-locking method and apparatus.
The phase-locking feature of the invention described above provides a means for repeatedly initiating a time sample at the same phase of the DPE signal. An alternative method for accomplishing such phase-locking is illustrated in FIG. 8B. Rather than using a stand-alone signal generator 40, signals S f1 and S f2 are generated by microcomputer 50. Two wave form buffers are established in the memory of computer 50'. The buffers 101,102 store the digitized time values for S f1 and S f2 .
Each buffer is set to an integer multiple of the length of the DPE period. After output of each point in the buffer, exactly one period of an integer multiple of the period of the DPE signal has elapsed. For example, if a buffer contains 1,000 points for an output signal, representing 1 micro-second per point, such buffer is equivalent to a DPE frequency of 1 kHz each time the information in the buffer is completed.
Another alternative approach, one not involving computer generation of the primary-tone signals, provides a computer clock running at the period of the DPE frequency. For example, if the clock is set to "tick" once per microsecond, 1,000 ticks would be equivalent to 1 millisecond, i.e., the period of a 1-kHz DPE. At the end of every 1,000 ticks, an interrupt would be generated to instruct the computer to initiate another time sample. If the time sample is longer than one period of the distortion-product frequency, the computer would simply wait until the next 1,000 ticks have elapsed. With the clock running continuously, the phase of the distortion product would be constant from sample to sample.
FIG. 9 illustrates still another apparatus and method for reducing noise when measuring DPE signals. A significant amount of body noise is created by the patient during the measurement. Coughing, sneezing and other body noises contaminate the DPE signal. FIG. 9 shows that two microphones 30A, 30B are placed in ear canal 16 to pick up the DPE signal. The output of one microphone 30A is applied via lead 120 to the plus input of differential amplifier 130. The output of a second less sensitive microphone 30B is applied via lead 122 through variable gain amplifier and phase shifter circuits 124, 126 via lead 128 to the minus input of differential amplifier 130. The output of microphone 30B is of less sensitivity so that the frequency component of S 2f1-f2 (the DPE signal) is missing from the signal applied to the minus input of differential amplifier. The gain and phase of this signal via lead 128 are then adjusted to yeild maximum cancellation when applied to differential amplifier 130. That part of the lower frequency signal appearing on lead 128 due to the bodily noise is relatively unchanged. As a result, the output of differential amplifier 130 produces on lead 132 a signal comprising the DPE signal, with the body noise signal greatly reduced.
Various modifications and alterations in the described methods and apparatus will be apparent to those skilled in the art of the foregoing description which does not depart from the spirit of the invention. For this reason, these changes are desired to be included in the appended claims. The appended claims recite the only limitation to the present invention. The descriptive manner which is employed for setting forth the embodiments is to be interpreted as illustrative but not limitative. ##SPC1## | Apparatus and method are disclosed for the recording of distortion product emission (DPE) levels in human beings. At least one microphone and a sound-delivery system is inserted in the external ear canal in a manner similar to that required to position a small hearing aid. Two primary tones T f1 , T f2 are applied simultaneously to the ear. The cochlea of the inner ear produces a DPE tone which is sensed by the microphone. DPE levels are sensed as a function of input frequencies f 1 and f 2 . Such DPE frequency is equal to 2f 1 -f 2 . Such DPE frequencies are collected in 100 Hz steps by adjusting f 1 and f 2 and maintaining a substantially constant ratio between f 1 and f 2 . Two output forms are created: an DPE audiogram and a DPE input/output function. Noise picked up by the microphone is reduced by averaging the DPE signal many times, yet causing each of the DPE signals that is averaged to be of the same phase as every other DPE signal. Random phase noise is reduced by the averaging process. Body noise may be reduced by using two microphones and applying the output of one such microphones to the plus input of a differential amplifier. The output of the other less sensitive microphone, after amplification and phase adjustment is applied to the negative input of such differential amplifier. The output of such amplifier results with the body noise signal substantially reduced, but with the DPE signal substantially unchanged. This abstract of the disclosure-is not intended to define the scope of the invention. | 0 |
This is a division of application No. 08/962,263 filed Oct. 31, 1997. This application is a continuation in part of U.S. patent application Ser. No. 08/362,995 filed Dec. 23, 1994 now U.S. Pat. No. 5,687,506 which is a continuation in part of U.S. patent application Ser. No. 08/281,620 filed Jul. 28, 1994 from which priority is claimed now U.S. Pat. No. 5,682,710.
FIELD OF INVENTION
This invention relates to a retractable screen system for a closure assembly and improvements thereof which allows the secure sliding and subsequent retraction of the screen from a operative position to a retracted position. The invention is preferably embodied in a window assembly but finds application also in large pivoting windows and patio doors.
BACKGROUND OF THE INVENTION
The reader is referred to Applicants Co-pending Applications abovementioned for teachings in relation to improvements to closure assemblies, the teachings thereof which are hereby incorporated by reference.
Screens are generally provided for doors, patio doors, and windows. One particular type of screen utilized for patio doors for example, includes a metal frame having a groove disposed around its edges. The screen is affixed to the frame by using a spline, a long extended piece of flexible material, which is forced into the groove capturing the edges of the screen. The screen is then slid in front of the opening when the patio door is moved to an opened position. The screen therefore permanently blocks the view of the occupant of the dwelling. The same is true for screens provided with double-hung windows, tilt and slide windows, and casement windows. The screen generally is always in position whether the window is opened or closed.
Various examples therefore have been developed by inventors to address this problem.
For example, U.S. Pat. No. 5,505,244 to Thumann describes a retractable covering for a door including a housing containing a roll of screen as best seen in FIGS. 2, 5 , 6 A and 6 B thereof. The cover may be affixed to a door adjacent the frame thereof as an after-market product.
Another example of an after-market type of product is found in U.S. Pat. No. 4,821,786 as best seen in relation to FIG. 6 therein, the structure is adapted to be mounted on one side of a door jamb to be releaseably connected to the other. The assembly is quite complicated and complex and may be considered as an add-on structure.
Similarly, U.S. Pat. No. 3,911,990 provides a screen in combination with a sliding door. The screen is disposed upon a spring-loaded roller installed on the exterior of the framing sections of the opening adjacent to the window frame.
U.S. Pat. No. 4,757,852 describes a box-like housing carrying a tube for paying out and taking up a mesh screen. The housing is fastened over a window or door and is not part of the framing section of the door.
U.S. Pat. No. 4,651,797 describes a roll-up screen door included in a narrow housing containing a conventional spring-biased roll onto which flexible screen material is taken up and paid out. The housing is mounted adjacent one side of a vertical curved strip along one side of the door casement opening. The front vertical edge portion of the screen material is anchored within a vertical groove of the anchoring strip as best seen in FIGS. 3 and 5. Again, the housing extends from the framing section and is not part thereof. A more complex arrangement is found in U.S. Pat. Nos. 4,359,081 and 4,261,524.
Referring now to U.S. Pat. No. 1,150,000 to Matthews, there is described a window screen coiled on a roller for installation on a window frame. The roller for the window is illustrated in FIG. 5 including a hook portion for hooking a complementary hook portion on the screen. The other edge of the screen includes a hook portion for engaging with the trim portion 34 .
U.S. Pat. No. 1,141,996 to Vanasdale describes another type of roller screen which may be attached to the sill or lintel portion of the frame by mounting brackets as best seen in relation to FIGS. 1 through 6.
None of the above-mentioned references teach or even infer the installation of a screen within the framing sections of a closure assembly such as a jamb. Each of the products may be considered as an after-market product which is installed upon, adjacent to, on or butting up against the framing section of the appropriate closure member. In essence, some of the installations are unsightly with a housing extending from the general plane of the home or window, extending either outwardly away from or inwardly toward the interior being closed by the closure member. It would therefore be advantageous to solve this problem by providing a screen assembly which may be contained within the framing sections of a closure assembly and which retracts into the frame member and which is substantially invisible until such time as needed.
U.S. Pat. No. 4,825,921 describes a screen assembly having supporting elements secured along the edge of the material as best seen in relation to FIGS. 4 and 7. The structure also includes a spring-biased element which rides in a track. As best seen in FIGS. 9 through 11, the screen is considered to be an add-on, after-market device as well.
U.S. Pat. No. 3,842,890 to Kramer describes a coilable closure device as best seen in FIGS. 1 and 18 which includes a frame including a side jamb and a storage jamb, 34 and 36 respectively. The coilable closure device does not include a post and includes a multiplicity of sections as best seen in FIGS. 1 and 6 which sections include elements extending up into and down into respective track areas provided with the frame. The material which coils upon itself is particularly plastic sheet including reinforcing ribs which also act as guiding elements for the sheet. However, nowhere within the reference does it teach the use of such a structure for a screen, but merely as a closure to replace a door between adjacent rooms, for example. Nowhere within the reference does it teach the combination of a closure member such as a window or patio door and a screen. This is simply not described. Therefore, one would not be motivated to solve the problem of combinations of closure members and screens by the reading of the Kramer reference.
Nowhere therefore within the prior art is there taught improvements to screen assemblies, wherein the entire screen assembly is contained within the framing sections found adjacent to a closure member in a closure assembly, for example a window assembly. Further, nowhere within the art is there found a roll-out screen assembly embodied in a cassette which may be readily inserted within the hollow of a framing section sized to receive said cassette or screen assembly. Further, nowhere in the prior art is there manufactured a screen having an abutment on one edge thereof for engaging with a cooperative abutment on the roller of a screen assembly which may be cut to size as desired to repair a roller screen assembly. Further, nowhere within the prior art is there found various improvements to roll-up screen assemblies to simplify their installation, adjustment and replacement.
Nowhere within the prior art is such a simplified improved screen assembly provided which retracts into the jamb, sill or header of the frame portion of a window assembly in the retracted position and which is preferably guided to its operative position in guides provided with the jamb, sill or header, and which allows for the manufacture of heavier screens in larger sections without continuously covering of the window.
It is therefore an object of this invention to overcome many of the deficiencies in the prior art stated above which allows for smooth and simple operation of a retractable screen which is capable of both sliding within a guide channel between the retracted and the operative positions and which at the retracted position is fully contained within the jamb, sill or header section of the closure assembly.
It is a further object of the invention to provide a retractable screen assembly of appropriate size and construction to replace existing retractable screen assemblies for casement, double hung and/or tilt and slide windows as well as patio doors.
It is further a primary object of this invention to provide a roll-up screen embodied in the frame of a closure assembly which is retractable into the frame itself without requiring an additional housing.
It is a further object of the invention to provide a roll-up screen assembly in the form of a cassette which may be mounted within the hollow of a framing section, which cassette includes a front facia portion to close the framing section.
It is yet a further object of this invention to provide a continuous roll of screen manufactured so as to be cut at a predetermined width and include an anchoring element disposed adjacent one edge of the screen so as to allow ease of installation of the original or replacement screen.
It is yet a further object of the invention to provide a method of manufacturing a screen.
It is yet a further object of the invention to provide a cassette which may be side mounted into an opening of the framing section and closed by an exterior facia element.
It is yet a further object of the invention to provide a closure assembly including a roll-up screen contained with one of its framing sections adjacent the closure member.
It is yet a further object of the invention to provide improvements in mounting brackets, facia elements, and screens.
Further and other objects of this invention will become apparent to a man skilled in the art when considering the following summary of the invention and the more detailed description of the preferred embodiments illustrated herein.
SUMMARY OF THE INVENTION
This invention relates to a retractable screen system for a closure assembly and improvements thereof which allows the secure sliding and subsequent retraction of the screen from a operative position to a retracted position. The invention is preferably embodied in a window assembly but finds application also in large pivoting windows and patio doors. The closure member may further comprise a window sash being a casement, double hung, or tilt and slide installation or, a door or a patio door.
There is therefore provided improvements to screen assemblies, wherein the entire screen assembly is contained within the framing sections found adjacent to a closure member in a closure assembly, for example a window assembly. Further a roll-out screen assembly is embodied in a cassette which may be readily inserted within the hollow of a framing section sized to receive said cassette or screen assembly. The screen has an abutment on one edge thereof for engaging with a cooperative abutment on the roller of a screen assembly which may be cut to size as desired to repair a roller screen assembly which simplifies their installation, adjustment and replacement.
There is also provided a simplified improved screen assembly which retracts into the jamb, sill or header of the frame portion of a window assembly in the retracted position and which is preferably guided to its operative position in guides provided with the jamb, sill or header, and which allows for the manufacture of heavier screens in larger sections without continuously covering of the window.
In a tilt and slide, casement or double hung window a retractable screen is provided disposed within the header, sill or jamb of the assembly which screen accumulates on and pays out from a spring biased roll disposed within said header, sill or jamb, the screen being retractable for egress or cleaning purposes, and available as desired by providing a detent on the opposing framing member engageable with a detent provided with the screen when in its operable position.
According to yet another aspect of the invention there is provided a window assembly comprising a retractable screen disposed within a framing portion of the assembly, the screen accumulating on and paying out from a spring biased roll disposed within said frame portion, the screen being retractable for egress or cleaning purposes, and available as desired by providing a detent on the opposite frame portion engageable with the screen when in its operable position.
According to yet another aspect of the invention there is provided a closure assembly comprising a retractable screen disposed within a framing portion of the assembly, said framing portion providing a pocket within which the screen is contained in use, said pocket being bound by three sides of said framing portion thereby forming said pocket, said pocket being closed by a separate cover closing said framing portion, preferably said retractable screen being mounted on said cover and being positioned in said pocket when the cover closing the pocket is installed preferably by clipping a detent provided with said cover in a channel provided with one of the sides of said framing portion providing the pocket, the screen accumulating on and paying out from a spring biased roll disposed within said frame portion, the screen being retractable for egress or cleaning purposes, and available as desired by providing a detent on the opposite frame portion engageable with the screen when in its operable position.
According to yet another aspect of the invention there is provided a continuous screen formed as a continuous web and adapted to be utilized for a retractable screen for windows, doors and the like having a predetermined width of screen determined by the width or length of the closure member frame, said width of said screen having two ends, preferably each of the ends having an anchor or key shaped element fixed thereto adapted to engage a detent on a handle proximate one end of the screen and adapted to engage a detent of a preferably spring biased, preferably hollow, roller utilized for taking up and letting out the screen in a coil upon said roller, alternatively the handle end of the screen alternatively having a tape or continuous strip of adhesive applied thereto so as to engage and be captured by a handle portion of said screen when utilized in a closure assembly, said screen and said anchor or key shaped elements being cut at a predetermined length to fit said roller when assembled and being installed with said closure assembly and preferably within a hollow of one of said frame sections, wherein said screen may be utilized as an original installation or as a replacement screen for an original installation.
According to yet another aspect of the invention, there is provided a retractable screen assembly for a closure assembly, said closure assembly including a closure member surrounded by framing portions from which the closure member is supported, said closure member including framing sections, one of said framing sections providing a pocket within which said screen assembly is retained in use, said screen assembly comprising a cassette engageable with the interior of a cover utilized for closing the framing portion and pocket of the closure assembly, preferably said pocket being located proximate the sealing end of the closure member, said retractable screen including a handle portion affixed thereto including a first detent, the opposite jamb from said pocket including a latching portion including a second detent which engages the first detent of the handle portion when the screen is in the fully open position, wherein said cassette may be installed within any convenient pocket disposed within the framing portions of a closure assembly and fixed in position once the cover covering the pocket is installed. In a preferred embodiment, brackets are provided having channels which capture preferably T-shaped guides on the interior of said cover which allow for the fixing of the brackets in relation to the specific screen assembly being installed, said screen assembly also including a hollow tube to which said screen is anchored via a detent on the tube and via a detent on one end of said screen, the other end of said screen including another detent for engaging with the detent of a handle portion of said assembly, said tube having inserted within the ends thereof a pin assembly which will not rotate in relation to said tube as a result of rib portions disposed with said assembly engaging rib portions disposed within the hollow of said tube, each of said pin assemblies including a pin for engaging a pin-receiving opening disposed with each of said brackets, wherein said brackets may be fixed with respect to the interior of said cover thereby fixing the entire screen assembly as a cassette, one of said brackets being adjustable in relation to said torque tube in order to allow for adjustment and variations from installation to installation, preferably said handle portion including telescoping guides which capture the ends of said screen and are retained within a hollow within said handle, said guides for riding within a channel disposed with opposite or opposing framing sections to guide the screen across the opening defined by said closure member when desired. In an alternative embodiment, the brackets may include a box-like element which rests at the bottom of a framing section and being locked in position because of the compatible dimension of the bracket with the framing section and adjustable in position in relation to that bottom in order to provide for variations in manufacturing.
According to yet another aspect of the invention, there is provided a method of assembling a retractable screen cassette comprising:
(1) providing a tube upon which said screen will coil up in use,
(2) providing a pin assembly insertable into the open ends of said hollow tube and being prevented from rotating with respect to said tube as ribs disposed with said tube, engaged ribs disposed with said pin assembly,
(3) providing a torsion spring having ends which are engageable with said pin assembly ends for providing the correct torsion and tensioning of said spring,
(4) inserting said spring within the hollow tube and inserting said pin assemblies within said hollow tube and fixing the ends of said pin assemblies to the tyne portions of said torsion spring,
(5) providing brackets from which said pin assemblies will be adjustably inserted, said brackets being locked in place with respect to the assembly, preferably either by engaging with a detent provided with a flexible cover or alternatively by engaging with the bottom of the framing section,
(6) adjusting said brackets in relation to the distance from one another so as to correctly tension and carry the screen assembly,
(7) fixing said screen on said screen assembly by anchoring said screen to said tube via a detent, preferably a T-shaped detent or key for engaging with a key slot on the tube or alternatively by using welding or adhesive, and coiling said screen upon said tube,
(8) fixing said opposite end of said screen to a handle portion either preferably by a T-shaped detent engaging a T-shaped detent with said handle, or by welding or an adhesive,
(9) coiling said screen upon said tube,
(10) preferably engaging said cover portion with said brackets,
(11) inserting said screen assembly within a pocket of said closure assembly in one of the framing portions thereof,
(12) covering said pocket with a flexible cover.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a tilt and slide window, wherein said windows move in a horizontal direction, illustrated in a preferred embodiment of the invention.
FIGS. 1A and 1B are partial schematic perspective views of casement style windows embodying the invention and depicting the motion thereof and illustrated in a preferred embodiment of the invention.
FIG. 1C is a partial schematic perspective view of straight line windows embodying the invention and depicting the motion thereof and illustrated in a preferred embodiment of the invention.
FIG. 1D is a partial cutaway view of the casement style windows of FIG. 1A depicting a rollaway screen thereof and illustrated in a preferred embodiment of the invention.
FIG. 2 is a front view of the window of FIG. 1 .
FIG. 2 a is a top view of the window of FIG. 1 .
FIG. 2 b is a end view of the window of FIG. 1 .
FIG. 3 is a double hung window assembly utilizing hardware similar to that of FIG. 1 and illustrated in a preferred embodiment of the invention.
FIG. 4 is a perspective illustration of the hardware only for a double hung window of FIG. 3 .
FIG. 5 is an exploded perspective view of the components of the hardware of FIG. 4 to be installed in a double hung window assembly.
FIG. 6 is a carrier design illustrated in a preferred embodiment of the invention which allows for ease of removal of a window from a window assembly and illustrated in an exploded perspective view.
FIG. 7 is an assembled view of the components of FIG. 6 .
FIG. 8 is a tilt and slide window assembly primarily for the hardware therefore and illustrated in an alternative embodiment of the invention.
FIG. 9 is a schematic view of the movement of the shoes of FIG. 8 illustrated in alternative of the invention.
FIG. 10 is a perspective illustration of a pulley arrangement installed at the corners of the window assembly of FIG. 8 and illustrated in alternative embodiment of the invention.
FIG. 11 is a close-up perspective view of a locking mechanism for the shaft assembly 30 illustrated in a preferred embodiment of the invention.
FIG. 12 is an end view of the locking mechanism of FIG. 11 illustrated in a preferred embodiment of the invention.
FIG. 13 is an end view of a locking block assembly illustrated in a preferred embodiment of the invention.
FIG. 13A is an end view of the track profile used in conjunction with the lock block assembly of FIG. 13 and illustrated in a preferred embodiment of the invention.
FIG. 13B is a top schematic view of the lock block assembly of FIG. 13 shown engaging the rack portion of the track and illustrated in a preferred embodiment of the invention.
FIG. 13C is a side cross-sectional view of the adjusting cap screw used to adjust the track within the sill or header or jamb portions and illustrated in a preferred embodiment of the invention.
FIG. 14 is a top view of the carrier for the shaft assembly of FIG. 17 and illustrated in a preferred embodiment of the invention.
FIG. 14A is a cross-sectional view through the diameter of the opening 35 b of FIG. 14 illustrated in a preferred embodiment of the invention.
FIG. 15 is an top end view of the sash portions for a tilt and slide window assembly from the opening end of the window and illustrated in a preferred embodiment of the invention.
FIG. 15A is a close up view of the section of the assembly of FIG. 15 where the sash abuts with the sill and illustrated in a preferred embodiment of the invention.
FIG. 16 is a schematic end view of a central locking system best seen in FIG. 17 and illustrated in a preferred embodiment of the invention.
FIG. 16A is an end view of the central locking system of FIG. 16 .
FIG. 16B specifically illustrates the latching plate and latch of the central locking system and illustrated in a preferred embodiment of the invention.
FIG. 17 is an exploded perspective view of a window sash for a tilt and slide or casement window illustrated in a preferred embodiment of the invention.
FIG. 18 is an exploded perspective view of the header, sill and jamb portions of the window assembly illustrating the track and its positioning in relation to the sill and header and illustrated in a preferred embodiment of the invention.
FIG. 19 is an exploded perspective view of a retractable screen assembly illustrated in one embodiment of the invention.
FIG. 20 is a similar view to that of FIG. 19 illustrating another embodiment of the invention.
FIG. 21 is a cross-sectional view of a frame portion containing the retractable screen illustrated in a preferred embodiment of the invention.
FIG. 22 is a schematic view of a screen manufactured in another embodiment of the invention illustrated in a preferred embodiment of the invention.
FIG. 23 is a schematic view of the installation of the screen of FIG. 22 in a retractable screen assembly and illustrated in a preferred embodiment of the invention.
FIG. 24 is a cross-sectional view of the hollow tube upon which the screen is rolled up and illustrated in one embodiment of the invention.
FIGS. 25A and 25B are side and end views of the pin assembly shown in FIG. 19 and illustrated in a preferred embodiment of the invention.
FIGS. 26A and 26B are side and end views of the slide illustrated in FIG. 19 and shown here in a preferred embodiment of the invention.
FIGS. 27A and 27B are side and end views of the bushing of FIG. 19 illustrated herein in a preferred embodiment of the invention.
FIGS. 28A through 28C are top end and side views of the mounting bracket of FIG. 19 illustrated in a preferred embodiment of the invention.
FIGS. 29A through 29C are side, top and end views of the guide portion illustrated in FIG. 19 and shown here in a preferred embodiment of the invention.
FIG. 30 is an end view of the screen handle illustrated in FIG. 19 and shown here in a preferred embodiment of the invention.
FIGS. 31A and 31B are top and side views of the screen lock illustrated in FIG. 19 and shown here in a preferred embodiment of the invention.
FIGS. 32A and 32B are top and side views of the latching plate of FIG. 19 and shown here in a preferred embodiment of the invention.
FIG. 33 is an end view of the sealing block shown in FIG. 19 and illustrated here in a preferred embodiment of the invention.
FIG. 34 is a side view of the cover portion for the jamb section of FIG. 21 and illustrated in a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, 2 through 2 b there is illustrated a tilt and slide window assembly. Therefore the assembly 5 includes an outer frame portion 10 which is normally hung within an opening established in a building (not shown). Normally nailing flanges are provided for this purpose attached to the outer frame 10 . The frame 10 includes top portions 17 and bottom portions 16 having tracks disposed therein, as best seen in relation to FIG. 2 . Within the tracks are contained a pivot assembly which will be hereinafter described. Primarily the pivot assembly includes a pinion 35 and carriers 38 and 37 interconnected by interconnecting portions 32 and 31 making up an interconnecting member 30 . The pinions move as the window 20 is slide in the track portion by the movement of the pinion 35 with respect to the rack 18 or 19 respectively. In this way the pinions 35 being interconnected remain parallel at all times in their motion along the track within which the rack 19 or 18 is disposed. The hardware is shown in normal view while the window assembly is shown in dotted lines, to illustrate the essence of the assembly.
Referring now to FIG. 2 there is illustrated the window of FIG. 1, wherein a window 20 and 40 is slidable within a track 15 and 17 upon a shoe 39 . The lower shoe 39 also is connected to a secondary show 39 a for carrying the window which includes rollers 39 b , 39 a 1 and 39 b 2 on the bottoms thereof respectively for ease of movement within track 17 . The pinion 35 rests within the shoe 39 as will be described hereinafter. The arrangement of the interconnecting portion 30 will also be described hereinafter. Window 40 therefore has its own interconnected system as can be best seen in relation to FIGS. 2 a and 2 b.
Referring now to FIG. 2 a there is illustrated the sash elements 20 and 40 and the rack portions 19 and 19 a which accommodate the motion of the pinion 35 along a full length of the track, as best in FIG. 2 b.
Referring to FIGS. 1, 2 to 2 b clearly the track portion 17 and 15 cooperate with the rack portions 19 and 19 a to provide for the pinion 35 and its motion when the window remain slidable within the track. By interconnecting the two pinion portions and hence the two pivot shoes, by interconnecting means 30 , the shoes remain in a substantially parallel position in relation to one another at all times. This overcomes the problem described in the background of the prior art. By remaining parallel it is almost impossible for the window therefore to come out of the track when the window is pivoted to be cleaned and therefore is no longer necessary to provide braking portions as in previously described inventions of Canadian Thermo Windows, as referred to in the background of the invention.
Referring to FIGS. 1A and 1B there is illustrated a casement style window having similar components to that found in relation to FIG. 1 with the exception of only one sash being provided being secured on shaft assembly 30 including portions 31 and 32 . A link L is provided secured proximate ends L 1 adjacent the center of the sash 21 proximate the bottom thereof and adjacent the track 18 adjacent the opening end of the window sash 21 . By positioning the sash in this manner a full range of pivoting motion is available. If the link end L 1 is removable than the window sash may be moved totally to the opposite end remote the pivoting end 21 b on shoe 39 . As with the case of the tilt and slide window a shoe 39 containing a pinion is provided. The pinion is connected to the shaft 30 and engages the rack 18 as it moves along the window sill and header in parallel arrangement between the upper and lower pivots maintained in parallel by the shaft 30 . In this manner the casement style window may be pivoted as normal to an open position, and the pivoting end may be moved to the other end of the window frame away from side 21 b to allow ease of cleaning. By supplying the hardware described without a casement sash the casement window may be assembled without the need for expensive pivots and linkages and without a great deal of assembly labour. As best seen in FIG. 1D for the casement style window in particular a rollaway screen S may be provided which is housed in jamb 17 a as illustrated. The screen S pulls across to engage detent D 1 with detent D 2 in jamb 16 a , whereat it may be locked. This allows a user to clean the glass of sash 21 on the inside without removing the screen.
Referring to FIG. 1C there is illustrated a tilt and slide type window similar to FIG. 1 with the exception that when closed the window sashes will be oriented in a straight parallel line with one another. In order for this to happen the rack provided 18 includes a portion 18 a made from fiber filled plastic or the like and joined at seam 18 c to an aluminum track 18 b . The sash 21 is therefore moveable as previously described on carrier 39 and rollers 39 a as urged by pinion 35 until the pinion reaches the curved portion of the track 18 a wherein the assembly 30 will move along the curve to the terminus of the track 18 t . The sash portion 21 a will then lock in behind the edge of the sash contained in track 18 ′ and be lockable at that position. The sash 21 ′(not shown) resides on assembly 30 ′ in track 18 ′. As pinion 35 ′ moves within the limits of rack 18 ′ the sash 21 cannot adopt a parallel position unless sash 21 ′ is in its fully closed position. Only then can the end 21 a adopt its fully closed position butting up against the sash 21 ′ at the end opposite the carrier assembly 30 and 39 .
Referring to FIG. 3 there is illustrated a double hung window assembly embodying the preferred embodiment of the hardware making up the invention substantially equal to that which is disclosed in FIG. 1, with the exception that a coil spring 31 a is provided around the connector portion 31 of the interconnecting portion 30 . By providing the interconnecting portion 31 with a spring 31 a it will no longer be necessary in a double hung window assembly to provide a sash balance, as the spring 31 a is pre-loaded to provide the necessary tension, much the same as a spring which is used in a garage door. In this example as a garage door goes up and down the spring is compressed and tensioned depending on the motion of the door and therefore provides for the return motion of the window assembly. Within the window assembly sashes 20 and 40 shown in ghost line are moveable with hardware substantially made up of a pivot or pinion 35 moving on a rack 18 and 19 respectively and being interconnected by the interconnecting portion 30 .
Referring to FIGS. 4 and 5 there is illustrated the hardware which is installed within the double hung window assembly of FIG. 3 . Pinions 35 therefore are provided, which seat within the carriers or shoes 39 . The pinion includes a shaped opening 35 a which is compatible with the bar stock 34 c and 32 a proximate the ends thereof. The pinion therefore will ride on the rack 18 and 19 within shoe 39 . Opposed supplementary portion 37 is provided to oppose the shoe 39 as it rides in the track. Therefore, referring to FIG. 2 b the portion 37 and 38 may be readily seen. A combined ratchet and pawl assembly is provided with portion 37 or at least connected therewith. The pawl assembly 37 c is resilient biased through the opening 37 d of member 37 so as to release the ratchet 34 b of shaft 34 when the window is to be removed from the assembly. Proximate the other end of the hardware there is provided a backing member 38 in a unique shaft extension 33 which includes portions 33 b , 33 d , 33 c and 33 a wherein the shaft end 32 a extends through. A locking nut 33 e is provided to lock the entire hardware together and to allow for ease of separation thereof. An adjustable connector 31 b is provided proximate the other end which allows for adjustment with regard to the length of section 32 of the shaft so as to allow variation in the sizes of the assembly supported. Portions 31 , 31 b , 32 , and 33 makeup the shaft assembly which allows for ease of installation, adjustment, alignment and removal of the sash assembly. Also the hardware therefore described provides for the interconnection of the pivot shoes proximate their sides and provides for parallel motion of the pivot shoes at all times thereby illuminating the need to lock the pivot shoes in the track assembly.
Referring to FIG. 6 there is a description of a different shoe construction which is useful when a window is removed, since the carrier will be locked in position when the window is removed for maintenance or for cleaning. Therefore the shoe 39 includes a spring b and a recess therefor and a supplementary portion 39 d and a finger a therefore wherein teeth c are provided on supplementary portion 39 d which teeth are biased by spring b against the pinion 35 to thereby lock against pinion 35 and prevent the motion of the carrier when the window is removed. A sloped wall d is provided with the carrier supplementary portion 39 d which is engaged by a separate simple latching and unlatching mechanism which thereby releases the supplementary portion away from the pinion or toward the pinion when the latch is opened. Therefore when the latch engages the supplementary portion d it will drive the supplementary portion 39 d away from the pinion 35 thereby allowing free motion of the pinion in normal circumstances. However when the latch is disengaged the portion 39 d will be free to move as biased by the spring b toward locking the pinion 35 via the teeth c of the supplementary portion 39 d . The alternate shoe of FIGS. 6 and 7 has an opening 39 a within which the extension 35 a passes to engage the connecting member 30 as previously described. The rollers 39 b engage with the notches as shown to improve the motion of the carrier in the track.
Referring now to FIGS. 8, 9 and 10 there is illustrated an alternative embodiment of the invention to maintain the carrier pivots 61 , 65 , 60 and 81 in substantially parallel alignment and thereby eliminate the need for braking mechanisms. FIG. 8 is illustrated as a tilt and slide frame in ghost line with the window 70 also shown in ghost line having pivot 75 and 71 . The pivots 75 and 71 engage with openings within the shoe 61 and 65 in the manner which is known. These pivot pins 75 and 71 may be removed from these shoes merely by retracting them from their locked positions. The sash 70 therefore is moved on the carrier 81 , 82 and 83 proximate the bottom thereof in the track portions as shown and within carrier 60 on the top thereof. A similar sash arrangement would be arranged for the other shoes as well but for simplicity sake this is not illustrated. The important aspect is that a cable 91 is connected to the carrier 60 and the carrier assembly 81 , 82 and 83 substantially as shown in FIG. 9, so that when the window moves toward the right hand side of the drawing that both carriers will move an equal amount by the movement of the cable maintaining the pivots 75 and 71 within the shoes 60 and 81 substantially parallel at all times. Similarly, a cable 90 is provided which moves in conjunction with the carrier 63 , 62 and 61 and the shoe 65 , as best seen in FIG. 9, so that as the shoe 65 is moved in a direction D 2 that the carrier 61 , 62 and 63 will also be moved in the direction D 2 . FIG. 9 therefore shows the path of the cable connecting the carrier described above.
In order to allow for the movement of the cable the unique pulley arrangement is illustrated in FIG. 10 wherein the cable will travel through the respective channels 107 , 108 and 105 a within the wheel 105 , or through 106 , 104 , 105 a within the opposite wheel or pulley 105 . Assembly 101 is therefore provided which is affixed within the window frame via opening 101 a and a fastener, not shown, which assembly allows for the movement of the cable and hence the carriers in a manner as best seen in FIG. 9 .
Referring now to FIGS. 11 and 12 there is provided a locking mechanism for the shaft 30 which may be used with any lousier assembly. A handle assembly H is provided including a stationary portion H 2 fixed to the sash 21 and a moveable spring biased portion H 1 biased to a continual locked position via spring leaf S 2 . The handle portion H 1 includes a pivot H 4 and detent portions H 5 and H 6 . Normally the spring S 2 will cause the handle portion H 1 to remain in engagement at detents H 5 and H 6 with gear portion or serrations 30 Z of the shaft 30 . Therefore the window or door is locked in that position and cannot be pivoted or slid. When a user engages the handle H 1 and presses it towards H 2 the detents H 5 and H 6 release from the gears 30 Z and hence the window or door may be repositioned as desired. At that repositioned location when the user releases the handles the window or door will again become locked.
Referring now to FIGS. 13, 13 a , 13 b , 13 c and FIG. 18, there is illustrated a track portion 18 and 19 which is to be installed within, as shown in FIG. 18, the sill and header 220 of a frame assembly also including upwardly extending jamb portions 220 a . The track portions 18 and 19 therefore are installed within the profiles as seen in FIGS. 2 b and 18 by the provision of a locking block assembly 200 which includes an adjuster nut 210 which engages the rack portion 18 x of the rack 18 a of the track profile 18 as best seen in FIG. 13 a . The profile therefore includes the rack 18 a , a riding portion for the rollers 18 e which will be explained hereinafter, and a recess 18 d wherein a carrier as best seen in relation to FIG. 14 rides with the exception of the rollers. The track 18 therefore must be locked in position in the sash 220 , and this is affected by the locking block 200 and the moveable nut 210 . As best seen in FIG. 13 c , the track is inserted into the sill profile as shown so that the carrier may ride on the track. The assembly of FIG. 17 for the sash is therefore engaged with the carrier. The block 200 therefore is screwed down through the profile 15 into the wooden frame member not shown via opening 15 c in the profile and 204 in the block 200 . Two fasteners 205 therefore are provided, and as shown in FIG. 13, they are inclined at an angle to the vertical in order to allow for the provision of an adjuster 206 which is accessible through-the opening 207 in the block 200 wherein a cap screw having a head 206 a having an allen key type access slot is provided. The threading 207 b extends down to the end 207 a proximate the nut 210 .
As best seen in FIG. 13, the lock block 200 and the locking nut 210 have a profile substantially as shown with a triangular shaped cut out provided adjacent the top thereof and wherein abutting portions 201 and 203 are provided to engage with the flanges 15 b and 15 a of the profile 15 of the sill portion 220 . The triangular cut-out portion includes an upwardly vertical face 202 a , and bottom 202 . Similarly the nut has a shoulder 211 provided and a substantially triangular shaped cut out 212 and an upwardly extending face 212 a for engaging with the sill profile 15 similar to that which is illustrated and described in relation to FIG. 13 . The rotation therefore of the cap screw 206 results in the movement of the nut 210 in relation to the block 200 which is fastened in position. The adjustment therefore of the screw allows for the thread to engage a threaded opening not shown in the nut 210 so that the rack portions 213 a provide engagement with the rack 18 a of the track portion 18 and will allow for fine adjustment in the positioning of the track 18 and the locking in position of the track. It has been found sufficient that by providing the block and the adjustment of the nut, it will sufficiently position and lock the track in position and allow for the adjustment of the track which will then further allow for the adjustment of the pivots as best seen in FIGS. 1, 1 a , 1 b , 1 c , FIG. 2, FIG. 3 and FIG. 17 so that the parallelism is not lost, and if fine adjustments once installed are required to the window sash to maintain the parallelism of the system, this is very easy to do. Should the system go out of parallel and require fine adjustment to restore the parallelism, a mere rotation of the head 207 is required for both the sill and headers 220 so that the system is squared.
The notch portion defined by the faces 202 a and 202 have a unique purpose in that the latch portion 251 as well as 250 , as best seen in FIG. 17, will engage with the face 202 a and provide a lock detent for the lock 251 . This adds reinforcement to the lock provided in that should the triangular shaped detent of the block not be provided, then the lock 251 would engage flange 15 a and in time would wear out that flange in that particular locking position. The nut 210 has a similar function so that either the nut or the block can function as the detent for the latch. Specifically in FIG. 18, the screw 206 is shown being engageable from the nut toward the block, and in fact it is accessible in either direction as shown in FIG. 13 and FIG. 18 without changing the advantages of the system. For access purposes, depending on the installation and the type of window, it may be easier to adjust as shown in FIG. 18 as opposed to FIG. 13 . Preferably the block is made from fiber-filled nylon. Alternatively, the block may be made from aluminum. The nut may be made from fiber-filled nylon as well.
Referring to FIGS. 14, 14 a and 18 , there is illustrated a carrier 39 x which includes a pivot portion 35 for engaging with the shaft portion 32 and 34 c of the pivot assembly and for carrying that shaft assembly and the pivoting end of the sash in the track 18 and 19 respectively of FIG. 18 . The carrier includes a portion 39 y provided therewith to carry the rollers 39 b therein. This is very similar to the carrier illustrated and described in the previous descriptions and more specifically in relation to FIGS. 1 a and 1 b, with the exception that the details of the carrier were not shown at that time in relation to the thrust wheel 35 c provided on the bottom.
The carrier, as best seen in FIG. 1 a therefore rides on the rollers on the track profile seen in FIG. 13A on the surfaces 18 e for the roller wheels 39 b and in the notch or cut-out recess 18 d for the side portions adjacent the roller 39 b at 39 z . The pinion portion 35 therefore has an opening 35 b for receiving the shaft 32 which extends toward the bottom of the opening 35 d and which opening 35 b as best seen in FIG. 14 is compatible with the shape of the shaft 32 . The outer surface 35 a of the opening 35 b is compatibly shaped with the opening in the carrier so that the opening 35 b may be accessible to the shaft 32 . At the bottom of the pinion portion 35 is a thrust wheel carrying portion 35 e which carries the thrust wheel 35 c . The thrust wheel 35 c therefore rides in between the shoulders 18 c and 18 b on the surface 18 d of the track profile 18 . The thrust wheel is provided to accommodate any wind load which may be placed on the system when the window is opened. Further, in the normal meshing of gears with a rack, there is a thrusting force created as the pinion 35 moves on the rack 18 x . Therefore, the thrusting wheel will engage from time to time the shoulders or the surfaces defined by the shoulders 18 c and 18 b so as to maintain the parallelism and the accuracy of the installation of the window system. A pinion gear 35 a is therefore provided between the thrust wheel 35 c and the pivot receiving opening 35 b which operates substantially as described in relation to FIG. 1 A and FIG. 1 in that as the window rotates the pivot rotates causing the gear 35 a to rotate and move on the track. This is particularly advantageous when the pivot assembly is provided on a casement window as best seen in relation to FIG. 1A in that it is desirable to have the window move away from a pocket provided in the window jamb as best seen in relation to FIG. 1D so that the sash profile will not engage the jamb profile but will readily clear the jamb profile as the window is opened. For example, as best seen in FIG. 1D, proximate the top thereof, it may be readily seen that a pocket is provided in the jamb profile so that the pivot assembly 30 is accommodated at that end of the window. However, a flange portion unlabelled engages the sash cover portion so that within the jamb J 1 there is a pocket J 2 provided which improves the seal of the window in that the cover portion SC extends into the pocket J 2 when the sash is closed. However, when the sash is pivoted as in the case with the casement window of FIG. 1C, the pinion gear when pivoted will move the sash and the sash cover SC out of the pocket J 2 away from the jamb J 1 and provide suitable clearance so that the sash cover SC will not engage with the jamb portion J 3 which is a flange and therefore will clear easily the pocket and all its enabling portions. When the casement window is closed, the opposite happens and the sash cover SC will engage the pocket J 2 and be moved in position with the pivoting of the window to the closed position.
The rollers 39 b therefore provide a smooth motion of the closure system in relation to the track which would not be present if the rollers were not provided since the track is made from aluminum. The rollers are not absolutely essential in every embodiment, however, it is preferred.
Referring now to FIG. 15, there is illustrated two sashes side by side shown in end view. The sashes are made substantially as constructed in relation to FIG. 17 wherein the sash 220 is defined by a central I-shaped portion 227 having an opening therein and two side abutting portions 225 and 226 . A pocket therefore for receiving the glass G is defined at 222 . Fin seal portions 221 are therefore provided for abutting the glass G which contains the normal known seal portion SX. The window sash profiles also include flange portions 224 proximate the opening opposite the glass G. Within that opening there is provided in use a closed cell caulking foam which is compressible at portion 240 . This portion extends totally along the sash profile within the opening as shown with the exception of the portion adjacent the pivoting assembly. A cover portion therefore is provided at 230 which engages the tab portions 224 proximate each side of the sash profile. This cover portion when inserted is flexed downwardly as the closed cell foam 240 is compressed as best seen in FIG. 15 a so that the flange portions of the cover at 230 a engage with the flange portion of the sash at 224 to provide a compressed seal for the track cover 230 . The track cover is defined as a track cover although it does occupy the sash as a component thereof in that as the sash is closed over the opening defined between the flange portion 16 a and 16 b as best seen in FIG. 15 a , the snap cover portion will extend down into and engage with the flanges 16 a and 16 b , thus covering the track and snapping into position each time the sash is opened and closed. The typical seals BX and BY are provided as is known in the art.
Alternatively, as best seen in FIG. 1D, the sash covers may include alternative embodiments shown proximate the jamb portions 16 a and 17 a of the window assembly. Alternatively, a cover portion may be provided over the track portion 15 of sill portion 220 and header portion 220 of FIG. 18 that engages with the sash profile in a similar way to that of the track cover of FIG. 15 a with the exception that the track cover only extends over the second half of the track, that is to say the second half not carrying the window. For example as shown in FIG. 2, the wheel portion 39 a may be eliminated and the track cover may extend along the track portion opposite the pivot assembly so that the sash may slide on the track cover and be assisted to be supported by that track cover only in the second half of the track profile thereby eliminating the second carrier of FIG. 2 . The track cover therefore in FIG. 2 as an example would extend from the carrier 39 a toward the left side of the page to allow the pivot assembly 35 to move to approximately the position of the present carrier 39 a wherein it would engage the track cover. In the movement of the carrier 35 to that position, the other end of the window would already be supported by the track cover. This installation therefore would eliminate the carrier 39 a.
Referring now to FIG. 16B, there is provided locking detents 250 and 251 which engage with the locking detent portions 202 and 212 of the lock and nut portions 200 and 210 . These locking portions 250 therefore and 251 are operated by a handle 260 as best seen in FIG. 16A which is rotatable to cause the motion of the rack portion 265 and the detent 250 into and out of the locking abutment provided with the lock block and the lock nut 200 and 210 respectively. In FIGS. 16, 16 A and 16 B, the installation is provided for a casement window assembly. In the United States Patent Application described in the Summary of the Invention which was incorporated by reference, there is no provision of a casement-style window lock. Nor was there the provision of a lock block or nut detents 210 and 200 respectively. The handle therefore 260 is rotated by the user which causes the movement of the corresponding pinion gear 261 , the rotation of the pinion gear 261 affects the movement of the rack 265 , and the latch engaging portion 250 a and 251 a carried within the housings 255 and 254 respectively as best seen in relation to FIG. 17 . The rotation of the pinion will therefore also cause the motion of the rack portion 266 sufficiently as provided by the opening 266 a of said rack portion to allow for engagement of said rack portion with said rack portion 265 with the bottom portion affecting the latching and unlatching of detent 251 . Intermediate the two latching portions for the casement window is provided a second pinion 267 which is rotated effectively by the movement of the rack portion 266 . Rotation of the pinion 267 causes rotation of the pinion sector 268 which is engaged with the locking detent 269 for the latch plate 270 and the detent 271 thereof. This latch plate is typical for casement windows as is the movement of the lock 269 , i.e. the rotation thereof. However, with the central locking system provided with this invention, it is the one handle operation of both the detents 250 and 251 and the casement window lock 269 which is in combination the essence of the central locking system. Alternatively, the casement window portion may be left out and the essence of the locking system therefore includes the locking block in the track which provides a detent for the locks 250 and 251 respectively.
As best seen in relation to FIG. 17, there is provided a cover C(x) which hooks into the sash profile similarly to the cover 230 previously described in relation to FIGS. 15 and 15A through which the handle portion 260 extends. Therefore, the latch assembly is contained within the sash profile, and the only portion extending outside of the sash profile is the handle portion. This handle portion is considerably smaller than the normal handle portion provided with a casement window which is typically rotary, and there is a tremendous elimination of components for a casement-type window. In fact, this will be described hereinafter.
Referring to FIG. 17, there is shown an exploded perspective view of the window assembly which will fit into the track profile similar to FIG. 18, but more specifically which may be designed for a casement window. The sashes 220 are provided with an opening 227 wherein a corner connector 280 is provided which extends into the opening 227 proximate all four corners and eliminates the necessity for welding. Clip portions 281 bite into the vinyl and are tapered in a direction so as to prevent the removal of the corner connectors once inserted within opening 227 . This snap lock feature therefore provides for the installation of the corner connectors and the quick fastening of the sash profile around the glass G. The track covers 230 are therefore provided and snapped into position once the closed cell foam, best seen in FIG. 15 a at 240 , is inserted within the opening of the sash profile. The hardware including the carriers, best seen in FIG. 18, which are then assembled within the opening opposite the glass of the sash proximate each jamb portion in use. The hardware therefore including the top and bottom track engaging portion 39 x and 37 x , the shaft 32 , the connector 31 b x, the other shaft 31 , and the small shaft 34 c are provided proximate the pivoting end of the window assembly within the sash profile enclosed by a cover similar to that of cover CX. The central lock as described in relation to FIGS. 16, 16 A and 16 B is therefore inserted within the other opening of the sash profile and assembled and covered by the cover CX. The window sash is now available for installation within the frame assembly of FIG. 18 once the carrier portions 39 x are engaged with the respective shafts 32 and 34 c . The block portions 200 are therefore locked in position once the track is installed in the frame, and the nut portions are adjusted to allow for the parallelism of the carriers 39 x within the tracks to ensure the parallelism of the sash so that it rides well within the track portions. The window is therefore assembled.
For a casement window, all of the prior art levers and latch mechanisms are substantially eliminated. This means a great deal to window manufacture in that there are a considerable number of screws and fasteners to hold down the prior art lever linkages of the prior art systems. In the present invention, only the latch block fasteners are provided. The rest of the window assembly merely snaps together with a friction fit of the sash profiles, the sash profile covers and the frames. A minimum of assembly labour is therefore required with the installation of this window assembly. In one particular situation where an old style double-hung window is installed within an opening, it may be conveniently removed by an installer and the present invention may be installed in any of its embodiments including a casement window.
This is heretofore unknown in that a casement window occupies a certain standard space in the industry, and because of the linkage systems and the known systems, it is not possible to provide a larger window. With the present invention, a larger casement window may be provided which is easily installed with the minimum amount of labour and assembly time required. Should the window now be mis-alligned for any reason, it may be easily adjusted by the rotation of the screw 206 provided. A sophisticated user therefore could easily adjust this once instructed over the phone by an installer, or alternatively the installer may return for a quick adjustment at any time. Also, the window assembly is less likely to go out of adjustment because of the great care taken in the development of the precision of the assembly.
A method therefore of assembling the window may be considered as described in the above-mentioned description wherein, firstly the sash components are assembled by the quick fastening feature of the corner locking portions which are inserted within the opening of the sash profiles provided and provide one-way friction fit. The closed cell caulking is therefore inserted within the top and bottom of the sash assembled and these portions are covered by the track covers by the compression of the closed cell foam and the engagement of the tabs of the track cover with the tabs of the sash profile. The hardware is then installed along the vertical portions of the sash within the openings thereof opposite the glass which is then covered by a sash cover portion provided. The hardware located proximate the pivoting end is therefore installed on the carrier portions and inserted within the track portion within the sill and header, for example of a window assembly. The window is therefore closed in position with the sash covers or track covers located proximate the sill and header snapping into the frame and closing any path for air to enter the window and pass the primary seals provided as best seen in relation to the FIG. 15 A. The track covers also provide blockage of light, air and the friction fit of the sash into the track portions. By providing a track cover along the track remote the pivoting end of the window, this track cover may be used as support as well for the window assembly.
In another embodiment not shown, a double casement window is provided which is provided in a straight-line window, that is to say a frame is provided wherein a central mullion is disposed. A central mullion separates two casement windows, one opening as a mirror image of the other and containing all of the elements described above in relation to the pivot assembly and the central locking system and track system.
Referring now to FIGS. 1 and 1D, there is illustrated a retractable screen contained within the opening of the jamb within a framing section for a window assembly having a header 17 , a sill 15 , and two side jambs 5 and 10 . The side jambs 5 and 10 are somewhat identical with the exception of the details herein provided. One of said jambs 5 or 10 , or for that matter in alternative embodiments sill 15 and or header 17 may contain a retractable screen stored on a tube. This may be seen in relation to FIG. 21 which is comparable to FIG. 1 D. The screen assembly 300 includes a tube 305 having a pair of ridges 305 a contained within the hollow 300 a thereof, said hollow 300 a for receiving a spring 301 being a torsion spring having two ends 301 a and 301 b . Said ends 301 b and 301 a for anchoring into the assembly and for ensuring that the spring stays in constant torsion loading. A pin assembly 310 and 311 are disposed proximate each end of said tube 305 . The pin 310 includes an opening 310 a for receiving the end 301 a of said torsion spring 301 . Likewise, the insert 302 includes an opening 302 a for receipt of the end 301 b of the torsion spring 301 . The insert 302 engages the pin portion 311 . The pin portion 310 engages the bushing portion 312 . The pin portions 310 b and 311 b are inserted within mounting brackets M 1 and M 2 for mounting in the hollow of the jamb section. The rib portions 305 a and 305 b engage with corresponding rib portions provided with the pin section 311 and the bushing 312 to prevent rotation of the pins with respect to the tube unless the tube itself is rotated. With respect to the brackets M 1 and M 2 , spacers S 1 may be provided to orient and correctly space the screen assembly in the jamb portion or pocket within which the spring assembly retracts. The screen S is manufactured from a flexible material and has disposed proximate the ends thereof screen welding material or adhesive to adhere to the roller 305 and to the joint provided with respect to the handle portion 320 illustrated best in relation to FIG. 30 . The other end of the screen is inserted within the alligator-type locking jaw of FIG. 30 between elements 320 a and 320 b to capture the screen portion S 2 therein. The screen portion 320 also includes a seal portion 321 which will be described hereinafter which locks and is retained within a channel 322 provided on one edge of the aluminum handle portion. Openings 325 and 326 are provided with the handle assembly 320 so as to retain the guide portions 330 therein. The guide portions 330 are contained within the openings 325 and 326 of the handle portion 320 so as to guide the screen assembly as it pays out from the jamb in a track portion provided with the header and sill portion of the framing sections. A latch portion and a latching plate 350 are shown with the assembly. The latching plate 350 is affixed to the opposite jamb for engaging with the latching member 340 wherein the detents mate and cooperate to retain the screen in its closed position. A seal 321 is contained within a seal receiving channel 320 a to seal against the opposite jamb and prevent bugs from entering the living space. The guide members 330 include a leg 330 a which are compatibly shaped with the opening 325 within the handle portion 320 . The handle portion 320 is extruded from aluminum to form all of the details thereof. The bracket portions M 1 and M 2 are mounted within a pocket P as seen in FIG. 1 containing the roll 305 . A cover plate 350 therefore is provided which snaps into place via the leg portion 350 a being inserted within an opening provided adjacent the jamb pocket. The jamb pocket therefore is defined by three sides 10 a , 10 b and 10 c against which the closure member buts up against and seals. This will be described hereinafter in relation to FIG. 21 . The screen assembly, and particularly the brackets of FIG. 19 are therefore installed within the frame pocket P of FIG. 21 as being keyed into said frame pocket and engaged with the rear wall 10 c of the jamb 10 . The roller cassette 300 is then installed within the pocket P being pre-tensioned and wherein the pin portions 311 b and 310 b are inserted within openings O 1 and O 2 within said brackets, and the adjustment is provided via the bottom bracket M 2 including the spacer S 1 with the supplemental adjustment M 3 to ensure that the roller is properly placed in the system. The tension may be adjusted if required by removing the snap-on cover portion 350 at any time. The handle portion 320 is specifically sized to be received within the opening defined between the cover 350 and the adjacent jamb portion 10 b.
Referring now to FIG. 20, there is illustrated a similar cassette assembly for a retractable screen to that of FIG. 19 with the exception of the mounting brackets and the particulars of the screen. All other elements are identical or substantially identical. The brackets 360 therefore engage the generally T-shaped guide 350 b of the snap-on cover 350 proximate the generally T-shaped channels 360 b disposed therewith as best seen in relation to FIG. 28 b . Only one of the T-shaped channels or pockets 360 b therefore engage the T-shaped guide 350 b which allows for a certain amount of adjustability in relation to the positioning and pretensioning of the screen assembly 300 . The cover is therefore utilized as a chassis to hold the screen brackets and hence the screen cassette. The edges of the screen S 1 and S 2 are therefore provided with adhesive in the form of a tape system to mount the edge S 1 onto the hollow tube 305 and to mount the edge S 2 into the screen-receiving pocket of the handle portion 320 at 320 a . The glides 330 at the end of the handle portion 320 telescope to accept manufacturing installation variations prior to snapping them into the flexible frame track provided thereby providing a seal for the screen pocket and guide rails.
Referring now to FIGS. 21, 22 and 23 , the screen embodiments shown in FIGS. 19 and 20 may be utilized with a screen assembly as best seen in relation to FIGS. 22 and 23 which include generally T-shaped key portions S 1 and S 2 which are generally T-shaped and which engage with generally T-shaped openings 305 x and 350 x within the tube 305 and within the handle 350 in one embodiment of the invention thereof. By providing such a keyed relationship between the handle and the screen, screen replacement becomes very easy eliminating the need for adhesives and the general cutting of screen sections. The screen width indicated as Z therefore is a constant for all screens. Therefore, one continuous screen may be manufactured having the keyed portions located and anchored to the ends thereof as one continuous roll of screen having a predetermined size or width Z which may be cut to the desired length as the only variable dimension when making the screen assemblies of FIGS. 19 and 20 and/or replacing the broken screen which might result under normal wear of FIGS. 19 and 20.
Referring now to FIGS. 1D and 21, the screen assembly 310 included in the jamb does not compromise the typical framing size and standards nor interfere with the window function. Clearly the closure member or window 21 may be swung outwardly away from the jamb and be sealed against the seal 21 a in a closed position. Alternatively, when the window is a tilt and slide, the window 21 may be slid away from the jamb 10 . When the window is in the closed position, there is no need for the screen to be utilized. Therefore, the screen assembly 300 remains hidden within the jamb portion 10 of the window assembly. An esthetically pleasing result therefore is pleasant without the unsightly screen being present and without the unsightly lines of an additional housing added onto the jamb section 10 . The cover portion 350 including the guide 350 b may equally be utilized on the side 10 b of the jamb 10 . That is to say it is not necessary to have the cover 350 close the three-sided jamb sections 10 a , 10 b and 10 c from the front face thereof as shown in FIG. 21 . Equally, the side face 10 b and in one embodiment a preferred approach will be utilized for the cover facing 350 wherein the cover therefore is not observable at the front of the jamb 10 but only at the side making a much more esthetically pleasing installation.
Referring to FIGS. 24, 25 A, 25 B, 26 A, 26 B, 27 A and 27 B, there is illustrated the tube of FIG. 24 having a predetermined diameter and having rib portions 305 a provided therewith which engage with the compatible detents provided with the pin assembly at 311 a which prevents the rotation of the pins with respect to the hollow tube 305 . In this way, the torsion spring 301 and its effort can not slip in relation to the pins 311 b and 310 b . Similarly, the pin assembly embodying 302 as rib portions 302 b to prevent rotation thereof with respect to the tube portion 305 when engaged with the pin assembly portion 311 . An opening 302 a is provided to engage the spring end 301 b and help in establishing the loading and the constant torsion of the assembly. Similarly, the pin portion 310 has an opening 310 a for engagement with the end of the spring 301 a prior to insertion within the bushing 312 which also includes rib portions 312 a.
Referring now to FIG. 28A, there is illustrated the bracket of FIG. 20 which bracket 360 includes a pin-receiving opening and a pair of generally T-shaped openings 360 b for receiving the guide portion 350 b of the flexible cover 350 . Only one of the openings 360 b is utilized depending on whether the bracket is being utilized as a top or as a bottom bracket. Clearly, the bracket has adjustability in that it may slide along the guide 350 b in the flexible cover to the predetermined position to turn by the distance separating the pins 311 b and 310 b in the screen assembly. The brackets then may be fixed in position utilizing glue or the like and may be fastened to the opposite wall 10 c of the jamb 10 of FIG. 21 using conventional methods. It is recommended that the fastening be a removable fastener type allowing for repair of the screen assembly.
Referring now to FIGS. 29A and 29C, there is illustrated the glide portion 330 shown in FIGS. 19 and 20 which glide portion has a generally T-shaped guide-receiving portion 330 b to retain the channel. The member 330 a therefore is provided to be inserted within the opening 325 of the handle portion 320 to seal the entire assembly. Said foot 330 a can be moved in and out of the opening 325 to allow for adjustment as is required.
Referring now to FIG. 30 in relation to FIGS. 19 and 20, the handle portion 320 is therefore shown including alligator jaw-like portions 320 a and 320 b as seen in FIG. 20 for capturing the edge S 2 of the screen S when the portion 320 b is crimped and moved toward the edge of portion 320 a capturing the screen therebetween via serrated edges 320 i of the side 320 b of the joint. An opening 325 is provided for receipt of the guide portion 330 . The handle portion 320 i allows a user to remove the screen as required.
Referring now to FIGS. 31 a , 31 b , 32 a and 32 b , there is illustrating the latching portions of the screen assembly comprising items 340 and 350 . The portion 340 is mounted on the handle portion 320 and is clipped in position via a hook portion 340 b to be retained within a slot 320 i and 340 as best seen in FIG. 19 . This latching portion engages the latching plate of FIGS. 32A and 32B which is mounted via mounting openings 350 b of the latching plate 350 . The opposite jamb is utilized to mount the latching plate 350 so that as the screen moves across the opening framed by the frame assembly, the detent or latch portion 340 a engages the latch portion 350 a of the latching plate to retain the screen in its operative position. This can be released of course by disengaging the latching portions 340 a and 350 a respectively wherein the screen may be retracted within the opening in the jamb 10 of the framing section.
Referring now to FIG. 33, there is illustrated the but seal 321 which is anchored in position within the groove 320 a of the handle portion 320 via legs 321 a . The bug seal 321 therefore buts up against the opposite jamb portion not shown via edge 320 b , that is the same jamb portion to which the latching plate of FIGS. 32A and 32B is mounted.
Referring now to FIG. 34, there is illustrated the cover portion 350 for the assembly of FIG. 20 which includes an arm or leg portion 350 a which is received within the channel 10 x of FIG. 21 which includes a locking edge at 350 b to retain said arm 350 a within the compatible groove 10 x which also includes a detent at 10 y to correspondingly lock the flange in position. The element 350 c therefore is disposed within the interior side of the cover 350 to be received within the channels or guides shown in FIGS. 28A through 28C at 360 b and thereby retain the mounting brackets for the screen assembly in the position required allowing the adjustment thereof and final fixing in relation thereto.
Those skilled in the art will also appreciate the fact that a screen assembly having two ends separated by a predetermined distance and being formed as a continuous screen which may be cut as required at a predetermined distance as set out by the length of the tube 305 . The anchor portions S 1 and S 2 are a fixed distance and are manufactured with the screen on a continuous length of screening which may be cut as required including cutting these anchor portions as best seen in relation to FIG. 23 . This makes screen replacement very easy.
The entire assembly therefore 300 is provided as a cassette totally assembled and insertable into the jamb opening defined by the three sides of the jamb 10 at 10 a , 10 b and 10 c . It is only necessary to provide the cassette integral with the cover portion 350 which may be either the front cover which clips in position as shown in FIG. 21 or a side cover, not shown, but easily determined by those skilled in the art from the teachings herein.
As many changes can be made to the invention without departing from the scope of the invention, it is intended that all material contained herein be interpreted as illustrative of the invention and not in a limiting sense. | A reinforcing block for a closure tilt latch, comprising a body fastened in a closure track fastened to a frame, said body having a top and bottom and having a locking detent extending therein said locking detent providing a vertical face extending toward said top of said body from intermediate said top and bottom, the tilt latch being compatible with the vertical face of said locking detent, wherein when said latch engages said detent said block provides a reinforcement path to the closure frame to strengthen the loading capability of said closure and to reduce the risk of the latch from disengaging said track under loading which track would be subject to distortion had the block not been utilized. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/150,405 filed on Feb. 6, 2009 entitled “Double-Sided Slip-Resistant Material and Method of Making Same” which is incorporated fully herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to slip resistant material and more particularly, relates to a slip resistant, lightweight cloth-like material useful for products such as, but not limited to, a drop cloth for the moving and painting industry.
BACKGROUND INFORMATION
[0003] There is often a need for lightweight protective material such as drop cloths to cover floors and furniture during moving, construction or other activities such as painting and decorating. One problem that has consistently been struggled with for such material is the need of the material to be relatively impervious to liquids such as water and paint.
[0004] The prior art has dealt with the problem of waterproofing lightweight cloth materials by placing a plastic coating on one or both sides of a paper or cloth material. Unfortunately, although this makes the product waterproof, it also makes it very slippery. If a painter cannot place a ladder on the material without fear that it will slip out from under him or her, they are not apt to use it.
[0005] There have been some prior art attempts at making non-slip surfaces but this relates mostly to roofing materials or more permanent material such as floor tapes and the like.
[0006] Accordingly, what is needed is a lightweight, reusable, puncture resistant, cloth like material that is generally impervious to water and other liquids while providing at least one surface that is a non-slip surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:
[0008] FIG. 1 is a perspective schematic view of a portion of a system for making the slip resistant material according to the present invention; and
[0009] FIG. 2 is a schematic diagram of the travel path of the double-sided slip resistant material of the present invention after the material has been blown showing incorporation of a machine direction orienter (MDO) in-line in the manufacturing process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] The present invention features a two-sided slip resistant material made by the blown film process, which process is well known in the industry, comprising the co-extrusion of multiple layers to produce a finished film composite having the desired characteristics described herein.
[0011] As illustrated in FIG. 1 , a film blowing machine (not shown but well known in the art) produces a film “bubble” 10 comprising, in the preferred embodiment and without limiting the present invention, 3 layers or films: A, B and C. In the preferred embodiment, layer A, (the inside most layer of the bubble) is a heat sealable thermoplastic layer of approximately 0.2-2 mils in thickness having a softening point in the range of 110° to 200° F. which facilitates gluing of the two “A” layers together at a low temperature, as will be described below. Layer A may be an EVA, EMA, LDPE or POP resin based layer. An advantage of using an Ethyl Vinyl Acetate (EVA) layer is that the VA (vinyl acetate) content may be adjusted to achieve the desired softening point of the layer to facilitate its gluing to an adjacent similar layer.
[0012] Layer B, the central or center layer, is preferably a flexible polyolefin layer having a thickness of approximately 0.5-2 mils. Suitable material for the center “B” layer include, LDPE, LLDPE, TPO, and POE. In addition to the resin this layer may also include a colorant, UV stabilizer, UV absorber and antioxidant, which will be exposed during the manufacturing process after the formation of the collapsed bubbles in the C layer. An example of a potential UV Stabilizer is Chimassorb 994™; examples of potential antioxidants include Irganox 1010™, Irganox 1076™ and Irgafos 168™; and an example of a potential UV Stabilizer is Cyasorb UV-531™.
[0013] The C layer (the outermost layer of the film which forms the top and bottom of the finished film product) is also a flexible polyolefin layer. This layer, however, contains a “blowing” agent that causes the film to form many small “bubbles” on the exterior surface 12 of the C layer. The blowing agent creates a gas in the extruder during the melting process and this gas is distributed throughout the “C” layer and is soluble in the molten plastic due to the high extruder pressure. When the film exits the blown film die, there is a drop in pressure, and bubbles form in the “C” layer. By, stretching and cooling the film, the bubbles collapse forming a rough, nonslip open celled surface 12 .
[0014] The blowing agent can be either a physical blowing agent (PBA) such as carbon dioxide or butane, or an exothermic or endothermic chemical blowing agent (CBA) such as a sodium bicarbonate and citric acid mixture, which decomposes under heat during the extrusion process and produces a gas.
[0015] In the preferred embodiment, the preferred flexible polyolefin is a polyolefin elastomer (POE) such as Dow Chemical's “Engage” product preferably, Engage grade 8003. After considerable experimentation, it has been determined that not all polyolefin elastomers are suitable for the skid resistance application. A resin with appropriate melting point, and softness to create bubbles that are very rubbery, flexible and have a high Coefficient of Friction (COF) creating a surface with significant “slip” resistance is required. These characteristics, which can be found in the Engage 8003 product include: flexural modulus less than 200 MPa, and Durometer hardness (Shore A) less than 100.
[0016] In addition to the polyolefin elastomer, layer C may also include a coloring agent, to color the finished product, a UV stabilizer, UV absorber and antioxidant, as well as a grit material such as ultra-high molecular weight polyolefin which will adhere to the outside of the bubbles formed by the blowing agent and add additional slip resistance to the finished film.
[0017] Near the top of the bubble 14 , two rollers 16 , 18 (top nip rollers) are utilized to “collapse” the bubble 14 causing both sides of the bubble to come together. In the preferred embodiment, one of the rollers is a rubber roller while the other is a metal nip roller, which is heated. The temperature of the nip is such that it is above the softening point of the resin in the “A” layer. This causes the two inside “A” layers to fuse together forming a single film structure.
[0018] The processing of the fused film layer 20 is shown schematically in FIG. 2 . After the film 20 leaves the nip rollers 16 / 18 , the film enters a set of in-line rollers 24 - 30 , which serve as a Machine Direction Orienter (MDO) 22 . The MDO rollers 22 serve as a post treatment of the film, annealing or conditioning the film to take any stresses out of the film and to remove any variation in film thickness. The MDO section consists of 2 sets of 2 rollers each. The first two rollers 24 / 26 are heated to above the glass transition temperature of the resin of the inside A layer of the film 20 . These rollers operate at a speed, which is the same as the speed at which the blown film 20 is manufactured.
[0019] The next two rollers 28 / 30 are cooling rollers operated at a temperature in the range of 80-100° F. In addition, the cooling rollers 28 / 30 are operated at a speed of 2% to 10% faster than the line or manufacturing speed at which the first 2 rollers 24 / 26 operate, thus causing the now fused, double-sided film to stretch in the region and direction indicated generally by arrow 32 . The MDO section anneals the film, gives it a second heat treatment annealing the film and relieving it of any stresses.
[0020] The pair of cooling rollers 28 / 30 serve to cool the film down before it is wound into a roll for later use. Although the use of an MDO is known in the art, it is not known to place such a device “in line” in the manufacturing process. Typically, in the prior art, a film is blown, wound onto a roll, subsequently unwound into an MDO for stretching, and then rewound before use. Accordingly, the present invention provides a double-sided non-slip, waterproof, plastic film which is easy and relatively inexpensive to manufacture and which is very slip resistant on both sides, and can be used for numerous applications such as painter's drop cloths, non-slip protective coverings, moving cloths and the like.
[0021] Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the allowed claims and their legal equivalents. | A double-sided, slip resistant material is produced using a blown film process which produces a film having an interior heat sealable layer, a core layer of flexible polyolefin and an exterior polyolefin elastomer layer in combination with a blowing agent and optionally grit to produce a double-sided slip resistant material. A number of rollers are provided after nip rollers have fused the film together, and which form part of a machine direction orienter (MDO) that is used in line in the manufacturing process to heat, and then cool and condition (anneal and relieve any stresses and/or thickness inconsistencies in the film) prior to the film being wound onto a roll for storage. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates in general to a latent material having various controlled shrinkage tensions and patterns. The present invention is also directed to a method of making the these materials. These materials are useful in the formation of personal care articles.
BACKGROUND OF THE INVENTION
[0002] Personal care products have revolutionized modern lifestyle and are of great convenience to society. Such products generally are relatively inexpensive, sanitary and quick and easy to use. There are many different types of personal care products having different functions and appearances. These include, among others, absorbent incontinence products, such as diapers, training pants and adult incontinence garments; feminine care products, such as pantiliners and sanitary napkins; and tissue products, such as facial tissue and toilet tissue.
[0003] Each of these products may include many different features and appearances even among the same type of product. For example, some diapers are designed to be more absorbent while others are designed to be more comfortable. As such, there are large number of materials used in making these products and a corresponding number of processes needed to make these different materials. The large number of materials used can make the processes for making the personal care products complicated and/or expensive.
[0004] Microwave energy has been primarily used for food processing. However, recently, it has been used in industry-heating processes, especially to apply microwave technology on consumer personal care articles, such as disposable absorbent products. This microwave energy has been used with some elastomeric materials. Generally, the equipment used in the process to control the elastic material while in a state of tension is generally complex. Additionally, the process can be difficult to control and will sometimes result in a finished material that is wrinkled. The complex equipment is needed because of the difficulty in maintaining the elastic materials in a tension state while consistently and accurately attaching additional materials under low drawing and high web speed.
[0005] Conventional latent polymeric materials are more like thermoplastics which appear to be flat and in a non-elastic state at room temperature. Latent polymers can be made by pre-stretching elastic materials. The stretched condition can be maintained by means of forming crystallization or intermolecular forces, such as hydrogen bonding or ionic association. The latent polymers are temperature sensitive materials and can be converted into elastics by applying enough heat to overcome the intermolecular forces. The macromolecule chains of latent polymers can return to their equilibrium state and regain their elastic characteristics. Such a process is called activation of a latent polymer.
[0006] Activation of a latent polymer has conventionally be done using hot air heating. It is well known that conventional heat activation is generally accomplished by passing the latent polymer, which is laminated between non-woven facings, through a heated air duct for a period of time. It typically takes several seconds to raise the latent polymer temperature for activation, which results in retraction and regains elasticity. Such a heating process requires large capital investments, huge space, vast amounts of energy, and manufacturing inefficiencies.
[0007] Accordingly, what is needed is a single material that may be modified as needed to achieve many different shapes and functions, thereby making the formation of the personal care articles simpler. Also what is needed is a latent polymeric material that may be activated using microwave radiation, thereby reducing the cost and complexity associated with the process of making these materials. Finally, what is needed is a personal care product, such as a disposable absorbent product, that incorporates these latent polymer films.
SUMMARY OF THE INVENTION
[0008] The present invention provides a latent polymer film material that may be modified as needed to produce different three-dimensional patterns and different tensions. Therefore, this film material may be used to perform different functions in personal care articles that, heretofore, required several different film materials. As such, the film material of the present invention can reduce the number of processes needed to make personal care products, as well as reducing the number of types of materials used.
[0009] The present invention is able to achieve these advantages by providing a heat-sensitive latent polymer film that may be modified through the use of microwave sensitizers that are applied to a polymer film and activated. Depending on the amount of sensitizer used, its placement on the polymer film and the degree of activation, different patterns may be formed on the polymer film. In addition, different tensions may also be achieved, thereby permitting the material to have different functions within the personal care product.
[0010] The sensitizers used are selected based upon their dielectric loss factor and the desired final film characteristics. The sensitizers are applied to the heat-sensitive latent polymer material using printing or coating means and then are “activated” using a high speed microwave activation process. The sensitizer turns the microwave energy into heat energy, thereby causing the heat-sensitive polymer film to shrink and results in the thermoplastic latent polymer becoming a thermoplastic elastomer. The amount of heat released from the sensitizer during microwave radiation will depend on the amount of sensitizer used and the nature of the sensitizer, as well as microwave power. Using more sensitizer with a higher dielectric loss factor will result in more heat being generated and, thus, a higher degree of shrinkage of the latent polymer material. Using less sensitizer with a lower dielectric loss factor will result in less heat being generated and a lower degree of shrinkage. Different tensions in the final material may therefore be produced, with the “tension” being defined as the degree of elasticity of the material corresponding to the degree of shrinkage of the latent material. Accordingly, in contrast to prior art heated air methods, microwave energy provides high efficiency and selective heating, can be quickly turned on and off, requires minimal set-up time, space and lower cost capital investment.
[0011] The latent material may be “patterned” by applying the sensitizer only to portions of the material, while leaving other portions with no sensitizer. Upon application of the microwave radiation, the areas having the sensitizer will shrink, while the areas with no sensitizer will remain the same. This aspect allows the present invention to be modified as needed to form a material having any desired three-dimensional pattern and/or tension.
[0012] These and other features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIGS. 1 a and 1 b are photographs showing a polymer film according to one embodiment of the present invention before exposure to microwave radiation (FIG. 1 a ) and after exposure to microwave radiation (FIG. 1 b ).
[0014] [0014]FIGS. 2 a - d are photographs showing a polymer film according to one embodiment of the present invention before exposure to microwave radiation (FIG. 2 a ) and after exposure to microwave radiation with different amounts and locations of sensitizer (FIGS. 2 b 2 d ).
[0015] FIGS. 3 - 5 are photographs showing different patterns on a polymer film according to one embodiment of the present invention that are created by microwave radiation with a microwave sensitizer applied.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention is directed to a polymer film that may be customized to form three-dimensional patterns in the film and/or to create a film having different tensions to permit the polymer film to perform a plurality of different functions when used in personal care articles. By being able to use a single material, the films of the present invention are able to simplify the process needed to manufacture these personal care articles. The present invention uses a heat-sensitive latent polymer film material that may be modified to produce these different three-dimensional patterns and/or different tensions.
[0017] The heat-sensitive latent polymer film used is modified through the use of microwave energy and a sensitizer material that is placed on the polymer film in select areas. The sensitizer is capable of transforming microwave radiation into heat energy. This heat energy then causes the heat-sensitive polymer film to shrink in areas where the sensitizer is located. The shrinkage may be used to form different three-dimensional patterns in the film and/or may be used to produce different tensions in the film. Generally speaking, the greater the amount of sensitizer used and/or, the higher its dielectric loss factor, the higher the degree of shrinkage that will occur, which depends on the maximum shrinkage capacity of the latent film.
[0018] In use, the present invention provides a heat-sensitive latent polymer film that is desired to be treated to produce a polymer film having a desired tension and/or a desired pattern on the film. The film includes the heat-sensitive latent polymer film and a sensitizer. The latent polymer film composite may be activated to achieve the different patterns and tensions. The sensitizer is applied to the polymer film using a coating process such that when microwave radiation is used to activate the latent polymer composite, the sensitizer converts the microwave radiation to heat. The heat will cause the polymer film to shrink. The polymer film will not shrink in areas having no sensitizer. As such, the polymer film may be customized to form the different tensions and/or patterns. Then, the present invention may be used in a personal care article, such as a diaper, feminine care article, or adult incontinence device.
[0019] The polymer film is desirably selected based upon the desired final characteristics of the film, its use in the personal care article, the type and amount of sensitizer used, and the level of microwave radiation to be used in activating the sensitizer. The heat-sensitive latent polymer film may be selected from a variety of different materials. Examples of polymer films useful in the present invention include, but are not limited to, Exxon 601; polyether; polyether-polyamide copolymer; polyamide; polyester; polyurethane; polyacrylates; polyester-polyamide copolymer; polyvinylacetate; and ethylene-propylene copolymer. Desirably, the polymer is Exxon 601 or PEBAX®, a polyether-polyamide copolymer available from Elf ATOCHEM. Exxon 601 is a proprietary polymer (U.S. Pat. Nos. 4,714,735 and 5,182,069) comprising from about 20 to about 30 wt. % olefinic elastomer, from about 60 to about 75 wt % ethylene copolymer, from about 4 to about 10 wt. % processing oil, and less than about 5 wt. % other additives.
[0020] The thickness of the film may vary depending upon the desired final use of the film. However, one of the advantages of the present invention is that the film may very thin, i.e. from about 1 mil to about 5 ml, which is unlike the films of the prior art.
[0021] Alternatively, the polymer material used in the present invention may be in the form of strands. These strands are typically larger than regular fibers and may have a thickness of from about 0.1 mm to about 2.0 mm.
[0022] The sensitizer used will depend on the polymer film used, the pattern and/or tension to be formed, the dielectric loss factor of the sensitizer, the amount of sensitizer desired to be used, and level of microwave radiation to be used in activating the sensitizer. The sensitizer is placed on the polymer film and then activated. The dielectric loss factor of the sensitizer will affect the amount of heat released by the sensitizer when exposed to microwave radiation and, consequently, the degree of shrinkage of the polymer film. Examples of sensitizers useful in the present invention include, but are not limited to, homopolymers, block and random copolymers of polyether, polyethylene glycol, and polyether-polyethylene glycol block copolymers; ionic polymers and copolymers, such as polyacrylic acid-sodium salt polymers and copolymers; metal salts; and organic solvents, such as ethanol, isopropanol, water, and combinations thereof. Desirably, the sensitizers comprise from about 10 to about 40 wt. % of polymer or copolymer, from about 2 to about 15 wt. % metal salt, and from about 30 to about 70 wt. % alcohol or water. Desirably, the sensitizer is a polyacrylic acid-sodium salt polymer comprising about 50 g of polyacrylic acid in about 400 g of 1.0 mol NaCl solution. Other sensitizers can be made from inorganic chemicals such as metal particles and metal oxides, such as aluminum, copper, zinc and their oxides, various ferrite e.g. barium and magnesium ferrite and carbon black. In general, a sensitizer used in the present invention is designed to absorb microwave radiation at a frequency of from about 900 to about 3000 MHz, and desirably at about 915 MHz or at about 2450 MHz.
[0023] In addition to the polymer film and the sensitizer, the latent materials of the present invention may include other materials, depending on the desired final characteristics of the film. For example, surfactants or cosolvents may be used to adjust the surface tension of the sensitizer on the latent polymer film.
[0024] Once the polymer film and sensitizer have been selected, the sensitizer is applied to the polymer film in the desired amounts and locations such that when microwave radiation is used, the desired final characteristics of the final film will be achieved. The sensitizer may be applied to the polymer film using a variety of different methods including, but not limited to, screen printing; roller coating; melt blown coating; bead coating; ultrasonic spray coating, or by directly incorporating the sensitizer into the latent polymer by blending or compounding technologies.
[0025] Once the sensitizer has been applied to the polymer film, the different tensions and/or patterns in the film are created by activating the sensitizer under microwave radiation such that heat is generated, thereby causing shrinkage in the desired areas of the polymer film. Microwave energy is an electromagnetic energy which has wavelengths from 1.0 cm to 1.0 m corresponding to frequencies in the range of 3×10 8 to 3×10 10 Hz. It is noted that the frequencies are in between IR and radio frequencies and only two standard microwave frequencies are generally available for use in the present invention, 915 MHz and 2450 MHz.
[0026] Desirably, the sensitizer is activated using a high speed microwave activation process. This process desirably uses a microwave oven set at a power of about 900 W and a frequency of about 2450 MHz. A representative microwave oven that may be used in the present invention is the TM-010 mode tubular-type microwave oven available from IBM. In the activation process, the polymer film having the sensitizer thereon is placed on a web. The web is then started and the polymer film is passed through an area where it is subjected to microwave radiation. As the film passes through the radiation, the radiation activates the sensitizer. The sensitizer turns the radiation into heat energy, thereby causing shrinkage of the polymer film. The greater the dielectric loss factor of the sensitizer and the greater the amount of sensitizer, the greater the amount of heat released and the greater the degree of shrinkage of the polymer film, which is in the limitation of the film shrinkage capacity.
[0027] However, to ensure the selective shrinkage of the polymer film to only those areas containing the sensitizer, other process parameters may need to be considered. If the speed of the web is too slow, areas of the polymer film not having any sensitizer may shrink as the radiation may heat the polymer film, thereby causing shrinkage of the polymer film directly. Accordingly, it is desired that the web move at a sufficient speed to reduce this likelihood. Desirably, the web moves at a rate of greater than about 200 feet/minute. More desirably, the web moves at a rate of greater than about 250 feet/minute. Most desirably, the web moves at a rate of greater than about 300 feet/minute. A high speed web is desired for use in a production line.
[0028] Additionally, the level of radiation is desired to be as high as possible such that the web speed can be faster. However, due to the microwave absorbency of the film, the processes of the present invention are generally limited by the dielectric loss factor (e″) of the materials employed. Generally, microwave energy is absorbed by molecules through the polarization or dipole reorientation (or rotation) of the function groups, and/or by ionic movements, which is translated into thermal energy. As a result, materials can be heated using microwave irradiation in the molecular level. The heat is generated within each molecule and thereby a uniform heating pattern can be created in the material. In this manner, the material can be heated up very efficiently as compared to conventional heating.
[0029] The dielectric heating of a material is dependent on the dielectric properties of a material, which can be described by two parameters: the dielectric constant (e′) and the dielectric loss factor (e″). If the dielectric loss factor is too low, the material will be transparent to microwave radiation, regardless of the microwave power. As such, the higher the dielectric loss factor of the material, the higher the microwave power can be and the higher the web speed can be. Generally, it is desired that the materials used will permit the microwave power to be greater than about 1.0 kW. More desirably, the microwave power is greater than about 3.0 kW and most desirably, the microwave power is greater than about 6.0 kW.
[0030] After the desired patterns and/or tensions have been incorporated into the polymer film, the film may be used in a process or system designed to manufacture personal care articles. The personal care articles may include only a single film according to the present invention, or may use a plurality of different films. These different films may be similar in nature or they may each have different patterns and/or tensions, depending on their desired use within the personal care article.
[0031] The present invention is further illustrated by the following examples, which are not to be construed in any way as imposing limitations upon the scope thereof. On the contrary, it is to be clearly understood that resort may be had to various other embodiments, modifications, and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the present invention and/or the scope of the appended claims.
EXAMPLES
EXAMPLE 1
[0032] In this Example, the heat-sensitive latent polymer film was Exxon 601 from Exxon. As discussed, Exxon 601 comprises from about 20 to about 30 wt. % olefinic elastomer, from about 60 to about 75 wt % ethylene copolymer, from about 4 to about 10 wt. % processing oil, and less than about 5 wt. % other additives. The original size of cross section of the Exxon 601 film was 104 mm. The sensitizer was ASS-2 (50 g of polyacrylic acid (MW=5100) in about 400 g of 1.0 mol NaCl solution). The sensitizer was applied using an ultrasonic spray coating technique. The sensitizer was applied in a continuous wave pattern. The average amount of sensitizer ASS-2 used was 3-4 gsm addition. However, in the center (with 15-20 mm wide) the amount of sensitizer ASS-2 used was 5-6 gsm. One side edge (about 6-10 mm wide) had no sensitizer applied. Microwave radiation was applied to the film. The web speed was 300 ft/min and the power was 2.0 kW using high efficiency microwave oven model TM-010 mode tubular-type microwave oven available from IBM.
[0033] The average amount of shrinkage was about 55%, with continuous wave pattern obtained after microwave radiation. Additionally, the amount of shrinkage in the center thickness (which had the larger amount of sensitizer) was increased to about 0.0005 inches as compared to the original thickness of the film of about 0.0002 inches. In the areas with an average amount of sensitizer of 3-4 gsm, the average thickness of the film after shrinkage was about 0.00025 to about 0.0003 inches. No shrinkage was found and no change of the thickness observed in the areas where no sensitizer was applied. The samples are shown in FIG. 1. FIG. 1 a shows the original film, while FIG. 1 b shows how the film has shrunk from microwave radiation.
EXAMPLE 2
[0034] In this Example, the polymer film from Example 1 was coated with sensitizer ASS-1 (50 g of polyacrylic acid (MW=2000) in about 400 g of 1.0 mol NaCl solution) in two sections. One section was coated using a brush to form a dried coating thickness of the sensitizer in the range of 0.001˜0.002 mm. The other was slightly coated with the same sensitizer to form a dried coating thickness of less than about 0.0005 mm. No sensitizer was located in the middle region between the two sections. Microwave radiation was applied to the film. The web speed was 300 ft/min and the power was 2.0 kW. FIG. 2 a shows the original film, while FIGS. 2 b - c show how the film has shrunk from microwave radiation. In FIG. 2 b , less sensitizer was used than in FIG. 2 c . FIG. 2 d shows the polymer film wherein the entire film was spray coated with the ASS-1 sensitizer.
[0035] The average shrinkage for the first section after microwave radiation was more than 40% with a thickness increasing from original 0.0002 inches to amount 0.0005-0.0006 inches. As a comparison, the second section with less sensitizer coated its shrinkage was less than 10%. The middle region showed no change in the thickness and no shrinkage from the original after microwave radiation.
EXAMPLES 3-5
[0036] In these Examples, the polymer film from Example 1 was coated with a sensitizer composition in various patterns. The sensitizer composition comprised about 20 to about 50 wt. % polyethylene-polyethylene glycol block copolymer and/or polypropylene glycol and polyethylene glycol block copolymer; about 30 to about 70 wt. % 1.0 and/or 2.0 mol NaCl solution, and less than about 1.0 wt. % CS-1 surfactant (BASF). The sensitizer was applied to the polymer film using a screen printing process. Next, the samples were exposed to microwave radiation using a conventional microwave-cooking oven (Sharp Mode Carousel) having an output power of 900W at a frequency of 2450 MHz. The oven used a Teflon support plate to minimize microwave energy absorption by the glass plate. The samples were exposed to radiation for about 5 seconds. The results can be seen in FIGS. 3, 4 and 5 , which show how the selective application of the sensitizer and the subsequent exposure to microwave radiation resulted in latent polymer films having different shapes and/or tensions.
[0037] Those skilled in the art will recognize that the present invention is capable of many modifications and variations without departing from the scope thereof. Accordingly, the detailed description and examples set forth above are meant to be illustrative only and are not intended to limit, in any manner, the scope of the invention as set forth in the appended claims. | A latent material having various controlled shrinkage tensions and patterns and a method of making the same. The materials include polymer materials that are capable of absorbing microwave energy. Different degrees of shrinkage of the material may be controlled to create different tensions in the material. Additionally, various stereo and three-dimensional patterns may be generated on the material. These materials may be used in the formation of personal care articles. The materials are made by incorporating a polymer material onto the film, wherein the polymer material is capable of turning microwave energy into heat. Upon exposure to microwave radiation, the heat will cause the latent material to shrink. The use of different types and amounts of polymer materials will result in a latent material having different tensions and patterns. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority from Korean Patent Application No. 10-2016-0017547, filed on Feb. 16, 2016, the disclosure of which is incorporated herein in its entirety by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to washing machines, and more particularly, to liquid additive supply devices for washing machines.
BACKGROUND
[0003] In general, detergent is added to washing machines and dispensed for washing laundry during washing cycles. A washing machine typically uses a detergent dispenser to supply and dispense detergent to the washing machine. The detergent dispenser has a drawer-type detergent supply device. A user can pull out the detergent supply device partially to add detergent.
[0004] As extraneous material such as dust or the like is likely introduced into the detergent supply device together with the detergent, detergent residue can build up in the detergent supply device. Especially after a long period of non-use, the residue tends to become stuck in the detergent supply device. In a conventional detergent dispenser, the detergent supply device is not designed to be detached from the detergent dispenser by a user, making it difficult to clean the detergent residue at the bottom of the detergent supply device.
[0005] To solve this issue, a detergent supply device removably mounted to a detergent dispenser has been developed. However, because such detergent supply device is installed in an internal space of a washing machine, it is difficult for a user to remove the detergent supply device from, or place it back into, the detergent dispenser.
PRIOR ART DOCUMENTS
Patent Documents
[0000]
Patent Document 1: Korean Patent Application Publication No. 10-2008-0092199 (published on Oct. 15, 2008)
SUMMARY
[0007] Embodiments of the present disclosure provide a liquid additive supply device that can be easily removed from and attached back to the detergent dispenser on a washing machine by a user. Thereby, a user can advantageously clean the liquid additive supply device conveniently. According to an embodiment of the present invention, a liquid additive supply device for a washing machine, the liquid additive supply device includes a main body coupled to a detergent dispenser of the washing machine and configured to contain a liquid additive; an accommodation part provided in the detergent dispenser; a magnetic body coupled to the main body; and a mounting/demounting detection sensor coupled to the accommodation part and configured to detect a presence proximity of the magnetic body with respect to the mounting/demounting detection sensor and to generate a sensing signal accordingly.
[0008] Further, the magnetic body is disposed on a lower surface of the main body.
[0009] Further, the mounting/demounting detection sensor is disposed on an outer surface of the main body.
[0010] Further, a liquid additive supply device further includes an accommodation part in the detergent dispenser. The main body is removably accommodated within the accommodation part.
[0011] Further, a liquid additive supply device further includes a control unit configured to receive the sensing signal from the mounting/demounting detection sensor and to determine a presence of the main body within the accommodation part.
[0012] Further, a liquid additive supply device further includes a notification device configured to receive a control signal generated by the control unit and to generated an indication of the presence of the main body within the accommodation part.
[0013] Further, the main body comprises: a first storage part configured to store a first liquid additive; and a second storage part configured to store a second liquid additive.
[0014] The main body further comprises a nozzle configured to receive liquid additives supplied from the first storage part and the second storage part and to guide the first and the second liquid additives upward from a lower portion of the main body to an upper portion thereof.
[0015] The magnetic body is disposed in a front region of the main body where the first and the second liquid additive are supplied.
[0016] A bottom surface of the main body is downwardly inclined from the front region of the main body toward a rear region of the main body where the nozzle is located.
[0017] Further, a liquid additive supply device further includes a buoyancy body rotatably and hingedly coupled to a lower portion of the main body and comprising a liquid additive residual amount detection magnetic body; and a residual amount detection sensor coupled to the main body and configured to sense proximity of the buoyancy body.
[0018] Further, the residual amount detection sensor is disposed on an outer surface of the main body in a position facing the buoyancy body.
[0019] Further, a liquid additive supply device further includes a cover part operable to cover a top opening of the main body.
[0020] Also in one embodiment, a washing machine includes a detergent dispenser comprising an accommodation part and configured to dispense a liquid additive for washing laundry; a liquid additive supply device coupled to the detergent dispenser. The liquid additive supply device comprises a main body removably coupled to the detergent dispense and configured to contain a liquid additive; a magnetic body coupled to the main body; and a mounting/demounting detection sensor coupled to the accommodation part and configured to detect a presence of the main body within the accommodation part by sensing a magnetic field of the magnetic body.
[0021] Further, the liquid additive supply device further comprises a filter configured to partition the main body into a first main body portion and a second main body portion.
[0022] Further, the liquid additive supply device further comprises a nozzle disposed in a bottom portion of the second main body portion and configured to receive the liquid additive from the main body and to transport the liquid additive upward from a lower portion of the main body to a an upper portion thereof.
[0023] Further, the magnetic body is disposed on a lower surface of the first main body portion. The mounting/demounting detection sensor is disposed on an outer surface of the main body in a position facing the magnetic body.
[0024] Further, a bottom surface of the main body is downwardly inclined from a front region of the main body toward a rear region of the main body where the nozzle is located.
[0025] Further, the liquid additive supply device further comprises: a buoyancy body rotatably coupled to a lower portion of the main body and comprising a first magnetic body; and a residual amount detection sensor coupled to the main body and configured to: sense proximity of the buoyancy body by detecting a magnetic field of the first magnetic body; and generate a signal indicative of an amount of the liquid additive contained in the main body.
[0026] Further, the residual amount detection sensor is disposed on an outer surface of the main body in a position facing the buoyancy body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 illustrates a perspective view of an exemplary washing machine according to one embodiment of the present disclosure.
[0028] FIG. 2 illustrates an assembled perspective view of an exemplary liquid additive supply device for a washing machine according to one embodiment of the present disclosure.
[0029] FIG. 3 illustrates an exploded perspective view of the exemplary liquid additive supply device for a washing machine according to one embodiment of the present disclosure.
[0030] FIG. 4 illustrates a view of a mounting/demounting detection magnetic body and a mounting/demounting detection sensor of the liquid additive supply device for a washing machine according to one embodiment of the present disclosure.
[0031] FIG. 5 illustrates an exemplary control mechanism of the liquid additive supply device for a washing machine according to one embodiment of the present disclosure.
DETAILED DESCRIPTION
[0032] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.
[0033] One or more exemplary embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings, in which one or more exemplary embodiments of the disclosure can be easily determined by those skilled in the art. As those skilled in the art will realize, the described exemplary embodiments may be modified in various different ways, all without departing from the spirit or scope of the present disclosure, which is not limited to the exemplary embodiments described herein.
[0034] It is noted that the drawings are schematic and are not necessarily dimensionally illustrated. Relative sizes and proportions of parts in the drawings may be exaggerated or reduced in their sizes, and a predetermined size is just exemplificative and not limitative. The same reference numerals designate the same structures, elements, or parts illustrated in two or more drawings in order to exhibit similar characteristics.
[0035] The exemplary embodiments of the present disclosure illustrate ideal exemplary embodiments of the present disclosure in more detail. As a result, various modifications of the drawings are expected. Accordingly, the exemplary embodiments are not limited to a specific form of the illustrated region, and for example, include a modification of a form by manufacturing.
[0036] FIG. 1 illustrates a perspective view of an exemplary washing machine according to one embodiment of the present disclosure. FIG. 2 illustrates an assembled perspective view of an exemplary liquid additive supply device for a washing machine according to one embodiment of the present disclosure. FIG. 3 illustrates an exploded perspective view of the exemplary liquid additive supply device according to one embodiment of the present disclosure. FIG. 4 illustrates an exemplary mounting/demounting detection magnetic body and an exemplary mounting/demounting detection sensor of the liquid additive supply device according to one embodiment of the present disclosure.
[0037] Referring first to FIG. 1 , the washing machine 5 includes a cabinet 30 , a tub 40 , a drum 50 and a detergent dispenser 1 . The washing machine 5 may be a drum type washing machine having a rotatable the drum 50 . However, the washing machine 5 is not limited to any specific type.
[0038] The cabinet 30 includes an exterior housing of the washing machine 5 . The tub 40 , the drum 50 and the like may be installed within the cabinet 30 . The detergent dispenser 1 may be assembled at the top of the cabinet 30 .
[0039] In addition to the tub 40 , the drum 50 and the detergent dispenser 1 , various other components of different functions may be enclosed in the cabinet 30 . For example, in the cabinet 30 , there may be installed a detergent supply pipe (not shown) configured to couple the detergent dispenser 1 to the tub 40 , so that the detergent contained in the detergent dispenser 1 can be carried and dispensed to the tub 40 . An electric motor may be configured to provide power to the drum 50 . A water supply device (not shown) may be used to supply washing water into the tub 40 . A drying device (not shown) may be used to dry the objects (e.g., laundry) inside the tub 40 . A drain device (not shown) may be configured to drain the washing water outside the cabinet 30 .
[0040] The tub 40 has a cylindrical structure used to accommodate washing water. It is horizontally positioned within the cabinet 30 . The tub 40 may receive detergent from the detergent dispenser 1 , may receive washing water from the water supply device. Washing water can be drained from the tub 40 to the outside of the cabinet 30 through the drain device.
[0041] The drum 50 may be rotatably installed inside the tub 40 and coupled to a motor. The drum 50 can contain laundry or other washing objects during operation. The laundry is stirred with the rotation of the drum 50 and washed with the washing water and detergent supplied into the tub 40 .
[0042] The detergent dispenser 1 may include a liquid additive supply device 10 removably coupled to an accommodation part 2 inside the detergent dispenser 1 and a preliminary additive supply device 20 integrally formed with the detergent dispenser 1 .
[0043] Referring to FIGS. 2 to 4 , the liquid additive supply device 10 according to one embodiment of the present disclosure may include: an accommodation part 2 formed in the detergent dispenser 1 ; a main body 100 removably accommodated within the accommodation part 2 and configured to store liquid additive. A mounting/demounting detection magnetic body 200 is installed at the bottom of the main body 100 . A mounting/demounting detection sensor 300 is installed on an outer surface of the main body 100 , facing the mounting/demounting detection magnetic body 200 . The detection sensor 300 is configured to sense the presence or approaching of the mounting/demounting detection magnetic body 200 to generate a sensing signal. A control unit 400 can receive the sensing signal from the mounting/demounting detection sensor 300 and accordingly determine the presence or absence of the main body 100 in the accommodation part 2 .
[0044] A buoyancy body 500 is rotatably and hingedly coupled to the lower portion of the main body 100 and includes a residual amount detection magnetic body 510 for sensing the residual amount of liquid additives, such as liquid detergent or fabric softener. A residual amount detection sensor 600 is installed on the outer surface of the main body 100 in a position facing the buoyancy body 500 . A cover part 700 is configured to selectively cover an upper portion of the main body 100 . A notification device 800 is configured to receive a control signal from the control unit 400 and accordingly notify a user of the presence or absence of the main body 100 in the accommodation part 2 .
[0045] The liquid additive supply device 10 can contain a liquid additive (e.g., liquid detergent or fabric softener) to be supplied into the tub 40 during a washing process. Furthermore, the preliminary additive supply device 20 can contain another additive, for example preliminary additive (e.g., powdery detergent or preliminary fabric softener) to be supplied to the tub 40 during a washing cycle. A preliminary additive may be used when the liquid additive supply device 10 is separated from the accommodation part 2 of the detergent dispenser 1 .
[0046] Since the detergent dispenser 1 extends along the width of the cabinet 30 (e.g., the left-right direction of the cabinet 30 when the washing machine is positioned for operation) at the top of the cabinet 30 , the liquid additive supply device 10 and the preliminary additive supply device 20 have relatively large capacities for a liquid additive and a preliminary additive.
[0047] Hereinafter, descriptions will be made primarily on the liquid additive supply device 10 that is removably accommodated within the accommodation part 2 of the detergent dispenser 1 .
[0048] The main body 100 may include two storages parts, for example a first storage part 110 for containing a first additive (e.g., liquid detergent), and a second storage part 120 for containing a second additive (e.g., fabric softener for example). Hereinafter embodiments are described using a liquid detergent storage part 110 and a fabric softener storage part 120 as example, but the present disclosure is not limited to any specific type of additives that can be added in the storages parts 110 and 120 .
[0049] A nozzle 130 in the main body 100 receives liquid additives from the liquid detergent storage part 110 and the fabric softener storage part 120 and carries the liquid additives upward from the lower portion of the main body 100 to the upper portion thereof.
[0050] In this case, the bottom wall of the main body 100 may be downwardly inclined from a front region (where the liquid additives are supplied) toward a rear region where the nozzle 130 is positioned. In this way, the liquid additives can flow under gravity in the main body 100 , which prevents the liquid additives from sticking to the lower portion of the main body 100 as would occur if the liquid additives remain static.
[0051] A filter 135 having a removable structure may be mounted within the main body 100 . The filter 135 can filter dust or other extraneous material mixed in the liquid additives (e.g., which may be introduced inadvertently or for instance by a child), thereby preventing the nozzle 130 from being clogged by the dust or the extraneous material.
[0052] Thus, the main body 100 may be partitioned into a first main body portion A and a second main body portion B by the filter 135 . More specifically, when viewed from the installation position of the filter 135 (as shown in FIG. 3 ), the second main body portion B refers to a rear region adjoining the nozzle 130 and the first main body portion A refers to a front region opposite to the nozzle 130 .
[0053] The liquid detergent storage part 110 and the fabric softener storage part 120 may be partitioned by a partition wall 115 . Thus, the liquid detergent stored in the liquid detergent storage part 110 and the fabric softener stored in the fabric softener storage part 120 may be used as a main liquid detergent and a main fabric softener, respectively.
[0054] The liquid detergent may be stored in the liquid detergent storage part 110 . In this case, a large amount of liquid detergent capable of performing a washing operation multiple times may be stored in the liquid detergent storage part 110 .
[0055] A liquid detergent residual amount detection buoyancy body 500 a may be installed in a lower portion of the liquid detergent storage part 110 . A liquid detergent residual amount detection magnetic body 510 may be installed within the liquid detergent residual amount detection buoyancy body 500 a and configured to generate a magnetic field.
[0056] The liquid detergent residual amount detection buoyancy body 500 a may be hingedly coupled to one side of the main body 100 through a connecting arm 520 . The liquid detergent residual amount detection buoyancy body 500 a may swing about a hinge by the buoyancy exerted by the liquid detergent contained in the liquid detergent storage part 110 .
[0057] A residual amount detection sensor 600 may be installed on the outer surface of the main body 100 in a position facing the liquid detergent residual amount detection buoyancy body 500 a . In this case, the residual amount detection sensor 600 may be a liquid detergent residual amount detection sensor 600 a (see FIG. 4 ). The liquid detergent residual amount detection sensor 600 a may sense approach of the liquid detergent residual amount detection buoyancy body 500 a . More specifically, the liquid detergent residual amount detection sensor 600 a may sense the magnetic field of the liquid detergent residual amount detection magnetic body 510 that is installed within the liquid detergent residual amount detection buoyancy body 500 a . Thus it can sense the approach of the liquid detergent residual amount detection buoyancy body 500 a without contacting the liquid detergent residual amount detection buoyancy body 500 a.
[0058] Fabric softener may be stored in the fabric softener storage part 120 . A fabric softener residual amount detection buoyancy body 500 b may be installed in a lower portion of the fabric softener storage part 120 . In this regard, a fabric softener residual amount detection magnetic body 510 configured to generate a magnetic field may be installed within the fabric softener residual amount detection buoyancy body 500 b.
[0059] The fabric softener residual amount detection buoyancy body 500 b may be hingedly coupled to one side of the main body 100 through a connecting arm 520 . The fabric softener residual amount detection buoyancy body 500 b may swing about a hinge by the buoyancy exerted by the fabric softener in the fabric softener storage part 120 .
[0060] A residual amount detection sensor 600 may be installed on the outer surface of the main body 100 in a position facing the fabric softener residual amount detection buoyancy body 500 b . In this case, the residual amount detection sensor 600 may be a fabric softener residual amount detection sensor 600 b (see FIG. 4 ). The fabric softener residual amount detection sensor 600 b may sense approach of the fabric softener residual amount detection buoyancy body 500 b . More specifically, the fabric softener residual amount detection sensor 600 b may sense the magnetic field of the fabric softener residual amount detection magnetic body that is installed within the fabric softener residual amount detection buoyancy body 500 b , thereby sensing the approach of the fabric softener residual amount detection buoyancy body 500 b without directly contacting the fabric softener residual amount detection buoyancy body 500 b.
[0061] Thus, if the liquid detergent storage part 110 and the fabric softener storage part 120 contain sufficient liquid detergent and fabric softener, the liquid detergent residual amount detection buoyancy body 500 a and the fabric softener residual amount detection buoyancy body 500 b swing upward and away from the bottom of the main body 100 by a certain distance. Consequently, the intensity of the magnetic field sensed by the residual amount detection sensors 600 a and 600 b becomes smaller.
[0062] In this configuration, based on the sensing signals transmitted from the residual amount detection sensors 600 a and 600 b , it can be determined whether there are sufficient liquid detergent and/or fabric softener in their respective storage parts 110 and 120 . Furthermore, a user interface device such as a display device or a buzzer device can be used to notify a user of the respective levels of the liquid additives in the storage parts 110 and 120 .
[0063] On the other hand, if the residual amount of the liquid detergent and/or the fabric softener in the liquid detergent storage part 110 and the fabric softener storage part 120 are insufficient, the liquid detergent residual amount detection buoyancy body 500 a and/or the fabric softener residual amount detection buoyancy body 500 b move toward the liquid detergent residual amount detection sensor 600 a and the fabric softener residual amount detection sensor 600 b . As a result, the intensity of the magnetic field sensed by the liquid detergent residual amount detection sensor 600 a and the fabric softener residual amount detection sensor 600 b becomes larger.
[0064] Thus, based on the sensing signals transmitted from the residual amount detection sensors 600 a and 600 b , it can be determined that liquid additives in the liquid detergent storage part 110 and/or the fabric softener storage part 120 are deficient. Furthermore, a control signal can be generated and used to enable the notification device (such as a display device or a buzzer device) to notify a user of the shortage of either or both types of liquid additives.
[0065] In general, a larger amount of liquid detergent is used than fabric softener during washing. Thus, the height of the liquid detergent storage part 110 may be configured larger than the height of the fabric softener storage part 120 . In other words, the liquid detergent storage part 110 may be larger than the fabric softener storage part 120 . However, this discussion is nothing more than one example and may be modified without departing from the scope of the present disclosure.
[0066] The nozzle 130 may be installed in each of the liquid detergent storage part 110 and the fabric softener storage part 120 . One open end of the nozzle 130 may be disposed adjacent to the bottom surface of the main body 100 (e.g., the second main body portion B). The other end of the nozzle 130 may be coupled to a suction pump (not shown) installed separately. During a washing operation, the liquid additives may be carried upward from the lower portion of the main body 100 through the nozzle 130 . Thus, even if the main body 100 is separated from the accommodation part 2 of the detergent dispenser 1 , the liquid additives stored in the main body 100 do not flow outward.
[0067] A mounting/demounting detection magnetic body 200 may be installed on the bottom surface of the main body 100 (e.g., the first main body portion A) in the front region of the main body 100 where the liquid additives are supplied. In this case, the mounting/demounting detection magnetic body 200 may be installed within a groove portion having a height capable of covering the thickness of the mounting/demounting detection magnetic body 200 . Even when the mounting/demounting detection magnetic body 200 is installed on the bottom surface of the main body 100 , the main body 100 may be easily accommodated within the accommodation part 2 . For example, the mounting/demounting detection magnetic body 200 may be a permanent magnet or an electromagnet.
[0068] The mounting/demounting detection sensor 300 may be installed at the accommodation part 2 in a position facing the mounting/demounting detection magnetic body 200 . The mounting/demounting detection sensor 300 may sense the magnetic field of the mounting/demounting detection magnetic body 200 and accordingly generate a sensing signal. The sensing signal is transmitted to the control unit 400 . In this case, the sensing signal generated by the mounting/demounting detection sensor 300 may be an “on”-signal which indicates that the main body 100 is accommodated within the accommodation part 2 . Alternatively, the sensing signal may be an “off”-signal which indicates that the main body 100 is not within the accommodation part 2 .
[0069] Based on the sensing signals transmitted from the mounting/demounting detection sensor 300 , the liquid detergent residual amount detection sensor 600 a and the fabric softener residual amount detection sensor 600 b , the control unit 400 can determine the presence (or absence) of the main body 100 in the accommodation part 2 and the sufficiency (or insufficiency) of the liquid detergent and/or the fabric softener stored in the main body 100 . Based on such a determination, the notification device 800 may operate to notify a user of the presence of the main body 100 in the accommodation part 2 and the sufficiency of the liquid detergent or the fabric softener left in the main body 100 .
[0070] More specifically, if the main body 100 is accommodated within the accommodation part 2 , the control unit 400 may receive from the mounting/demounting detection sensor 300 an “on”-signal which indicates that the main body 100 is present within the accommodation part 2 . If the main body 100 is removed from the accommodation part 2 , the control unit 400 may receive from the mounting/demounting detection sensor 300 an “off”-signal which indicates that the main body 100 is not located within the accommodation part 2 .
[0071] The cover part 700 may selectively cover the upper portion of the main body 100 . The cover part 700 may include: a main cover 710 provided with a knob portion having a knob groove 714 and a detergent supply portion for supplying the liquid additives; a liquid detergent supply hole 720 in the detergent supply portion of the main cover 710 and configured to supply the liquid detergent; a fabric softener supply hole 730 in the detergent supply portion of the main cover 710 and configured to supply the fabric softener; and an auxiliary cover 740 coupled to the main cover 710 and configured to open or close the liquid detergent supply hole 720 and the fabric softener supply hole 730 . The fabric softener supply hole 730 is spaced apart from the liquid detergent supply hole 720 .
[0072] As the liquid detergent storage part 110 and the fabric softener storage part 120 are covered by the cover part 700 , dust or the like can be prevented from entering the storage parts 110 and 120 . This can also prevent a user from putting extraneous material into the storage parts 110 a and 120 .
[0073] Furthermore, a user may easily remove the main body 100 from the accommodation part 2 using the knob groove 714 in the cover part 700 . It can prevent the liquid additives from overflowing from the main body 100 when the main body is removed 100 from the accommodation part 2 , e.g., by a user.
[0074] Hereinafter, the operation and function of the liquid additive supply device 10 according to one embodiment of the present disclosure will be described with reference to FIG. 5 .
[0075] FIG. 5 illustrates the configuration of an exemplary liquid additive supply device according to one embodiment of the present disclosure.
[0076] Referring to FIG. 5 , if a user inserts the main body 100 into the accommodation part 2 of the detergent dispenser 1 , the mounting/demounting detection magnetic body 200 and the mounting/demounting detection sensor 300 are in close proximity with each other. Thus, the magnetic field of the mounting/demounting detection magnetic body 200 may be sensed by the mounting/demounting detection sensor 300 . At this time, based on the intensity of the magnetic field thus sensed, the mounting/demounting detection sensor 300 may generate a sensing signal (e.g., an “on”-signal) which indicates that the main body 100 is within the accommodation part 2 of the detergent dispenser 1 . The mounting/demounting detection sensor 300 may then transmit the sensing signal to the control unit 400 .
[0077] Accordingly, the control unit 400 may generate a control signal for controlling the notification device 800 such as a display device 810 , a buzzer device 820 or the like. Through the notification by the notification device 800 , a user may recognize the presence of the main body 100 within the accommodation part 2 . At this time, the control unit 400 may control the operation of either or both of the display device 810 or the buzzer device 820 .
[0078] On the other hand, if the main body 100 has been removed from the accommodation part 2 of the detergent dispenser 1 , the mounting/demounting detection sensor 300 cannot sense the magnetic field of the mounting/demounting detection magnetic body 200 . Thus, the mounting/demounting detection sensor 300 may generate a sensing signal (e.g., an off-signal) which indicates the absence of the main body 100 in the accommodation part 2 . The control unit 400 may then receive the sensing signal and may operate the notification device 800 such as the display device 810 or the buzzer device 820 , thereby notifying a user of the fact that the main body 100 does not exist within the accommodation part 2 . At this time, the control unit 400 may control the operation of either or both of the display device 810 or the buzzer device 8200 .
[0079] In this case, the control unit 400 may issue a washing process suspension command to stop a washing process or prevent the start of a washing process. However, this is nothing more than one example. The control unit 400 may issue a command to enable a washing process to be performed using powdery detergent and fabric softener contained in the preliminary additive supply device 20 . Accordingly, a user can determine, without having to visually or otherwise directly check, the existence of the main body 100 within the accommodation part 2 of the detergent dispenser 1 .
[0080] In addition, if the liquid detergent and/or the fabric softener are sufficiently stored in the liquid detergent storage part 110 and the fabric softener storage part 120 , the liquid detergent residual amount detection buoyancy body 500 a and the fabric softener residual amount detection buoyancy body 500 b swing upward by the buoyancy force of the liquid detergent and the fabric softener and so are lifted away from the lower portion of the main body 100 by a predetermined distance. Thus, the intensity of the magnetic field sensed by the liquid detergent residual amount detection sensor 600 a and the fabric softener residual amount detection sensor 600 b becomes smaller.
[0081] At this time, based on the sensing signal transmitted from the liquid detergent residual amount detection sensor 600 a and the fabric softener residual amount detection sensor 600 b , the control unit 400 may determine that liquid detergent and/or fabric softener are sufficiently stored in the liquid detergent storage part 110 and the fabric softener storage part 120 .
[0082] On the other hand, if the residual amount of the liquid detergent and/or the fabric softener remaining in their respective storage parts 110 and 120 is insufficient, the liquid detergent residual amount detection buoyancy body 500 a and/or the fabric softener residual amount detection buoyancy body 500 b move toward the liquid detergent residual amount detection sensor 600 a and the fabric softener residual amount detection sensor 600 b . Consequently, the intensity of the magnetic field sensed by the liquid detergent residual amount detection sensor 600 a and/or the fabric softener residual amount detection sensor 600 b becomes larger.
[0083] Based on the sensing signals transmitted from the liquid detergent residual amount detection sensor 600 a and the fabric softener residual amount detection sensor 600 b , the control unit 400 may determine that the liquid detergent and the fabric softener stored in the liquid detergent storage part 110 and the fabric softener storage part 120 are insufficient. The control unit 400 may notify a user of the shortage of the liquid detergent and the fabric softener through the notification device 800 such as the display device 810 or the buzzer device 820 .
[0084] According to the embodiment of the present disclosure described above, a user can easily mount a liquid additive supply device to or demount it from an accommodation part in a detergent dispenser.
[0085] Reference has been made in detail to the preferred embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. While the disclosure is described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the disclosure to these embodiments. On the contrary, the disclosure is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the disclosure as defined by the appended claims. Furthermore, in the detailed description of embodiments of the present disclosure, numerous specific details have been set forth in order to provide a thorough understanding of the present disclosure. However, it will be recognized by one of ordinary skill in the art that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the embodiments of the present disclosure. The drawings showing embodiments of the disclosure are semi-diagrammatic and not to scale and, particularly, some of the dimensions are for the clarity of presentation and are shown exaggerated in the drawing Figures. Similarly, although the views in the drawings for the ease of description generally show similar orientations, this depiction in the Figures is arbitrary for the most part. Generally, the disclosure can be operated in any orientation.
[0086] Although certain preferred embodiments and methods have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such embodiments and methods may be made without departing from the spirit and scope of the disclosure. It is intended that the disclosure shall be limited only to the extent required by the appended claims and the rules and principles of applicable law. | A liquid additive supplying device in a washing machine. The liquid additive supplying device is removably accommodated in an accommodation part of the detergent dispenser system of the washing machine. A magnetic body and a magnetic sensor in the liquid additive supplying device interplay to detect the presence of the liquid additive supplying device within the accommodation part. The liquid additive supplying device includes another pair of magnetic body and magnetic sensor for detecting the amount of liquid additive contained therein. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to a process for preparing a non-woven fabric having a surface covered with microfiber that can advantageously be used to produce cleaning cloths and mops. In particular, the present invention relates to a process for preparing “double layer” composite textile materials formed by a microfiber surface layer and a non-woven fabric supporting layer.
BACKGROUND OF THE INVENTION
[0002] There are known procedures for the production of non-woven fabrics produced with mechanical needle-punching and spunlace or hydroentangled technologies and/or optionally subsequently bonded by means of thermal bonding of thermoplastic fibers and/or by adding resins or latexes in general.
[0003] These non-woven fabrics are used to produce cleaning cloths or to produce mops. According to prior art techniques to produce needle-punched non-woven felts with mechanical needle-punching systems, these felts are optimally used to produce cleaning cloths, and have the advantage of having a low density and consequently a relatively high volume with respect to the weight per square meter. Moreover, regardless of the type of fibers used, their mass creates a mechanical volume that increases their absorption capacity. Their volumetric mass with low weight density per cm 3 also allows the production of articles such as mops or swabs that must have a volume in addition to a cleaning surface. Cloths obtained with this process are formed by fibers with a fineness greater than 1 dtex (macrofibers) and are produced by subjecting both surfaces of the fiber layer to mechanical needle-punching, optionally followed by a thermal bonding process to increase the mechanical consistency of the cloth, or using chemical binders such as acrylic resins, EVA, rubber latexes and the like by means of spray application, impregnation using padding machines or by coating or the like according to prior art. The disadvantage of this type of technology if used to produce microfiber non-woven fabrics is that the majority of the fibers remain inside the thickness of the non-woven fabric and accordingly their cleaning capacity is not used: therefore costs are also higher due to the use of microfibers for the whole thickness of the non-woven fabric structure.
[0004] With another prior art technique, known as spunlace or hydroentangled, non-woven fabrics are produced with a higher weight density, generally greater than 0.16 g/cm 3 , with respect to those produced through the mechanical needle-punching process: these fabrics have the characteristic of greater compactness and low thickness with respect to non-woven fabrics produced with mechanical needle-punching systems having the same basis weight per square meter and the same fiber composition. Said process is generally used to produce microfiber non-woven fabrics as it also splits the splittable microfiber into filaments: it is performed on both surfaces of a mat of extruded continuous filaments deriving from microfibers coming from production systems using spunbonded and/or meltblow technologies or from staple fiber mats coming from carding systems.
[0005] The drawback of this production process is that to obtain a thickness that is sufficiently high to allow easy handling for use as cleaning cloths, or to produce strip mops, the weight per square meter of the product must be greatly increased, thus increasing costs due to the quantity of fibers used. Moreover, increasing the weight of the product in this way leads to high production costs, as high pressure water jets are required during the hydroentanglement process to achieve bonding of the fibers inside the layer of non-woven fabric.
[0006] Another type of non-woven fabric is represented by microfiber and macrofiber bonded materials produced by thermal bonding of a microfiber layer with a macrofiber layer, optionally subsequently calendering the double layer thus obtained, where each layer has been prepared previously according to the techniques described above. However, this thermal process is costly from the viewpoint of energy and due to the use of hot melt glues which are required to allow adhesion of the two different layers.
SUMMARY OF THE INVENTION
[0007] The object of the present invention is to produce a non-woven fabric for cleaning cloths using a process capable of solving and overcoming all the aforesaid drawbacks of prior art.
[0008] A further object is that of providing a process of this type that can also be used to obtain a double-layer textile material in which the layers have very different unit weights or densities from each other, guaranteeing sufficient mechanical consistency of the material without macrofiber impurities on the microfiber surface.
[0009] Yet another object of the present invention is to provide a process to obtain a double-layer textile material in which the microfiber layer is thin without decreasing the cleaning power of the non-woven fabric.
[0010] These objects are achieved by a process in accordance with the invention having the characteristics listed in the appended independent claim 1 .
[0011] Advantageous embodiments of the invention are apparent from the dependent claims. The present invention relates to a process for preparing a non-woven fabric material, where a supporting layer is bonded with a microfiber cleaning layer, comprising:
[0000] (a) needle-punching of a mat formed by at least one layer of carded web of macrofibers and at least one layer of carded web of microfibers, and
(b) treatment of the needle-punched mat by means of spunlace/hydroentangled technology with high pressure water jets to split the microfibers into filaments.
[0012] The needle-punching (a) and the subsequent treatment (b) are performed and applied from the same side and, i.e. only on the free side (i.e. the side not in contact with the microfibers) of the microfiber layer of the bonded non-woven fabric material.
[0013] The macrofiber layer to be used in step (a) can be pre-needled, needle-punched or even only constituted by a plurality of folded or carded webs. The effect of the use of the macrofiber layer is achieved provided that a microfiber web layer is deposited over said macrofiber layer and that subsequent needle-punching (a) is performed only from this microfiber side.
[0014] In practice, the first mechanical needle-punching step produces a non-woven fabric, which is used as base for application to one of the two surfaces of a splittable fiber web, in this case splittable microfibers and, again with the prior art mechanical needle-punching technique, this surface web of fibers is entangled to take, through mechanical action, the fibrils of the microfiber inside the lower layer of non-woven fabric so as to cover one of the two surfaces and to bond the two layers of non-woven fabric though entanglement of the fibrils of the surface layer with those of the layer below. In this manner, the fibril is given its direction by the needle that conveys it inside the lower supporting layer, without contaminating the microfiber layer with less prestigious macrofibers, which instead would occur in the case of bonding only using mechanical needle-punching, as in the art needle-punching is also performed on the other side (lower) of the material. Following this operation, surface bonding is applied using the prior art technique of hydroentanglement, again only from one side on which the microfibers have been deposited so as to entangle the fibres of the surface and in the case of microfibers, also to split the fibrils so as to produce microfibers as a result of hydroentanglement.
[0015] The non-woven fabric thus produced can be used as is, or can be subsequently dyed and/or coated on one or both sides and/or printed, to produce dry and/or moistened cloths for cleaning, to produce mops or for uses in the medical sector, where fabrics with different densities and compositions are required, and in all those applications that require the efficacy of microfiber which, due to the physical structure of the fibers of which it is composed, removes dirt very effectively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Reference shall now be made to the accompanying FIGS. 1 and 2 , which represent schematically in cross section, respectively the textile material before step (a) and after the process in order to better illustrate the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The term “bonded material” 100 , illustrated in FIG. 2 , is intended herein to identify a material composed of two superimposed layers 1 and 2 formed by different fibers that have been subjected to processing through which they have been mutually bonded. The mechanical needle-punching step (a) is carried out according to prior art.
[0018] The treatment with high pressure water jets used in step (b) of the present process is a technology known in the art also called spunlacing or hydroentangling. See for example U.S. Pat. No. 3,485,706, or the description of patent application EP 1359241 incorporated herein by reference.
[0019] The non-woven fabric 100 is prepared according to the following procedure: the fibres constituting the supporting layer 2 , having deniers greater than 1 dtex (illustrated with a light line), are fed on a conveyor belt from a first carding system. The fibers of said supporting layer 2 are then bonded, for example with water jets or mechanical needle-punching, as in the carded web the fibers are maintained joined through mutual bonding but break up and separate if subjected to traction.
[0020] The splittable microfiber fibers (illustrated with a heavy line) are fed from a second carding system in the form of one or more air-formed webs, on top of the free surface of the previously formed macrofiber supporting layer 2 . By means of the needle-punching operation (a) of the mat formed by two layers 1 and 2 which is positioned on the conveyor belt, part of the microfibers of the upper layer 1 are driven and bonded with part of the macrofibers of the lower layer 2 , as illustrated in FIG. 2 . In this way part of the microfiber fibers of the layer 1 are bonded with part of the fibers of the lower supporting layer 2 below as the needle drives the fibrils 3 from the upper layer 1 to the lower layer 2 for the entire depth (thickness) of the material (mat) creating a coupling point between the two layers as shown in FIG. 2 .
[0021] Then, by means of a device with high pressure water jets, pressure is applied to the free surface of the upper layer 1 of the mat 100 along the lines of the nozzles to perform step (b); said lines represent longitudinal bonding lines along which the microfibers are bonded to a greater degree with the macrofibers below. In this bonding operation final entanglement of the microfibers occurs, with formation of the cleaning layer fixed to the supporting layer, at said longitudinal bonding lines, preferably spaced apart from one another so that they are alternated. Along said lines the fibres are more compressed due to the water jet and therefore, when the lines are spaced apart, the microfiber surface has embossments or micro-embossments (illustrated in FIG. 2 without reference numeral) alternated with said lines that represent grooves. In this step (b) very fine water jets are used with pressures up to 80/400 bar produced by hydraulic injectors (or spray nozzles) distributed in various ways, mutually adjacent and in contact with one another, or suitable spaced apart so as to create different paths. In practice the high energy of the water jets is transferred to the fibers, bonding them. Subsequently, the bonded material obtained is air-dried and wound on a reel or can be coated with resins, preferably acrylic resins, on the macrofiber side to obtain fabrics with one side similar to chamois leather, which are very effective for cleaning glass.
[0022] Macrofibers can be used as fibers for the lower layer 2 , with the same or different density, made of viscose, polypropylene, nylon, rayon, cellulose, mixed viscose and polyester, cotton and the like, or alternatively, of regenerated or recycled materials, for example 100% recycled PET, or of a mixture of 70% regenerated cellulose fibres and 30% recycled PET fibres. A preferred composition of macrofibers contains 70% of viscose and 30% of polyester, or a 50/50 mixture of viscose/polyester.
[0023] The unit weight of the macrofiber layer 2 can range from 50 g/m 2 to 300 g/m 2 , preferably greater than 100 g/m 2 , for example comprised between 180 and 280 g/m 2 , more preferably comprised between 200 and 250 g/m 2 . It is understood that macrofibers with greater unit weight, such as 400 g/m 2 , could also be used without departing from the spirit of the present invention.
[0024] The fibers of the microfiber layer 1 are, as stated, preferably splittable fibers formed, for example, by polyester/polyamide, having deniers of around 1-2 Dtex before being split and capable of generating microfilaments (multi filaments) having deniers below 1 Dtex. This microfiber can have a unit weight similar to that of the macrofiber layer 2 or lower, preferably lower, for example comprised between 40-70 g/m 2 .
[0025] A preferred embodiment of the textile material obtained by the present process provides a microfiber layer 1 with unit weight comprised between 60-70 g/m 2 and a non-woven fabric macrofiber layer 2 with unit weight comprised between 200 and 250 g/m 2 .
[0026] The total thickness of the textile material and/or of its single layers is not binding for the purposes of the present invention. For example, to produce mops, a non-woven fabric with total thickness from 1 mm to 3 mm and with a thickness of the microfiber layer from 0.3 mm to 1 mm can be used.
[0027] Numerous advantages can be achieved due to the present process. In fact, it is possible to use a microfiber with low unit weight as the mechanical resistance of the material is given by the less prestigious macrofiber layer 2 , thus using a smaller quantity of microfiber with consequent reduction of costs. Moreover, an economic saving is obtained with respect both to the thermal bonding process and to a conventional spunlace process, as due to the initial bonding performed with mechanical needle-punching, lower water pressures can be used.
[0028] Moreover, the presence of embossments on the microfiber surface provides an improved cleaning power with respect to conventional microfiber cloths as it is even rougher and more abrasive with a “spatula” effect that allows more effective removal of dirt and grease with respect to conventional microfiber cloths.
[0029] The materials obtainable from the present process can be used as non-woven fabric to produce cleaning devices and/or medical textiles, for example to produce mops, conventional floor cloths, cloths for glass and for any other type of surface, sponges, dry and/or moistened cloths for cleaning, or cloths for use in the medical sector where fabrics with different densities and compositions are required, and in all those applications in which the efficacy of microfiber is required.
[0030] In practice the non-woven fabric material 100 formed by a microfiber cleaning layer 1 and a macrofiber supporting layer 2 , wherein said layers are bonded by needle-punching and subsequent treatment of the microfiber surface with high pressure water jets, and provided with the technical characteristics described above, such as thickness, total unit weight or weight of the single layer, materials, the presence of embossments, etc., is particularly suitable for producing cleaning devices and/or medical textiles, said material being preferably obtainable from the process as described above.
[0031] Numerous modifications and variations of detail within the range of those skilled in the art could be made to the present embodiment of the invention, all however falling within the scope of the invention expressed by the appended claims. | There is described a process for preparing a “double layer” non-woven fabric having a non-woven fabric surface covered with microfiber including needle-punching of a mat formed by at least one carded web of macrofibers and at least one carded web of microfibers and subsequent treatment of the mat with high pressure water jets to split the microfibers into filaments | 3 |
FIELD OF THE INVENTION
[0001] The invention relates to a textile machine, especially a spinning preparation machine with a drafting device. The drafting device has several drive disks for driving machine elements, especially drafting device rollers, and has at least one endless belt surrounding at least two drive disks.
BACKGROUND OF THE INVENTION
[0002] Textile machines that employ drafting devices are widely known. Three roller pairs are provided in drafting frame RSB-D 35 of the Rieter company that have a circumferential speed that increases from the entrance of the drafting device to the exit of the drafting device. The particular lower roller of the drafting device rollers is driven by flat belts for producing a drive that is as slippage-free as possible to provide for an orderly drafting of the slivers [slubbing]. The upper rollers are pressed against the lower rollers, thus clamping the yarn [fiber] material running through between them.
[0003] It turned out that flat belts have many advantages over the earlier toothed-type belts still frequently used at times but that an undesired elongation slippage can result due to the relatively high elasticity of the flat belt. This springiness of the flat belt occurs in particular during a dynamic change of speed so that errors result in the transfer behavior. In addition, a re-adjustment must be performed in the case of an irreversible elongation and the sliding slippage produced as a consequence thereof. In contrast thereto, toothed-type belts, that, in addition, are relatively easy to manipulate, have less of a tendency to slip but have the disadvantage that that they run unevenly when contaminated. In addition, toothed-type belts exhibit the so-called polygon effect in which knocks occur due to the teeth folding into the gaps between the teeth. One other disadvantage is the fact that no continuous translation change is possible with toothed-type belts.
SUMMARY OF THE INVENTION
[0004] It is therefore a principal purpose of the present invention to create an improved drive for drive disks in a textile machine. Additional advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
[0005] This principal purpose is solved for a textile machine by a belt comprising at least two longitudinal ribs on one side that are received in corresponding longitudinal grooves of at least one drive disk that are on the circumferential side and run in the circumferential direction.
[0006] Several advantages result from using a belt longitudinally profiled with ribs and grooves in accordance with the invention. One advantage is the fact that the belt is guided more precisely in the longitudinal direction in comparison to a flat belt due to its rib-and-groove structure. A centered belt course is always guaranteed by means of the at least two longitudinal ribs. Therefore, the use of such a belt is also possible in the case of not absolutely parallel shafts [axes]. In addition, no periodic errors occur in the case of contamination in comparison to a toothed-type belt with its transverse grooves. Also, no polygon effect disturbs the even running, as is the case for toothed-type belts. Therefore, greater dynamics with better transfer properties can also be achieved with the belts exhibiting the longitudinal rib-and-groove structure.
[0007] On the whole, a very even, almost oscillation-free running can be achieved in contrast to toothed-type belts. Moreover, the stiffness of such a belt and its modulus of elasticity are greater than in a flat belt, so that a more precise transfer behavior results, especially in the case of dynamic changes of speed. Thus, a more favorable dynamic behavior can be achieved at such changes of speed with the belt in accordance with the invention.
[0008] Furthermore, a continuous translation change is possible when using the cited belt in accordance with the invention, which is a serious disadvantage with toothed-type belts in particular.
[0009] Also, greater translation conditions [ratios] and greater belt speeds can be achieved with the drive of the invention compared to the previously used belts, e.g., belt speeds of 60 m/s. Since the contact surface is greater due to the longitudinal profiling compared to a flat belt with the same belt width, on the whole greater performances [power] can be transferred. In this manner, very high speeds of the drive disks and therewith in particular of the drafting device rollers can be achieved so that sliver delivery speeds of distinctly more than 1000 m/min with a high degree of precision of the drafted sliver are possible.
[0010] Another advantage over traditional toothed-type belts is the fact that the use of belts with rib-and-groove structure in accordance with the invention makes possible crossed or bent belt drives in which the axes of two looped drive disks do not run parallel to or at 90° to one another. This significantly increases the structural play during the construction of the machine.
[0011] Further, the circumferentially running grooves of the drive disks can be produced relatively simply by turning using a shaping chisel with any desired diameter. Turning has the additional advantage that no graduation with a fixed number of teeth (as in the case of a toothed-type belt) is necessary. The forming of running grooves of the drive disks is simpler and easier as compared to creating recesses in the drive disk use with tooth-type belt, whereby, the recesses of the drive disks for toothed-type belts must be laboriously milled or tapped.
[0012] The ribbed belt comprises in an especially preferred manner more than two longitudinal ribs running parallel to each other. The plurality of ribs with longitudinal grooves arranged between them assure on the one hand a uniform distribution of force over the entire belt width and on the other hand guarantee an especially good frictional connection.
[0013] The at least two longitudinal ribs can be designed in a wedge shape [V-shape] in an advantageous embodiment. This results in a wedge-rib [V-ribbed] belt known from other areas of application that has an extremely high flexibility so that great translation ratios can be achieved even with very small drive disks (e.g., 1:40). Also, great counterflections can be achieved with such a belt so that a versatile use with a low space requirement is possible.
[0014] The side of the belt opposite the ribs and grooves can be designed in various manners. In one variant, this opposite side is designed to be flat, so that during the deflection of the belt this flat side runs on a drive disk. This drive disk can have either the cited rib-and-groove profiling in the longitudinal direction or a smooth surface or even a toothed profile.
[0015] Alternatively, for example, the belt may also have a profile on its side facing away from the longitudinal ribs, which has at least two longitudinal ribs, or the belt may have a profile with transverse ribs, that is, a tooth profile. In the first-cited instance of a double profiling with longitudinal ribs, the front and the back side of the belt can be used in accordance with the invention, which is especially advantageous given differences in the direction of rotation of two shafts.
[0016] A cleaning effect of the belt can be achieved in the case of a profiling on only one side as well as one on both sides by deflection on both sides, a suitable looping angle and by a differing flexion, so that the dirt can fall out of the grooves and does not settle on the surfaces of the drive disks.
[0017] Cleaning devices, e.g., permanently arranged brushing-off devices or nozzles with a blowing pulse can be used to clean the belt grooves and/or the drive disks.
[0018] Several driven disks can be simultaneously driven with particular preference by a drive disk through the means of the rib belt or wedge-rib belt. This possibility results from the fact that greater performances can be transferred in comparison to flat belts. Thus, one drive shaft and several driven shafts can be arranged on one belt line. The intermediate shafts required in the state of the art can be eliminated. The number of belts and, in particular, the number of shafts and supports can thus be reduced in comparison to the known, comparable textile machines, which can lower expenses. Also, on the whole smaller masses to be driven result, so that the massive inertias are also smaller and therefore greater machine dynamics can be achieved. In addition, only the one belt needs to be slackened if several change gears are to be replaced on this belt line, e.g., for adjusting a different sliver fineness of the drafted material or for adapting the machine to different textile materials. Previously, in order to replace any change gear the associated belt had to be slackened.
[0019] In another aspect of the invention, the textile machine includes a device by means of which the at least one belt can be adjusted independently of its length and the diameter of the at least one looped drive disk to a belt tension that is substantially the same in all instances. In the traditional toothed-type belt drives, the belt tension is adjusted by the operator according to his own judgment or with the aid of an appropriate measuring device to a value that is fixed at first. In the case of known flat belts, their theoretical tension can be fixed with the aid of a clamping screw arranged on a tensioning lever. A tensioning or deflection roller for the flat belt is arranged on the spring-loaded tensioning lever. Thus, even the tensioning roller is held in its place by fixing the clamping screw. If the flat belt or the previously cited toothed-type belt expands in a non-elastic manner, the belt tension is reduced; so that it must be readjusted by the user. A different spring may have to be used during a replacement of the drive disk by a drive disk with a different circumference.
[0020] In contrast thereto, in the cited aspect of the invention, the belt tension adjusts itself to a value that is substantially the same in all instances without the user actively adjusting the belt tension by using force or the like, so the expense for maintenance and replacement is reduced. The belt tension can adjust itself in this instance to the predetermined value independently of the size of the drive disk or the length of the belt used. Measurement of the belt tension and an unclear reliance on values gained from experience are no longer necessary.
[0021] To this end, the device comprises in an especially preferably manner at least one movably mounted tensioning roller or deflection roller for belt tensioning that is force-loaded and thus correspondingly tensions the belt to the predetermined force without the user having to intervene. To this end, the tensioning roller is mounted, e.g., in a linearly guided carriage on which the force is to be applied by the device. In this manner, a predetermined belt tension can be realized even with different change gear diameters or when adjusting different roller settings. The belt tension adjusts itself in the case of different diameters of change drive disks or the case of belts with different lengths by shifting the tensioning roller to a constant value when the looping angle (engagement angle) of the belt around the tensioning roller is approximately 180° according to a preferred embodiment. If this angle number is deviated from, the belt tension for change gears with a different diameter assumes different values. However, these different values can be in the tolerated range, depending on the area of application. Thus, it is possible that looping angle is in a range between approximately 170° and 190° or also in a range between 160° and 200°.
[0022] The cited tensioning roller is preferably loaded directly or indirectly with a spring force that is preferably applied by a gas spring. A gas spring has the particular advantage that the force-path characteristic curve runs approximately horizontally, so that, in the case of the cited looping angle of approximately 180°, a constant belt tension can be adjusted even given different deflections of the tensioning roller due to, e.g., belt expansion or after a replacement of drive disks with different diameters.
[0023] In addition, if the gas spring is advantageously provided with a damping, oscillations of the at least one belt during the operation of the machine can be largely prevented.
[0024] In an alternative advantageous embodiment, the tensioning roller can be fixed in its position by a fixing device in order to avoid oscillations during operation here too. The fixing device, e.g., a clamping screw, can act on the above-cited carriage to this end in accordance with the embodiment, thereby fixing it in its position. Loosening the fixing device brings the belt to the predetermined tension on account of the loading of force that is then active, so that subsequently only the fixing device must be reactivated. The operator, therefore, does not have to re-tension the belt himself. During a replacement of one drive disk by a drive disk with a different diameter, the looping of the tensioning roller with a looping angle of approximately 180° thus makes possible a rapid and automatic belt tensioning up to the loosening and re-fixing of the fixing device.
[0025] Alternatively, the belt tension can also be constantly tensioned continuously, that is, without a fixing in place of the tensioning roller, during the operation of the machine. An example of such a constant and continuous tensioning is the above-cited gas spring with damping. A constant compensation of the longitudinal tolerance of the belt is achieved therewith. Also, the service life of the belt is increased by the continuous adjusting of the optimum tension. Thus, in this embodiment, no fixing device is necessary.
[0026] Advantageous further developments of the invention are described further in the following description.
[0027] The invention is explained in detail in the following with reference made to the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 shows a transmission plan of a drafting frame;
[0029] FIG. 2 shows a drive disk with a wedge-rib belt in a sectional view;
[0030] FIG. 3 shows a bent section of a wedge-rib belt in a cross-sectional view;
[0031] FIG. 4 shows a belt with a wedge-rib profile on both running-surface sides in a cross-sectional view;
[0032] FIG. 5 shows a belt with a wedge-rib profile on the one running-surface side and with a toothed profile on the other running-surface side in a cross-sectional view; and
[0033] FIG. 6 shows a schematic view of a device for belt tensioning.
DETAILED DESCRIPTION
[0034] Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are shown in the figures. Each example is provided to explain the invention, and not as a limitation of the invention. In fact, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. It is intended that the present invention cover such modifications and variations.
[0035] A transmission plan of a drafting frame with drafting device 2 is shown in FIG. 1 . The various elements of drafting frame 1 are driven by two motors 3 , 40 . The first motor 3 is provided for driving elements in front of drafting device 2 as well as for driving two front drafting device rollers, whereas the second motor 40 drives the last drafting device roller as well as elements located after drafting device 2 . In order to transfer power from the drive disks onto the driven disks, the invention provides that belts with at least two longitudinal ribs on one running side are at least partially provided.
[0036] The transmission plan of FIG. 1 is explained in detail in the following. The first motor 3 drives drive disk 6 via drive shaft 5 . This drive disk 6 exhibits a rib-and-groove structure in a circumferential direction (see FIG. 2 ). Wedge-rib belt 7 is tensioned via drive disk 6 and drives four driven disks 8 , 14 , 16 , 21 located in front of drafting device 2 . For its part, driven disk 16 drives driven disk 17 via a shaft which disk 17 causes driven disk 19 to rotate via belt 18 . This driven disk 19 drives transport rollers 20 arranged on both sides of it for drawing slivers out of feed cans (not shown). Only the drawing of two slivers from the cans closest to drafting device 2 is shown here; normally, six or eight slivers are drawn off from a corresponding number of feed cans set up in series and in pairs. The two driven disks 14 drive two transport rollers 15 running in the same direction (on which a jockey roller rolls in a known manner), which transport the slivers that have been brought together in the meantime to drafting device 2 .
[0037] The following driven disk 8 drives deflection drive 9 and the correspondingly deflected belt 10 drives the two disks, running in opposite directions, of a known groove-sensing roller pair with the aid of drive disk 12 and belt 11 . With the aid of groove sensing roller pair, the fluctuations in the sliver cross section are determined for being leveled out in drafting device 2 .
[0038] The last driven disk 21 driven by belt 7 is connected via shaft 22 to two driven disks 23 , 26 . The device disk 23 drives lower entrance roller 30 with the aid of belt 24 and another driven disk 25 . The driven disk 26 drives lower middle roller 31 with the aid of another belt 27 and another driven disk 29 . The particular upper rollers (not shown) are cause to rotate by being pressed against lower rollers 30 , 31 .
[0039] The second motor 40 is connected via drive shaft 41 to two drive disks 42 , 51 . Driven disk 42 causes two calander rollers to rotate in opposite directions via belt 43 on the one hand with driven disk 44 for driving lower exit roller 32 and on the other hand with driven disk 45 and with the aid of a known transmission [changeover] 46 (driven here with a toothed belt). The sliver (shown in dotted lines) given off from the exit roller pair with running direction A is transported by calander rollers 48 into sliver conduit 49 arranged in rotary plate 50 and deposited from the latter into rotating can 59 . Calander rollers 48 as well as the can stock together with can 59 are shown tilted in the transmission plan of FIG. 1 by 90° relative to the drafting device.
[0040] Finally, rotary plate 50 is driven via the other drive disk 51 connected to shaft 41 . To this end, belt 52 is looped around drive disk 51 , which belt drives driven shaft 53 and driven disk 54 coupled to it. Driven disk 54 is permanently connected to driven disk 55 that drives the rotary plate via belt 56 . Can plate 58 is driven via driven disk 54 by means of drive 57 in order to selectively cause can 59 to rotate during the filling process.
[0041] FIG. 2 shows cut drive disk 70 in a sectional view. Drive disk 70 includes ribs 71 and grooves 72 running on its circumferential surface in the circumferential direction. Belt ribs 81 of wedge-rib belt 80 engage into disk grooves 72 whereas disk ribs 71 engage into belt grooves 82 . An intermediate space is present between the particular ribs and grooves so that the ribs and grooves contact each other substantially non-positively on their steep flanks.
[0042] FIG. 3 shows a section of wedge-rib belt 80 in a slightly curved form . It is particularly apparent that ribs 81 start from belt back 83 . The running surface 85 facing away from the rib structure is designed in a plane surface. The flat running side 85 can not only drive a drive disk with a smooth circumferential surface, but also, e.g., the flat running side 85 can drive a drive disk having a rib-groove structure in the circumferential direction like drive disk 70 .
[0043] A few or all belts 7 , 18 , 24 , 27 , 43 , 52 in accordance with FIG. 1 can be designed as wedge-rib belts. The correspondingly looped drive disks preferably also have a corresponding rib-groove profiling in the longitudinal direction.
[0044] FIG. 4 shows another embodiment of a belt 180 with longitudinal rib structure 86 , 87 on two sides of the running surface. Both sides of this belt 180 can therefore be used for an optimal driving of appropriately designed drive disks and/or driven disks with ribs and grooves in the circumferential direction.
[0045] Belt 280 in accordance with FIG. 5 comprises longitudinal rib-groove structure 86 on one side of the running surface and toothed profile 89 on the other side of the running surface. In this manner, the belt 280 can be used in machines comprising both drive disks with ribs and grooves running in the circumferential direction as well as drive disks with a toothed profile.
[0046] FIG. 6 shows wedge-rib belt 80 [looped around drive disk 70 and driven disk 75 a and 75 b . A special tensioning device 93 is provided for tensioning belt 80 . Belt 80 is guided by deflection disk 90 and loops around tensioning roller 95 at a looping angle α of approximately 180°. Furthermore, tensioning roller 95 is connected to tensioning lever 96 supported around rotary shaft 98 . The direction of pivoting of tensioning lever 96 is designated with f 2 . Tensioning lever 96 is loaded by a spring, such as gas spring 99 with stamp 99 a . A constant force is applied in direction f 1 on the tensioning lever 96 by the stamp 99 a of gas spring 99 , so that tensioning roller 95 , that is linearly guided (see arrow f 3 ) in carriage 94 , is loaded with a constant force. In this manner, an always constant tension of wedge-rib belt 80 results due to the 180° looping and the use of gas spring 99 . Even in the instance of an irreversible expansion of belt 80 , it is constantly held at the predetermined tension by gas spring 99 .
[0047] In order to avoid any oscillations during operation, carriage 94 (or also tensioning lever 96 ) can be clamped fast by clamping screw 97 or some other fixing device so that tensioning roller 95 is power-loaded except to monitor the tensioning force or for a subsequent tensioning by gas spring 99 . To this end, clamping screw 97 is loosened so that the belt tension can automatically readjust itself, and subsequently clamping screw 97 is retightened.
[0048] If one of driven disks 75 a , 75 b is replaced by the other one, at first the belt tension is reduced by pivoting the tensioning lever 96 . If clamping screw 97 is used, it is also loosened. After having pivoted the tensioning lever 96 back, the same belt tension is then automatically adjusted for the new driven disk 75 a or 75 b by virtue of the power-loading by gas spring 99 as for the replaced drive disk 75 b and 75 a . The clamping screw can subsequently be retightened. Any other manual intervention by the user is unnecessary.
[0049] In another, even simpler embodiment clamping screw 97 is not present. Instead, gas spring 99 is designed to be damped in order to avoid oscillations of belt 80 during operation. The construction is otherwise the same as the one shown in FIG. 4 .
[0050] Looping angle α of 180° does not have to be absolutely maintained if a certain error can be accepted without this resulting in a noticeable or significant loss of quality in the resulting sliver. The belt tension is different at an angle α deviating from 180° when using driven disk 75 a than that when using driven disk 75 b . Looping angle α can be, e.g., between approximately 160° and 200°. For example, in some practical examples, a looping angle of 170° still shows good results.
[0051] The present invention is not limited to the exemplary embodiments shown and described. Modifications within the scope of the patent claims are readily possible. Thus, even other longitudinal rib profiles than the wedge ribs shown can be used. It will be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. | A textile machine, especially a spinning preparation machine, included a drafting device having several drive disks for driving machine elements, especially drafting device rollers. At least one endless belt surrounds at least two of the drive disks. The belt comprises at least two longitudinal ribs on one side that are received in corresponding longitudinal grooves on the circumference side and running in the circumferential direction of at least one drive disk in contact with the endless belt. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a survey system and apparatus for evaluating the results. More particularly, it relates to a remotely accessible system for the collection of employee or non-employee survey responses to quantify various criteria relating to the operation of an organization.
2. Description of the Prior Art
In an increasingly competitive marketplace, business entities strive to improve leadership, quality, customer satisfaction and other criteria that directly or indirectly relate to the ultimate profitability of the enterprise. Empirical evidence has established that business operations that excel in distinct and measurable attributes are far more likely to be profitable in commerce. As an example, the “Baldrige Index” is made up of publicly traded U.S. companies that have received the Malcolm Baldrige National Quality Award during the years 1988 to 1996. The Secretary of Commerce and the National Institute of Standards and Technology (“NIST”) were given the responsibility, under Public Law 100-107, to develop and administer the Award with cooperation and financial support from the private sector. NIST “invested” a hypothetical 1,000 in each of the six whole company winners of the Baldrige Award. The investments were tracked from the first business day of the month following the announcement of award recipients (or the date they began public trading) to Dec. 1, 1997. Adjustments were made for stock splits. Another 1,000 was hypothetically invested in the Standard and Poor's Index 500 (“S&P”) at the same time. NIST found that the group of six outperformed the S&P 500 by more than 2.7 to 1, achieving a 394.5 percent return on investment compared to a 146.9 percent return for the S&P 500. Therefore, it is desirable for an organization to administer periodic assessments of its operations.
The detailed assessment of a business operation is often a difficult, expensive, and time-consuming task. Typically, upper level management may knowingly or inadvertently affect the accurate measure of information gathered for the assessment. Outside consultants are often employed to interview and observe the operation of the enterprise on-site. However, management may wish to influence the data for a number of reasons. Upper level management may be greatly affected by the results of the evaluation and may attempt to direct the outside consultant only to well performing operations, shielding problem areas from discovery. In addition, the outside consultant may interview subordinate employees in the presence of their supervisor. This creates a poor environment for gaining candor from the subordinate employee on potential areas of improvement that are the responsibility of the supervisor.
An evaluation by an outside consultant may require the consultant to travel to different geographical locations to assess a large operation with continuity. The consultant may also require the employee to stop productive work to allow time for the assessment interview. It is time-consuming for an independent consultant to conduct individual employee interviews, record the data, and assemble the information into a useful form. Furthermore, should a business wish to conduct periodic evaluations, there is no guarantee that the same consultant will be available. Therefore, the company cannot be assured that the next independent assessment performed will have the same consistency. Nor is there any assurance that secondary evaluations will produce meaningful results comparable to previous exercises.
Should the company attempt to apply known economic principles to an “in-house” self-assessment, there is the potential that more harm than good may come from the endeavor. Many organizations begin the process of self-assessment with a shallow understanding of the performance criteria sought or the optimal method in which to gather the information. This self-assessment suffers from an inseparable relationship between the company's own evaluator and the upper management that may exert influence, not only on the examinees, but also on the examiner.
Previous attempts have been made to provide business-related surveys such as described in U.S. Pat. No. 5,551,880 to Bonnstetter et al. (the '880 patent) which is incorporated herein by reference. The '880 patent describes a system for predicting the potential success of an individual for a particular job or task. A survey is conducted wherein the employee or potential employee submits information on behavioral and value preferences. The information is then analyzed and compared against standards for behavior and values previously resolved for specific employment. In a preferred embodiment of the '880 patent, the behavior and value questions are administered through software and evaluated via a predetermined algorithm. However, the system analyzes the individual employee and not the business entity as a whole. Nor does the '880 patent describe an independent party to administer the survey to ensure confidentially, honesty, and a full disclosure of the employee's perceptions of the business entity.
Therefore, there is a need in the art for a method and apparatus to provide a reliable self-assessment survey process that can be easily administered and scored with the accuracy and completeness of a well developed written narrative self-assessment.
There is a further need in the art to integrate existing telecommunication technologies to avoid the time and labor intensive ordeal of the paper and pencil process or other traditional means of survey administration. This would allow the database of both individual responses and cumulative data to be completely external to the organization being assessed.
There is a further need in the art to provide confidentiality to organizations and their employees participating in the survey. This provides a distinct opportunity to benchmark the data to industry peers and to provide the objective assurance that all data is accurate and verifiable by a reliable survey administrator organization.
However, in view of the prior art in at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how the identified needs could be fulfilled.
SUMMARY OF THE INVENTION
The present invention solves significant problems in the art by providing a telecommunications infrastructure that supports the efficient, confidential and accurate measure of performance criteria relating to the performance of an organization. A predetermined set of performance criteria are measured by the use of an automated employee and non-employee interview system whereby recorded responses are stored in a database which is utilized for a quantitative evaluation of various aspects of a business enterprise.
The present invention comprises an array of survey questions for evaluating a plurality of predetermined criteria relating to the performance of an organization. A survey administrator controls a data-gathering interface means for employees or non-employees of the business to confidentially record answers to the survey questions. For each individual employee survey, the data-gathering interface records the employee's identification, their job classification and a business identifier. Pertinent data is also collected for each non-employee participating in the survey. The data-gathering interface may comprise an Internet web server, a touch-tone telephone entry system, a paper and pencil system that compiles the answers by scanning them automatically, and other existing or to-be-developed interface means as well. For example, an additional data-gathering interface means could be provided in the form of a personal computer having appropriate software. A respondent could save his or her survey responses on a diskette and mail the diskette to the survey administrator, or email the responses to the survey administrator as an attached file. This would enable a respondent to prepare answers and send them to the survey administrator while the respondent is on a flight, on the road, or otherwise away from a permanent office environment.
The survey administrator maintains a database of the responses to the survey questions and has the ability to archive past response data. The survey administrator then applies a selected formula to the survey data to evaluate the performance of the organization and produces a quantifiable result based on a plurality of business categories.
In a preferred embodiment, an organization wishing to evaluate the performance of various key aspects of its operations selects one or more business performance models. Each business performance model is measured using predetermined questions for employees of the business. A survey administrator performs the administration of the predetermined questions so that confidentially in the interview process insures candid answers to the questions. In one embodiment, responses to the questions are gathered utilizing an Internet web server and are stored either locally on the server or at a remote location for the survey administrator to later compile and analyze. The web server provides the opportunity to quickly and efficiently gather information, particularly where various offices of an organization are separated by substantial geographic distance. The web server also may operate 24 hours per day at relatively low cost and permit a plurality of employees to enter in responses at the same time.
In an alternative embodiment, a telephone system utilizing dual-tone multi-frequency (“DTME”) input provides a means for employees to confidentially record information relating to the performance of a company. The DTMF entry has the advantage of not requiring the employee to have a machine capable of accessing the web server over the Internet. Using DTMF entry, the employee logs on using a code provided by the survey administrator. Once within the telephone system, pre-recorded questions are audibly played to the employee. At the conclusion of each question, the employee is prompted to record their response by depressing numerals on the telephone.
In another embodiment, non-employees participate in the survey as well. However, the questions propounded to non-employees may differ from the questions propounded to employees.
The data is readily compiled into a useable database format. At the conclusion of the data gathering stage, the survey administrator can easily analyze the recorded information and produce a report to the business entity evaluating the entity based on the pre-selected business performance criteria desired. Furthermore, the operation of the invention is highly reproducible and consistent. A baseline assessment can be repeated over time, allowing the organization to track quantifiable results and improvements.
It should be noted that the current invention has a wide range of applications which may include health care accreditation, educational institution assessment, and similar tasks. For example, the current invention may be applied to a Performance-based Organizational Effectiveness & Efficiency Tracking Program (“POET”) wherein the organizational effectiveness and efficiency of child welfare organizations are measured in addition to performance indicators essential to success in a managed care environment.
An advantage of the invention is that a complete assessment of a large corporation may be completed more rapidly and efficiently than using independent consultants that interview onsite. The reduced costs and speed permit a business to conduct more frequent performance evaluations that can be utilized to operate the business more profitably.
Another advantage of the invention is that employees of the business are provided with the opportunity to submit honest and candid answers to potentially sensitive questions. Because the opportunity for external influence to affect the employee's response is curtailed, the final evaluation of the business entity is more likely to uncover problem areas in its operations that may be subsequently improved.
Another advantage of the invention is that the infrastructure of the evaluation is highly consistent over time. This permits the business entity to periodically measure itself against previous assessments.
These and other important objects, advantages, and features of the invention will become clear as this description proceeds.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a diagrammatical view of the survey process according to the invention;
FIG. 2 is a diagrammatical view of an Internet-based method of retrieving and recording employee responses;
FIG. 3 is an illustrative example of a survey question presented to a user from an Internet web server;
FIG. 4 is a diagrammatical view of a telephone-based method of retrieving and recording employee responses; and
FIG. 5 is an illustrative example of an organization's performance scorecard based on the Malcolm Baldrige criteria.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, it will there be seen that the organization subject to the survey is denoted by the reference number 10 as a whole. Virtually all business entities have the following job classifications: executive staff 30 , management staff 40 , support staff 50 , and customer contact staff 60 as integral employee components which support most all business functions of the enterprise. It is each of these job classifications of employees who form the internal pool of respondents of the business entities. The login procedures for these internal respondents will be discussed in more detail later.
In another embodiment of the invention, an external pool of respondents is also included. The external pool of respondents may include consumers, customers or clients of the business entity, i.e., those who are not employees or otherwise a part of the internal group of respondents. The external pool of respondents may also be adjusted as desired to include members of the board of directors or trustees, suppliers or vendors, people who perform outsourced operations, competitors, partners, consultants, or any other relevant external respondent entity. The login procedure for these external respondents is similar to the login procedure for internal respondents, except that said login procedure identifies all members of the external pool of respondents as such and by their specific category such as customer, vendor, or the like. External respondents may also be queried as to their age, frequency of contacts with the business entity, and other information deemed pertinent.
In many organizations there are one or more consultants or holders of other job titles who are on the business premises daily and whom might seem to be employees of the organization even though they are technically independent contractors. There are other jobs as well where the distinction between employee or non-employee may not be easily ascertainable. This invention does not depend upon any legal analysis of who should be considered internal or external to the organization as a matter of legal definition because in some cases a non-employee such as an outside consultant might best be included as a member of the internal pool of respondents for survey purposes. Therefore, for convenience purposes, and not in any strict legal sense, the members of the pool of internal respondents are herein deemed employees of the organization, and the members of the pool of external respondents are herein deemed non-employees of the organization. A survey administrator is free to determine the respective members of the pools of internal and external respondents in any way that best serves the purposes of the survey without regard to strict legal determinations of the legal status of the individual members of either pool.
The system obtains information from individual employees or other respondents regarding their perception of performance criteria existing in the workplace. This is accomplished by utilizing a performance criteria survey. This survey is administered and controlled by a survey administrator denoted 20 . The survey data is obtained by a data-gathering interface 70 . The data-gathering interface may comprise a variety of telecommunication mediums which may include touch-tone telephone systems, hypertext language format (“HTML”) Internet web servers, client-server wide area networks (“WANs”) or local area networks (“LANs”). Data-gathering interface 70 acts as a conduit to receive survey data 90 in response to a plurality of predetermined survey questions. Each question contains several important aspects of a business function linked to vital performance abilities of the organization.
The results of the survey are stored in a database 100 for a baseline analysis of performance criteria and may also be used longitudinally in later intervals of time. Prior survey data from prior years 110 and 120 may be archived by the survey administrator 20 and later utilized as a base-line reference to the current evaluation of the organization. Once a requisite number of respondents or all respondents complete surveys, an analysis 140 is performed on the survey data 90 by the survey administrator 20 and then communicated back to the organization 10 .
FIG. 2 provides an overview of an Internet-based data and tracking system. A remote user terminal 160 accesses an Internet web server 70 through a public switched network (“PSN”) 190 . The survey administrator 20 provides the organization 10 with a series of codes for the login 210 and test administration to begin. Typically, the organization 10 will choose an alphanumeric password of ten digits or less for identification of the organization 10 as a whole. The survey administrator 20 records said password and opens it for usage in protected area of the website. Next the survey administrator 20 assigns a chronological range of numbers sufficient to match the total number of respondent employees or non-employees elected and eligible to sit for the survey. To begin the login 210 process, the respondent accesses the world wide web and web server 70 using its uniform resource locator (“URL”). The URL may be provided as a numerical-based Internet protocol (“IP”) address or may be accessed by a registered domain name via a domain name server (“DNS”).
It should also be noted that alternatives to web-based Internet communications may be employed. The alternatives may include 3270 emulation, VT-100, ASCII or separate client-server applications.
In a preferred embodiment, the first web page that appears offers an overview of the survey system, including its methodology of data collection, processing and aggregation. This page also offers the user a link to proceed directly to the test. When this option is chosen a new screen appears which displays test selection criteria with a sample Likert scale. At the bottom of this screen, the user is prompted to complete three empty fields for password protection entry. The first field is for the business ID 220 password that represents a unique identification of the organization. The second field is for job classification entry 230 that may include coding for employee classifications of executive staff 30 , management staff 40 , support staff 50 or direct customer contact staff 60 . It may also include coding for external respondents, mentioned above, such as customers, suppliers, and the like, and there may be a different code, if desired, for each category of external respondents. The third field is for a unique employee ID 240 that relates to the preset numbers matching the number of employees as indicated above.
Once this information is entered a confirmation process 250 is triggered that compares this keyed-in information to the information on server 70 . If a match is detected the server then determines as at 260 if the user has previously initiated the survey. If the user has previously initiated the survey, a cache 280 record of the user's answers is accessed and the user is only presented with the survey questions that were not answered.
If a mismatch 170 in passwords is detected during the login process 210 , an error screen is displayed and the user has the ability to reenter the three identification codes 220 , 230 , and 240 . It should be noted that additional fields may be added to the login process which may include length of employment, demographics and other data. Alternatively, a single login ID may be utilized which individually identifies the employee's organization, job classification and personal identification.
Upon successful login 210 and confirmation 250 , the survey is commenced as at 270 with a series of questions presented in HTML format. Under each question is a form input section coded in HTML which may comprise a check box, radio button, or edit box. Alternatively, other input means compatible with the user's web browser may be utilized including ActiveX or Java. Responses to the input means are stored in a database 100 that may reside on the web server or at a remote location. The questions and answer input forms may be configured on a single scrollable page or on individual HTML pages joined by hyperlinks.
FIG. 3 discloses a sample question screen as viewed through an Internet web browser comprising a plurality of input sections to each survey question topic. Users are prompted to respond to each of the questions in one or more components. In the following example, there are three components. Component A queries whether the respondent believes a specific performance criteria exists in their workplace. Component B queries the respondent to weigh their level of agreement or disagreement to a functional extrapolation of component A. Component C asks the respondent to check one of many methods how such a performance criteria could be improved.
In the example of FIG. 3 two question components are presented. Question 1 proposes a query on the perceived leadership skills in the company and provides for a Boolean response. The first query is followed up by another query that requests a quantified response with seven possible entries. In the preferred operation of the Internet system, none of the responses are selected when the user first downloads the page to their web browser. Each response must be completed for the “next question button” to become available for next question cueing and for the responses of that user to be filed in the database 100 . Should the user attempt to skip over the questions without responding, the internal controls validate whether a response has been entered and repeat the same page to the user until a completed response is received by the web server. In a preferred embodiment, JavaScript is utilized to validate completed responses. The question-to-question responses are temporarily stored in a cache 250 until all survey questions are completed and the data is then committed to database 100 for analysis. An interrupt feature is available to all respondents who are unable to finish the survey in one sitting. If the respondent stops and logs off, he or she may restart the survey at any later time, by simply re-entering the password, job classification code and test ID. This procedure opens an incomplete survey and restores it to the last position or next available question from data stored in cache 250 . When all questions are completed and a “save last answer question” button is selected, the survey is flagged as done 260 for final database 100 entry. Analysis 140 is available when all users complete their survey. Data from this part of the survey helps the organization evaluate the current level of organizational consistency about perceptions of effectiveness and efficiency between and among different levels of staff, across all operations, between staff members, and between and among the pool of external respondents as well, if any. As improvements are made the organization can re-visit the assessment in future years to track scores in key areas, to monitor improvements and to encourage greater performance. A score card system also provides a context for an organization's scores to be compared to the respective scores of other organizations.
In the touch-tone telephone embodiment shown in FIG. 4, the questions are audibly prerecorded for playback. The employee or non-employee is given a telephone number to call with a set of access codes which may comprise a business ID, job classification and employee ID, if applicable, as described in connection with FIG. 2 . The user dials into the system from a standard touch-tone phone 300 . The user is prompted for each identifier which is entered by pressing the numbers of the touch-tone telephone. When a key is pressed on a touch-tone telephone, a DTMF signal is emitted which is correlated to the numeral on the keypad by a system processor. These systems are widely used in automatic call distributor (“ACD”) systems utilized by call centers and by banks and financial institutions to provide automated account information. In the example, after the user is authenticated prerecorded segments 320 of the survey are played back to the user. As an option, the user may press the STAR (*) or POUND (#) key on their telephone to repeat the last playback segment. After a survey question is audibly presented to the user, the user then may answer the question depending on the response options using a DTMF input 330 . For a Boolean question which requires a “yes” or “no” response, the user may be prompted to press “1” for “yes” or “2” for “no.” Alternatively, should the survey question require a quantitative response, the user may be prompted to enter a range of numbers on the telephone keypad. For example, should the user “Almost Always Disagree,” they would depress “1.” If the user “Rarely Agrees,” they would depress “2.” The scale may continue so that should the user “Almost Always Agrees,” they would depress “7.” However, it should be noted that the telephonic entry is not limited to single digits. For example, should the user be required to indicate a percentage numeral of 55%, the entry may be executed by depressing in sequence: “5,” “5,” and then the “#” key. Should the user fail to respond to the system with a DTMF signal 330 within a predetermined period of time, the system may replay as at 340 the previous question proposed.
Both the Internet-based and telephonically-based system preferably time-stamp the entries wherein each time a response is posted to the web server or entered into the telephone system, a corresponding record of the date and time is also stored in the database. This may be utilized for an assessment of the amount of time needed on average to complete the evaluation and when each employee submitted their responses to the survey.
FIG. 5 illustrates a diagrammatical overview of an organization's total quality output scorecard based on the Malcolm Baldrige criteria. However, other performance measurements and formulas may be applied within the scope of this invention. The purposes of the Baldrige Assessment are to promote an understanding of the requisites for performance achievement and competitiveness for business entities and to promote the sharing of information on successful business practices. The Baldrige Assessment consists of seven criteria: (1) leadership, (2) strategic planning, (3) customer and market focus, (4) information and analysis, (5) human resource development and management, (6) process management, and (7) business results.
Leadership is evaluated by the ability of senior executives to guide the company and how the company addresses it responsibilities. Strategic planning examines how the company sets strategic directions and how it determines key action plans. Customer and market focus examines how the company determines the requirements and expectations of customers and markets. Information analysis examines the management, effective use, and analysis of data and information to support key company processes and the company's performance management system. Human resource development and management examines how the company enables its workforce to develop its full potential and how the workforce is aligned with the company' objectives. Process management examines aspects of how key production, delivery and support processes are designed, managed, and improved. Business results are examined by the company's performance and improvement in its key business areas: customer satisfaction, financial and marketplace performance, human resources, supplier and partner performance, and operation performance. Business results are also evaluated by the performance of the company relative to its competitors.
In a preferred embodiment, each question has both a yes/no and weighted score component so that data can be accurately tallied with sophisticated analysis and report generation. Instead of using a simple 1-5 Likert scale which is subject to a wide range of interpretation, the current invention uses quantified behavioral descriptors, dramatically increasing score reliability. As previously illustrated in FIG. 3 a written question is followed by a quantified (percentage-tagged) behavioral description. This form of test construction yields an increase in the consistency and accuracy of ratings as well as greater coherence of linkages between business processes. The method of utilizing a written question followed by a quantified description is well known in the health care industry. In health care it was discovered that by obtaining input this way from a cross section of functions and levels throughout the organization, a performance profile can be developed that not only identifies strengths and areas for improvement, but deployment gaps as well. This is something that written narrative assessments alone do not effectively provide. Accurate survey data, based on behavioral follow-up questions, can be used to compare or benchmark organizations within and among industries, and can also support longitudinal performance studies.
The system represents an item by item, group by group. performance improvement digest that allows management the ability to recognize the linkage between performance of key processes to quality improvement outcomes (including the future allocation of resources to achieve such outcomes).
The system does this by compiling each respondent's raw data and generating a written digest of an organization's strengths and opportunities for improvement. Data is gathered and assembled to provide an organization with a detailed analysis in the form of a printed report. Responses in the database 100 are analyzed as at 140 and reported in several ways. The database table is constructed to include vertical columns formatted with mathematical formulas representing yes or no response totals, raw Likert averages, adjusted Likert averages and Organizational Success Ratios (“OSRs”). Dividing the adjusted Likert by the raw Likert produces an OSR. This number can be represented in the form of a ratio or quotient and generally as a two place decimal ranging from 0.01 to a perfect 1.00. The OSR is used to profile the system's highest and lowest scores in performance improvement, representing current quality strengths and weaknesses in the business entity.
The OSR data collected from the employees and non-employees, if any, is consistent across the organization. The results can present a clear profile of strengths and current weaknesses from which the business entity can plan appropriate actions. Each OSR is then converted to a Baldrige equivalency formula that converts the two place decimal point to a percentage. The percentage number is then applied line by line to re-create the points available in each section found in the sample table. The “maximum” points for each category of the Malcolm Baldrige National Quality Award is listed with the actual score.
As illustrated in FIG. 5, a maximum of 450 points for the “business results” category may be obtained, even if the sample organization returned only 160 points. To convert each business category result to a ratio, the total points achieved in each category is divided by the overall maximum number of points possible for the category. Thus, 160 divided by 450 equals 0.356 or 35.6 percent. By converting each business category measurement to a ratio, the organization may easily obtain a quantifiable assessment of its performance.
It will be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
Now that the invention has been described, | A system for providing accurate, quantifiable and reproducible assessments of an organization's performance based on predetermined criteria. The system includes a telecommunications infrastructure administered by a survey administrator. Employees or non-employees of a company or other organization to be evaluated log on to the system and answer a plurality of questions relating to various aspects of the business entity's operations. The information may be obtained through Internet communications, through touch-tone telephone systems, and in many other ways including the use of personal computers, diskettes and email, or even manually including the use of pencil and paper where penciled-in answers are read by a scanner. The data is stored in a database and subsequently analyzed by the survey administrator for evaluation and forecasting of the business entity's performance. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to telecommunications in general, and, more particularly, to forwarding telephone calls at a private branch exchange.
BACKGROUND OF THE INVENTION
[0002] [0002]FIG. 1 depicts a block diagram of the salient components of telecommunications network 100 in the prior art. Telecommunications network 100 comprises Public Switched Telephone Network 101 , wireline terminal 102 , wireless terminal 103 , private branch exchange 105 , and wireline terminals 106 - 1 through 106 -N.
[0003] Private branch exchange 105 is capable of switching incoming calls from Public Switched Telephone Network 101 via one or more transmission lines to one of wireline terminals 106 - 1 through 106 -N. Private branch exchange 105 is also capable of handling outgoing calls from any of wireline terminals 106 - 1 through 106 -N to Public Switched Telephone Network 101 via one or more transmission lines that connect private branch exchange 105 to Public Switched Telephone Network 101 .
[0004] In addition, private branch exchange 105 is capable of also forwarding each incoming call to a telephone number in Public Switched Telephone Network 101 . The forwarded-to telephone number in Public Switched Telephone Network 101 can correspond to a terminal such as wireless terminal 103 .
[0005] [0005]FIG. 2 depicts the address spaces that are relevant to telecommunications network 100 in the prior art. The term “address space” refers to an addressable region of telephone service. Address space 104 represents the addressable region served by Public Switched Telephone Network 101 . Address space 107 represents the addressable region served by private branch exchange 105 . A distinction is made between address space 104 and address space 107 because the same telephone number has two different meanings in each address space.
[0006] Private branch exchange 105 exists in both address space 104 and address space 107 and acts as a bridge or gateway between the two address spaces. When a calling party places a call to someone served by private branch exchange 105 , the calling party uses a dialing sequence that includes a telephone number belonging to Public Switched Telephone Network 101 and residing in address space 104 . As part of the dialing sequence, the calling party also uses an extension number that allows access to one of the terminals residing within address space 107 .
[0007] [0007]FIG. 3 depicts a flowchart of the tasks that are relevant to processing an incoming call in the prior art. To accomplish tasks 301 through 303 , private branch exchange 105 maintains a table that correlates Public Switched Telephone Network number to private branch exchange extension. Table 1 depicts an illustrative table that correlates Public Switched Telephone Network number to private branch exchange extension.
TABLE 1 Call Forwarding Database Public Switched Private Branch Telephone Network Exchange Extension Number 732-555-0102, x11 201-555-1236 732-555-0102, x12 908-555-3381 . . . . . . 732-555-0102, x99 212-555-6784
[0008] At task 301 , private branch exchange 105 receives a call from Public Switched Telephone Network 101 , which is originated by wireline terminal 102 .
[0009] At task 302 , private branch exchange 105 forwards the call to a first telephone number. The first telephone number exists in the address space of the private branch exchange, namely address space 107 , and can be associated with one of wireline terminals 106 - 1 through 106 -N. The first telephone number is represented as the private branch exchange extension in Table 1.
[0010] At task 303 , private branch exchange 105 also forwards the call to a second telephone number. The second telephone number exists in the address space of Public Switched Telephone Network 101 , namely address space 104 , and can be associated with a wireless terminal such as wireless terminal 103 .
[0011] Referring to the example in Table 1, the call, placed to 732-555-0102, extension 11 (i.e., shown in the first row), is connected to private branch exchange extension 11 and is also forwarded to Public Switched Telephone Number 201-555-1236.
SUMMARY OF THE INVENTION
[0012] The present invention enables an incoming call to a private branch exchange to be forwarded to a private branch exchange extension and to a number in the Public Switched Telephone Network that is selected based on one or more criteria. For example, various embodiments of the present invention select the number in the Public Switched Telephone Network based on the calling-party's number, the incoming line to the private branch exchange, the dialed number, the calendrical time, the location of a terminal, and/or environmental factors.
[0013] The illustrative embodiment of the present invention comprises: receiving a first call that is associated with a first calling-party telephone number; forwarding the first call to a first telephone number, wherein the first telephone number exists in the address space of a private branch exchange; and forwarding the first call to a second telephone number, wherein the second telephone number exists in the address space of the Public Switched Telephone Network; wherein the first telephone number and the second telephone number are based on the first calling-party telephone number.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 depicts a schematic diagram of telecommunications system 100 in the prior art.
[0015] [0015]FIG. 2 depicts a schematic diagram of address space 104 and address space 107 in the prior art.
[0016] [0016]FIG. 3 depicts a flowchart of tasks relevant to processing an incoming call in the prior art.
[0017] [0017]FIG. 4 depicts a schematic diagram of telecommunications system 400 , in accordance with the illustrative embodiment of the present invention.
[0018] [0018]FIG. 5 depicts a block diagram of private branch exchange 405 , in accordance with the illustrative embodiment of the present invention.
[0019] [0019]FIG. 6 depicts a flowchart of the salient tasks that are relevant to calling-party telephone number, in accordance with the illustrative embodiment of the present invention.
[0020] [0020]FIG. 7 depicts a flowchart of the salient tasks that are relevant to incoming line, in accordance with the illustrative embodiment of the present invention.
[0021] [0021]FIG. 8 depicts a flowchart of the salient tasks that are relevant to dialed number, in accordance with the illustrative embodiment of the present invention.
[0022] [0022]FIG. 9 depicts a flowchart of the salient tasks that are relevant to calendrical time, in accordance with the illustrative embodiment of the present invention.
[0023] [0023]FIG. 10 depicts a flowchart of the salient tasks that are relevant to location of terminal, in accordance with the illustrative embodiment of the present invention.
[0024] [0024]FIG. 11 depicts a flowchart of the salient tasks that are relevant to environmental condition, in accordance with the illustrative embodiment of the present invention.
DETAILED DESCRIPTION
[0025] [0025]FIG. 4 depicts a block diagram of the salient components of telecommunications network 400 in accordance with the illustrative embodiment of the present invention. Telecommunications network 400 comprises Public Switched Telephone Network 401 , wireline terminal 402 , wireless terminals 403 - 1 through 403 -M, wherein M is a positive integer, and the network-facing part of private branch exchange 405 , all situated within the address space of the Public Switched Telephone Network, namely address space 404 , and interconnected as shown. Telecommunications network 400 also comprises the extension-facing part of private branch exchange 405 and wireline terminals 406 - 1 through 406 -N, wherein N is a positive integer, all situated within the address space of the private branch exchange, namely address space 405 , and interconnected as shown. It will be clear to those skilled in the art how to make and use Public Switched Telephone Network 401 , wireline terminal 402 , wireless terminals 403 - 1 through 403 -M, and wireline terminals 406 - 1 through 406 -N. It will be clear to those skilled in the art, after reading this specification, how to make and use private branch exchange 405 .
[0026] Private branch exchange 405 is capable of handling incoming calls from Public Switched Telephone Network 401 via one or more transmission lines for the purpose of forwarding each call to a telephone number corresponding to one of wireline terminals 406 - 1 through 406 -N (i.e., in address space 407 ). In addition, private branch exchange 405 is capable of forwarding each incoming call to a telephone number in address space 404 . The telephone number in address space 404 can correspond to one of wireless terminals 403 - 1 through 403 -M. Private branch exchange 405 is also capable of handling outgoing calls from any of wireline terminals 406 - 1 through 406 -N to Public Switched Telephone Network 401 via one or more transmission lines.
[0027] [0027]FIG. 5 depicts a block diagram of the salient components of private branch exchange 405 in accordance with the illustrative embodiment of the present invention. Private branch exchange 405 comprises: switch matrix 501 , processor 502 , memory 503 , clock 504 , environmental sensor 505 , and wireless terminal location estimator 506 , interconnected as shown.
[0028] Switch matrix 501 is a circuit that is capable of receiving call-related data and traffic from Public Switched Telephone Network 401 , forwarding call-related data to processor 502 , and accepting commands from processor 502 . In addition, switch matrix 501 is capable of handling outgoing calls from wireline terminals 406 - 1 through 406 -N. Switch matrix 501 also is capable of forwarding call traffic to wireline terminals 406 - 1 through 406 -N and also to wireless terminals 403 - 1 through 403 -M in Public Switched Telephone Network 401 . It will be clear to those skilled in the art how to make and use switch matrix 501 .
[0029] Processor 502 is a general-purpose processor that is capable of performing the tasks described below and with respect to FIGS. 6 through 11. It will be clear to those skilled in the art, after reading this specification, how to make and use processor 502 .
[0030] Memory 503 is capable of storing programs and data used by processor 502 . It-will be clear to those skilled in the art how to make and use memory 503 .
[0031] Clock 504 is capable of tracking calendrical time at one or more levels of granularity, such as months, days of the week, days of the month, time of day, etc. Clock 504 can generate the time internally or it can obtain the time from another source or both. Processor 502 uses the calendrical time tracked by clock 504 . It will be clear to those skilled in the art how to make and use clock 504 .
[0032] Environmental sensor 505 is capable of tracking one or more environmental conditions. Environmental conditions can include rain, wind, sunshine, air quality, presence of seismic activity, etc. Environmental sensor 505 can directly sense the environment or it can store environmental data obtained from another source or both. It will be clear to those skilled in the art how to make and use environmental sensor 505 .
[0033] Wireless terminal location estimator 506 is capable of tracking the location of one or more of wireless terminals 403 - 1 through 403 -M. Wireless terminal location estimator 506 can directly determine the location of the wireless terminal or it can store location data obtained from another source or both. It will be clear to those skilled in the art-how to make and use wireless terminal location estimator 506 .
[0034] [0034]FIG. 6 depicts a flowchart of the salient tasks that are relevant to calling-party number and are performed by the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 6 can be performed simultaneously or in a different order than that depicted.
[0035] To accomplish tasks 601 through 606 , private branch exchange 405 maintains a table that correlates physical private branch exchange extension, alert pattern, and Public Switched Telephone Network number to calling-party telephone number. Each unique combination of calling-party telephone number, physical private branch extension, and alert pattern characterize a specific called entity, referred to as a “virtual station.” Table 2 depicts an illustrative version of this table.
TABLE 2 Call Forwarding Database Based on Calling-Party Telephone Number Virtual Station Physical Private Branch Public Switched Calling-Party Exchange Alert Telephone Network Telephone Number Extension Pattern Number 609-555-0102 1 1 201-555-1236 516-555-9981 1 2 908-555-3381 . . . . . . . . . . . . 732-555-3456 N 1 212-555-6784
[0036] The calling-party telephone number identifies the person (or terminal) originating a telephone call. It will be clear to those skilled in the art how to use calling-party telephone number.
[0037] At task 601 , private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a first call that is associated with a first calling-party telephone number. For example, wireline terminal 402 can originate the call as the first calling party.
[0038] At task 602 , private branch exchange 405 forwards the first call to a first telephone number, wherein private branch exchange 405 selects the first telephone number based on the first calling-party telephone number. The first telephone number exists in the address space of the private branch exchange, namely address space 407 , and can be associated with one of wireline terminals 406 - 1 through 406 -N. The first telephone number is represented as physical private branch exchange extension in Table 2.
[0039] Private branch exchange 405 can also forward to the first telephone number alerting information that is also based on the first calling-party telephone number. The particular alert pattern that is forwarded can be used to provide distinctive ringing. The distinctive ringing can be used, for example, by multiple users of a single wireline terminal (e.g., wireline terminal 406 - 1 , etc.) to help determine the recipient of the call prior to answering. It will be clear to those skilled in the art how to forward alert information.
[0040] At task 603 , private branch exchange 405 also forwards the first call to a second telephone number, wherein private branch exchange 405 selects the second telephone number based on the first calling-party telephone number. The second telephone number exists in the address space of Public Switched Telephone Network 401 , namely address space 404 , and can be associated with one of wireless terminals 403 - 1 through 403 -M.
[0041] Referring to the example in Table 2, the first call, received from calling-party telephone number 609-555-0102, is forwarded to physical private branch exchange extension 1 with alert pattern 1 applied and is also forwarded to Public Switched Telephone Number 201-555-1236.
[0042] At task 604 , some time later, private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a second call that is associated with a second calling-party telephone number. For example, wireless terminal 403 - 1 can originate the call as the second calling party.
[0043] At task 605 , private branch exchange 405 forwards the second call to the first telephone number, wherein private branch exchange 405 selects the first telephone number based on the second calling-party telephone number.
[0044] Private branch exchange 405 can also forward to the first telephone number alerting information that is also based on the second calling-party telephone number. The particular alert pattern that is forwarded can be used to provide a distinctive ring. As depicted in Table 2, the alert pattern associated with the second calling-party telephone number (i.e., alert pattern “2”) can be different that associated with the first calling-party telephone number (i.e., alert pattern “1”).
[0045] At task 606 , private branch exchange 405 also forwards the second call to a third telephone number, wherein private branch exchange 405 selects the third telephone number based on the second calling-party telephone number. The third telephone number exists in the address space of Public Switched Telephone Network 401 and can, for example, be associated with one of wireless terminals 403 - 1 through 403 -M.
[0046] Referring to the example in Table 2, the second call, received from calling-party telephone number 516-555-9981, is forwarded to physical private branch exchange extension 1 with alert pattern 2 applied and is also forwarded to Public Switched Telephone Number 908-555-3381.
[0047] [0047]FIG. 7 depicts a flowchart of the salient tasks that are relevant to incoming line and are performed by the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 7 can be performed simultaneously or in a different order than that depicted.
[0048] To accomplish tasks 701 through 706 , private branch exchange 405 maintains a table that correlates physical private branch exchange extension, alert pattern, and Public Switched Telephone Network number to incoming line. Each unique combination of incoming line, physical private branch extension, and alert pattern characterize a specific called entity, referred to as a “virtual station.” Table 3 depicts an illustrative version of this table.
TABLE 3 Call Forwarding Database Based on Incoming Line Virtual Station Physical Private Branch Public Switched Exchange Alert Telephone Network Incoming Line Extension Pattern Number 732-555-0001 1 1 201-555-1236 732-555-0002 1 2 908-555-3381 . . . . . . . . . . . . 732-555-9999 N 1 212-555-6784
[0049] The incoming line is a transmission path terminated at private branch exchange 405 that is capable of carrying a call from Public Switched Telephone Network 401 . There are multiple ways to designate an incoming line; in the illustrative embodiment, incoming line is designated using telephone number. It will be clear to those skilled in the art how to use incoming line.
[0050] At task 701 , private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a first call that is associated with a first incoming line.
[0051] At task 702 , private branch exchange 405 forwards the first call to a first telephone number, wherein private branch exchange 405 selects the first telephone number based on the first incoming line. The first telephone number exists in the address space of the private branch exchange, namely address space 407 , and can be associated with one of wireline terminals 406 - 1 through 406 -N. The first telephone number is represented as physical private branch exchange extension in Table 3.
[0052] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the first incoming line.
[0053] At task 703 , private branch exchange 405 also forwards the first call to a second telephone number, wherein private branch exchange 405 selects the second telephone number based on the first incoming line. The second telephone number exists in the address space of Public Switched Telephone Network 401 , namely address space 404 , and can be associated with one of wireless terminals 403 - 1 through 403 -M.
[0054] Referring to the example in Table 3, the first call, received on incoming line 732-555-0001, is forwarded to physical private branch exchange extension 1 with alert pattern 1 applied and is also forwarded to Public Switched Telephone Number 201-555-1236.
[0055] At task 704 , some time later, private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a second call that is associated with a second incoming line.
[0056] At task 705 , private branch exchange 405 forwards the second call to the first telephone number, wherein private branch exchange 405 selects the first telephone number based on the second incoming line.
[0057] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the second incoming line.
[0058] At task 706 , private branch exchange 405 also forwards the second call to a third telephone number, wherein private branch exchange 405 selects the third telephone number based on the second incoming line. The third telephone number exists in the address space of Public Switched Telephone Network 401 and can, for example, be associated with one of wireless terminals 403 - 1 through 403 -M.
[0059] Referring to the example in Table 3, the second call, received on incoming line 732-555-0002, is forwarded to physical private branch exchange extension 1 with alert pattern 2 applied and is also forwarded to Public Switched Telephone Number 908-555-3381.
[0060] [0060]FIG. 8 depicts a flowchart of the salient tasks that are relevant to dialed number and are performed by the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 8 can be performed simultaneously or in a different order than that depicted.
[0061] To accomplish tasks 801 through 806 , private branch exchange 405 maintains a table that correlates physical private branch exchange extension, alert pattern, and Public Switched Telephone Network number to dialed number. Each unique combination of dialed number, physical private branch extension, and alert pattern characterize a specific called entity, referred to as a “virtual station.” Table 4 depicts an illustrative version of this table.
TABLE 4 Call Forwarding Database Based on Dialed Number Virtual Station Physical Private Branch Public Switched Exchange Alert Telephone Network Dialed Number Extension Pattern Number 732-555-8435 1 1 201-555-1236 732-555-9858 1 2 908-555-3381 . . . . . . . . . . . . 732-555-0475 N 1 212-555-6784
[0062] The dialed number is a telephone number assigned to represent a specific pair of physical private branch exchange extension and Public Switched Telephone Network number. Dialed number is the telephone number that the calling party specifies while dialing (e.g., 732-555-8435, etc.), instead of the actual physical number associated with a terminal being called (e.g., extension 1 at private branch exchange 405 , etc.). It will be clear to those skilled in the art how to use dialed number.
[0063] At task 801 , private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a first call that is associated with a first dialed number.
[0064] At task 802 , private branch exchange 405 forwards the first call to a first telephone number, wherein private branch exchange 405 selects the first telephone number based on the first dialed number. The first telephone number exists in the address space of the private branch exchange, namely address space 407 , and can be associated with one of wireline terminals 406 - 1 through 406 -N. The first telephone number is represented as physical private branch exchange extension in Table 4.
[0065] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the first dialed number.
[0066] At task 803 , private branch exchange 405 also forwards the first call to a second telephone number, wherein private branch exchange 405 selects the second telephone number based on the first dialed number. The second telephone number exists in the address space of Public Switched Telephone Network 401 , namely address space 404 , and can be associated with one of wireless terminals 403 - 1 through 403 -M.
[0067] Referring to the example in Table 4, the first call, received for dialed number 732-555-8435, is forwarded to physical private branch exchange extension 1 with alert pattern 1 applied and is also forwarded to Public Switched Telephone Number 201-555-1236.
[0068] At task 804 , some time later, private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a second call that is associated with a second dialed number.
[0069] At task 805 , private branch exchange 405 forwards the second call to the first telephone number, wherein private branch exchange 405 selects the first telephone number based on the second dialed number.
[0070] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the second dialed number.
[0071] At task 806 , private branch exchange 405 also forwards the second call to a third telephone number, wherein private branch exchange 405 selects the third telephone number based on the second dialed number. The third telephone number exists in the address space of Public Switched Telephone Network 401 and can, for example, be associated with one of wireless terminals 403 - 1 through 403 -M.
[0072] Referring to the example in Table 4, the second call, received for dialed number 732-555-9858, is forwarded to physical private branch exchange extension 1 with alert pattern 2 applied and is also forwarded to Public Switched Telephone Number 908-555-3381.
[0073] [0073]FIG. 9 depicts a flowchart of the salient tasks that are relevant to calendrical time and are performed by the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 9 can be performed simultaneously or in a different order than that depicted.
[0074] To accomplish tasks 901 through 906 , private branch exchange 405 maintains a table that correlates physical private branch exchange extension, alert pattern, and Public Switched Telephone Network number to calendrical time. Each unique combination of calendrical time, physical private branch extension, and alert pattern characterize a specific called entity, referred to as a “virtual station.” Table 5 depicts an illustrative version of this table.
TABLE 5 Call Forwarding Database Based on Calendrical Time Virtual Station Physical Private Branch Public Switched Exchange Alert Telephone Network Calendrical Time Extension Pattern Number Morning 1 1 201-555-1236 Afternoon 1 2 908-555-3381 . . . . . . . . . . . . Saturday N 1 212-555-6784
[0075] Calendrical time can be used to track repeating occurrences of time, such as a specific part of each month (e.g., the first week of the month, etc.), of each week (e.g., Tuesdays, etc.), of each day (e.g., mornings, etc.), and so on. For example, private branch exchange 405 might have to handle calls one way if the calls are received in the morning, versus another way if the calls are received during another time of the day. It will be clear to those skilled in the art how to use calendrical time.
[0076] At task 901 , private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a first call that is associated with a first calendrical time.
[0077] At task 902 , private branch exchange 405 forwards the first call to a first telephone number, wherein private branch exchange 405 selects the first telephone number based on the first calendrical time. The first telephone number exists in the address space of the private branch exchange, namely address space 407 , and can be associated with one of wireline terminals 406 - 1 through 406 -N. The first telephone number is represented as physical private branch exchange extension in Table 5.
[0078] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the first calendrical time.
[0079] At task 903 , private branch exchange 405 also forwards the first call to a second telephone number, wherein private branch exchange 405 selects the second telephone number based on the first calendrical time. The second telephone number exists in the address space of Public Switched Telephone Network 401 , namely address space 404 , and can be associated with one of wireless terminals 403 - 1 through 403 -M.
[0080] Referring to the example in Table 5, the first call, received at the calendrical time of morning, is forwarded to physical private branch exchange extension 1 with alert pattern 1 applied and is also forwarded to Public Switched Telephone Number 201-555-1236.
[0081] At task 904 , some time later, private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a second call that is associated with a second calendrical time.
[0082] At task 905 , private branch exchange 405 forwards the second call to the first telephone number, wherein private branch exchange 405 selects the first telephone number based on the second calendrical time.
[0083] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the second calendrical time.
[0084] At task 906 , private branch exchange 405 also forwards the second call to a third telephone number, wherein private branch exchange 405 selects the third telephone number based on the second calendrical time. The third telephone number exists in the address space of Public Switched Telephone Network 401 and can, for example, be associated with one of wireless terminals 403 - 1 through 403 -M.
[0085] Referring to the example in Table 5, the second call, received at the calendrical time of afternoon, is forwarded to physical private branch exchange extension 1 with alert pattern 2 applied and is also forwarded to Public Switched Telephone Number 908-555-3381.
[0086] [0086]FIG. 10 depicts a flowchart of the salient tasks that are relevant to location of terminal and are performed by the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 10 can be performed simultaneously or in a different order than that depicted.
[0087] To accomplish tasks 1001 through 1006 , private branch exchange 405 maintains a table that correlates physical private branch exchange extension, alert pattern, and Public Switched Telephone Network number to location of terminal. Each unique combination of location of terminal, physical private branch extension, and alert pattern characterize a specific called entity, referred to as a “virtual station.” Table 6 depicts an illustrative version of this table.
TABLE 6 Call Forwarding Database Based on Location of Terminal Virtual Station Physical Private Branch Public Switched Location of Exchange Alert Telephone Network Terminal Extension Pattern Number Chicago 1 1 201-555-1236 New York 1 2 908-555-3381 . . . . . . . . . . . . Munich N 1 212-555-6784
[0088] The location of terminal refers to the position of a selected terminal, as tracked by private branch exchange 405 . For illustrative purposes, this specification uses the location of wireless terminal 403 - 1 as the location of terminal. It will be clear to those skilled in the art how to use location of terminal and how to select a particular terminal to evaluate the location of.
[0089] At task 1001 , private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a first call that is associated with a first location of terminal.
[0090] At task 1002 , private branch exchange 405 forwards the first call to a first telephone number, wherein private branch exchange 405 selects the first telephone number based on the first location of terminal. The first telephone number exists in the address space of the private branch exchange, namely address space 407 , and can be associated with one of wireline terminals 406 - 1 through 406 -N. The first telephone number is represented as physical private branch exchange extension in Table 6.
[0091] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the first location of terminal.
[0092] At task 1003 , private branch exchange 405 also forwards the first call to a second telephone number, wherein private branch exchange 405 selects the second telephone number based on the first location of terminal. The second telephone number exists in the address space of Public Switched Telephone Network 401 , namely address space 404 , and can be associated with one of wireless terminals 403 - 1 through 403 -M.
[0093] Referring to the example in Table 6, because the location of wireless terminal 403 - 1 is Chicago, the first call is forwarded to physical private branch exchange extension 1 with alert pattern 1 applied and is also forwarded to Public Switched Telephone Number 201-555-1236.
[0094] At task 1004 , some time later, private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a second call that is associated with a second location of terminal.
[0095] At task 1005 , private branch exchange 405 forwards the second call to the first telephone number, wherein private branch exchange 405 selects the first telephone number based on the second location of terminal.
[0096] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the second location of terminal.
[0097] At task 1006 , private branch exchange 405 also forwards the second call to a third telephone number, wherein private branch exchange 405 selects the third telephone number based on the second location of terminal. The third telephone number exists in the address space of Public Switched Telephone Network 401 and can, for example, be associated with one of wireless terminals 403 - 1 through 403 -M.
[0098] Referring to the example in Table 6, because the location of wireless terminal 403 - 1 is New York, the second call is forwarded to physical private branch exchange extension 1 with alert pattern 2 applied and is also forwarded to Public Switched Telephone Number 908-555-3381.
[0099] [0099]FIG. 11 depicts a flowchart of the salient tasks that are relevant to environmental condition and are performed by the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 11 can be performed simultaneously or in a different order than that depicted.
[0100] To accomplish tasks 1101 through 1106 , private branch exchange 405 maintains a table that correlates physical private branch exchange extension, alert pattern, and Public Switched Telephone Network number to environmental condition. Each unique combination of environmental condition, physical private branch extension, and alert pattern characterize a specific called entity, referred to as a “virtual station.” Table 7 depicts an illustrative version of this table.
TABLE 7 Call Forwarding Database Based on Environmental Condition Virtual Station Physical Private Branch Public Switched Environmental Exchange Alert Telephone Network Condition Extension Pattern Number High Humidity 1 1 201-555-1236 Low Humidity 1 2 908-555-3381 . . . . . . . . . . . . High Ozone Level N 1 212-555-6784
[0101] The environmental condition refers to a particular state (e.g., high, low, etc.) of a monitored attribute (e.g., humidity, etc.) at a particular location. The location can be, for example, the location of private branch exchange 405 . It will be clear to those skilled in the art how to select and use environmental condition, how to quantify the state, and how to select a particular location to evaluate the environmental condition of.
[0102] At task 1101 , private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a first call that is associated with a first environmental condition.
[0103] At task 1102 , private branch exchange 405 forwards the first call to a first telephone number, wherein private branch exchange 405 selects the first telephone number based on the first environmental condition. The first telephone number exists in the address space of the private branch exchange, namely address space 407 , and can be associated with one of wireline terminals 406 - 1 through 406 -N. The first telephone number is represented as physical private branch exchange extension in Table 7.
[0104] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the first environmental condition.
[0105] At task 1103 , private branch exchange 405 also forwards the first call to a second telephone number, wherein private branch exchange 405 selects the second telephone number based on the first environmental condition. The second telephone number exists in the address space of Public Switched Telephone Network 401 , namely address space 404 , and can be associated with one of wireless terminals 403 - 1 through 403 -M.
[0106] Referring to the example in Table 7, because the environmental condition is high humidity, the first call is forwarded to physical private branch exchange extension 1 with alert pattern 1 applied and is also forwarded to Public Switched Telephone Number 201-555-1236.
[0107] At task 1104 , some time later, private branch exchange 405 receives from Public Switched Telephone Network 401 , in well-known fashion, a second call that is associated with a second environmental condition.
[0108] At task 1105 , private branch exchange 405 forwards the second call to the first telephone number, wherein private branch exchange 405 selects the first telephone number based on the second environmental condition.
[0109] Private branch exchange 405 can also forward to the first telephone number alerting information, described earlier, that is also based on the second environmental condition.
[0110] At task 1106 , private branch exchange 405 also forwards the second call to a third telephone number, wherein private branch exchange 405 selects the third telephone number based on the second environmental condition. The third telephone number exists in the address space of Public Switched Telephone Network 401 and can, for example, be associated with one of wireless terminals 403 - 1 through 403 -M.
[0111] Referring to the example in Table 7, because the environmental condition is low humidity, the second call is forwarded to physical private branch exchange extension 1 with alert pattern 2 applied and is also forwarded to Public Switched Telephone Number 908-555-3381.
[0112] It is to be understood that the above-described embodiments are merely illustrative of the present invention and that many variations of the above-described embodiments can be devised by those skilled in the art without departing from the scope of the invention. It is therefore intended that such variations be included within the scope of the following claims and their equivalents. | A method for handling incoming calls at a private branch exchange is disclosed. A distinction is made between the address space of the Public Switched Telephone Network and the address space of the private branch exchange handling the incoming calls. The method disclosed accounts for one or more conditions present in the associated network and forwards calls to telephone numbers in the different address spaces based on the conditions present. | 7 |
BACKGROUND TO THE INVENTION
This invention relates to a retractable mechanism for a writing element.
In well known writing instruments of the ball point type, the writing element comprises a refill which contains the writing fluid and has a writing tip of known ball point construction. Where the writing element is desired to be retractable between an extended position in which the writing tip is projected out of a housing for writing purposes and a retracted position in which the writing tip is retracted wholly within the housing for avoiding the inadvertent transfer of writing fluid, a retractable mechanism is provided.
More especially this invention relates to a retractable mechanism for a writing element comprising a plunger, passage means defining a passage in which said plunger is constrained to move in the longitudinal direction of said passage, a pair of latch means oppositely disposed when viewed in a plane normal to said longitudinal direction, a latch member reciprocally displaceable in said longitudinal direction by means of said plunger, said latch member having a pair of laterally extending latch arms oppositely directed and each disposed for engagement with a respective one of said latch means, one of the latch means defining a forward, projected position of the writing element and the other of the latch means defining a rearward, retracted position of the writing element, when present the writing element is resiliently biased to urge the latch member rearwardly in its longitudinal direction to ensure that one of said abutment means engages with its associated latch means, advance of the plunger in the forward longitudinal direction releasing the engaged one of the abutment means from its latch means whereby the latch member may be displaced laterally to ensure alignment of the other of said abutment means with its associated latch means thereafter to engage therewith whereby the writing element may be displaced between its retracted and projected positions (or vice versa) in response to successive depressions of the plunger. Such a retractable mechanism is referred to herein as a retractable mechanism as hereinbefore defined.
One prior art retractable mechanism disclosed in United Kingdom Pat. No. 804,903 has the features of the retractable mechanism hereinbefore defined. The plunger has a pair of strike faces which alternately on successive depressions of the plunger strike respective ones of two cam faces on the latch member. The latch member has a rearward limb which at its rearward end defines the pair of cam faces individually associated with the plunger strike faces. The rearward limb of the latch member has a pair of latch rockers, or pivots, each of which is a pivot for a fulcrum action of the latch member thereabout when in contact with a respective interior wall portion of the passage. These latch rockers and the cam faces are located on opposite sides of a longitudinal centre line through the rearward limb of the latch member. The rearward limb extends from a base of the latch member having a planar forward bearing surface which seats on an adaptor cap fitted on the rearward end of the writing element and also carries the laterally extending oppostely directed abutment means, which are termed latch arms in that patent. Also in that patent the latch means are termed latch shoulders. In the operation of this prior art retractable mechanism, assuming the mechanism is assembled and operational, one of the latch arms will be in engagement with its respective latch shoulder (say the rearward latch shoulder defining the retracted position of the writing element). With the writing element retracted, the cam face on the side of the latch member remote from the engaged latch arm should be positioned such that, as the plunger is depressed, a respective one of the plunger strike faces strikes that cam face to advance the latch member longitudinally in the passage. This action maintains the latch rocker (or pivot), on the same side of the latch member as the engaged latch arm, in contact with the interior wall of the passage and, as the latch member advances sufficiently to release the engagement between the latch arm and the rearward latch shoulder, the force of the plunger strike face acting on the cam face causes the latch member to pivot about the latch rocker and displace the other latch arm laterally towards the forward latch shoulder which it engages when the plunger advances latch member forwardly below the forward latch shoulder. When the plunger is released, the resilient bias acting on the writing element causes the latch member to pivot at the point of engagement between the latch arm and the forward latch shoulder to bring the other latch rocker into contact with the interior wall of the passage adjacent thereto and thereby align the other cam face (the one nearest to the latch arm engaged with the forward latch shoulder) for contact by its associated plunger strike face on the next depression of the plunger. The next depression of the plunger similarly releases the now engaged latch arm from the forward latch shoulder, and the force of the strike face on the cam face effects pivoting of the latch member about the latch rocker in contact with the passage interior wall resulting in lateral alignment of the other latch arm with the rearward latch shoulder. Thus, the rearward latch shoulder is engaged by its associated latch arm when the plunger is released and the latch member moves rearwardly due to the resilient bias acting on the writing element. After this engagement, the other latch rocker (or pivot) is brought similarly into engagement with the passage interior wall adjacent thereto such that the cam face on the latch member required for the next depression of the plunger is aligned for contact by its respective strike face.
In U.K. Pat. No. 804,903, the correct alignment of the cam faces on the latch member for contact of the required one of them by its associated plunger strike face when the plunger is next depressed is critical to the operation of this retractable mechanism. Likewise, the location of the latch rockers or pivots on the sides of the latch member rearward limb is critical. Furthermore, a high degree of precision of alignment in the assembly of the components is critical to reliable operation of this retractable mechanism. The embodiment illustrated in the patent requires a multiplicity of components which can lead to high material costs, high production labour costs and the problem of high failure rates in an automated assembly situation.
SUMMARY OF THE INVENTION
The present invention seeks to provide a retractable mechanism in which the displacement of the latch member is effected more reliably, more simply and requires simpler and fewer component features. By specifying simpler components or component features, the present invention also seeks to facilitate reliable automated assembly, lower component costs and labour costs, and fewer rejects following post assembly inspection. The present invention specifically seeks to employ a latch member which does not require, during assembly, critical alignment of its rearward limb with respect to its lateral position relative to the plunger.
According to the present invention there is provided a retractable mechanism for a writing element as hereinbefore defined characterised in that the latch member has a rearwardly extending limb with opposite faces configured for linear contact with contiguous portions of the passage interior walls, the plunger contacting the rearward end of the rearward limb on each successive depression thereof, the latch member having fulcrum means at a forward portion thereof for engagement with the writing element (when present), wherein, in use, depression of the plunger advances the latch member with its rearward limb in sliding contact with the passage interior wall contiguous with the last engaged latch means whereby the resultant of the depression force on the plunger and the resilient bias on the writing element laterally displaces latch member such that the abutment means remote from the last engaged latch means is longitudinally aligned with its associated latch means, and thereafter release of the plunger enables the now aligned abutment means and latch means to engage followed by rocking for the latch member about its fulcrum means to place a respective face of the rearwardly extending limb of the latch member in linear contact with that portion of the passage interior wall contiguous with the now engaged latch means thereby positioning the rearwardly extending limb of the latch member in readiness for the next depression of the plunger.
Embodiments of this invention have the advantage that during assembly there is no critical lateral alignment of the latch member relative to the plunger since subsequent contact between the plunger and the latch member merely requires the forward end of the plunger to act on the rearward end of the latch member. Component features and parts are greatly simplified and lend themselves to cost reductions in component materials, simplified and reliable automated assembly and fewer inspection rejections with the economic savings which result.
It is a preferred feature of one embodiment of the invention that each latch means (5,6) and its associated latch arm (11,12) have co-operating means (15,16) to facilitate a pivot action therebetween, and wherein when, following depression of the plunger (4) to release the last engaged latch arm (11,12), the latch member (7) is urged rearwardly then the respective one of the faces (21,22) of the limb (23) moves rearwardly in sliding contact with the co-operating means (15) of a latch means (5,6) thereby laterally positioning the latch member (7) such that the resilient bias (A) acting on the writing element (1) is effective to cause said pivot action between the now engaged latch arm (11 or 12) and latch means (5 or 6). It is important to ensure by the sliding contact of the limb (23) with the co-operating means (15), specifically a pivot edge, that the co-operating means (15,16) are brought into register since this also ensures that the line of action of writing element (1) (due to its resilient bias in the rearward direction) on the latch member (7) is effective to rock the latch member (7) about its fulcrum (9) and effective to bring about the pivot action between the co-operating means (15,16). If this line of action of this force (A) was too near the side wall (of the engaged latch means and latch arm), then the requisite pivot action and rocking of the latch member would not occur.
It is also a feature of the preferred embodiment that the rearwardly extending limb (23) has side faces (21,22) which are linear when viewed in a plane normal to said longitudinal direction, said latch arms (5,6) on by the forward portion (8) of the latch member (7) being arranged laterally of the limb (23) and being configured to define therewith notches (16) for co-operation with pivot edges (15) on the latch means (5,6) to facilitate sliding contact between said pivot edges (15) and the side faces (21,22) to bring said pivot edges (15) and notches (16) into register for pivot action therebetween, and said fulcrum means (9) on said forward portion (8) of the latch member (7) depends below said latch arms (5,6) for engagement with the writing element (1), whereby rearward movement of the writing element caused by the force (A) of its resilient bias brings the pivot edges (15) and notches (16) into register and ensures that the latch member (7) is able to rock about its fulcrum (9).
It is a further feature of the preferred embodiment that the passage defining means (2) and the latch means (5,6) are integral, the latch means (5,6) being arranged at laterally opposite and axially spaced locations at the end of the passage (3) communicating with the latch member (7), the latch member (7) alternately contacting opposite portions (13, 14) of the passage (3) contiguous with respective ones of the latch means (5,6) according to which of its latch arms (11,12) is engaged with a latch means (5,6).
DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings in which:
FIG. 1 shows schematically and in elevation, partly in section a retractable mechanism for a writing element in the retracted position of the element;
FIGS. 2 to 5 show diagrammatically the operation of the retractable mechanism in transferring the writing element from the retracted position of the member in FIG. 1 to the advanced position of the member in FIG. 5;
FIGS. 6 to 8 show diagrammatically the operation of the retractable mechanism transferring the writing element from the advanced position of FIG. 5 to the retracted position of FIG. 1;
FIG. 9 shows a writing instrument incorporating a retractable mechanism according to the embodiment of FIG. 1;
FIGS. 10A and 10B show a section in elevation and a bottom or transverse view looking from the forward end respectively of a second embodiment of a latch member of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In FIG. 1 there is shown schematically a retractable mechanism for a writing element 1. Passage defining means 2 define a passage 3 in which a plunger 4 is constrained to move in the longitudinal direction of the passage 3. A pair of latch means 5,6 are oppositely disposed, when viewed in a plane normal to the longitudinal direction of passage 3. These latch means 5,6 are also mutually spaced in the longitudinal direction of passage 3; as will become clear the latch means 5,6 determine advanced or projected and retracted positions of the writing element 1. A latch member 7 is reciprocally displaceable in the longitudinal direction of passage 3 by means of the plunger 4. Latch member 7 has one forward end 8 defining a pivot edge 9 for engagement with the end face 10 of the writing element 1. A pair of latch arms 11,12 extend laterally of the latch member 7 in opposite directions and each of the latch arms 11,12 is disposed for engagement with an associated one of the latch means 5,6.
The writing element 1 is resiliently biased (by means not shown, but see FIG. 9) in the direction of arrow A to urge the latch member 1 in said longitudinal direction until one of the latch arms 11,12 contacts its associated latch means 5,6: as shown in FIG. 1 latch arm 11 contacts latch means 5. The plunger 4 may be advanced against the bias acting on the latch member 7. From the position shown in FIG. 1 an actuating advance of the plunger 4 causes the latch member 7 to be angularly displaced about its pivot edge 9 and about its position of contact with the plunger 4 to the extent necessary for the other of the latch arms 12 to be aligned with its associated latch means 6 (as will be explained below with reference to FIGS. 2 to 5). As will also be explained below, release of the plunger 4 (after an actuating advance thereof) allows the latch arm 12 so aligned to engage its associated latch means 6. This engagement between latch arm 12 and latch means 6 is maintained until a further advance of the plunger 4 is effected.
In this embodiment, it is a preferred feature that each latch means 5,6 and its associated latch arm 11,12 is configured to facilitate a pivot action therebetween. After the plunger 4 is retracted, under the influence of the bias acting on latch member 7, to the extent that one of the latch arms 6 engages its associated latch means 12 (as in FIG. 4), pivot action of the latch member 7 is initiated and continues until the latch member 7 abuts that portion 14 of the passage 3 contiguous with the latch means 6 (FIG. 5). In this embodiment, the latch means 5,6 each define a pivot edge 15 and the latch arms 11,12 each define a notch 16 for line contact with the respective pivot edge 15 about which line contact the pivot edge 15 executes this pivot action.
As shown in FIG. 1, the passage defining means 2 and the latch means 5,6 are integral and form part of a casing for the retractable mechanism. The latch means 5,6 are arranged at laterally opposite and axially spaced locations at the end 17 of the passage 3 communicating with the latch member 7. The latch member 7 alternately contacts (FIGS. 1 and 5) opposite portions 13, 14 of the passage 3 continguous with respective ones of the latch means 5,6 according to which of its latch arms 11,12 is engaged with a latch means 5,6.
The operation of the retracted mechanism in transferring the writing element 1 between the retractable position of the member in FIG. 1 and the advanced position of the member in FIG. 5 will now be described. With the mechanism in its FIG. 1 attitude, the plunger 4 is advanced by a force applied to the end thereof 18 which extends outside the passage 3. This force overcomes the bias acting on the latch member 7 and causes plunger 4, latch member 7 and writing element 1 to advance in direction of arrow B (FIG. 2). This advance initially releases the latch means 11 from the latch arm 5. The forces A & B are not co-linearly directed, but rather act along separate, spaced longitudinally extending paths with respect to the passage 3. This gives rise to a couple which results in a force (FIG. 3) in the direction of arrow F. Until latch arm 12 passes longitudinally below the latch means 6, the force F simply urges the latch member 7 laterally of the passage 3 to maintain contact between the passage wall 14 and the latch member 7. Continued advance of the plunger 4 causes the latch member 7 to advance to a position in which the latch arm 12 is longitudinally below the latch means 6 (FIG. 3). As the latch member 7 advances further (downwardly in FIG. 2), the latch member 7 no longer contacts the passage wall 14 and in consequence the force F urges the latch member 7 laterally across the cavity 19 towards a position in which the latch arm 12 is below the latch means 6 and contacts the side wall 20. As the latch member 7 effects this lateral displacement, this displacement is accompanied by a pivoting action of the rearwardly extending limb 23 of the latch member 7 about its position of contact with the plunger 4. In addition, during the lateral displacement of the latch member 7, displacement of the upper end 10 of the writing element 1 towards the side wall 20 also occurs (as shown in FIG. 3). This displacement of the upper end 10 is possible if the writing element 1 is flexible (as in the case of some refills of writing instruments) and also if the mounting of a rigid writing element 1 (which is not shown and which is at the end of member 1 remote from end 10) is such as to allow tilting of the member 1.
When after advancing plunger 4 to position the latch member 7 with the latch arm 12 longitudinally below the latch means 6, the plunger 4 is released, then the bias acting on writing element 1 causes the writing element 1 to urge the latch member 7 upwardly until, as shown in FIG. 3, the latch arm 12 contacts the latch means 6 and engages therewith. This engagement is retained until plunger 4 is next advanced.
In this preferred embodiment, latch arm 12 is provided with notch 16 which engages in line contact with a pivot edge 15 on the undercut latch means 6. This facilitates pivot action of the latch member 7 about the pivot edge 15 as illustrated in FIG. 4. The pivot action about pivot edge 15 results from the bias acting upwardly on the writing element 1 which is also applied to the latch member 7 and creates the couple G. In consequence, latch member 7 continues to pivot about the pivot edge 15 until contacting the portion 14 of the passage 3 contiguous with the latch means 6, as shown in FIG. 5.
The rearward movement of the latch member 7 is accompanied by the pivot edge 9 moving away from the side wall 20 in the cavity 19. As may be seen from FIGS. 1 and 5, the latch member 7 is contoured at its upper side faces 21, 22 for linear contact with the portions 13, 14 of passage 3 in its retracted and advanced attitudes shown in these Figures. This configuration of the side faces 21, 22 of the latch member 7 on the limb 23 leads to the limb 23 having a substantially triangular section as seen in FIGS. 1 to 5. Limb 23 and pivot end 8 are longitudinally oppositely disposed on latch member 7 relative to latch arms 11, 12.
It is important to note that, as the latch member 7 moves rearwardly from its FIG. 3 position to its FIG. 4 position, sliding contact between the pivot edge 15 and the side face 22 of the limb 23 ensures that the latch member 7 moves laterally to a position in which the pivot edge 15 and notch 16 are in register for subsequent pivot action therebetween. Furthermore, this lateral movement of the latch member 7 ensures that the resilient bias acting on the writing element is effective to cause the requisite pivot action between the now engaged latch arms 12 and latch means 6. In addition this is then accompanied by rocking of the latch member 7 about its fulcrum means 9. This places the side face 22 of limb 23 in linear contact with the passage portion 14 contiguous with the latch means 6 thereby positioning the limb 23 of the latch member 7 in readiness for the next depression of the plunger 4. The plunger 4 returns to its rearward position due to the bias acting on the writing element 1. It is possible to bias the plunger 4 so that, when released, it returns under its own bias to its rearward position.
The operation of the retractable mechanism in transferring the writing element 1 from the advanced position of FIG. 5 to the retracted position of FIG. 1 will now be described also referring to FIGS. 6 to 8. This operation is analoguous to that described above for the advance of the writing element 1. FIG. 6 shows schematically the release of the latch arm 12 from the latch means 6 as it is about to occur with the plunger 4 being urged in the direction of arrow B. At the same time, force F urges latch member 7 towards side wall 24 of cavity 19 aligning latch arm 11 with latch means 5. Contact between the latch member 7 and side wall 24 occurs with the plunger 4 depressed as shown in FIG. 7. At this point, limb 23 is still in contact with passage portion 14. On release of the plunger 4, the bias acting on the writing element 1 causes the latch member 7 to be urged upwardly until latch arm 11 contacts and engages latch means 5 (FIG. 8). During this movement, as the latch member 7 contacts side wall 24 the upwardly directed bias force A also tends to rotate the latch member 7 in the sense urging limb 23 towards passage portion 13. As shown in FIG. 8, when the latch arm 11 with its notch 16 engages pivot edge 15 of latch means 5, the couple G causes limb 23 to pivot about pivot edge 15. This pivot action continues until side portion 21 of limb 23 contacts wall portion 13 of passage 3 in the retracted position of the writing element 1 shown in FIG. 1. Again, the engagement between latch arm 11 and latch means 5 is maintained due to the bias on element 1 until plunger 4 is next advanced. Also pivot edge 9 is moved away from the side wall 24 from its FIG. 8 position to its FIG. 1 position.
A writing instrument incorporating the retractable mechanism of FIG. 1 is shown in FIG. 9 which is an elevational view, partly in section of a ball-point pen. The pen has a hollow casing 31 which is provided at its forward end 32 with an internal shoulder 33 and a bore 34 of reduced diameter with respect to the hollow interior 19 of the casing 31. The bore 34 is of a suitable diameter for a ball-point refill 36 to be slidingly displaced therein for the purpose of displacing a tip portion 35 between its retracted position and its advanced writing position.
The refill 36 is resiliently biased towards its retracted position by means of a spring 37 which bears upon the shoulder 33 and a crimp 38 on the refill 36. The refill 36 is restrained from further displacement towards the top of the casing 31 by contact with the pivot edge 9 on the latch member 7 of the retractable mechanism. Since the retractable mechanism is that of FIG. 1, the same reference numerals are employed for like parts in FIG. 9 and a complete description of its structure and operation will not be repeated. The casing 31 is provided with a hollow closure member 39 which is threadedly connected thereto at 40. The plunger 4 of the retractable mechanism is located in a passage 3 of the closure member 39 and by known conventional means not shown, is retained within the passage 3. Assembly of the ball-point pen requires the spring 3 and refill 36 to be placed in the casing 31. The plunger 4 is then arranged in the closure member 39. Then the latch member 7 is placed in the passage 3. The latch member 7 will automatically take up its correct position in use and no particular lateral alignment is required at this assembly stage which represents a significant advantage over the prior art mechanism. Finally, the casing member 31 and closure member 39 are threadedly connected together.
In the aforegoing embodiment of the retractable mechanism of FIGS. 1 to 8, the latch member 7 is shown to be provided with a pivot edge 9 which rests on the face 10 at the end of the refill 36. The pivot edge 9 provides fulcrum means for pivot action of the latch member 7 about the end face 10 of the refill 36. In a modification shown in FIGS. 10A and 10B, the latch member 7' may be provided with a recess to receive the upper end of the refill 36. The recess may be formed by a cavity having faces defining a dihedral angle. Such a recess will enable the latch member 7' to perform its required pivot action about the end of the refill. | A retractable mechanism for a writing element especially the expendable refill of a ball-point writing pen, is disclosed. A manually depressible plunger (4) advances a latch member (7) biased to retract the plunger (4). The latch member (7) has a pair of latch arms (11,12) one of which in an advanced or retracted position thereof engage a latch means (5,6). Depression of the plunger (4) releases the engaged latch arm (11 or 12) from its latch means (5,6). The resultant of the force on the plunger (4) and bias on the writing element (1) then laterally aligns the other latch arm (12 or 11) with its latch means (6 or 5). On release of the plunger (4), the bias on the writing element (1) brings a co-operating notch (16) and pivot edge (15) of the aligned latch arm (11,12) and latch means (5,6) into register for pivot action therebetween. This pivot action and rocking of the latch member (7) about its fulcrum (9) positions the latch member rearward limb (23) in readiness for the next depression of the plunger (14) whereby the writing element (1) may be displaced between its retracted and projected positions (or vice versa) in response to successive depressions of the plunger (4). | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electronically controlled timepieces, and more particularly to a circuit whose components are simplified so that they may be easily fabricated in a monolithic integrated circuit.
2. Prior Art
Most electronic circuits used in conventional electronic timepieces require several separate electronic components whose fabrication by monolithic integrated circuit techniques is extremely difficult.
In a typical electronic timepiece as shown in the block diagram of FIG. 1, electric signals from an oscillator means are detected by a mechanical-electrical transducer and, after appropriate control and amplifying functions are performed by an electronic circuit, the modified signals are used to supply energy to sustain the vibration of the oscillator by means of an electromechanical transducer. Thus each component is a link in a closed loop. The signal from the oscillator means is relayed and transformed by suitable means to a time display device.
The electronic circuit shown in FIG. 2 is commonly employed in prior art electronic timepieces of the balance wheel, tuning fork and sound fragment types. A phase sensing coil, Ls, is usually part of the electro-mechanical transducer. Transistor Qo and circuit elements, C, R, and parasitic capacitance Cx correspond to an amplifying and control circuit, and drive coil, L D , is part of the electromechanical transducer. The oscillator means may be a tuning fork having small permanent magnets on its tines or a balance wheel having appropriately disposed magnetic elements. An electromagnetic flux linkage serves to couple the energy between the oscillator means and the transducers. A major reason why the circuit illustrated in FIG. 2 cannot be converted to a monolithic integrated circuit is due to the difficulty in fabricating the resistor and capacitor elements according to integrated circuit techniques. For example, circuit values required for the balance wheel type are 0.47 μF for capacitance and 10 megohms for resistance, and for the tuning fork type 0.22 μF for capacitance and 2.2 megohms for resistance for the circuit illustrated in FIG. 2. The achievement of these capacitance and resistance values using ordinary bipolar fabrication techniques has been considered difficult. However, it has recently been possible (Koehler, U.S. Letters Pat. No. 3,727,151) to fabricate the circuit shown in FIG. 2 according to monolithic integrated circuit techniques for electronic timepieces of the tuning fork type, using the values of C = 200 pF, R = 100 megohms, and super-gain bipolar transistors having hFE = 5000. While mass fabrication of capacitors in the 200 pF range is feasible, the values of transistor hFE and resistor R profitably attainable for mass fabrication under ordinary bipolar techniques are approximately 1 megohm for resistor R and about 1000 for transistor hFE. Understandably, therefore, the above-mentioned prior art presents a great many problems for mass fabrication that an extremely low yield is obtained and the circuit cannot be put into practical use.
We have, using new fabricating and circuit technologies, previously disclosed a method of fabricating an electronic circuit (shown in FIG. 3) which can be converted to a monolithic integrated circuit device (U.S. Pat. No. 3,905,188). The circuit is divided into three major blocks:
1. a first block, comprising capacitor C 1 , resistors R 1 - R 4 , and transistors Q 1 - Q 3 , which is an amplitude control component of the oscillator and which processes signals from the coil Ls portion of a mechanical-electrical transducer by differentiation with capacitor C 1 ;
2. a second block, comprising resistors R 5 - R 8 and transistors Q 4 - Q 11 , which is an amplifier for amplifying signals from the transducer Ls received through capacitor C 2 ; and
3. a third block, comprising resistor R 9 and capacitor C 2 , which is a time constant component to control the resonant frequency of the circuit.
The maximum values employed in this circuit are a resistance of 500 megohms, a capacitance of 2000 pF, and an npn transistor having an hFE in the range of 500. A novel feature of the above invention when compared with conventional bipolar circuits resides in the resistor and capacitor components. The resistor, R 9 , employs an element (hereinafter referred to as MOS-R) comprising a drain of depletion-type MOS transistor as one terminal, and source, gate and base plate connected in series as the remaining terminal. The capacitor, C 2 , has a metal-oxide-alumina-oxide silicon structure (hereinafter referred to as MO'AOS), using said metal layer as one terminal and the silicon layer as the remaining terminal. Although a similar capacitance can be obtained from a common MOS formula for the capacitor, i.e., metal-oxide-silicon, the aforementioned MO'AOS formula is more advantageous for fabrication when combined with MOS-R. Even with this fabricating technique, the circuit is still complex as can be seen in FIG. 3.
Consider the operating principle of the device shown in FIG. 2. Normally, transistor Qo will be biased to be approximately at the cut-off point. When a switch is closed and a step voltage from the circuit voltage supply is applied to the node of coil Ls and the RC tank circuit, the voltage across the RC tank circuit will ring about the cut-off point of transistor Qo. The collector current will therefore have an impulse frequency as determined by the RC tank circuit. If the resonant frequency of the collector current or RC tank circuit is matched to the resonant frequency of a mechanical oscillator or a tuning fork, a sympathetic voltage and current may be set up in sensing coil Ls. The voltage induced in coil Ls will reinforce the resonant ringing of the RC tank circuit and a self-sustaining oscillation will be set up. Thus, the time constant of the RC tank circuit must be chosen to match the resonant frequency of the oscillator means. If RC time constant is shorter than the oscillator's resonant value, the base bias will oscillate too fast to drive the collector current at the oscillator's resonant frequency. The oscillator will accordingly be driven at a frequency less than its resonant frequency. The reverse situation can easily be surmised. As a consequence, excessive power may be consumed or the oscillator means may fail to resonate with sufficient amplitude to drive the clock mechanism.
When used in a timepiece of the balance wheel type, the FIG. 2 circuit having ordinary transistor hFE values requires the values of R = 10 megohms, C = 0.47 μF, and produces a time constant of 4.7 second; whereas the FIG. 3 circuit without the first circuit block, the amplitude control component, requires the values of R 9 = 500 megohms, C 2 = 200 pF, and has a time constant of 0.1 second. Thus, the prior art circuit illustrated in FIG. 3, having only the second and third blocks, the amplifier and time constant components, produces resonant oscillation having a shorter period and a higher frequency than the FIG. 2 circuit, making the FIG. 3 circuit unsuitable as a drive circuit for a balance wheel type timepiece. The time constant R 9 C 2 needs to be an order of magnitude higher. However, the fabrication of a capacitor and resistor having a RC product in the range of 1 to 10 seconds is entirely impractical according to present integrated circuit mass production techniques. However, our prior art circuit, illustrated in FIG. 3, has a low enough effective resonant frequency so as to be successfully coupled to balance wheel oscillators.
A major drawback of the FIG. 3 circuit lies in the amplitude control component, the first block, whose function is to lengthen the time constant of the second and third circuit blocks, i.e. the amplifier and time constant components, in order to make the circuit usable in balance wheel timepieces. The design criteria and tolerances of the circuit portion denoted as the first block in FIG. 3 are very critical and the overall performance of the circuit is extremely sensitive to small variations. Without exception even the most careful mass production processes have obtained very small yields of this circuit and small improvements in yields are difficult to achieve and are obtained only at high cost.
Therefore, what is needed is an integrated circuit amplifier and oscillator which is capable of being combined with a mechanical oscillator, and which is adapted to economical and practical mass production techniques without requiring large resistance, capacitance or transistor hFE values.
BRIEF SUMMARY OF THE INVENTION
Applicants have found that the aforementioned amplitude control component, the first block of the FIG. 3 circuit, can in fact be omitted contrary to the anticipation, when the circuit is applied to a timepiece of the tuning fork type having a tuning fork with a certain resonant frequency. On the basis of this general hint, a simpler timepiece has been developed for practical use.
Accordingly, the primary object of this invention is to provide an electronic circuit for electronically controlled timepieces consisting of a monolithic integrated circuit comprising a multistage amplifier.
Another object of this invention is to provide an electronic circuit for electronic timepieces in which an amplitude control means is unnecessary.
Still another object of this invention is to provide a variety of different types of electronic timepieces applying the circuit to various oscillator means.
The novel features which are considered to be characteristic of the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the components of an electronic timepiece.
FIG. 2 illustrates an example of a commonly known drive circuit for an electronic timepiece.
FIG. 3 shows a prior art monolithic integrated circuit.
FIG. 4 shows an embodiment of the monolithic integrated circuit of the timepiece of this invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a general arrangement of an electronic timepiece in the form of a block diagram, where electric signals from an oscillator means are picked up by a mechanical-electrical transducer and after appropriate control and amplifying functions are performed by an electronic circuit, the modified signals are used to supply energy to sustain the vibration of the oscillator means by means of an electro-mechanical transducer.
The electronic circuit of this invention generally comprises a multistage amplifier including feedback resistors, capacitors and active elements as a one-chip monolithic integrated circuit. The resistors may preferably have a two-terminal element, where one terminal of said element is the drain of a MOS transistor of the depletion type and the other terminal of said element is a source, gate and substrate connected in series and the capacitor may have a metal-oxide-alumina-oxide-silicon structure where said metal is one terminal and said silicon is the remaining terminal.
Now referring to FIG. 4 which specifically shows an embodiment of the circuit applicable to the timepiece of this invention, a capacitor C 11 , resistors R 11 , R 12 , R 13 , R 14 , and R 15 , npn bipolar transistors Q 21 - 26 and Q 28 , and pnp bipolar transistor Q 27 are arranged in the following manner. Each terminal of said resistor R 11 , R 12 , R 13 , R 14 is connected, together with the emitter of bipolar transistor Q 27 to a positive voltage terminal of a power source, while the remaining terminal of said resistors is arranged such that R 11 connects to collectors of transistors Q 21 and Q 22 and base of transistor Q 23 , R 12 connects to collectors of transistors Q 23 and Q 24 and the base of transistor Q 25 , R 13 connects to the collector of transistor Q 25 , and R 14 connects to the collector of transistor Q 26 and the base of transistor Q 27 . The emitters of the transistors are arranged such that the emitter of transistor Q 21 connects to the base of transistor Q 22 , the emitter of transistor Q 23 connects to the base of transistor Q 24 , the emitter of transistor Q 25 connects to the base of transistor Q 26 , and the collector of transistor Q 27 connects to the base of transistor Q 28 , and emitters of transistors Q 22 , Q 24 , Q 26 and Q 28 connect to the minus voltage terminal of the power source. Each terminal of resistor R 15 and capacitor C 11 is connected to the base of transistor Q 21 , and the remaining terminal of said resistor R 15 is connected to the collector of transistor Q 28 , while the remaining terminal of said capacitor C 11 is connected to said mechanical-electrical transducer, and one terminal obtained by joining said resistor R 15 and collector of transistor Q 28 is connected to said electro-mechanical transducer.
As compared with the prior art circuit shown in FIG. 3, the first block, the amplitude control component, is omitted in the FIG. 4 circuit. In the operation, if R 15 = 50 megohms, and C 11 = 150 pF, the circuit of FIG. 4 has a time constant of 7.5 × 10.sup. -8 sec.; and if R = 2.2 megohms, C = 0.22 μF, the circuit of FIG. 2 has a time constant of RC = 4.84 × 10.sup. -1 sec. (One reason for this is that the amplifier characteristics will change when more than one transistor is used. For example, since the circuit of FIG. 4 requires twice as much base bias as the circuit of FIG. 2, this fact alone increases the time constant by two.) In addition, a greater difference in input impedance is expected because the gain in the circuit of FIG. 4 is much greater than that in the circuit of FIG. 2. Another reason resides with the mechanical tuning fork oscillator in which the Q value of the resonance is considerably greater than that in a balance wheel oscillator. In other words, the circuit of FIG. 4 tends to be pulled into resonance at the resonant frequency of the mechanical tuning fork and therefore is much more stable than when used in combination with a balance wheel oscillator. This is why it is possible to omit the amplitude control component from the circuit illustrated in FIG. 3 and simplify it to a circuit having only the amplifier and time constant components as shown in FIG. 4, by modifying the circuit according to resonant frequency and resonance Q values of the tuning fork oscillator.
The amplifier component of the FIG. 4 circuit is essentially of an input-output phase inverter amplifier, which is capable of large gains through a multi-stage inverter, rather than through a single transistor which is incapable of obtaining sufficiently large gains. In the preferred embodiment, an input-output phase inverter amplifier is used as shown in FIG. 4, since the output of the mechanical-electrical transducer and the input of the electro-mechanical transducer in a tuning fork driven timepieces are of the phase-inverter type. However, the circuit should be designed accordingly if the mechanical oscillator calls for a non-inverting type of amplifier.
As discussed above, a drive circuit using a circuit comprising a multi-stage amplifier component and a time constant component which are modified to match the resonant frequency, Q value of a tuning fork allows one to fabricate a monolithic integrated circuit of fewer components and having higher yields.
While there have been shown and described a preferred embodiment of a monolithic integrated circuit for an electronic timepiece of the tuning fork type, application to timepieces of the balance wheel type, the sound fragment type and the like with oscillators having high resonance frequencies and high Q values is possible by making modifications and changes which are obvious to one with ordinary skill in the art without departing from the essential spirit of the present invention. | An electronic timepiece having an electronic circuit which comprises a monolithic integrated circuit including a multistage amplifier. The amplifier of the circuit is so designed that an amplitude control component, which has been considered indispensable in the existing art, is unnecessary in the circuit, whereby various types of electronic timepieces are obtainable in a simple and compact manner by applying the monolithic circuit to different types of oscillator means. | 6 |
FIELD OF TECHNOLOGY
[0001] This disclosure relates generally to fields of electronics and electrical technology, and more particularly to a power supply management.
BACKGROUND
[0002] A voltage bus may be powered by a number of voltage supplies. The voltage supplies may be in parallel. If a particular voltage supply fails another voltage supply may be activated. For example, the particular voltage supply may be in an active state and the other voltage supply may be in an inactive state to conserve power. However, activation of the other voltage supply may take a period of time. During the period of time, the voltage to the voltage bus may be interrupted. A load of the voltage bus may be damaged as a result of the interruption of the voltage to the voltage bus.
SUMMARY
[0003] This summary is provided to comply with 37 C.F.R. §1.73, requesting a summary of the invention briefly indicating the nature and substance of the invention. It is submitted with the understanding that it will not be used to limit the scope or meaning of the claims.
[0004] Several methods and system to implement efficient management of power supply are disclosed.
[0005] In an exemplary embodiment, an apparatus of a voltage supply includes a power supply providing a voltage. The apparatus includes an active supply module communicating with a supply voltage to a voltage bus through an ORing element. The active supply module may be coupled with the power supply. The apparatus also includes a redundant supply module providing an additional voltage to the voltage bus if the active supply module fails, through an additional ORing element. The redundant supply module may be coupled with the power supply in parallel with the active supply module. Further, the apparatus includes an automatic changeover module detecting a failure of the active supply module disabling the active supply module and enabling the redundant supply module to supply the additional voltage supply to the voltage bus. Furthermore, the apparatus also includes a voltage bus coupled with a load. The active backup module may be provided through a supplemental ORing element, a backup voltage to the voltage bus if the overall voltage value of the voltage bus decreases below a specified voltage value. The active backup module may include a power source.
[0006] In an exemplary embodiment, a method of a voltage supply includes communicating a supply voltage to a voltage bus through an ORing element. The voltage supply may detect a failure to communicate to the voltage bus through the ORing element. The voltage supply may disable the communication to the voltage bus through the ORing element. Further, the method includes transmitting another supply voltage to the voltage through another ORing element in parallel to the ORing element. In addition, the method includes supplying an additional voltage to the voltage bus through an additional ORing element if a communication of the supply voltage through the ORing element fails. The method also includes providing a backup voltage to the voltage bus through a supplemental ORing element if the overall voltage value of the voltage bus decreases below a specified voltage value.
[0007] An exemplary embodiment includes a system of voltage supply. The system of a voltage supply includes a voltage supply unit providing a voltage to an active supply and/or a redundant supply. The voltage supply may also include an active supply to supply the voltage to a load via a bus. Further, the system includes a redundant supply providing the voltage to the load if the active supply is disabled. The system also includes a control module to determine a failure of the active supply, to automatically disable the active supply and to enable the redundant supply if the active supply is disabled. Further, the system also includes an active backup supply providing an additional voltage with an ORing element to the load via the bus. The active backup supply may be provided during a period of an automatic disabling of the active supply until an enabling of the redundant supply. The additional voltage may be less than the voltage to the load supplied by the active supply.
[0008] The methods, systems, and apparatuses disclosed herein may be implemented in any means for achieving various aspects, and may be executed in a form of a machine-readable medium embodying a set of instructions that, when executed by a machine, cause the machine to perform any of the operations disclosed herein. Other features will be apparent from the accompanying drawings and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
[0010] FIG. 1 is a system view illustrating active power supplies providing power to a load connected to a voltage bus, according to one embodiment.
[0011] FIG. 2 is a system view illustrating a supply of power to a voltage bus under normal operating conditions, according to one embodiment.
[0012] FIG. 3 is a system view illustrating transition of active power supply to an inactive state, according to one embodiment.
[0013] FIG. 4 is a system view illustrating activation of a redundant supply module, according to one embodiment.
[0014] FIG. 5 is a process flow illustrating management of a supply voltage, according to another embodiment.
[0015] Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.
DETAILED DESCRIPTION
[0016] Several systems and a method for an active backup auto changeover voltage bus are disclosed.
[0017] Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments.
[0018] FIG. 1 is a system view illustrating active power supplies providing power to a load connected to a voltage bus, according to one embodiment. In particular, FIG. 1 illustrates an active backup module 100 , a voltage bus 102 , an ORing element 104 , a stored energy charge line 106 , an active supply module 108 A-N, a redundant supply module 110 , an automatic changeover module 112 , a power supply 114 and a system load 116 A-N, according to one embodiment.
[0019] The power supply 114 may be any source of power. In other embodiments, it may be a voltage or a current input. The source of electrical power may be a as rectifier, inverter, linear regulator, switching power supply, a transformer, a generator or an alternator.
[0020] An active supply module 108 A-N includes a source of electrical power. The system load 116 A-N is a device that receives electrical power. The active supply module 108 A-N may be implemented in hardware and software or in other example embodiments in hardware alone.
[0021] The active backup module 100 provides a voltage to the system load 116 A-N. The active backup module 100 includes a power supply that supplies power to the voltage bus 102 during a period when the voltage value of the voltage bus 102 drops below a specified level. The transition may occur during a switching of an active supply module 108 to a redundant supply module 110 . During the transition, the power to the system load 116 A-N may be provided by the active supply module 108 B and active supply module 108 N.
[0022] The automatic changeover module 112 includes both firmware and software functionalities. The automatic changeover module 112 may be coupled with a server in other example embodiments. The automatic changeover module 112 detects a failure of the active supply module 108 A, disables the active supply module 108 A and enables the redundant supply module 110 to supply the additional voltage supply to the voltage bus 102 . For example, in a particular example embodiment, the switching of one or more power supply from active state to an inactive state may occur with the help of automatic changeover module 112 . The active supply module 108 A-N generates the required voltage from the power supply 114 . The automatic changeover module 112 detects the failure of the active supply module 108 A-N. The automatic changeover module 112 may be implemented in hardware and software or in other example embodiments in hardware alone. The active supply module 108 A-N and/or the redundant supply module 110 are voltage sources that may be designed to supply the power requirement to the system load 116 A-N in an entity.
[0023] The redundant supply module 110 is coupled in series with the power supply 114 and in parallel with the active supply module 108 A-N. If the active supply module 108 fails the automatic logic changeover module 112 deactivates the active supply module 108 . The automatic logic changeover module 112 then activates the redundant supply module 108 . In other example embodiments, there may be a plurality of redundant supply modules.
[0024] The voltage bus 102 is a medium (e.g., a wire, a cable) for transfer of power from the power supply 114 to the system load 116 A-N. The voltage bus 102 may be coupled to the system load 116 A-N.
[0025] The active back module 100 provides additional backup power to the system load 116 A-N during an event of failure of one or more active supply modules 108 A-N and during the period of activation of the redundant supply module 108 . The active backup module 100 provides surge power if the overall voltage of the voltage bus 102 drops below a threshold voltage value.
[0026] The ORing operation is achieved with the ORing element 104 . An ORing element 104 may be an ORing diode, an ORing Mosfet and/or any other semiconductor device utilizing OR logic.
[0027] The stored energy charge line 106 couples the voltage bus 102 to a batter included in the active backup module 100 . The stored energy charge line 106 recharges a battery.
[0028] FIG. 2 is a system view illustrating a supply of power to a voltage bus under normal operating conditions, according to one embodiment. In particular, FIG. 2 illustrates an active backup module 200 , a voltage bus 202 , an ORing element 204 , a stored energy charge line 206 , an active supply module 208 A-N, a redundant supply module 210 , an automatic changeover module 212 , a power supply 214 , a system load 216 A-N and a current a 218 , according to one embodiment.
[0029] In the example embodiment, the active supply module 208 A-N generates the current α 218 required for the system load 216 A-N at an instance T=1. The active supply module 208 A—is in an active state of generating power to the voltage bus 202 . During normal operating condition, a redundant supply module 210 is in an inactive and does not consume power. The redundant supply module 210 is in a non-operating condition and does not provide the load power. The redundant supply module 210 remains in a non-operating condition when the active supply module 208 A-N is operating. The active backup module 200 does not yet provide the backup voltage to the voltage bus 202 during an activation period of the redundant supply module 210 as the current a 218 maintains a sufficient voltage value in voltage bus 202 .
[0030] FIG. 3 is a system view illustrating transition of active power supply to an inactive state, according to one embodiment. In particular, FIG. 2 illustrates an active backup module 300 , a voltage bus 302 , an ORing element 304 , a stored energy charge line 306 , a deactivated supply module 326 an active supply module 308 B-N, a redundant supply module 310 , an automatic changeover module 312 , a power supply 314 , a system load 316 A-N, current β 318 , current Δ 330 , the sum of current β and current Δ 322 , according to one embodiment.
[0031] In an example embodiment, the active supply module 308 B generates the current β. The active supply module 308 A may be in an inactive state at an instance T=2. The automatic changeover module 312 has disabled the deactivated supply module 326 which has failed. The redundant supply module 310 is in the process of being activated. The current β 318 is generated by the active supply module 308 B and active power supply 308 N. The current β 318 does not include any current from the deactivated supply module 326 and therefore is now less than current a 218 of FIG. 2 . Thus, there is a voltage value in the voltage bus 302 that is less than the specified value. The active backup module 300 is automatically activated and provides a backup voltage to the voltage bus 302 . This is represented by the current Δ 330 . In this particular embodiment, current Δ 330 is the difference between in the current α 218 and current β 318 . Consequently, the voltage supplied to the system load 216 remains substantially constant during the activation of the redundant voltage supply module 210 despite the failure of deactivated supply module 326 .
[0032] FIG. 4 is a system view illustrating activation of a redundant supply module, according to one embodiment. In particular, FIG. 4 illustrates an active backup module 400 , a voltage bus 402 , an ORing element 404 , a stored energy charge line 406 , an active supply module 408 A-N, a redundant supply module 410 , an automatic changeover module 412 , a power supply 414 , a system load 416 A-N, current α′ 418 and a deactivated supply module 426 .
[0033] In an example embodiment, the current α′ 420 is generated by active supply module 408 B, active supply module 408 N and the redundant supply module 410 . The operation occurs at an instance T=3 which represents the time after the redundant supply module 410 has been activated. Current α′ 420 is greater than the specified threshold for activating the active backup module 400 . Current α′ 420 is substantially equal to Current α 218 of FIG. 2 . Consequently, the active backup module 400 is no longer supplying a voltage to the voltage bus 402 at T=3.
[0034] The currents of FIGS. 2-4 may be represented by power and/or voltage values in other example embodiments.
[0035] FIG. 5 is a process flow illustrating management of a supply voltage, according to another embodiment. In operation 502 , a supply voltage to the voltage bus 102 communicates through the ORing element 104 . The ORing operation is a selection of power from any of the active supply module 408 A-N and the redundant supply module 410 . In operation 504 , a failure to communicate the supply voltage to the voltage bus 102 through the ORing element 104 is detected. For example, the automatic changeover module 112 detects the failure to communicate the supply voltage to the voltage bus 102 . In operation 506 , a communication of the supply voltage to the voltage bus 102 disables through the ORing element 104 . The automatic changeover module 112 may perform this operation.
[0036] In operation 508 , another supply voltage to the voltage bus 102 through the ORing element is transmits in parallel to the ORing element 104 . In operation 510 , an additional voltage to the voltage bus 102 through the additional ORing element 104 is supplied if a communication of the supply voltage through the ORing element 104 fails. In operation 512 , a backup voltage to the voltage bus 102 through a supplemental ORing element is provided if the overall voltage value of the voltage bus 102 decreases below a specified voltage value. In operation 514 , the stored energy sources is charged through a line coupled with the voltage bus 102 . For example, the stored energy charge line 106 may a battery that serves as the stored energy source of the active backup module 100 . FIG. 1-FIG . 4 provides example structures for performing operation 502 through operation 514 .
[0037] Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments. For example, the various devices, modules, analyzers, generators, etc. described herein may be enabled and operated using hardware circuitry (e.g., CMOS based logic circuitry), firmware, software and/or any combination of hardware, firmware, and/or software (e.g., embodied in a machine readable medium). For example, the various electrical structure and methods may be embodied using transistors, logic gates, and electrical circuits (e.g., application specific integrated (ASIC) circuitry and/or in Digital Signal Processor (DSP) circuitry).
[0038] Particularly, the invention may be enabled using software and/or using transistors, logic gates, and electrical modules (e.g., application specific integrated ASIC circuitry) such an active backup module, an active supply module, a redundant supply module, an automatic changeover module and other module.
[0039] In addition, it will be appreciated that the various operations, processes, and methods disclosed herein may be embodied in a machine-readable medium and/or a machine accessible medium compatible with a data processing system (e.g., a computer system), and may be performed in any order (e.g., including using means for achieving the various operations). Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | Several methods and a system to implement an efficient power supply management are disclosed. In one embodiment, an apparatus of a voltage supply includes a power supply providing a voltage. The apparatus includes an active supply module communicating with a supply voltage to a voltage bus through an ORing element. The apparatus also includes a redundant supply module providing an additional voltage to the voltage bus if the active supply module fails, through an additional ORing element. The redundant supply module may be coupled with the power supply in parallel with the active supply module. Further, the apparatus includes an automatic changeover module detecting a failure of the active supply module disabling the active supply module and enabling the redundant supply module to supply the additional voltage supply to the voltage bus. Further, the apparatus also includes a voltage bus coupled with a load. | 8 |
This application claims the benefit of U.S. Provisional application Ser. No. 60/089,630 filed Jun. 16, 1998.
FIELD OF THE INVENTION
The present invention relates to a method of producing potassium sulfate and more particularly, the invention relates to a method of synthesizing pure potassium sulfate from brines of ammonium sulfate with up to 12% Na 2 SO 4 impurities.
BACKGROUND OF THE INVENTION
The prior art has established countless methods of preparing potassium sulfate. Typical of the known methods is exemplified by U.S. Pat. No. 4,588,573, issued May 13, 1986, to Worthington et al. In this reference, potassium chloride and sulfuric acid are reacted. Although meritorious, the method requires sulfuric acid which is generally expensive and requires special conditions for handling.
The co-production of potassium sulfate, sodium sulfate and sodium chloride is taught in U.S. Pat. No. 5,552,126, issued to Efraim et al., Sep. 3, 1996. Progressive precipitations with an evaporation step are requisite for the process. As is well known in chemical process design, costly energy consuming unit operations add to the overall operating expenses for the process which are translated to the profit margin. Accordingly, it is most desirable to avoid such operations in processes.
U.S. Pat. No. 5,549,876, issued Aug. 27, 1996, to Zisner et al., provides methodology for potassium sulfate production involving differential contacting. Potash, water and sodium sulfate are placed in a differential countercurrent contactor to produce the potassium sulfate.
Potassium chloride and sulfuric acid are reacted and the resulting mixture kneaded to produce potassium sulfate, as disclosed by Iwashita et al., in U.S. Pat. No. 4,342,737, issued Aug. 3, 1982.
Other methods of manufacture include fractional crystallization of sulfate ores or by the Hargreaves process.
It would be most desirable for potassium sulfate production to be achieved without the use of acids, high energy input or other such unit operations. The present invention provides for such a process.
SUMMARY OF THE INVENTION
One object of the present invention is to provide an improvement in potassium sulfate preparation.
Generally speaking, the process results in the formulation of useful products during the synthesis of the potassium sulfate with recovery of sulfate and potassium in excess of 95% completely in the absence of evaporation. This significant feature has particular importance in terms of energy efficiency and thus the costs of the process.
A further object of one embodiment of the present invention is to provide a method of producing potassium sulfate from a source containing ammonium sulfate, comprising the steps of:
contacting potassium chloride and ammonium sulfate in a mixer at a temperature of between 20° C. and 40° C.;
precipitating a first precipitate of double salt in a filtrate;
mixing, in a second mixing step, the filtrate with potassium chloride;
generating a second filtrate containing ammonium and potassium chloride and a second precipitate of double salt;
mixing the second double salt precipitate with the first precipitate in a solution of potassium chloride;
precipitating a third precipitate of potassium sulfate and a third filtrate;
recirculating the third filtrate into the second mixing step;
mixing the second filtrate in a mixing tank at a temperature of less than 70° C. in a solution of less than 10% by weight sodium chloride, calcium chloride and sodium sulfate; and
generating a syngenite precipitate and a fourth filtrate.
Another object of one embodiment of the present invention is to provide a method of producing potassium sulfate from a source containing ammonium sulfate, comprising the steps of:
contacting potassium chloride and ammonium sulfate in a mixer at a temperature of less than 30° C.;
precipitating a first precipitate of double salt in a filtrate;
mixing, in a second mixing step, said filtrate with potassium chloride;
generating a second filtrate containing ammonium and potassium chloride and a second precipitate of double salt;
mixing said second double salt precipitate with said first precipitate in a solution of potassium chloride;
precipitating a third precipitate of potassium sulfate and a third filtrate;
recirculating said third filtrate into said second mixing step;
mixing said second filtrate in a mixing tank at a temperature of less than 70° C. in a solution of less than 10% by weight sodium chloride, calcium chloride and sodium sulfate;
generating a syngenite precipitate and a fourth filtrate;
mixing, in a sealed mixing tank at a temperature of about 80° C., said fourth filtrate with less than about 18% by weight sodium chloride, about 23.6% ammonium chloride and lime or hydrated lime;
recovering ammonia from said fourth filtrate;
passing said fourth filtrate into an air scrubber and further removing ammonia from calcium chloride and sodium chloride;
passing said fourth filtrate into an ammonium scrubber to generate ammonium sulfate;
passing said syngenite precipitate into a mixing tank at a temperature of about 70° C. in the presence of ammonium bicarbonate;
generating a calcium carbonate precipitate and a fifth filtrate containing potassium sulfate and ammonium sulfate; and
recycling said fifth filtrate to at least one of the mixing steps.
Having thus described the invention, reference will now be made to the accompanying drawing illustrating a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the process flow diagram according to one embodiment of the present invention; and
FIG. 2 is a schematic illustration of the process flow diagram according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Potassium sulfate is a valuable chemical commodity, typically employed in analytical chemistry, cement mixes and fertilizer for chloride sensitive crops such citrus and tobacco crops. The compound is also used in the manufacture of glass, alum and is used as a food additive.
Referring now to the drawing, the overall process is broadly denoted by numeral 10 . The feedstock material 12 includes solid potassium chloride and ammonium sulfate in an amount less than about 40% by weight (NH 4 ) 2 SO 4 . The compounds are mixed in a mixing tank 14 , which tank 14 is heated to between 25° C. and 30° C. in order for the conversion of the compounds to double salt. After sufficient mixing, the solution is passed into a separator 16 , an example of which is a cyclone. The resulting solid is K 2 SO 4 ·(NH 4 )·2SO 4 , double salt. The first filtrate is subsequently passed into a second mixing container 18 into which is added additional potassium chloride brine. The container is heated similarly to container 14 and once mixed, the solution is separated by separator 20 . The resulting second filtrate is subjected to further unit operations to be discussed hereinafter.
The second precipitate from mixing tank 18 as well as the first precipitate from tank 14 are combined in a third heated container 22 together with saturated potassium chloride brine. The product is then separated by separator 24 into a third filtrate for recycle into container 18 and a third solid comprising potassium sulfate crystals in a size distribution of approximately 20 mesh to about 150 mesh. In this portion of the circuit, the yield is approximately 95% SO 4 and 80% potassium.
Returning now to the second filtrate from the separator 20 , the same contains ammonium chloride, sodium chloride (approximately 10%) and potassium chloride. This is passed into a fourth mixing container 26 together with calcium chloride and sodium sulfate. The container 26 is kept at a temperature of between 25° C. and 70° C. The resulting mixture is separated with separator 28 into a solid, namely syngenite (CaSO 4 ·K 2 SO 4 ·xH 2 O) which washed with water and retained for additional unit operations. The liquid is passed into a fifth sealed mixing container 30 containing lime or hydrated lime. The container is maintained at a temperature of about 80° C. in order to liberate ammonia (approximately 98% by volume). Residual ammonium is passed into air scrubber 32 resulting in the generation of calcium chloride/sodium chloride brine. This may be subjected to further processing to produce CaCl 2 or NaCl, disposed of in deep well injection or returned to the ocean.
Further processing includes additional scrubbing of the ammonium in scrubber 34 to which may be added sulfuric acid to result in the generation of ammonium sulfate, a useful fertilizer. Returning to the syngenite, the same is passed into a sixth mixer 36 maintained at 70° C. to which ammonium bicarbonate has been added. The mixture is passed into a separator 38 to generate calcium carbonate precipitate with a +95 brightness and a filtrate containing potassium sulfate and ammonium sulfate. The filtrate may be recycled to the initial steps of the process.
In an alternative method, FIG. 2 illustrates a flow chart where potassium sulfate is formulated from ammonium sulfate contaminated with sodium sulfate. As is well known in the art, contaminated ammonium sulfate is not useful as a vendible high quality fertilizer.
Numeral 40 denotes the overall process for FIG. 2 . Ammonium sulfate and potassium chloride are mixed together in mixing tank 42 at a temperature of between 30° and 40° C. such that there is only enough water to saturate either the ammonium sulfate or potassium chloride. The mixture is passed into a separator 44 to produce 80% to 90% potassium sulfate crystal containing approximately 10% to 20% ammonium sulfate. The crystal product is filtered and/or washed (not shown) added to a solution of saturated potassium chloride brine in mixing vessel 46 at a temperature of 30° C. The solution is filtered with filter 48 with the solid fraction containing in excess 98% pure ammonium sulfate. The crystals, once centrifuged and washed have been found to have a purity in excess of 99.5%.
The potassium chloride brine from vessel 46 is recycled to mixing vessel 42 ; the brine from vessel 42 contains between 20% and 30% ammonium chloride and preferably between 22% and 25%, 10% or less sodium chloride and 15% or less potassium chloride.
The heated brine is reacted with sodium sulfate and either calcium chloride or calcium sulfate dihydrate in vessel 50 at approximately 30° C. to precipitate the soluble potassium chloride as syngenite, CaSO 4 ·K 2 SO 4 (x)H 2 O at separator 52 .
The syngenite salt is then filtered and washed (not shown) to remove the residual chloride brine. The salt is then heated in vessel 54 at a temperature of between 70° C. and 90° C. together with water and a source of ammonia and carbon dioxide or ammonium bicarbonate to convert the calcium sulfate to calcium carbonate. The calcium carbonate is separated in separator 56 . Since the ammonium sulfate and the SOP are soluble, the calcium carbonate precipitate is filtered and washed with water to remove entrained ammonium sulfate etc.
The calcium carbonate precipitate is of a sufficiently high quality and size to provide utility as a bulk paper filler of +95 brightness on blue light. The filtrate is recycled to vessel 42 as indicated by A in FIG. 2 .
The filtrate from separator 52 is heated in vessel 58 at a temperature of between 60° C. and 100° C. and reacted with lime to yield a brine of calcium chloride, sodium chloride and ammonia gas. The ammonia gas is recovered for further purposes.
As an example, the following is a calculation and the chemistry involved in the process of FIG. 2 .
EXAMPLE 1
Sodium Sulfate/Ammonium Sulfate is a Solid
Step 1
(NH 4 ) 2 SO 4(S) +KCl (l) +H 2 O+Na 2 SO 4(S) →(K 2 SO 4 ) 8 ·(NH 4 ) 2 SO 4 ) 2(S) +NH 4 Cl (l) +KCl (l) +NaCl (l) +H 2 O
Step 2
(K 2 SO 4 ) 8 ·((NH 4 ) 2 SO 4 ) 2(S) +KCl (l) +H 2 O→(K 2 SO 4 ) (S) +(NH 4 ) 2 SO 4(l) +KCl (l)
Step 3
NH 4 Cl (l) +NaCl (l) +KCl (l) +H 2 O+CaCl 2(l) +Na 2 SO 4(S) +→CaSO 4 ·K 2 SO 4 xH 2 O+NH 4 Cl (l) +Na 4 Cl (l) +KCl (l) +H 2 O
Step 4
CaSO 4 ·K 2 SO 4 xH 2 O+NH 4 HCO 3(l) →CaCO 3(S) +(NH 4 ) 2 SO 4(l) +(K 2 SO 4 ) (l)
Step 5
NH 4 Cl (l) +Na 4 Cl+H 2 O+CaO→NH 3(g) +CaCl 2 +NaCl+KCl+H 2 O
Some of CaCl 2 can be recycled to Step 3 but if that Cl builds up in the circuit; then one has to precipitate the CaCl 2 as CaSO 4 ·2H 2 O and send the solid gypsum as the recycle.
Sample Calculation
Feed 25% (NH 4 ) 2 SO 4 with 10% Na 2 SO 4 @ 30° C. S.G. 1.300 therefore solution contains:
325
g (NH 4 ) 2 SO 4
80% conversion
130
g Na 2 SO 4
100% conversion
845
g H 2 O
1300
g
Add solid KCl 291 + 135 + 120 (excess) = 546 g
A)
Solids
B)
Liquid
500.8
g K 2 SO 4
304
g NH 4 Cl
65
G (NH 4 ) 2 SO 4
106
g NaCl
566
g Double Salt
120
g KCl
30
g KSO 4
845
g H 2 O
1405
g
A)
Double Salt + 150 g KCl + 470 H 2 O
Solids
B)
Liquid
556
g K 2 SO 4
68
g NH 4 Cl
30
g K 2 SO 4
77
g KCl
470
g H 2 O
645
g
B)
Liquid
304
g NH 4 Cl
106
g NaCl
168.2 g CaSO 4 H 2 O + 102 g Na 2 SO 4
120
g KCl
30
g K 2 SO 4
845
g H 2 O
1405
g
D)
Solids (sygenite) - 140 g K 2 SO 4 +168 g → CaSO 4 .2H 2 O = 309 g
E)
Liquid
304
g NH 4 Cl
189
g NaCl
14
g KCl
14
g K 2 SO 4
845
g H 2 O
1366
g
D)
Solids (sygenite) - 308 g + 152 g NH4HCO 3 + 750 g H 2 O →
F(solids) + G(liquid)
F)
CaCO 3
G)
Liquid Recycle to Step 1
129
g NH 4 SO 4
140
g K 2 SO 4
750
g H 2 O
1019
g
E)
Liquid
(Brine)
304
g NH 4 Cl +
253
g CaCl2
189
g NaCl + 130 g CaO → NH 3(gas)
189
g NaCl
120
g KCl
14
g KCl
30
g K 2 SO 4
14
g K 2 SO 4
845
g H 2 O
845
g H 2 O
1405
g
1315
g
Recycle of G increases the circuit efficiency and one can adjust the material balance to the desired recycle and recovery. Discharge brine is deep well injected or evaporated to produce CaCl 2 brine for sales. Estimated K recovery can be calculated to be: KCl exit = 14 g K 2 SO 4 exit = 14 g = 11.9 g KCl } 26 g Therefore: 1 - 26 546 × 100 = 95.2 % SO 4 Recovery: 1 - 8 324 × 100 = 97.5 %
This process compares favourably to any current commercial process, but without evaporators.
Although embodiments of the invention have been described above, it is not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention. | A process is provided for producing potassium sulfate by reacting ammonium sulfate and potassium chloride at a temperature of about 30 to 40° C. to produce a slurry containing K 2 SO 4 ·NH 4 ·2SO 4 double salt, and reacting this double salt with an aqueous solution containing potassium chloride at a temperature of about 30° C. to produce a slurry containing potassium sulfate. The slurry containing potassium sulfate is subjected to a solids/liquid separation step to obtain potassium sulfate crystals having a size in the range of about 20 mesh to about 150 mesh. | 2 |
The present invention concerns a control device for the rotary motor of a watch.
In order to keep the operation of a rotary motor smooth pulses must be applied to the driving coil in phase with the a.c. voltage induced on the terminals of the coil. A simple method consists in using a zero detector controlling a logic circuit which delivers positive driving pulses during the positive period of the a.c. voltage, or negative driving pulses during the negative period of the a.c. voltage. For applications to clock or watch making in which the motor is most frequently controlled at a constant speed, this system has very serious disadvantages. The efficiency is low, thus implying high consumption and a short battery life. The speed of rotation is considerably dependent on the load torque of the motor and since the load torque in a watch is very variable, there will be considerable risk of instability of the control coil.
SUMMARY OF THE INVENTION
According to the present invention there is provided a control device for the rotary motor of a watch, comprising: a first zero detector, the input of which is connected to a coil of the motor and the output of which is connected to a delay device; a second zero detector, the input of which is connected to the coil of the motor via a capacitor, which may be short-circuited by a switch controlled by the output of the delay device; and a logic circuit, delivering driving pulses to the coil during the time in which the second detector and the delay device simultaneously deliver an output signal.
The time during which drive pulses are delivered depends on the period T of the voltage induced on the terminals of the coil according to the formula (T/2 - 2t) in which t represents the delay provided by the delay device. The value of this formula is zero for T = 4t, which sets a minimum period, hence a maximum speed of rotation independently of the load torque of the motor. However, this time is symmetrically distributed relatively to the maximum voltage induced, thus automatically ensuring the best possible efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, by way of example, a block circuit diagram of the device according to the present invention.
FIG. 2 shows the voltage waveforms at different points of the circuit.
DETAILED DESCRIPTION
In FIG. 1 a driving coil M1 is connected to the input of a first zero detector 1, the output of which is connected to the input of a delay device 2 which introduces a delay t in the engaging or coupling process. The input of a second zero detector 3, connected to the coil M1 via a capacitor C1, may be short-circuited by an MOS transistor T1, the gate of which is connected to the inverse output of the delay device 2. The output of the delay device 2 and of the second zero detector 3 are applied to the input of an AND gate 5, together with the output of a pulse generator 4. The output of the AND gate 5 is applied to the coil M1.
Examination of the waveforms shown in FIG. 2 will readily reveal the operation of the device. The voltage on the terminals of the coil (point A) is applied to the first zero detector which gives a positive signal during the positive half of the induced voltage (point C). The delay device introduces a delay in the engaging or coupling process and presents at the output a positive signal retarded by the time t relatively to its input (point D).
The input of the second zero detector is short-circuited whenever the output D of the delay device 2 is at zero. When this output passes to 1, the short-circuit is interrupted and the voltage of the coil M1 is transmitted by the capacitor C1 (point B). It will be seen that the voltage at the input B becomes positive, then becomes negative again. The output of the second zero detector 3 delivers a positive signal when its input is positive (Point F). It will be noted that the duration of this signal is symmetrically distributed relative to the maximum induced voltage. The driving pulses delivered by the pulse generator 4 (point E) are applied to the coil M1 when the voltages at the points D and F are simultaneously positive, a fact which can be ascertained at the points A and B.
The ratio between the duration of the positive signal at Point F and the period T is equal to ##EQU1## For t = T/4, the ratio is zero and the motor no longer receives any driving pulses.
It will therefore be seen that the power delivered to the motor, which is a function of the above ratio, is completely dependent on the period, a feature which tends to stabilise the speed of rotation of the motor.
This device is particularly useful when the motor is phase-controlled, since the feature of introducing a considerable reduction of power as a function of the speed eliminates the risks of instability of the control coil and makes it possible to dampen very rapidly the oscillations due to external disturbances. The operation may be controlled very simply by adjusting the time delay t. When the motor is advanced in phase, t should be greater than To/4; if the motor is retarded in phase, t should be less than To/4, To being the gating period. | A control device for the motor of a watch including first and second zero detectors and a delay device for providing gating signals to an AND gate to enable transmission of driving in phase with the a.c. voltage induced in the coil.
BACKGROUND OF THE INVENTION | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to a portable cabinet equipped for rolling movement over a surface with an appendage housed inside, said device having separate, compartmentalized trays or containers for receiving, organizing, storing and transporting a plurality of collectible items for holiday such as ornaments, strands of lights, and related accessories, as well as for hobbies and crafts. As the popularity of holiday tree decorating grows dramatically, the need arose for a convenient and practical means to receive, organize, store and transport delicate collectibles.
In the past, delicate collectible items, lighting, and related accessories for the holiday have been stored in large plastic storage containers wherein the contents thereof cannot be secure from damage or breakage. There are no separate compartments or dividers to prevent contents from shifting, breaking or being destroyed.
The prior art is replete with reference to various types of organizers and portable storage devices. The prior art is not designed, intended, or adaptable for holiday, hobby, and crafting.
U.S. Pat. No. 4,444,418, to Goldstein, is directed to a carrying case for information and product samples. This case is particularly adapted for artwork or other similar, substantially flat material.
U.S. Pat. No. 3,913,711, to Schmid, relates to a portable display case comprising a pair of containers detachably connected to each other. Each container has a hingably connected cover portion that may be laid flat to support the compartment in a vertical position allowing display of goods contained therein.
None of these prior art patents relate to a portable cabinet and organizer with separate, compartmentalized trays or containers adaptable for receiving, organizing, storing and transporting a plurality of delicate collectibles.
The present invention meets these special objectives by a unique design and assembly. The manner by which such objectives are achieved will become apparent upon reading the following Specification, particularly when read in conjunction with the accompanying drawings.
BRIEF SUMMARY OF THE INVENTION
The invention relates to a portable cabinet with an appendage housed inside, said device having plurality of separate, compartmentalized tote tray or container for receiving, organizing, storing and transporting a plurality of collectible items for holiday and related accessories such as ornaments, one or more strand of lights, hobbies and crafts.
It is another object of this invention to provide a versatile, portable, efficient system to transport and adequately hold collectibles securely in a cabinet and within its inner compartment. This device housed inside the cabinet has separate, compartmentalized trays/containers with dividers that prevent items from shifting, bumping other items.
It is also an object of this invention to provide a storage and transportation cabinet with a plurality of trays that are reliable, convenient, and efficient in use, yet relatively inexpensive in construction.
It is a further object of this invention to provide a rigid storage and transporting device to store various collectible items and prevent its contents from shifting and becoming damaged or destroyed.
It is still another object of the present invention to provide an organizer which can be conveniently fit into an outer container of varying size and shape and which can also be partitioned into inner compartments.
It is a yet further object of this invention to provide a secure and reliable method of keeping strands of holiday lights from becoming twisted, tangled, damaged and broken.
Further objects of the present invention will be apparent from the description herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view of the front closed cabinet according to this invention;
FIG. 2 is a perspective view of the front opened portable cabinet of the present invention;
FIG. 3 is a perspective view of the back and side front view of the portable cabinet opened illustrating the hinged side cabinet of the present invention;
FIG. 4 is a perspective view of the opened latch assembly of the portable cabinet and storage cabinet of the present invention;
FIG. 5 is a back and side elevational view of an embodiment of the cabinet in an upright position illustrating the roller mechanism and handle displayed;
FIG. 6 is a perspective elevational view of the opened cabinet and storage caddy of the present intention illustrating latch and snap assembly with proper alignment of plurality of horizontal trays and empty chamber with plurality of shelves for rounded trays;
FIG. 7 is a second perspective view of the front and back portable cabinet of the present invention opened in upright position illustrating proper alignment of boxes for light strands and plurality of trays/containers nested together;
FIG. 8 is a perspective view of the lid and base components, forming the container;
FIG. 9 is a schematic front view of the horizontal panel for securing light strands;
FIG. 10 is a perspective front and side view of rectangular box open illustrating proper alignment and placement of light strand and angled bottom;
FIG. 11 is a schematic view of the portable cabinet and storage caddy of the present invention with the cabinet open and internal chambers, tote trays or containers displayed illustrating functionality and use.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates generally to a portable cabinet equipped for rolling movement over a surface with an appendage housed inside, said device having separate, compartmentalized trays or containers for receiving, organizing, storing and transporting a plurality of collectible items such as ornaments and strands of lights and hobbies and/or crafts. The components of this invention are made of any suitable materials, preferably molded plastic.
Thus it is apparent that in accordance with the present invention, an apparatus that fully satisfies the objectives, aims and advantages is set forth above. While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, permutations and variations will become apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended that the present invention embrace all such alternatives, modifications, and variations as fall within the scope of the appended claims.
Referring to the drawings and specifically FIGS. 1 , 2 , 3 , 5 , 6 , 7 , and 11 , there is illustrated a portable cabinet and caddy organizer 7 and 11 according to the present invention. FIG. 1 illustrates the portable cabinet and caddy organizer in the closed transportable position, FIG. 6 , illustrates the enclosure for the portable cabinet and caddy organizer in an open position, in a partially assembled state, and FIGS. 7 and 11 illustrates the portable cabinet and caddy organizer assembled. It will be appreciated that the assembled portable cabinet and organizer shown by FIGS. 6 and 7 are devoid of items such as ornaments, lights, collectibles, or the like, as well as such additional elements being deleted from the drawing for clarity of illustration.
FIG. 5 refers to rollers 4 , which engage the rigid body portion for support, are mounted about adjacent to the bottom of portion of wall member 22 and 23 . The rollers 4 are preferably position at the junction of rear panel 22 and the bottom of wall member 23 . The rollers 4 are positioned to at least partially support the weight of the cabinet 14 when in the upright, or at rest position. The rollers 4 are operable to enable rolling movement of the cabinet across a surface when in an inclined position. The rollers 4 are preferably, molded plastic but may be any caster of a type known to those skilled in the art and may be mounted with an axle, snap or any other suitable material known to those skilled in the art.
The push/pull handle or gripping bar as shown in FIG. 5 is preferably a rigid handle, having two legs and a gripping member 3 . The handle, which may also be stationary, is mounted on the cabinet 5 about adjacent to the rigid body portion at the top portion of wall member 20 . The handle 3 , which preferably, also includes a locking mechanism (not shown) for locking the handle in the retracted position, may be employed by the user to effect rolling movement of the cabinet 5 across the surface.
The portable cabinet and organizer as shown in FIG. 3 , includes an enlarged six-sided trunklike enclosure or housing FIGS. 2 and 3 defined primarily by an upright cabinet FIG. 3 having an openable door 1 associated with one side thereof.
The upright cabinet as shown by FIGS. 2 , 3 and 6 , includes generally parallel and horizontally extending top and bottom walls 22 and 23 which are rigidly and permanently joined to generally parallel and vertically extending side walls 24 and 28 . All of these walls 24 , 25 26 and 28 , in turn are rigidly joined to a generally vertically enlarged rear walls 22 and 23 . Thus the formed cabinet has a front side 1 which is open so as to provide access to the rather large interior compartment FIGS. 2 , 6 , 7 , and 11 defined by the cabinet.
The front side or opening 1 of the cabinet 3 is adapted to be closed by the door 1 , the latter including a generally peripheral edge wall 22 - 30 defined between generally parallel and horizontally extending top and bottom edge walls 22 - 30 , the latter being rigidly and permanent joined by parallel and vertically extending side edge walls 24 and 25 . The peripheral edge wall is in turn joined to a vertically enlarged front wall or panel 26 which, in cooperation with the edge wall, causes the door 1 to define therein a compartment 8 which extends throughout substantially the full extent of the door but is of shallow horizontal depth. The bottom of this compartment 10 is defined by an inner flat panel which extends between the edge wall 24 and overlies the front panel 26 . When the door 1 is closed onto the cabinet FIG. 3 , the shallow door compartment 8 faces and is in open communication with the front side of the larger and deeper cabinet compartment 8 .
The door 1 is connected to the cabinet 2 by a vertically elongated hinge 6 which defines a vertically extending hinge axis disposed adjacent the front edge of the side wall 24 and 26 , whereby the door 1 can be horizontally hingedly swung between the closed and open positions illustrated respectively by FIGS. 3 , 6 and 7 .
The side edge of the door remote from the hinge preferably has a conventional latch 5 FIGS. 4 , 6 and 7 which cooperates with the cabinet when in the closed position so as to hold the door closed, such latch being typically activated in a conventional manner.
As shown by FIG. 6 , the cabinet interior compartment 8 and 10 is preferably provided with appropriate organizer supports or elements positioned within the compartment 8 and 10 so as to cooperatively function as part of a portable cabinet and organizer. For example, in the illustrated embodiment the cabinet FIG. 6 stationarily mounts therein a first horizontal shelf 7 disposed so as to extend horizontally across the compartment adjacent the upper portion thereof but in slightly downwardly spaced relation from the top wall 1 ( a ). A further stationary shelf 7 ( b ) also extends horizontally across the cabinet compartment, this latter shelf 7 ( f ) being positioned approximately midway between the top and bottom walls of the cabinet. The elevation of shelf 7 in a preferred embodiment is approximately at work surface or table height relative to the floor. A horizontally enlarged slidable shelf or tray 7 ( b ) is also mounted on the cabinet at an elevation slightly below the shelf 7 ( a ). This tray or shelf 7 ( b ) is horizontally movably supported on conventional telescopic drawer slides 7 ( b ) which mount to the underside of shelf 7 ( a ), whereby tray 17 and 19 can be slidably moved between a storage position within the cabinet as illustrated in FIG. 7 ; and a use position illustrated in FIG. 11 wherein the container 19 ( d ) projects outwardly from the front of the cabinet. When in the use position illustrated by FIG. 11 , tray 19 can be readily used.
Cabinet shown in FIG. 6 , also mounts therein various chambers and fixtures which cooperate to define a useable storage space when the portable cabinet and organizer is in the assembled position of FIG. 11 . For example, in the illustrated embodiment the door 1 mounts thereon vertically, the latter being secured at the back of the shallow compartment 2 so as to extend across the inner surface of the front panel adjacent the upper end of the door.
Considering now the door 1 in the illustrated embodiment, also is provided with a drawer unit 12 and 13 which are disposed within the bottom compartment 8 directly above the bottom wall 33 , and is again supported so that the drawer can be slidably moved inwardly and outwardly from the storage position into an access position illustrated by FIGS. 7 and 11 so as to access the upwardly opening compartment 8 thereof. If desired, a further tote tray drawer can be movably supported on the cabinet directly below the drawer being supported so as to be movable into an open position similar to the previous drawer as illustrated by FIGS. 6 and 11 . The trays/containers permit storage of significant collectible items therein, both during utilization of the cabinet and organizer when the cabinet and organizer is in the position of FIG. 11 for storage.
The cabinet bottom 2 supports and stores therein an enlarged organizer, the latter being storable in an upright position within the shallow compartment 10 substantially as illustrated by FIGS. 6 , 7 and 11 . There is also provided a horizontally elongated top bracket/clasp 11 positioned within the shallow compartment of the door adjacent the upper end thereof. This bracket/clasp 11 extends horizontally across the door compartment, and has leverlike arms 11 at opposite ends thereof which joins the opposite side edge walls of the tray door to permit the bracket/clasp 11 to be vertically moved to accommodate removal of the tote tray about a horizontal hinge axis. This enables the bracket/clasp 11 to be moved slightly from a lowermost position as illustrated in FIG. 7 wherein it overlaps and engages the tote tray in the underside compartment 10 , thereby trapping the storage tray and holding it securely in the bottom compartment, and in a lower storage position shown in FIGS. 6 , 7 and 11 , when the cabinet is resting on a flat surface and wherein the bracket/clasp is disposed directly adjacent the bottom edge wall 10 .
The door 1 also mounts thereon, adjacent the lower free corner thereof (i.e., the lower corner remote from the hinge 6 ), a roller assembly 4 adapted to be disposed in stationary and load-bearing engagement with a support surface or floor when the door 1 is in the open position so as to not only maintain the door 1 stationary relative to the cabinet 7 , but to also prevent load-bearing induced distortion of the door and cabinet which may otherwise interfere with proper utilization of the cabinet and organizer and specifically of the components associated therewith.
As indicated in FIG. 2 , the bottom edge wall of the bottom 2 is disposed a small distance above the bottom wall 10 of the cabinet 3 and 5 , thus providing sufficient space for accommodating the caster without unduly increasing the structural complexity of the lower edge of the door.
When the portable cabinet and organizer is in the open position as shown in FIGS. 2 , 3 and 5 , the cabinet 2 and door 1 function not only to support collectibles and equipment such as the shelves, drawers.
As shown by FIGS. 6 , 7 and 11 , the horizontal tote tray has one or more horizontally elongated device that is approximately 17 inches in length that fit in one bracket therein on opposing ends of the tray to organize and hold strands of lights in place and keep lights tangle-free.
As indicated in FIGS. 7 and 11 storage container has generally rounded components each with a top that aligns and mates in face-to-face relation with interlocking lips to hold items in the chamber. The containers are slidably mounted therein the storage cabinet from top to bottom. Components are of any suitable material, preferably molded plastic.
As illustrated in FIGS. 6 , 7 and 11 , one or more elongated, generally rectangular components are incorporated in the storage caddy chamber, each with a dedicated top and base and handle member, held in place by a pair of clasps 11 woven into the interior recessed sidewalls of the storage apparatus. The tote trays FIG. 11 slide in and out of the recessed storage chamber FIG. 7 for access and convenience in storage of collectibles.
While the portable cabinet and storage caddy organizer has been illustrated and described above incorporating various collectibles, equipment, and accessories (such as shelves, tote tray or container drawers, light comb, and the like) which are believed desirable to provide a portable cabinet and organizer having a minimal but comprehensive selection of usable features, nevertheless it will be appreciated that other structures or features can alternately or optionally be provided within the enclosure if desired.
The cabinet FIG. 12 will normally have a depth which is several times the average depth of the door compartment. Similarly, the enclosure 12 will normally have a height which is significantly greater than either the horizontal width or depth of the closed enclosure. In a typical construction, a cabinet will be a depth of about 17 inches, a width of about 17 inches, and a height of about 27 inches.
When transporting of the portable cabinet and storage caddy organizer as shown in FIGS. 7 and 11 of this invention is desired, then the portable cabinet and storage caddy organizer can be stored intact in an upright position with the door closed and latched so that the overall enclosure is in the closed position illustrated by FIG. 1 or tilt the cabinet and organizer rearwardly to permit the casters to rest on the a flat surface such as a floor or table.
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.
LEGEND
1 . Cabinet Top (Door) or Front
2 . Cabinet Bottom or Back
3 . Handle
4 . Wheel Assembly
5 . Cabinet Latch Assembly
6 . Hinge Assembly
7 . Shelf
8 . Interior Top Chamber Compartment
9 . Caddy Appendage
10 . Interior Bottom Caddy Chamber Compartment
11 . Clasp
12 . Tote Tray Top
13 . Tote Tray Bottom
14 . Tote Tray Handle
15 . Tote Tray Light Comb
16 . Tote Tray Latch
17 . Single Tray
18 . Container Lid
19 . Container Base
20 . Handle Panel
21 . Center Caddy Panel
22 . Left Bottom Rear Wall
23 . Right Bottom Rear Panel
24 . Left Side Bottom Panel
25 . Right Side Bottom Panel
26 . Right Front Horizontal Panel
27 . Right Front Caddy Panel
28 . Center Front Horizontal Panel
29 . Left Caddy Panel
30 . Left Front Horizontal Panel
31 . Cabinet Feet (not shown)
32 . Bottom Floor Wall
33 . Front Floor Wall
34 . Horizontal Tray Shelf | A combination rolling cabinet and storage assembly for storing and transporting collectibles therein, having: a top and bottom compartment; top and bottom walls joined by opposed side walls all joined to an upright rear wall, the cabinet defining an interior compartment accessible through an open upright front side of the door between open and closed positions; a base cabinet including wheels and a retractable/extendible pulling handle for locomoting; at least one additional cabinet connectable on top of the base cabinet; upper storage apparatus connectable on top of the base cabinet; a plurality of removable tote tray drawers or containers, and light holder carried in trunklike housing between top compartment and bottom compartment; can be loaded or unloaded upright or laying on floor or flat surface; and components are made of any suitable materials, preferably plastic. | 0 |
This is a continuation of application Ser. No. 505,178, filed Sept. 11, 1974 and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to dental burs and, more particularly, to dental burs of the type in which the cutting head is formed from carbide blanks which are fixedly connected to one end of stems or shanks formed from conventional steel for attachment to the chuck of a dental handpiece. The present invention more specifically pertains to the type of dental burs in which the burs are provided with a plurality of cutting teeth that extend longitudinally of the cutting head, each tooth being provided with a cutting edge spaced circumferentially even distances from adjacent cutting edges, said cutting edges being formed by grinding operations. When forming the cutting heads from carbide, diamond grinding wheels are conventionally used to form the edges by grinding operations.
The invention also pertains to dental burs in which the cutting edges are of the helical type. Dental burs of the type to which the present invention pertains are provided with a chip-receiving gash or groove adjacent one edge of each tooth and the opposite edge of the tooth is formed by a so-called relief surface which provides clearance immediately to the rear of the cutting edge of each tooth and thus, offer no resistance relative to the sidewall of a cavity, for example, which is being prepared in a tooth by the use of said bur.
One of the objectives of burs of this type which presently are in use is to provide a chip-receiving gash or groove having a depth adequate to accommodate chips removed from a tooth in which the bur is operating but, in order to provide a gash or groove of substantial depth, it is necessary at present to sacrifice some of the strength of the cutting edge which is afforded by the relief surface that backs up the cutting edge when rotating in operative direction. This is due to the fact that, in order to grind a relatively deep chip-receiving gash or groove, it is necessary to form a relatively steep relief surface which results in a sharper cutting edge than otherwise and, particularly when the bur is formed from carbide, which is quite brittle, the sharper cutting edge is more readily subject to chipping when encountering hard substances than if the cutting edge were less sharp and a larger angle extended between the opposite faces of the cutting edge. The foregoing phenomenon is particularly prevelant when carbide burs having helical teeth thereon are ground by means of formed or shaped grinding wheels operating, for example, about a fixed axis while the bur is rotated about its axis when being fed forwardly against the periphery of the grinding wheel during such axial rotation of the bur to provide the helical outline of the cutting teeth by simultaneously forming the cutting face and relief surface with a single cutter during a single pass along the blank to form each tooth. Under such circumstances, the grinding of cutting teeth on carbide burs has, historically, been achieved by the use of profile diamond grinding wheels of commercial type.
Also in regard to the grinding of carbide burs of the type referred to by the use of profile grinding wheels, especially in regard to making burs having helical teeth extending generally in axial direction of the bur, a certain amount of generation of the curved surface which forms both sides of each tooth is necessary and this generally results in the formation of a cutting face having a negative cutting rake on said surface as distinguished from a positive cutting rake which is more efficient than a negative rake, as well as a relief surface which has a lesser angle between the clearance surface and a plane perpendicular to the cutting face at the cutting edge of each tooth.
The foregoing deficiencies and undesirable characteristics of conventional carbide burs, which are manufactured at present by conventional techniques and are commonplace in the trade, are obviated by the present invention in which superior cutting teeth on a carbide type bur are provided having improved structural and operational characteristics which tapered fissure burs and on inverted cone burs, details of which are set forth in detail hereinafter.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide a dental bur, especially a dental bur of the carbide type, which has a carbide head provided with a series of teeth helically extending axially thereon, each tooth having a relatively deep chip-receiving gash along a flat radially extending cutting face defining one side of each tooth and the opposite side of each tooth being defined by a relief surface which is convex in cross-section to provide substantial resistance to wear and chipping of the cutting edge.
Ancillary to the foregoing object, it is a further object of the present invention to arrange said flat cutting face on one side of each tooth so as to extend radially in a manner to provide a positive cutting rake but, due to the convex relief surface on the opposite side of each tooth, there is no sacrifice in the strength of each cutting blade, especially the resistance thereof to chipping, notwithstanding the fact that the chip-receiving gash is substantially deeper than similar gashes provided on conventional burs, the root surface of said chip-receiving gashes or grooves also being concave in cross-section and merging with said flat cutting face of each tooth a substantial distance radially inward from the cutting edge of each tooth to afford maximum cutting efficiency for said cutting faces which define one side of each tooth as aforesaid.
It is a further object to provide a cutting bur in which the teeth are of the helical type, the chip clearance gash or groove is formed by a grinding wheel as a first operation, and the relief surface is formed by a second grinding wheel in a second grinding operation, both of said surfaces being generated by the grinding wheel when forming such helical teeth.
It is a further object of the present invention to provide cutting teeth of the type described above in which the relief surface on each tooth meets the adjacent wall of the chip-receiving gash or groove along a blunt rounded ridge which extends longitudinally along and between each adjacent pair of cutting edges of the teeth, said arrangement permitting employment of a smaller radial relief angle than permitted normally in the grinding of straight tooth burs by profiled grinding members.
Still another object of the invention is to provide said flat cutting face on each tooth so as to be of substantial radial dimension of said surface which is between 20% and 30% of the radial dimension of the head, the optimum percentage being substantially 25% of said radial dimension.
Still another object of the invention is to define said convex relief surface of each tooth in cross-section by means of a radius extending substantially from the root of the chip clearance gash adjacent the diametrically opposite tooth of the cutting head.
Ancillary to the foregoing, it is another object of the invention to form said convex relief surface to extend at an angle from each cutting edge wherein the angle between the plane perpendicular to the flat cutting face of each tooth and a plane tangent to said relief surface at the cutting edge of each tooth is not substantially in excess of 30°.
Still another object of the invention is to form the helix angle of the teeth relative to the axis of the bur to be substantially between 10° and 30°, with an optimum helix angle of substantially 12°.
A still further object of the invention is to provide the cutting faces of the head, at the ends thereof opposite the shank end, with cutting points defined on one side by end grooves having concave root surfaces and extending radially toward the axis of the head in alignment with the ends of the chip-receiving gashes between said teeth and said end grooves extending at an acute angle to the cutting edges of the teeth, one sidewall of the end groove between each successive pair of teeth being nearly parallel to an axial plane extending along the axis of the head and intersecting the flat radial cutting face of each tooth to define a substantially stubby cutting tip at the intersection of said radial cutting face and relief surface of each tooth with said one sidewall of each end groove, and the other sidewall of said end grooves sloping gradually toward the cutting point of the next tooth to provide relief for said cutting points while providing substantial material mass circumferentially rearward of said cutting points relative to the direction of rotation of said bur.
Details of the foregoing objects and of the invention, as well as other objects thereof, are set forth in the following specification and illustrated in the accompanying drawings comprising a part thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 respectively show an outer end elevation and a side elevation of one type of dental bur of the prior art in which the teeth are of a helical type.
FIG. 3 is an outer end view of a dental bur comprising the preferred embodiment of the present invention, said view showing the cutting tips at the outer end of the bur, as well as the outline of the cutting teeth which extend longitudinally of the bur.
FIG. 4 is a fragmentary elevation comprising a side view of the dental bur illustrated in FIG. 3, and in which the longitudinal teeth are of the helical type.
FIG. 5 is a transverse sectional view of the embodiment of improved dental bur illustrated in FIGS. 3 and 4 as seen on the line 5--5 of FIG. 4, said sectional view being on a substantially larger scale than employed in FIGS. 3 and 4 for purposes of showing numerous details of the shape of the cutting teeth of the bur and the surfaces which define the same.
FIG. 6 is a fragmentary end elevation of a portion of the outer end of the dental bur shown in FIG. 3, as seen on the line 6--6 thereof for purposes of illustrating the details of the cutting tips at the outer end of each cutting blade, the scale employed in FIG. 6 being substantially larger than that in FIG. 3.
FIG. 7 is a view similar to FIG. 5 but being diagrammatic for purposes of illustrating details of the manner in which the preferred embodiment of the dental bur shown in FIGS. 3-6 is formed by the preferred processes described hereinafter for grinding said bur from a bur blank.
DETAILED DESCRIPTION
A typical type of conventional helical dental bur of the carbide type is illustrated in end view, in FIG. 1, and in fragmentary side elevation in FIG. 2, for purposes of contrasting certain characteristics thereof with the preferred construction of the dental bur comprising the subject matter of the present invention, a preferred embodiment of which is illustrated in FIGS. 3-7. As indicated above, in regard to grinding the helical flutes, grooves or chip-receiving gashes 10 to form the helical cutting edges 12, it is conventional to form said flutes, grooves or gashes by means of using a contoured diamond wheel which is operable about a substantially fixed axis extending transverse to the axis of the bur 14, and the bur is advanced to the grinding wheel while being rotated about the axis of the bur in order to form the helical cutting edges 12. As a result, the substantially concave flutes, grooves or gashes are substantially ogee in end view as is clearly evident from FIG. 1, due to said surface being generated by said profiled wheel. As a result, a number of deficiencies are produced, as follows:
Among the foregoing of such deficiencies and objectionable features are the facts that the cutting face 16, which extends along each tooth has a negative rake as distinguished from a positive rake as is clearly apparent from FIG. 1. Another deficiency is that the chip-receiving gashes 10 are only of limited depth because, if the same were to be provided with a greater depth, the relief surface 18 which defines the opposite side of each cutting edge 12 from the cutting face 16 would be at a sharper angle with respect to said cutting faces and thereby weaken the tooth and render the same more prone to chipping. As long as the compound chip-receiving gashes 10 and relief surfaces 18 are generated by a single grinding wheel when making a helical type bur, it is necessary to sacrifice strength in favor of depth of chip-receiving gash or vice versa.
In contract to the foregoing, the present invention provides a bur 20 which, particularly by reference to FIG. 5, will be seen to have a chip-receiving groove or gash 22 which is of a much greater depth in a radial direction than in the conventional bur shown in FIG. 1 and is defined along one side by a radially extending flat cutting face 24 which defines one side of the cutting edge 26 of each tooth 28. The opposite surface of each cutting edge 26 is defined by a relief surface 30 which is convex in cross-section and merges with the adjacent side surface 32 of the chip-receiving gash 22 along a blunt, rounded ridge 34 which extends longitudinally along the head of the bur 20. The preferred location of the ridge 34 is approximately midway between the successive cutting edges 26 but other locations thereof within reasonable limits are possible. Further, it will be seen that the edge of the concave groove or gash 22 which merges with the flat cutting face 24 in no way interferes with the radial dispostion of the face 24 of substantial radial dimension which provides a positive cutting rake, as clearly illustrated by the dotted line 36 comprising projections of said cutting faces 24 radially inward toward the axis of the head of the bur. Forming the compound surface of 22 and 30 which meet along the blunt rounded ridge 34 is best achieved in connection with the forming of helical teeth having helical cutting edges 26. This is due to the fact that the full contour of each tooth 28 readily is formed by generation resulting from the use of a diamond wheel 36, a fragmentary portion of the edge of which is illustrated in FIG. 5 relative to the gash 22.
It will be seen that the preferred type of diamond wheel 36 has a flat face 38 and a beveled edge 40 resulting in a sharp peripheral edge 42. The wheel 36 rotates about an axis extending transverse to the axis of the bur 20 and is fixed relative to the machine which supports and operates it. In the preferred operation of the machine in which the burs 20 are formed, the blank burs have a cylindrical outer surface 44 on the head thereof, as shown in outline in FIGS. 5 and 7. In making the initial grinding cut for each tooth, the flat cutting face 24 thereof is continuously formed along one side of each tooth by the sharp peripheral edge 42 of the diamond wheel 36 and the flat face 38 thereof. Rotation of the bur blank about its axis and axial feed is effected by the machine on which it is formed. The helix angle of the teeth with respect to the axis of the bur, as illustrated in FIG. 4, is approximately 12°, which is the preferred optimum angle. However, said helix angle may vary within a range of between 10° and 30° within the spirit of the present invention.
As the bur blank is rotated about its axis and axially fed, the concave root surface of each groove or gash 22, as clearly shown best in FIGS. 5 and 7 in enlarged detail, is generated and said initial cut to form said chip-receiving grooves or gashes 22 is defined on one side by the cutting face 24, shown in FIG. 7, and on the opposite side by the slightly convex outline 46, which is best shown in FIG. 7. The bur blank is indexed one aliquote space after each initial cut has been made and the next successive initial cut is formed in the blank until all of the initial cuts have been made by the grinding action of the diamond wheel 36 to form the gashes 22.
The bur then preferably is advanced to another station on the grinding machine where another diamond wheel, not shown, but preferably similar to the wheel 36, progressively forms the relief surfaces 30 by removing additional amounts of material 48 from the bur blanks, as shown by the cross-hatched illustration thereof in FIG. 7. The removal of the additional amounts of material 48 by said diamond wheel preferably is accomplished by the wheel rotating in a direction by which the grinding is accomplished from the cutting edges 26 toward the gashes 22. As a result, this is a sharpening cut and no final or additional finishing operations for the cutting edges 26 are required, thereby minimizing the cost of production of such burs. Such final grind or cut is made preferably by a finer grit diamond grinding wheel to insure against any ragged edge being formed since smooth cutting edges afford the longest life in carbide burs.
The relief surfaces 30 described above comprise an arc generated by a radius extending substantially from the root of the gash of the diametrically opposite tooth on the bur, as indicated by the dotted radius line 50. As also described above, this relief surface joins the side edge of the gash 22, which is opposite the flat cutting face 24, along a blunt, rounded ridge 34. This provides adequate relief rearward of the cutting edges 26 of the teeth without sacrificing strength, while at the same time providing a chip-receiving gash 22 of substantial depth and, in general, having a much greater radial dimension than any chip-receiving gashes in conventional dental burs.
In conventional burs, the clearance surface rearward of the cutting edges is coincident with a straight edge extending between adjacent cutting teeth. From FIG. 5, it will be seen that the tangent line 52 is above the next adjacent cutting edge 26, thus providing a stronger relief surface 30 to permit the cutting edge to resist chipping or other damage.
Further, according to the present invention, the angle between the tangent line 52 and line 54 which is perpendicular to the flat cutting face 24, at the cutting edge 26 of the tooth, is approximately 24° but this is stated for purposes of being exemplary rather than restrictive. Further, the radial dimension of the blunt rounded ridge 34 relative to the cutting edge 26 of each tooth should always be less than the radial dimension between the root of the gash 22 and the blunt rounded ridge 34. In FIG. 5, the latter dimension is indicated by a bracket labeled a and the former is indicated by a bracket labeled b.
Another preferred characteristic of the chip-receiving groove or gash 22 is that, as illustrated near the right-hand side of FIG. 5, the additional radial dimension of the actual bottom of the gash 22 beyond the inner edge of the flat cutting face 24 preferably is between 40% and 60% of the radial dimension of the flat cutting face. Said additional radial dimension of the innermost surface of gash 22 is indicated e and the radial dimension of the flat cutting face is indicated by f. In accordance with the present invention, it is preferred that the radial dimension of the flat cutting face f should be within a range between 20% and 30% of the radius g of the cutting head of the bur, all of which dimensions are illustrated in FIG. 5.
The shape of the cutting teeth 28, as illustrated in FIGS. 3-7 and as described above is such as to provide ample relief clearance rearwardly of the cutting edges 26 of the teeth while, nevertheless, affording adequate backup mass of the material from which the head of the bur is formed so as to resist undue wear and especially the possibility of chipping the cutting edge due to the stubby nature of the cutting teeth in cross-section adjacent the cutting edge and this stubby configuration is present for substantially half of the radial width of the teeth between successive cutting edges before the adjacent sides of the chip-receiving grooves or gashes 22 commence to extend radially inward at a greater rate than the clearance surfaces 30 in order to provide chip-receiving grooves or gashes 22 of very substantial depth and fully adequate to accommodate the chips resulting from operation of the burs in the preparation of tooth structure for restorative purposes. Such grooves or gashes 22 also are provided in a manner which in no way interferes with the flat radial cutting faces 24 which provide positive cutting rakes for each tooth without sacrificing strength thereof, while at the same time providing very substantial resistance to chipping of the cutting edges 26.
The present invention also provides improvements for the outer ends of the bur, especially the cutting tips 56 which respectively are formed at the outer end of each cutting edge 26, as best shown in FIG. 6. Referring also to FIG. 3, it will be seen that each cutting tip 56 is formed by grinding a radial groove 58, shown in end view in FIG. 3, but also illustrated in side elevation in FIG. 6 with respect to a single tooth 28. The radial groove also extends from the outer ends of the chip-receiving gashes 22, inward toward the axis of the bur at an acute angle to the cutting edges 26 of the teeth. Said grooves preferably are formed by a cutting wheel of the diamond type similar to wheel 36 which operates to generate the groove 58, as the bur is rotated slowly about its axis and, by the time the cutting wheel reaches the portion of each tooth on which the relief surface 30 occurs, a more gradually sloping outer end surface 60 is formed by the cutting wheel. Such configuration results in backing up the cutting tips 56 for strength and resistance to chipping, while at the same time, providing adequate clearance surfaces for chips.
While the invention has been described and illustrated in its several preferred embodiments, it should be understood that the invention is not to be limited to the precise details herein illustrated and described since the same may be carried out in other ways falling within the scope of the invention as illustrated and described. | A helical dental bur having a shank provided on one end with a cutting head having a series of similar teeth extending longitudinally and spaced evenly around the circumference thereof; said teeth each having a flat cutting face extending from the cutting edge radially toward the axis of the head to form one side of said tooth and provide a positive cutting rake therefor, a relative deep chip gash adjacent said face, and a convex relief surface extending from the cutting edge toward said gash adjacent the next succeeding tooth to form the opposite side of each tooth, said convex relief surface permitting said chip gashes to be substantially deeper than such gashes in conventional burs without sacrificing strength of said teeth to resist chipping and breakage of said cutting edges, as well as including the benefit of said flat cutting face which extends radially to provide said positive cutting rake. | 0 |
This is a continuation of application Ser. No. 07/603,083 filed on Sep. 25, 1990 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a multiprocessor system, and in particular relates to a multiprocessor system which is capable of reducing overhead due to required synchronization among the processors and to ineffective scheduling. The overhead is reduced as much as possible to improve system performance and to provide effective usage of processor resources.
2. Background of the Problem
The advance of VLSI methods has provided multiprocessor systems with each system having many processors. Parallel processing, which enables one to perform tasks rapidly through the use of a plurality of processors, is also gaining in importance. In such multiprocessor systems, sometimes one processor uses the result of a process performed by another processor. In this situation, acknowledgement of the completion of that process, an important aspect of synchronization, is required. In order for a plurality of processors to operate in cooperation with one another, synchronization among processors is thus seen to be indispensable.
Conventional synchronization techniques are now described. In a computing system, control of real hardware resources are performed by an operating system (hereinafter referred to as an "OS"). A user or programmer describes operations by using the concept of "process" which virtualizes a real processor. Real processors are allocated to processes, one processor to one process, under control of an OS to perform the operations. Such allocation is referred to as "process scheduling" (hereinafter referred to simply as "scheduling").
In parallel processing, a plurality of processes which should operate in cooperation with one another are created, and parallel processing proceeds, keeping synchronization among the processes. Conventionally, the following two methods have been employed for synchronization. The first is the performance of synchronization through an OS, and the second is through the use of shared memory among processes. For synchronization, some kind of shared entity is required which enables the exchange of information among processes which are synchronized with one another. The first method uses an OS as the entity, and the second uses a memory. The problems associated with these two methods are now described. In the case where synchronization is achieved through an OS, a process which does not establish synchronization is removed from the allocated processor and enters a sleeping or idle state, and the freed processor is allocated to another process. In such a way, processor resources are effectively used. The synchronization through an OS however causes an undesirable overhead. The repetition of entering a sleeping state and thereafter receiving an allocation produces a degradation in performance. If the granularity of a program is large enough, the overhead can be neglected. In most cases it is not however negligible.
In the case that synchronization is achieved using busy and wait states and a shared memory rather than using an OS, the above overhead problem can be avoided. However, another problem can occur. As mentioned above, an OS dispatches one process to one processor at a time. During a single scheduling operation, the 0S cannot usually assign a plurality of processes to a plurality of processors at one time. For example, consider a program where a plurality of processes are created for parallel processing and they operate in synchronization with one another. Depending on the scheduling operation, some processes in the group can be dispatched to processors and the remaining processes can be in an idle state waiting for dispatching. In this case, a process can try to establish synchronization with another process which is not scheduled to any processor and then an ineffective busy and wait condition can occur. An example is a case where processes are dispatched to processors as shown in FIG. 1, and the processes A1, A2 and A3 are in a loop of busy waiting (in synchronization) for use of the operational result of process A4. In such a case, while CPU time is being consumed, programs will not proceed until process A4 gets dispatched to one of the actual processors upon rescheduling by a time slice operation or the like. In addition to the scheduling problem, when a "barrier synchronization" (that is, when a plurality of processes each wait for the others at a point) is performed through a shared memory, exclusive memory accesses for the synchronization occurs in a concentrated fashion in the multiprocessor, thus raising the problem of overhead due to contention of data communication paths and the like.
As indicated from the above, process synchronization and scheduling are very much correlated. For applications involving certain kinds of parallel processing programs, adjustment of scheduling can improve performance. In a conventional OS, however all processes are scheduled based on the same algorithm, so that scheduling cannot be adapted to individual processes.
The following are relevant to the background of the present invention.
1. "Stellix: UNIX for a Graphics Supercomputer", Proceedings of the Summer 1988 USENIX Conference, Jun. 20-24, 1988, San Francisco, Calif., USENIX Association, pp. 321-330, Thomas J. Teizeira & Robert F. Gurwitz.
This article appears to disclose that a fault signal is generated by hardware when all the processes are in a wait state during synchronization operation by a special instruction stream for synchronization. However, that article does not even suggest that a process itself should check certain conditions using processor information in a shared memory (as stated later, the information desired includes data on dispatching of processes to processors, on grouping of processes and on process synchronization) to issue a rescheduling request and to provide effective process synchronization.
2. IBM Technical Disclosure Bulletin Vol. 32, No. 1, Jun. 1989, pp. 260-262, "DEVICE THAT PROVIDES FOR CONTENTION-FREE BARRIER SYNCHRONIZATION IN A MULTIPROCESSOR".
3. IBM Technical Disclosure Bulletin Vol. 31, No. 11, April 1989, pp. 382-389, "LOW-COST DEVICE FOR CONTENTION-FREE BARRIER SYNCHRONIZATION".
The above articles (2) and (3) disclose hardware configurations for performing barrier synchronization in a concentrated fashion, but does not even suggest any design for synchronization waiting.
4. H. S. Stone, "High Performance Computer Architecture", Addison-Wesley, Reading, Mass., 1987.
This text book provides a tutorial explanation about barrier synchronization in general.
SUMMARY OF THE INVENTION
To achieve the above object, according to one aspect of the present invention, synchronization through the use of a shared memory is employed to decrease overhead. Information about system processor resources is made available from processes. The information provided includes data on dispatching of processes to processors, on grouping of processes and on process synchronization. A process in a loop for synchronization waiting checks the information about the system processor resources in addition to synchronization variables, and after that, when the resultant check determines that synchronization cannot be established in a short time under that situation, the process stops the busy waiting operation, and returns control to the scheduler so that the scheduler does rescheduling or changes the dispatching of processes.
According to another aspect of the present invention, a dedicated register is prepared for each processor for barrier synchronization wherein a plurality of processes are simultaneously waiting, and a dedicated communication path is also provided for exchanging information among the registers, so that the overhead of barrier synchronization is reduced.
Further hardware to support checking for processor resource information is provided to reduce additional overhead additionally caused by checking. In this case, initiation of rescheduling is signaled by an interrupt.
Furthermore, the scheduler may be user-customizable so as to enable suitable rescheduling. In addition, the scheduler may be configured in a hierarchical manner so that customization under the control of an OS is achieved. In other words, each group of processes operating in parallel to perform an application is under control of a user scheduler for that application. In addition, in order to reduce the overhead of interruption which is indicative of rescheduling, and in order to enable the use scheduler to communicate with other processors asynchronously with reduced overhead, interruption by processors is made hierarchical and interruption of lower priorities may be made available to the user. In this configuration, when interruption occurs during the running of the user application (during user mode operation), control is only transferred to an interruption program which is set by the user in advance, and need not be transferred to the OS (kernel mode operation).
Accordingly, it is an object of the present invention to provide a multiprocessor system capable of reducing overhead due to synchronization among processors, and to reduce ineffective scheduling.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, 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 block diagram illustrating the conventional method for dispatching processes to processors;
FIGS. 2 to 5B are block diagrams illustrating conditions for rescheduling requests used in a preferred embodiment of the invention;
FIG. 6 is a flow chart describing the above embodiment;
FIG. 7 is a flow chart describing the corresponding part of the conventional method to the flow shown in FIG. 6;
FIGS. 8 to 10 comprise two flow diagrams and a block diagram describing modified versions of the above preferred embodiment of FIG. 6;
FIG. 11 is a block diagram describing a further modified version of the embodiment of FIG. 10;
FIGS. 12 and 13 are block diagrams illustrating a detailed configuration of the embodiment shown in FIG. 6;
FIG. 14 is a flow chart illustrating the configuration of FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
Section 1. Explanation of principle
Subsection 1.1 Context of the invention
Since one of the objects of the present invention is to reduce the overhead arising out of synchronization, the invention employs the busy waiting approach using shared memory or the like. The use of an OS causes overhead increase as previously stated. Accordingly, the following two problems occur as described above:
(1) One or more processes, each ineffectively waiting for synchronization, are dispatched to processors, and then waste processor resources.
(2) During barrier synchronization, exclusive memory accesses are concentrated, and contention for a data path causes an overhead.
First, the problem (1) is detailed and the direction to resolve it is shown. Consider a case where a plurality of processes are together performing a certain operation in cooperation with one another (parallel processing). And assume that during this operation, more than one other process is in a waiting state for synchronization. And further assume that the first process comes off a waiting state, and that the other processes are waiting for the former process output or calculation result. Also assume that the number of processes is larger than the number of processors, so that all of the processes cannot be dispatched to the processors simultaneously. In this situation, since synchronization is achieved through a shared memory, the OS cannot determine whether or not a process is in a waiting state. Therefore, depending on scheduling, only the processors waiting for synchronization can be dispatched, and the process which is not at a synchronization waiting state and should be performed at the highest priority can be in a state waiting for dispatching. In this case, the processor resources continue to be wasted until the process not waiting for synchronization gets dispatched to a processor upon a change in rescheduling via timer interruption occurring at a certain interval.
To resolve the wasted resources problem, an event has to be determined where all the processors are occupied with processes waiting for synchronization. Accordingly, in a busy waiting loop waiting for synchronization, not only synchronization variables but also information related to system processor resources are checked. Depending on the result of checking, under some situations the operation is stopped and the control is transferred to the OS and rescheduling is performed to change the dispatching of processes to processors. In that approach, the number of processes doing ineffective synchronization waiting can be reduced and the system processor resources are more effectively used. A method for identifying such situation is detailed in subsection 1.2, and a method of rescheduling is provided in subsection 1.3.
Next, the problem of concentrated exclusive memory accesses during barrier synchronization is addressed and an approach to resolve it is put forth. When barrier synchronization is achieved in a system having N processors by using one synchronization variable, exclusive manipulation to the variable is required at least N times. Memory operations for that manipulation are serialized, so that overhead increases as a function of N. In particular, the overhead problem becomes serious when granularity of processes in barrier synchronization are almost the same size and all the processes are dispatched to processors simultaneously, that is, in the situation where there are no processes awaiting dispatching.
To avoid the kind of overhead described above, a control variable dedicated to barrier synchronization is provided in a dedicated register (a flag is used in the present invention) for each processor, and modification among the registers is achieved through a dedicated communication path for synchronization information (signal lines of a broadcast type are also used in the present invention). Using such facilities, barrier synchronization is achieved without an increase in communication volume over a data communication path. Of course, when one or more processes are awaiting dispatching, an operation according to the problem resolving approach (1) is performed. A detailed configuration is described in Section 2.
Subsection 1.2 Conditions for switching processes and detection method for the conditions
Conditions under which a process waiting for synchronization gives up the dispatching by itself are now described and information is provided concerning system processor resources that are required to check for these conditions. Thus here is introduced the idea of "a group of processors", to manage processor resources effectively. Basically, processes in synchronization with one another by a shared memory constitute a group. In other words, processes each belonging to different groups do not keep busy waiting synchronization with one another using the shared memory. Processors each "belong to" groups of the processes running on the processors. Processors to which one group of processes are dispatched constitute a group of processors. In FIG. 1, processes A1, A2, A3 and A4 constitute one group of processes, and according to the dispatching as shown, CPU1, CPU2 and CPU3 constitute one group, and CPU4 belongs to another group. When using a UNIX-like OS (UNIX is a trademark of AT&T), a Parent Process Identifier (PPID) can be used as a group identifier.
Drawings are provided to facilitate understanding the embodiment, and drawing notations which are referred to later are now described. Regarding "process A2w", the beginning "A" indicates the group name, and the next "2" indicates its number in the group, and the following "w" indicates that the process is waiting for synchronization. For a process not waiting for synchronization, "r" rather than "w" is used. Processes surrounded by broken lines at the left sides of the figures are shown as ones which are waiting to be dispatched.
The following are examples of conditions, upon each of which, a process waiting for synchronization stops its operation and requests a process switch:
[1] All of the processors in the group of processes concerned are waiting for synchronization and one or more processes are waiting for dispatching. See FIG. 2(a).
[2] All of the processes in the group of processes concerned are dispatched to processors and waiting for synchronization at one time; this event occurs due to programming errors (deadlock). See FIG. 3.
[3] The processor concerned is a member of a group which consists of processes performing a barrier synchronization, and one or more members of the group is waiting for dispatching but not waiting for synchronization. See FIG. 4(a).
[4] The number of processors waiting for synchronization in the group of the process concerned is more than "n", and one or more processes are waiting for dispatching ("n" is a value which an OS or user can set).
[5] The number of processes waiting for synchronization in the group of the processes concerned is more than "n", and one or more processes in the group of the process concerned are waiting for dispatching. See FIG. 5.
Each of [1], [2] and [3] is a condition for improving the theoretical effectiveness, and each of [4] and [5] is a condition for doing the same by determining "n" heuristically, or from experience. Depending on the application which is running, "n" is adjusted in order to improve efficiency. With respect to conditions [4] and [5], instead of the number of processors waiting for synchronization, the ratio of the number of processors in the group to the number of processors waiting for synchronization in the group is used.
Information about system processor resources, which are required for checking the above conditions are as follows:
#MSG (the number of M Group CPU's): the number of processors which belong to the group of the process concerned (the number of processes in the group of the process concerned, which are dispatched to processors).
#MWC (the number of M Group Waiting CPU's): the number of processors which belong to the group of the process concerned and is waiting for synchronization.
#MGP (the number of M Group Processes): the total number of processes belonging to the group of the process concerned.
#PRQ (the number of Processes in Run Queue): the number of processes waiting to be dispatched.
#MPRQ (the number of M Group Processes in Run Queue): the number of processes waiting to be dispatched in the group of the process concerned.
#MNWR (the number of M Group Not-Waiting Processes in Run Queue): the number of processes waiting to be dispatched but not waiting for synchronization in the group of the process concerned.
#TVPS (Threshold Value for Process Switch): the value "n" mentioned above.
These values should be referenced by a user process at a low cost and the values stored as variables which can be accessed both by users and an 0S kernel. With respect to data integrity and access privilege, it is noted that only #MWC is set by a user application process. Other values are set only by an OS scheduler. The scheduler modifies these values at each scheduling time as needed.
An efficient busy waiting synchronization method is described with reference to the flowchart of FIG. 6, which also comprises a step for checking conditions for switching processes described previously. The specific method and the like for checking the conditions depends on the number and variety of processes waiting to be synchronized. In this description, in order to facilitate a better understanding, the reader is directed to the example as shown in FIG. 6. Reference to the details shown therein are made below.
FIG. 7 shows a conventional loop for waiting. In FIG. 6, a synchronization variable is checked at the beginning of the procedure (S1) in order to incur as little overhead as possible as compared with the conventional method. The ideal case is one in which synchronization is established and the synchronization variable is set to a value established before checking the synchronization variable a first time. If synchronization has completed, a waiting operation is immediately terminated. Only if the first time check indicates that synchronization has not completed, does the processor enter a synchronization waiting state (S2). In this state, variables to be affected by the entrance, for example, #MWC etc., are modified (S3). Information about system processor resources is read out (S4); determination is made of whether or not the process concerned should be terminated; and the scheduler is requested to reschedule processes depending on the above mentioned conditions (S5). If either of the conditions is fulfilled, variables to be affected are modified (S6), and the scheduler is invoked using a system call for transferring control of the processor and the like (S7). If neither of the conditions is fulfilled, synchronization variables are newly checked (S11). If synchronization is not established, operation returns to the read-out step of processor resource information and the procedure is iterated. If synchronization is established, the processor concerned completes the synchronization waiting state, and then affected variables (#MWC etc.,) are modified (S12), and the waiting operation is terminated (S9). When the process which has transferred control of the processor is again dispatched to that processor or another processor, the operation joins the flow taken when neither of the conditions for process switching is fulfilled (S8, S10).
The blocks surrounded additionally by broken lines are involved with exclusive and indivisible access to the shared memory (#MWC). In a system having a shared bus, these accesses are performed with lock operations. It is likewise in the following other figures.
In some hardware configurations, a problem exists in regard to concentrated access to shared variables. The problem is raised because variables defining processor resources shared by processors are accessed in the innermost loop. In a system without hardware units, such as memory caches which are capable of keeping consistency of content ("snoopy" caches), the shared memory may be frequently accessed at a high cost, and communication contentions over communication paths may be raised. This problem also exists in conventional approaches to this problem in which access to synchronization variables, which are shared variables, is similarly made in the most inside loop. Accordingly, this is not a problem caused only by the present invention. In the following description, it is assumed that the system has hardware such as caches capable of keeping consistent memory content.
As shown in FIG. 8, in a system having "snoopy" caches, a spin lock is used to suppress the necessity for ineffective process switching, without increasing overhead. In particular, in the method shown in FIG. 6, a plurality of processes can fulfill either of the conditions of process switching at one time and many process switching requests can then be concentrated. Accordingly, as shown in FIG. 8, operations requesting process switching are set as critical sections and controlled exclusively to prevent such a concentration of requests. It should be noted that if exclusive access (a bus lock, etc.) to the shared memory for exclusive control of the critical section occurs in the most inside loop of the busy waiting operation, accesses to the shared memory are concentrated and the overhead becomes large. In this regard, in the innermost loop, no critical section is provided and instead the conditions for process switching are only checked, and if either of the conditions is fulfilled, a critical section is entered to check the conditions again (spin lock, S4', S5' ). In addition, in the method shown in FIG. 8, when the scheduler switches among processes and modifies variables which define system processor resources, accesses are exclusively controlled. Details are omitted in FIG. 8 insofar as portions are analogous to the corresponding portions of FIG. 7.
A waiting state flag (PWF: Process Waiting state Flag) and a waiting state counter (PWC: Process Waiting state Counter), as shown in FIG. 6, are prepared for each process, and using these data the scheduler calculates the value of #MNWR, and also determines scheduling. A detailed description is given below in subsection 1.3.
For a program having a relatively fine granularity, the new method causes a larger overhead than conventional methods. For example, when a group of processes frequently requires synchronization and the processes are dispatched to processors at one time, synchronization is established immediately after entrance to a waiting state, so that the loop of synchronization waiting is performed only one or two items. Processing cost for one loop of the synchronization waiting in the new method is, apparent from FIGS. 7 and 8, higher than the conventional method. Therefore in the case of one or two loops performed, the overhead required for operations beginning with synchronization establishment (any process can modify a synchronization variable) and ending with detection of the establishment and termination of the waiting procedure, is not negligible. To resolve this problem, a hardware mechanism is provided which detects outside a processor whether or not the processor is in a synchronization waiting state. As a result, a hardware mechanism can determine whether or not processes in a synchronization waiting state should be switched and inform the processor of fulfillment of either of the conditions by providing an interrupt. The processor then performs synchronization waiting as shown in FIG. 9. Accordingly, even in the above mentioned severe case, the overhead of the new method can be comparable to conventional methods.
Subsection 1.3 Improved Rescheduling
FIGS. 2, 4 and 5 show examples of the progression of rescheduling states after the fulfillment of conditions [1], [2] and [3] respectively (as defined and identified above via bracketed numbers). When a plurality of processes are waiting to be dispatched, it is important in terms of efficiency to correctly select which processes are dispatched to processors. Further in FIG. 3, a deadlock occurs in regard to group A, so that rescheduling halts the performance of all the processes in group A. How the scheduler performs the rescheduling operation is now described. In addition, when more processes than processors perform parallel processing together, rescheduling inevitably occurs, and when the granularity is fine it occurs frequently. Accordingly, it is very desirable to suppress as much as possible overhead which is due to rescheduling and to make parallel processing more applicable. A hierarchically driven scheduler which provides such reduced overhead is described below.
The above mentioned values of waiting state flag (PWF) and waiting state counter (PWC) are data used by the scheduler to calculate #MNWR and to assist the scheduler in performing rescheduling. The initial values of both are "0", and PWF indicates by "1" that the process concerned is in a waiting state, and PWC indicates the frequency with which the process enters a synchronization waiting state. Using PWF and PWC, a process detects whether or not it is in the same synchronization state as other processes. With this result, even if condition [2] is not fulfilled, a deadlock can sometimes be detected. For example, when all the processes in a group are in a synchronization waiting state and all the processes keep the same synchronization waiting state after all the processes are dispatched once to a processor, a deadlock is indicated. The operation should be then terminated. Further, a scheduling method can be employed which assigns a priority to one or more processes not waiting for synchronization. For barrier synchronization, PWCB (Process Waiting Counter for Barrier) is provided carefully. PWCB, unlike PWC, indicates how frequently the process performs waiting operations. That is, PWCB is modified immediately before checking synchronization variables at the beginning of FIG. 6. When all the processes in a group keep barrier synchronization, all of the synchronization values of PWCG match one another, so that processes to be scheduled next can be determined. It should be noted that, as shown in FIG. 4(c) and (d), a process waiting to be dispatched and also waiting to be synchronized, gets out of synchronization while waiting for establishment of synchronization. Accordingly, it is necessary to modify #MNWR upon establishment of synchronization.
In addition to the above, for some applications, information about the combinations of processes which are synchronized with one another frequently can be obtained in advance. Scheduling depending on information particular to each application provides better results.
Next, hierarchization of the scheduler is described.
Scheduling is usually performed by the kernel of the OS. Hence, in order for a user process to get rescheduling started, a system call is required to the kernel. The scheduler in the OS cannot however generally perform adaptive scheduling for each application. In addition, the kernel of the OS and user processes share much data, so that procedures for communication become complicated and overhead also increases. Furthermore, a system call itself causes a heavy overhead, so that it is difficult to switch among processes frequently.
To resolve these problems, a scheduler is hierarchized. A part of the scheduler for allocating real processors is conventionally referred to as a "kernel scheduler", and user schedulers are provided under the control of that kernel scheduler (see FIG. 10). A user scheduler is provided for each group of processes which execute an application in cooperation with one another, and its scheduling method is determined by a user in accordance with the operation. The kernel scheduler controls all of the real processors, and it assigns one or more real processors for each process group. Each user scheduler performs scheduling among processors assigned to it. In addition, the user schedulers do not operate in the kernel (kernel mode) but on the user side (user mode). Accordingly, the user schedulers do not need system calls for process switching and they do not cause any overhead. This improves efficiency.
When one of the switching conditions is fulfilled, control is transferred to a corresponding user scheduler, which in turn selects one or more processes to be dispatched in accordance with a scheduling algorithm suited for the corresponding process group, and after that the control is transferred to the processes. In that way, processes are switched in the group without overhead for a system call. FIG. 11 shows an example where the group A performs process switching using a user scheduler based on condition [3].
The kernel scheduler receives from each process group the number of processors which it requests, and performs scheduling in such a manner that the request from each group is satisfied as much as possible. The kernel scheduler is initiated upon timer interruption for time sharing or upon a system call during input/output operation of a peripheral device or upon a request or return of processor resource from a user scheduler. When scheduling by the kernel scheduler causes one or more free processors to be required, the processors of the lowest priority group are taken (preempted).
In a configuration where the determination of conditions for process switching in regard to synchronization is implemented in hardware and a processor is informed of fulfillment of conditions by interruption, user schedulers are designed to be initiated by the interruption. In a conventional processor which discriminates during operation between the kernel side and the user side, control is transferred to the kernel after the interruption. Use of such conventional processors requires that the control be returned to a user with overhead suppressed as much as possible during that interruption. In this regard, processors having a hierarchical interruption function, which is described below, allow interruption without overhead on the user side. That is, processors are provided with interruptions of different priorities, and some interruption of lower priorities are assigned to interruption of the user mode. Upon such interruption, control is transferred in the user mode to a routine designed by the user. The remaining types of external interruption are to the kernel mode as is conventional. Further interruption in the user mode is designed by modifying an interruption mask (switching between enabled and disabled states of each interruption) as the user chooses. When such an interruption in the user mode occurs for synchronization and asynchronous communication among processors in a group, control is never transferred to the kernel and overhead is this decreased. For interruptions from the synchronization mechanism, control is designed to be directly transferred to the user scheduler.
Section 2. Detailed Configuration
Next, the detailed configuration of the synchronization mechanism is described. In this configuration, to reduce the overhead of a busy waiting operation, determination of conditions for process switching is preferably implemented in hardware. The scheduler is designed as hierarchized according to the description in subsection 1.3, and preferably implemented in software. In the following, the hardware for the synchronization mechanism and an operation of busy waiting used in that mechanism are mainly described.
FIG. 12 shows the whole configuration, in which a shared bus 1 is used as a data communication path. For processors CPU1, CPU2, . . . , CPUn, synchronization controllers SC1, SC2, . . . , SCn are provided respectively. The synchronization controllers are connected to synchronization bus 2 (signal lines of broadcasting type) which consists of the same number of signal lines as the processors. Each processor and its corresponding synchronization controller is connected via a data line for read/write operations of registers and flags in the controller and via an interruption line (for the above mentioned interruption in the user mode) from the controller to the processor.
FIG. 13 shows the configuration of synchronization controller SC1. It should be noted that other synchronization controllers have the same configuration. In this figure, individual lines of synchronization bus 2 are assigned to system controllers SC1, SC2, . . . , SCn respectively, and each of the system controllers provides output signals (binary value of "0" or "1") on only its corresponding signal line. The signal generated corresponds to a synchronization output flag (SOF) in the corresponding controller or a barrier synchronization output flag (BSOF). When SOF (or BSOF) is reset, a "0" signal is provided on the line. In the initial state, SOF and BSOF are reset, and SOF (BSOF) is set before the relevant processor enters a synchronization loop using shared memory 4, and it is reset after the processor passes through the loop (see FIG. 9). Accordingly, the signal line in the synchronization bus corresponding to each process waiting for synchronization is set to "1". In addition, in the synchronization controller, a group register 3 is provided, which is set to "1" by the corresponding scheduler at the location corresponding to the processors belonging to the group of the corresponding processor. Therefore, the synchronization controller determines whether or not each of the processors belonging to its group is in a synchronization waiting state.
The synchronization controller has two operation modes. Mode 1 corresponds to the above mentioned problem (1), and mode 2 to problem (1) in barrier synchronization and the above mentioned problem (2) (condition [3]). While each controller assumes only one mode at a time, different modes are assumed for different groups. Switching of the modes is performed using a register (MODE) in each controller.
Registers and flags common in a group can be written simultaneously through a shared bus. That is, the scheduler can output, on the shared bus, a command with a designated group. This command modifies registers in the controllers in the designated group. Likewise, the scheduler can modify registers in any processor other than one connected to the scheduler.
As shown in FIG. 13, registers or the like which can be set in such a manner by the scheduler include Group Register 3, MODE, UM, KM, PRQ flag, TVPS1, TVPS2, MPRQ flag, MVWR flag and PCOUNT. Among those flags, UM and KM are interruption masks for the user scheduler and the kernel scheduler respectively. When either of them is set, interruption of the processor is prohibited. Of course, the kernel scheduler can modify all the registers and flags. PRQ flag, TVPS1, TVPS2, MPRQ flag and MNWR flag are for storing information about processor resources. PRQ flag, MPRQ flag and MNWR flag correspond to #PQR, #MPRQ and #MNWR respectively (in subsection 1.2). When the count is "0", then the flag is reset, and when the count is other than "0", then the flag is set. TVPS1 (or TVPS2) is a register for setting a value to be compared to the value of #MWC for conditions [1], [2], [4] and [5] (as described above). For example, in order to check conditions [ 1] or [2], h1 is set by #MGC. PCOUNT is a counter for counting occurrences of preemption processes in a group by the kernel. The counter is counted up when the kernel scheduler preempts, and it is counted down when the user scheduler operates for the preemption. Accordingly, the controller can keep enough information about the occurrence of preempting and prevents erroneous operation.
First, operation in mode 1 is described. As mentioned above, the controller has registers or the like for storing information about processor resources, and the scheduler sets values for the registers or the like. For #MWC, the synchronization controller monitors the synchronization bus and keeps informed. The above mentioned conditions [1] to [5] about the system status are checked by the hardware mechanism, and upon the fulfillment of either of the conditions an interruption signal is supplied to the processor, and rescheduling by the OS is requested.
Next, operation in mode 2 is described. In addition to the above mentioned registers and flags, a read only barrier synchronization establishment flag (BF) is provided in the synchronization controller. It should be noted that the scheduler can perform a read/write operation without side effect. The BF flag is set to "0" when the MNWR flag is rest to "0", PCOUNT is "0", and all the processors in the group of the process concerned are waiting for synchronization. After the processor reads "1" as the flag bit, the controller performs the following operations and automatically resets the flag. First, the controller sets its synchronization line and BSOF to "0", and when the MPRQ flag is not "0", then the MNWR flag in the controller is set to "0". After that, the BF flag is reset. The program uses the BF flag for waiting. Although in mode 1, BSOF is set and the synchronization line is "1" in mode 2. Like the automatic resetting of BSOF, the BF flag is automatically set upon the first reading immediately after the establishment of synchronization. Accordingly, there is no need to set the BF in the busy waiting operation. Likewise, the count-up of PWCB can be automated. The waiting operation is accordingly shown in the flow chart of FIG. 14. To prevent erroneous operations during creation or deletion of processes by the scheduler, the following control scheme is implemented. For example, when processes are created to participate in barrier synchronization, the MNWR flag in the controller is set to "1" to prohibit interruption, and after all the processes are created, a correct MNWR flag is set and an interruption is allowed. Further, the synchronization controller checks for condition [3] and generates interruption to the processor to switch processes when the condition is fulfilled. It should be noted that when PCOUNT is other than "0", the same control scheme is implemented as when the #MNWR flag is not "0", and an erroneous operation is prohibited.
The registers in controllers SC1, SC2, . . . , and SCn are modified as required each time processes are switched, and SOF, BSOF, BF, MNWR flags and the like of each controller for the processor which is about to change processes, are kept behind before that change, and when the previous process is dispatched again in the future, the kept values are used to set the flags again.
As described above, in accordance with this invention, when processes executed in synchronization with one another on a multiprocessor system are dispatched to real processors simultaneously, an overhead is very small, and further even when all of the processes cannot be dispatched simultaneously due to the limited number of processors and scheduling methods, the processor resources are used efficiently.
While the invention has been described in detail herein in accord with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention. | A method and apparatus for synchronizing and scheduling multiple processes in a multiprocessor of processor resources as supplied from the processes. Through hierarchical and user controllable grouping of processes, overhead associated with processor allocation and synchronization is reduced. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is related to a method, system, and program for a data transfer operation with respect to source and target storage devices in a network.
[0003] 2. Description of the Related Art
[0004] The Small Computer System Interface (SCSI) extended copy command allows one application in a network to issue a command to another device, referred to as the copy manager, to copy data from one set of source logical devices to another set of target logical devices, where the source and target logical devices may be separate from the system initiating the command. The extended copy command is issued to a copy manager that is responsible for copying data from the source device(s) to the destination device(s). Further details of the SCSI extended copy command are described in the publication “SCSI Primary Commands-2 (SPC-2)”, Rev. 20, Reference No. ISO/IEC 14776-312 : 200x (Jul. 18, 2001), which publication is incorporated herein by reference in its entirety.
[0005] In a Fibre Channel Storage Area Network (SAN), each device is identified with a fixed identifier that does not change, such as a World Wide Name (WWN) assigned at the factory, and a temporary Fibre Channel static address assigned during initialization by the Fibre Channel fabric. If an administrator or program is unaware of these changes to the static Fibre Channel address of the device, then an extended copy operation using an invalid Fibre Channel address as the source or target device would result in an error. If the old incorrect address points to a different device than the one intended to be the source or target, then the wrong storage device would be involved in the copy operation. This could result in the unintended loss of important data by overwriting an unintended target storage device or copying an unintended source.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0006] Provided are a method, system, and program for performing a data transfer operation with respect to a source and target storage devices in a network, wherein storage devices in the network are assigned temporary network addresses. Device information is maintained and includes for each identified device a fixed address that does not change and a temporary network address. A data transfer request is received to transfer data between a source and target devices. The network is queried to determine changes to the temporary network addresses of the storage devices in response to receiving the data transfer request and the device information is updated to include any changed determined temporary network addresses for the storage devices. A data transfer command is constructed to transfer data between the source and target storage devices, wherein the data transfer command includes the temporary network addresses of the source and target devices in the device information.
[0007] In further implementations, the network comprises a Fibre Channel network, the temporary network address comprises a Fibre Channel address, and the fixed address comprises a world wide name and logical unit number for the device.
[0008] Still further, the data transfer request may comprise a backup request to backup data from the source device to the target device. Alternatively, the data transfer request may comprise a restore request to restore backed-up data from the source device to the target device.
[0009] Described implementations provide techniques to perform a data transfer operation in a manner that minimizes the risks associated with specifying a wrong source or target address for the data transfer, including data errors and destruction of existing data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
[0011] [0011]FIG. 1 illustrates a network computing environments in which aspects of the invention are implemented;
[0012] [0012]FIGS. 2 and 3 illustrate information included in a device database and backup database, respectively, in accordance with implementations of the invention;
[0013] [0013]FIGS. 4 and 5 illustrate operations performed to backup and restore data, respectively, in a network environment in accordance with implementations of the invention; and
[0014] [0014]FIG. 6 illustrates a computing architecture that may be used to implement the network components described with respect to FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] In the following description, reference is made to the accompanying drawings which form a part hereof and which illustrate several embodiments of the present invention. It is understood that other embodiments may be utilized and structural and operational changes may be made without departing from the scope of the present invention.
[0016] [0016]FIG. 1 illustrates a server-free network computing environment in which certain embodiments of the invention are implemented. Two host systems 2 a , 2 b , are connected to two networks, shown as a Local Area Network (LAN) 4 , using the Ethernet protocol, and a Storage Area Network (SAN) 6 , using the Fibre Channel protocol. In alternative implementations, networks and connections other than SAN and LAN may be used to implement the two networks 4 , 6 to which the hosts 2 a , 2 b connect. A data mover 8 , backup storage device 10 , and storage system 11 on which logical volume 12 resides are shown as coupled to the SAN 6 . The logical volume 12 may include user data. Host 2 a includes a storage client 14 program to perform storage client operations, such as managing the backup and restore of data on volume 12 . The host 2 b includes a storage server 16 program to perform storage server operations in response to requests from multiple storage clients 14 , such as managing the backup and restore of the data with respect to storage clients 14 , discovering devices in the SAN 6 , ensuring all the required paths defined between devices in the SAN 6 exist, mounting and positioning tape devices, recording information about the backup/restore operations in a database, etc. A topology database 18 is further coupled to the SAN 6 fabric and includes information on all the devices connected to the SAN 6 , such as the Fibre Channel addresses, world wide names, LUN numbers, serial numbers, vendor identification, etc. The topology database 18 , also known as the Fibre Channel name server, is created during initialization of the SAN 6 and devices coupled to the SAN 6 may access information in the topology database 18 to determine information about other devices connected to the SAN 6 with which they may communicate.
[0017] The host systems 2 a , 2 b may comprise any computing device known in the art, such as a server class machine, workstation, desktop computer, etc. The backup storage device 10 may comprise a mass storage device known in the art suitable for backing-up data, such as a tape storage device, e.g., a tape library, or one or more interconnected disk drives configured as a Redundant Array of Independent Disks (RAID), Just a Bunch of Disks (JBOD), Direct Access Storage Device (DASD), etc. The storage system 11 may comprise a mass storage device comprised of hard disk drives in any configuration, or another type of storage device. The data mover 8 may comprise a SAN data gateway, router or any other device suitable for moving data from one component to another in a network. The data mover 8 is capable of accessing the data in the volume 12 . In further implementations, the data mover 8 may have alternative connections to the volume 12 or backup storage device 10 , such as through a Small Computer System Interface (SCSI) connection separate from the SAN 6 or LAN 4 . In certain implementations, the storage system 11 may include disk drive storage and the backup storage device 10 may be comprised of tape media or hard disk drives. The storage system 11 in which the volume 12 is configured may include additional volumes accessible to the SAN 6 . Moreover, additional hosts, storage systems, backup storage systems, data movers, etc. may be coupled to the networks, and there may be additional networks therebetween.
[0018] The storage client 14 would initiate an operation to backup or restore data at the volume 12 by communicating the request for such operation to the storage server 16 via LAN 4 . The storage server 16 would then prepare a copy command, such as the SCSI extended copy command, to perform the copy operation between the volume 12 and backup storage device 10 to implement the backup or restore operation, and send the copy command to the data mover 8 to perform the data copy operation. Further details of a server free backup are disclosed in the publication “IBM Tivoli Storage Manager Version 5.1: Technical Guide”, document no. SG24-6554-00 (Copyright International Business Machines Corp., June 2002), which publication is incorporated herein by reference in its entirety.
[0019] To manage backup and restore operations, the storage server 16 maintains a device database 20 including information on each device in the SAN 6 with which the storage server 16 interfaces and a backup database 22 including information on backup data sets managed by the storage server 16 .
[0020] [0020]FIG. 2 illustrates information that may be included in each record 50 in the device database 20 for each storage device and storage volume accessible to the storage server 16 , including:
[0021] World Wide Name (WWN) 52 : The world wide name is a unique identifier assigned by the manufacturer, usually 64 bits.
[0022] LUN 54 : provides a logical unit name assigned to a logical device, where a storage system may have multiple LUNs. Each disk drive storage, which may include storage system 11 , has a logical volume name, as well as LUNs.
[0023] Fibre Channel Address 56 : A temporary address assigned automatically each time an interconnect initializes. A device may receive a new address each time a Fibre channel is reconfigured and reinitialized from the Fibre Channel component running the initialization routine.
[0024] Device Name 58 : an arbitrary name assigned to the device, which may comprise a descriptive name.
[0025] Serial Number 60 : A unique identifier assigned to the device by the manufacturer.
[0026] [0026]FIG. 3 illustrates information that may be included with each record 60 in the backup database 22 including information on backed-up data sets. Each backup record 60 includes:
[0027] Backup ID 62 : a unique identifier of the record providing information on a backup.
[0028] Backup Storage Location 64 : the logical volume name including the backed-up image or object. For instance, when the backup storage device 10 comprises a tape device, the backup data would be stored within one logical volume on the tape.
[0029] Offset Into Backup Location 66 : an offset in units of bytes, fixed blocks, records or a file mark of the start of the backup data in the backup device.
[0030] Size of Backup Data Set 68 : The number of bytes of the backed-up data.
[0031] Client Name 70 : the name of the storage client 14 that initiated the backup operation, which may comprise the device name 58 (FIG. 2) assigned to the device.
[0032] File Name 72 : a name of the file to backup, i.e., the identifier the client uses to access the data.
[0033] [0033]FIGS. 4 and 5 illustrate operations performed by the storage server 16 to perform backup and restore operations, respectively. With respect to FIG. 4, the backup operation would begin when the storage server 16 receives (at block 100 ) a backup request from one storage client 14 , including the serial number 60 of the source volume to backup. This backup request may be communicated using a backup command implemented in the backup program providing the storage client 14 and server 16 , such as the Tivoli® Storage Manager client and server. (Tivoli is a registered trademark of International Business Machines, Corp.) The storage server 16 would select (at block 102 ) a backup target device (WWN and LUN) from the device database 20 , where the selected backup device may comprise one or more volumes from one or more backup storage devices 10 (e.g., tape devices), to store the source volume 12 being backed-up.
[0034] To ensure that the correct Fibre Channel address is used with the copy command to perform the backup operation, the storage server 16 would query (at block 104 ) the SAN 6 using Fibre Channel discovery commands to rediscover the Fibre Channel addresses for the WWN and LUN of all Fibre Channel devices in the device database 20 and update (at block 106 ) device records 50 (FIG. 2) in the device database 20 with any changed Fibre Channel addresses determined from the discovery.
[0035] The storage server 16 then constructs (at block 108 ) an extended copy command specifying the source (the requested volume to backup) and the target device (the selected backup volume). To identify the source and target volumes in the extended copy command, the storage server 16 may include the Fibre Channel addresses of the source and target devices indicated in the device database 20 , the length of the source data to transfer and target data to write, which is the length of the image to backup, and the block addresses where the source data begins in the source device 12 and the backup begins in target device 10 . If the backup storage location is in a tape device, then the block address of where to write the backup image may comprise a record or file mark number. The extended copy command may include additional information on the source and target locations, such as the WWN and LUN number, as well as other information and parameters.
[0036] The storage server 16 transfers (at block 110 ) the extended copy command to the data mover 8 to copy the specified data at the source volume 12 to the specified target volume in the backup storage device 10 . A backup record would be added (at block 112 ) to the backup database 22 providing information on the backed-up data set, including the location of the source 70 and target 64 , length of backup 68 , and offsets into source 72 and target 66 storage devices (FIG. 3) where the backup data is stored.
[0037] [0037]FIG. 5 illustrates the operations the storage server 16 performs to accomplish a restore operation. The storage client 14 would transmit a restore request to the storage server 16 including a file name and client name of the volume to restore. In response (at block 150 ) to receiving such restore request, the storage server 16 would query (at block 152 ) the backup database 22 to locate the backup record 60 having the client name 70 of the storage client 14 that initiated the request and the specified file name 72 . To ensure that the correct Fibre Channel address is used with the copy command to perform the restore operation, the storage server 16 would query (at block 154 ) the SAN 6 using Fibre Channel discovery commands to rediscover the Fibre Channel addresses for the WWN, LUN, and/or serial number of all Fibre Channel devices in the device database 20 and update (at block 156 ) device records 50 (FIG. 2) in the device database 20 with any changed Fibre Channel addresses for those rediscovered Fibre Channel devices.
[0038] The storage server 16 then determines (at block 157 ) the Fibre Channel address 56 from the device database record 50 identifying the client name in the restore request in the device name field 58 . The storage server 16 then constructs (at block 158 ) an extended copy command specifying the source (backup storage location in backup record) and target device (the determined Fibre Channel address of device having client name of device to restore). The source and target devices specified in the extended copy command would be identified by the Fibre Channel address 54 of source and target devices indicated in the device records 50 in the device database 20 of the target specified in the restore request and the source identified in the backup storage location field 64 of the located backup record 60 . The extended copy command may further include as parameters the length of the source data to transfer and target data to write, which is the size 68 of the backup data set in the located backup record 60 (FIG. 3); block address where the source backup data to restore begins in the source device, which is the offset into the backup location 66 in the located backup record 60 ; and block address where the restore begins in the target device, which is the offset into the source data location in backup record 72 . If the backup storage location to restore is in a tape device, then the block address of where to restore the backup image may comprise a record or file mark number. The extended copy command may include additional information on the source and target locations, such as the WWN and LUN number, as well as other information and parameters. The storage server 16 then transfers (at block 160 ) the generated extended copy command to the data mover 8 to copy the specified data at the backup storage device 10 to the target volume 12 being restored.
[0039] With the described implementations, before performing an extended copy backup or restore, which offloads the data movement from the storage server to a data mover device, the Fibre Channel addresses are confirmed so that the current and correct Fibre Channel address are specified in the extended copy command. This avoids any errors or destruction of existing data that would result from using an invalid Fibre Channel address.
Additional Implementation Details
[0040] The backup and restore operations described herein may be implemented as a method, apparatus or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof. The term “article of manufacture” as used herein refers to code or logic implemented in hardware logic (e.g., an integrated circuit chip, Programmable Gate Array (PGA), Application Specific Integrated Circuit (ASIC), etc.) or a computer readable medium, such as magnetic storage medium (e.g., hard disk drives, floppy disks, tape, etc.), optical storage (CD-ROMs, optical disks, etc.), volatile and nonvolatile memory devices (e.g., EEPROMs, ROMs, PROMs, RAMs, DRAMs, SRAMs, firmware, programmable logic, etc.). Code in the computer readable medium is accessed and executed by a processor. The code in which preferred embodiments are implemented may further be accessible through a transmission media or from a file server over a network. In such cases, the article of manufacture in which the code is implemented may comprise a transmission media, such as a network transmission line, wireless transmission media, signals propagating through space, radio waves, infrared signals, etc. Thus, the “article of manufacture” may comprise the medium in which the code is embodied. Additionally, the “article of manufacture” may comprise a combination of hardware and software components in which the code is embodied, processed, and executed. Of course, those skilled in the art will recognize that many modifications may be made to this configuration without departing from the scope of the present invention, and that the article of manufacture may comprise any information bearing medium known in the art.
[0041] In the described implementations, the network across which the backup and restore occurred comprised a Fibre Channel SAN network. In alternative implementations, the network may comprise any type of network known in the art that assigns temporary network addresses to the devices coupled to the network. In such additional implementations, the storage server would have to confirm the temporary network address using fixed identification information before initiating the data movement operation to avoid invalid address errors.
[0042] In the described implementations, the SCSI-3 Extended Copy Command was used to transfer data between devices. In alternative implementations, other commands in alternative formats may be used to perform the device-to-device copy operations described herein.
[0043] In the described implementations, the address checking and extended copy command was used to perform a restore or backup operation. In additional implementations, the extended copy command of the described embodiments may be used for any other type of data transfer operation known in the art to transfer data between volumes.
[0044] In described implementations, the storage client would specify the user data volume to backup and restore, and the storage server would then determine the backup location to use for the backup or restore. In alternative implementations, the storage client may specify both the user data volume and backup location to use in the backup or restore operation. Still further, to perform a restore, the storage client may specify the backup record in the backup database, which would provide the source and target of the restore.
[0045] In the described implementations, the fixed address or identifier of the network devices comprises the WWN, LUN, and serial number. In alternative implementations, other device information may be used to provide a fixed, permanent address of the devices, such as a serial number and vendor information.
[0046] In the described implementations, when rediscovering the Fibre Channel addresses, the storage server would check all the Fibre Channel addresses in the device database. In alternative implementations, the storage server may only rediscover the Fibre Channel addresses of the volumes that are the source and target of the extended copy command.
[0047] [0047]FIGS. 4 and 5 describe specific operations occurring in a particular order. In alternative implementations, certain operations may be performed in a different order, modified or removed. Morever, steps may be added to the above described logic and still conform to the described implementations. Further, operations described herein may occur sequentially or certain operations may be processed in parallel. Yet further, operations may be performed by a single processing unit or by distributed processing units.
[0048] [0048]FIG. 6 illustrates one implementation of a computer architecture 300 of the network components shown in FIG. 1, such as the host, data mover, storage device, etc. The architecture 300 may include a processor 302 (e.g., a microprocessor), a memory 304 (e.g., a volatile memory device), and local storage 306 (e.g., a nonvolatile storage, such as magnetic disk drives, optical disk drives, a tape drive, etc.). The local storage 306 may comprise an internal storage device or an attached or network accessible storage. Programs in the local storage 306 are loaded into the memory 304 and executed by the processor 302 in a manner known in the art. The architecture further includes a network card 308 to enable communication with a network. An input device 310 is used to provide user input to the processor 302 , and may include a keyboard, mouse, pen-stylus, microphone, touch sensitive display screen, or any other activation or input mechanism known in the art. An output device 312 is capable of rendering information transmitted from the processor 302 , or other component, such as a display monitor, printer, storage, etc.
[0049] The foregoing description of the implementations has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many implementations of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | Provided are a method, system, and program for performing a data transfer operation with respect to a source and target storage devices in a network, wherein storage devices in the network are assigned temporary network addresses. Device information is maintained and includes for each identified device a fixed address that does not change and a temporary network address. A data transfer request is received to transfer data between a source and target devices. The network is queried to determine changes to the temporary network addresses of the storage devices in response to receiving the data transfer request and the device information is updated to include any changed determined temporary network addresses for the storage devices. A data transfer command is constructed to transfer data between the source and target storage devices, wherein the data transfer command includes the temporary network addresses of the source and target devices in the device information. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. application Ser. No. 11/124,026, filed on 6 May 2005, entitled “Footwear Orthosis,” presently pending.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIALS SUBMITTED ON A COMPACT DISC
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns orthopedic footwear for post-surgical or diabetic patients.
2. Description of Related Art
Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
In current technology, post-surgical or diabetic patients use orthopedic footwear with a modified bottom sole that makes the foot take a determined and forced inclination. Decompression is caused either only on the forefoot or only on the heel, avoiding contact of the injured part of the foot.
At this moment, post-surgical or diabetic patients use orthopedic footwear on the market which decompresses the forefoot or the heel of the patient with modifications on the front or back part of the bottom sole. A forced inclination is allowed to the foot in this way, obtaining the total absence of contact of the injured front or the back parts of the foot on the ground.
The bottom sole of this footwear is rigid and has a flat middle part, which has total contact with the ground. For three quarters thereof, the bottom sole is raised at the front or back part at an inclination of about 30 degrees.
The particular bottom sole of the above-mentioned orthopedic footwear presents the inconvenience of a difficult deambulation caused by the forced inclination of the patient's foot.
Furthermore, all of the orthopedic footwear for diabetics on the market at present, have a bottom sole with a completely flat part, which has total contact with the ground which provokes the drawback that the sheer force is concentrated in the corresponding plantar area.
A type of sole for orthopedic footwear, as described in U.S. Pat. No. 5,827,210 to Antar, is made up of a middle flat part bordered by a front part and a back part. The front part and back part are both convex towards the outer side in such a way to determine a rolling motion during the deambulation. This movement is caused by the total contact of the middle flat part of the bottom sole with the ground and by the action of the back part of the bottom sole which comes into contact with the ground by a heightened position to the ground underfoot like the front part.
The drawback of the Antar patent is that the middle flat part of the bottom sole having total contact with the surface underneath all the central plantar area is under a constant sheer force.
The aim of the present invention is to provide sanitary orthopedic footwear, for use by post-surgical or diabetic patients, produced using shock-absorbing and antibacterial material. There is a bottom sole, conceived on the ortho-dynamic concept and characterized by a ramp that allows cushioning of the shock during the landing phase of the foot, in such a way to determine a correct deambulation in the central phase of the march and a rotation in the take-off phase. This is made possible by the front and back parts of the bottom sole that are both convex and the part that has contact with the ground, that is only 8-12 mm long and on the Chopart line so as to have a constant instability of this bottom sole. This deliberate instability is necessary to avoid the concentration of the sheer force on the user's foot and in particular in the tarsal or metatarsal part.
Another aim of the present invention is to allow the use of sanitary orthopedic footwear in post-surgical or diabetic patient care, which can also be adapted to a highly-bandaged foot. The bottom sole of the present patent application, which is ambidextrous, includes two or more variations in four or more sides. The orthopedic footwear for post-surgical or diabetic patients can easily be used by patients who have different needs.
Another aim of the present invention is to provide sanitary orthopedic footwear for post-surgical or diabetic patients, characterized by a particular rigidity made possible by inserting a very rigid and crushproof insert in the inside of the bottom. This insert has a particular design and is made using antibacterial materials; it is washable and light.
Another aim of the present invention is to provide sanitary orthopedic footwear for post-surgical or diabetic patients characterized by a bottom sole having a groove in which bandages and/or medicines can be inserted. Two or more layers of particular plantar insole are characterized by modular and interchangeable elements, which can also be inserted. These allow localized sheer force reduction corresponding to diabetic foot ulcerations or plantar lesions.
These and other aims are achieved by the invention that is the subject of the present patent application relative to sanitary orthopedic footwear for post-surgical or diabetic patients in which the ambidextrous bottom sole is based on a ortho-dynamic concept, including a groove of at least 10 mm in depth. The off-loading plantar insole and/or medicine can be inserted in the groove. Each of the front and back parts of the bottom sole are convex. The only contact point with the surface underneath is on the Chopart line and is limited to 8-12 mm. For these reasons, during the deambulation the bottom sole is not, at any time, completely and continuously in contact with the surface underneath. This determines its constant, in this way avoiding sheer force on the patient's foot and in particular in the metatarsal, tarsal and central parts.
BRIEF SUMMARY OF THE INVENTION
The present invention has an ambidextrous bottom sole. In a higher part thereof, there is a groove of at least 10 mm of depth, in which off-loading plantar insoles or medicine or bandages can be inserted. These have been built-in using an ortho-dynamic concept which allows the patient a controlled deambulation and to that end, to avoid sheer force on the plantar part of the foot and in particular on the metatarsal and/or tarsal part.
To avoid the above-mentioned drawbacks of the prior art, the bottom sole of the orthopedic footwear, which is the subject of the present patent, has only a single point of contact, being only a few millimeters long (8-12 mm) with the surface underneath. It has a highly defined convexity at the front and the back. Furthermore the point of contact with the ground in the static phase has been deliberately placed in correspondence to the Chopart line of the foot.
The Chopart line is the defined neutral line that separates the anklebone scaphoid and the heel cuboid joints, statistical studies have shown the lowest possibility of diabetic plantar lesions on this line.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Other characteristics and advantages of the invention will result from a form of implementation of the present invention, preferred but not exclusively sanitary orthopedic footwear for post-surgical or diabetic patients in medical use. The present patent application is illustrated approximately in the drawings.
FIGS. 1 , 1 / a , and 1 / b are side elevation views of the bottom sole in the three positions from the deambulation phase of the sanitary orthopedic footwear for post-surgical or diabetic patients.
FIG. 2 is an exploded elevation view of the bottom sole of the footwear of the present patent application, showing a section of the bottom sole, the rigid insert insert and the three-plantar insole system that are removed from the bottom sole.
FIG. 3 is a top plan view of one of the three modular and interchangeable plantar insoles that make up the plantar insole system.
FIG. 4 is another side elevation view of the orthopedic footwear of the present invention.
FIG. 5 is an exploded perspective view shoeing the bottom sole, the rigid insert, and the three-plantar insole system.
DETAILED DESCRIPTION OF THE INVENTION
The rigidity of the bottom sole 1 is obtained by an element called a “rigid insert 5 ”, which is inserted into the bottom sole 1 in an opposite groove 10 , having a function of avoiding flexing and torsion in the entire plantar area of the foot, both in a static or dynamic phase. The groove having a depth (D) of at least 10 mm. This rigid insert 5 is extremely resistant to repeated flexes, moulded with a very rigid, light, uncrushable, antibacterial and washable material. The molds are the exclusive property of the company that is presenting this patent application. This rigid insert 5 is characterized by a particular rigidity, lightness and uncrushability, and it has a completely flat structure 5 a on the upper part which is in contact with the foot and lower structure 5 b that follows the lines of the bottom sole 1 to which it is attached. This is to ensure that the foot rests on a completely flat surface without modifying the deambulation created by the deambulation ramp of the bottom of the present patent application.
Orthopedic footwear for diabetic patients must allow the total decompression of the patient's foot where the diabetic plantar ulceration is present. To achieve this result, the diabetic footwear that has a bottom sole 1 that has the shape and characteristics as described above, offering the possibility to insert a series of three multi-level, washable off-loading plantar insole 7 a , 7 b , 7 c with different mechanical and shock-absorbent characteristics for each layer in the groove 10 of the sole bottom. Each of these plantar insoles is characterized by three modular and exchangeable systems 8 a , 8 b , 8 c , being used to change hardness and softness in such a way to guarantee the total off-load of the injured part of the foot according to the patient's needs.
All of the orthopedic footwear has uses for either diabetic patients or sanitary use, being available on the market at present and being removable by the patients themselves.
As many scientific studies have demonstrated that irremovable off-loading devices for diabetic foot lesions shorten considerably the healing time of lesions, by reducing patient's non-compliance during the treatment, the present invention includes a non-removable system which consists of the application of inserts for the passage of disposable self-blocking strips that, once sealed, do not allow patient to reopen the footwear and remove it.
Non-removable system consists of two inserts of flexible semi-rigid material with a eyelet in the middle, anchored at the external upper sides of the upper. These inserts allow the insertion of a plastic strip with disposable pressure fastening system (of the kind commonly available on market) which is provided with the device.
This kind of strip in soft and flexible material passes through the holes of the two lateral inserts and, once closed on its opposite extremity, the device will be blocked at the minimum height of the ankle or at the maximum height of the shin-calf and it cannot longer be reopened or removed if not by cutting it by means of proper cutting tool.
Non-removable systems allow a physician to fix the sanitary orthopedic footwear for diabetic patients or sanitary use to the patient's foot. The non-compliant patient could remove the orthopedic footwear from his/her foot independently. The bottom sole 1 comprises a lower surface having a back portion 2 , a front portion 3 and a central portion 4 disposed in correspondence with the Chopart line between the back portion 2 and the front portion 3 .
In FIGS. 1 , 1 adjacent and 1 body 74 , the bottom sole 1 is shown with a deambulation ramp an inclination of with an underlying surface with an angle β 1 of when the foot lands on the back part ( 2 ) (FIG. 1 adjacent) and an angle of β 2 of 110° in the taking off phase the front part ( 3 ) (FIG. 1 body 74 ). In the static phase, the the central portion 4 is in contact with ground and the deambulation ramp 6 has an inclination of an angle β 0 of 90° with respect to the underlying surface ( FIG. 1 ). The bottom sole ( 1 ) is characterized by the fact that in the deambulation phase inclination of the deambulation ramp with respect to the underlying surface goes from 70° of the back part ( 2 ) to an inclination of 90° in the central part ( 4 ) which increases up to 110° at the front part ( 3 ).
Furthermore, the front portion 3 and the back portion 2 are both convex and have the same convexity. The convexity of the back portion of the bottom sole is such that the back portion can roll on the underlying surface until the planar upper surface 5 a of the rigid surface is inclined at an angle α 1 of 20° with respect to the underlying surface. The convexity of the front portion 3 of the bottom sole is such that the front portion 3 can roll on the underlying surface until the planar upper surface 5 a of the rigid inert is inclined at an angle α 1 of 20° with respect to the underlying surface. The central portion 4 is on the Chopart line 6 and has a length L of 8 to 12 millimeters. These characteristics ensure that the bottom sole is never completely and continuously in contact with the underlying surface so as to cause a constant imbalance of the contact point the bottom sole ensure that the concentration of shear force is not present on the patient's foot, especially on the tarsal, metatarsal and central parts of the foot.
To achieve this result, it is also necessary that the bottom sole ( 1 ) is rigid to avoid its flexions and torsions. The rigid insert ( 5 ) is inserted into the bottom sole groove 10 . The rigid insert ( 5 ) also shown in FIG. 2 , is made with antibacterial, washable material and is characterized by a high resistance to repeated flexions, lightness and its uncrushability. This rigid insert ( 5 ) is characterized by a structure that permits the flat higher surface 5 adjacent that has contact with the foot and the lower surface 5 body 74 that follows the shape of the bottom sole to which it is attached. In such a way, it does not alter the deambulation created by the ramp of the bottom sole.
Another component of the bottom sole of the above mentioned type of orthopedic footwear is the series of two or more multilayer plantar insoles ( 7 / a ), ( 7 / b ), ( 7 / c ) in FIG. 2 , with mechanical and shock-absorbent characteristics with different characteristics and that are produced using washable and disinfectable materials.
FIG. 3 is a view one of the two or more plantar insoles described in the previous paragraph seen from above, each of which is made up of two or three modular elements and which are interchangeable between the three pieces. The forefoot ( 8 / a ) is represented as a part thereof. The central plantar insole ( 8 / b ) is another part, and back part ( 8 / c ) is represented by the back part of the plantar insole.
This series of two or more modular plantar insoles ( 7 / a ), ( 7 / b ) and ( 7 / c ), each of which is made up of one element with three modular and interchangeable elements ( 8 / a ), ( 8 / b ) and ( 8 / c ) makes it possible to alter the hardness and elasticity according the patients' needs and to guarantee the total off-load of the diabetic foot ulceration or plantar lesions.
The bottom sole that is the subject of this patent application is furthermore characterized by a ambidextrous shape that allows us to create post-surgical footwear that can be used either by diabetic patients or for sanitary use in two or more variations and in four or more lengths and so it can be easily used according to the various needs of the patients
FIG. 4 shows the elevation view of the footwear again, at the front and back parts of the bottom sole, being convex and with the central portion limited to 8-12 mm.
The invention thus conceived can be subjected to many modifications and variants, all of these enter the sphere of the invented concept, furthermore the materials and sizes of the above mentioned invention, illustrated in the accompanying designs and later laid claim to, can be made according to the needs. | The present invention is an apparatus and method of orthopedic footwear for post-surgical or diabetic patients or for sanitary use. The footwear has an ambidextrous bottom sole. In a higher part thereof, there is a groove of at least 10 mm, in which an off-loading plantar insoles or medicine or bandages can be inserted. These have been built-in the bottom sole using an ortho-dynamic concept which allows the patient a controlled deambulation. To that end, the present invention prevents sheer force on the plantar part of the bottom sole and the foot and in particular on the metatarsal and/or tarsal part of the foot. | 0 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to an 8-stroke cycle rotary engine. More particularly, the present invention relates to an 8-stroke rotary engine that utilizes a pair of master combustion chamber and slave combustion chamber to increase fuel efficiency.
[0003] 2. Description of the Related Art
[0004] U.S. Pat. No. 4,159,700 mentioned a “Internal combustion compound engines” wherein a multi-cycle piston engine is provided.
[0005] U.S. Pat. No. 5,056,471 mentioned a “Internal combustion engine with two-stage exhaust” wherein a multi-cycle piston engine with additional piston for harvesting power from exhaust gas is provided.
[0006] U.S. Pat. No. 2,988,065 mentioned a “Rotary internal combustion engine” wherein a four-cycle rotary engine is provided.
[0007] U.S. patent application Ser. No. 10/619,147 mentioned a “Eight-stroke internal combustion engine utilizing a slave cylinder” wherein a eight-stroke piston engine is provided.
SUMMARY OF THE INVENTION
[0008] It is well known that four-cycle and other multi-cycle rotary engines produce exhaust gases that contain un-used energy in the form of un-burnt gasses. Many different approaches have been used to both try to capture the un-used energy within these unburned gases and to try to reduce atmospheric emissions caused by inefficient combustion.
[0009] The rotary engines also suffers poor efficiency due to its short power stroke and large heat loss surface area.
[0010] It is a primary objective of the present invention to provide 8-stroke rotary engine which is fuel-efficient, reliable, and environmental-friendly.
[0011] It is also an objective of the present invention to provide an 8-stroke rotary with cooler working temperature to decrease heat loss.
[0012] It is also an objective of the present invention to provide an 8-stroke rotary with multiple power stroke.
BREIF DESCRIPTION OF THE DRAWINGS
[0013] FIGS. 1 to 10 are simplified drawings which show a plurality of successive rotational positions of both master combustion chamber and slave combustion chamber in cross-section perpendicular to the axis of rotation;
[0014] FIG. 11 and FIG. 12 are simplified structural illustration of the epitrochoids of master combustion chamber and slave combustion chamber and their location relative to each other.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0015] Referring now to FIG. 11 and FIG. 12 , the present invention comprises, a master engine housing 11 , a slave engine housing 21 , a master rotor 13 with three apex portions 14 , a slave rotor 23 with three apex portions 24 , an intermediate wall 30 , a primary coordinating channel 31 , a secondary coordinating channel 32 , a master-to-slave exhaust channel 33 , a master intake port 15 , a slave intake port 25 , a slave exhaust port 26 , an eccentric cam 34 connected with an output shaft (not shown), and ignition means 36 .
[0016] The 8-stroke cycle rotary engine is generally similar to the type of rotary engine disclosed in the aforementioned patent, therefore it will not be described in detail here beyond what is necessary to disclose the features of the invention. Details such as sealing means, lubrication means, ventilating means, transmission, ring gears and center gears are omitted in the drawings for clarification purpose.
[0017] A master engine housing 11 having a master combustion chamber 12 of a multi-lobe profile which is basically an epitrochoid and in which the lobes are joined by regions disposed relatively near to the engine axis;
[0018] A slave engine housing 21 having a slave combustion chamber 22 of a multi-lobe profile which is basically an epitrochoid and in which the lobes are joined by regions disposed relatively near to the engine axis;
[0019] The master rotor 13 has a generally triangular profile with three apex portions 14 having sealing cooperation with the inner surface of the master engine housing 11 to form three master working chambers between the master rotor 13 and the master engine housing 11 . These three master working chambers are distinguished form each other by the reference letters 12 a, 12 b, and 12 c.
[0020] The slave rotor 23 has a generally triangular profile with three apex portions 24 having sealing cooperation with the inner surface of the slave engine housing 21 to form three slave working chambers between the slave rotor 23 and the slave engine housing 21 . These three slave working chambers are distinguished form each other by the reference letters 22 a, 22 b, and 22 c.
[0021] The working cycle of 8-stroke cycle rotary engine is a 8-stroke cycle operated with both the master rotor 13 and the slave rotor 23 . Referring now to the drawings, and particularly to FIGS. 1-10 , wherein the master combustion chamber 12 and the slave combustion chamber 22 are shown in successive rotational positions, diagrammatically illustrating each phase position of the master rotor 13 and the slave rotor 23 .
[0022] During the operation of 8-stroke cycle rotary engine, the master working chamber 12 a co-acts with the slave working chamber 22 a, the master working chamber 12 b co-acts with the slave working chamber 22 b, the master working chamber 12 c co-acts with the slave working chamber 22 c. Each master working chamber requires a correspondent slave working chamber to complete its 8-stroke cycle.
[0023] In order to clearly explain in a comprehensive manner, the following description of the 8-stroke cycle operation of 8-stroke cycle rotary engine exclusively refers to the master working chamber 12 a and the slave working chamber 22 a. It should be readily understood that the other two pairs of master working chambers and slave working chambers are operating with identical procedures.
[0024] FIG. 1 shows the phase position of the master working chamber 12 a at the beginning of the first stroke. During the first stroke, the master working chamber 12 a is located adjacent to the master intake port 15 . As the first stroke commences, the master working chamber 12 a is open to the master intake port 15 and is fed in with air-fuel mixture until the volume of the master working chamber 12 a reaches its maximum intake volume, at which point the slave working chamber 12 a is closed to the slave intake port 25 . At the beginning of the first stroke, the slave working chamber 22 a is at half-stroke phase position of the preceding 8-stroke cycle.
[0025] FIG. 2 shows the phase position of the slave working chamber 22 a at the beginning of its second stroke. During the second stroke, the slave working chamber 22 a is located adjacent to the slave intake port 25 . As the second stroke commences, the slave working chamber 22 a is open to the slave intake port 25 and is fed in with air until the volume of the slave working chamber 22 a reaches its maximum intake volume, at which point the slave working chamber 22 a is closed to the slave intake port 25 . At the beginning of the second stroke, the master working chamber 12 a is at half-stroke phase position of the first stroke.
[0026] FIG. 3 shows the phase position of the master working chamber 12 a at the beginning of the third stroke. As the third stroke commences, the air-fuel mixture inside the master working chamber 12 a is compressed, the volume of the master working chamber 12 a starts decreasing from a maximum volume condition to a minimum volume condition. At the beginning of the third stroke, the slave working chamber 22 a is at half-stroke phase position of the second stroke.
[0027] FIG. 4 shows the phase position of the slave working chamber 22 a at the beginning of the fourth stroke. As the fourth stroke commences, the air inside the slave working chamber 22 a is compressed, the volume of the slave working chamber 22 a starts decreasing from a maximum volume condition to a minimum volume condition. At the beginning of the fourth stroke, the master working chamber 12 a is at half-stroke phase position of the third stroke.
[0028] FIG. 5 shows the phase position of the master working chamber 12 a at the beginning of the fifth stroke, at which point the master working chamber 12 a is located adjacent to ignition means 36 on the inner surface of the master housing 31 . When the volume of the master working chamber 12 a is compressed to a minimum condition, the compressed air-fuel mixture inside the master working chamber 12 a is ignited with ignition means. The master working chamber 12 a then goes through the fifth or the first expansion stroke as its volume starts increasing. At the beginning of the fifth stroke, the slave working chamber 22 a is at half-stroke phase position of the fourth stroke. After the air-fuel mixture inside the master working chamber 11 is ignited, at approximately one-third stroke phase position of the fifth stroke, the master rotor 13 and the slave rotor 23 are so positioned that the primary coordinating channel 31 is open between the master working chamber 12 a and the slave working chamber 22 a, thus, the slave working chamber 22 a starts pushing the air insid the slave working chamber 22 a into the master working chamber 12 a to provide more air for expanding and generating the first power stroke to the output shaft 35 .
[0029] FIG. 6 shows the phase position of the slave working chamber 22 a at the beginning of the sixth stroke, at which point the master working chamber 12 a is at half-stroke phase position of the fifth stroke, the working medium inside the master working chamber 12 a is still expanding, while most of the air inside the slave working chamber 22 a is pushed into the master working chamber 12 a , and the primary coordinating channel 31 is closed. As the sixth stroke commences, the secondary coordinating channel 32 is open between the master working chamber 12 a and the slave working chamber 22 a, the working medium then starts to transfer into the slave working chamber 22 a and to expand thereto. During the sixth stroke, both the master working chamber 12 a and the slave working chamber 22 a are expanding and generating the second power stroke to the output shaft 35 .
[0030] FIG. 7 shows the phase position of the master working chamber 12 a at the beginning of the seventh stroke, the master working chamber 12 a has expanded to its maximum volume. As the seventh stroke commences, the volume of the master working chamber 12 a starts decreasing, and the working medium inside the master working chamber 12 a is being pushed into the slave working chamber 22 a. At approximately one-third stroke phase position of the seventh stroke, the master-to-slave exhaust channel 33 starts to open between the master working chamber 12 a and the slave working chamber 22 a , which allows the working medium to exhaust into the slave working chamber 22 a at more efficient rate. At the beginning of the seventh stroke, the slave working chamber is at the half-stroke phase position of the sixth stroke, as more working medium is pushed into the slave working chamber 22 a, the slave working chamber 22 a continues to expand.
[0031] FIG. 8 shows the phase position of the slave working chamber 22 a at the beginning of the eighth stroke, the slave working chamber 22 a has expanded to its maximum volume, the secondary coordinating channel 32 is starting to close. During the eighth stroke, all the working medium inside the master working chamber 12 a is pushed into the slave working chamber 22 a, and the working medium inside the slave working chamber 22 a is exhausting through the slave exhaust port 26 . At approximately one-third phase position of the eighth stroke, the secondary coordinating channel 32 is completely close between the master working chamber 12 a and the slave working chamber 22 a , then the rest of the working medium inside the master working chamber 12 a is pushed into the slave working chamber 22 a through the master-to-slave exhaust channel 33 . As shown in FIG. 9 , at the half-stroke phase position of the eighth stroke, all the working medium inside the master working chamber 12 a is transferred to the slave working chamber 22 a, and the master working chamber 12 a is at the beginning of the first stroke of the next 8-stroke cycle. At the same time, the master-to-slave exhaust channel 33 is closing up, and the working medium inside the slave working chamber 22 a continues to exhaust through the slave exhaust port 26 . As shown in FIG. 10 , all the working medium inside the slave working chamber 22 a has exhausted through the slave exhaust port 26 , thus it completes the 8-stroke cycle. At the same time, the slave working chamber 22 a is at the beginning of the second stroke of the next 8-stroke cycle, and the following procedures are identical to the 8-stroke cycle described above.
[0032] According to the amount of air required for the first stroke and the second stroke, a charged intake may be essential for 8-stroke cycle rotary engine.
[0033] It should be understood that the invention is not limited to the embodiment described above. Modifications and variations of the embodiment described above will occur to those skilled in the art without leaving the spirit and scoop of the present invention. The scope of the invention is defined with reference to the following claims. | An 8-stroke cycle rotary engine utilizes a pair of master combustion chamber and slave combustion chamber to increase the fuel-efficiency. 8-stroke cycle includes mater intake stroke, slave intake stroke, master compression stroke, slave compression stroke, master expansion stroke, slave expansion stroke, master-to-slave exhaust stroke, and slave exhaust stroke. | 5 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to toys and more particularly to a toy food processor which may be manually operated to simulate the operation of a conventional food processor in slicing elongated vegetable products, such as carrots and cucumbers, into sliced segments.
It is an object of the invention to provide a toy food processor of the character described which may be easily and safely operated by children.
It is a further object of the invention to provide a toy food processor of the character indicated which is of rugged low cost construction.
It is still another object of the invention to provide for use in a toy food processor of the character described, a single and easily manipulatable food slice module containing a plurality of simulated slices of food product, the slices of which may be readily released and expelled from the toy food processor.
The invention, both as to its organization and method of operation, together with further objects and advantages thereof, will best be understood by reference to the following specification, taken in connection with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present improved toy food processor with the module of simulated slices of food product disposed alongside the processor;
FIG. 2 is a top plan view of the toy food processor shown in FIG. 1;
FIG. 3 is a sectional view taken along lines 3--3 in FIG. 2; and
FIG. 4 is a sectional view taken along lines 4--4 in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and more particularly to FIG. 1 thereof, the present improved toy food processor is there shown as comprising a processor 10 and a separable sliced food module 11 which is adapted to be mounted within the processor 10 in the manner more fully explained below. The processor 10 comprises a two-part housing 12 consisting of a lower base housing 13 of substantially square configuration upon which is fixedly mounted a substantially cylindrical closed top upper housing 14. A discharge chute 15, parts of which are formed integrally with the housings 13 and 14, projects outwardly from the side of upper housing 14 and terminates in a discharge opening 15a which overlies the downwardly slanting front wall 13a of the base housing 13. This discharge opening is normally closed by a small door 16 which is pivotally supported along its upper edge between the sides of the chute 15 by means of a pivot pin 17 and is gravity based to its illustrated closed position.
Along the cylindrical side wall of the housing 14, this wall is provided with a parallel side vertically extending opening 18 therethrough which communicates at its upper end with a slot 19 extending inwardly from the outer edge of the top closure wall of the housing in the manner best shown in FIG. 2 of the drawings. The slot 19 is partially surrounded by an open topped cylindrical member 20 which simulates the food product input hopper of a conventional food processor and is fixedly mounted upon the top wall of the housing 14. As shown, the cylindrical member 20 is provided with a slot 20a throughout its height which overlies and is coincident with the slot 19.
For the purpose of closing the opening 18 when the processor 10 is in use, a door 21 is provided which is pivotally mounted on the housing 14 along the edge of the opening 18 by means of a pivot pin 22 and has a finger hole opening 21a therethrough to facilitate manual opening and closing of the door. This door functions as a carrier for the food slice module 11. To this end, it is provided at its upper end with a V-shaped laterally extending flange 21b which is adapted to underlie the top wall of the housing 14 when the door is closed and is provided with an inwardly extending V-shaped slot 21c which is adapted to receive the head end of the holding rod embodied in the module 11 in the manner more fully explained below.
As best shown in FIGS. 1 and 3 of the drawing, the food slice module 11 comprises a plurality of separable simulated food slices 11a formed of metal or a plastic material which are arranged in stacked relationship and are provided with aligned centrally disposed openings 11b extending therethrough. For the purpose of holding these slices in stacked relationship, a holding rod 23 is provided which extends through the openings 11b and the lower end of which is releasably connected to the bottom end slice 11c as best shown in FIG. 3 of the drawings. More specifically, the end slide 11c is provided with a centrally disposed bore 11d which is adapted to form a press fit relationship with the lower end of the rod 23 and thus hold the other slices 11a on the rod 23. When the module 11 is disengaged from the dispensing unit, as shown in FIG. 3 of the drawings, the holding rod 23 is equipped with a finger manipulatable knob 23a at the upper end thereof the lower end of which terminates in a laterally extending flange 23b which is displaced from the top surface of the uppermost slice 11a. A cam 24 is securely mounted on the underside of the top wall of the housing 14 to engage the upper edge of the uppermost slice 11a as the door 21 is closed and thus break the releasable connection between the lower end slice 11c and the lower end of the holding rod 23 in the manner more fully explained below.
In order to dispense the simulated food slices 11a from the processor 10, dispensing means are provided which comprises a pair of rotatable dispensing arms 25a and 25b fixedly mounted upon the upper end of a rotatable shaft 26. This shaft extends through a bearing opening in the top wall of the base housing 13 and is journalled for rotation in an upwardly directed bearing hole formed in the top of a bearing pedestal 27, the pedestal 27 being fixedly mounted on the bottom wall of the housing 13. During rotation, the dispensing arms 25a and 25b pass freely beneath a slice directing vane 28 which slants inward from the side wall of the housing 14 to the center of this housing in the manner best shown in FIG. 2 of the drawings. At its outer end adjacent the left side of the chute 15 as viewed in FIG. 2, this vane is rigidly connected to the side wall of the housing 14 and at its inner end it carries a bearing part 29 in which the top end of the shaft 26 is journalled.
For the purpose of imparting rotary movement to the shaft 26 and thus to the dispensing arms 25a and 25b, manually operable drive means are provided which comprises a bevel gear 29 fixedly mounted on the shaft 26, a meshing gear 30, a shaft 31 upon which the gear 30 is fixedly mounted and a manually operable crank 32 fixedly mounted on the outer end of the shaft 31. At its inner end, the shaft 31 is journalled in the bearing pedestal 27 and at its outer end this shaft is supported for rotation in a bearing opening through the side wall of the base housing 13. As will be noted, all moving parts of the processor are disposed within the two housings 13 and 14 thereby to obviate the possibility of small finger entanglement with these parts.
In order to enhance the attractiveness of the described toy processor to children, a noise maker is provided within the base housing 13. This noise maker comprises a leaf spring 33, the fixed end of which is pin mounted on the pedestal 27 and the free end of which is shaped to engage the teeth of the bevel gear 30. More specifically, the free end of the spring 33 is so shaped and positioned as to slide over the teeth of the bevel gear 30 and thus produce a clicking noise during rotation of this gear in one direction and to engage one of the teeth of the gear 30 to prevent rotation of the gear and the connected movable parts in the reverse direction.
The mode of operating the above-described toy food processor should be apparent from the foregoing description. Briefly summarized, however, use of the toy processor is initiated by assembling the simulated food slices 11a on the holding rod 23 and tapping the end slice 11c onto the end of this rod to complete the module assembly. The module 11 is then hung on the door 21 by inserting the upper end of the rod into the slot 21c allowing the knob flange 23b to come to rest on the top surface of the door flange 21b. With the module in place, the door 21 may be closed. As this door is moved from its open position illustrated in FIG. 2 to its closed position illustrated in FIG. 1, the upper edge of the uppermost simulated food slice 11a comes into engagement with the cam 24 and is forced downwardly to effect disengagement of the bottom slice 11c from the lower end of the rod 23. This slice 11c is thus forced from the holding rod 23 and is held in the path of rotation of the dispensing arms 25a and 25b by the top wall of the housing 13. The toy processor is now ready to dispense the simulated food slices from the interior of the housing 14.
To this end, the crank 32 is manually operated to rotate the shaft 3 and thus rotate the dispensing arms about the axis of rotation of the shaft 26 in an obvious manner. As the dispensing arms are thus rotated in a clockwise direction as viewed in FIG. 2, the arm 25b, for example, engages the side of the end slice 11c and sweeps it around the inner surface of the housing 14 over the top wall of the housing 13 until it engages the vane 28. Further rotation of the dispensing arm 25b forces the food slice 11c down the slope of the vane 28, down the discharge chute 15 and out the mouth of the chute beneath the door 16. As the slice 11c is moved from beneath the next uppermost slice by the dispensing arm 25b, the next uppermost slice drops down to rest on the top wall of the housing 14 and the remaining slices of the stack drop down a corresponding amount. In this position, the next uppermost slice is picked up by the dispensing arm 25a and discharged from the housing 14 in the exact manner just explained by reference to dispensing of the slice 11c. Thus, as rotation of the arms 25a and 25b continues, the slices 11a are successively discharged from the housing 14 at the rate of two slices for each complete revolution of the shaft 26. In this connection, it is pointed out that clearance between the lower end of the holding rod 23 and the top wall of the housing 13 is such that only one slice 11a can drop free from the lower end of the rod 23 when the underlying slice is removed by one of the dispensing arms 25a and 25b. It is also pointed out that during rotation of the shaft 31 to effect the above-described slice dispensing operation, the end of the leaf spring 33 cooperates with the teeth of the bevel gear 30 to produce a clicking noise which is pleasing to children. It is also emphasized that reverse rotation of the dispensing arms 25a and 25b in a counterclockwise direction as viewed in FIG. 2 is prevented through engagement of the end of the spring 33 with one of the teeth of the bevel gear 30.
After all of slices 11a have been dispensed from the toy processor in the manner just explained, the door 21 can be opened using the finger hole 21a for that purpose, following which the holding rod 23 can be removed from the slot 21c and the slices 11a reassembled thereon, all in a manner which will be fully apparent from the foregoing explanation.
While the best mode of practicing the invention has been illustrated and described, it will be understood that various modifications may be made in the illustrated embodiment of the invention which are within the true spirit and scope of the invention as defined in the appended claims. | A toy food processor includes a housing and a bowl in the shape and appearance of a food processor. Various food items are provided which may be removably mounted in an accessible compartment of the bowl. Mounting of a particular food item within the compartment positions the item for slicing by the food processor. A manual crank rotates a cutter blade which successively slices segments from the bottom of the food item and discharges the slices through a chute on the front of the bowl. | 0 |
FIELD OF INVENTION
[0001] The present invention relates generally to a Top Drive Pipe Spinner (TDPS). The TDPS is a tool that allows for the setting of casing without a specialized crew or any additional power source. By employing the weight of the existing top drive to set slips on the casing collar, the TDPS allows one casing to be threaded onto the next in a timely and efficient manner. The casing tongs of the TDPS use passive release weight to release the casing collar from the casing to allow for the successive insertion of another casing section. The top drive spins the TDPS and compresses the unit onto the casing, then lifts the unit and releases the casing when desired.
BACKGROUND
[0002] The use of a top drive technology has led to substantial improvements in efficiency and safety in drilling over the past 15 to 20 years. By contrast, methods for running casing, even with top-drive technology, have remained relatively unchanged. Traditional methods of running casing require the use of a special teams employed solely for the purposes of running casing, at significant cost to the driller. Additionally, these teams must be brought in, thus slowing the drilling process.
[0003] Power tongs are an established method to run casing in coordination with the drilling rig hoisting system. The power tong method allows the pipe segments to be mated with threaded ends between sequential segments as they are added to the string being installed in the well bore (or removed and disassembled). The power tong method, however, does not support other beneficial functions such as allowing the casing to be filled while moving the pipe. Previous methods and equipment do not include a tool that can run casing while serving other beneficial and time saving functions. For example, filling the pipe with fluid and the tool doubling use as a circulating tool to replace the fill tube when desired.
[0004] With top-drive technology coming into the drilling arena, drilling rigs equipped with top drives have enabled new methods of running casing and other tubulars. The top drive can be equipped with known running tools to grip and seal between the proximal pipe segment and the top drive quill (wherein quill is meant to include drive string components that may be attached, the distal end effectively acting as an extension of the quill).
[0005] Various devices have been developed to accomplish top-drive running casing. These devices are used in coordination with the top drive and allow rotating, pushing, and filling of the casing string with drilling fluid while running, thus removing the limitations of the power tong method. Simultaneously, automation of the gripping mechanism combined with the inherent advantages of the top drive reduces the necessity of a specialized team of skilled personnel who are being compensated for hard labor in sometimes hazardous conditions. These devices, with their independent operation without associated personnel, allow for increased safety and efficiency.
[0006] To handle and run casing with these top drive tubular running tools, the string weight is transferred from the top drive to a support device when the proximal or active pipe segments are being added or removed from the otherwise assembled string. This function is typically provided by an “annular wedge grip” axial load activated gripping device that uses “slips” or jaws placed in a hollow “slip bowl” through which the casing is run, where the slip bowl has a frusto-conical bore with downward decreasing diameter and is supported in or on the rig floor. The slips then acting as annular wedges between the pipe segment and the proximal end of the string and fusto-conical interior surface of the slip bowl, tractionally grip the pipe but slide or slip downward and thus radially inward on the interior surface of the slip bowl as string weight is transferred to the grip. The radial force between the slips and pipe body is thus axial load and self-activated or “self-energized”, i.e., considering the tractional capacity the dependent and string weight the independent variable, a positive feedback loop exists where the independent variable of string weight is positively fed back to control the radial grip force with conotonically acts to control tractional capacity or resistance to sliding, the dependent variable.
[0007] Similarly, the torque applied to the active pipe segment must also be reacted out of the proximal end of the assembled string. This function is typically provided by tongs which have grips that engage the proximal pipe segment and an arm attached by a link such as a chain or cable to the rig structure to prevent rotation and thereby react torque not otherwise reacted by the slips in the slip bowl. The grip force of such tongs is similarly typically self-activated or “self-energized” by positive feedback from the applied torque load.
[0008] Multiple documents describe tools that can be used to run casing with the use of a top drive. For instance, U.S. Pat. No. 8,042,626 describes such a tool for use with a top drive that allows for rapid engagement, release, hoisting, pushing and rotating. The casing is engaged within the tool through rotation that is assisted by hydraulics.
[0009] However, no tool has been shown to work with the top drive, which is simple, requires no outside energy source, and maintains the integrity of the casing. Thus, there is a need for a casing tool that employs the top drive and is easily used, removing the need for personnel to run casing. A self-activated tool would be particularly advantageous; requiring no outside energy source for its proper function.
SUMMARY OF THE PRESENT INVENTION
[0010] The present invention is a top drive pipe spinner (TDPS) that substantially obviates the needs or problems due to the limitations and disadvantages of the related art.
[0011] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structural properties particularly pointed out in the written description and claims, as well as the appended drawings.
[0012] To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the TDPS includes a top drive connection, bolts, turning sub with inverted taper, inverted slips, release weight, and a fill tube with fluid release valve.
[0013] The present invention grips casing from its exterior, thus preventing detrimental damage to the casing. Tools that grip from the interior can make marks on the casing and where the operator needs to swab the fluid out of the casing, the imperfections of markings on the interior of the casing can deteriorate the rubber swab cup.
[0014] Moreover, the present invention requires no outside energy for proper functioning by using the existing top drive and turning sub. The present invention requires little maintenance and can be used efficiently for long periods of time.
[0015] The TDPS of the present invention is a durable and resilient tool. The tool may be used for many years without substantial maintenance or repair. The TDPS of the present invention may be used for up to 9 years without repair. Thus, the TDPS of the present invention offers many advantages over the prior art.
[0016] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
[0017] The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a cross section of one embodiment of the TDPS, with the slips disengaged of the present invention.
[0019] FIG. 2 is a cross section of one embodiment of the TDPS, with the slips engaged of the present invention.
[0020] FIG. 3 is a top view of an embodiment of the TDPS of the present invention.
[0021] FIG. 4 is a bottom view of the TDPS of the present invention, as in one embodiment.
[0022] FIG. 5 is a view of the inverted slip of the TDPS, as in an embodiment of the present invention.
[0023] FIG. 6 is a cross section view of the fill tube and fluid release valve of the TDPS, as in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference characters will be used throughout the drawings to refer to the same or like parts.
[0025] FIG. 1 shows a cross section view of the TDPS of the present invention with the top drive connection 100 at the top of the TDPS. This connection 100 mates with an existing top drive to secure the TDPS in place. In one preferred embodiment of the present invention, the top drive connection 100 is threaded into the top head drive. Other methods of securing the top drive connection 100 to the top head drive are contemplated. In the preferred embodiment, the top drive connection 100 is about 8 inches long and 6 inches in diameter. The top drive connection 100 extends just through the top plate 102 and can be connected to the top plate 102 by welding. In the preferred embodiment the top drive connection 100 and top drive plate 102 can be made as one piece in manufacturing, lending to the durability and integrity of the TDPS of the present invention. As is known to those skilled in the art, other methods of securing the top drive connection 100 to the top plate 102 could be used, such as welding, and the like.
[0026] The top plate 102 connects the top drive connection 100 to the turning sub 103 and fill tube with fluid release valve 107 . The top plate 102 is secured to the turning sub 103 by a plurality of bolts 101 on the upper surface of the top plate 102 (as is illustrated more particularly in FIG. 3 ). In one preferred embodiment, the top plate is approximately 1 inch in thickness. Other methods of securing the top plate 102 to the turning sub 103 are contemplated such as screws or other fasteners such as clamps that provide secure and removable fastening. and other known fastening means. Where the drive connection 100 and top plate 102 are one piece as described above, the top plate is removable from the turning sub 103 , thus allowing access to the slips 106 and release weight 104 .
[0027] In the preferred embodiment, the turning sub is 12 inches OD, and 8 inches ID. Moreover, the turning sub is approximately 2 feet long. The bottom half of interior of the turning sub is an inverted bevel. In one preferred embodiment, the inverted bevel is approximately 8 inches long. The bevel is approximately 11¾ inches inside diameter at its bottom most point, and 8 inches inside diameter with the wall thickness being approximately 2 inches thick at the topmost point (at the midsection of the turning sub), and approximately ⅛ inch thick at the bottom most point (at the end of the turning sub). Thus, the angle of the inverted bevel is approximately 15°. In the preferred embodiment, the turning sub extends approximately 3 inches below the bevel. In other embodiments, the angle of the bevel may be lower or higher, such as 10°, 20°, or 25°. As is known by those in the art, changing the bevel to a steeper degree (i.e., 25°) may be accomplished by shortening of the length of the bevel. In such an instance the O.D. at the top and the bottom of the bevel would be the measurements above, and the slips would have a shorter distance to travel. The preferred embodiment described above, at a 15° degree angle, will accommodate casing collars from 4½ inches to 6 inches. However, other embodiments that accommodate 6½ to 8⅝ inches, or 10 inches to 13 inches are contemplated by the present invention. Those embodiments require the scaling up of the dimensions herein provided.
[0028] As shown in FIGS. 1 and 2 the top plate 102 connects to the turning sub/spinner body 103 . In one preferred embodiment, the spinner body 103 is approximately 8 inches ID 12 inches OD and 24 inches in length.
[0029] As shown further in FIG. 1 , a release weight 104 assists the tool in properly aligning and securing the casing to the TDPS of the present invention. The release weight 104 sits on top of the slip segments to assist in releasing slip segments from casing after completion of attaching one segment of casing to another. The release weight 104 also assists in allowing the slip segments 106 to move synchronously to one another. Moreover, the release weight 104 is capable of movement upward and downward to efficiently allow casing to be secured within the TDPS. As seen in FIG. 1 , the release weight 104 is in a downward position when the slips are disengaged, there being space between the top plate 102 and the release weight 104 . When the release weight 104 is in the downward position, approximately 6 inches of space exist between the top of the release weight 104 and the top plate 102 .
[0030] The fill tube and fluid release valve 107 shown in FIGS. 1 and 2 and detailed in FIG. 6 , allows the filling of casing/pipe while running each joint eliminating the need to stop and fill casing after a certain amount of pipe is ran. Having to stop and fill pipe periodically takes several hours when pipe is ran thousands of feet deep. Filling pipe with fill tube as each joint of pipe is ran saves valuable time and money since laid pipe will be full of fluid when the bottom is reached allowing operations to proceed. Filling as the pipe is run also eliminates air within the pipe, which is disadvantageous and inefficient. Details of the fill tube fluid release valve 107 are described below.
[0031] As shown in FIG. 1 the bottom of the release weight 104 secures the plurality of inverted slips 106 in the TDPS of the present invention. The release weight 104 is in the top twelve inches of pipe below the top drive connection 100 . The release weight 104 sits on the slip segments 106 , thus securing the slips 106 and preventing from hanging and moving in position. The details of the inverted slips 106 are further illustrated in FIG. 5 and described below. When the slips are disengaged position as illustrated in FIG. 1 , the release weight 104 is in the downward position and the slip segments 106 are not in contact with the casing collar 108 . The casing collar 108 has not yet been secured by the slip segments, and the fill tube and pressure release valve have not extended into the casing 109 .
[0032] The inverted slips 106 as shown in FIG. 1 grip the casing collar 108 from its exterior, as shown in FIG. 2 when the slips are engaged. The casing collar 108 being connected to the casing 109 to be run. That casing 109 being placed through a rotary table at its opposite end to be threaded to a separate casing located below the ground and within the rotary table, once engaged as shown in FIG. 2 .
[0033] In practice, the top head drive connection 100 is threaded to the existing top head drive. The casing 109 , containing the casing collar 108 are moved to be received by the TDPS. The casing collar 108 is received by the inverted slips 106 of the TDPS after. As the casing 109 and collar 108 become substantially vertical, the top head drive (not shown) moves downward providing the weight to engage slip segments 106 , providing enough downward pressure to cause slip segments 106 to grip the exterior of the casing collar 108 and engage the slips 106 as illustrated in FIG. 2 .
[0034] The release weight 104 keeps slip segments 106 in a downward position when not engaged and assists in making slip segments 106 move synchronously. For instance, if the casing collar 108 is placed into the TDPS at an awkward angle, and that casing depresses only one slip segment, without a release weight, the casing can become entangled in the slip segments. The casing would then need to be removed from the tool and repositioned. The release weight 104 maintains the slip segments 106 in position relative to each other, such that if the casing 108 is moved into the TDPS at an awkward angle, any one slip segment 106 will maintain its position, thus forcing the casing collar 108 into the proper position with efficiency and ease. In one embodiment of the present invention, the dimensions of the release weight 104 are 7½ O.D. by 6½ long, weighing approximately 40 lbs.
[0035] The existing rotary table contains a previously existing casing within that rotary table. The new casing 109 is set to thread to the previous casing within the rotary table. The weight of the TDPS of the present invention is sufficient for the two casing pieces to be in contact.
[0036] When the existing top drive connected to the TDPS is actuated and the slips 106 of the TDPS are engaged as in FIG. 2 , the turning sub 103 rotates, threading the casing 109 into the casing previously existing within the rotary table. Once threaded, the top drive and TDPS moves upward and the release weight pushes slip segments downward, by only the force of gravity, and away from pipe, and the casing collar 108 is released (see FIG. 1 ), allowing the casing 109 to move down within the earth and allow the process to begin again.
[0037] FIG. 2 shows a cross section view of the TDPS with the spinner engaged. This position is achieved where the top drive is connected to the TDPS and the top drive is pressing downward with its weight. In this position, note that the release weight 104 is in close proximity to the top plate 102 , the slip segments 106 are in contact with the casing collar 108 and the fill tube and fluid release valve 107 extends into the casing 109 .
[0038] FIG. 3 shows a top view of the TDPS. The top drive connection 100 is a threaded pipe to be received by the user's existing top drive. As shown in FIG. 3 , a plurality of bolts 101 are used to secure the top plate 102 . In one preferred embodiment, approximately 6 bolts are used. As is well known, any different number of bolts may be sufficient to secure the top plate 102 . Other fasteners are contemplated, as well as other means of coupling the top plate 102 to the turning sub 103 . Note the top drive connection 100 can be made as one piece with the top plate 102 as shown in this illustration. Alternatively, the top drive connection 100 can be welded to the top plate 102 . As is well known in the art, other methods of securing the top drive connection 100 to the top plate 102 are well known and are contemplated by the present invention. Moreover, it is contemplated that the top drive connection 100 , top plate 102 , can be made as one piece, as stated above.
[0039] FIG. 4 shows a bottom view of the TDPS of the present invention. The outer periphery is the turning sub 103 . The slip segments 106 are secured by T-slots 400 cut into the turning sub 103 (See FIGS. 1 and 2 ). The slip segments are cavity backed and form a T to be inserted into the T-slots 400 that have been cut into the turning sub 103 . In the preferred embodiment, the T-slots 400 are constructed as part of the turning sub 103 , thus lending to the integrity of the TDPS of the present invention. Alternatively, T-slots 400 can be welded onto the turning sub 103 using appropriate pieces such as angle irons and the like. The top plate 102 secures the top drive connection 100 to the turning sub 103 . Also shown in FIG. 4 are the plurality of inverted slips 106 . The slips 106 engage the casing collar 108 at the interior of the TDPS, and each of the T-slots 400 house one of the plurality of slips 106 . FIG. 4 also illustrates the bottom portion of the fill tube with fluid release valve 107 . The fill tube with fluid release valve 107 reside within the TDPS at its approximate center.
[0040] FIG. 5 shows an illustrative side view of one of the plurality of slips 106 used in the TDPS. In one preferred embodiment, approximately 5 slips 106 are used to create the TDPS. As is well known by those in the art, other numbers of slips, such as 3, 6, 7, 8 and more than 8 can be used to create the present invention. Slips are commonly used in the oil industry. Slips are commonly used to grip and hold the upper part of a drill string to the drill floor of an oilrig. The present invention repurposes these slips by inverting them so that they may efficiently run casing by inverting the slip.
[0041] The release weight 104 illustrated in FIGS. 1 and 2 contacts with the release weight plate 500 at the topmost portion of the slip (see FIG. 5 ). The release weight plate 500 contacts the engaging body 501 of the slip when in the exterior position. In the preferred embodiment, the slip body 501 is approximately 4 inches in length. Below the engaging body 501 is the engaging plate 502 , which comes into contact with the casing collar 108 to engage the slips 106 as the casing 109 is received by the TDPS. When disengaged, the engaging plate 502 has an exterior position to the center of the TDPS. The casing collar 108 pushes upward on the engaging plate 502 causing the slips 106 to move upward and inward to grip the casing collar 108 . In this engaged position, the engaging plate 502 moves toward the interior position (closer to the center of the TDPS). At all times the engaging plate 502 is substantially perpendicular to the turning sub 103 . Additionally, note the dimensions of the slip will necessarily change if scaling the TDPS to suit larger casing, the present figures are for a 4″ drill pipe, 4½″, or 5½″ casing collar.
[0042] Further shown in FIG. 5 , the engaging plate 502 is connected to the slip body 503 , which is substantially perpendicular to the turning sub 103 on the interior side, and angled outward from the interior on the opposite side, the slip body 503 resembling a shark-fin type shape. On the interior edge perpendicular to the engaging plate 502 of the slip body 503 is the slip deye 504 . The slip deye 504 has a jagged interior-facing edge to grip the exterior of the casing collar 108 when the TDPS is engaged. The length of the slip deye 504 in the preferred embodiment, is approximately 4½ inches. The length of the slip body, in its entirety, is approximately 7 to 11 inches (wherein the slip body extends approximately 2 and ½ inches from the posterior end of the slip deye). The slip deye 504 is substantially parallel with the turning sub 103 . In the preferred embodiment, the slip is constructed of a durable metal such as steel, other suitable alloys, or metallurgic materials.
[0043] When the slip is in the engaged position, the slip deye 504 is in an interior position, closer to the center of the TDPS. When the slip is disengaged, the slip deye 504 is in an exterior position, closer to the exterior of the TDPS. In the preferred embodiment, where the TDPS is running casing with a 5 and ½ inch collar, there is ¼ inch around the collar 108 where the TDPS is not engaged. The slips then move to contact the collar when the TDPS is engaged. This same TDPS that can run casing with a 5½ inch casing collar, can also be used for a 4 inch drill pipe or 4½ inch casing collar.
[0044] While the slip is well known, inverting the slip to be used in this manner is novel and unknown to those in the art. The slip deyes 504 of the present invention are durable, and capable of use for extended periods of time, up to 9 years of regular use. Alternatively, deyes 504 can be used to run at least approximately 300,000 ft of pipe before being replaced. When slip deyes 504 become dulled, new deyes may be replaced.
[0045] FIG. 6 illustrates the fill tube and fluid release valve 107 shown in FIGS. 1 and 2 . The fill tube and fluid release valve has an uppermost threaded region 304 that secures the fill tube and fluid release valve to the top drive connection 100 and thus the TDPS. The fill tube 300 extends from the threaded region 304 down to the fluid release valve 303 . The fluid release valve 303 is functionally comprised of a ball seat 301 , ball check 305 , and tension spring 302 . The fluid release valve 303 allows for the controlled filling of casing while eliminating errant spills on the rig floor. When a predetermined pressure is reached by an existing mud pump (for instance 150 psi), the pressure overcomes the tension spring 302 , which allows the ball check 305 to move away from the ball seat 301 , allowing fluid to be pumped into casing 109 being joined to the previously existing casing within the rotary table. Once the predetermined amount of fluid is pumped into the casing 109 (see FIGS. 1 and 2 ) the pump is disengaged and when the pressure drops below the 150 psi, then ball check 305 , move back up to seat 201 to the locked position as the tension spring 302 engages and flow of fluid is stopped. It is contemplated that rather than the ball seat and check system, a valve could be employed that is pressure dependent or manually operated to allow the filling of the casing in a controlled manner. Any such mechanized release system capable of responding to pressure would be appropriate for use in the TDPS of the present invention, as is known by those skilled in the art.
[0046] For example, where a 4½ inch casing holds 0.68 gallons per foot, to fill a 40 foot joint approximately 26 gallons of fluid would be dispensed through the fluid release valve. However, where a 5½ inch casing holds approximately 1 gallon per foot, a 40 foot joint would use approximately 40 gallons of fluid. Thus, the amount of fluid dispensed by the TDPS is dependent upon the size of the joint and the diameter of casing.
[0047] The dimensions provided above are for one preferred embodiment of the TDPS. Dependent on the size of casing to be run, dimensions of the TDPS will necessarily change. In the preferred embodiment described above, the TDPS can run 4 inch drill pipe, 4½ inch and 5½ inch casing. In this embodiment, the smallest tool joint measured on the drill pipe is approximately 4¾ inch, making the interior position approximately 4½ inches in diameter (the diameter of the circle formed by the plurality of slips). For the purposes of this example, note that the casing collar on a 4½ inch casing is approximately 5 inches in diameter; and where a 5½ inch casing is used, the casing collar is approximately 6 inches. Where a 5½ inch casing is used, the exterior position of the slips would be approximately 6½ inches. Also note, as stated above, to achieve a steeper bevel, the length of the bevel may be modified without modifying other parameters. Moreover, components of the TDPS will be made of a durable material such as steel, other alloys, metallurgic materials, iron, or the like.
[0048] It will be apparent to those skilled in the art that various modifications and variations can be made in the TDPS of the present invention without departing from the scope or spirit of the invention and that certain features of one embodiment may be used or interchangeably in other embodiments. Thus, it is intended that the present invention cover all possible combinations of the features shown in the different embodiments, as well as modifications and variations of this invention, provided they come within the scope of the claims and their equivalents. All measurements are approximate and the size of the insert will vary with the scale remaining close to the preferred embodiment described. | The present invention relates generally to a Top Drive Pipe Spinner (TDPS). The TDPS is a tool that allows for the setting of casing without a specialized crew or any additional power source. By employing the weight of the existing top drive to set slips on the casing collar, the TDPS allows one casing to be threaded onto the next in a timely and efficient manner. The casing tongs of the TDPS use passive release weight to release the casing collar from the casing to allow for the successive insertion of another casing section. The top drive spins the TDPS and compresses the unit onto the casing, then lifts the unit and releases the casing when desired. | 4 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention generally relates to cooling apparatuses, and particularly to a cooling apparatus utilizing coolant flow and agitation.
[0003] 2. Description of Related Art
[0004] In the past, heat generated by a typical central processing unit (CPU) of a computer can be adequately removed by a conventional cooling apparatus utilizing heat sinks and air fans. However, because of recent advances in technology, chip density and CPU speed have increased resulting in more heat being given off by the CPU, as such the conventional cooling apparatus can no longer efficiently remove heat from the CPU.
[0005] In order to increase the efficiency in removing heat, coolant such as water is used to help cool the CPU. A coolant-cooling apparatus uses a circulating channel between a heat source and a heat-dissipation part, and the coolant flows in the circulating channel. The coolant absorbs heat from the heat source, and transports the heat to the heat-dissipation part. The heat-dissipation part dissipates the heat to air. Furthermore, the coolant-cooling apparatus also utilizes a pump to drive the coolant to flow circularly in the circulating channel.
[0006] However, the heat source, the heat-dissipation part, and the pump are disposed independently from each other in different position along the circulating channel, resulting in the coolant-cooling apparatus occupying valuable space in the computer. Thus, the coolant-cooling apparatus occupying a large space in a computer is and will be a shortcoming as the computer gets smaller.
[0007] Therefore, improvements for a cooling apparatus are needed in the industry to address the aforementioned deficiency.
SUMMARY
[0008] A cooling apparatus is for dissipating heat from an electronic device. The cooling apparatus includes a casing, an impeller, and a motor. The casing is for absorbing the heat and allowing coolant to flow therein. The impeller is received in the casing. The motor is received in the casing, and is for providing a force to drive the impeller to rotate to force the coolant to flow. The coolant flows between the casing and the motor to take the heat away.
[0009] Other advantages and novel features of the present invention will become more apparent from the following detailed description of preferred embodiment when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a disassembled view of a cooling apparatus in accordance with an exemplary embodiment.
[0011] FIG. 2 is disassembly view of the cooling apparatus of FIG. 1 , viewed from another side.
[0012] FIG. 3 is an assembly view of the cooling apparatus of FIG. 1 .
[0013] FIG. 4 is a cross-sectional view taken along line IV-IV of FIG. 3 .
DETAILED DESCRIPTION
[0014] Reference will now be made to the drawings to describe a preferred embodiment of the present cooling apparatus.
[0015] Referring to FIGS. 1 , 2 , 4 , a cooling apparatus 100 in accordance with an exemplary embodiment is used to cool a central processing unit (CPU) (not shown) using water as coolant. The cooling apparatus 100 includes a casing 10 , a motor 20 , and an impeller 30 . The motor 20 and the impeller 30 are received in the casing 10 . The coolant is received in a space enclosed between the casing 10 and the motor 20 . The motor 20 is configured for rotating the impeller 30 . A plurality of vanes 315 is formed on the circular periphery of the impeller 20 . When the motor 20 rotates, it drives the impeller 30 to also rotate, thus the coolant is forced by the vanes 315 to flow.
[0016] The casing 10 includes a base 11 , a lid 13 , a sealed loop 15 , an inner gasket 17 , and an outer gasket 19 . The base 11 is used for contacting with the CPU to absorb heat from the CPU, and supporting the other components. The lid 13 is used for cooperating with the base 11 to enclose the motor 20 and the impeller 30 .
[0017] The base 11 includes an annular wall 111 to position the lid 13 . The lid 13 includes an intake 131 by which the coolant is admitted into the casing 10 , and an outlet 133 through which the coolant flows out of the casing 10 . The sealed loop 15 , the inner gasket 17 , and the outer gasket 19 are clamped between the annular wall 111 and the lid 13 to prevent the coolant from flowing out of the casing 10 .
[0018] The sealed loop 15 defines an outer recess 157 in its outer side surface (not labeled) and an inner recess 159 in its inner side surface (not labeled). The inner gasket 17 is embedded in the inner recess 159 and is sleeved around the annular wall 111 . The outer gasket 19 is sleeved on the outer recess 157 and is compacted against an inner side surface 137 of the lid 13 . The base 11 also defines a first hole 113 within a range of the annular wall 111 for leading an electrical wire 231 (referring to FIG. 4 ) to pass therethrough. In the embodiment, the electrical wire 231 is used to transmit electrical signals to the motor 20 .
[0019] The motor 20 includes a sealed device 21 , a drive coil 23 received in the sealed device 21 , a bearing 25 , and an annular magnet 27 sleeved around the sealed device 21 . The annular magnet 27 can be rotated with respected to the sealed device 21 .
[0020] The sealed device 21 includes a first cap 211 , a supporting board 213 cooperating with the first cap 211 to protect the drive coil 23 from the coolant, and an annular gasket 215 elastically clamped between the first cap 211 and the supporting board 213 to closely seal a gap therebetween. The supporting board 213 defines a second hole 2131 corresponding to the first hole 113 . The electrical wire 231 is electrically connected to the drive coil 23 through the second hole 2131 . Therefore, the drive coil 23 is protected from the coolant using a combination of the first cap 211 , the supporting board 213 , and the annular gasket 215 .
[0021] The first cap 211 includes an inner lid surface 2111 , an outer lid surface 2113 , and a bearing housing 2115 formed in the center of the inner lid surface 2111 and the center of the outer lid surface 2113 . When viewed from a side of the inner lid surface 2111 , the bearing housing 2115 extends vertically from the center of the inner lid surface 2111 as a post, while viewed from a side of the outer lid surface 2113 , the bearing housing 2115 is recessed downwardly from the center of the outer surface 2113 to define a cavity thereof.
[0022] The drive coil 23 sleeves around the bearing housing 2115 via a guiding hole (not labeled) in the center of the drive coil 23 . The bearing 25 is received in the bearing housing 2115 . The annular magnet 27 is tightly wedged into the impeller 30 .
[0023] The impeller 30 includes a second cap 31 and a shaft 33 protruding vertically from the center of a coping 313 of the second cap 31 . The second cap 31 includes the coping 313 , an annular wall 311 extending downwardly from the coping 313 , and the vanes 315 formed on circular periphery of the annular wall 311 . The annular magnet 27 of the motor 20 is tightly wedged into the second cap 31 . When the motor 20 operates, the annular magnet 27 is driven by a magnetic force generated by the drive coil 23 to rotate, thereby the second cap 31 is also rotated with the annular magnet 27 . The shaft 33 passes through a through hole 251 of the bearing 25 .
[0024] Therefore, the bearing housing 2115 of the sealed device 21 , the bearing 25 , and the shaft 33 of the impeller 30 collectively form a rotatable device to help the impeller 30 rotate with respect to the sealed device 21 .
[0025] In operation, referring to FIGS. 3 , 4 , the coolant flows into the casing 10 via the intake 131 , and fills up a space between the casing 10 and the sealed device 21 . Power is supplied to the drive coil 23 , and the drive coil 23 generates the magnetic force to rotate the annular magnet 27 . Then the second cap 31 is rotated by the annular magnet 27 , thus the vanes 315 rotates and pushes the coolant to flow. The cooling apparatus 100 is set on the CPU, with the base 11 closely attached to the CPU to absorb the heat generated from the CPU. The coolant takes the heat away from the base 11 , and flows out of the casing 10 via the outlet 133 .
[0026] As mentioned above, the cooling apparatus 100 utilizes the casing 10 to absorb the heat, and utilizes the motor 20 to force the coolant to take the heat away, and especially the motor 20 is received in the casing 10 . Therefore, the cooling apparatus 100 has a comparative small size that can be used in computers with small footprints.
[0027] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A cooling apparatus is for dissipating heat from an electronic device. The cooling apparatus includes a casing, an impeller, and a motor. The casing is for absorbing the heat and allowing coolant to flow therein. The impeller is received in the casing. The motor is received in the casing, and is for providing a force to drive the impeller to rotate to force the coolant to flow. The coolant flows between the casing and the motor to take the heat away. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. Ser. No. 09/766,443, filed Jan. 19, 2001.
TECHNICAL FIELD
[0002] The present invention relates generally to nonwoven fabrics and their method of production, and more particularly to a process for making stabilized, highly durable hydroentangled webs, comprising a blend of textile length fibers where a portion of same are thermally fusible, and where such fabrics are suitable for commercial dyeing operations, most particularly jet-dye processes.
BACKGROUND OF THE INVENTION
[0003] Nonwoven fabrics are used in a wide variety of applications where the engineered qualities of the fabric can be advantageously employed. These types of fabrics differ from traditional woven or knitted fabrics in that the fabrics are produced directly from a fibrous mat eliminating the traditional textile manufacturing processes of multi-step yarn preparation, and weaving or knitting. Entanglement of the fibers or filaments of the fabric acts to provide the fabric with a substantial level of integrity. However, the required level of fabric integrity when such fabrics are used in highly abrasive environments is not possible by entanglement alone, and thus it is known to apply binder compositions or the like to the entangled fabrics for further enhancing the integrity of the structure.
[0004] U.S. Pat. No. 3,485,706, to Evans, hereby incorporated by reference, discloses processes for effecting the hydroentanglement of nonwoven fabrics. More recently, hydroentanglement techniques have been developed which impart images or patterns to the entangled fabric by effecting hydroentanglement on three-dimensional image transfer devices. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, hereby incorporated by reference, with the use of such image transfer devices being desirable for providing fabrics with the desired physical properties as well as an aesthetically pleasing appearance.
[0005] In general, hydroentangled fabrics formed on the above type of three-dimensional image transfer devices exhibit sufficient strength and other requisite physical properties as to be suitable for a number of textile applications.
[0006] However, many desired applications have requirements for commercial dyeing and wash durability, which are generally beyond the design capability of such fabrics. Typically, home or commercial laundering or the rigors of commercial dye house processes have a deleterious effect on these hydroentangled or imaged fabrics. The clarity of the raised image is reduced or “washed out” and the fabric surface becomes abraded with fibers forming pills on the fabric surface. Physical strength characteristics can also be reduced.
[0007] Heretofore, chemical binder systems have been developed that provide high abrasion resistance to nonwoven, woven or knitted fabrics. Other binder compositions can provide durability to laundering and commercial dyeing processes. However, it will be appreciated that application of chemical binders also increases the complexity of the fabric manufacturing process and adds cost to the fabric thus produced. The use of such compositions also requires specialized equipment to mix and apply the binder formulations as well as to dry and cure the binder compositions after application to the fabrics.
[0008] The addition of binder compositions has an effect on the fabric properties. The use of such binders generally produces fabrics which are stiffer than like fabrics produced without the binder application. Such stiffness will be recognized as being undesirable for apparel fabrics, where softness, suppleness and drapeability are highly preferred.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a process for making nonwoven fabrics which exhibit the desired durability to commercial dye house processing, most particularly jet-dye processing, as well as acceptable softness and drapeability. This is achieved by the inclusion of fusible fibers, preferably in the form of bicomponent fibers, most preferably nylon or polyester bicomponent fibers, into the fibrous matrix of the substrate web. Such fibers, when the entangled and patterned web is subjected to temperatures above the melting point of the lower melting component of the bicomponent fibers, acts to provide enhanced mechanical stability to the fibrous matrix of the web. An imaged nonwoven fabric with this added degree of mechanical stabilization has been found to be durable to commercial dye house processing, in particular to the mechanically aggressive jet-dye processing, and able to retain the imparted image quality under harsh mechanical conditions.
[0010] A process for making a jet-dye process-durable nonwoven fabric in accordance with the present invention comprises the steps of providing a fibrous matrix to form a precursor web comprised of a blend of textile length fibers where at least a portion of those fibers are bicomponent, thermoplastic fibers. The fibrous component of the precursor web can be in the form of a fibrous batt or matrix containing a single homogenous blend of fusible fibers or in a layered fibrous batt having either the same or different fusible fiber blend ratios in each fibrous batt sub-layer, with the matrices consolidated to form the precursor web. The precursor web is positioned on a three-dimensional image transfer device with hydroentangling of the precursor web on the image transfer device effected to form an entangled and imaged web, with the image transfer device imparting the fibrous matrix with a three-dimensional spatial arrangement.
[0011] Subsequent to the hydroentanglement and imaging of the web, the temperature of the web is elevated, such as during drying of the web, so that the lower melting point component of the bicomponent fusible fibers is softened or melted and acts to thermally bond fibers in the web together. The three-dimensional spatial arrangement of the fibrous matrix is thus secured. This results in an enhanced mechanical stability such that the highly durable fabric of the present invention is capable of being commercially dyed, without deleterious effects on aesthetic or physical properties. The commercial dye processing produces, as the final product, a colored, highly durable, imaged nonwoven fabric.
[0012] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be more easily understood by a detailed explanation of the invention including drawings. Accordingly, drawings which are particularly suited for explaining the invention are attached herewith; however, is should be understood that such drawings are for explanation purposes only and are not necessarily to scale. The drawings are briefly described as follows:
[0014] FIG. 1 is a diagrammatic view of a hydroentangling apparatus for practicing the process of the present invention by which a durable, imaged nonwoven fabric is formed;
[0015] FIG. 2 is an illustration of the features of a three-dimensional image transfer device which can be employed in the apparatus of FIG. 1 for practicing the present invention;
[0016] FIG. 2 a is a view taken along lines A-A of FIG. 2 ;
[0017] FIG. 2 b is an isometric view of the features illustrated in FIG. 2 ;
[0018] FIG. 3 is an isometric illustration of the features of a three-dimensional image transfer device which can be employed in the apparatus of FIG. 1 for practicing the present invention;
[0019] FIG. 3 a is a plan view of the features shown in FIG. 3 ;
[0020] FIG. 4 is an illustration of the features of a three-dimensional image transfer device which can be employed in the apparatus of FIG. 1 for practicing the present invention;
[0021] FIG. 5 is a view taken along lines A-A of FIG. 4 ;
[0022] FIG. 6 is a view taken along lines B-B of FIG. 4 ;
[0023] FIG. 7 is an isometric illustration of the features shown in FIG. 4 ;
[0024] FIG. 8 is plan view of an imaged nonwoven fabric of the present invention after Brush Pill testing;
[0025] FIG. 9 is plan view of an imaged nonwoven fabric of the present invention without activation of the fusible fiber component, after Brush Pill testing;
[0026] FIG. 10 is plan view of an imaged nonwoven fabric of the present invention after Brush Pill testing; and
[0027] FIG. 11 is plan view of an imaged nonwoven fabric of the present invention without activation of the fusible fiber component. after Brush Pill testing.
DETAILED DESCRIPTION
[0028] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0029] With reference to FIG. 1 , therein is illustrated a hydroentangling apparatus, generally designated 10 , which can be employed for practicing the process of the present invention for manufacture of a durable, jet-dyed imaged nonwoven fabric. The apparatus is configured generally in accordance with the teachings of U.S. Pat. No. 5,098,764, to Drelich et al., hereby incorporated by reference. The apparatus 10 includes an entangling belt 12 which comprises a hydroentangling device having a foraminous forming surface upon which hydroentangling of a precursor web P, for effecting consolidation and integration thereof, is effected for formation of the present nonwoven fabric. The precursor web P is then hydroentangled and imaged on a three-dimensional image transfer device (ITD) at drum 18 under the influence of high pressure liquid streams (water) from manifolds 22 .
[0030] In accordance with the present invention, at least a portion of the fiber or filament web consists of thermally fusible fibers, also called binder fibers, most preferably bicomponent fibers, that are activated through drying or heat setting steps that follow the imaging step. This blend of fusible fibers with the other fibers of the web provides for the subsequent thermal bonding of the fibers in the matrix. The result is an enhancement of the mechanical stability of the preferred spatial arrangement of the entangled fibers which result from the hydroentangling and imaging steps. This enhanced stability provides an entangled web with high durability such that the fabrics thus produced are capable of withstanding commercial dye house processing without deleterious effects on physical and aesthetic properties. Further, these fabrics, either before or after dyeing, exhibit softness and drapeability that is superior to similarly entangled and imaged fabrics that are stabilized by the application of a chemical binder system.
[0031] As will be appreciated, the thermoplastic fusible fiber has a melt temperature less than the melt temperature or the decomposition temperature of the base fiber. The fusible fiber is selected from the group consisting of polyamide homopolymers, polyamide co-polymers, polyamide derivatized polymers, and combinations thereof. Alternatively, the fusible fiber is selected from the group consisting of polyester homopolymers, polyester co-polymers, polyester derivatized polymers, and combinations thereof. The base fiber is selected from the group consisting of natural fibers, thermoplastic fibers, thermoset fibers, and combinations thereof. The thermoplastic fiber can be polyester, while the natural fiber can be rayon.
[0032] Referring again to FIG. 1 , subsequent to the hydroentanglement, the entangled and imaged web can be dewatered, as generally illustrated at 20 , with the temperature of the web then elevated by heated air, such as by use of an oven or dryer 22 . The temperature of the web can be elevated by heated surface contact, such as by use of steam cans. Elevation of the web temperature to the melting point of the fusible fibers or fusible component of the bicomponent fusible fibers acts to thermally bond the fibers of the matrix together and thus secure the preferred arrangement of the fibers in the entangled and imaged web.
[0033] After the heat setting step, a soft, durable, entangled and imaged nonwoven fabric is provided, which is suitable for further textile finishing. The fabric may be dyed, printed or finished by other techniques and used in apparel, home furnishing, upholstery or any number of applications. Notably, wash durability, pill-resistance and drape characteristics of sample fabrics, described hereinafter, meet the requirements for “top of bed” applications, that is, applications for home use such as comforters, pillows, dust ruffles, and the like.
[0034] For each of the tested samples, a precursor web was formed by carding the blend of fibers in the specified ratio. Each precursor web was subjected to high pressure water jets prior to imaging for consolidating and integrating the precursor web, with the pre-imaging entanglement being effected with four manifolds at 14 , each with three strips of orifices. The orifices were uniformly 0.005 inches in diameter and 50 orifices per inch of strip length. The entangling manifolds were operated at 100, 300, 600 and 800 psi, sequentially.
[0035] Imaging was accomplished at imaging drums 18 using a three dimensional image transfer device and a series of three manifolds 22 with 0.0047 inch diameter orifices spaced at 43 orifices per inch. Each of the three manifolds was operated at 2800 psi. The overall line speed was 60 feet per minute.
[0036] The entangled and imaged web of each of the tested fabrics was dewatered and thereafter dried and heat set at a temperature satisfactory to melt the lower melting point component of the fusible fibers. For example, the temperature used to heat set nylon bicomponent fiber samples was in the range of about 216° C., and for polyester/copolyester fusible fiber samples was in the range of about 130° C. The heat setting step is accomplished at process speeds compatible with the entangling and patterning process such that the drying and heat setting step would be in a continuous process with the rest of the manufacturing steps. The heat setting step acts to enhance the mechanical stability of the preferred spatial arrangement of the entangled fibers in the web, thereby providing the high degree of durability required for the final commercial dyeing process.
[0037] After heat setting, the resultant fabrics exhibit sufficient durability to withstand commercial dye house processing, such as exemplified by jet-dyeing, such as in a jet dyeing apparatus. Ajet-dyeing apparatus can be configured in accordance with known arrangements, such as exemplified by U.S. Pat. No. 3,966,406, hereby incorporated by reference. In general, jet-dye processing consists of a high-temperature, piece-dyeing machine that circulates the dye liquor through a Venturi jet, thus imparting a driving force to move the fabric through the process. Speeds of 80 to 300 meters per minute are standard for this type of operation. The fabric is totally immersed in the dye bath which is contained in the closed dye vessel, such that the process is discontinuous from the rest of the manufacturing process described for the present invention.
EXAMPLES
Example 1
[0038] An imaged nonwoven fabric having a before dyeing-basis weight of three-ounces per square yard was prepared using a fiber blend of 90 percent weight of base fiber to 10 weight percent fusible fiber. Base fibers utilized were Wellman 472, 1.2 denier polyester staple fibers. The heat fusible fibers were obtained from Dupont de Nemours as Type 3100 nylon bicomponent fibers. Type 3100 is a sheath/core bicomponent fiber where the core is nylon 6,6 and the sheath is nylon 6. The material fabricated in this example utilized an entangling drum 12 in the form of “left hand twill” as depicted in FIG. 2 . A heat setting temperature of 216° C. was suitable for fabrics containing this fusible fiber. In the course of preparation of samples of the present fabric, it was discovered that a heat-setting temperature more than about 10% above the recommended temperature resulted in undesirable stiffness.
Example 2
[0039] An imaged nonwoven fabric made in accordance with Example 1, wherein the alternative a blend ratio of 75 percent weight base fiber and 25 percent weight fusible fiber were employed.
Example 3
[0040] An imaged nonwoven fabric made in accordance with Example 1, wherein the alternative a blend ratio of 50 percent weight base fiber and 50 percent weight fusible fiber were employed.
Example 4
[0041] An imaged nonwoven fabric having a before dyeing-basis weight of three-ounces per square yard was prepared using a fiber blend of 90 percent weight of base fiber to 10 weight percent fusible fiber. The base fiber for this blend was comprised of a Wellman 472, a 1.2 denier polyester staple fiberand the fusible fiber was a Wellman 712P, a sheath/core copolyester/polyester bicomponent fiber. A heat setting temperature of 130° C. was suitable for fabrics containing this fusible fiber., Steam dry cans were set at 130° C. for drying and heat setting the fabrics after entangling and imaging, as illustrated in FIG. 1 and utilizing an entangling drum 12 as depicted in FIG. 2 .
Example 5
[0042] An imaged nonwoven fabric made in accordance with Example 4, wherein the alternative a blend ratio of 75 percent weight base fiber and 25 percent weight fusible fiber were employed.
Example 6
[0043] An imaged nonwoven fabric made in accordance with Example 4, wherein the alternative a blend ratio of 50 percent weight base fiber and 50 percent weight fusible fiber were employed.
Example 7
[0044] An imaged nonwoven fabric made in accordance with Example 1, wherein the alternative a blend ratio of 85 percent weight base fiber and 15 percent weight fusible fiber were employed on a image transfer device having a patterned termed “pique” and depicted in FIG. 3 .
Example 8
[0045] An imaged nonwoven fabric made in accordance with Example 1, wherein the alternative a blend ratio of 85 percent weight base fiber and 15 percent weight fusible fiber were employed on an image transfer device having a patterned termed “octagon and square” and depicted in FIG. 4 .
Example 9
[0046] An imaged nonwoven fabric made in accordance with Example 1, wherein the alternative a blend ratio of 85 percent weight base fiber and 15 percent weight fusible fiber were employed on a image transfer device having a pattern termed “20×20”, which refers to a rectilinear forming pattern having 20 lines per inch by 20 lines per inch configured in accordance with FIGS. 12 and 13 of U.S. Pat. No. 5,098,764, except mid-pyramid drain holes were omitted. Drain holes are present at each corner of the pyramids (four holes surrounded each pyramid). The “20×20” pattern is oriented 45 degrees relative to the machine direction, with a pyramidal height of 0.025 inches and drain holes having a diameter of 0.02 inches.
Example 10
[0047] An imaged nonwoven fabric having a before dyeing-basis weight of 3.5 ounces per square yard was prepared using a fiber blend of 85 percent weight of base fiber to 15 weight percent fusible fiber. The base fiber for this blend was comprised of an “ECHOSPUN” Wellman recycled PET fiber of 1.8 denier and the fusible fiber was a KOSA 252 , a sheath/core copolyester/polyester bicomponent fiber of 3.0 denier. The entangling drum 12 used was provided with a pattern referred to as “12×12”, which refers to a rectilinear forming pattern having 12 lines per inch by 12 lines per inch configured in accordance with FIGS. 12 and 13 of U.S. Pat. No. 5,098,764, except mid-pyramid drain holes are omitted. A heat setting temperature of 184° C. was suitable for fabrics containing this fusible fiber, using a through-air drier as depicted at 22 in FIG. 1 .
Example 11
[0048] An imaged nonwoven fabric made in accordance with Example 10, wherein the alternative the imaged nonwoven fabric was not subjected to elevated temperature, and therefore the fusible fiber was not activated.
Example 12
[0049] An imaged nonwoven fabric having a before dyeing-basis weight of 3.0 ounces per square yard was prepared using a fiber blend of 85 percent weight of base fiber (the base fiber itself comprised of a blend of 59 weight percent “MODAL” Lenzing high-modulus rayon of 1.5 denier to 41 weight percent Wellman 472, a 1.2 denier polyester staple fiber) to 15 weight percent fusible fiber. The fusible fiber was a KOSA 252, a sheath/core copolyester/polyester bicomponent fiber of 3.0 denier. The entangling drum 12 used was in a configuration referred to as “33×28”, which refers to a rectilinear forming pattern having 33 lines per inch by 28 lines per inch configured in accordance with FIGS. 12 and 13 of U.S. Pat. No. 5,098,764, except mid-pyramid drain holes are omitted. A heat setting temperature of 190° C. was suitable for fabrics containing this fusible fiber, using a through-air drier as is commercially available.
Example 13
[0050] An imaged nonwoven fabric made in accordance with Example 12, wherein the alternative the imaged nonwoven fabric was not subjected to elevated temperature, and therefore the fusible fiber was not activated.
[0051] Samples 4 and 5 were found to be soft and drapeable. Sample 6, containing 50 weight percent of the fusible fiber was stiff. This was attributed to the higher content of the polyester fusible fiber.
[0052] As shown in Table 1, Examples 1, 2, 3, and 4 (Samples 1 to 4) were successfully jet dyed after heat setting then tested for appearance after repeated home launderings as per test protocol AATCC 124-1996. No application of chemical binders was required to obtain the positive results. These examples were also tested under protocol Federal Test Method 191A, Method 5206, “Stiffness of Cloth, Drape and Flex, Cantilever Bending Method”, the results provided in Table 2. Table 3 presents standard ASTM fabric quality test results for Examples 7 through 9 (Samples 7 to 9). Examples 10 through 13 were tested under ASTM D3511-82 for abrasion resistance. The results of activating the fusible fiber versus not activating the fusible fiber are shown in FIGS. 8 through 11 . Example 10, depicted in FIG. 8 , and Example 12 depicted in FIG. 10 , both exhibits the reduction in pilling caused by abrasion against a high friction surface. Example 11, depicted in FIG. 9 , and Example 13, depicted in FIG. 11 , which are the corresponding imaged nonwoven fabrics whereby the fusible fiber is not activated, shows that significant abrasion and loss of image quality are apparent.
TABLE 1 Sample ID 1 st Wash Cycle 5 th Wash Cycle 1 3.5 3.5 2 3.5 3.5 3 3 5 4 3 5
[0053]
TABLE 2
Sample 1
Sample 2
Sample 3
Sample 4
Length
Width
Length
Width
Length
Width
Length
Width
9.1
4.9
10.7
5.7
9.3
4.2
9.3
4.7
8.3
4.7
11.2
6.2
9.1
4.2
9.7
5.0
8.5
4.7
11.5
6.2
8.7
4.3
9.1
4.9
8.2
4.8
11.8
6.5
9.5
4.3
9.1
4.8
8.0
4.6
10.7
6.5
9.1
3.8
9.3
4.8
8.4
4.7
11.2
6.2
9.1
4.2
9.3
4.8
average
average
average
average
average
average
average
average
[0054]
TABLE 3
Test Sample
Basis Weight
Brush Pill Rating
Tensile--MC
Tensile--CD
Elongation--MD
Elongation--CD
Sample 7 - Before
3.70
1
64.7
47.3
67.5
109.3
Fusible Activation
Sample 7 - After
3.89
3
72.6
46.6
39.2
115.9
Fusible Activation
Sample 8 - Before
3.48
1
69.1
50.8
75.1
130.1
Fusible Activation
Sample 8 - After
3.53
3
70.8
48.2
41.6
118.3
Fusible Activation
Sample 9 - Before
2.37
1
48.5
24.4
53.0
132.2
Fusible Activation
Sample 9 - After
2.71
4
52.9
20.5
41.6
123.1
Fusible Activation
[0055] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims. | A nonwoven fabric, and method of production, are disclosed, wherein the nonwoven fabric comprises textile length fibers with a portion being thermally fusible. The fabric exhibits sufficient durability to withstand commercial dyeing processes, with the resultant fabric finding widespread applicability by virtue of its durability and aesthetic appeal. | 3 |
BACKGROUND OF THE INVENTION
Totally synthetic antihypercholesterolemic and hypolipemic compounds represented by the following general structural Formula (I): ##STR1## and specific derivatives thereof, all of which being the enantiomers having a 4(R) configuration in the tetrahydropyran moiety of the trans racemate shown in Formula (I) are disclosed in U.S. Pat. No. 4,375,475. One class of especially preferred compounds are those compounds of the Formula (I) wherein A is hydrogen, E is --CH═CH-- and R 3 is a substituted phenyl radical in the 6-position. The synthesis of these 6-[2-[1,1'-biphenyl]-2-yl-ethenyl]pyranones disclosed in U.S. Pat. No. 4,375,475 proceeds through an intermediate benzaldehyde of the Formula (II) ##STR2## wherein R 1 , R 2 , X and Y are described therein, and an intermediate aryl-2-propenal of the Formula (III) ##STR3## wherein R 1 , R 2 , X and Y are described therein.
The intermediate benzaldehyde compounds of the Formula (II) which are 3,5-dichloro-4'-fluoro-1,1'-biphenyl-1-carboxaldehyde; 3,5-dimethyl-4'-fluoro-1,1'-biphenyl-2-carboxaldehyde; 3,3',5-trimethyl-4'-fluoro-1,1'-biphenyl-2-carboxaldehyde; and 3,3',5,5'-tetramethyl-1,1'-biphenyl-2-carboxaldehyde are claimed in U.S. Pat. No. 4,322,563. A process for the preparation of these compounds is also disclosed therein.
SUMMARY OF THE INVENTION
This invention relates to a novel process for the preparation of intermediates in the totally synthetic antihypercholesterolemic agents, 6-[2-[1,1'-biphenyl]-2-yl-ethenyl]pyranones. The novel process involves a highly efficient nickel-catalyzed aryl cross-coupling reaction which utilizes commercially available reagents and starting materials and affords products which are easily isolated and purified.
DETAILED DESCRIPTION OF THE INVENTION
A process for the preparation of a compound represented by the following general Formula (IV) ##STR4## wherein: R 1 and R 2 independently are:
(1) chloro;
(2) fluoro; or
(3) C 1-4 alkyl;
R 4 is
(1) --CN;
(2) --CO 2 R 5 ;
(3) --CH(OR 5 ) 2 ;
(4) --CH═CHCN;
(5) --CH═CHCO 2 R 5 ; or
(6) --CH═CHCH(OR 5 ) 2 in which R 5 is C 1-4 alkyl; and
X and Y independently are:
(1) hydrogen;
(2) chloro;
(3) fluoro;
(4) C 1-4 alkyl; or
(5) C 1-4 alkoxy
comprises reacting a compound of the Formula (V): ##STR5## wherein R 1 , R 2 and R 4 are defined above, and R 6 is halogen, such as chloro, bromo or iodo, with a compound of the Formula (VI) ##STR6## wherein X and Y are defined above, and R 7 is
(1) ZnR 8 ;
(2) MgR 8;
(3) CdR 8 ; or
(4) Li
in which R 8 is halogen or a radical represented by the following formula: ##STR7## wherein X and Y are defined above, in the presence of a nickel catalyst.
The intermediate benzaldehyde compounds of the Formula (II) are readily prepared by (1) the reduction of the appropriate products the nickel-catalyzed aryl cross-coupling reaction of this invention, the compounds of the Formula (IV) wherein R 4 is --CN or --CO 2 R 5 or (2) the acid hydrolysis of the compounds of formula (IV) wherein R 4 is --CH(OR 5 ) 2 . Similarly, the intermediate aryl-2-propenal compounds of the Formula (III) are readily prepared by (1) the reduction of the compounds of Formula (IV) wherein R 4 is --CH═CHCO 2 R 5 or --CH═CHCN or (2) the acid hydrolysis of the compounds of the formula (IV) wherein R 4 is --CH═CHCH(OR 5 ) 2 .
In a preferred embodiment, the compounds prepared by the process of this invention are those compounds of the Formula (IV) wherein R 1 and R 2 are in the 3- and 5-positions and independently are chloro, fluoro or methyl; and X and Y independently are chloro, fluoro, methyl or methoxy.
In a most preferred embodiment the compounds prepared by the process of this invention are:
(1) 4'-fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-carbonitrile;
(2) E-3-(4'-fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-yl)-2-propenoic acid nitrile;
(3) 4'-fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-carboxaldehyde;
(4) E-3-(4'-fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-yl)-2-propenal; and
(5) Methyl E-3-(4'-fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-yl)-2-propenoate.
The nickel-catalyzed aryl cross-coupling reaction of this novel process is conducted at a temperature between 10° and 65° C., preferably at 20°-25° C., for between 0.5 and 6 hours in an inert solvent. Illustrative of such inert solvents are: hydrocarbons, such as hexane, toluene, cyclohexane or the like; and ethers, such as diethyl ether, tetrahydrofuran, dimethoxyethane and the like or mixtures thereof. The preferred solvent is tetrahydrofuran.
The amount of reactants that is employed in the cross-coupling reaction may vary between 0.5 and 1.5 equivalents of the Compound (V) to each equivalent of the Compound (VI). However, equimolar amounts of the reactants are preferred. The compound of the formula (VI) wherein R 7 is ZnR 8 is a preferred reactant.
The nickel catalysts which are employed in the aryl cross-coupling reaction are organophosphine coordinated nickel dihalide complexes wherein the organophosphine is selected from the group consisting of:
(1) triphenylphosphine;
(2) tri-o-toluylphosphine;
(3) 1,2-bis(diphenylphosphino)ethane;
(4) 1,3-bis(diphenylphosphino)propane;
(5) 1,1'-bis(diphenylphosphino)ferrocene;
and the like and the halide selected from chloride, bromide or iodide. The preferred nickel catalyst is bis(triphenylphosphine) nickel dichloride. Prereduction of the nickel catalyst with diisobutylaluminum hydride prior to its introduction into the reaction mixture may be carried out but is not preferred. The amount of catalyst required in this reaction varies between 0.25 and 10 percent molar percent, with 3 percent preferred.
It should be noted that the organophosphine ligands are critical to avoid undue isomerization of the olefin geometry (i.e. interconversion of the E configuration to the Z configuration) during the cross-coupling reaction when R 4 is --CH═CHCN, --CH═CHCO 2 R 5 or --CH═CHCH(OR 5 ) 2 . The mole ratio of organophosphine to nickel may vary between 1 to 4 although the optimum ratio is 2.
The reduction of the compounds of the Formula (IV), wherein R 4 is --CN, --CO 2 R 5 , --CH═CHCN or --CH═CHCO 2 R 5 , is conducted at a temperature between -40° and 0° C., preferably at -40° C., for between 0.5 and 4 hours in an inert solvent. Illustrative of such inert solvents are: hydrocarbons, such as hexane, toluene, cyclohexane and the like; halocarbons, such as methylene chloride, ethylene dichloride and the like; ethers, such as, tetrahydrofuran, diethyl ether, dimethoxyethane and the like or mixtures thereof. The preferred solvent is toluene.
The reducing agents which may be employed include diisobutylaluminum hydride, sodium triethoxyaluminum hydride, lithium aluminum hydride, Raney nickel in formic acid or stannous chloride with hydrogen chloride. Preferably diisobutylaluminum hydride is employed. The amount of reducing agent may vary between 1.0 and 2.0 equivalents, with 1.05 equivalents preferred.
The following examples illustrate the present invention and as such are not to be considered as limiting the invention set forth in the claims appended hereto.
EXAMPLE 1
Preparation of 4'-Fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-carboxaldehyde
(a) 2-Bromo-4,6-dimethylaniline hydrobromide (1a)
A 1 1, 3-necked round-bottom flask, equipped with an overhead stirrer, thermometer, and addition funnel was placed in a heating mantle and charged with 2,4-dimethylaniline (60 g, 0.495 mol), propionic acid (450 ml) and water (2 ml). Rapid stirring was initiated as a solution of bromine (93 g, 0.582 mol) in propionic acid (50 ml) was added over 5 minutes. The resulting slurry was stirred at 85°-90° C. for 40 minutes while monitoring the progress of the reaction by high pressure liquid chromatography (HPLC). After cooling to ambient temperature, ethylene was bubbled through the mixture to discharge the color. After cooling to 10° C. and a 15 minute age, the mixture was filtered. The product was washed with chilled propionic acid (150 ml) then hexane (400 ml) added portionwise. The white to cream colored solid was air dried with final drying accomplished under vacuum. The Compound 1a was obtained as a fine white powder.
(b) 2-Bromo-4,6-dimethylbenzonitrile (lb)
The Compound 1a (14.0 g, 49.8 mmol) was slurried in a solution of water (40 ml) and concentrated hydrochloric acid (6 ml) then cooled to -1° C. A solution of sodium nitrite (3.8 g, 55.0 mmol) in water (15 ml) was added over 15 minutes maintaining an internal temperature of 0° C. After a subsequent 10 minute age, the resulting yellow solution was neutralized by slow addition of a solution of potassium carbonate (2.0 g) in water (5 ml) at 0° C. over a 10 minute period. A cloudy mixture resulted with a pH of 6.5. In a separate vessel, a solution of sodium cyanide (12.8 g, 261 mmol) and cuprous chloride (6.4 g, 64.6 mmol) in water (30 ml) was prepared, toluene (30 ml) was added and the two-phase mixture cooled to 0° C. The diazonium salt mixture was added over 15 minutes to vigorously stirred toluene/aqueous NaCN-CuCl mixture at 4°-6° C. The mixture was warmed to 20° C. over 1 hour then heated to 50° C. and aged for 5 minutes. The mixture was allowed to recool to 20° C. After filtration, the mixture was diluted with ethyl acetate (125 ml) and the layers separated. The organic phase was washed successively with water (200 ml), 4 N aqueous hydrochloric acid (200 ml), and saturated brine solution (200 ml). The organic phase was treated with activated charcoal (1.4 g), dried over magnesium sulfate, filtered and the solvent removed in vacuo to yield the Compound 1b as an orange solid.
(c) 4'-Fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-carbonitrile (1c)
A dry 500 ml, 3-necked round-bottom flask equipped with a thermometer, addition funnel, and condenser was purged with nitrogen then charged with magnesium turnings (6.3 g, 0.265 mol) and sieve-dried tetrahydrofuran (60 ml). A solution of 5-bromo-2-fluorotoluene (33.5 g, 0.177 mol) in tetrahydrofuran (110 ml) was added over 40 minutes maintaining an internal temperature of 50° C. The mixture was allowed to cool to ambient temperature then transferred via cannula to a nitrogen-purged, dry, 500 ml 3-necked round-bottom flask equipped with an overhead stirrer and containing freshly fused zinc chloride (19.35 g, 0.142 mol). An internal temperature of 18° C. was maintained during the addition. A dry, nitrogen purged 50 ml round-bottom flask was charged with dichlorobis(triphenylphosphine)nickel (II) (2.32 g, 0.0035 mol) and dry tetrahydrofuran then cooled to 0° C. A 25% solution of diisobutylaluminum hydride in toluene (4.7 ml) was gradually added allowing the black mixture to warm to 20° C. A portion of the Compound 1b (2 g, 0.0095 mol) was added and the mixture aged 15 minutes at 20° C. After cooling the Grignard solution to 6° C., the nickel catalyst solution was added via cannula. The remaining Compound 1b (28 g, 0.133 mol) was added and the mixture stirred at 20°-25° C. for 2.5 hours. The reaction mixture was diluted with ethyl acetate (200 ml), and washed successively with water, and saturated brine solution. The organic extracts were stirred over activated charcoal (1.4 g) for 15 minutes, dried over sodium sulfate, filtered and the solvent removed in vacuo to yield a yellow solid. The crude product was dissolved in refluxing 85% aqueous ethanol (300 ml), aged at room temperature overnight, cooled to 0° C. then filtered. The filter cake was washed with cold aqueous ethanol and dried yielding the Compound 1c as a yellow solid (mp 98°-100° C.).
(d) 4'-Fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-carboxaldehyde
A 250 ml round-bottom flask was charged with toluene (80 ml) and the Compound 1c (30 g, 0.14 mol) and cooled to -40° C. Diisobutylaluminum hydride (98 ml, 0.147 mol, 1.5 molar solution in toluene) was added at -40° C. then aged at that temperature for 1 hour. The solution was added to a rapidly stirred solution of 3 N aqueous hydrochloric acid (700 ml) at 35° C. After stirring overnight the mixture was diluted with toluene (200 ml) and the layers separated. The toluene extract was dried over sodium sulfate, filtered and the solvent removed in vacuo to yield an oil. Chromatography on silica gel (150 g) eluted with 30% methylene chloride in hexane yielded the title compound as a cream colored solid.
EXAMPLE 2
Preparation of E-3-(4'-Fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-yl)-2-propenal
(a) E-2-Bromo-4,6-Dimethyl-Cinnamonitrile (2a)
A 5 1, 3-necked round-bottom flask, equipped with an overhead stirrer, thermometer and addition funnel was charged with 2-bromo-4,6-dimethylaniline hydrobromide (713 g, 2.54 mol) and acetone (1.9 1). The slurry was cooled to 15° C. and 48% aqueous hydrobromic acid (450 ml, 4.0 mol), was added. The mixture was cooled to -4° C. then a solution of sodium nitrite (219 g, 3.17 mol) in 400 ml of water was slowly added with vigorous stirring while maintaining an internal temperature of 0° C. Acrylonitrile (550 ml) was charged and the reaction mixture was degassed under vacuum then purged with nitrogen. Cuprous bromide (3.0 g, 0.021 mol) was charged and the mixture stirred with gradual warming to ambient temperature over 6 hours. The mixture was aged with stirring, for 6 additional hours. The mixture was concentrated under vacuum, collecting 3 1 of solvent. The residue was diluted with toluene (3 1), the organic extract was washed with 3×500 ml of water, dried over sodium sulfate, filtered, and concentrated to a volume of 1 1. The dark concentrate was charged with triethylamine (1.2 1) and heated at 80°-90° C. under nitrogen for 6.5 hours. The mixture was concentrated under vacuum to a thick slurry then diluted with toluene (2.5 1). The organic phase was extracted 2×500 ml with 3 N aqueous hydrochloric acid, 2×500 ml with water, then dried over sodium sulfate. After filtration the toluene extract was treated with activated charcoal (10 g) at ambient temperature then filtered through super-cel. Removal of the solvent in vacuo yielded a yellow oil which solidified on standing. The crude nitrile was dissolved in a solution of cyclohexane (525 ml) and hexanes (840 ml) with heating. The mixture was gradually cooled to 3° C., filtered, washed with 500 ml of cold hexane and dried in vacuo to yield the Compound 2a as a light yellow solid (mp 95°-96° C.). The crystallization mother liquors contained an additional product.
(b) E-3-(4'-Fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-yl)-2-propenoic acid nitrile (2b)
A dry 250-ml, 3-necked round-bottom flask, equipped with a thermometer, addition funnel, and condenser was purged with nitrogen then charged with magnesium turnings (3.5 g, 0.144 mol) and sieve-dried tetrahydrofuran (30 ml, water content:0.02 mg H 2 O/ml). Asolution of 5-bromo-2-fluorotoluene (23 g, 0.122 mol) in 50 ml of tetrahydrofuran was added over 45 minutes maintaining an internal temperature of 40°-50° C. This mixture was allowed to cool to 25° C. over 1 hour. The mixture was filtered into a dry, nitrogen-purged 250-ml round-bottom flask. A 1.33M solution of zinc bromide in tetrahydrofuran (48 ml, 0.064 mol) was added over 10 minutes with stirring while maintaining a temperature between 25°-30° C. A light gray slurry resulted. The aryl zinc slurry was cooled to 25° C. and the Compound 2a (24 g, 0.102 mol) and bis(triphenylphosphine)nickel dichloride (2.0 g, 0.003 mol) are successively charged. The temperature was maintained at 30° C. for 2.5 to 4 hours. Upon verification of completion, the reaction mixture was immediately added to 1.5 molar aqueous hydrochloric acid (200 ml) and extracted with ethyl acetate (100 ml). The organic phase was washed with water (150 ml), dried over sodium sulfate (25-30 g), filtered and concentrated in vacuo to give a dark yellow oil which solidified upon standing. The crude product was dissolved in methylene chloride (50 ml) then applied to a column containing silica gel (70 g) packed in hexane. The column was eluted with 600 ml of methylene chloride to yield the title compound as a yellow solid. HPLC analysis indicates a weight percent purity of 82%. The product was dissolved in hot methanol (50 ml), gradually cooled to ambient temperature and aged overnight with stirring. Crystallization was initiated by seeding at 40° C. The mixture was cooled to -15° C., aged for 30 minutes, and filtered. The crystals are washed with 15 ml of cold (-20° C.) methanol and dried in vacuo to give the Compound 2b as a light yellow solid (mp 86°-87° C.). HPLC analysis indicated a weight percent purity of 99.5%.
(c) E-3-(4'-Fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-yl)-2-propenal
A 5-1, 3-necked round-bottom flask, equipped with an overhead stirrer, thermometer and addition funnel was charged with sieve-dried toluene (1.3 1) and the Compound 2b (265 g, 1.0 mol). The mixture was cooled to -45° C. and a solution of diisobutylaluminum hydride (625 ml, 25% solution in toluene) was added over 1 hour, maintaining an internal temperature of -40° C. Upon verification of complete reaction, methanol (50 ml) was carefully added. The reaction mixture was added to a vigorously stirred mixture of 3 N hydrochloric acid (1.5 1) and ice. The mixture was heated at 45° C. for 30 minutes, recooled to ambient temperature and the phases separated. The upper (organic) phase was washed with 3×400 ml of water, dried over sodium sulfate, filtered and concentrated in vacuo to give a yellow-red oil. The crude product was filtered through a column containing silica gel (1.25 kg) eluting with methylene chloride to yield, after concentration, the title compound as a yellow solid (mp 78°-81° C.).
EXAMPLES 3-8
Following the general procedures of Examples 1 and 2, the following compounds of the Formula (IV) are prepared from the appropriate starting material.
______________________________________CompoundNumber R.sub.1 R.sub.2 R.sub.4 X Y______________________________________3 3-Cl 5-Cl --CN 4'-F H4 3-Cl 5-Cl --CH═CH--CN 4'-F H5 3-CH.sub.3 5-Cl --CN 3'-CH.sub.3 4'-F6 3-CH.sub.3 5-Cl --CH═CH--CN 3'-CH.sub.3 4'-F7 3-CH.sub.3 5-CH.sub.3 --CN 3'-CH.sub.3 5'-CH.sub.38 3-CH.sub.3 5-CH.sub.3 --CH═CH--CN 3'-CH.sub.3 5'-CH.sub.3______________________________________
EXAMPLES 9-14
The reduction of the compounds of Examples 3-8 under standard conditions yields the following compounds of the Formulae (II) and (III):
______________________________________CompoundNumber R.sub.1 R.sub.2 X Y______________________________________ 9 and 10 3-Cl 5-Cl 4'F H10 and 12 3-CH.sub.3 5-Cl 3'CH.sub.3 4'F11 and 14 3-CH.sub.3 5CH.sub.3 3'CH.sub.3 5'CH.sub.3______________________________________
EXAMPLE 15
Preparation of Methyl E-3-(4'-fluoro-3,3',5-trimethyl-[1,1'-biphenyl]-2-yl)-2-propenoate
(a) E-2-bromo-4,6-dimethyl-cinnamate
A 250 ml 3-necked, round-bottom flask, equipped with an overhead stirrer, thermometer and addition funnel was charged with 2-bromo-4,6-dimethylaniline hydrobromide (25 g, 0.089 mol), and acetone (66 ml). The slurry was cooled to -4° C. and 48% aqueous hydrobromic acid (15.8 ml) was added. A solution of sodium nitrite (7.6 g) in water (10 ml) was added over 0.5 hour maintaining an internal temperature of 0° C. After 0.25 hour age, methyl acrylate (26.4 ml) was charged and the reaction mixture degassed under vacuum then purged with nitrogen. Cuprous bromide (0.105 g) was added and the mixture stirred at 25° C. for 4 hours. The solvent was removed in vacuo, toluene (100 ml) was charged and the aqueous phase removed. The toluene extract was washed with water (2×30 ml), dried over sodium sulfate, filtered and concentrated in vacuo to give a yellow oil. Tri-n-butylamine (52 ml) was charged and the mixture heated at 120°-125° C. for 12 hours. The reaction was monitored by thin layer chromatography (tlc) (silica gel plates, eluting with 5% ethyl acetate in hexane). The mixture was poured into ice water (100 ml) and acidified with 3 M aqueous hydrochloric acid then extracted with toluene. The toluene extract was washed with 3 M aqueous hydrochloric acid, water, dried over sodium sulfate, filtered, and concentrated in vacuo to give a dark yellow oil. Chromatography on silica gel (200 g), eluted with 5% ethyl acetate in hexane yielded the title compound as a light yellow liquid. NMR 60 (60 MHz, CDCl 3 , δ): 7.60 (d, 1H, J=16 Hz), 7.20 (bs, 1H), 6.80 (bs, 1H), 6.00 (d, 1H, J=16 Hz), 3.71 (s, 3H), 2.28 (s, 3H), 2.22 (s, 3H).
(b) Methyl E-3-(4'-Fluoro-3,3'-5-trimethyl-[1,1'-biphenyl]-2-yl)-2-propenoate
A dry 50 ml round bottom flask was charged with magnesium turnings (0.916 g, 38.1 mmol) and sieve-dried tetrahydrofuran (15 ml). A solution of 5-bromo-2-fluorotoluene (4.5 g, 23,8 mmol) in tetrahydrofuran (10 ml) was added over 15 minutes maintaining an internal temperature of 45° C. The resulting solution was transferred to a dry 50 ml round bottom flask containing freshly fused zinc chloride (2.0 g, 14.9 mmol) and aged with stirring for 0.5 hour at 25° C. After mixture was cooled to -5° C., Compound 15a (5.0 g, 18.58 mmol) and bis(triphenylphosphine) nickel dichloride (0.607 g, 0.9 mmol) were charged and the mixture heated at 20°-25° C. for 12 hours, at which time complete disappearance of Compound 15a was evident from HPLC analysis. The mixture was diluted with cold 3 M aqueous hydrochloric acid and extracted with ethyl acetate. The ethyl acetate extract was washed with water, dried over magnesium sulfate, filtered and concentrated in vacuo to yield a yellow oil. Chromatographic purification on a silica gel column (100 g) eluted with 1.6 1 of hexane and 1.6 1 of 30% methylene chloride in hexane yielded the title compound as a yellow oil. NMR (60 MHz, CDCl 3 ,δ), 7.50 (d, 1H, J=15 Hz), R 7.25-7.00 (bm, 5H), 5.65 (d, 1H, J=15 Hz), 3.60 (s, 3H), 2.35 (s, 3H), 3.25 (bs, 6H). | A novel process for the preparation of intermediates in the totally synthetic antihypercholesterolemic agents, 6-[2-[1,1'-biphenyl]-2-yl-ethenyl] pyranones, involving a highly efficient nickel catalyzed aryl cross-coupling reaction is disclosed. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. provisional application No. 60/459,163, filed on Mar. 31, 2003, incorporated herein by reference in its entirety. The subject matter of this application is related to U.S. patent application Ser. No. 10/673,383 filed on Sep. 26, 2003 as attorney docket no. Doshi 57-6-22-18-34, incorporated herein by reference in its entirety (herein “Doshi '03”) and U.S. patent application Ser. No. 10/673,056 filed on Sep. 26, 2003 as attorney docket no. Alfakih 1-1-1-6-2, also incorporated herein by reference in its entirety (herein “Alfakih '03”)
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to optical networks and, more specifically, to cost reduction and restoration time improvement in mesh optical networks.
[0004] 2. Description of the Related Art
[0005] Reliability and cost are two parameters that drive the design of modem day networks. To support high reliability, it is typical to provide path redundancy for services. To control costs, it is common to attempt to maximize the utilization of available resources and generate redundant paths in consideration of multiple-cost criteria.
[0006] Generally, reliability is supported by providing both a primary path and a restoration path for each service in the network. In the event of a failure along the primary path for a service, the service is switched over to the associated restoration path. For optical mesh networks, one challenge is to support restoration times that are comparable to those provided by SONET/SDH networks with self-healing rings (e.g., 10-100 ms restoration times). To help reduce network restoration time in optical mesh networks, a number of approaches have been considered, including improving restoration signaling and associated algorithms, and improving the switching speed of cross-connection infrastructure switching elements.
SUMMARY OF THE INVENTION
[0007] One factor that determines a lower bound on restoration time is the maximum number of cross-connections to be performed at a single network element in the event of a failure. Assuming everything else is constant, the larger the number of cross-connections, the longer the restoration time. Thus, path planning can be performed which minimizes restoration time by carefully selecting primary and restoration paths for demands within a network such that the worst-case number of cross-connections is minimized across all possible single-event failures in the network.
[0008] On the other hand, the choice of primary and restoration paths for demands in a network can also affect the cost of a network where the magnitude of the effect on cost can be different depending on the cost metric that is considered (e.g., administrative weight, bandwidth, distance cost, and/or the degree to which restoration bandwidth between multiple disjoint primary paths can be shared).
[0009] Problems in the prior art are addressed in accordance with principles of the present invention by a method and apparatus for restoration-path planning that minimizes network cost while meeting an upper bound on restoration time associated with single-event failures in a mesh network.
[0010] In certain embodiments, network-cost minimization is a function of maximizing the utilization of network resources and can include the maximization of sharing of network resources (e.g., restoration bandwidth), while restoration time is bounded by application of an optimization that reduces the worst-case number of cross-connections that must be performed in a network in the event of a single element (e.g., node or link) failure.
[0011] One optimization involves two phases. The first phase of the optimization involves finding two node-disjoint paths for each service demand within a network such that the maximum link bandwidth in the network is minimized and the link bandwidths within the network are substantially leveled. The second phase involves identifying the primary and restoration paths for each service demand within the network such that the worst-case number of cross-connections at any node within the network is minimized across all possible single-event failures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which:
[0013] [0013]FIG. 1 illustrates a method for minimizing cost within a network while meeting restoration-time requirements via the minimization of cross-connections within the network according to one embodiment of the present invention.
[0014] [0014]FIG. 2 illustrates another method for minimizing cost within a network while meeting restoration-time requirements via the minimization of cross-connections within the network according to another embodiment of the present invention.
DETAILED DESCRIPTION
[0015] Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
[0016] Cost and Restoration Time
[0017] Network designers typically are faced with more than one constraint in the process of network design. Although it may be important to a service provider to find a network path plan that meets the restoration-time goals of a client, it is also important, from a competitive perspective, for the service provider to do so with minimum cost. To this end, one embodiment of the present invention combines restoration-time-minimization techniques such as those discussed in Alfakih '03 with resource-sharing-maximization techniques such as those discussed in Doshi '03. As can be appreciated by one skilled in the art, there are a number of different ways to implement a solution to this problem. In the following, two exemplary procedures are discussed.
[0018] Cost Relaxation with Fixed Restoration-Time Bound
[0019] One embodiment of the present invention is illustrated by the procedure of FIG. 1. As shown in steps 102 and 104 , the network topology and traffic demands, respectively, for the network are input. In step 106 , the variable MinXC# is set to the graph-theoretical minimum number of cross-connections (XCs) for the network topology and traffic demands that were input in steps 102 and 104 . Also, in step 106 , the variable k is initialized to CostDelta, a value (e.g., one) that represents the cost relaxation step size that will be used by the procedure. In step 108 , set A is set equal to the set of the primary/restoration path plans for the network that minimize cost (e.g., maximizes sharing per Doshi '03).
[0020] Next, in step 110 , the variable MinCost is set equal to the maximum cost of any of the path plans in set A. The “cost” can be a bandwidth cost, administrative cost, distance cost, or a combination of one or more of those or other cost metrics that are important to the network planner, other than restoration time, which is considered separately in this implementation.
[0021] In step 112 , set B is set equal to the set of primary/restoration path plans for the network whose worst-case number of XCs required at any one node after considering all possible single-event failures is less than or equal to XC#max, where XC#max is a bound on the maximum number of cross-connections that can be tolerated in the network according to some quality-of-service agreement between the service provider and the client. So, for example, if the service agreement is a bound of 300 ms, and the time for a single cross-connection is 10 ms, XC#max would be 30. XC#max, in actual implementations, may be a function of a number of different variables including traffic, message bundle sizes, signaling bandwidth, signaling processor speed, and message buffers sizes, as would be understood to one skilled in the art. XC#max is always greater than or equal to MinXC# and is sometimes initialized to be some predefined offset from MinXC#, for example XC#max=MinXC#+XC#delta.
[0022] Next, in the test of step 114 , set C is assigned to be the intersection of sets A and B and this intersection is compared with the null set {0}. If C is not equal to the null set, then this means that each of the path plans in C has a maximum number of cross-connections that is within the service agreements of the network operator and also has minimum cost. In this case, the method terminates at step 116 with a set C of one or more path plans that meet the restoration time goals of the service provider at minimal cost.
[0023] If the intersection of the two sets in step 114 is null, then, in step 118 , set A is set equal to the set of all primary/restoration path plans whose cost is less than (MinCost+k). In other words, the cost constraint is relaxed by one unit of CostDelta. In step 120 , k is incremented by CostDelta, and, in step 122 , the value of k is checked against the variable CostDeltaLimit, which had been initialized to a value (e.g., 20) that would prevent the procedure from selecting a network plan whose cost was beyond allowable bounds. If the value of k is too large, then the procedure completes with an error in step 124 . If not, then processing returns to step 114 as described earlier.
[0024] In one or more embodiments, step 108 of FIG. 1 can involve use of algorithms that use multiple-cost criteria for primary/restoration path selection (see, e.g., Doshi '03), and step 112 can involve use of a multiple-phase optimization that yields path plans that exhibit a minimum number of cross-connections required at any given node in the event of a failure (see, e.g., Alfakih '03). As described in Alfakih '03, the first phase involves finding two node-disjoint paths for each service demand within a network such that the maximum link bandwidth in the network is minimized and the link bandwidths within the network are leveled. The second phase involves further constraining a commercial solver with cost goals and identifying the primary and restoration paths for each service demand within the network such that the worst-case number of cross-connections at any node within the network is minimized across all possible single-event failures within the cost constraints.
[0025] Dual Phase Solver
[0026] A two-phase embodiment of the present invention is illustrated by the procedure of FIG. 2. In step 202 , the network topology and traffic demands, respectively, for the network are input. In step 204 , a parameter WC#XC (worst-cast number of cross-connects) is set to a value between (1) the quantity MinXC# (minimum cross-connect number), a graph theoretical minimum number of cross-connections given the network topology and traffic demands that were input in step 202 , and (2) the quantity WC#XC_Limit, a limit on the largest value of the WC#XC parameter that would be considered acceptable based on, e.g., a service-agreement requirement on network restoration time.
[0027] In step 206 (phase D, a commercial solver is run to find two node-disjoint paths for each service demand within the network such that the maximum link bandwidth in the network is minimized and the link bandwidths within the network are substantially leveled. (Two paths are referred to as node-disjoint if they have no intermediate (i.e., transit) nodes in common.) Note that one parameter used by the solver is the current value of WC#XC. Its role in the solver is to essentially limit the solution space from which the solver can select the path pairs.
[0028] In step 208 , a test is performed to see if the solver found a feasible solution in step 206 (given the current value of WC#XC). If not, then, in step 210 , the value of WC#XC is increased by a small increment (i.e., the constraint is relaxed somewhat), and the new value of WC#XC is then tested in step 212 to determine if it exceeds the limit WC#XC_Limit. If it does exceed the limit, then the procedure terminates in step 214 . Otherwise, the procedure returns to step 206 .
[0029] For a suitably large value of WC#XC_Limit, in step 206 , a feasible solution will eventually be found and the test of step 208 will then pass. In this case, step 216 (phase II) is performed. Here, a solver is used for path planning. The result of the solver is that one path of each node-disjoint path pair that was found in step 206 is assigned to be a primary path for the pair's associated demand, and the other path is assigned to be the restoration path for the demand. This path planning is performed to find a path plan from within the solution space, which path plan has the characteristic that the worst-case number of cross-connections at any node within the network is minimized across all possible single-event failures.
[0030] In step 218 , a test is performed to see if the worst-case number of cross-connections of the resulting path plan is less than or equal to the current value of WX#XC. If the test of step 218 passes, then, in step 220 , a cost for the path plan is calculated, and the plan and its cost are saved. Next, in step 222 , a constraint is formulated and added to the primary/restoration path assignment that prevents the identical path plan from being obtained the next time step 216 is performed. The path planning is then reattempted in step 216 with the additional constraint.
[0031] Eventually, the test in step 218 will fail when no more path plans can be found in step 216 that satisfy the constraint that the worst-case number of cross-connections is less than or equal to WC#XC. In this case, as shown in step 224 , all the solution-limiting constraints previously added in step 222 are eliminated. In step 226 , constraints or conditions are added to the load-balancing problem of step 206 to prevent the previous path-pair solution from being generated. The modified load-balancing problem is then re-solved in step 206 at the current value of WC#XC.
[0032] This process is repeated for increasing values of WC#XC until eventually the value exceeds WC#XC_Limit at step 212 , in which case the procedure terminates in step 214 . At this point, assuming WC#XC_Limit was chosen sufficiently large, a number of primary/restoration path plans have been stored along with their costs. These plans all have an acceptable number of worst-case cross-connections (i.e., no worse than WC#XC_Limit). The user can search these path plans for the minimum-cost plan, or can perform a tradeoff between cost and restoration time within this limited set of plans.
[0033] Note that, alternatively or additionally, step 216 can include constraints that drive the solver toward minimum-cost path plans. These constraints can be derived from multiple-cost criteria including consideration of sharing of restoration bandwidth between disjoint path failures as discussed in Doshi '03.
[0034] Path Costs
[0035] Generally, there are a number of different metric that can be applied in calculating paths for demands within a network. Various algorithms including shortest path, minimum bandwidth, and fewest hops have been proposed in the art. As networks become more complex, these cost criteria become more complex as well. For example, the cost of path administration and reconfiguration costs of various types (measured in, for example, restoration time) can also be considered along with bandwidth costs and administrative costs. Further, multiple cost criteria, weighted relative to their importance to the path-planning algorithm, can be considered concurrently. As discussed in Doshi '03, link state information (e.g., bandwidth allocation) and sharing information can be used to compute cost-efficient connection routes within a network. For path computation, link state can be reduced to an equivalent link cost and then route-computation algorithms can be considered that minimize the total path cost—where the path cost is considered to be the sum of the link costs. Depending on the possibility of sharing bandwidth on the restoration path, link costs will be different when restoration bandwidth can be shared compared to the when it cannot. (Note that when network bandwidth can be shared, sharing information can be used to compute more cost-efficient paths through the network. This can be achieved by incorporating sharing information in the link-cost metric). The two cases are described below.
[0036] No-Sharing
[0037] Link-cost calculation can be based on the administrative weight (AW) of the link, the link capacity (LC), and link's available capacity (AC). Under light and medium link utilization (LU), where LU is less than a specified utilization threshold (UT) (i.e., LU≦UT), link cost w is set equal to the AW, i.e., w=AW. Hence, under light load conditions, the link-calculation algorithm will assign links to services according to the preferences (i.e., administrative weights) assigned by the network operator. When the link load is high (LU>UT), however, the link weights are preferably calculated with the objective of load balancing and revenue maximization. The generic formula for the link cost w in this high link utilization region is based on the inverse of available capacity:
w = AW · MWC A C f ( 1 )
[0038] where MWC is the maximum weight coefficient (i.e., an additional scaling factor introduced to provide continuity between the two regions of light and heavy loads) and f is an exponentiation factor (nominally set to 0.4) used to modify the available capacity variable AC. Motivation, a detailed model, and additional numerical support for this approach of weight calculation based on the inverse of available capacity are described in Dziong, Z., “ATM Network Resource Management,” McGraw-Hill, 1997, (herein “Dziong '97”) incorporated herein by reference in its entirety.
[0039] Sharing
[0040] When sharing information is available, it can be used to compute more cost-efficient (more optimal) primary and restoration paths. For example, an algorithm can be designed to compute for each possible primary path the lowest cost restoration path by utilizing the sharing information. Then from the set of all primary and restoration paths, the pair that requires least amount of additional capacity can be chosen. This path computation algorithm using the sharing information can give considerably better paths then an algorithm using no sharing information.
[0041] Sharing information can be used in finding the least cost restoration path for a given primary path. It requires adjustment of the link cost (lowering of it) based on the amount of sharing that is possible on a link along the restoration path of a particular primary path. This can be achieved by computing the sharing degree of each link in the network given the primary path. (Note that only links that are disjoint to the primary path need to be considered).
[0042] The sharing degree is defined as the maximum number of additional (unit bandwidth) primary services (along the proposed primary path) that can be added to the link without increasing the restoration bandwidth requirement of the link. In a sense, this metric provides a network planner with an idea of the restoration headroom on a link with respect to the proposed primary path. The higher the sharing degree, intuitively, the better the choice of the primary path for the new service, since a larger sharing degree for a primary path would allow future demands to be added along that path without the need to reserve additional restoration bandwidth.
[0043] Sharing degree can be calculated from an aggregate node-link vector V nla representation of sharing information and a primary path node-link vector V pnl representation according to the following relationship:
SD =the maximum value m for which max{ m·V pnl +V nla }=RB,
[0044] where RB is the current reservation bandwidth on the link under consideration.
[0045] A less accurate measure of sharing degree can be calculated using a compact representations of the aggregate node-link vector. Note that, here, less accurate means that the sharing degree only provides a conservative indication of which links may be better, but it does not provide the exact bandwidth available for sharing for a particular primary path.
[0046] Sharing degree can be calculated from the node-aggregate vector V na representation of sharing information and the primary path node vector V pn representation according to the following relationship:
SD =the maximum value m for which max{ m·V pn +V na }=RB.
[0047] Sharing degree can also be calculated using the binary representation of node-link or node vector. In case availability of sharing information in terms of the binary node-link vector V nlb for a link, the sharing degree can be computed by first deriving a binary primary path node-link vector V pnlb from the primary path node-link vector V pnl (in the similar fashion as V nlb can be derived from V nla ), then taking an OR of the V pnlb (binary primary path node-link vector) and V nlb (binary node link vector representation of the sharing information on the link), and then taking the bit AND of the resulting vector. This will result in a sharing degree of one if the sharing is possible and zero otherwise. Note that the sharing degree obtained in this manner using the binary node-link vector does not give the exact amount of sharing that is possible on the link for the primary path. It only indicates that if the sharing is possible or not.
[0048] Similarly, a more crude sharing degree can be derived by using the binary node vector information.
[0049] In one implementation, the link cost is calculated according to the following equation, which considers the sharing degree (SD) calculated as discussed earlier:
w = AW ( 1 + SD ) .
[0050] When bandwidth sharing is possible for a link, it would appear that there is no immediate bandwidth-related cost for new restoration path reservation using that link. However, when applying the Markov decision theory framework described in Dziong '97, there is a cost. This follows from the fact that the cost should be considered during the whole connection-holding time, not just at the instant of a new connection arrival. The Markov process makes it possible to consider the probabilistic cost of using the link, since, even if sharing is possible at the moment of connection arrival, in the future, with some probability, the other shared connections can be terminated and the new connection will be the sole occupant of the reserved bandwidth on that link, and hence incur a cost for reserving additional restoration bandwidth in the network. While exact calculation of such a cost seems to be very difficult, if possible, one can use this argument to employ a non-zero link cost even when sharing is possible. In one implementation, this fact can be accommodated by calculating link cost according to the following equation:
w = AW ( 1 + b · SD ) ( 2 )
[0051] where b is a specified coefficient.
[0052] While the embodiments of this invention have been discussed with respect to implementations that pre-compute pathways, they may equally well be applied to implementations where some or all of the computation or optimization of alternative routes is computed after the failure is detected and in some cases may involve fault isolation in the alternative route determination.
[0053] While this invention has been described with respect to specific costs typically minimized in path planning algorithms inclusive of costs that are a function of sharability of network resources, other costs and multiple cost criteria can be considered, as would be understood to one skilled in the art.
[0054] While this invention has been described with respect to restoration associated with situations involving single-point failures, the concepts, and in particular, the link-state description, can be extended to multiple-point failure situations, as would be understood to one skilled in the art.
[0055] While this invention has been described with reference to illustrative embodiments, this description should not be construed in a limiting sense. Various modifications of the described embodiments, as well as other embodiments of the invention, which are apparent to persons skilled in the art to which the invention pertains are deemed to lie within the principle and scope of the invention as expressed in the following claims.
[0056] Although the steps in the following method claims, if any, are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those steps, those steps are not necessarily intended to be limited to being implemented in that particular sequence. | A restoration path planner minimizes cost while meeting restoration-time constraints of a network by reducing the worst-case number of cross-connections that must be performed in a network in the event of a single element failure. The planner involves optimization that identifies primary and restoration path plans for demands within the network such that the worst-case number of cross-connections at any node within the network is minimal and/or bounded. Embodiments further constrain the cost of the path plan. In one embodiment, restoration time is bounded and cost is relaxed until a solution is found. In another embodiment, the restoration time bound is relaxed to a limit while path plans and their costs are stored. These plans can later be chosen amongst for the desired balance of cost and restoration time. At least one approach to minimization of network cost involves maximizing sharing within restoration path plans. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a needle thread holding device in a sewing machine provided with a thread cutting unit.
According to a conventional sewing machine having a thread cutting unit, a thread drawn from the lastly stitched point of a workpiece or a fabric is required to be cut when the sewing operation is terminated. In this case, if the needle thread length between a needle eye and the exact cutting point is insufficiently short, the needle thread may be easily disengaged from the eye of the needle at a start phase of a subsequent sewing operation. Therefore, the thread cutting must be made so that sufficient residual thread length can be provided between the needle eye and the exact cutting point in order to retain the thread to be still engaged with the thread hole at the start timing of the subsequent sewing operation. However, if the residual thread length is excessively long, the residual thread may be stitched in an entangled manner at the next sewing operation in a nest fashion, to thereby degrade stitching quality.
To avoid these drawbacks, a thread holding device which is adapted to hold the needle thread has been provided so as to provide optimum length of the residual needle thread at the time of thread cutting. That is, the thread holding device holds the cut end portion of the thread after the thread cutting operation in order to provide sufficiently small residual length of the thread yet preventing the thread from being disengaged from the eye of the needle in the next sewing operation. However, in the conventional thread holding device, excessively high tension may be imparted on the needle thread during a time period in which the needle thread is released from the thread holding device thereby overcoming the thread retaining force thereof in accordance with the feeding of the workpiece after the start of the subsequent sewing operation. Accordingly, a stitch balancing thread tension may be disorganized, and a stitched workpiece may be shrunk.
In another aspect, at a start timing of the sewing operation, a presser foot located at its non-operative position is moved downwardly to its operative position for depressing the workpiece onto a workpiece supporting surface of the sewing machine. However, in order to perform prompt sewing operations, prior to the depression of the workpiece by the pressure foot, the sewing machine may have been energized for starting actual stitching. In this case, however, the workpiece is not stably held. Therefore, a knot between the needle thread and a bobbin thread is not provided to cause a skip stitching. In a conventional sewing machine having an automatic pressure bar lifter, the sewing machine is energized after the workpiece is stabilizingly held by the pressure foot. However, such sequence does not meet with the prompt sewing work, and an operator may be dissatisfied with such dull sewing sequence if compared with the conventional rhythmical sewing work, i.e., sewing start prior to the complete depression of the workpiece by the pressure foot.
SUMMARY OF THE INVENTION
It is therefore, an object of the present invention to overcome the above described drawbacks and to provide an improved needle thread holding device in a sewing machine capable of providing a residual needle thread having sufficiently small length at the time of thread cutting in the terminal phase of the sewing operation yet preventing the thread from being released from an eye of a needle at the start phase of the subsequent sewing operation, and avoiding disorganized stitch balancing thread tension.
Another object of the invention is to provide such a needle thread holding device in which no skip stitch occurs even upon the energization of the sewing machine prior to an exact depression of a pressure foot against a workpiece.
These and other objects of the invention will be attained in the present invention by providing a needle thread holding device in a sewing machine, the sewing machine including a needle for passing a needle thread therethrough and having upper needle position and a lower needle position, workpiece supporting means, a pressure foot selectively movable between an operative position for pressing the workpiece onto the workpiece supporting means and a non-operative position spaced away from the workpiece, sewing machine energization signal generating means adapted to generate a sewing machine energization signal in accordance with a manipulation by an operator, a thread cutting unit for cutting threads stitched into the workpiece at a terminal phase of a sewing operation, and an improvement comprising holding means, drive means, pressure foot position detection means, and control means. The holding means is provided at the pressure foot or at a position adjacent thereto. The holding means is selectively movable between a needle thread clamping position for clamping the needle thread which has been cut by the cutting unit and a needle thread releasing position for releasing the cut needle thread. The drive means is connected to the holding means for selectively moving the holding means to one of the needle thread releasing position and the needle thread clamping position. The pressure foot position detection means is provided for detecting a position of the pressure foot and for generating a signal indicative of the non-operative position of the pressure foot. The control means is connected to the pressure foot position detection means for maintaining the holding means at its thread clamping position when the pressure foot is at its non operative position in accordance with the non-operative position signal after cutting the needle thread.
In one embodiment of the invention, the control means is also connected to the sewing machine energization signal generating means and the needle position detector for maintaining the holding means at its thread clamping position during a predetermined number of stitches at a starting phase of a next sewing operation in accordance with the sewing machine energization signal from the sewing machine energization signal generating means after cutting the needle thread and, in accordance with the needle position signal from the needle position detector.
Upon completion of the sewing operation, the pressure foot is positioned at its operative position (workpiece pressing position), and the thread stitched into the workpiece and drawn therefrom is subjected to cutting by the cutting unit while the workpiece is pressedly supported on the workpiece supporting surface. In this case, the holding means positioned at the pressure foot or at a position adjacent thereto is positioned on a standby position (thread releasing position), so that the cut needle thread is releaseably maintained.
When the pressure foot is shifted from its operative position to the non-operative position after thread cutting, the pressure foot position detection means detects the non-operative position of the pressure foot and generates the position detection signal. In response to the signal, the control means acknowledges that the pressure foot is moved away from the workpiece, and at the same time, the control means controls the drive means so that the holding means is moved from its thread release position to the thread clamping position. Accordingly, the cut needle thread is clamped by the holding means. While maintaining this clamping state, if the sewing machine energization signal is issued from the signal generating means, the control means maintains this needle thread clamping state during a predetermined number of stitches at a starting phase of the sewing operation in accordance with the needle position signal sent from the needle position detector. Thereafter, the control means controls the drive means, so that the holding means is moved from its clamping position to the thread releasing position, to thus release the needle thread from the holding means.
Therefore, even if the needle thread is subjected to cutting in such a manner that the thread length between an eye of the needle and the exact cut position is small, thread cast-off and disorganization of the stitch balancing thread tension can be obviated at the starting phase of the next sewing operation. Further, even if the new sewing operation is started prior to the complete seating of the pressure foot onto the workpiece, skip stitch can be eliminated, and a first knot is surely provided by the needle thread and the bobbin thread at the first stitch. Accordingly, prompt sewing operation is achievable for an expert operator without any sense of incongruity.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings;
FIG. 1(a) is a plan view showing a pressure foot and neighboring components in a sewing machine according to one embodiment of this invention;
FIG. 1(b) is a plan view particularly showing a movable blade used in one embodiment of this invention;
FIG. 1(c) is a cross-sectional view showing front end portions of the movable blade and a stationary blade;
FIG. 2(a) is a side elevational view showing an arm portion of the sewing machine according to the embodiment of this invention;
FIG. 2(b) is an enlarged side elevational view showing an arrangement of a pressure foot and associated movable and stationary blade and spring member.
FIG. 3 is a rear partial view showing the arm portion;
FIG. 4 is a partial bottom view showing a pressure foot operation mechanism according to the embodiment of this invention;
FIG. 5 is a partial front view showing the arm portion;
FIG. 6 is a block diagram showing a control means of the sewing machine according to one embodiment of this invention; and
FIG. 7 is a timing chart for description of operational timed relationship among various signals.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A needle thread holding device in a sewing machine according to one embodiment of the present invention will be described with reference to accompanying drawings.
In FIGS. 2(a) and 2(b), a sewing machine has an arm portion 1 which vertically movably supports a needle bar 2 whose lower end portion is attached with a needle 2a. The needle bar 2 is reciprocally movable in a vertical direction in synchronism with a movement of a thread trapping means (not shown) provided in a bed portion 3 in order to obtain stitching to a workpiece fabric. Further, the arm portion 1 vertically movably supports a pressure bar 4 whose lower end portion is provided with a pressure foot 5 formed with a needle passing hole 5a. By the vertical movement of the pressure bar 4, the pressure bar 4 has an operative position and a non operative position. In the operative position, the pressure foot 5 depresses the workpiece, at a position adjacent the needle descent position, toward a workpiece supporting surface 3a of the bed portion 3, whereas in the non operative position, the pressure foot 5 is moved away from the workpiece supporting surface 3a (the pressure foot 5 is moved upwardly).
The pressure foot 5 is formed with a guide passage 6 extending in a workpiece feeding direction and in parallel with the workpiece supporting surface 3a. In upper and lower wall surfaces of the guide passage 6, there are provided a thread catching spring 7(rectangular shape in FIG. 1(a), and positioned at the upper wall surface of the passage 6 as shown in FIG. 2(b)) and a stationary blade 8(rectangular shape in FIG. 1(a) and positioned at the lower wall surface of the passage 6 as shown in FIG. 2(b)). Further, as shown in FIGS. 1(b), 1(c) and 2(b), a movable blade 9 is slidably disposed within the guide passage so as to pass through a space defined between the thread catching spring 7 and the stationary blade 8. The movable blade 9 has an intermediate portion formed with an elongated slot 10, and the pressure foot 5 is provided with a pin 11 which extends through the slot 10. By the engagement between the pin 11 and the slot 10, slidable moving range of the movable blade 9 is defined. The thread catching spring 7 is adapted to tightly hold a leading end portion of the needle thread which has been cut by the blades at a position between the movable blade and the thread catching spring 7. One end portion (rightmost edge portion) of the thread catching spring 7 is positioned more rightwardly than a rightmost end portion of the stationary blade 8 as shown in FIG. 1(a), whereas leftmost edge portions of the spring 7 and the blade 8 are aligned with each other as shown in FIG. 2(b).
Further, as shown in FIGS. 1(b) and 1(c), the movable blade 9 has a front portion provided with a blade edge 9a, a notched portion 12 and a thread handling portion 13, and has a rear portion provided with a linking pin 14 protruded therefrom. The blade edge 9a is adapted to cut the needle thread T passing through the eye of the needle 2a in cooperation with the stationary blade 8.
More specifically, as best shown in FIG. 1(c), the movable blade edge 9a has a frusto-semi-spherical and hollow shape obliquely extending downwardly from a lower surface of the movable blade body. That is, a hollow portion 9b is formed in the blade edge 9a so as to provide an acute edge, and an axis of the hollow portion 9b extends obliquely as shown in FIG. 1(c). Further, the stationary blade 8 has a tip end face 8b which is slanted in a direction parallel to the axis of the hollow portion 9b of the blade edge 9a.
The notched portion 12 is adapted for trapping the needle thread, and the thread handling portion 13 is adapted to direct the needle thread T into the notched portion 12 along its slanting edge when the movable blade 9 is moved leftwardly in FIG. 1(a).
As shown in FIGS. 1(a) through 2(b), the movable blade 9 has a standby or a thread releaseable position P1 shown by a solid line. In this standby state, the thread handling portion 13 is positioned at one side (left side in FIG. 2(a)) of and adjacent to the needle passing hole 5a. Further, the movable blade 9 has a trapping position P2 shown by a broken line where the thread handling portion 13 moves across the needle passing hole 5a to be placed on another side (right side in FIG. 2(a)). Furthermore, the movable blade 9 has a thread cutting position or thread clamping position P3 where the blade edge 9a engages the stationary blade 8 and at the same time the blade slidably moves (moves leftwardly in FIG. 2(a)) over the thread catching spring 7 for clamping the cut thread between the movable blade 9 and the spring 7.
As shown in FIGS. 2(a), 2(b) and 3, a bracket 15 is fixedly attached to a rear face of the arm portion 1, and a needle thread trapping solenoid 17 and a needle thread cutting solenoid 18 are mounted in a vertical orientation on the bracket 15 with a predetermined space therebetween. These solenoids 17 and 18 have a compatible or a commonly used plunger 16. In the vicinity of the plunger 16, a supporting plate 19 extends from the bracket 15 for pivotably supporting an intermediate portion of a connecting lever 20 and one end of the connecting lever 20 is connected to the plunger 16. Further, a supporting piece 21 also extends from the bracket 15, and an operation shaft 22 vertically movably passes through the supporting piece 21. One end (upper end in FIGS. 2(a) and 2(b)) of the operation shaft 22 is pivotally connected to another end of the connecting lever 20.
A supporting arm 23 is fixed to the bracket 15, and an intermediate portion of a L-shaped intermediate lever 24 is pivotably connected to the supporting arm 23. The L-shaped intermediate lever 24 has a rear arm portion 24 pivotably connected to another end (lower end) of the operation shaft 22, and has a bifurcated portion 25 engageable with the linking pin 14 protruding from the movable blade 9. Further, a pair of upper and lower adjusting nuts 26 and 27 are threadingly engaged with the operation shaft 22 at opposite sides with respect to the supporting piece 21, and a first coil spring 28 is disposed over the operation shaft 22 between the upper nut 26 and the supporting piece 21. A second coil spring 29 is also provided between the lower nut 27 and the supporting piece 21. By changing engagement positions of the adjusting nuts 26 and 27, biasing forces of the coil springs 28 and 29 can be controlled.
With the structure of the arm portion 1, when the both solenoids 17 and 18 are held in deenergized states, the movable blade 9 has the standby or thread releasable position P1 shown by the solid line because of the balancing of the biasing forces of the two coil springs 28 and 29 through the operation shaft 22 and the intermediate lever 24. In this state, the thread handling portion 13 at the front end of the movable blade 9 is positioned at the left side of the needle passing hole 5a as described above. On the other hand, upon only energization of the upper solenoid 17, i.e., the needle thread trapping solenoid 17, the plunger 16 is moved upwardly, so that the operation shaft 22 is moved downwardly through the connecting lever 20 to angularly rotate the L-shaped intermediate lever 24 in a counterclockwise direction in FIGS. 2(a) and 2(b), to thereby move the movable blade 9 rightwardly through the linking pin 14. As a result, the thread handling portion 13 moves across the needle passing hole 5a to have the thread trapping position P2.
Furthermore, upon only energization of the lower solenoid 18, i.e., the needle thread cutting solenoid 18, the plunger 16 is moved downwardly, so that the movable blade 9 is slidably moved leftwardly in FIGS. 1(a), 1(b) and 1(c) through the connecting lever 20, the operation shaft 22 and the intermediate lever 24. Therefore, the blade edge 9a engages the stationary blade 8, and has the cutting or thread clamping position P3 where the blade 9 is slidingly moved with respect to the thread catching spring 7.
In the above structure, the thread catching spring 7 and the movable blade 9 constitute a holding means, and the solenoids 17, 18, the connecting lever 20, the operation shaft 22, the intermediate lever 24 and the coil springs 28 29 constitute a drive means M which performs positional switching of the holding means between the cutting or thread clamping position P3 and the standby or thread release position P1.
As shown in FIGS. 4 and 5, an oil pan 31 is disposed below the bed portion 3 for accumulating lubricating oil so as to supply the oil to various mechanical components of the sewing machine. The oil pan 31 is provided with a manipulation mechanism for manipulating the vertical motion of the pressure foot 5 by a knee.
As best shown in FIG. 5, an operation rod 39 is provided which is vertically movable and extends through the oil pan 31. The operation rod 39 is operatively coupled to the pressure foot through a conventional linking mechanism (not shown). The operation rod 39 has a descent position shown by a solid line in FIG. 5 where the pressure foot 5 has an operative position through the linking mechanism. The operation rod 39 has an ascent position shown by two dotted chain line in FIG. 5 where the pressure foot 5 has a non-operative position.
Further, as shown in FIG. 4, a pair of shaft holders 31a, 31b protrude from a bottom surface of the oil pan 31 with a space therebetween, and a rotatable shaft 32 is rotatably supported by the shaft holders 31a, 31b. As shown in FIGS. 4 and 5, one end of the rotatable shaft 32 is integrally connected to one end portion of an inverted L shaped manipulation member 34 through a coupling segment 33, so that the manipulation member 34 is pivotably movable about an axis of the rotatable shaft 32 in response to the rotation thereof. The manipulation member 34 has another end provided with a knee pad 35.
An operation segment 36 is provided integral with the rotatable shaft 32 and at a position adjacent to the one of the shaft holders 31b. As best shown in FIG. 5, the operation segment 36 is provided with wings 36a and 36b extending perpendicular to the axial direction of the rotatable shaft 32, and rotation regulating shafts 37 and 38 are threadingly engaged with the wings 36a and 36b, respectively. One of the wings 36a is abuttable on a bottom planar end of the operation rod 39. Tip ends of the rotation regulating shafts 37 and 38 are abuttable on the bottom face of the oil pan 31 for restricting or regulating rotation amount of the rotatable shaft 32 For this, adjusting nuts 37a and 38a are threadingly engaged with the rotation regulating shafts 37 and 38, respectively for adjusting threading advancing length thereof, to thereby control vertically moving stroke length of the operation rod 39.
A torsion spring 30 is disposed over the rotatable shaft 32 for normally urging the one of the rotation regulating shafts 38 toward the oil pan 31. In this state, the operation rod 39 has a descent position where the wing 36a is positioned away from the rod 39, and the inverted L-shaped manipulation member 34 has a standby position shown by a solid line in FIG. 5. On the other hand, if the knee pad 35 is depressed against the biasing force of the torsion spring 30, the member 34 is angularly moved about the axis of the rotatable shaft 32 to obtain a manipulating position shown by a two dotted chain line in FIG. 5. In this case, the wing 36a is brought into contact with the bottom end face of the operation rod 39, and the latter is urged upwardly to have its ascent position shown by a broken line in FIG. 5. Further, the rotation regulating shaft 37 is brought into abutment with the oil pan 31 for restraining further angular rotational movement of the manipulation member 34.
Moreover, as shown in FIG. 4, one of the shaft holders 31a is provided with a switch table 40 on which a microswitch 41 is attached as detection means. The microswitch 41 has a contact lever 42 whose tip end portion is provided with a roller. In accordance with opening and closing motion of the contact lever 42, a pressure bar lift signal is generated. On the other hand, at a position adjacent the switch table 40, an actuation piece 43 is provided integral with the rotatable shaft 32, so that the actuation piece 43 is also angularly rotatable together with the angular rotation of the shaft 32. The actuation piece 43 is formed with a cam portion 44 which includes a pair of flat portions 44a, 44b whose heights of camming surfaces are different from each other and an inclined portion 44c connecting between the two flat cam portions 44a and 44b.
When the manipulation member 34 is held at its standby position shown by the solid line in FIG. 5, one of the flat cam surface portions 44a of the cam portion 44 of the actuation piece 34 is engaged with the roller of the contact lever 42 as shown by a solid line in FIG. 4. On the other hand, when the manipulation member 34 is angularly moved to its manipulating position shown by the two dotted chain line in FIG. 5, the roller of the contact lever 42 is successively brought into engagement with the inclined portion 44c and the other flat portion 44b because of the angular rotation of the actuating piece 43 as shown by a two dotted chain line in FIG. 4, prior to the abutment of the wing 36a against the operation rod 39. By the successive engagement of the roller with the inclined and second flat cam surfaces 44c and 44b, the contact lever 42 is depressed, so that the microswitch 41 generates the pressure bar lift signal. Incidentally, in FIG. 5, switch table 40, the microswitch 41 and the actuation piece 43 are not delineated for better understanding of the construction.
Next, an electrical construction in the sewing machine of this invention will be described with reference to FIG. 6.
A central processing circuit (CPU) 50 constitutes a control means to which a read only memory (ROM) 51 and a random access memory (RAM) 52 are connected. Stored in the ROM 51 is an overall operation program for controlling overall operation of the sewing machine. Further, in the RAM 52, various data is stored for controlling driving or energization of the sewing machine.
An output interface 55 is connected to the CPU 50, and a sewing machine motor 53 for driving the sewing machine is connected to the interface 55 through a sewing machine motor driving circuit 56. A bobbin thread cutting solenoid 54 is connected to the output interface through a bobbin thread cutting drive circuit 57 for connecting the bobbin thread cutting unit to a drive source. Further, the above described needle thread trapping solenoid 17 and the needle thread cutting solenoid 18 are connected to the output interface 55 through a needle thread trapping drive circuit 58 and a needle thread cutting drive circuit 59, respectively. Thus, CPU 50 sends control signals to the motor 53 and the solenoids 54, 17, 18 such as sewing machine drive signal, bobbin thread cutting signal, needle thread trapping signal and needle thread cutting signal.
Further, CPU 50 is connected to an input interface 63 to which is connected a sewing machine energization signal generating circuit 61 which generates such a signal in accordance with a pedaling condition of a foot pedal 60. Further, the input interface 63 is connected to a needle position detector 62 which detects upper and lower needle positions for generating an upper needle position signal and a lower needle position signal. Furthermore, the above described microswitch 41 is also connected to the CPU through the input interface 63. In response to foot pedal-in and pedal-return motions of the foot pedal 60, the sewing machine energization signal generating circuit 61 generates a pedal-in and pedal-return signals, and these signals are transmitted to the CPU 50. Moreover, an upper needle position signal and lower needle position signal are transmitted from the needle position detector 62 into the CPU 50, and the above described pressure bar lift signal is transmitted from the microswitch 41 into the CPU 50.
With the structure, thus organized, operation sequence in the sewing machine will next be described with reference to a timing chart shown in FIG. 7.
During operational state of the sewing machine based on the forward pedal-in of the foot pedal 60, the needle thread trapping solenoid 17 and the needle thread cutting solenoid 18 are controlled to be in deenergized states(f1, g1) by the CPU 50. As a result, the movable blade 9 is held at its standby position P1 shown in FIG. 1(a) through the linking lever 20, the operating shaft 22 and the intermediate lever 24. When predetermined stitching work is terminated, the needle 2a is stopped at its lower needle position (c1)
If the thread cutting is to be carried out with the lower needle position, a pedal return signal is inputted into the CPU 50 (b1) for starting the thread cutting operation upon return pedaling of the foot pedal 60. In response to this signal (b1), the CPU 50 outputs the sewing machine drive signal (h1) to the sewing machine motor 53 so as to operate the sewing machine at a low speed. At the same time, the CPU 50 generates the bobbin thread cutting signal (e1) so as to interposedly cut the bobbin thread between the thread trapping unit (not shown) and the workpiece.
After time elapse of the continuous low speed operation of the sewing machine, the needle position detector 62 transmits the upper needle position signal (d1) to the CPU 50. In response to this signal, the CPU 50 stops sending the sewing machine drive signal (h2) and the bobbin thread cutting signal (e2) so as to stop rotation of the sewing machine motor 53 and to deenergize the bobbin thread cutting solenoid 54.
Subsequently, the CPU 50 has a standby state for about 20 ms, and then, the needle thread trapping solenoid 17 is energized (f2) for a predetermined period T1. In accordance with the energization of the solenoid 17, the plunger 16 is moved upwardly, so that the movable blade 9 is moved from its standby position P1 to the trapping position P2 through the linking lever 20, the operation shaft 22 and the intermediate lever 24. By this movement, the needle thread T is guided into the notched portion 12 by means of the thread handling portion 13.
After elapse of the predetermined period T1, the needle thread trapping solenoid 17 is deenergized (f3) and simultaneously, the needle thread cutting solenoid 18 is energized (g1) for a predetermined period T2. By this energization, the plunger 16 is moved downwardly, so that the movable blade 9 is slidingly moved from its trapping position P2 to the cutting or thread clamping position P3. Accordingly, the blade edge 9a of the movable blade 9 is brought into engagement with the stationary blade 8, to thereby cut the needle thread T. The cut end of the thread (which thread is not the cut away thread but the thread still engaged with the eye of the needle) is tightly held between the movable blade 9 and the thread catching spring 7.
After elapse of the predetermined period T2, the needle thread cutting solenoid 18 is deenergized (g2) by the CPU 50. In response to the deenergization, the movable blade 9 is slidingly moved from its cutting position P3 to its standby position P1. In this sliding movement of the movable blade 9, the cut end portion of the thread T (a leading end portion) is still held by the movable blade 9 and the thread catching spring 7 with a holding force smaller than the force applied by the blade 9 and the spring 7 when the blade 9 is positioned at the thread cutting position P3. Thus, the needle thread clamping operation is completed.
Therefore, according to the needle thread holding device of this invention, after the needle thread is subjected to cutting on the pressure foot 5 positioned at its operative position, the cut leading end portion of the needle thread is held by the pressure foot 5. Accordingly, residual length of the needle thread suspended from the eye of the needle 2a can be reduced after cutting, and further, release of the residual thread from the needle eye can be obviated.
According to the present invention, if the workpiece is to be replaced by a new workpiece for the next sewing, the manipulation member 34, the rotatable shaft 32, the operation segment 36 and the actuation piece 43 are integrally angularly rotated in a counterclockwise direction (FIG. 5) upon depression of the knee pad 35. By the angular rotation, the contact lever 42 of the microswitch 41 is depressed by the actuation piece 43 before the wing 36b of the operation segment 36 abuts the lower end face of the operation rod 39. Therefore, the microswitch 41 generates the pressure bar lift signal (il). In response to the signal, the CPU 50 will again energize the needle thread cutting solenoid 18 (g3) so as to again move the movable blade 9 from its standby position P1 to the thread clamping position P3. Accordingly, the cut end portion of the needle thread is firmly held by the movable blade 9 and the thread catching spring 7. After the firm holding of the thread, the pressure foot 5 is displaced from its operative position to its non operative position in accordance with the lifting operation of the operation rod 39 by the wing 36a. As described above, the pressure foot 5 is connected to the operation rod 39 by way of the linking mechanism (not shown.
While maintaining the non-operative position of the pressure foot 5, the workpiece is replaced by a new workpiece, and thereafter, the new stitching to the new workpiece is intended to be started. In this case, an ordinary operator may start the stitching by pedaling-in the foot pedal 60 simultaneous with the release of her knee from the knee pad 35 in an attempt to perform prompt sewing work. However, it takes several time periods for completely recovering the operative position of the pressure foot 5 after the release of the knee from the knee pad 35, since mechanical power transmission from the manipulation member 34 to the pressure foot 5 requires several time periods due to various interlinkage of the mechanical segments such as the components 32, 36 and due to mechanical interference between the microswitch 42 and the actuation piece 43. Consequently, the actual sewing work is started at a timing earlier than the actual depression timing of the pressure foot 5 onto the workpiece. Due to this time lag, conventionally, a knot attendant to the first stitch may not be provided.
In contrast, according to the present invention, after the input of the pressure bar lift signal into the CPU 50 and subsequent input of the pedal-in signal thereinto, the needle thread cutting solenoid 18 is maintained in its energized state (see g3 in FIG. 7) for firmly holding the cut leading end portion of the needle thread between the movable thread 9 and the thread catching spring 7 until predetermined numbers N of the respective downward needle position signal and upward needle position signal are inputted into the CPU from the needle position detector 62 (in the illustrated embodiment, N=1, see c2 and d2). Therefore, in the present invention, at the first stitch, the needle thread is not released from the eye of the needle 2a and a knot of the needle thread and the bobbin thread can be surely provided irrespective of the non-pressurized holding of the workpiece onto the workpiece supporting surface by the pressure foot 5, since the cut leading end portion of the needle thread is securely held between the movable blade 9 and the thread catching spring 7.
Thereafter, upon termination of the input of the N times upper needle position signal (d3), the needle thread cutting solenoid 18 is deenergized (g4), so that the movable blade 9 is returned from the thread clamping position P3 to the standby or thread releasable position P1. In this instance, the thread clamping force given by the movable blade 9 and the thread catching spring 7 is reduced. In accordance with feeding of the workpiece attendant to the continuous operation of the sewing machine, the cut leading end portion of the thread is easily released from the movable blade 9 and the thread catching spring 7, Accordingly, no abnormal or excessive tension is applied to the needle thread, to thereby provide sufficient stitch balancing thread tension.
In view of the above, in the thread holding device according to the above described embodiment, the needle thread can be cut while providing a reduced length of the residual thread from the eye of the needle 2a, since the thread can be cut at a pressure foot 5 which is located adjacent to the needle 2a. Therefore, thread entanglement or nest-like stitching is avoidable, which otherwise occurs if the residual cut needle thread has excessively large length.
Further, after cutting the needle thread, the cut leading end portion of the needle thread is firmly clamped for a period starting from a timing immediately before the lifting of the pressure foot and ending at a one stroke movement of the needle at the first stitching in the subsequent sewing operation. Accordingly, a knot of the needle thread and the bobbin thread can be provided without fail despite of the fact that the residual thread has a reduced length. If the knot attendant to the first stitch is provided, the subsequent numbers of stitches can surely be provided, since the needle thread and the bobbin thread are securely held by the workpiece by the first knot. Consequently, skip stitching and thread cast-off can be obviated even if the pressure foot 5 reaches the workpiece at a delayed timing for starting the subsequent sewing operation, and as a result high grade stitching is attainable.
Moreover, after one stroke movement of the needle 2a, the thread clamping force given by the movable blade 9 and the thread catching spring 7 is weakened, and accordingly, stitch balancing thread tension is not degraded, and no shrinkage occur in the workpiece.
While the invention has been described in detail and with reference to specific embodiments thereof, it would be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention. | A sewing machine having a needle thread cutting unit and a needle thread holding device for holding a cut leading end portiion of the thread drawn from an eye of a needle. The needle thread holding device includes a holding means provided at the pressure foot. The holding means is movable between a needle thread clamping position and a needle thread releasing position. The holding device also includes drive means connected to the holding means for selectively moving the holding means to one of the needle thread releasing position and the needle thread clamping position, pressure foot position detection means for detecting a position of the pressure foot, needle position detector for generating a needle position signal indicative of the upper needle position and the lower needle position, and control means connected to the pressure foot position detection means the sewing machine energization signal generating means and the needle position detector. The controlling means maintains the holding means at its thread clamping position when the pressure foot is at its non-operative position after cutting the needle thread. The controlling means also maintains the holding means at its clamp position during a predetermined number of stitches at a starting phase of a next sewing operation. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to mobile electronic devices. More particularly, the present invention relates to a method and apparatus for indicating mobile electronic device status and/or state.
BACKGROUND OF THE INVENTION
[0002] The use of mobile electronic, or communication devices has increased dramatically over recent years as users wish to be able to be stay connected when they are away from a landline telephone or desktop computer. Some mobile communication devices also serve as a personal digital assistant for tracking meetings and daily activities. For users who are on the go, ease of use and speed are typical priorities. As speed is important, users typically start to use their device without verifying the status of the device since they are so concentrated on making a call, checking email or their calendar, among other things.
[0003] There are times when users attempt to use their mobile communication device while the device is in a locked mode. Frustration sets in once the user realizes that their mobile electronic device is in the locked mode and has to be unlocked for the user to use the device.
[0004] Typically, users are required to look at their display screen in order to determine the status, or state, of their device. This is, however, not an easy task since the user has to focus on what is being displayed on the display screen and divert their attention away from other tasks at hand. With the size of the screens in mobile communication devices, this information may not be immediately available to the user without having to stare intently at the screen for a few seconds. Furthermore, information concerning the device state, or status, is not readily available to the user.
[0005] It is, therefore, desirable to provide a novel method and apparatus for indicating mobile communication device status.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
[0007] FIG. 1 is a front view of a mobile electronic device;
[0008] FIG. 2 is a schematic view of apparatus for indicating mobile electronic device status; and
[0009] FIG. 3 is a flowchart outlining a method of indicating mobile electronic device status.
DETAILED DESCRIPTION
[0010] Generally, a method and system for indicating mobile electronic device status is provided.
[0011] Turning to FIG. 1 , a schematic diagram of an embodiment of a mobile communication device is shown. The mobile communication device 10 includes a display 12 along with a keyboard/keypad area 14 having a keyboard 16 installed. Between the display 12 and the keyboard 16 is a set of keys, or buttons, 18 and a trackball 20 .
[0012] In one embodiment, a set of LEDs is located underneath the trackball of the mobile electronic device. As will be disclosed, the set of LEDs provide a visual indication to a user relating to a status of the mobile communication device. The LEDs may be a single colour LED or may be multi-coloured to provide a spectrum of colours. Other methods of providing visual or colour indicators to a user are also contemplated.
[0013] It will be appreciated that “colour” can be defined in many ways, for example in terms of human perception, pigments used in paint, collections of wavelengths of light, or “colour spaces”. Arguably the most famous colour space for the purposes of video displays is RGB space, so named because each displayable colour is represented by the red, green and blue components (each often, but not necessarily, specified as having integer values in a range from 0 to 255) that, when added together, create a colour. However, the RGB colour space does not always conform to human expectations for a colour system. For example, adding pure red and pure green yields yellow, and the “midpoint” between pure red and green is a very dingy shade of yellow.
[0014] Many other colour spaces are known for defining colours, typically by means of three coordinates, and formulas for mapping one space to another. A system known to many who use popular graphics programs such as Photoshop™ is HSL space, in which the coordinates represent hue, saturation and luminance. Hue is measured on a circular scale corresponding to the additive colour wheel (red, yellow, green, cyan, blue, magenta). Saturation is zero for grey tones (i.e. colours having all RGB components equal) and reaches the maximum value for colours having at least one RGB component equal zero. Luminance is related to the perceived brightness of the colour, but in an inconsistent manner; for example, yellow and blue have the same luminance. There are related systems such Hue-Saturation-Value and Hue-Saturation-Brightness.
[0015] A more faithful representation of perceived brightness is found in the Y coordinate (also called luminance) of YUV space, one version of which is used in the JPEG image compression scheme. In the absence of the two chrominance coordinates U and V, pixel-by-pixel luminance information alone is all that is needed to form a blank-and-white, o.e. grey-tone, version of an image.
[0016] In varying colours to represent changes in the state of a dynamic characteristic, it is frequently advantageous—both conceptually and from a programming standpoint—to represent and transform the colours in HSL or YUV space, even though a conversion of colour coordinates to RGB values will ultimately be needed to drive a video display. As one example, a simple rotation of a hue from one value to another may involve first increasing one of the primary additive colours (red, blue and green) and then decreasing a different one. As another example, ‘greying-out’ a graphic image by decreasing the saturation of each of its pixels typically requires simultaneously changing all three RGB values for each pixel. It will be understood that the discussion relating to the colours in the follow description may also be enhanced by these other colour characteristics or spaces.
[0017] Turning to FIG. 2 , apparatus for implementing a method of indicating mobile electronic device status is shown. The apparatus 50 , located within the mobile electronic, or communication, device 10 , includes a processor 52 , which may be a mobile electronic device processor or a separate processor, a database 54 and a set of LEDs 56 .
[0018] The database 54 stores information, preferably in the form of a table, which includes a list of mobile communication device statuses and a colour (or intensity of a colour) associated with each of the device statuses. The processor 52 monitors the status, or state, of the device 10 and communicates with the database 54 to retrieve the information stored in the database 54 . The processor 52 also communicates with the set of LEDs 56 to transmits signals to produce a colour to illuminate the trackball. It will be understood that the area surrounding the trackball may also be illuminated by the set of LEDs as well as the area surrounding the set of buttons 18 . In the following description, whenever there is mention of the trackball being illuminated, it will be understood that the area surrounding the trackball and/or the set of buttons may also be illuminated. It would be beneficial to have a means for indicating mobile communication device status or state whereby the user is provided a visual indication. This visual indication may be enhanced by an audible or tactile indicator.
[0019] In one embodiment, the apparatus 50 is designed to indicate when the trackball 20 can be used to initiate an action. In other words, the user can simply glance at the mobile electronic device to look at the colour of the light illuminating the trackball 20 to determine the state of the electronic device. In this embodiment, the set of LEDs 56 are preferably red, yellow and green with red representing a locked mode whereby use of the device is password protected, yellow representing a password mode whereby a user is entering a password in order to exit the locked mode and green representing an unlocked mode whereby the device may be used. The colours have been arbitrarily selected for this example and it will be understood that other colours may be used. The selection of red, yellow and green in the current embodiment represents traffic light colours with which a user will be more familiar. The database 54 stores the information relating to the various device statuses and the corresponding colour representing the status.
[0020] In this example, it is assumed that the mobile communication device 10 is initially in a locked mode whereby a red LED illuminates the trackball 20 .
[0021] In operation, the processor 52 monitors the status of the mobile electronic, or communication, device 10 and determines that the device is in the locked mode (step 100 ). The processor 52 continues to monitor the mobile electronic device to determine if the status has changed (step 102 ). If no change is sensed, the processor 52 continues to monitor the status (step 100 ). When the user decides to use the device, the processor 52 senses a change in the status from the locked, or password protected, mode to the password mode. The processor 52 then accesses the database 54 (step 104 ) to retrieve the colour (Yellow) associated with the password mode and transmits a signal to the set of LEDs 56 (step 106 ) causing the LEDs to provide a yellow light to illuminate the trackball 20 . The set of LEDs 56 then provide the necessary illumination to the trackball (step 108 ). The yellow-illuminated trackball provides a visual to the user that the mobile communication device is in the password mode. The processor 52 then returns to monitoring the status of the mobile communication device (step 100 ).
[0022] After the user has logged in correctly, by entering the correct password, the mobile communication device 10 is in the unlocked mode. Once the device 10 is in the unlocked mode, the user may freely access the applications within the mobile electronic device and to use the trackball. When the processor 52 senses this status change (step 102 ), the processor 52 accesses the database 54 (step 104 ) to determine the colour (Green) corresponding to the unlocked mode. The processor 52 then transmits a signal to the set of LEDs 56 (step 106 ) to provide a green colour to the trackball 20 , indicating the unlocked mode. The green LED or LEDs are turned on (step 108 ) and the processor 52 then returns to monitoring and determining the mobile communication device status (step 100 ).
[0023] By illuminating the trackball 20 from underneath the trackball, a user is able to quickly glance at their mobile communication device 10 to determine its status which in this case is the mode in which the mobile communication device is in.
[0024] In another embodiment, the set of LEDs 56 are used to indicate different user profiles associated with the ring volume of the mobile communication device 10 . In this embodiment, a single coloured LED may be used to indicate the status, however, the intensity of the illumination provides the indicator status to the user. The table below provides an example of the information stored in the database 54 for this embodiment.
Profile Colour Intensity Loud 100% Vibrate Flashing Quiet 0% Default 50%
[0025] In operation, assuming that the mobile communication device 10 is in the default user profile, the set of LEDs 56 provides illumination at an intensity of 50% to the trackball 20 . When the processor 52 senses that the user has changed their user profile (step 102 ), the processor 52 accesses the database 54 (step 104 ) to retrieve the intensity level corresponding to the new user profile. If the user profile is changed to Loud, the processor 52 retrieves the intensity level (100%) corresponding to the loud user profile and transmits a signal to the set of LEDs 56 (step 106 ) to provide light at an intensity of 100%. Similarly, if the new user profile is the Vibrate user profile, the LEDs receive a signal from the processor 52 to provide a flashing light to illuminate the trackball 20 and if the new user profile is Quiet, the set of LEDs is turned off so that no light is provided to illuminate the trackball 20 (step 108 ).
[0026] The intensities which have been selected above are for example only and are not meant to be restrictive to the implementation of the method or system. It will be understood that for this embodiment, the selected intensities must be distinguishable to the human eye such that the user can simply glance at the mobile communication device to determine the current user profile.
[0027] In yet a further embodiment, the method and apparatus are provided for indicating a status of an application on the mobile communication device. For instance, if a user has a meeting set up in a calendar application, the colour green may indicate that the user has a meeting coming up within the next hour, more specifically that there are between 10 and 60 minutes before the meeting. The colour yellow may be used to indicate that there is between 5 and 10 minutes left before the meeting. The colour red may be used to indicate that there is less than five minutes before the meeting. A flashing red light may be used to indicate that the scheduled meeting time has passed. Therefore, when the user sees a red light illuminating the trackball 20 , the user knows that the meeting is starting within 5 minutes and therefore needs to proceed to the meeting in order to ensure they are not late. Although solid colours are preferred, the colours may be mixed to indicate different time frames within the ranges provided. Furthermore, different light characteristics such as saturation or intensity may be used to provide the necessary visual indication to the user.
[0028] As with the examples above, the processor 52 continuously monitors the time frame status of the meeting and accesses the database 54 whenever the time frame status has changed to retrieve the colour corresponding with the new time frame status. The new colour (or colour intensity) is then used to illuminate the trackball 20 . This provides the user with a visual indicator on the face of the mobile communication device allowing the user to quickly glance at their device to determine the amount of time before their meeting or appointment or more broadly, the time frame status. There is no need for the user to look at the display to find out the exact time of day to determine the amount of time before the meeting as the colour illuminating the trackball provides a general visual indicator with the necessary information to the user in a quicker manner.
[0029] In yet a further embodiment, the method and apparatus may be used to indicate a status of the mobile communication device battery. In one example, a possible colour representation may be if the battery has a battery life of 50% or more, the set of LEDs provides a green light, if the battery has a battery life of between 15 and 50%, the set of LEDs provides a yellow light and if the battery has a battery life of less than 15% (indicating a need for recharging), the set of LEDs provides a red light.
[0030] It will be understood that other mobile communication device statuses and states such as connectivity or email status may also be displayed using the methods and apparatuses described in this specification.
[0031] Along with visual indications, the mobile electronic device may also provide audible or tactile indicators to enhance the method and system. For example, tactile indicators such as altering the temperature of the device to indicate device state, or status to a user. Also, vibration of the mobile communication device or the provision of a message on the display may be provided to enhance the visual indicators.
[0032] In an alternative embodiment, the illumination of the trackball 20 may be used to indicate one mobile communication device status, or state, such as the device state, the illumination of the area surrounding the trackball 20 may be used to indicate a second mobile communication device status, or stat, such as user profile information while the illumination of the area surrounding the set of buttons 18 may be used to indicate a third mobile communication device status, or state, such as the battery level. Depending on the number of areas available for illumination, any number of different mobile communication device statuses may be displayed for the user.
[0033] In a further embodiment, instead of constantly monitoring the mobile communication device status, each time a status changes, a signal may be transmitted to the processor 52 indicating the change thereby causing the processor 52 to access the database 54 for the colour information, or indicator information. In this manner, the processor does not have to constantly monitor the status of the mobile communication device.
[0034] In yet a further embodiment, the indicators may be associated with any type of user input apparatus and is not restricted to simply a trackball. For instance, the button area or under the keys of the keypad/keyboard.
[0035] The above-described embodiments are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope, which is defined solely by the claims appended hereto. | Apparatus for indicating mobile electronic device status comprising a database for storing mobile electronic device status information and associated colour information; a set of light emitting diodes (LEDs); a processor for retrieving the colour information based on the mobile electronic device status and transmitting a signal based on the colour information to the set of LEDs; wherein the set of LEDs provide a light corresponding to the colour information to illuminate an area of the mobile communication device to indicate the mobile electronic device status. | 7 |
FIELD OF THE INVENTION
(General) This invention relates to apparatus for use in the user initiated and controlled delivery of educational and entertainment television programming from remotely located electronic libraries, and conventional cable television sources, to the users physical location.
BACKGROUND OF THE INVENTION
(Addresses Educational Needs) As residents of a community have different educational needs, and there is a need for a system for electronically delivering audio-visual educational programming from an electronic library to the learners physical location, and it is desirable to deliver educational programming when the learner desires such programming, and it is required that learners have the ability to start, stop, fast-forward and rewind the playing of such programming; apparatus is needed to provide for such requirements. This invention provides for such educational needs.
(A Form of Pay TV) Although an educational electronic library and delivery system may be publically funded by a community library or a public educational institution, the sponsoring agencies may wish to incorporate such a service on a user pay basis. In addition, private educational institutions may desire to make use of such apparatus. When so employed the system becomes a form of pay television.
(Elimination of Monopoly) Presently competing cable TV operators within a franchise area are faced with the uneconomical prospect of duplicate distribution networks. Usually this has resulted in an avoidance of competition, the result being that a single operator monopolizes the distribution of cable TV programming within a franchise area. Potential competing operators are discouraged from entering into competition within a franchise area as the duplicate distribution network has a potential of only 50% of the return of a monopoly franchise area of equal investment cost. It is observed that approximately 15% of the capital investment in a cable TV distribution system is in primary trunking costs compared with 85% in the secondary distribution network. If the secondary distribution network could be made available for use by competing cable TV operators and duplication of same avoided, then the probability of a plurality of cable operators competing for business within an area becomes economically feasible.
(Accessability Limits) An educational electronic library and delivery system requires the ability to provide all residents of an urban society, who have a desire to access and a means to pay for such educational services, the ability to access the widest possible variety of programming at the time desired with the minimum of conflict between users. All pay TV systems employed to date severely restrict user choice as the apparatus provided is limited in its capacity to simultaneously access and deliver the required quantity and variety of programs.
(Prior-Art-Bradley, switching/bus techniques) Most cable TV systems in use today frequency division multiplex a plurality of subscription television channels and a plurality of pay per view channels onto a single coaxial cable for transmission and distribution to residences. A few also allocate some channel capacity for the transmission of user selected video-on-demand programming from a central library to user's residences. An example of such apparatus is given in an associate prior patent, Bradley, Stretten, Stretten and Wentzel (U.S. Pat. No. 4,878,245). The prior Bradley et al. patent teaches that user programming choice can be expanded by using the same radio-frequency TV channels to carry different programming by separating duplicate frequencies onto a plurality of physically separate transmission paths, each path serving a separate group of subscribers, where each user controls a radio frequency isolation switch to permit the user to access extra channels when desired.
In a previous associated patent, Bradley, Stretten, Stretten and Wentzel (U.S. Pat. No. 4,878,245), each community of about 100 homes was provided an individual fiberoptic fiber as the transmission facility from a central electronic library to the community. With this previous proposed arrangement the quantity of programs that could be simultaneously delivered is restricted by the capacity of the fiber link. Also if a single library serves the entire urban centre, many of the communities of 100 homes would be very distant from the library making the cost of adding additional fiberoptic transmission facilities expensive. In addition different communities have different educational and cultural needs. For example, an Italian community would want programming different than a Hispanic community, a low income community would have a greater need for basic job skills programming than a high income community. Therefore, it would be more efficient to store and transmit special interest programming from a library located in the neighborhood community than transmit such programming over a long distance from the central library. This previous proposal suggests no alternative to a single centralized electronic library.
Programming should therefore be classified and distributed among a network of libraries in order to reduce implementation cost and improve transmission efficiencies. Programming for which there is a common interest, and high demand, should be distributed from a central library. Programming of local interest and modest demand should be stored and distributed from libraries located in the neighborhood community. Programming of common interest but very low demand should be distributed from the central library for short term storage at a local library where it is available for user access and control. The apparatus embodied herein improves upon the distribution efficiency by taking into consideration the differing nature of and demand for programming.
(VCR Like Control) In addition our previous embodiment provided user control of only the starting of the delivery of a program. No means is provided for the user to control the stopping, fast forwarding, rewinding, or replaying of a program. As the educational user needs to have access to the ordering and control link at all times to permit control over the delivery of the programming an alternative to the public telephone network, as proposed in our previous patent, was required in order to avoid telephone facility blocking problems.
(Control Path Blocking) Another object of this invention is the provisioning, for each of a plurality of users, an ordering and control link that is effectively available for user at all times, and that is intrinsically secure.
The provisioning of the start/stop, wind/rewind feature is another reason for not locating educational programming at the central library as learners could tie up expensive, long transmission facilities for extended periods of time.
(Prior Art Sub-Centres) Nakajima et al (U.S. Pat. No. 4,538,176) and Yabicki et al (U.S. Pat. No. 4,518,989), proposed an electronic library system with optional sub-centres located between the location of where the video/audio files are stored and the end user. The purpose of sub-centres is to reduce the cost of potentially long transmission lines from the central program file to the end user. Sub-centres do not store files for direct access by users but only have buffer memory capability to permit high speed transmission from the central file and the sub-centre and real-time retransmission to the user. The apparatus as embodied in both patents fails to address the special needs of educational programming services, the savings realized by storing some programs near the physical location of the end user and other programs at a central location, and the congestion problems associated with the use of the public telephone network for control and ordering.
(Security) Most pay TV systems, including the Bradley et al previous embodiment, simultaneously deliver the same programming to a plurality of physical location within the unique fiberoptic fed neighborhood. Our previous embodiment uses a combination of filters and switches to block the delivery of programs to a potential users television receiver should the potential user not wish to pay for the programming. Physical security means are required to prevent unauthorized users from receiving the pay programming by tampering with the filters and switches. Occasional physical inspection is required to deter tampering. Most other pay TV systems use addressable encryption or jamming apparatus to prevent programming, for which a potential user has decided not to pay or is not permitted to purchase, from being intelligently received. The three most common methods of defeating such apparatus are; by transferring the internal unique descrambler identity keys from an authorized unit to an unauthorized unit thus making both units identical as far as addressing signals are concerned, by extracting the decoded descrambling keys from an authorized descrambling device and programming into an unauthorized descrambler; by relocating an authorized descrambler from a physical location where it is permitted to be used to a location where it is not (for example, from a private residence where private viewing is permitted to a public establishment where public viewing is denied).
Each of the above security systems have only a limited lifetime. Some months or years after installation methods of defeating the apparatus become widespread and the system operator is required to change out the security apparatus. Another object of this invention is the proposal of a security method that is intrinsically secure, that does not require the use of encryption or jamming apparatus.
This embodiment improves upon the security method embodied in our previous patent by moving the point of programming denial into a single secure neighborhood building or structure, thus eliminating the need for physical inspection of a plurality of apparatus distributed throughout the neighborhood.
(Bulk Problems) The disadvantage of feeding every user location from a single neighborhood distribution point is that should coaxial cable be used the physical bulk of the cable becomes a burden.
This embodiment improves upon Nakajima and Yabicki by using conventional telephone paired copper wires, or low cost fiber optics as the transmission medium from the neighborhood library to the users physical location. Should the length of the transmission line from the local library to the user's location be less than typically 2 km., then the video and audio signals are transmitted via conventional telephone cable, one pair for the video and one pair for the audio, from the local library to the home. Should the distance be longer or a higher bandwidth be required (for the simultaneous transmission of 2 to 4 Amplitude Modulated Vestigial Sideband (AM VSB) RF channels), then this embodiment proposes the use of a low cost optical transmission line consisting of a low cost optical energy source, and a relatively low bandwidth, high loss fiber. By using paired telephone cable or optical transmission, as opposed to coaxial cable transmission, the physical bulk of the cabling can be reduced as both are small compared with that of conventional coaxial cable transmission systems.
Nakajima and Yabicki, indicates the use of electrical transmission methods. They require no encryption or jamming apparatus but either they must utilize a greater number of subcentres which expands their physical security needs, or cable bulk becomes a problem; a problem that they have failed to address.
(Prior Art Problems-security/blocking) Typical examples of user controlled video-on-demand pay TV system are that outlined by Monslow et al. (U.S. Pat. No. 4,890,320) and Abraham (U.S. Pat. No. 4,590,516; 4,567,512; and 4,521,860). Both the Maslow and Abraham apparatus combine a plurality of user ordered programming for multiplexed transmission over a conventional cable TV system from a video library source to a user's residence, and at each of the plurality of physical locations to which the programming is delivered is located a device to permit the intelligent viewing of only programs so ordered from that location. Both fail to consider the problem of migrating receiving apparatus. This is a serious concern as a descrambler located at a user's private residence which is authorized to receive a boxing match, for example, may be relocated for use to a public establishment where viewing of the match is not authorized. Both propose the use of the public telephone network as the ordering link between the subscriber's residence and the library. The use of both the public telephone network and a conventional CATV distribution system represent potential blocking problems. Congestion can appear in both the ordering path and the delivery path.
(Non Blocking Need) Another object of this invention is to design a delivery path that is expandable on an as required basis to ensure that as the demand for programming grows the system is capable of being modified to meet the demand.
(Copy Protection) A concern of programming copyright owners is that electronically delivered programming once received can be recorded and copied for unauthorized distribution. Present art discourages recording by altering the nature of the video signal such that subsequent recording is interfered with. Users who wish to make a business out of such a practice use video signal restoration apparatus to restore the video signal to a recordable form thus defeating the copy security system. Another object of this invention is a system of imbedding in the video signal information that allows the user responsible for the unauthorized distribution practice to be determined.
(Payment Responsibility) Another object of this invention is apparatus for securely enabling the purchasing of programming and/or consumer goods. The implementation of such a feature requires that the physical location of the user be correctly identified and is free from tampering, and that the personal identification of the ordering user be identified and valid for the ordering address. The purpose being to minimize problems associated with users denying responsibility for payment.
SUMMARY OF THE INVENTION
The objects of the invention are as follows:
1. To economically and efficiently provide for the educational and entertainment needs of an urban centre by providing the required access to a plurality of electronic programming by a plurality of residences, businesses and schools located throughout the urban centre, with a minimum of conflict between the needs of the plurality of users.
2. To provide for the educational and entertainment needs of an urban centre by providing end users with the ability to select programming for delivery to their location when they require it.
3. To provide for the educational and entertainment needs of an urban centre by providing end users with the ability to start, stop, replay, rewind, and fast forward programming as their needs require.
4. To provide for the economic needs of an educational and entertainment pay television system by providing for the needs of the system to confirm the identity of an ordering user for the purpose of charging for access to and use of programming.
5. To secure the delivery of programming, without the use of encryption or jamming apparatus, such that programming being ordered by, paid for, and delivered to an authorized user's physical location can not be received at a non-paying unauthorized user's physical location.
6. To minimize the construction cost associated with each user's physical location being individually fed from a central community access point.
7. To provide for a means of discouraging unauthorized copying and distribution of delivered programming.
8. To provide for the economic needs of a pay television system by providing for the needs of the system to confirm the identity of a purchasing user for the purpose of charging for consumer goods sold through the use of the system.
9. To provide for the economic needs of a plurality of cable TV undertakings competing within a given cable TV franchise area.
In accordance with one aspect of the invention there is provided a secure, hierarchial, video-on-demand television signal distribution network having at least one local community library serving a plurality of geographically proximate subscribers, each community library providing at least one video distribution bus for attachment of a plurality television channel tuners, one tuner for each subscriber, to tune a selected television channel on said video distribution bus for delivery of the tuned television signal over dedicated television signal delivery lines to the subscriber, each said library having: a plurality of television program record and playback units for recording television programming and playing back previously stored television programming, each television program record and playback unit provided with a channel tuner for tuning a television channel to be recorded and further provided with a tuneable television signal modulator for modulating the playback television signal to a selectable channel, each modulator terminated on said video distribution bus; and a user control signal path for carrying user selection and control data from the subscriber premises to the local community library whereby the user programming choices and control may be acted on by the local library in response to user input to select or control the television signal to be delivered or being delivered to the user over the dedicated television signal delivery line serving the user; and a central library serving said local libraries having a wide bandwidth television signal delivery link extending therebetween for delivery of television programming to said local libraries for storage on said program record and playback units or for delivery to a user served by said local library, further including a control data communications path extending between said central library and each said local library whereby user selection and control signalling may be effected co-operatively by the central and local library.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, which illustrate embodiments of the invention:
FIG. 1 is an overview of the embodied hierarchial network of electronic libraries.
FIG. 2 is a functional block diagram that shows, the interconnection of the major components of the hierarchial network of electronic libraries, and the identification of the major components of the central electronic library, the neighborhood local library and the apparatus located at user's residences.
FIGS. 3A and 3B are functional block diagrams that show the apparatus for formulating and multiplexing, Type A Video-on-Demand (VOD) signals onto one of a plurality of Type A Buses, Type B Video-on-Demand (VOD) signals onto one of a plurality of Type B Buses, and the method of providing a low cost opportunity for one of a plurality of cable TV operators to have access to a dedicated Type C bus.
FIG. 4 is a functional block diagram that shows the central library apparatus for inserting identification information for the purpose of identifying the source of unauthorized duplication of Type B VOD programming for commercial profit purposes.
FIG. 5 is a functional block diagram that shows a location for the insertion of the copy deterrent information which inserts an identification code unique for each user's physical location.
FIG. 6 shows a wireless remote control transmitter used to provide users with, library control and access functions, including the ability to place orders for programs and consumer goods.
FIG. 7 is a functional block diagram that shows, apparatus for permitting the user to have user controlled selection of any of a large plurality of channels distributed on a plurality of buses each of which can carry as many RF television channels as can be offered by a cable TV operator using conventional technology, and apparatus provided for the purpose of generating text information, such as directory of offered programming information and consumer product ordering information, in response to each users request and control signal input.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1 there is shown an overview of the hierarchial network of electronic libraries. A typical user's residence 1 is shown, alternately an educational institution classroom could be substituted. The user shown receives television signals from a local electronic neighborhood library 2. The neighborhood library is typically located within 2 kilometers of the user's location. User requested television programming is transmitted from the local library to the users location over a dedicated television signal delivery line 3. Preferably this transmission line is conventional telephone cable or a low cost, low bandwidth fiberoptic fiber, although a narrow bandwidth minature coaxial cable could be substituted. A plurality of high capacity, wide bandwidth television signal delivery links 4, preferably, fiberoptic fibers, connects the local library with the central library 5. These high channel capacity wide bandwidth television signal delivery links are used to transmit low demand and/or local interest programming from the central library to the local library for storage at the local library, said local library stored programming is available for subsequent access by neighborhood users such as 1 homing on said local library. Said fiberoptic link is also available for the distribution of general demand, high interest programming, said programming is available for direct access by users from the central library without storage at local libraries. A plurality of fiberoptic links 6 is also provided for the purpose of permitting users to access programming stored at any of the plurality of local neighborhood libraries.
We have discovered that to maximize video access and control for users while minimizing the investment necessary to provide the user desired control and variety of programming, it is useful to categorize or classify the programming into categories referred to herein as Class "A" Video on Demand (Class "A" VOD), Class "B" VOD and Class "C" VOD. Other classes may arise, however, the above 3 are fundamental to understanding the configuration of apparatus described in accordance with the present invention.
Type "A" VOD programming is indicated by a stored video program sought to be individually controlled by the user to permit pausing, rewinding, fast-forwarding etc. of the actual program source where the program source is, from a network contention point of view, low demand. That is, the chance or incidence of 2 or more users simultaneously seeking access to the video program is small. Examples of this type of programming are educational movies used by the teacher or instructor to assist in the delivery of educational information to students. The teacher needs to pause the movie to permit dialogue at critical points and to rewind the movie to allow previous points to be reviewed etc. Also in this category of video program would be cultural or special interest titles (i.e. yesterday's broadcast news).
Type "B" VOD programming is indicated by a stored video program sought to be individually controlled by the user to permit pausing, rewinding, fast-forwarding etc. of the actual program source where the program source is, from a network contention point of view, high demand. That is, the chance or incidence of 2 or more users simultaneously seeking access to the video program is large. Examples of this type of programming are new release movies for which there is a general pent up demand for viewing. The user of such a movie would prefer to select the title to be viewed and have the commencement time be as close to the request as possible, i.e. be viewed on demand. It is also preferable to allow such a user to have the ability to rewind or backup the movie to review missed spots or to fast-forward the movie to advance to a desired subsequent portion.
Type "C" VOD programming is indicated by a video program that may be live or stored but is not individually controlled by the user, where the program source is, from a network contention point of view, high demand. That is, the chance or incidence of 2 or more users simultaneously seeking access to the video program is large. Examples of this type of programming are traditional broadcast TV carried on the cable media, live events such as sports events or national addresses by the Government or a public agency etc. The user of such a video program prefer to select the content or title to be viewed and have the event unfold with any other involvement.
FIG. 2 shows the interconnection of the major components of the hierarchial network of electronic libraries, and the identification of the major components of the central electronic library, the neighborhood local library and the apparatus located at user's residences. It also shows three different embodiments of user control signal paths and three different embodiments of the dedicated television signal delivery lines.
With reference to FIG. 2 there is shown the central library 5. The central library contains three basic types of apparatus, the central storage and playback apparatus 7 where programming is stored on a variety of media, magnetic tape, laser discs, and computer memory, for subsequent transmission to local libraries, the master control and billing computer 8 which records user usage for billing purposes and controls the starting and stopping of the video/audio storage and playback apparatus located in the local library. Also shown is the interface apparatus 9, 10 and 11 for receiving and transmitting electronic transmissions from and to a plurality of user's telephone instruments 14 and a plurality of local neighborhood libraries. A plurality of Dual Tone Multifrequency (DTMF) Receivers 9 receives user command signals via conventional telephone cable 12, using a dial up public switched telephone network (PSTN) 13 that links the central library 5 to a plurality of user's telephone sets 14 located at a plurality of user's physical locations 1A. The master billing and control computer 8 transmits voice coded computer information via 12, 13 and 14 to assist the user in inputting commands, using methods known to those versed in the art. A plurality of control data communications modems 10 are incorporated to enable the high speed transmission of data signals to and from a plurality of local library control computers 15 located in each of a plurality of local electronic libraries 2. For security reasons, the control data communications path 17 is preferably a dedicated voice circuit assigned by the telephone carrier; by way of illustration, it is shown as a copper conductor cable. The data link transmits usage data and control commands from the local library to the central library, and control commands from the central library to the local library. The control commands transmitted from the central library master computer determine what programming is stored on what storage/play device located at the local library. A basic component of the local library is a local storage, modulation and RF bus network 18, said network has as input television program signals, both Class A, and Class B Video on Demand (VOD) signals transmitted to it via a plurality of fiber optic transmission facilities 19, and a plurality of television signal equal access points (EAP) 20 that may be used by television programming providers to distribute their programming over the network.
If the number of record/store/playback apparatus provided at a local library is n units, the number of record/store/playback apparatus storing programming and available for access by users at any one time is n-x units. The specific x units of apparatus not available for access at any given point in time are alternately available for the purpose of recording programming being downloaded to the local library from the central library. Thereby permitting the infinite discreet rotation of available programming over time.
Example user locations 1A, 1B, and 1C terminate the reception of transmitted programming at the user's television receiving apparatus 21. Programming is transmitted to each user's location using the most economical of the following transmission means, fiber optics, coaxial cable, or paired copper conductor.
In user access method "A", twisted pair copper conductor 3A is employed as the dedicated television signal transmission line between the local library 2 and each of the plurality of neighborhood user locations 1A. Baseband video transmitter 28 is designed to pre-emphasize the transmitted baseband video signal to compensate for high frequency capacitive roll-off effects and possible color subcarrier intermodulation distortion that will be introduced by the twisted pair copper conductor 3A when used as the transmission medium for the high frequency signals of the base band video signal. The so conditioned video signal is then amplified and converted to a balanced impedance relative to ground output by video baseband transmitter 28 and carried to a user location. The associated audio signal being amplified and applied in a balanced to ground configuration to a second telephone cable pair (not shown) for simultaneous transmission to said user's location. At said user's location the separate audio and video signals are AM VSB modulated onto an RF carrier by Baseband Receiver 37 for subsequent reception by user's TV receiving apparatus 21.
User generated control and selection signals are transmitted from the user location to the local library control computer by using public switched telephone network 13 by dialling the master control and billing computer 8 and using the dual tone multifrequency (DTMF) tones produced by the telephone 14. The origin of the programming selection and control signalling being received by the master billing and control computer is assured by employing one of two possible methods. Firstly, the user may be required to enter an identity and/or security code known only to the user served by dedicated television delivery path 3A. Alternately, the billing and control computer can be equipped to identify the incoming caller by using automatic number identification (ANI) used, for example, in toll billing for long distance calls.
In User access method "B", fiber optics is employed as the dedicated television signal transmission line between the local library 2 and each of the plurality of neighborhood user locations 1B. This configuration is the preferred embodiment of the dedicated television signal transmission line 3B as it provides the most bandwidth to each user with the least amount of cable bulk at the local community electronic library 2 end. Radio frequency television signals are modulated onto a lightwave medium via a plurality of photonic transmitters 22. The transmitted optical signal is received from the fiber optic dedicated television signal transmission line 3B by photonic receiver 24. Photonic receiver 24 converts the received optical signal into a radio frequency signal which is transmitted to the user's TV 21 via coaxial cable 25.
User input to the network for selection and control of the programming being received or being selected to be received can be communicated to the control computer via the user's telephone set located at the user location 1B (not shown, but see 14 in user access method "A"). Alternately, programming selection and control signals can be communicated to the control computer 15 through user operation of a wireless transmitter 28 which transmits a low data speed wireless signal to wireless receiver 29. Wireless receiver 29 then converts the wireless signal to an electrical signal for transmission over a user control signal path 30B, which is a copper transmission path that is dedicated to the individual user. Thus the origin of the programming selection and control signal is assured by the immovable physical path in the form of a dedicated user control signal path 30B.
In user access method "C" coaxial cable is employed as the dedicated television signal transmission line 3C between the local library 16 and each of the plurality of neighborhood user locations 1C. Radio frequency television signals are amplified for transmission by a plurality of transmitters 26, coaxial cable 32 connects said amplifier apparatus to the high frequency transmit port of High/Low Coupler 33, coaxial cable 3C connects the high frequency output port of High/Low Coupler 27 to the high frequency input port of High/Low Coupler 34, and coaxial cable 35 connects the high frequency output port of High/Low Coupler 34 to user's television receiving apparatus 21. Selection and control signals can be communicated to the control computer 15 through user operation of a wireless transmitter 28 which is connected to the low frequency input port of the High/Low Coupler 34 where the user control signal path 30C is carried in the reverse direction on the coaxial cable to High/Low Coupler 27 the low frequency output port of which is connected to the local control computer 15. Thus, in this configuration, the coaxial cable 3C is a 2 way transmission apparatus with the high frequency TV signals going in one direction and the low frequency user control data signals going in the other direction, a technique that is well known to practitioners of the art. Thus the origin of the programming selection and control signal is assured by the immovable physical path in the form of dedicated coaxial cable 30C.
It will be understood that user input to the network for selection and control of the programming being received or being selected to be received can be communicated to the control computer via the user's telephone set located at the user location 1C (not shown, but see 14 in user access method "A"). In such a case, the need for High/Low Couplers 34 and 27 at each end of the coaxial cable 3C is eliminated as the coaxial cable is no longer a 2 way transmission apparatus; it is reduced to carrying high frequency TV signals in one direction only.
Referring now to FIGS. 3A and 3B which shows the apparatus for formulating and multiplexing Type A Video-on-Demand (VOD) signals onto one of a plurality of Type A Buses, for formulating and multiplexing Type B Video-on-Demand (VOD) signals onto one of a plurality of Type B Buses, the method of eliminating the cable TV monopoly by providing a low cost opportunity for each cable TV operator to have dedicated access to one of a plurality of Type C buses and providing the opportunity for users to select the bus and cable TV programming of their choice.
With reference to FIGS. 3A and 3B there is shown the apparatus for receiving programming transmitted to one of a plurality of local neighborhood electronic libraries, and the apparatus for processing said programming for subsequent distribution on radio frequency distribution busses.
Shown is one of a plurality of Type A Video-on-Demand Buses, one of a plurality of Type B Video-on-Demand Buses, and one of a plurality of Type C Cable Television buses.
Type A programming is stored for access by users in a video library comprising a plurality of record and playback units 45. At any period in time, some of the record and play units are off-line and not available for access by users; said units are available at that time for receiving and recording programming downloaded from the central library. By so doing the Type A VOD programming available at a local library is continually being changed, and by said continuous change the capacity of the transmission facility from the central library to the local library for Type A VOD programs need not be large. Said transmission facility is labelled as 4 in FIG. 1, and as 38 in FIG. 3A and is shown as a single fiber optic fiber. A fully equipped single fiber has a capacity as high as 864 program down loads per day with each program being 2 hours in duration and download load being in real time, a minimum equipped fiber would have a capacity of 12 downloads per day of 2 hour programs at real time. The fully equipped fiber carries 72 television channels and the minimum equipped fiber 1 channel.
Should the facility be a coaxial cable transmission line from the central library, or a coaxial cable feed from a source other than the central library such as a television receive only satellite earth station, the facility is shown as 39 in FIG. 3A.
All programming selection, recording and playback operations are controlled by information received by the local library control computer 15 from either the master control and billing computer 8 via control data communications path 17, or the User via the user control data signal path 30, as previously described in reference to FIG. 2 describing embodiments 30A, 30B and 30C.
The central library Master Control and Billing Computer 8, in FIG. 2, transmits signals on control data communications path 17 advising the local control computer 15 to ready recording apparatus for the reception of Type A VOD programming about to be downloaded to said local library 2 on fiber optic link 38; it also instructs the Local Control Computer 15 as to which one of a plurality of record units 45 the programming is to be recorded on, and informs the Local Control Computer 15 as to the radio frequency television channel the program will be transmitted on.
For example, should the programming be transmitted on fiber optic feed 38, the Local Control Computer 15, having previously been advised of said transmission by Master Control and Billing Computer 8 over control data communications path 17, sends control data via input selector control signal path 41 to the input selector 40 to enable reception of programming from said fiber optic feed 38 and internal photonic receiver circuitry 60 so as to receive a plurality of television signals, electrically formulated, by way of example, as radio frequency amplitude modulated vestigial side band (AM VSB) signals; said RF signals are fed to distribution unit 42 via selector switch 61, said distribution unit 42 distributes said signals to a plurality of tunable, addressable demodulators 44. Said tunable demodulators are controlled by the Local control computer 15 via tuneable, addressable demodulator control path 43, the audio and video outputs of said demodulators is applied to the input of one of a plurality of record and playback units 45. Local Control Computer 15 controls the recording operation of the record and playback units 45 over control path 46. Upon reception of a user request signal on of a plurality of user control signal paths 30, said Local Control Computer 15 transmits a play signal to the record and playback units 45 stores information as what program was ordered by what user and the time and date of the request, said ordering information is subsequently transmitted via control data communications path 17 to the Master Control and Billing Computer 8 in FIG. 2. Video and audio signals corresponding to said programming request are modulated by the RF modulator 47 associated with the record and playback unit 45 playing said requested programming. Typically each of the plurality of Type A RF Buses 49 could carry up to 72 separate simultaneous programs. Each of said busses 49 has a plurality of outputs one of which is dedicated to each of the plurality of user locations 1 associated with said local neighborhood library 2. Typically, there are up to 600 user locations fed from each local neighborhood library.
The central library's Master Control and Billing Computer, 8 in FIG. 2, transmits signals on control data communications path 17 advising the local control computer 15 to ready recording apparatus for the reception of Type A VOD programming about to be received by said local library 2 from satellite receiving antenna system 64, it also instructs the Local Control Computer 15 as to which one of a plurality of record units 45 the programming is to be recorded on. For example, should the satellite television programming be received on coaxial cable 39, the Local Control Computer 15, having previously been advised of said transmission by Master Control Computer 8 over control data communications path 17, sends control data to the input selector 40 to enable reception of programming from said coaxial cable 39, said input selector switch tunes its internal satellite receiving apparatus 62 via control signal path 41 so as to receive an audio and a video signal. Said tuning signals received by input selector 40 over control signal path 41 control the positioning of the satellite receiving antenna, polarization selection, and video and audio subcarrier selection. Antenna positioning control signals are transmitted to satellite antenna 64 by control path 63. Said video/audio signals are VSB AM modulated by the satellite receiving apparatus onto an RF television channel carrier and distributed to a plurality of tunable, addressable demodulators 44 and subsequently to a plurality of record and playback units 45. Local Control Computer 15 controls the digitally controlled tuner/demodulator 44 over control path 43, and also controls the recording operation of the record and playback units 45 over control path 46. Upon reception of a user request transmission over one of a plurality of user control signal paths 30, said Local Control Computer 15 addresses the desired record and playback unit 45 and transmits a play signal to said addressed unit, said unit stores the transmitted program. Video and audio signals corresponding to said programming request are modulated by the RF modulator 47 associated with the record and playback unit 45 playing said requested programming. Typically, each of the plurality of Type A RF Buses 49 could carry up to 72 separate simultaneous programs. Each of said busses 49 has a plurality of outputs one of which is dedicated to each of the plurality of user locations 1 associated with said local neighborhood library 2. Typically, there are up to 600 user locations fed from each local neighborhood library.
The central library's Master Control and Billing Computer 8, in FIG. 2, transmits signals on control data communications path 17 advising the local control computer 15 as to the name and duration, and channel assignments given to Type B Video-on-Demand programming about to be or being transmitted from the central library 5 to the local neighborhood library 2 for access by users 1 via one of a plurality of Type B distribution busses 54. The typical duration of each Type B VOD program would be about two hours. Typically, each of a plurality of Type B programs would be transmitted on 24 different radio frequency television channels with the start time of transmission being delayed 5 minutes from the start of the first transmission to the start of the second, and being delayed 5 minutes from the start of the second transmission to the start of the third transmission, etc. The purpose of so doing is to provide the user with the ability to effectively pause his or her reception of said programming 5 minutes, 10 minutes, 15 minutes, etc., so as to permit the user with the opportunity to replay programming or to take a break from viewing. Typically 72 RF TV channels would be received on each fiber, or 1 fiber has the capacity to carry 3 separate Type B Video-on-Demand programs, where each of said programs offers said 24 separate viewing opportunities spaced 5 minutes apart in playing time. The preferred embodiment is for each fiber to carry the 72 channels in a VSB AM frequency division multiplex form, with each of said 72 channels being modulated onto different television channel. Channel frequencies are repeated on fibers feeding different Class B buses. The photonics receivers 52 converts the signals from optical to electrical form. The broadband RF amplifiers 53 each amplify the 72 TV channels prior to their being combined onto the radio frequency distribution bus 54. Each of said busses 54 has a plurality of outputs one of which is dedicated to each of the plurality of user locations 1 associated with said local neighborhood library 2. Typically there are up to 600 user locations fed from each local neighborhood library.
Referring to the Type "C" Cable TV BUS portion of FIG. 3, there is shown a television signal equal access point 20 which allows equal access by television programmers to distribution of their television signals by the network. The preferred embodiment is for each equal access point to be a single coaxial cable type feed for carrying 1 to 72 channels in a VSB AM frequency division multiplex form to broadband amplifier 57, with each of said 1 to 72 channels being modulated onto different television channel. Channel frequencies are repeated on different coaxial cables feeding different Class C buses. The broadband RF amplifiers 57 each amplify the 72 TV channels prior to their being combined onto the radio frequency distribution bus 58. Each of said busses 58 has a plurality of outputs 59 one of which is dedicated to each of the plurality of user locations 1 associated with said local neighborhood library 2. Typically there are up to 600 user locations fed from each local neighborhood library.
FIG. 4 shows the central library apparatus for inserting identification information for the purpose of identifying the source of unauthorized duplication of Type B VOD programming for commercial profit purposes.
Video play unit 65 is one of 4 shown but one of 72 provided for each fiberoptic fiber, each of which has a capacity of carrying 3 Type B programs to a local library as previously said, each program being played on 24 video play units 65, each play unit starts the play of the program 5 minutes after the start of the previous unit thus providing the user the opportunity to effectively pause or replay the program from 5 minutes to 120 minutes after initial playing has begun on the first of said video play units. Each of the plurality of video play units 65 feeds one of a plurality of vertical blanking interval (VBI) data inserters 66. The output of each of the plurality of VBI data inserters are provided to insert information into the vertical blanking interval of the played program. The inserted VBI information identifies the time and date of the transmission and the identity of the local library to which the program is being transmitted for subsequent distribution to local neighborhood community users. Each of the plurality of VBI data inserters 66 feeds one of a plurality of character generators 67. The character generators are provided to insert information into the visible video of the played program. The inserted video information identifies the time and date of the transmission and the identity of the local library to which the program is being transmitted for subsequent distribution to local neighborhood community users. Said information is distributed throughout the program so as to be difficult to remove without deleting valuable program information. Either the VBI data inserter or the character generator may be deleted. It is desirable but not necessary to incorporated both deterrent methods.
FIG. 5 shows the local library apparatus for inserting identification information for the purpose of identifying the source of unauthorized duplication of Type B VOD programming for commercial profit purposes. This apparatus enhances the copy protection information provided by the central library disposed equipment described in relation to FIG. 5 as it identifies the specific user location to which the programming is being transmitted compared to the identification of only the local library to which the programming is being distributed. When Type B VOD programming is selected for distribution to one of a plurality of user locations by the bus selector switch 91 in FIG. 7, 72 channels of Type B programming is switched through the bus selector switch from one of a plurality of Type B buses 54 to a tunable frequency converter 94. The Local Control Computer 14, that also controls the bus selector switch 91 via control path 93 in FIG. 7, addresses the tunable RF converter that is provided on a dedicated basis to the ordering user location and transmits digital tuning information via control path 101 in FIG. 5 to the addressed converter 94. The RF television channel that has been ordered by said ordering user is tuned to and demodulated, the demodulated video output of which is input to a dedicated VBI data inserter 99 which inserts time, date and user location identification information throughout the vertical blanking interval of the video signal. The output of said VBI data inserter is connected to the dedicated character generator 100 which inserts time, date and user location identification information throughout the visible portion of the video signal. Said information is distributed throughout the program so as to be difficult to remove without deleting valuable program information. As is the case in the apparatus shown in FIG. 4 either the VBI data inserter or the character generator may be deleted. It is desirable but not necessary to incorporate both deterrent methods.
The wireless remote control shown in FIG. 6 is provided for the purpose of providing the user with a user friendly apparatus for requesting programming directory information and, possibly, consumer goods as well. By pressing source button 77 the user can transmit to the local library a request to access any one of a plurality of video distribution buses. Two Source buttons are shown, one for toggling upward through the available buses and the other for toggling downward through the available buses.
A user may review a listing of the available programming offered on the selected bus by pressing one of the two directory buttons 78. Subsequent pressing of the Up Directory button permits the user to scroll upward through the directory of offered programming and by pressing the Down Directory button permits the user to scroll back down through the directory listing for the selected bus. The program listed in the middle of the directory listing shown on the TV screen is highlighted on said screen for the purpose of identifying the program that would be ordered should the user press the File Select button 79 at that time.
When the user has requested Type "A" VOD programming, pressing the Play button 80 initiates the start of the playing of the previously selected program. Similarly pressing the Stop button 81 halts the play operation. Pressing the Rewind button 82 permits the user to rewind the played program, the amount rewound depends on the amount of time that the user has the rewind button depressed. Similarly the pressing of the Fast Forward button 83 permits the user to fast forward through the selected program.
Should the user have selected a Type B VOD program, pressing the Rewind 5 min. button 84 results in the user's dedicated tunable RF converter 94 being re-tuned to an RF TV channel delivering the selected programming but delayed 5 minutes relative to the previously selected channel. Subsequent pressing of the Rewind 5 minute button permits the user to jump back an additional 5 minutes, etc. Similarly pressing the Fast Forward button 85 permits the user to jump forward to an RF TV channel which is also carrying the selected program but the playing of which is 5 minutes ahead of the previously selected RF channel.
The ten digit keypad 86 is provided for the purpose of permitting the user to input a Personal Identification Number or PIN number. The insertion of the PIN number permits the user to order consumer goods, said consumer goods being advertised on a consumer goods advertising channel. Said advertising channel being distributed on one of the plurality of Type C Cable TV buses 58 (although alternatively it may be transmitted to the local library 2 from a central source by satellite, coaxial cable or fiberoptic cable and distributed on a fifth bus type).
The transmission of said PIN number also permits the user to have the payment for said ordered goods authorized to be charged to a previously approved line of credit or credit card. By pressing the Purchase button 87 the ordering of the advertised goods, seen at the instant that said goods are visible on said ordering user's TV receiving apparatus screen 21, is initiated. Upon reception of such a request the local control computer 15 switches the video signal then being delivered to the user to the Directory or D Bus, the D Bus 92 is shown in FIG. 6 as is the Bus Selector Switch 91 and the local control computer 15. The Local Control Computer, transmits a text message to a previously idle D Bus RF television channel, switches said ordering user's bus selector switch to the D Bus, tunes said ordering user's RF frequency converter to said previously idle RF television channel, for the purpose of transmitting a request to said ordering user's television receiving apparatus. Said request asks said ordering user to enter said PIN number. Should a valid PIN number be entered within a specified time period the Local Control Computer 15 then transmits a series of messages to the purchasing user's TV 21 that asks the user to identify, using the keypad 86, the credit card type, credit card expiry data and credit card number to which the purchase is to be charged. Upon receipt of the required information the control computer then transmits a text description of the product ordered and requests the purchaser to confirm the product ordered by pressing the Purchase button 87 for a second time. Alternately should the Stop button 81 be pressed the order is cancelled. The Local Control Computer 15 then transmits all required ordering information to the central Master Computer and Billing Computer 8 for order processing.
FIG. 7 shows apparatus for permitting the user to have user controlled selection of any of a large plurality of channels. A plurality of buses are shown, each of which carries a plurality of radio frequency, frequency division muitiplexed television channels. Each bus typically would have a capacity of 72 of such channels, which is a typical maximum number of channels that could be delivered by a cable TV operator using conventional cable TV delivery apparatus. Although only one of each of the Type A Video-on-Demand Bus 49 and one Type B Video-on-Demand Bus 54 are shown, and only one Type C Cable TV Bus 59 and one Type D Directory Bus 92, it is understood from the earlier disclosure in relation to this invention that, typically, there would be employed a plurality of each bus in use at each local library 2.
User input control signals are transmitted to the Local library Control Computer 15, which performs functions as a directory generator, on a plurality of signal paths 30 as previously embodied in FIG. 2. The local library control computer 15 reacts to a user request for a specific bus and program by addressing the dedicated bus selector switch 91 which is provisioned for the requesting user's location, by transmitting to that selector switch via control path 93 instructions for it to connect the appropriate bus to the digitally tunable RF television channel frequency converter 94. The switching technology used may be any of the methods described in Bradley et al. in U.S. Pat. No. 4,878,245.
Also shown in FIG. 7 is the apparatus provided for the purpose of generating text information, such as the previously referred to directory of offered programming, and consumer product ordering information and prompts. Said directory of offered programming information is transmitted in response to user control and is typically different from text information being delivered to other users at the same time. Said text information being displayed on the user's TV screen. Said text information is converted from data format to video format and modulated onto one of a plurality of RF television channels by one of a plurality of video drivers and modulators 92. Said RF television channels are frequency division multiplexed onto one of a plurality of directory or D Buses 92. Said D Bus output is amplified and split into 600 separate outputs, one of which is applied via signal path 97 to each of the bus selectors 91 dedicated to an end user location. Bus selection is controlled by control signal path 93, and RF channel selection is controlled by turning signal path 95. The ordered program is transmitted to an RF modulator, baseband audio and video amplifiers or photonic transmitter via signal path 96 for subsequent transmission to the user's location as shown in FIG. 2.
It will be understood that various modifications will occur to those skilled in the art without departing from the inventive concept, whose scope it is desired to define only by the appended claims. | Disclosed is an improved system for the delivery of entertainment and educational programming from a plurality of electronic libraries to a plurality of users. Users actuate a hand operated control device to: review a listing of available programming; enable the delivery of a program from a library; or control the delivery of forwarding and rewinding through the programming, and authorizing the purchase of advertised consumer goods by entering in personal identification numbers. The network of libraries and the paths for delivering the programming stored therein is arranged for optimum transmission efficiency and maximum access capacity. The key idea in optimizing transmission efficiency and access capacity is to recognize that programming can be grouped into different classes, and that not all classes of programs should be stored in all libraries. High demand entertainment programming should be stored and delivered from a central source whereas low demand educational or cultural programming should be stored and delivered from a local neighborhood library where there is a special interest in such programming. The system is intrinsically secure and encryption is not required. Programs are not delivered to any physical address other than that of the ordering user. Apparatus is employed to discourage the unauthorized copying of delivered programming. The system also permits the delivery of conventional cable television signals on a competitive basis. Apparatus is employed that maximizes access capacity and minimizes investment cost. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a novel fluorine-containing olefin, and more particularly to a novel fluorine-containing olefin useful as a monomeric material for preparing fluorine-containing polymers.
It is an object of the present invention to provide a novel fluorine-containing olefin.
A further object of the present invention is to provide a novel fluorine-containing olefin having a functional group.
A still further object of the present invention is to provide a novel fluorine-containing olefin which is copolymerizable with ethylenically unsaturated compounds and provide fluorine-containing copolymers useful as raw materials for paints and fluororubbers curable at room temperature.
These and other objects of the present invention will become apparent from the description hereinafter.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a fluorine-containing olefin of the formula:
CF.sub.2 ═CF(CF.sub.2).sub.m (CH.sub.2).sub.n OH
wherein m is 0 or an integer of 1 to 10 and n is an integer of 1 to 4.
The fluorine-containing olefins of the present invention are copolymerizable with ethylenically unsaturated compounds such as ethylene and propylene, and ethylenically unsaturated fluorine-containing compounds such as tetrafluroethylene, chlorotrifluoroethylene and 1,1-difluoroethylene. The copolymers of the fluorine-containing olefin of the invention and other olefins can be utilized as raw materials for room temperature curing fluoro-resin paints and fluoro-rubbers.
DETAILED DESCRIPTION
The novel fluorine-containing olefin of the present invention having the formula (1):
CF.sub.2 ═CF(CF.sub.2).sub.m (CH.sub.2).sub.n OH (1)
wherein m is 0 or an integer of 1 to 10 and n is an integer of 1 to 4, can be synthesized, for instance, by preparing a compound of the formula (2):
CF.sub.2 X.sup.1 CFX.sup.2 (CF.sub.2).sub.m (CH.sub.2).sub.n OH (2)
wherein X 1 and X 2 are the same or different and each is chlorine or bromine, and m and n are as defined above, and causing chlorine and/or bromine to eliminate from the compound (2).
The compound (2) can be prepared by various processes, for instance, by the following processes (a), (b) and (c).
(a) The compound (2) is prepared by reducing a compound of the formula (3):
CF.sub.2 X.sup.1 CFX.sup.2 CF.sub.2 COOR (3)
wherein X 1 and X 2 are as defined above, and R is a lower aliphatic group or an alicyclic group, with a reducing agent as used in a usual reduction reaction, e.g. hydrogen (used with a catalyst such as platinum oxide or palladium), lithium aluminum hydride, sodium borohydride or lithium borohydride. The reaction is carried out in a solvent such as water, ethers or alcohols at a temperature of 5° to 100° C., usually at a reflux temperature of the reaction solvent used. Examples of the solvent are, for instance, diethyl ether, dibutyl ether, tetrahydrofuran, dioxane, N-methylmorpholine, methanol, and the like. In case of using hydrogen as a reducing agent, the reaction pressure is usually from 1 to 150 atms, and in case of other reducing agents, the reaction is conducted at atmospheric pressure. The amount of the reducing agent is from a stoichiometric amount to 10 times the stoichiometric amount.
(b) In another process for preparing the compound (2), a compound of the formula (4):
CF.sub.2 X.sup.1 CFX.sup.2 (CF.sub.2).sub.m I (4)
wherein X 1 , X 2 and m are as defined above, is reacted with ethylene by using a radical-producing compound, e.g. peroxides and azo compounds, as a catalyst, by ultraviolet radiation, or by heating, to generate iodine radical, thereby producing a compound of the formula: CF 2 X 1 CFX 2 (CF 2 ) m CH 2 CH 2 I wherein X 1 , X 2 and m are as defined above. A reaction solvent such as a halogenated hydrocarbon or water may be employed. The compound (2) is obtained by reacting the thus produced compound with chlorosulfonic acid and water in that order. In this oxidation reaction, a reaction solvent such as a halogenated hydrocarbon may be employed. Examples of the peroxides are, for instance, t-butyl peroxyisobutyrate, t-butylperoxy(2-ethylhexanoate), isobutyryl peroxide and di-isopropyl peroxydicarbonate. Examples of the azo compounds are, for instance, azobisisobutyronitrile. Both the above-mentioned former ethylene addition reaction and latter oxidation reaction are conducted at a temperature of 15° to 200° C. The reaction pressure is from 1 to 50 atms for the ethylene addition reaction and from 1 to 10 atms for the oxidation reaction.
(c) The compound (2) is also prepared by subjecting the compound (4) and allyl alcohol to a radical reaction in the same manner as in the above process (b) to produce a compound of the formula: CF 2 X 1 CFX 2 (CF 2 ) m CH 2 CHICH 2 OH wherein X 1 , X 2 and m are as defined above, and then reducing the resulting compound. The former reaction is carried out usually at a temperature of 15° to 150° C. and a pressure of 1 to 10 atms. The latter reduction reaction can be conducted in the same manner as in the process (a).
The compound (2) as obtained by the above processes (a), (b) and (c) is reacted with a dehalogenation agent such as zinc, magnesium, tin, sodium or potassium to eliminate chlorine and/or bromine. The reaction is carried out at a temperature of 0° to 150° C., preferably 50° to 100° C., at a pressure of 1 to 10 atms in a reaction solvent such as water, dimethylformamide, methanol or acetone.
The present invention is more specifically described and explained by means of the following Examples. It is to be understood that the present invention is not limited to the Examples, and various changes and modifications may be made in the invention without departing from the spirit and scope thereof.
EXAMPLE 1
[Synthesis of CF 2 ═CFCH 2 CH 2 OH]
(1) A liter autoclave equipped with a stirrer and a thermometer was charged with 1 mole (279 g) of CF 2 ClCFClI and 3 g of t-butyl peroxyisobutyrate. After degassing, ethylene was supplied to the autoclave and the reaction was carried out at a temperature of 70° to 80° C., while maintaining the inner pressure at 5 kg/cm 2 G with supply of ethylene, until no ethylene was consumed. The reaction mixture was taken out and was rectified, thus CF 2 ClCFClCH 2 CH 2 I (boiling point: 68° to 70° C. at 25 mmHg) was obtained in a yield of 96%.
(2) A 1 liter flask equipped with a stirrer and a thermometer was charged with 0.5 mole (151.5 g) of CF 2 ClCFClCH 2 CH 2 I and 1 mole (116.5 g) of chlorosulfonic acid, and the reaction was carried out at 40° C. for 24 hours. The obtained reaction mixture was added dropwise to water, and the under oil layer was taken out and rectified to give 82 g of CF 2 ClCFClCH 2 CH 2 OH (yield: 83.7%).
(3) A 1 liter flask equipped with a stirrer, a thermometer, a reflux condenser and a dropping funnel was charged with 300 ml of water and 100 g of zinc, and 0.5 mole (98.5 g) of CF 2 ClCFClCH 2 CH 2 OH was added dropwise to the flask at a temperature of 50° to 60° C. The inner temperature rose to 80° C. by heat generation with start of the reaction. After the completion of the dropwise addition, the reaction was continued at 80° C. for 5 hours. The obtained organic compound was rectified to give CF 2 ═CFCH 2 CH 2 OH (boiling point: 93° C. at 760 mmHG). The yield throughout the steps (1) to (3) was 73%.
The obtained product was subjected to nuclear magnetic resonance (NMR) analysis. The results are shown below.
NMR data in which fluorine atom and hydrogen atom are indicated as follows: ##STR1##
______________________________________.sup.19 F (external standard: CF.sub.3 COOH, high magnetic fieldside: +, hereinafter the same)Fluorineatom +δ (ppm) Spin-spin bond (Hz)______________________________________a 26.9 d, d, t, J.sub.gem = 89, J.sub.cis = 34, J.sub.F - H = 2b 47.0 d, d, t, J.sub.trans = 114, J.sub.gem = 89, J.sub.F- H = 4c 97.8 d, d, t, J.sub.cis = 34, J.sub.trans = 114, J.sub.F- H = 21______________________________________
______________________________________.sup.1 H (internal standard: tetramethylsilane, hereinafter the same)Hydrogenatom δ (ppm) Spin-spin bond (Hz)______________________________________d 2.57 d, m, J.sub.F- H = 21e 3.83 t, J.sub.H-- H = 7f 4.4 s______________________________________
EXAMPLE 2
[synthesis of CF 2 ═CFCF 2 CF 2 CH 2 CH 2 OH]
A 1 liter autoclave equipped with a stirrer and a thermometer was charged with 1 mole (279 g) of CF 2 ClCFClI, 5 g of t-butyl peroxyisobutyrate and 100 g of water. After degassing, tetrafluoroethylene was supplied to the autoclave and the reaction was carried out at a temperature of 70° to 80° C., while maintaining the inner pressure at 3 kg/cm 2 G with supply of tetrafluroethylene. After the completion of the supply of 1 mole of tetrafluroethylene, the reaction mixture was allowed to stand for some time and the reaction was finished. The reaction mixture was rectified. Employing the thus obtained product, the desired compound CF 2 ═CFCF 2 CF 2 CH 2 CH 2 OH was prepared in the same manner as in the steps (2) and (3) of Example 1. The boiling point of the final product was 107° C. at 200 mmHg, and the yield throughout the whole reactions was 77%.
The results of NMR analysis are shown below.
NMR data in which fluorine atom and hydrogen atom are indicated as follows: ##STR2##
______________________________________.sup.19 FFluorineatom +δ (ppm) Spin-spin bond (Hz)______________________________________a 14 d, d, t, J.sub.gem = 60, J.sub.cis = 40, J.sub.F-- F = 6b 30.3 d, d, t, t, J.sub.trans = 116, J.sub.gem = 60, J.sub.F-- F = 28.5c 111.4 d, d, m, J.sub.trans = 116, J.sub.cis = 40,d 42.7 me 37.8 t, m, J.sub.F- H = 18______________________________________
______________________________________.sup.1 HHydrogenatom δ (ppm) Spin-spin bond (Hz)______________________________________f 2.4 t, t, J.sub.F- H = 18, J.sub.H-- H = 7g 3.9 t, J.sub.H-- H = 7h 4.6 s______________________________________
EXAMPLE 3
[Synthesis of CF 2 ═CFCF 2 CH 2 OH]
A 1 liter flask equipped with a stirrer, a thermometer, a reflux condenser and a dropping funnel was charged with 5.5 g of LiAlH 4 . After replacing air in the flask with nitorgen, 200 ml of diethyl ether was added dropwise to the flask through the dropping funnel. Thereafter, 200 ml of a diethyl ether solution of 0.1 mole (26.1 g) CF 2 ClCFClCF 2 COOCH 3 was added dropwise to the flask through the dropping funnel over about 2 hours with stirring, and diethyl ether was then refluxed for about 15 minutes under heating.
The reaction mixture was cooled to room temperature, and water was added to the flask to decompose the unreacted LiAlH 4 . The reaction mixture was then acidified with diluted hydrochloric acid. An organic layer was taken out, and rectified to isolate CF 2 ClCFClCF 2 CH 2 OH (boiling point: 85° C. at 30 mmHg). The yield was 85%.
Dechlorination reaction was then carried out in the same manner as in the step (3) of Example 1 to give CF 2 ═CFCF 2 CH 2 OH (boiling point: 96° C. at 760 mmHg). The yield throughout the whole reactions was 70%.
The results of NMR analysis are shown below.
NMR data in which fluorine atom and hydrogen atom are indicated as follows: ##STR3##
______________________________________.sup.19 FFluorineatom +δ (ppm) Spin-spin bond (Hz)______________________________________a 18.8 d, d, t, J.sub.gem = 68, J.sub.cis = 37, J.sub.F-- F = 6b 33 d, m, J.sub.trans = 13c 112.5 d, d, m, J.sub.cis = 37, J.sub.trans = 113,d 35.1 m______________________________________
______________________________________.sup.1 HHydrogenatom δ (ppm) Spin-spin bond (Hz)______________________________________e 4.0 t, J.sub.H- F = 115f 4.7 s______________________________________
EXAMPLE 4
[Synthesis of CF 2 ═CFCH 2 CH 2 CH 2 OH]
A 1 liter flask equipped with a stirrer, a thermometer, a reflux condenser and a dropping funnel was charged with 279 g of CF 2 ClCFClI and 3.5 g of azobisisobutyronitrile. After heating to 90° C. with stirring, 75 g of allyl alcohol was added dropwise to the flask through the dropping funnel. The reaction was further continued at a temperature of 90° to 95° C. for 15 hours. The unreacted starting material was removed from the reaction mixture under reduced pressure to give 303 g of CF 2 ClCFClCH 2 CHICH 2 OH.
To the above product were added 500 ml of diethyl ether and 25 g of LiAlH 4 , and the reduction reaction was carried out under reflux of diethyl ether to give 125 g of CF 2 ClCFClCH 2 CH 2 CH 2 OH. The yield was 65%.
Dechlorination reaction was then carried out in the same manner as in the step (3) of Example 1 to give CF 2 ═CFCH 2 CH 2 CH 2 OH (boiling point: 95° C. at 155 mmHg). The yield throughout the whole reactions was 55%.
The results of NMR analysis are shown below.
NMR data in which fluorine atom and hydrogen atom are indicated as follows: ##STR4##
______________________________________.sup.19 FFluorine +δatom (ppm) Spin-spin bond (Hz)______________________________________a 29.9 d, d, t, J.sub.gem = 92, J.sub.cis = 33, J.sub.H- F = 2b 48.5 d, d, t, J.sub.trans = 116, J.sub.gem = 92, J.sub.H- F = 4c 97.5 d, d, t, J.sub.trans = 116, J.sub.cis = 33, J.sub.F- H = 22______________________________________
______________________________________.sup.1 HHydrogenatom δ (ppm) Spin-spin bond (Hz)______________________________________d 2.6 d, m, J.sub.F- H = 22e 2.05 q, J.sub.H-- H = 7f 3.86 t, J.sub.H-- H = 7g 5.33 s______________________________________
EXAMPLE 5
A 1 liter glass autoclave was charged with 400 g of tetrafluorodichloroethane, 250 ml of water, 2 g of di-isobutyryl peroxide and 5.5 g of the monomer synthesized in Example 2. After degassing, a monomer mixture of 1,1-difluoroethylene and chlorotrifluoroethylene in a molar ratio of 9:1 was supplied to the autoclave, and the polymerization was carried out at 40° C. for 21 hours with stirring, while maintaining the pressure at 8 kg/cm 2 with supply of the monomer mixture and adding 1 g of di-isobutyryl peroxide and 5 g of the monomer synthesized in Example 2 every 5 hours. The pressure is released, and the reaction mixture was taken out, washed with water and dried at 80° C. to give 85 g of a copolymer.
In 70 g of isobutyl acetate was dissolved 30 g of the copolymer, and 13 g of hexamethylene diisocyanate trimer was added to the solution. The solution was cast onto an aluminum plate and cured. The cured film was transparent and glossy and had a pencil hardness of 2H. The film was also subjected to an accelerated weathering test by Weather-O-Meter for 4,000 hours, but there was little change and the film had a very excellent weatherability as compared with a polymethyl methacrylate film tested simultaneously.
In addition to the ingredients used in the Examples, other ingredients can be used in the Examples as set forth in the specification to obtain substantially the same results. | A fluorine-containing olefin of the formula: CF 2 ═CF(CF 2 ) m (CH 2 ) n OH wherein m is 0 or an integer of 1 to 10 and n is an integer of 1 to 4, which is copolymerizable with various ethylenically unsaturated compounds and provide fluorine-containing copolymers useful as raw materials for room temperature curing paints, fluorine-containing rubbers and the like. | 2 |
BACKGROUND OF THE INVENTION
[0001] The present invention is directed to the field of arts of crafts. In particular, the present invention is directed to an apparatus that can be safely used to heat and melt substances known as thermographic resins or embossing powders. In particular, the present invention is directed to use with a very coarsely ground type of embossing powder referred to as Ultra Thick Embossing Powder or UTEE. The embossing powders, in the melted state, are used to coat various shaped items with the embossing powder to create various jewelry items and other molded artifacts. In addition, the present invention can also be utilized to melt other crafting materials such as candle wax, glue, crayons, soap, etc.
[0002] One of the currently available methods for melting embossing powders and other substances is to utilize a hair dryer to apply heat to a container in which the material to be melted is placed. There are also some crude integrated hot pot type devices. However, these prior methods suffer from various disadvantages. Among these disadvantages are a lack of control temperature selection and inconsistent application of heat. These disadvantages result in unreliable, mis-coloring (black) of the heated material which obscures the resulting color(s) of the heated material. The prior devices are also poorly shaped for accommodating the user, are non-ergonomic and not well balanced.
[0003] An object of the present invention is to provide an integrated hot pot that solves these problems with the presently available methods and devices. Thus, the present invention is directed to an ergonomically and stylishly designed hot pot that allows the user to achieve their goals and to safely use the hot pot for crafting applications.
SUMMARY OF THE INVENTION
[0004] The present invention comprises an arts and craft assembly for melting crafting materials comprising a non-heat conducting two piece tray—a top comprising an upper surface and a lower surface or base with a plurality of stabilizing legs provided thereon; a heating pan adapted to be received in and sandwiched between the upper surface and lower surface of the tray and comprising a source for generating heat to melt the crafting material; and a heating conducting vessel into which the crafting material to be melted will be placed that is adapted to be placed in thermal contact with the heating pan in the base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a perspective view of the assembly of the present invention.
[0006] [0006]FIG. 2 is an exploded perspective view illustrating the components of the assembly of the present invention.
[0007] [0007]FIG. 3 is a side view of the assembly of the present invention.
[0008] [0008]FIG. 4 is a front view of the assembly of the present invention.
[0009] [0009]FIG. 5 is an illustration of a use of the assembly of the present invention.
[0010] [0010]FIG. 6 is an illustration of a use of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The present invention will now be described by means of a presently contemplated embodiment thereof. However, the scope of the present invention should not be limited by the embodiment described herein.
[0012] [0012]FIG. 1 illustrates an overall perspective view of a hot pot assembly 10 according to the present invention. FIG. 2 illustrates an exploded view of the parts comprising the hot pot assembly 10 .
[0013] The hot pot assembly 10 comprises a generally pie-shaped bowl 12 . It is presently contemplated that the pie shaped bowl 12 will be fabricated from heat conducting metal and will be coated with a non-stick material such as Teflon®. The bowl 12 is presently contemplated to be a replaceable item of the hot pot assembly 10 .
[0014] The hot pot assembly 10 further comprises an ergonomically designed non-heat conducting base 14 . The base 14 comprises a generally pie-shaped opening 15 that is generally adapted to receive the bowl 12 . The base 14 as shown in this embodiment is fabricated of one-piece construction but it is contemplated that the base 14 could also be fabricated from two separate pieces that would snap together to facilitate repair or replacement of component parts. The perimeter of the base 14 also comprises two openings 16 that, with the rail, function as (finger) grips for the user and three formed legs 18 that function to stabilize the hot pot assembly 10 .
[0015] The hot pot assembly 10 further comprises a pie-shaped heating pan assembly 20 . As shown in FIG. 2, the heating pan assembly 20 will be first received in opening 15 and will be attached to base 14 by a plurality of fastening devices such as machine screws 22 . The heating pan assembly 20 comprises an electrical connection 24 for connection to an AC power source. In the embodiment illustrated in FIG. 2, the electrical connection 24 is adapted to receive a removable power cord 25 . However, those of ordinary skill in the art will recognize that a non-removable power cord could be hard wired into the heating pan without departing from the spirit or scope of the present invention. When an AC power source is electrically connected to the heating pan assembly 20 , the surface temperature of the heating pan 24 will be raised. The heating pan assembly 20 further comprises an electronic heating control and read out assembly 26 . The assembly 26 will be received on the upper lip 21 of the heating pan assembly 20 and fastened thereto. As illustrated in FIG. 1, a sliding switch 28 is disposed on top of the hot pot assembly 10 that allows the user to select specific temperatures and, therefore, to reliably control the temperature of the hot pot. Through this reliable temperature control, miscoloring of the heated material will be minimized.
[0016] After the heating assembly 20 is received in base 14 , the removable and replaceable bowl 12 is received in the hot pot assembly 10 on top of the heating pan assembly 20 . The bowl 12 is removable and not permanently fastened to the hot pot assembly 10 . However, the bowl 12 is in thermal contact with the heating pan assembly 20 . Therefore, when the heating pan assembly 20 is connected to the AC power source and its surface temperature raised as described above, the surface temperature of bowl 12 will be raised accordingly.
[0017] During use, the crafting material to be melted would be placed inside the bowl 12 . The crafting material could be UTEE, regular embossing powder, candle wax, glue, crayons, soap, etc. The AC power source would be connected to the heating pan assembly 20 as described above. The user would set the appropriate heating temperature by means of the sliding switch 28 . The surface temperature of the heating pan 24 will be raised in response to the connection to the AC power source and in turn the surface temperature of the bowl 12 will be raised. As the surface temperature of the bowl 12 reaches the melting point of the material placed therein, the material will become molten and ready for use.
[0018] The use of the hot pot assembly 10 is illustrated by reference to FIGS. 5 and 6. As noted above, the base 14 is fabricated from non-heat conducting material. Therefore, even when the hot plate and bowl 12 become hot, the base will not be hot to the touch. If the user is operating directly out of the bowl 12 as shown in FIG. 6 by dipping craft items in the molten material, the user can achieve enhanced finger dexterity by comfortably resting his or hands on the raised areas of the perimeter ring of the base and not be burned due to the elevated temperature required to melt the material. If the user wants to pour the molten crafting material into another vessel such as a mold for creating certain shaped items, the base 14 facilitates that as well as shown in FIG. 5. Since the base 14 will not be hot to the touch, the user can grip the base 14 through the openings 15 . The intended finger grip locations are marked for both visual and physical identification offering a point that is properly balanced. The pie shape of the bowl 12 and the position and shape of the spout on the narrow end of the bowl 12 facilitates safe pouring of the molten crafting material. As shown, with or without the control module in FIG. 5, the user picks up the entire hot pot assembly 10 by means of the handles 15 and then pours the material from the narrow end of the bowl 12 . As shown in FIG. 3, the heating pan's lowest heat surface 13 is positioned at an angle to the horizontal. It is lower toward the rear and higher toward the front narrow end of the bowl 12 to provide greater control for pouring.
[0019] Those of ordinary skill in the art will recognize that the embodiments just described merely illustrate the principles of the present invention. Many modifications may be made thereto without departing from the spirit and scope of the invention as set forth in the following claims. | An arts and crafts hot pot is described. The arts and crafts hot pot is used to melt various types of materials such as thermographic resins, crayons, glue etc. The materials are used in the fabrications of various craft items. | 5 |
TECHNICAL FIELD
The present invention relates generally to running software applications, and, more particularly, to an application's relationship to its run-time environment.
BACKGROUND OF THE INVENTION
The relationship of a typical software application to its run-time environment is growing more complex for at least four interrelated reasons. First, environments are themselves growing more complex. The rise of telecommunications often allows an application to take advantage of, or requires an application to be aware of, services and resources provided by remote computing devices located throughout the environment. Each remote device may present its own set of communications peculiarities, such as novel protocols or real-time response constraints. The number of possible interactions grows exponentially with the number of devices and applications involved in one computing task, and all of these interactions need to be managed efficiently. Second, environments may change their characteristics over time. For example, a given application may always need to secure a specific type of resource from a specific type of remote server, but the identities of the servers available to provide that type of resource may change moment by moment. At the same time, new services may be introduced and old services may disappear. Third, the application may need to run in multiple environments. The number of possible environments is proliferating as, for example, hardware and software platforms are optimized for particular uses. Even if an application's relationship to any one environment were to remain unchanged (unlikely for the reasons discussed above), the growth in number and diversity of possible environments leads to a demand for an increase in the flexibility, and thus the complexity, of the application's environmental interactions. Compounding the well known difficulties of developing an application to meet diverse requirements of diverse environments, a new environment may arise whose requirements were unforeseen when the application was developed. Fourth, applications themselves are becoming increasingly complex. For example, an application that formerly ran as one thread on a single, stand-alone computing device may now be reconstituted to run as multiple, interacting threads on multiple devices spread throughout the globe and connected by telecommunications links. One application may need to serve multiple purposes and must be able to present itself accordingly, for instance by providing a variable range of services dependent upon the sophistication of its current users. (In this situation, the requirements of the application's users are considered to be part of the application's environment.) As can be appreciated, these four reasons act in concert, the effects of each contributing, often in unpredictable ways, to the magnitude of the effects of the others.
As an especially pointed example of this situation, consider the case of an application designed to test other applications. (To differentiate between the application doing the testing and the application being tested, the former will be called the “test system” while the latter will be called the “application under test.”) The four reasons given above for increased complexity apply here to a heightened extent because the reasons may apply both to the relationship of the application under test to its run-time environment (its run-time environment including the test system) and to the relationship of the test system to its own run-time environment. As one example, to thoroughly exercise the application under test, the test system should exercise all aspects of the application under test's environmental interactions, through a range of possible environments and as those environments change. For any given environment, the test system may need to call upon different aspects of the application under test for different types of testing, such as basic variation testing, regression testing, and stress testing. This may require that the test system run multiple copies of the application under test at the same time, and each copy may be performing multiple tasks simultaneously. While the test system is coordinating all of these activities of the application under test, the test system still needs to handle its own complex interactions with its own environment, such as reporting test results, trapping execution errors, and detecting other potentially harmful aspects of the application under test's environmental relationship (such as dead locks and memory leaks). It is clear from this example that developing an application in the face of multiple, changing environments can be very challenging, and that the challenges are heightened when developing a test system.
Developers often address complexity in their application's relationships by designing aspects of the application that can be configured to meet changing circumstances. An application's configuration parameters can then be set when the application is run (or when it is compiled). Different sets of configurable parameters are set to reflect different aspects of the application's relationship to its run-time environment. Of course, when building flexibility into an application by means of configurable parameters, the developer predicts the range of needs in the possible set of run-time environments so that the configurable parameters, and the application's response to them, can be set.
Useful as configurable parameters are, it can still be extremely difficult to correctly initialize all of these parameters in a complex application's configuration. Subtle errors may arise from mismatches between one part of an application and other parts of the same application, or between the application and other applications in its environment. Mismatches include unexpected events, unplanned for sequences of events, data values outside the range of normalcy, updated behavior of one application not matched by updates in its peers, etc. Difficult as configuration is for one application, it is exponentially more difficult to configure multiple applications (such as the combination of a test system and an application under test) so that they interact with their environments and with each other in a predictable fashion. Adding to the difficulty of creating correct configurations, a configuration may change with time. Applications may be used in an environment, such as a testing environment, in which their configurations may be changed every time they operate. An application may need to run in an environment whose parameters are beyond the range envisaged by the application's developer and so beyond the range of its configurable parameters. In addition to these considerations, it is not desirable for an application developer to devote too much time to configuration issues: they distract the developer from working on issues at the core of the application and they may require environmental expertise foreign to the developer. Indeed, the expertise needed to correctly develop an application's configurable relationships may exist in no one person.
Developing an application's flexibility so that the application can respond correctly regardless of the environments within which it must run and then managing that flexibility in the face of multiple, changing environments are becoming increasingly burdensome. There is a need to contain the burgeoning complexity of an application's relationship to its run-time environment and to separate relationship issues from core application issues.
SUMMARY OF THE INVENTION
In view of the foregoing, the present invention provides a framework for managing an application's relationship to its run-time environment and an engine that accepts the framework as input and runs the application within the environment. Aspects of the framework and of the engine may be changed to suit a changing environment without changing the application itself. By managing details of the application's relationship to its environment, the invention leaves application developers free to focus on the specific tasks of the application. Standard methods for providing services and resources allow some aspects of application development to become standardized. Standard interfaces to, for example, error trapping, progress tracking, and resource use and abuse reporting are developed for use by any application.
As an example, the application may be a software test suite. The invention allows the test suite to be run single- or multi-threaded and with individual tests within the suite running consecutively or concurrently, all without altering the underlying tests. The framework and engine are parameterized to accommodate different testing goals, such as basic variation testing, regression testing, and stress testing, without changing the test suite itself. For any application being tested by the test suite, the engine provides deadlock and leak detection, progress monitoring, and results logging.
BRIEF DESCRIPTION OF THE DRAWINGS
While the appended claims set forth the features of the present invention with particularity, the invention, together with its objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:
FIG. 1 is a block diagram generally illustrating an exemplary computing system environment that supports the present invention;
FIG. 2 is a block drawing showing how pieces of an exemplary embodiment of the invention fit together;
FIGS. 3 a and 3 b are a function-flow diagram showing an application's relationship to functions provided by the framework;
FIG. 4 is a data structure diagram showing the framework according to one embodiment of the invention;
FIG. 5 is a flow chart showing one way to populate the framework data structures of FIG. 4 ;
FIGS. 6 a , 6 b , 6 c , and 6 d are a flow chart showing how an exemplary engine can run the functions that make up an application;
FIG. 7 a is a data structure diagram showing the argument passed to the functions run in FIGS. 6 a , 6 b , 6 c , and 6 d; FIG. 7 b is a data class diagram showing variables used when running these functions; and
FIG. 8 is similar to FIGS. 3 a and 3 b but has been particularized to show the functions of the IOHammer Test Suite example.
DETAILED DESCRIPTION OF THE INVENTION
Turning to the drawings, wherein like reference numerals refer to like elements, the invention is illustrated as being implemented in a suitable computing environment. The following description is based on embodiments of the invention and should not be taken as limiting the invention with regard to alternative embodiments that are not explicitly described herein. Section I presents an exemplary computing environment in which the invention may run. Section II describes exemplary embodiments of the invention's framework and engine, showing their structures and operations. To better illustrate the concepts presented in Section II, Section III presents the details of an actual application, the IOHammer Test Suite, developed for use with the invention.
I. An Exemplary Computing Environment
In the description that follows, the invention is described with reference to acts and symbolic representations of operations that are performed by one or more computers, unless indicated otherwise. As such, it will be understood that such acts and operations, which are at times referred to as being computer-executed, include the manipulation by the processing unit of the computer of electrical signals representing data in a structured form. This manipulation transforms the data or maintains them at locations in the memory system of the computer, which reconfigures or otherwise alters the operation of the computer in a manner well understood by those skilled in the art. The data structures where data are maintained are physical locations of the memory that have particular properties defined by the format of the data. However, while the invention is being described in the foregoing context, it is not meant to be limiting as those of skill in the art will appreciate that various of the acts and operations described hereinafter may also be implemented in hardware.
Referring to FIG. 1 , the present invention may reside in a computing device with any of many different computer architectures. For description purposes, FIG. 1 shows a schematic diagram of an exemplary computer architecture usable for these devices. The architecture portrayed is only one example of a suitable environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Neither should the computing devices be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in FIG. 1 . The invention is operational with numerous other general-purpose or special-purpose computing or communications environments or configurations. Examples of well known computing systems, environments, and configurations suitable for use with the invention include, but are not limited to, mobile telephones, pocket computers, personal computers, servers, multiprocessor systems, microprocessor-based systems, minicomputers, mainframe computers, and distributed computing environments that include any of the above systems or devices.
In its most basic configuration, a computing device typically includes at least one processing unit 102 and memory 104 . The memory 104 may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.), or some combination of the two. This most basic configuration is illustrated in FIG. 1 by the dashed line 106 . The devices may have additional features and functionality. For example, they may include additional storage (removable and non-removable) including, but not limited to, PCMCIA cards, magnetic and optical disks, and magnetic tape. Such additional storage is illustrated in FIG. 1 by removable storage 108 and non-removable storage 110 . Computer-storage media include volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules, or other data. Memory 104 , removable storage 108 , and non-removable storage 110 are all examples of computer-storage media. Computer-storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory, other memory technology, CD-ROM, digital versatile disks (DVD), other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage, other magnetic storage devices, and any other media which can be used to store the desired information and which can be accessed by the computing device. These devices may also contain communication channels 112 that allow a device to communicate with other devices. Communication channels 112 are examples of communications media. Communications media typically embody computer-readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and include any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communications media include wired media, such as wired networks and direct-wired connections, and wireless media such as acoustic, radio, infrared, and other wireless media. The term computer-readable media as used herein includes both storage media and communications media. The devices may also have input components 114 such as a keyboard, mouse, pen, a voice-input component, a touch-input device, etc. Output components 116 include screen displays, speakers, printer, etc., and rendering modules (often called “adapters”) for driving them. Each of the devices has a power supply 118 . All these components are well know in the art and need not be discussed at length here.
II. The Framework and the Engine
The invention creates data structures and functions to form a consistent framework around an application, connecting the application to the application's run-time environment. Because this framework is created in a consistent manner for every application and with well defined properties, it allows the invention to provide to applications common support and management features that would otherwise have to be built into each application. These features enable an application, written once, to run without modification in different run-time environments, even in environments with characteristics unforeseen at the time the application was written.
FIG. 2 shows how pieces of an exemplary embodiment of the invention fit together. The engine 200 uses the framework data structures 202 to run the application 204 . The application may be an executable or, as in the case shown in FIG. 2 , it may be a collection of related, executable sub-applications 206 . As an example, expanded upon in Section III below, the application may be a suite of tests developed to exercise one feature of the computing environment 100 or one application under test (not shown). Each sub-application is then a particular test (called a “variation”) in the suite.
The framework data structures 202 consist of two major parts, the application table 208 and the parameter table 210 . The application table contains information about each sub-application and includes special functions created by the invention as part of the framework. The parameter table holds variables used by the engine 200 and by the sub-applications 206 when they run. These two tables are described further with reference to FIG. 4 . In addition to these two main parts, the framework data structures include references to other framework functions created by the invention. The operating system 212 is shown to emphasize that the engine may use services provided by the operating system when running the sub-applications.
FIGS. 3 a and 3 b show the relationships among an application 204 's sub-applications 206 and the framework functions created by the invention. These Figures are not meant to be a detailed flow chart (see FIGS. 6 a , 6 b , 6 c , 6 d and accompanying text, below), but are meant instead to introduce the functions. In the function names in FIGS. 3 a and 3 b , “module” refers to the application 204 (possibly consisting of a collection of sub-applications 206 ) and its related framework. The module check function 300 is a framework function that checks to see if the resources needed to run the application are available. If a needed resource is not available, then the engine might as well stop right there and report the problem. The module check function checks for all resources needed by any of the sub-applications 206 . A module initialize function 302 (which may be incorporated with the module check function into one function) does whatever initialization is required across sub-applications, such as securing resources and initializing global variables that reflect the current run-time environment.
After the module-level checks and initialization, sub-applications 206 in the application 204 are run. Depending upon the application's requirements, these sub-applications may be run consecutively, concurrently, or in some combination of the two. For example, the application may be a test suite targeting a communications application. One sub-application may represent an originator of a communications session, a second sub-application may represent a peer communicating device, while a third sub-application performs the function of a protocol analyzer. These three sub-applications would be run concurrently. In any case, a global initialize function 304 is called to begin the processing of each sub-application. This function works on environmental variables at a level between the generality of the module initialize function 302 and the thread initialize function 306 . This division of initialization into separate levels is one method employed by the invention to provide flexible, yet consistent, management of the run-time environment. Of course, if the application consists of only one sub-application, then the global initialize function may be merged into the module initialize function.
Sub-applications 206 may sometimes be run as multiple, concurrent threads. For example, the sub-application may be a variation in a test suite application 204 . To regression test the features of an application under test, it may be sufficient to run the variation as a single thread. On the other hand, multiple, concurrent threads can be run to stress test the application under test. To capture the details inherent in running the sub-application as a variable number of threads, the invention provides a thread initialize function 306 .
With the run-time environment set up, the invention runs the sub-application 206 itself. As it runs, the sub-application can call on the framework data structures 202 (discussed below with reference to FIGS. 4 , 7 a , and 7 b ) for information coming from its run-time environment. The framework data structures also contain information directing the engine 200 to run the sub-application multiple times, as shown in box 308 . When that is complete, a sub-application test function 310 is provided to survey the work performed by the sub-application and report on what it finds. For each time that the sub-application is run in the box 308 loop, a sub-application post function 312 is run in the box 314 loop. This function cleans up changes wrought by the sub-application function, possibly freeing storage seized by the sub-application. A sub-application post test function 316 ensures that the sub-application-specific clean up is complete. Box 318 allows for the possibility that, for some special cases, often involving tests, the whole series of sub-application functions may be run multiple times.
The end of the process of running an application 204 mirrors the beginning. Each thread ends with a thread terminate function 320 . Then each sub-application 206 ends with a global terminate function 322 . Finally, the whole application ends with a module terminate function 324 and a module clean up function 326 .
Note that the break down into the particular framework functions shown in FIGS. 3 a and 3 b is meant to be illustrative only. The services provided to the application by the framework can be provided in numerous other, equivalent ways. For some applications, or for some run-time environments encountered by an application, some of the functions illustrated may be combined, others may be eliminated. It should be noted, however, that the division of an application into a set of multiple functions (whether those shown in FIGS. 3 a and 3 b or some other set) is one way in which the invention separates environmental issues from issues more particular to the application itself. This division simplifies the task of writing the application so that, when run in the flexible framework of the functions shown in FIGS. 3 a and 3 b and the framework data structures 202 , it can respond to varied and changing run-time environments without the necessity of changing itself.
FIG. 4 presents an example of the data fields that may make up the framework data structures 202 . A module table 400 begins with three fields that distinguish this module from others: the module version 402 , the module name 404 , and a text description of the module 406 . In some implementations, each module may specify a category 408 to which the application 204 belongs. For example, test suites may be categorized as “Basic Variation Tests,” “Regression Tests,” and “Stress Tests.” This categorization could be useful to run all test suites of a certain type against an application under test.
Next come references to several of the framework functions discussed with reference to FIGS. 3 a and 3 b . A print usage function 410 might be provided to provide guidance to a user wanting to run the application 204 within this framework. The process arguments function 412 processes command line arguments and sets global variables accordingly. The last two entries shown are references ( 414 and 416 ) to the parameter table 210 and application table 208 of this module.
The parameter table 210 contains one entry 418 for each parameter that can be set and passed when the application 204 is run. Some of these parameters are defined by the application developer, others are standard for all applications. The standard parameters are described below with reference to steps 600 , 602 , 604 , and 606 of FIG. 6 a . Each parameter table entry contains a parameter name 420 and a description 422 . Next comes a field of flags 424 , indicating, for example, whether the parameter is mandatory. The data type of the parameter is indicated in field 426 and the address where its value is stored is given in field 428 . Any data of the user's choice may be stored in the final field 430 .
The application table 208 contains an entry 432 for each sub-application 206 . After identifying the sub-application by name 434 , description 436 , and category 438 , a flags field 440 specifies run-time characteristics such as whether this sub-application is enabled to be run and whether it should run in a separate thread. The execution factors field 442 contain values that are multiplied by loop counter parameters set by the user to arrive at the actual number of times a loop is performed. For example, if the user sets the sub-application count parameter (discussed below with reference to step 604 of FIG. 6 a ) to three and the corresponding execution factor is two, then the loops controlled by boxes 308 and 314 will each be performed six times. Normally the execution factors are all set to one.
The following fields refer to framework functions discussed with reference to FIGS. 3 a and 3 b . The timers field 444 specifies a minimum (usually set to zero) and maximum time to wait before running the sub-application 206 . A user data field 446 allows the storage of any data at the choice of the user.
FIG. 5 shows an example of how the framework encapsulating an application 204 can be built. In step 500 , the user begins the creation process by naming the application and specifying the number and names of the parameters 420 and the number and names of the sub-applications 434 . For example, the command:
wttautogen.exe SPfail -p:2 SpsrvPort CrashTypeFlag -v:2 Crash Restart
generates a framework for an application named SPfail with two parameters SpsrvPort and CrashTypeFlag. The SPfail application contains the two sub-applications Crash and Restart. The command next prompts the user to specify the data types of the parameters. The command then begins to automatically create the framework functions and populate the framework data structures 202 .
In step 502 , the command creates a parameter table 210 with an entry 418 for SpsrvPort and one for CrashTypeFlag. Because the command knows nothing of these parameters beyond their data types, it populates the parameter table entries with default values. In a similar manner, the command creates in step 504 an application table 208 with an entry 432 for the Crash sub-application and one for Restart.
The command creates a module table 400 that refers to the parameter table 210 and the application table 208 in step 506 . It too is populated with default values. The default values for the module table and for the application table include default framework functions. For example, a thread initialize function 306 specific to the Crash sub-application 206 within the SPfail application 204 is put into Crash's application table entry 432 .
At this point, a framework has been created, but it reflects very little of the what the application developer had in mind for his application 204 . The development work is mostly concentrated into step 508 . There, the developer edits the created framework functions and data structures to match his conception of the application. He may, for example, choose to leave some framework functions unaltered, but would certainly flesh out the default sub-application functions 206 . The present invention does not remove the development of the application from the developer. Rather, it provides a framework that encapsulates the application and removes from the developer much of the burden of dealing with variability in the application's run-time environment.
FIGS. 6 a , 6 b , 6 c , and 6 d show how the framework data structures 202 and framework functions come together when an application 204 is run. FIG. 6 a also shows how parameter values are gathered that affect the operation of the engine 200 and the sub-applications 206 .
In steps 600 , 602 , 604 , and 606 , a user asks to run an application 204 and sets parameters for the run. Note that these steps are separated for purposes of this discussion: in some embodiments, all parameters are set in one step. In step 600 , the user specifies which sub-applications 206 to run. For example, the command:
SPfail -test:Crash -!test:Restart
runs the Crash sub-application of the SPfail application but prevents the Restart sub-application from running. (The keyword “test” is used to specify a sub-application for historical reasons.)
In step 602 , the user sets flags for the sub-applications 206 to be run. The format is:
SPfail -param:<sub-application name or all> <parameter name> <parameter value>
so that the command:
SPfail -param:Crash mint 10
sets the minimum wait time (part of the timers field 444 ) before calling the Crash sub-application to ten seconds. Other timers and the flags in field 440 can also be set this way.
The user in step 604 sets sub-application control factors. Table 1 is an exemplary list of these factors. The descriptions in the Table are sufficient for most parameters so only a few are mentioned here. The loop counters specified in the command line are multiplied by the execution factors 442 to arrive at the actual number of times the loops are performed. When the application 204 is a test suite, the tests in it are often run over and over again to stress the application under test. This is done by setting the loop counters to high values. As a check on this, parameters can be set that terminate the run of the test suite when a maximum run time is reached or when a maximum number of sub-applications (test variations) have been run. By setting the logging level, the user controls the level of detail in the reported results. An example command setting some of these parameters is:
SPfail -test:Crash -MRT:1200 -MS:50 -log:spfail.log -LL:7 -threads:3
The sub-application Crash of application SPfail is run 50 times or for 1200 seconds (whichever comes first). Results are logged at a “World” level to the file spfail.log. During the run, the number of threads executing is limited to three.
TABLE 1
Parameter (Abbreviation)
Description
Maximum Run Time (MRT)
Exit after running for MRT seconds.
Seed
Set the seed for a random number
generator.
Maximum Sub-applications
Exit after running the sub-application
(MS)
MS number of times.
Server
Log the results to this server.
Dynamic Link Library (DLL)
Load this library for the run.
Log
Log the results to this file.
Logging Level (LL)
Specify the level of detail to put into
the log: 1 = stress; 2 = error; 3 =
warnings; 4 = default; 5 = details; 6 =
entry; 7 = world.
Loop Count (LC)
Run through everything this many
times.
Inner Loop Count (ILC)
Run the loop controlled by box 630 this
many times.
Sub-application Count (SC)
Run the loops controlled by boxes 620
and 626 this many times.
ID
The user tags this process with a unique
numeric identifier. (This number is
unrelated to the process ID given to
processes by the operating system 212.)
Threads
This is the default number of threads to
run.
Cluster Name
Run the application in this cluster.
Step 606 allows the user to specify debugging and error control information. Table 2 lists some of the possibilities here. These concepts are familiar in the industry, but putting this functionality into the framework produces the advantage of relieving the developer from having to implement these controls in each application.
TABLE 2
Parameter (Abbreviation)
Description
Debug Break (DB)
Break into the debuggers: 2 = break
only for the computer on which the
sub-application is running; 3 = break
for all nodes of the cluster and client.
Fatal Errors
Do a forced exit when one of these
errors is encountered.
Included Debug Errors (IDE)
Perform a debug action when one of
these errors is encountered.
Break Action (BA)
Perform these debug actions (ORed
together): 1 = exit after the sub-
application runs; 2 = exit if the sub-
application fails (default); 4 = exit
without cleaning up; 8 = return true
error value rather than returning 777;
16 = exit by terminating all separate
threads when sequential sub-
applications are complete.
Catch Unhandled Exceptions
Yes or no.
The engine in step 608 uses the information gathered in the previous steps and information stored in the framework data structures 202 to create the sub-application data structure 700 for this run. That data structure is discussed with reference to FIGS. 7 a and 7 b.
Step 610 through the End on FIG. 6 d is a straightforward procedure for running the framework functions discussed with reference to FIGS. 3 a and 3 b . As mentioned in reference to those Figures, threads within a sub-application and separate sub-applications may be run consecutively or concurrently. The loops controlled by boxes 634 and 638 are not meant to imply the necessity of purely sequential operation.
A pointer to the sub-application data structure 700 of FIG. 7 a is passed as the input argument to the framework functions. The first member of the structure, lpGlobalData 702 , points to the global data class 716 portrayed in FIG. 7 b . Fields 704 and 706 are used by the framework functions to pass data among themselves. The szPrefix field 708 is a string that uniquely identifies a thread. Its particular value is not important; in one embodiment, it is formed from a concatenation of the number of the thread with the name of the sub-application 434 . The dwIndex field 710 is the number of the thread. Field 712 , dwCurrentInnerLoopCount, keeps track of the number of times that the loop controlled by box 630 has been executed, while field 714 , dwCurrentSub-applicationCount, does the same for the loops controlled by boxes 620 and 626 .
The global data class 716 of FIG. 7 b is a collection of useful values. As their names indicate, several of these fields store values set in steps 602 , 604 , and 606 of FIG. 6 a . Field 720 , bClean, indicates whether the clean up function 326 should be called at the end of the application's run. If field 722 , bCheck, is set to True, then the module check function 300 is run without running any of the sub-applications 206 . Field 724 , bPerf, tells the engine to check for memory leaks.
III. A Detailed Example: The IOHammer Test Suite
The concepts presented above may be more easily grasped in the context of a concrete example. In this section, a straightforward test suite, called “IOHammer,” is presented. IOHammer stresses a computer's hard disk by quickly writing to it. IOHammer is presented in terms of its framework data structures 202 and its framework functions. FIG. 8 , a variation on FIGS. 3 a and 3 b , shows how the framework functions fit together. While IOHammer as presented is written for Microsoft's “WINDOWS” operating system, the present invention is not restricted to any particular operating environment. Note that IOHammer is presented purely as an example for explaining the concepts presented above, and no guarantees are made as to its completeness or utility.
Beginning with the framework data structures 202 , the following is the module table 400 . The module table has NULLs for some of the framework functions: module clean up 326 , module check 300 , print usage 410 , and process arguments 412 . In keeping with the flexibility offered by the framework, these functions may be defined if they are useful, or, as in the simple case presented here, left undefined at the application developer's discretion.
//
// IOHammer Module Table (400): This points to the other
tables.
//
WTTMODULETABLE IOHammerMasterEntry =
{
_TEXT(“1.0.001”),
// 402
_TEXT(“IOHammer”),
// 404
_TEXT(“IOHammer Master Entry”),
// 406
_TEXT(“”),
// 408
NULL,
// 326
NULL,
// 300
NULL,
// 410
NULL,
// 412
IOHammerInitialize,
// 800
IOHammerTerminate,
// 812
IOHammerParameterTable,
// 210
IOHammerApplicationTable,
// 208
};
The IOHammer test suite is defined to take two parameters. As seen from the following parameter table 210 , one parameter is the size of a write buffer and the other is the disk drive that IOHammer will exercise. If no disk drive is set, then IOHammer will exercise all accessible disk drives.
//
// IOHammer Parameter Table (210) with two entries.
//
static WTTPARAMETERTABLE
IOHammerParameterTable[] =
{
{
// 418
_TEXT(“size”),
// 420
_TEXT(“Size of buffer in terms of # volume sectors”),
// 422
0,
// 424
WTT_DWORD,
// 426
(LPVOID) &dwSectorsPerBuffer,
// 428
NULL
// 430
},
{
// 418
_TEXT(“drive”),
// 420
_TEXT(“The drive to run on. Must have a \\”),
// 422
0,
// 424
WTT_PSTRING,
// 426
(LPVOID) &pszDriveLetter,
// 428
NULL
// 430
}
};
The IOHammer test suite has only one sub-application, so its application table 208 has only one entry 432 . As is often the case, the execution factors 442 are all set to one. As in the module table 400 , some functions are not defined: global initialize 304 , global terminate 322 , sub-application test 310 , sub-application post 312 , and sub-application post test 316 .
//
// IOHammer Application Table (208) with only one entry.
//
static WTT_APPLICATION_ENTRY
IOHammerApplicationTable[] =
{
{
// 432
_TEXT(“IOHammer”),
// 434
_TEXT(“Hammer all disks with IOs”),
// 436
_TEXT(“”),
// 438
WTT_ENABLED,
// 440
1, 1, 1, 1,
// 442
NULL,
// 304
NULL,
// 322
IOHammerThreadInitialize,
// 802
IOHammerThreadTerminate,
// 810
IOHammerVariationWrite,
// 804
NULL,
// 310
NULL,
// 312
NULL,
// 316
NULL, NULL,
// 444
NULL
// 446
}
};
As seen from FIG. 8 , the first framework function to run is IOHammerInitialize 800 . Because IOHammer is a simple test suite, this function incorporates the functionality of the framework functions module check 300 and module initialize 302 . As only one sub-application is defined for this test suite, this function also incorporates the functionality of the global initialize function 304 . IOHammerInitialize sets up a list of disk drives to exercise, allocates write buffers for the drives, and exits with an error if various initial conditions are not met.
//
// DESCRIPTION: IOHammerInitialize (800).
// This is the module initialize function, called at the start. It allocates and sets up the
// buffers for the reads and writes. All threads use the same write buffer and have
// separate read buffers.
//
// PARAMETERS:
// None.
//
// PRE-CONDITIONS:
// Called before the test (IOHammerVariationWrite 804) is run.
//
// POST-CONDITIONS:
// Memory is allocated and ready to do the test variation.
//
// RETURN VALUE:
// Status from WTTInitialize, VirtualAlloc, etc.
//
DWORD IOHammerInitialize( )
{
// 26 drive letters plus a NULL for each plus a NULL at the end.
TCHAR
szDriveLetters[26 * 3 + 1];
TCHAR
*pszTmp;
PTStringCollection::iterator
itDrive;
int
iDriveIndex;
// Exit with error if no cluster name is specified.
if(!pWTTGlobalData->pszClusterName)
WTTLOG_ERR_RETURN(ERROR_INVALID_PARAMETER);
dwRet = WTTLogInitialize(NULL, NULL);
if(dwRet == ERROR_SUCCESS)
{
// Hide the log unless WTTSHOWLOG is set in the environment.
if(!MiscIsEnvVarSet(_TEXT(“WTTSHOWLOG”)))
pWTTGlobalData->dwLogFlags &= ~(TLS_WINDOW |
TLS_MONITOR);
dwRet = WTTInitialize(NULL);
}
LOG_SETLEVEL(0);
//
// If a drive has been specified, use it. Else, use all drives that can be seen and
// that are appropriate.
//
if(pszDriveLetter != NULL)
{
// Use the specified drive. Double NULL-terminate the string!
_tcscpy(szDriveLetters, pszDriveLetter);
szDriveLetters[_tcslen(szDriveLetters) + 1] =_T(‘♯0’);
}
else
{
// Use all available drives.
DWORD dwCount =
GetLogicalDriveStrings(ARRAY_LENGTH(szDriveLetters),
szDriveLetters);
// Exit with error if no drives are available.
if(dwCount == 0)
{
dwRet = GetLastError( );
goto ret;
}
}
// Make a comma-separated list of drives.
int
len;
pszTmp = szDriveLetters;
while((len = _tcslen(pszTmp)) != 0)
{
pszTmp[len] = L ‘,’;
pszTmp = &pszTmp[len + 1];
}
// Exit with error if no drives are found.
if(_tcslen(szDriveLetters) == 0)
{
dwRet = ERROR_INVALID_PARAMETER;
goto ret;
}
assert(szDriveLetters[_tcslen(szDriveLetters) −1 ] ==_T(‘,’));
szDriveLetters[_tcslen(szDriveLetters) −1 ] = _T(‘♯0’);
MiscConvertToStringList(stlstDrives, szDriveLetters, L ‘,’);
RemoveDrives(stlstDrives);
// Exit with error if no drives are found.
if(stlstDrives.size( ) == 0)
{
dwRet = ERROR_INVALID_PARAMETER;
goto ret;
}
(void)memset(aszWriteBuffs, 0, ARRAY_LENGTH(aszWriteBuffs));
(void)memset(aiWriteBuffSizes, 0, ARRAY_LENGTH(aiWriteBuffSizes));
// Get the sector size for each drive.
for(iDriveIndex = 0, itDrive = stlstDrives.begin( ); itDrive != stlstDrives.end( );
itDrive++, iDriveIndex++)
{
DWORD
dwSectorsPerCluster,
dwBytesPerSector,
dwNumberOfFreeClusters,
dwTotalNumberOfClusters;
// Exit with error if cannot get sector size.
if(!GetDiskFreeSpace(**itDrive, &dwSectorsPerCluster,
&dwBytesPerSector, &dwNumberOfFreeClusters,
&dwTotalNumberOfClusters))
{
dwRet = GetLastError( );
goto ret;
}
// Allocate a buffer for this drive and store in global info. Then write to it.
aszWriteBuffs[iDriveIndex] = (TCHAR *)VirtualAlloc(NULL,
dwBytesPerSector * dwSectorsPerBuffer, MEM_RESERVE |
MEM_COMMIT, PAGE_READWRITE);
// Exit with error if cannot allocate buffer.
if(aszWriteBuffs[iDriveIndex] == NULL)
{
dwRet = GetLastError( );
goto ret;
}
// Write to the buffer.
aiWriteBuffSizes[iDriveIndex] = dwBytesPerSector *
dwSectorsPerBuffer;
(void)memset(aszWriteBuffs[iDriveIndex], ‘X’,
aiWriteBuffSizes[iDriveIndex])
}
ret:
}
For each thread that will be run, the IOHammerThreadInitialize function 802 sets up a write file on each disk drive that will be exercised.
//
// DESCRIPTION: IOHammerThreadInitialize (802).
//
// PARAMETERS:
// pData
//
DWORD IOHammerThreadInitialize(PWTT_VARIATION —
DATA pData)
{
PTStringCollection::iterator
itDrive;
HANDLE
hFile;
// Create the handles array and hang it off the pData.
NULL-terminate it.
HANDLE* phFiles = new HANDLE[stlstDrives.size( ) + 1];
phFiles[stlstDrives.size( )] = NULL;
pData->lpThreadData = phFiles;
// Create a file for each drive.
for(itDrive = stlstDrives.begin( ); itDrive != stlstDrives.end( );
itDrive++)
{
// Build filename.
TCHAR szID[33];
_stprintf(szID, _T(“%p”), pWTTGlobalData->dwPID);
TString stFileName = **itDrive + szID;
stFileName += pData->szPrefix;
stFileName += _T(“.dat”);
*phFiles = CreateFile(stFileName, GENERIC_READ |
GENERIC_WRITE, 0, NULL, CREATE_ALWAYS,
FILE_ATTRIBUTE_NORMAL | FILE_FLAG_NO —
BUFFERING,
NULL);
// Exit with error if cannot create file.
if(!*phFiles)
{
dwRet = GetLastError( );
break;
}
else
phFiles++;
}
}
The IOHammer test suite as presented here has only one sub-application. The IOHammerVariationWrite sub-application 804 writes to the files set up in the IOHammerThreadInitialize function 802 , using the write buffers allocated in the IOHammerInitialize function 800 .
//
// DESCRIPTION: IOHammerVariationWrite (804).
//
// PARAMETERS:
// pData
//
DWORD IOHammerVariationWrite(PWTT_VARIATION —
DATA pData)
{
DWORD dwNumberOfBytesWritten;
int iDriveIndex = 0;
// Write the buffer to the file named according to this thread.
HANDLE *phFiles = (HANDLE *)pData->lpThreadData;
// Write from buffer to file.
while(*phFiles)
{
// Exit with error if write to file fails.
if(!WriteFile(*phFiles, aszWriteBuffs[iDriveIndex],
aiWriteBuffSizes[iDriveIndex],
&dwNumberOfBytesWritten,
NULL))
{
dwRet = GetLastError( );
break;
}
phFiles++;
}
}
The IOHammerThreadTerminate function 810 cleans up by closing and deleting the files set up by the IOHammerThreadInitialize function 802 .
//
// DESCRIPTION: IOHammerThreadTerminate (810).
//
// PARAMETERS:
// pData
//
DWORD IOHammerThreadTerminate(PWTT_VARIATION —
DATA pData)
{
PTStringCollection::iterator itDrive;
// First close the files. The handles are in the user data.
HANDLE *phFiles = (HANDLE *)pData->lpThreadData;
while(*phFiles)
{
// Exit with error if cannot close a file.
if(!CloseHandle(*phFiles))
{
dwRet = GetLastError( );
goto ret;
}
phFiles++;
}
// Now delete file for each drive.
for(itDrive = stlstDrives.begin( ); itDrive != stlstDrives.end( );
itDrive++)
{
TCHAR szID[33];
// Build filename.
_stprintf(szID, _T(“%p”), pWTTGlobalData->dwPID);
TString stFileName = **itDrive + szID;
stFileName += pData->szPrefix;
stFileName += _T(“.dat”);
// Exit with error if cannot delete file.
if(!DeleteFile(stFileName))
{
dwRet = GetLastError( );
break;
}
}
ret:
}
The IOHammerTerminate function 812 incorporates the functionality of the global terminate 322 , module terminate 324 , and module clean up 326 functions. It frees the write buffers allocated by the IOHammerInitialize function 800 .
//
// DESCRIPTION: IOHammerTerminate (812).
//
// PARAMETERS:
// None.
//
DWORD IOHammerTerminate( )
{
PTStringCollection::iterator itDrive;
for(int iDriveIndex = 0; iDriveIndex < stlstDrives.size( );
iDriveIndex++)
{
// Exit with error if cannot free a write buffer.
if(!VirtualFree(aszWriteBuffs[iDriveIndex],
aiWriteBuffSizes[iDriveIndex], MEM_DECOMMIT))
{
dwRet = GetLastError( );
break;
}
}
// Erase the drive list.
stlstDrives.DeleteAll( );
}
It can be appreciated from this example that for applications much more complicated than IOHammer, the framework itself does not become more complicated. The framework may incorporate more parameters, and more of the framework functions may be defined, but the framework substantially separates issues of the application's run-time environment from issues of the application's core functionality.
In view of the many possible embodiments to which the principles of this invention may be applied, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of invention. Therefore, the invention as described herein contemplates all such embodiments as may come within the scope of the following claims and equivalents thereof. | Disclosed are a framework for managing an application's relationship to its run-time environment and an engine that accepts the framework as input and runs the application within the environment. Aspects of the framework and engine may be changed to suit a changing environment without changing the application itself. By managing details of the environment, the invention leaves developers free to focus on the specific tasks of the application. The framework also allows the engine to provide standardized services such as deadlock and leak detection, progress monitoring, and results logging. As an example, the application may be a software test suite. The invention allows the test suite to be run single- or multi-threaded and with individual tests within the suite running consecutively or concurrently. The invention can be parameterized to accommodate different testing goals, such as basic variation testing, regression testing, and stress testing, without changing the test suite itself. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ignition apparatus of an internal combustion engine wherein the generation of ignition sparks is prevented when the engine is reversely rotated.
2. Description of the Prior Art
FIG. 1 is a circuit diagram showing a conventional ignition apparatus of an internal combustion engine. In the diagram, a rotor 1 is driven by an engine (not shown) in the direction indicated by an arrow 2. The rotor 1 projects to a predetermined extent between positions A and B.
A sensor 3 is set to face the rotor 1 and detects first and second crank angle positions of the engine. The sensor 3 consists of a coil (winding), a magnet, and the like.
As shown in FIG. 2, when the front edge portion A of the projection faces the sensor 3, the sensor 3 outputs a positive voltage signal as a first angle signal. When the rear edge portion B of the projection passes in front of the sensor 3, the sensor 3 outputs a negative voltage signal as a second angle signal.
An anode of a diode 4 is connected to the output of the sensor 3 and a cathode is connected to a set input terminal S of a flip-flop circuit (hereinafter, referred to as FF) 6, respectively.
A cathode of a diode 5 is connected to the output of the sensor 3 and an anode is connected to a reset input terminal R of the FF 6, respectively.
Therefore, the sine wave of the output voltage of the sensor 3 passes through the diode 4 and is input to the set input terminal S of the FF 6, thereby setting the FF 6. The negative wave passes through the diode 5 and is input to the reset input terminal R of the FF 6, thereby resetting the FF 6.
A Q output of the FF 6 is input to a base terminal of a transistor 7 and a collector terminal is connected to a primary winding of an ignition coil 8.
The other end of the primary winding of the ignition coil 8 is connected to a (+) terminal of a battery 10 and a secondary winding is connected to the ground (the minus side potential of the battery 10) through a spark plug 9.
FIG. 3 shows an operation waveform diagram which assists in explaining the opertion of the circuit of FIG. 1. FIG. 3(a) shows a waveform of the output voltage of the sensor 3; FIG. 3(b) a waveform of the set input voltage of the FF 6; FIG. 3(c) a waveform of the reset input voltage of the FF 6; FIG. 3(d) a waveform of the Q output voltage of the FF 6; FIG. 3(e) a waveform of a collector voltage of the transistor 7; and FIG. 3(f) a waveform of a secondary output voltage of the ignition coil 8.
The operation will now be described. When the front edge portion A of the projection of the rotor 1 faces the sensor 3 due to the rotation in the direction of the arrow 2 of the rotor 1, the sensor 3 generates a positive voltage as shown in FIG. 3(a). A pulse such as that shown in FIG. 3(b) is input to the set input terminal S of the FF 6. Thus, the FF 6 is set and the output voltage at a Q output terminal of the FF 6 is set to high level as shown in FIG. 3(d).
Since the Q output of the FF 6 is at the high level, the transistor 7 is turned on (is made conductive) and a current flows through the primary winding of the ignition coil 8.
When the rotor 1 further rotates and the rear edge portion B of the projection passes in front of the sensor 3, the sensor 3 generates a negative voltage. Thus, a pulse as shown in FIG. 3(c) is input to the reset input terminal R of the FF 6 and the FF 6 is reset and the output voltage at the Q output terminal of the FF 6 is set to a low level.
Since the Q output of the FF 6 is at the low level, the transistor 7 is turned off (is made non-conductive) and the current to the primary winding of the ignition coil 8 is shut off. At this time, a high voltage as shown in FIG. 3(f) is generated on the secondary side of the ignition coil 8 and an ignition spark is obtained at the spark plug 9. In this manner, the above operations are periodically repeated in accordance with the rotation of the rotor 1 as shown in FIG. 3.
Since the conventional ignition apparatus of an internal combustion engine is constructed in the manner explained above, even though the operations described above involve no inconvenience, when the engine is started, the following drawbacks become apparent.
Assuming that the rotation of the rotor 1 in the direction of the arrow 2 is the forward rotation and the rotation in the direction opposite to the arrow 2 is the reverse rotation, when the rotor 1 is rotating forwardly, an output as shown in FIG. 4 is generated from the sensor 3 as explained above. In FIG. 4, t 4 represents the output of the sensor 3 when the front edge portion A of the projection faces the sensor 3 and t 5 indicates the output of the sensor 3 when the rear edge portion B faces the sensor 3.
On the other hand, when the rotor 1 is rotating reversely, the sensor 3 generates an output as shown in FIG. 5. The polarity (high or low level of the signal) of the output voltage of the sensor 3 which faces the crank angle position is opposite (in FIG. 5, t 4a denotes the output signal of the sensor 3 when the rear edge portion B faces the sensor 3 and t 5a indicates the output signal of the sensor 3 when the front edge portion A passes in front of the sensor 3).
Consideration will now be given to the case, where after the front edge portion A of the rotor 1 faces the sensor 3 in the forward rotation, the rotor 1 starts to reversely rotate before the rear edge portion B of the rotor 1 passes in front of the sensor 3, and the portion A passes in front of the sensor 3 during this reverse rotation. As shown in FIG. 6 [a in FIG. 6(a), d in FIG. 6(b), e in FIG. 6(c), and f in FIG. 6(d) are respectively the same as those in FIGS. 3(a), 3(d), 3(e), and 3(f)], the transistor 7 is turned on by the high level signal generated from the sensor 3 at time t 1 as shown in FIG. 6(c). The transistor 7 is turned off by the low level signal generated from the sensor 3 at time t 2 as shown in FIG. 6(c). As shown in FIG. 6(d), a secondary high voltage output of the ignition coil 8 is generated, and an ignition spark is thus generated by the spark plug 9.
The ignition spark generated at the front edge portion A of the rotor 1 further facilitates the reverse rotation of the rotor 1.
As mentioned above, there is a problem in that an ignition spark may be generated at the time of reverse rotation of the engine and the engine may consequently be damaged or the like.
FIG. 7 is a circuit diagram showing another conventional ignition apparatus for an internal combustion engine. In the diagram, sensor means SM detects the crank angle position of an engine (not shown). The sensor means SM generates an output signal which is changed from the high level to the low level at a first angle position θ 1 synchronously with the rotation of the engine and also generates an output signal which is changed from the low level to the high level at a second angle position θ 2 of the engine. This output signal is set to the low level (the first state) for the interval from the first angle position θ 1 to the second angle position θ 2 and is set to the high level (the second state) for the interval from the second angle position θ 2 to the first angle position θ 1 .
The output of the sensor means SM is input to a base of a transistor 12. An emitter of the transistor 12 is connected to the ground [the (-) side potential of a battery 10]. A collector is connected to a (+) terminal of the battery 10 through a resistor 14.
A collector output of the transistor 12 is input to a base of a transistor 7. An emitter of the transistor 7 is connected to the ground. A collector is connected to the (+) terminal of the battery 10 through the primary winding of an ignition coil 8. A spark plug 9 is connected between a secondary output terminal of the ignition coil 8 and the ground.
FIG. 8 is an operation waveform diagram which will assist in explaining the operation of the apparatus shown in FIG. 7. FIG. 8(a) shows an output voltage of the sensor means SM. FIG. 8(b) shows a collector voltage of the transistor 12. FIG. 8(c) shows a collector voltage of the transistor 7. FIG. 8(d) shows a secondary output voltage of the ignition coil 8.
The operation of the prior art ignition apparatus shown in FIG. 7 will now be described. Since the first angle position θ 1 of the engine is detected at time point t 1 , the output signal of the sensor means SM is set to the low level and the transistor 12 is turned off. The transistor 7 is turned on (is made conductive) and a current therefore flows through the primary winding of the ignition coil 8.
Since the second angle position θ 2 of the engine is detected at time point t 2 , the output signal of the sensor means SM is set to the high level, the transistor 12 is turned on, and the transistor 7 is turned off (is made non-conductive). The following operation is similar to that of the prior art shown in FIG. 1.
However, assuming that the engine rotates in the reverse direction (the rotation in this case is referred to as reverse rotation) opposite to the present direction of rotation (the rotation in this case is referred to as forward rotation) of the engine at time t 6 before the engine arrives at the second angle position θ 2 , the engine passes through the first angle position θ 1 at time t 7 in the reverse rotation state, so the output signal level of the sensor means SM is inverted from low level to high level (this operation is opposite to that which takes place in the case where, when the engine passes through the first angle position θ 1 at time t 5 in the forward rotation state, the output signal level of the sensor means SM changes from high level to low level).
Since the output of the sensor means SM is set to the high level at time t 7 , the transistor 12 is turned on and the transistor 7 is turned off. Consequently, the current supply to the primary winding of the ignition coil 8 is shut off at time t 7 and an ignition spark is generated by the spark plug 9, thereby further promoting the reverse rotation of the engine in the same way as in the prior art shown in FIG. 1.
Thus the prior art shown in FIG. 7 has the same problem as the prior art shown in FIG. 1, such as the risk of engine damage or the like.
SUMMARY OF THE INVENTION
The object of the present invention has its object the solution of the problems mentioned above, and it is an object of the invention to obtain a safe ignition apparatus for an internal combustion engine in which the generation of ignition sparks at the time of reverse rotation of the engine is prevented, thereby avoiding the risk of engine damage.
This object is achieved by the provision in an ignition apparatus for an internal combustion engine according to the present invention of a detecting circuit for detecting that the engine is in a state of reverse rotation, and ignition blocking means for blocking ignition spark generation when such a state of reverse rotation is detected. The detecting circuit comprises means for measuring the duration of an output from a sensor means which causes current to flow in a primary winding of an ignition coil, and means for detecting whether the measured duration of time is longer than a predetermined time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram showing a conventional ignition apparatus of an internal combustion engine;
FIG. 2 is a waveform diagram showing an output of a sensor for one rotation of a rotor in the ignition apparatus of the internal combustion engine shown in FIG. 1;
FIG. 3 is an operation waveform diagram which assists in explaining the operation of the apparatus shown in FIG. 1;
FIG. 4 is a waveform diagram showing an output of the sensor at the time of forward rotation of the rotor illustrated in FIG. 1;
FIG. 5 is a waveform diagram showing an output of the sensor at the time of reverse rotation of the rotor shown in FIG. 1;
FIG. 6 is an operation waveform diagram which assists in explaining a state of ignition spark generation at the time of reverse rotation of the engine in the ignition apparatus of the internal combustion engine shown in FIG. 1;
FIG. 7 is a circuit diagram showing another conventional ignition apparatus of an internal combustion engine;
FIG. 8 is a waveform diagram which assists in explaining the operation of the circuit shown in FIG. 7;
FIG. 9 is a circuit diagram showing a first ignition apparatus of an internal combustion engine according to an embodiment of the present invention;
FIG. 10 is an operation waveform diagram which assists in explaining the operation of first embodiment shown in FIG. 9;
FIG. 11 is a circuit diagram showing a second embodiment of the present invention;
FIG. 12 is an operation waveform diagram which assists in explaining the operation of the second embodiment;
FIG. 13 is a circuit diagram showing a third embodiment of the present invention;
FIG. 14 shows a waveform diagram which assists in explaining the operation of the third embodiment;
FIGS. 15 and 16 illustrate circuit diagrams corresponding to fourth and fifth embodiments of the present invention; and
FIG. 17 is a waveform diagram which assists in explaining the operation of the fifth embodiment shown in FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will now be described with reference to the drawings. In regard to the figures, parts and components which are common to the embodiments shown in FIGS. 1 and 7 are designated by the same reference numerals and repetitive description thereof is omitted. Only those portions of the preferred embodiment which are different from FIGS. 1 and 7 will, in the main, be described below. FIG. 9 shows an embodiment for improving upon the prior art shown in FIG. 1.
In FIG. 9, the components indicated by reference numerals 1 to 10 are the same as those in FIG. 1. The components designated by reference numbers 21 and above are those which are additional to the arrangement of FIG. 1 and comprise the characteristic parts of the embodiment of FIG. 9.
In the embodiment, an inverter 21 receives the Q output of the FF 6 and inverts the phase. The output of the inverter 21 is transferred to a base of a transistor 22.
A resistor 23 is connected between a (+) terminal of the battery 10 and a collector of the transistor 22.
A capacitor 24 is connected between the collector of the transistor 22 and the ground. A time constant circuit is formed by both the resistor 23 and the capacitor 24.
Resistors 25 and 26 are serially connected between the (+) terminal of the battery 10 and the ground. The voltage at a junction (node I) between the resistors 25 and 26 is set to a predetermined level.
A (-) input terminal of a comparator 27 is connected to the collector of the transistor 22 and a (+) input terminal is connected to the node I between the resistors 25 and 26. The comparator 27 compares a charging voltage level of the capacitor 24 and the voltage level at the node I between resistors 25 and 26 and its output is inverted when the charging voltage level of the capacitor 24 is higher than the voltage level at the node I.
A detecting circuit 100 is constructed by the inverter 21, transistor 22, resistor 23, capacitor 24, resistors 25 and 26, and comparator 27.
Reference numeral 28 denotes a transistor. An emitter of the transistor 28 is connected to the (+) terminal of the battery 10, a base is connected to an output terminal of the comparator 27, and a collector is connected to the reset input terminal R of the FF 6, respectively. The transistor 28 is turned on or off in accordance with the output level of the comparator 27 and forms an inhibiting circuit for inhibiting the setting or resetting of the FF 6.
The operation will now be described. FIG. 10 is an operation waveform diagram provided to assist in explaining the operation of the circuit shown in FIG. 9. FIG. 10(a) to 10(d) show signals a to d in FIG. 9. FIGS. 10(e) to 10(h) indicate signals G, I, H, and J in FIG. 9. FIGS. 10(i) and 10(j) show signals e and f in FIG. 9.
The signal G in FIG. 10(e) denotes the output voltage of the inverter 21. The signal H in FIG. 10(g) shows the voltage at the (-) input terminal of the comparator 27. The signal I in FIG. 10(f) indicates the voltage at the (+) input terminal of the comparator 27. The signal J in FIG. 10(h) shows the output voltage of the comparator 27.
It is now assumed that the high level signal is generated from the sensor 3 at time t 10 as shown in FIG. 10(a). Thus, the signal b of FIG. 10(b) is input to the set input terminal S of the FF 6. The Q output of the FF 6 is set to a high level as shown in FIG. 10(d). The transistor 7 is turned on and current according to the signal e of FIG. 10(i) flows through the collector. Current starts flowing through the primary winding of the ignition coil 8.
On the other hand, the output G of the inverter 21 is set to a low level at time t 10 as shown in FIG. 10(e) and the transistor 22 is turned off. Thus, a charging current is supplied to the capacitor 24 through the resistor 23. The voltage across the terminals of the capacitor 24 starts increasing as shown in FIG. 10(g).
The increase in voltage of the capacitor 24 continues for the time interval between t 10 and t 11 . However, since this voltage does not reach the voltage level of I in FIG. 10(f), the output J [FIG. 10(h)] of the comparator 27 is held at the high level. Consequently transistor 28 is in the OFF state.
Hence, the low level signal generated by the sensor 3 at time t 11 passes through the diode 5 and the signal c shown in FIG. 10(c) is input to the reset input terminal R of the FF 6, thereby resetting the FF 6. The Q output of the FF 6 is set to a low level, the transistor 7 is turned off, the primary current of the ignition coil 8 is shut off, and an ignition spark is generated by the spark plug 9.
In a manner similar to the above, the charging of the capacitor 24 is started by the high level signal generated by the sensor 3 at time t 12 . When the charging voltage reaches the voltage level at the (+) input terminal of the comparator 27 at time t 13 before the next low level signal is generated by the sensor 3, the output of the comparator 27 is inverted and set to the low level. Thus, the transistor 28 in the OFF state is turned on, thereby setting the potential at the reset input terminal R of the FF 6 to the high level.
Thus, the low level output voltage is thereafter generated by the sensor 3 at time t 14 . However, this output signal cannot reach the reset input terminal R of the FF 6 and the Q output of the FF 6 is held in the set state, i.e., held at the high level.
The transistor 7 which was turned on at time t 12 is therefore held in the operative mode even after time t 14 . No ignition spark is generated by the spark plug 9 at time t 14 .
Since the time interval from t 12 to t 13 is equal to the time that passes until the voltage across the terminals of the capacitor 24 reaches the predetermined voltage level I, a desired time duration can be set by properly selecting the capacitance value of the capacitor 24 and the resistance values of the resistors 23, 25, and 26, respectively.
On the other hand, since the rear edge portion B of the rotor 1 is located at the ignition position at the time of forward rotation of the rotor 1, this position corresponds to the crank angle of the engine during the period from the schematic compression upper dead point to about 10° before the compression upper dead point.
Therefore, as shown in FIG. 6, after the front edge portion A of the rotor 1 has been brought to face the sensor 3 at time t 1 during the forward rotation, there is a high probability of the angle position at which the rotor 1 changes from the forward rotation to the reverse rotation at time t 3 being near the rear edge portion B of the rotor. This is because, as the sensor approaches the rear edge portion B of the rotor 1, the compression pressure of the engine rises and the reverse torque generated by the compression pressure causes reverse rotation of the engine, and this leads to problems.
For this reason, the time duration from t 1 to t 2 is generally made longer than that from t 4 to t 5 which is obtained by virtue of the forward rotation of the rotor 1 as shown in FIG. 4.
Consequently, the operating level of the comparator 27 can be practically set so that the comparator 27 does not operate upon forward rotation of the rotor 1 and only operates upon reverse rotation thereof.
FIG. 11 is a circuit diagram showing the second embodiment of the invention. In FIG. 11, reference numeral 31 denotes a starter employed to start the engine (not shown); 32 indicates a switch which is connected between the starter and the (+) terminal of the battery 10 and which serves to continue the current supply to the starter; and 33 an inverter which is connected to a node between the starter 31 and the switch 32 and which generates the inverted output voltage to the input voltage. Discriminating means 200 for determining whether or not current has been supplied to the starter 31 is comprised by the switch 32 and the inverter 33.
An inverter 34 is connected to an output terminal of the comparator 27 and generates the inverted output voltage to the input voltage. A two-input NAND gate 35 is provided and the output of the inverter 34 is supplied to the first input terminal of the NAND gate 35 and the output of the inverter 33 is supplied to the second input terminal. Only when both of the input signals at the first and second input terminals are at the high level does the NAND gate 35 output a low level signal. In other cases, a high level signal is output. The output of the NAND gate 35 is supplied to a base of the transistor 28.
The other parts of the arrangement are similar to what is shown in FIG. 9 and description thereof is omitted here.
The operation of the circuit of FIG. 11 will now be described. FIG. 12 is an operation waveform diagram illustrating the operation of the circuit shown in FIG. 11. FIGS. 12(a) to 12(h) are substantially the same as FIGS. 11(a) to 11(h).
A signal K in FIG. 12(j) corresponds to the output voltage of the inverter 34; a signal L in FIG. 12(k) to the voltage across the terminals of the starter 31; a signal M in FIG. 12(l) to the output voltage of the inverter 33; and a signal N in FIG. 12(m) to the output voltage of the NAND gate 35, respectively. FIGS. 12(n) and 12(o) are the same as FIGS. 10(i) and 10(j), respectively.
It is now assumed that the voltage of the capacitor 24 starts rising from time t 21 as shown in FIG. 12(g) and reaches the inversion level of the comparator 27 at time t 22 . At this point, the output of the comparator 27 falls from high level to low level.
Thus, the output K [FIG. 12(j)] of the inverter 34 is set to the high level at time t 22 . However, since the switch 32 is closed at this time, the voltage L of the starter 31 is at the high level, the output M [FIG. 12(l)] of the inverter 33 is set to the low level, and the output N [FIG. 12(m)] of the NAND gate 35 is set to the high level. Hence, the output N of the NAND gate 35 is held at the high level.
Therefore, since the transistor 28 is also in the OFF state, the low level output voltage which is generated by the sensor' 3 at time t 23 is input to the reset input terminal R of the FF 6, thereby resetting the FF 6. Thus, the Q output of the FF 6 changes from high level to low level, the transistor 7 is turned off, and an ignition spark is generated by the spark plug 9.
The switch 32 is opened at time t 24 , in other words, the current supply to the starter 31 is stopped. Thereafter, the charging is started from time t 25 . If the voltage H of the capacitor 24 exceeds the comparison voltage level I at time t 26 , the output voltage J of the comparator 27 is set to low level and the output voltage K of the inverter 34 is set to high level.
At this time, unlike the situation at time t 22 , the output voltage M of the inverter 33 is also at high level, so that the input voltage levels at the first and second input terminals of the NAND gate 35 are both set to high level.
The output of the NAND gate 35 is therefore set to low level at time t 26 , thereby turning on the transistor 28. The input voltage at the reset input terminal R of the FF 6 is set to high level by the switching on of the transistor 28. Therefore, the low level output signal which is generated by the sensor 3 at time t 27 does not reach the reset input terminal R of the FF 6, so that the FF 6 is held in the set state at time t 27 .
Thus, no ignition spark is generated by the spark plug 9. Since driving force generated by the starter 31 is applied during the time of current supply to the starter 31, there is hardly any situation where the engine fails to pass the compression upper dead point and hence goes into reverse rotation, while when no current is supplied to the starter 31, reverse rotation of the engine occurs easily. On the basis of this fact, the embodiment of FIG. 11 is constructed so as to improve upon the embodiment of FIG. 9.
FIG. 13 shows a third embodiment of the invention which improves upon the prior art shown in FIG. 7.
In FIG. 13, parts and components which are the same as those shown in FIG. 7 are designated by the same reference numerals, and description thereof is omitted. Only those portions which are different from FIG. 7 will, in the main, be explained.
In FIG. 13, resistors 15 and 29 are respectively connected to the output of the sensor means SM. The resistor 15 is connected between the base of the transistor 12 and the output of the sensor means SM. The resistor 29 is connected between a base of a transistor 23 and the output of the sensor means SM. When the output of the sensor means SM is at high level, both of the transistors 12 and 22 are turned on.
The components of a detecting circuit 100 are almost the same as those of the circuit shown in FIG. 9, expect that the resistor 23 and the transistor 22 are used instead of the inverter 21.
Numeral 300 denotes an ignition blocking means. In this means, a set/reset type flip-flop circuit (hereinafter, referred to as FF) 19 is set when a set input terminal S is set to high level, and is reset when a reset input terminal R is set to low level. The set input terminal S of the FF 19 is connected to an output terminal of the comparator 27. A resistor 20 is connected between the (+) terminal of the battery 10 and the reset input terminal R of the FF 19. A capacitor 21 is connected between the reset input terminal R of the FF 19 and the ground. After a power switch (not shown) has been closed, the reset input terminal R of the FF 19 is held at low level for a predetermined period of time. After the FF 19 has been reset, the reset input terminal R of the FF 19 is set to high level.
A base of a transistor 29 is connected to a Q output of the FF 19, an emitter is connected to the ground, and a collector is connected to the collector of the transistor 7, respectively. When the Q output of the FF 19 is at high level, the transistor 29 is turned on. When it is at low level, the transistor 29 is turned off.
The operation will now be described. FIG. 14 is a waveform diagram illustrating the operation of the above circuit. FIGS. 14(a) and 14(b) show signals a and b in FIG. 13, respectively. FIGS. 14(c) to 14(f) show signals F, E, G, and H in FIG. 13, respectively. FIGS. 14(g) and 14(h) show signals c and d in FIG. 13.
Thus, the signal E in FIG. 14(d) corresponds to the voltage at the (+) input terminal of the comparator 27. The signal F of FIG. 14(c) corresponds to the voltage at the (-) input terminal of the comparator 27. The signal G of FIG. 14(e) corresponds to the output voltage of the comparator 27. The signal H of FIG. 14(f) corresponds to the Q output voltage of the FF 19.
It is now assumed that the sensor means SM detects the first angle position θ 1 at time t 10 . At this time, the output of the sensor means SM is changed from high level to low level as shown in FIG. 14(a) whereby the transistor 12 is turned off, while the collector potential is set to high level as shown in FIG. 14(b) whereby the transistor 7 is turned on. Thus, the collector potential assumes the state shown in FIG. 14(g) and current flows through the primary winding of the ignition coil 8.
On the other hand, since the transistor 22 is also turned off at time t 10 , the charging of the capacitor 24 is started, flowing from the (+) terminal of the battery 10 through the resistor 23 as shown in FIG. 14(d).
The sensor means SM detects the second angle position θ 2 at time t 11 and the output of the sensor means SM is set to high level, so that both of the transistors 12 and 22 are turned on. At this time, since the engine has continuously been rotating in the forward direction, the time duration from time t 10 to time t 11 is relatively short. Therefore, the charging voltage of the capacitor 24 does not reach the predetermined voltage level which is determined by the resistors 25 and 26, as will be obvious from FIGS. 14(c) and 14(d).
Consequently, the output of the comparator 27 is held at the low level as shown in FIG. 14(e). The FF 19 maintains the reset state which was decided when the power switch (not shown) was closed before time t 10 . The Q output of the FF 19 is held at the low level as shown in FIG. 14(f).
Thus, since the transistor 29 is held in the OFF state, by turning on the transistor 12 at time t 11 , the transistor 7 is turned off and the current supply to the primary winding of the ignition coil 8 is shut off at time t 11 , an ignition spark thereby being generated by the spark plug 9 as shown in FIG. 14(h).
Next, in the case where the engine rotation is reversed before it reaches the second angle position θ 2 after the first angle position θ 1 has been detected at time t 12 and the first angle position θ 1 is again detected at time t 14 in the state of reverse rotation, a current first flows through the primary winding of the ignition coil 8 from time t 12 and the charging of the capacitor 24 is started in a manner similar to what happens at the time t 10 .
However, since the engine rotation is reversed during the foregoing process in this case, the period of time during which the output of the sensor means SM is at the low level is long. Accordingly, the charging voltage E of the capacitor 24 finally exceeds the voltage F [FIG. 14(c)] at the (-) input terminal of the comparator 27 at time t 13 .
Since the output of the comparator 27 is inverted to the high level at time t 13 [FIG. 14(e)], this inverted signal functions as a set input signal of the FF 19. The FF 19 is set and the Q output H [FIG. 14(f)] is set to the high level.
Since the reset input terminal R of the FF 19 is at the high level, the capacitor 24 is rapidly discharged at time t 14 . Even after the output of the comparator 27 has returned to the low level, the Q output H of the FF 19 is also held at the high level.
Therefore, when the sensor means SM detects the first angle position θ 1 at time t 14 during the reverse rotation, even though the transistor 7 is turned off, the current supply to the primary winding of the ignition coil 8 continues without being shut off since the transistor 22 is in the ON state from time t 13 . Thus, no unnecessary ignition spark is generated by the spark plug 9.
FIG. 15 shows a fourth embodiment of the invention which further improves upon the third embodiment and its characteristic feature is as follows. Since a transistor with a high withstanding voltage for use with high currents is needed as a transistor to be used for allowing or interrupting the supply of primary current to the ignition coil 8, the use of two transistors 7 and 29 as shown in FIG. 13 is costly. To solve this problem, the transistor 7 alone is used to allow or interrupt the supply of primary current to the ignition coil 8. Namely, an OR gate 34 is used to synthesize the signals before the transistor 5 is driven.
The OR gate 34 is of the two-input type. If either one of two input signals is at the high level, the OR gate 34 outputs a high level signal. Only when both of the input signals are at the low level does the OR gate 34 output a low level signal.
A first input terminal of the OR gate 34 is connected to the collector of the transistor 12 and a second input terminal is connected to the Q output of the FF 19. An output terminal of the OR gate 34 is connected to the base of the transistor 7. Ignition blocking means 200 is composed of the OR gate 34, the resistor 20, the capacitor 21 and FF 19.
In FIG. 15, when the Q output of the FF 19 is at the low level (before time t 13 in FIG. 14), an output of the OR gate 34 has the same phase as that of the signal at the first input terminal (when the input signal is at the high level, the output signal is also at the high level; if the input signal is at the low level, the output signal is also at the low level). Therefore, the primary current flows through the ignition coil 8 from time t 10 in FIG. 14 and the current supply is shut off at time t 11 and an ignition spark is generated.
On the other hand, after the Q output of the FF 19 has been set to the high level (after time t 13 in FIG. 14), the second input terminal of the OR gate 34 is set to the high level. Thus, even if the first input terminal is set to be either high or low level, the OR gate 34 outputs a high level signal and the transistor 7 is held in the ON state, the supply of primary current to the ignition coil 6 being left uninterrupted. Thus, no ignition spark is generated.
FIG. 16 is a circuit showing a fifth embodiment of the invention. An input terminal of an inverter 35 is connected to the Q output of the FF 19. The inverter 35 generates an output signal whose phase is opposite to that of the input signal. An output of the inverter 35 is input to a base of a transistor 32. An emitter of the transistor 36 is connected to the ground and a collector is connected to a cathode of a diode 37. An anode of the diode 37 is connected to the ground.
A resistor 38 is arranged between the base of the transistor 7 and the collector of the transistor 12. A resistor 41, a capacitor 40, and a diode 39 are serially connected. This serial circuit is connected between the base and collector of the transistor 7.
Namely, a negative feedback circuit is formed by the loop consisting of the collector of the transistor 7, resistor 41, capacitor 40, the anode of the diode 39, the cathode of the diode 39, and the base of the transistor 5.
On the other hand, a node of the capacitor 40 and the anode of the diode 39 is connected to a collector of the transistor 36. When the transistor 36 is turned on, the foregoing negative feedback circuit is made inoperative. When it is turned off, the negative feedback circuit is made operative.
In FIG. 16, the ignition blocking means 200 is comprised by the FF 19, resistor 20, capacitor 21, inverter 31, 35, transistor 36, diode 37, resistor 38, diode 39, capacitor 40, and resistor 41.
FIG. 17 is an operation waveform diagram of the fifth embodiment circuit shown in FIG. 16. In FIG. 17(g) shows an output voltage of the inverter 35. FIGS. 17(a) to 17(f) are the same as FIGS. 14(a) to 14(f). FIGS. 17(h) and 17(i) are the same as FIGS. 14(g) and 14(h).
In FIG. 17, the sensor means SM detects the first angle position θ 1 at time t 20 and the output of the sensor menas SM is set to the low level, so that the transistor 12 is turned off and the current flowing from the (+) terminal of the battery 10 to the resistor 14 passes through the resistor 38 and reaches the base of the transistor 7. Thus, the transistor 7 is turned on (no influence is exerted by the diode 29 because it is connected in the opposite direction).
Since the transistor 7 is turned on [FIG. 17(h)], the primary current flows through the ignition coil 8 and the capacitor 40 is discharged along the path consisting of the ground, diode 37, capacitor 40, resistor 41, the collector of the transistor 7, the emitter of the transistor 7, and the ground.
When the sensor means SM then detects the second angle position θ 2 at time t 21 and the output of the sensor means SM is set to the high level [FIG. 17(a)], the transistor 12 is turned on [FIG. 17(b)]. Since the Q output of the FF 19 is at the low level [FIG. 17(f)] at time t 21 , the output [FIG. 17(g)] of the inverter 35 is at the high level and the transistor 36 is turned on.
Therefore, when the transistor 12 is turned on and the transistor 7 is turned off, the charging current of the capacitor 40 flows along the path consisting of the (+) terminal of the battery 10, the primary winding of the ignition coil 8, resistor 41, capacitor 40, the collector of the transistor 36, and the emitter thereof, so the off state of the transistor 7 is not influenced.
Consequently, the primary current of the ignition coil 8 is shut off at time t 21 and an ignition spark is generated by the spark plug 9 [FIG. 17(i)].
On the other hand, when the transistor 7 is turned off and the transistor 36 is turned on, the foregoing charging circuit is formed, so that the capacitor 40 is charged with the side of the resistor 41 set to the (+) potential and the side of the diode 39 set to the (-) potential.
If the direction of engine rotation reverses before it reaches the second angle position θ 2 following detection of the first angle position θ 1 at time t 22 , the current supply of the primary current of the ignition coil 8 is started at time t 22 and the transistor 7 is turned on at time t 22 , so that the discharging of the capacitor 40 is started in a manner similar to what occurs at time t 20 .
However, since at this time, the period during which the output of the sensor means SAM is at low level is long, the, Q output of the FF 19 is inverted to high level at time t 23 . In response to this high level output signal, the output of the inverter 35 is also inverted to low level at time t 23 [FIG. 17(g)], and the transistor 36 is turned off.
When the sensor means SM detects the first angle position θ 1 at time t 24 during the reverse rotation, the transistor 12 is turned on and the transistor 7 is turned off while, at the same time, the potential at the collector of the transistor 12 starts increasing. The charging of the capacitor 40 is started along the path consisting of the resistor 41, capacitor 40, diode 39, the base of the transistor 7, and the emitter thereof. This results in a base current of the transistor 7 and functions to keep the transistor 7 in the ON state. Consequently, until the capacitor 40 is completely charged, the transistor 7 is slowly turned off from the ON state at a predetermined balance point as shown in FIG. 17(h).
Since the transition from the ON state to the OFF state of the transistor 7 at time t 24 is slow, the shut-off speed of the primary current of the ignition coil 8 is also slow. The secondary output voltage of the ignition coil 8 is at a very low level, so no ignition spark is generated by the spark plug 9.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. For example, the FF 19 (FIGS. 13, 15 and 16) may be reset at a trailing timing of the output of the sensor means SM, or the like, and the means for holding the detection output of the comparator 27 is not limited to the FF 19 since, for instance, a thyristor can also be used. In regard to FIG. 16, after the Q output of the FF 19 has been inverted by the inverter 35, the transistor 36 is driven. However, the transistor 36 can also be directly driven by the Q output of the FF 19.
The charging method of the capacitor 24 is not limited to the foregoing example; a constant current charging method may also be used. As an alternative method of measuring the time duration of the first state of the sensor means SM, it is also possible to use method of counting the number of pulses by utilizing an oscillator and a counter, or the like.
As a practical example of the sensor means SM, the following devices can be considered.
(i) A slit disk is attached such as to face a light emitting diode.
(ii) A contactless switch and a rotating rotor are combined.
(iii) A magnetic pickup and a rotating rotor are combined. | An ignition apparatus of an internal combustion engine includes a detecting circuit for detecting a state of the engine in which reverse rotation is taking place, and an ignition blocking circuit for blocking the generation of ignition sparks when such reverse rotation is detected. The detecting circuit comprises circuitry for measuring the duration of an output from a sensor circuit which allows current to flow in a primary winding of an ignition coil, and circuitry for detecting whether the measured time duration is longer than a predetermined time. | 5 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to a system and method for positively identifying individuals (i.e., citizens, customers, employees, patients, and subjects) at particular points of interest in the areas of health care (e.g., hospitals or doctor's offices), security (e.g., banks, airports, etc.), and any other situations where an individual's identity must be confirmed. This invention further relates to a database that contains individual biometric data along with commonly accessed identifying information about the individual. The additional identifying information is contained in another category of databases that manage information about individuals including, but not limited to, health care information, security issue information, and any other private information which an individual wants to protect.
BACKGROUND OF THE PRESENT INVENTION
In today's society, it is becoming increasingly important for entities to accurately confirm the identity of individuals. This is made clear especially in three areas of challenge to current society: 1) the passage and maintenance of health care records; 2) the problem of identity theft to criminals and loss of control of identity in reference to other individuals or entities in society; and 3) security issues of national protection as required by certain functions (e.g., such as opening a bank account must now be monitored).
In general, society currently relies on the confirmation of individuals through witnesses, identity cards, identity codes, and biometric identifiers. For example, a witness, (e.g., anyone from a casual acquaintance to a notary public) can confirm a person's identity. Also, identity cards and personal identification codes are utilized to authenticate an individual's identity. This system, however, is expensive and corruptible. Recognizing these deficiencies, attempts have been made to improve the situation.
One example of a present identification system is a computer system that remotely records the arrival and departure times of field-based employees at various work sites through a telephone network. Specifically, the system detects an employee's automatic number identification data and further collects personal identification codes from the caller. The automatic number identification and personal identification code are used to identify the calling telephone. Once identified, the system can record the arrival and departure times of the employee.
These systems have several disadvantages. First, automatic number identification (i.e. “Caller ID”) only indicates the telephone number of the particular telephone used to make the call. Automatic number identification information therefore does not affirmatively confirm the identity of an individual—only the location from which the individual is placing a telephone call. Similarly, personal identification codes are manually entered into a keypad by any individual and are therefore not reliable for confirming the identity of an individual. More specifically, mere receipt of a manually entered personal identification code does not assure that the person entering the personal identification code is the person assigned to the personal identification code.
Because these above systems are expensive, time consuming, or subject to misuse and abuse, biometric devices were created for use in identification and authorization. Generally, measurable and recordable body features (e.g., fingerprints, eye patterns, facial contours, or voice characteristics, etc.) are registered as biometric keys and, at the time of authentication, compared with the respective body features of a person to be authenticated.
A personal computer (“PC”) can be equipped with a device (e.g., a video camera) that makes it possible for the PC to record biometric information (e.g., facial features) and to reuse the information at a later time for authenticating an individual. The PC could grant access to a user only if it confirms the identity of the user by recognizing his or her facial features.
In any event, the above identification systems are currently used only on an ad hoc basis and are not connected to any national database. Furthermore, if a national database were implemented according to today's technology, the holder of the end data would not only have the individual's acquired data, but also the individual's unique identification information. Such systems do not protect the individual from fraud and abuse. Such systems cannot be currently regulated by US law to protect the identity of the individual from being passed to other entities. Over time the independence of the individual would be lost. In addition, they are also subject to fraud and abuse if implemented without a secured input device.
There currently exists a need for a national or international system that would allow authentication of an individual at any given time and location while at the same time protecting the individual from loss of identity. On 27 Apr. 2004, President Bush called for the majority of Americans to have interoperable electronic health records within ten years. David J. Brailer, M.D., Ph.D., National Coordinator for Health Information Technology, released his report, “The Decade of Health Information Technology: Delivering Consumer-centric and Information-rich Health Care,” on 21 Jul. 2004. In the report he calls for four goals in the strategic framework: 1) Informed Clinical Practice; 2) Interconnected Clinicians; 3) Personalized Care; and 4) Improved Population Health.
“The Uniting and Strengthening of America by Providing Appropriate Tools Required to Interrupt and Obstruct Terrorism” (USA Patriot Act) Act of 2001 (H.R. 3162-24 Oct. 2001) requires, among other things, the identification and verification by all financial institutions of accountholders and prospective accountholders (See, §326). Not only must an accountholder be identified and verified, records related to the accountholder, at a minimum name, address and other identifying information, must be maintained. In other words, a secure database is required.
Databases have been utilized for a number of years to store, sort and distribute information. Specifically, in the medical field, databases have been utilized to diagnose and treat patient diseases. David Bennahum illustrates the long known need for medical interconnectivity in an article entitled “Docs for Docs” in Wired Magazine in June 1995. He notes that doctors have been attempting to create a “virtual patient record” for years. Essentially, with the emergence of more efficient wireless networks, it was possible to link doctors, hospitals, insurance companies, and drug labs. As a result, doctors were able to record instructions, maintain medical information and receive general medical information from insurance companies and drug labs over a wireless network connecting several databases. Unfortunately, the system of interconnectivity has never occurred because the current system of authentication and security of the information electronically can not be secured in a timely, inexpensive manner that will not allow the possibility of identity loss.
There exists a need for a system that positively authenticates an individual and that is connected to a database for immediate retrieval of an individual's medical information. More specifically, patients visiting such places as doctor's offices, dentist's offices and hospitals often need to complete forms they have completed in the past. A system that positively identifies an individual and that retrieves all pertinent information about the individual (e.g., name, insurance carrier, etc.) is greatly desired provided identity loss cannot occur.
There exists a need for a secured system that allows an employee, client, patient, subject or citizen to interface with an organization, business, individual, or government agency when a positive identification for a form to be completed is required. Such form collections, authorizations, verifications and organization are increasingly costly and difficult to manage in a secure fashion. As more and more human abstract thought and information leaves the confines of the visible universe and enters the electronic “fifth dimension” in an ever growing world that occupies neither space nor time, where information about every individual can, as an electron around an atom, be every where and no where at the same time, it is important in the preservation of liberty that each individual's fifth dimension of abstract thought and information be protected and preserved as his or her own.
SUMMARY OF THE INVENTION
The present invention relates generally to a system of authentication and a means for retrieving information about the authenticated individual. More specifically, it allows a person to execute forms (e.g., consent forms) at any location across the world by submitting to a positive identification test. In turn, doctors and medical researchers can, for example, receive all pertinent information associated with the authenticated individual (e.g., medical history, allergies, consent forms, etc.).
The present invention relates to an inexpensive and secure system that can positively authenticate an individual and retrieve pertinent information regarding that individual while leaving his or her fifth dimension of abstract knowledge and information secured. The present invention further allows an entity to interact with the general population to retrieve, process, and organize secured completed forms in a way that allow centralization of information while protecting the autonomy of the individual.
An object of the present invention is to provide a system to allow an employee, client, patient, subject, or citizen to interface with an organization, business, individual, or government agency when a positive identification for a form to be completed is required. Another object of the present invention is to provide assured confirmation of an individual via a secure, tamper-proof system.
Yet another object of the present invention is to provide a system that can transmit its location when accessed to confirm the identity of the active user.
Yet another object of the present invention is to allow any entity (e.g., organization, business, individual, or government agency) that requires an individual to complete a form to ensure that the forms are properly signed and the identity of the signatory is verified.
Yet another object of the present invention is to allow any equipped entity (having the permission and verification of an individual) to access the individual's pertinent information, including all forms completed by the individual.
Another object of the present invention is to allow an individual to alter his or her pertinent information from a properly equipped personal computer.
Yet another object of the present invention is to allow an individual to fill out pertinent forms (i.e. agreements, authorizations, contracts, records, and transactions) at a convenient time and place.
Yet another object of the present invention is to allow communication of an individual's secured information from one Electronic Identification System's Biometrically Endorsed Repository Grid (“EISBERG”) to another, if he or she so chooses. If this decision is not made by the individual, then no communication may be made from an EISBERG with any other entity.
Other objects, features, and characteristics of the present invention, as well as the methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description with reference to the accompanying drawings, all of which form a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
A further understanding of the present invention can be obtained by reference to a preferred embodiment set forth in the illustrations of the accompanying drawings. Although the illustrated embodiment is merely exemplary of systems for carrying out the present invention, both the organization and method of operation of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention.
For a more complete understanding of the present invention, reference is now made to the following drawings in which:
FIG. 1 depicts an example of the Electronic Identification System for Form Location, Organization and Endorsement (“EISFLOE”) showing the flow of authentication and biometric parameter information between the components of the system.
FIG. 2 depicts an example of the Electronic Identification System's Comprehensive Authentication Process (“EISCAP”) that links an individual's biometric parameters with another piece of identification information in order to authenticate an individual in accordance with the invention.
FIG. 3 depicts an example of the Electronic Identification System's Biometrically Endorsed Repository Grid (“EISBERG”) that allows an individual to complete specific forms (e.g., consent forms) by connecting to a secure database according to the preferred embodiment of the present invention.
FIG. 4 depicts an example of an Electronic Identification System's Confirmed Unique Biometric Encounter (“EISCUBE”) for documenting the authentication of an individual according to the preferred embodiment of the present invention.
FIG. 5 depicts a top view of the preferred embodiment of the Electronic Identification System Machine (“EIS Machine”) for interfacing between an individual and the system of the present invention, showing means for collecting information (including biometric information) from an individual for verification purposes.
FIG. 6A depicts a front view of the interface of the preferred embodiment of the present invention, having a means for reading an identification card to authenticate the identity of an individual.
FIG. 6B depicts a rear view of the interface shown in FIG. 6A , showing electrical connection and outgoing data flow means for transferring collected information to the system.
FIG. 6C depicts a side view of the interface shown in FIG. 6A , showing a locator device and a writing utensil for use in signature confirmation.
FIG. 7 depicts an example of internal components of the interface of the preferred embodiment of the present invention for securely retrieving and utilizing an individual's biometric information for authenticating an individual.
FIG. 8 depicts an example of internal components of the interface of an alternate embodiment of the present invention for securely retrieving and utilizing an individual's biometric information for authenticating an individual.
FIG. 9A depicts a front view of the EIS Maker of the present invention, which is an alternative embodiment to the EIS Machine shown in FIG. 5 , without a digital camera, EIS Rink, or EIS Tray.
FIG. 9B depicts a side view of the EIS Maker shown in FIG. 9A , showing a locator device and a power switch.
FIG. 9C depicts a rear view of the EIS Maker shown in FIG. 9A , showing electrical connection and outgoing data flow means for transferring collected information to the system.
FIG. 10 depicts the ANI Network, which will exist for every individual that comes into the EISFLOE, shown in FIG. 1 , comprising four complexes: Dianoian, Levavian, Nepheshian, and Meodian.
FIG. 11 depicts the Dianoian Complex shown in FIG. 10 , comprising three Systems: Educational, Intellectual, and Personality.
FIG. 12 depicts the Levavian Complex shown in FIG. 10 , comprising three Systems: Habitual, Charitable, and Preferential.
FIG. 13 depicts the Nepheshian Complex shown in FIG. 10 , comprising three Systems: Political, Philosophical, and Religious.
FIG. 14 depicts the Meodian Complex shown in FIG. 10 , comprising five Systems: Medical, Legal, Vocational, Financial, and Relational.
FIG. 15 depicts the Medical System (“Asklepios”) shown in FIG. 10 , comprising six Groups: Epione, Hygeia, Algla, Iasis, Akesis, and Panacea.
FIG. 16 depicts an example of a plexus of interaction between EISBERGs if an individual so authorizes. A Med-e-Plexus of ACB EISBERG in Asklepios is denoted. Arrows represent authorization points before personal data is transmitted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, a detailed illustrative embodiment of the present invention is disclosed herein. However, techniques, systems and operating structures in accordance with the present invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiment. Consequently, the specific structural and functional details disclosed herein are merely representative, yet in that regard, they are deemed to afford the best embodiment for purposes of disclosure and to provide a basis for the claims herein, which define the scope of the present invention. The following presents a detailed description of a preferred embodiment (as well as some alternative embodiments) of the present invention.
Referring first to FIGS. 1 and 2 , an overview of the preferred embodiment of the present invention is depicted at the point of access by an individual. More specifically, the Electronic Identification System for Form Location, Organization and Endorsement (“EISFLOE”) 6 is shown, generally comprising three components: the point-of-access by a user of the system in EIS House 1 , Electronic Identification System's Comprehensive Authentication Process (“EISCAP”) 3 , and Electronic Identification System's Biometrically Endorsed Repository Grid (“EISBERG”) 5 , each of which will be described in more detail below.
EIS House 1 serves as the site where the user elects to authenticate a form. The meaning of “form,” includes but is not limited to, agreements, authorizations, contracts, records, and transactions relating to all aspects of the Automated Numerical Identifier Network (“ANI Network”) (as defined below). A form may embody a physical document or alternatively an electronic document (e.g., a fillable internet webpage). Internet Access Device (“IAD”) 7 (e.g., a computer terminal) and EIS Machine 13 interact within EIS House 1 . Importantly, EIS Machine 13 receives no electronic data input. Through communication line 17 , EIS Machine 13 interfaces with IAD 7 when called upon by EISBERG 5 , requesting that the individual enter his or her electronic identity into EIS Machine 13 . Once the individual activates EIS Machine 13 , the electronic message is attached to a web page in IAD 7 and sent through communication line 9 to EISBERG 5 . Simultaneously EIS Machine 13 sends the electronic identity out of EIS House 1 to EISCAP 3 through communication line 15 , as noted below, which is discussed in greater detail below.
Generally, a user of the system of the present invention wishes to authorize a specific form (e.g., consent form, tissue donation authorization form, do not resuscitate form, etc.) and accesses the system of the present invention at EIS House 1 , via IAD 7 . The information regarding the specific form can be collected in any manner as described in greater detail below. Initially, IAD 7 transmits information regarding the requested form over communication line 9 to EISBERG 5 . In response, EISBERG 5 retrieves the requested form from an internal storage area (e.g., database) and transmits the corresponding form information over communication line 11 to IAD 7 . The user utilizes an interface device, such as a terminal, at EIS House 1 to supply the information required by the form and utilizes EIS Machine 13 to initiate authentication of the form. Generally, EIS Machine 13 transfers an electronic code along with the form from IAD 7 to EISBERG 5 while simultaneously transferring a coded signal containing a user's biometric and identification information over communication line 15 to EISCAP 3 .
As described above, in the preferred embodiment of the present invention an individual requests a form (e.g., a web page form) via IAD 7 . IAD 7 can comprise any computer means connected to EIS Machine 13 that is equipped with the proper identification peripherals as described in greater detail below.
Although all communication lines are depicted as physically connected communication means, it is contemplated that all communication within the system of the present invention can be completed by any method of information transfer, including but not limited to telephone trunk lines, T1 data lines, and wireless communication means.
Generally, as shown in FIG. 1 , EIS House 1 includes Internet Access Device (“IAD”) 7 and EIS Machine 13 and may be located anywhere in the world. EIS Machine 13 provides a secured means for an individual to interface with an organization, business, individual, or government agency when a positive identification for a form to be completed is required. Because EIS Machine 13 is tamper-proof and will transmit its location when accessed, the active participation of the person being identified (i.e., the user) can be assured.
EIS Machine 13 is registered with EISFLOE system 6 and is assigned a unique identification code to confirm access when transmitting information to EISCAP 3 or EISBERG 5 . To access EISFLOE 6 , an individual who wishes to consider authorizing a form accesses IAD 7 by utilizing an interface (i.e., a terminal) in EIS House 1 . The user can enter information to indicate the desired form through any known means of collecting information, including, but not limited to, digital scan and keyboard means. EIS Machine 13 is capable of interfacing with IAD 7 in transmitting the response to a form that requires authentication over communication line 17 via IAD 7 to EISBERG 5 over communication line 9 .
EIS machine 13 also collects a user's identification information, which can be in the form of a number or other data. In the preferred embodiment, a user's identification information is the user's Social Security Number, but in alternative embodiments, a user's identification information may comprise a unique number assigned to the user or any other information that serves to uniquely identify the user (e.g., passport number, etc.). In addition, EIS machine 13 may collect a user's biometric information (e.g., digital picture, fingerprint, signature, DNA, etc.). Preferably, EIS Machine 13 is capable of transmitting a user's biometric information to EISCAP 3 over communication line 15 . In the preferred embodiment, EIS machine 13 is incapable of receiving any electronically transmitted information.
While transferring the user's identification and biometric information to EISCAP 3 , EIS Machine 13 authorizes IAD 7 to transmit the completed form to EISBERG 5 via communication line 9 . EISBERG 5 then awaits authentication from EISCAP 3 via communication line 4 . Once EISCAP 3 verifies the identity of the user, it communicates back to EISBERG 5 via communication line 2 . The signal that the form has been successfully completed is then sent via communication line 11 .
Referring now to FIG. 2 , the system and method of authenticating the user via EISCAP 3 is shown. This is where the individual is judged to be authentic. Generally, EISCAP 3 is the system of connections between databases containing user identification numbers, biometric information, and other identifiers (both biometric and non-biometric). More specifically, EISCAP Server 21 receives the identification and biometric information from EIS Machine 13 via communication line 15 . Additional information, such as the location of EIS Machine 13 (sent by Global Positioning System (“GPS”) 23 ) and the time of access (sent by atomic clock 25 ) are recorded in EISCAP Server 21 with the biometric and identification information sent from EIS Machine 13 . This grouping of information serves to uniquely identify the transaction and is assigned tracking number 27 . The grouping of information (“EISCUBE” 29 ) is sent to EISBERG Server 41 via communication line 31 , as depicted in FIG. 3 . In such a way, EISCAP 3 verifies the identity of the user of EIS Machine 13 in an accurate manner.
In the preferred embodiment of the present invention, EISCAP 3 further comprises security monitoring system 33 that tracks the input of information over communication line 15 , GPS 23 , and atomic clock 25 . EISCAP 3 records the transfer of information between EIS Machine 13 and EISCAP 3 in EISCAP database 35 . Security monitoring system 33 further recognizes any irregular information and isolates any potential errors for review. By recording potential errors in EISCAP database 35 , security monitoring system 33 ensures that EISCAP 3 can provide accurate authentication information in a secure manner.
Referring next to FIG. 3 , EISBERG 5 performs the function of managing the forms that require authentication. For example, EISBERG 5 contains a plurality of forms (e.g., consent forms for treatment, do not resuscitate forms, etc.) that require an individual's consent for execution. Different EISBERGs can be connected to EISFLOE system 6 based on desired function. For example, different EISBERGs can include: (1) Tissue Donation/Consent for Cancer Research (or other medical illness research); (2) Medical Outcome Data Consent Form; (3) Medical Procedure Consent Form; (4) HIPAA compliance in medical offices, clinics, hospitals, etc.; (5) Insurance fraud prevention; (6) Sign-in system for employees/customers; (7) Verification for services rendered at a given time and place; and (8) Organ Donation for state non-profit organ donation organizations for organ procurement.
As shown, in the preferred embodiment of the present invention, EISBERG 5 comprises EISBERG Server 41 for sending and receiving information via communication lines 2 , 4 , 9 , and 11 . Generally, as described in greater detail with respect to FIG. 1 , EISBERG 5 receives information from IAD 7 corresponding to the form requested by the user and transmits the requested form to IAD 7 via communication line 11 . Once the user completes the form using the inputs at EIS Machine 13 , IAD 7 transmits the completed form to EISBERG Server 41 to await authentication. Authentication occurs when EISBERG Server 41 communicates with EISCAP Server 21 via communication line 4 . Then as also described in greater detail with respect to FIG. 2 , EISBERG 5 receives information from EISCAP 3 (i.e., EISCUBE 29 ) verifying the identity of the user.
More specifically, EISBERG Server 41 receives and stores completed form information provided by IAD 7 over communication line 9 . EISBERG Server 41 further receives and stores EISCUBE 29 from EISCAP 3 over communication line 2 .
EISBERG Server 41 reviews EISCUBE 29 to ensure that the user has agreed to the content in the form transmitted to EISBERG 5 from IAD 7 . Once EISCUBE 29 is verified, EISBERG Server 41 matches EISCUBE 29 with the completed form sent to EISBERG 5 by IAD 7 and attaches EISCUBE 29 to the completed form to create a verified form. This verified form may then be retrieved at IAD 7 for internal use in EIS House 1 via communication line 11 .
It should be noted that signature information and photographic information can be collected-at EIS Machine 13 and utilized in the verification process in EISCAP 5 . Such signature and photographic information could be included in EISCUBE 29 and attached as part of the verified form in EISBERG 5 . All information received by EISBERG 5 (typically confidential or individual-sensitive information) remains within EISBERG Server 41 and can be used only in accordance with the agreement made with the individual. Such information is not transmitted to EISCAP 3 .
There is also a security program that runs at the EISCAP 3 for monitoring the system of EIS Machines and EISBERGs.
Referring next to FIG. 4 , shown is EISCUBE 29 utilized for authentication of the user at EIS Machine 13 . Specifically, EISCUBE 29 contains information such that the individual user can be positively authenticated. EISCUBE 29 is attached to a verified form to indicate that the form has been authenticated. Although EISCUBE 29 can comprise any number of personal identifiers, in the preferred embodiment depicted in FIG. 4 , EISCUBE 29 comprises user name 51 , user signature 53 , tracking number code 27 , grid coordinates 55 , and date and time of transaction 57 . EISBERG 5 attaches EISCUBE 29 to the proper form as a symbol to the EISFLOW system that the user has been authenticated and verified the information contained in the form.
Referring now to FIG. 5 , one embodiment of EIS Machine 13 is depicted. Specifically, FIG. 5 shows an example of the terminal associated with EIS Machine 13 , designed to receive identification and biometric information from the user. Shown is Liquid Crystal Display (“LCD”) 61 for display of requested information, EIS Keys 63 for entry of identification information, digital camera 65 for recording of biometric information such as facial features, EIS Crystal 67 for recording the user's fingerprint information, and EIS Rink 69 for entry of a user's signature. The inputted information is sent to EISCAP 3 as detailed above with respect to FIG. 1 . The cover of EIS Machine 13 is preferably fastened in such a way that it cannot be opened without deactivating the system.
Referring next to FIG. 6A , a front view of EIS Machine 13 is depicted. Specifically, in the preferred embodiment of the present invention, EIS Machine 13 is equipped with Digital Card Scan 71 having the ability to scan a user's identification card and transmit the individual's name to LCD 61 of FIG. 5 .
Referring next to FIG. 6B , a rear view of EIS Machine 13 is depicted, including electrical plug 73 for supplying power to EIS Machine 13 . In addition, it is preferable to have communication lines connected from EIS Machine 13 to outgoing server port 75 (e.g., communication line 15 of FIG. 1 ) and to an IAD access port 77 (e.g., communication line 17 of FIG. 1 ). In the preferred embodiment, outgoing server port only handles outgoing data and the electrical plug is fixed in position. Alternate embodiments of the invention include portable EIS Machines powered by batteries, fuel cells or other available power source.
Referring next to FIG. 6C , shown is a side view of EIS Machine 13 , including GPS Antenna 79 for transmitting the location of EIS Machine 13 to EISCAP 3 during the authentication process. EIS Machine 13 also comprises EIS Pick 81 , a utensil to allow a user to sign his or her signature on EIS Rink 69 . In addition, the preferred embodiment of EIS Machine 13 contains On/Off Switch 83 to control whether the machine is accessible at any given time.
Referring next to FIG. 7 , a cross section of the internal hardware of the preferred embodiment of EIS Machine 13 is depicted.
Specifically, as shown in FIG. 7 , hardware for LCD 61 , EIS Keys 63 digital camera 65 , EIS Crystal 67 and EIS Rink 69 (e.g., signature pad). In addition, hardware for digital card scan 71 is present within EIS Machine 13 . Memory 85 is located within EIS Machine 13 to store the information entered by the user. In the preferred embodiment of the present invention, memory 85 is flash memory and is erased entirely following each transaction. In this manner, no information is locally stored in EIS Machine 13 for any extended period of time, thereby eliminating any risk of user confidential information being stolen from EIS Machine 13 .
Referring next to FIG. 8 , shown is the hardware configuration of the preferred embodiment of EIS Machine 13 of the present invention. As depicted in FIGS. 5 and 7 , FIG. 8 shows LCD 61 , Camera 65 and Card Reader 71 . The preferred embodiment of EIS Machine 13 of the present invention further comprises circuit board 91 for connecting to the power source and the cover/screw entrance security system. Network Adapter 93 can comprise any standard network adapter for use with any high-speed data transfer connection, including wireless communication. Network adapter 93 is optimally configured to include encryption such that data is always forwarded across the network in a secure manner. GPS transmission device 95 can be activated for every data transmission to retrieve information to be sent to EISCAP 3 . GPS transmission device 95 can also be activated by EISCAP 3 in order to implement routine security checks.
FIGS. 9A-9C demonstrate a configuration of EIS Maker 8 which may in its present form accomplish similar tasks of EIS Machine 13 as in FIG. 1 . For identification purposes it only contains the biometric device (e.g., EIS Crystal 67 in this representation) and EIS Keys 63 for identification number. It would be used when more complete forms of identification are not required such as with a repeat user.
While the above description describes the preferred embodiment as it relates to obtaining authenticated consent forms, other embodiments of the present invention exist as well. FIGS. 10-16 generally depict several alternate embodiments of the present invention.
FIG. 10 represents an ANI Network (Automated Numerical Identifier Network) and a conceivable connection of EISBERGs. An ANI Network may be unique to every individual and is composed of multiple EISBERGs. In the preferred embodiment, an ANI Network is composed of EISBERGs that are structured to form groups, which are then structured to form systems. Systems are structured to form complexes, which ultimately form an ANI Network. Each individual's ANI Network 101 may contain multiple complexes. FIG. 10 depicts a preferred embodiment of a structure of complexes, namely the Dianoian Complex 103 , Levavian Complex 105 , Nepheshian Complex 107 and Meodian Complex 109 . A complex may be broken down into systems of EISBERGS, as clarified below with respect to FIGS. 11-14 . In the preferred embodiment, the Dianoian Complex 103 refers to the complex of EISBERGs in the ANI Network that are contained in the individuals' educational system, intellectual system, and personality system. It is intended to cover all aspects of activities, business, and transactions primarily related to the individuals' “mind” and its development. The Levavian Complex 105 refers to the complex of EISBERGs in the ANI Network that are contained in the individuals' habitual system, charitable system, and preferential system. It is intended to cover all aspects of activities, business, and transactions primarily related to the individual's “emotion” and its development. The Nepheshian Complex 107 refers to the complex of EISBERGs in the ANI Network that are contained in the individuals' political system, philosophical system, and religious system. It is intended to cover all aspects of activities, business, and transactions primarily related to the individuals' “soul” and its development. The Meodian Complex 109 refers to the complex of EISBERGs in the ANI Network that are contained in the individuals' medical system, legal system, vocational system, financial system, and relational system. It is intended to cover all aspects of activities, business, and transactions primarily related to the individuals' “strength” and its development.
FIG. 11 depicts the structure of three systems of EISBERGs that comprise the Dianoian Complex 103 . The Educational System (“Minerva”) 111 , Intellectual System (“Athena”) 113 and Personality System (“Galen”) 115 are each composed of groups of EISBERGs. Together, the three systems form the Dianoian Complex 103 .
FIG. 12 depicts the structure of three systems of EISBERGs that comprise the Levavian Complex 105 . The Habitual System (“Artemis”) 117 , Charitable System (“Hestia”) 119 and Preferential System (“Apollo”) 121 are each composed of groups of EISBERGs. Together, the three systems form the Levavian Complex 105 .
FIG. 13 depicts the structure of three systems of EISBERGs that comprise the Nepheshian Complex 107 . The Political System (“Zeus”) 123 , Philosophical System (“Thales”) 125 and Religious System (“Enlil”) 127 are each composed of groups of EISBERGs. Together, the three systems form the Nepheshian Complex 107 .
FIG. 14 depicts the structure of three systems of EISBERGs that comprise the Meodian Complex 109 . The Medical System (“Asklepios”) 129 , Legal System (“Hammurabi”) 131 , Vocational System (“Demeter”) 133 , Financial System (“Plutus”) 135 and Relational System (“Hera”) 137 are each composed of groups of EISBERGs. Together, the five systems form the Meodian Complex 109 .
FIG. 15 represents the structure of Medical System 129 , a component of the Meodian Complex 109 as depicted in FIG. 14 . Medical System 129 is comprised of Soothing Arts and Sciences Group (“Epione”) 139 , Health Maintenance Group (“Hygeia”) 141 , Physical Beauty Arts and Science Group (“Aigla”) 143 , Healing Treatment Centers Group (“Iasis”) 145 , Convalescence Arts and Sciences Group (“Akesis”) 147 and Pharmaceutical, Biotechnology, and Medical Equipment Group (“Panacea”) 149 . Each group is comprised of EISBERGs which represent the smallest entity that may store information. Each EISBERG is an independent unit capable of releasing information about an individual. Each individual may elect preferences as to how each EISBERG will release the individual's information. A plexus refers to the communication of various EISBERGs that an individual has linked together between and/or within groups, systems, or complexes that have been given authority by the individual to communicate information within the individual's ANI Network.
FIG. 16 represents a plexus formed in the Medical System 129 by the interaction of four groups of EISBERGs with independent organizations. Arrows represent authorization points before data is transmitted. Epione 138 and Hygeia 141 transmit information to Medical Research Organization 157 . Iasis 145 transmits information to Physician Clinics 151 , Hospital Companies 153 and American Cancer Biorepository Organization 155 . Physician Clinics 151 transmits information to Medical Research Organization 157 , Hospital Companies 153 and American Cancer Biorepository Organization 155 . State Cancer Registry Agency 159 receives information from American Cancer Biorepository Organization 155 , while Panacea 149 receives information from American Cancer Biorepository Organization 155 and Medical Research Organization 157 .
While the present invention has been described with reference to one or more preferred embodiments, such embodiments are merely exemplary and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. The scope of the invention, therefore, shall be defined solely by the following claims. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention. It should be appreciated that the present invention is capable of being embodied in other forms without departing from its essential characteristics. | Disclosed is a secure system of authentication including a means for retrieving information about an authenticated individual (i.e., citizens, customers, employees, patients, and subjects). More specifically, the system allows a person to execute forms (i.e., agreements, authorizations, contracts, records, and transactions) at any location across the world by submitting to a positive identification test. In turn, authorized personnel can receive all pertinent information associated with the authenticated individual. Importantly, the autonomy and the privacy of the individual with respect to his or her information are always maintained. | 6 |
FIELD OF THE INVENTION
The present invention generally relates to fuel processors and, more particularly, relates to a fuel processor system having gas recirculation for improved startup, shut down, turn down, and transient operation.
BACKGROUND OF THE INVENTION
As is well known to those skilled in the art, in order to heat rapidly the mass of a fuel processor to its proper operating temperature during a startup cycle, it is preferable to provide the largest possible heating gas flow therethrough. However, using fuel rich-combustion gas flow may exceed the temperature limits in the earlier stages of the fuel processor, thereby requiring additional stages to fully heat the remaining stages of the fuel processor.
During a shut down cycle, it is desirable to remove water from the fuel processor so that the water does not condense onto the catalysts when the fuel processor completely cools, which may damage the catalysts. Furthermore, it is also desirable to stop the fuel processor in a pressurized state so that when the fuel processor cools and the gases contract, the pressure the fuel processor remains above atmospheric pressure so that air is not drawn into the fuel processor. Conventional shut down methods cannot continue operating without water injection, as the ATR catalyst would get too hot.
During a turn down cycle, it is preferable to circulate a larger flow so that the residence times within the reactors are more constant. However, in conventional fuel processors, as the power level is turned down the flow is thus reduced and the residence times in each reactor increases. This increase in residence times may lead to auto-ignition in the inlet, reverse water gas shift in the PrOx, cell reversal in fuel cell stack due to non-uniform flow distribution of hydrogen containing reformate, and water collection in fuel cell stack.
During a transient cycle, it is preferable to have a constant flow through the reactors such that the pressure in the reactors remains generally constant, thereby minimizing the lag in transient response associated with filling or venting volumes of the fuel processor.
Accordingly, there exists a need in the relevant art to provide a fuel processor that is capable of rapid thermal start without the complexity of multiple stages or risk of oxygen exposure. Furthermore, there exists a need in the relevant art to provide a fuel processor that, during shut down, is capable of minimizing water in the reformate and be shut down at an elevated pressure to minimize condensation on the catalyst and air ingestion upon cooling. Still further, there exists a need in the relevant art to provide a fuel processor that, during turn down, is capable of minimizing auto-ignition in the inlet, reverse water gas shift in the PrOx, cell reversal in fuel cell stack due to non-uniform flow distribution of hydrogen containing reformate, and water collection in fuel cell stack. Yet further, there exists a need in the relevant art to provide a fuel processor that, during transient operation, is capable of maintaining a generally constant flow rate through to the fuel processor to minimize the lag time associated with filling or venting volumes of the fuel processor. Still further, there exists a need in the relevant art to provide a fuel processor that is capable of operating without water injection.
SUMMARY OF THE INVENTION
A fuel processor system capable of recirculating fuel processor system gases, such as reformate, anode exhaust, and/or combustor exhaust, through the fuel processor to provide a number of distinct advantages is provided. A fuel processor is also provided for converting a hydrogen-containing fuel to H 2 -containing reformate. The fuel processor system may also include a plurality of fuel cells discharging an H 2 -containing anode effluent and an O 2 -containing cathode effluent. A catalytic combustor is positioned in series downstream from the plurality of fuel cells and a vaporizer reactor is coupled to the catalytic combustor. A bypass passage interconnects an outlet of at least one of the group consisting of the fuel processor, the fuel cell, the catalytic combustor, and the vaporizer reactor to the inlet of the fuel processor. The bypass passage is operable to recirculate a fuel processor system gas to the inlet of the fuel processor.
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
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a schematic view illustrating a fuel processor system according to a first embodiment of the present invention;
FIG. 2 is a schematic view illustrating a fuel processor system according to a second embodiment of the present invention;
FIG. 3 is a schematic view illustrating a fuel processor system according to a third embodiment of the present invention; and
FIG. 4 is a schematic view illustrating a fuel processor system according to a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For example, the present invention is hereafter described in the context of a fuel cell fueled by reformed gasoline. However, it is to be understood that the principles embodied herein are equally applicable to fuel cells fueled by other reformable fuels. Furthermore, the present invention hereafter described in the context of a self contained fuel cell system having a reforming system and a fuel cell system. However, it is to be understood that the principles embodied herein are equally applicable to a reforming system only.
Referring to FIG. 1 , a fuel processor system, generally indicated as 10 , according to a first embodiment of the present invention is illustrated, which provides rapid startup capabilities. Fuel processor system 10 generally includes a fuel processor 12 , a fuel cell stack 14 , a catalytic combustor reactor 16 , and a vaporizer reactor 18 . Fuel processor 12 would typically include a primary reactor 12 . 2 such as a steam reformer or an autothermal reformer, a water gas shift (WGS) reactor 12 . 4 and a preferential oxidation (PrOx) reactor 12 . 6 .
Fuel processor system 10 is arranged such that a first fuel inlet stream 20 and a first water inlet stream 22 are introduced into fuel processor 12 to produce a reformate stream 24 according to conventional principles. During a startup cycle, an anode bypass valve 26 directs reformate stream 24 to an anode bypass passage 28 . It is necessary to initially bypass fuel cell stack 14 until “stack grade” (having CO content less than about 100 ppm) reformate is produced. In order to produce such stack grade reformate, it is necessary to heat the various components of fuel processor system 10 to their respective operating temperatures. Recirculated reformate in passage 30 from anode bypass passage 28 is drawn into a recirculation compressor 32 together with a first inlet air stream 34 .
First fuel inlet stream 20 is then introduced into fuel processor 12 . Reactions may be initiated in fuel processor 12 via a spark lit burner or by an electrically heated catalyst section (not shown). Heat produced by the reaction of first fuel inlet stream 20 and first inlet air stream 34 warms fuel processor 12 . First fuel inlet stream 20 and first inlet air stream 34 are introduced in proportions slightly rich of stoichiometric. This ensures that there is no excess oxygen, which could damage the catalysts within fuel processor 12 . Ordinarily, reactions near stoichiometric conditions produce damagingly high temperatures; however, with a large excess of recirculated reformate 30 acting as a diluent, the gas temperature within fuel processor 12 is maintained at an appropriate level.
A portion, generally indicated at 36 , of the flow through anode bypass passage 28 is exhausted to catalytic combustor reactor 16 . Under steady flow, this exhausted reformate 36 is equal to the total mass flow of first fuel inlet stream 20 , first inlet air stream 34 , first water inlet stream 22 and vaporizer steam 38 that passes through fuel processor 12 . This exhausted reformate 36 is reacted with a second inlet air stream 40 in catalytic combustor reactor 16 . Second inlet air stream 40 is directed to catalytic combustor reactor 16 via a stack air compressor 42 , a cathode bypass valve 44 , a cathode bypass passage 46 , and an exhaust passage 48 . Second inlet air stream 40 is bypassed around fuel cell stack 14 during startup to prevent drying of the membranes within fuel cell stack 14 . Heat from the reaction in catalytic combustor reactor 16 is integrated back into fuel processor 12 by vaporizing second water inlet stream 50 in vaporizer reactor 18 to produce vaporizer steam 38 , which typically is delivered to the PrOx-vaporizer or steam lines within fuel processor 12 . Exhaust gases from combustor 16 exits vaporizer reactor 18 through exhaust outlet 66 .
During the startup cycle, the fuel and air are completely consumed (stoichiometric conditions) for maximum heat release within fuel processor system 12 for rapid heating without excessively high temperatures. However, it is important to note that the temperature within the PrOx 12 . 6 may initially be relatively high at about 357° C. However, once the PrOx is heated, normal operation is such that cooling of the PrOx according to conventional methods can be used.
Referring again to FIG. 1 , once the various reactors within fuel processor 12 are warmed to their operating temperature, anode bypass valve 26 routes reformate stream 24 to fuel cell stack 14 via passage 52 . Second inlet air stream 40 is then directed by cathode bypass valve 44 to the cathode side of fuel cell stack 14 via passage 54 . The hydrogen from reformate stream 24 reacts with the oxygen from second air inlet stream 40 across a membrane electrode assembly within fuel cell stack 14 to produce electricity. Anode exhaust or stack effluent 56 from the anode side of fuel cell stack 14 includes a portion of hydrogen that is directed back to catalytic combustor reactor 16 to provide heat recovered in vaporizer 18 . Cathode exhaust 58 from the cathode side of fuel cell stack 14 includes oxygen also for use in catalytic combustor reactor 16 . Anode exhaust 56 and cathode exhaust 58 are combined in exhaust passage 48 and react in catalytic combustor reactor 16 . Vaporizer reactor 18 continues to provide vaporizer steam 38 to fuel processor 12 . Note that the PrOx air, within fuel processor 12 , is drawn from recirculation compressor 32 which contains only first inlet air stream 34 when anode bypass valve 26 directs reformate stream 24 to fuel cell stack 14 . Preferably, a reformate check valve 60 is disposed in exhausted reformate passage 36 to ensure that anode exhaust 56 and cathode exhaust 58 in exhaust passage 48 are not drawn into fuel processor 12 by recirculation compressor 32 .
As is well known in the art, catalysts, such as that which is often used in water gas shift reactors (i.e. CuZn), are often sensitive to oxygen and condensed water. Therefore, this is particularly important after shut down when the fuel processor cools and any water vapor condenses. That is, the reformate gases within fuel processors often have a very high water (steam) content (typically 30%), which condense when the fuel processor cools after shut down. Additionally, as the fuel processor cools the condensation of water and the cooling of gases within the fuel processor may cause a reduction in gas pressure sufficient to pull a vacuum even if valves at the inlet and exit seal a fuel processor. At this point, any leaks present in the various valves, fittings, or flanges may allow air into the fuel processor and potentially damage the water gas shift catalyst. Therefore, additional features are illustrated in FIG. 2 to address these shut down issues.
The fuel processor system 10 ′, shown in FIG. 2 , is the same as that described in reference to FIG. 1 , where like reference numerals are used to indicate like components. Referring to FIG. 2 , a recirculation valve 102 is positioned in recirculated reformate passage 30 and an exhaust valve 104 is positioned in exhaust reformate passage 36 . Recirculation valve 102 and exhaust valve 104 are used in conjunction to control the recirculation ratio (i.e., the ratio of recirculated reformate stream to the total reformate stream). That is, by opening recirculation valve 102 the flow of recirculated reformate 30 is increased, while opening exhaust valve 104 the flow of recirculated reformate 30 is decreased. Furthermore, opening both valves 102 , 104 decreases the pressure within fuel processor 12 . Recirculation valve 102 and/or exhaust valve 104 may be closed to prevent anode exhaust 56 and cathode exhaust 58 from being drawn into fuel processor 12 by recirculation compressor 32 .
The transition to normal operation for fuel processor system 10 ′, shown in FIG. 2 , is the same as described in reference to FIG. 1 .
Fuel processor system 10 ′, shown in FIG. 2 , further provide a means to shut down fuel processor 12 without water condensation or air ingestion. For shut down, reformate stream 24 is circulated to anode bypass passage 28 via anode bypass valve 26 . Exhaust valve 104 remains closed to cause higher pressures within fuel processor 12 . Recirculation valve 102 is then slightly opened to maximize pressure within the capacity of recirculation compressor 32 . During shut down, water is condensed and separated from reformate stream 24 in a condenser 106 , which is connected to the system coolant loop (not shown). In normal operation, condenser 106 is used as an anode pre-cooler before fuel cell stack 14 .
To further increase the pressure within fuel processor 12 during shut down, recirculation compressor 32 draws in first inlet air stream 34 . Preferably, the inlet to recirculation compressor 32 and the downstream side of circulation valve 102 are small in volume such that after recirculation compressor 32 is stopped, the pressure will remain high. Subsequently, the oxygen within first inlet air stream 34 will react with the hydrogen in recirculated reformate 30 within fuel processor 12 to produce additional heat, thereby increasing the pressure within fuel processor 12 . However, if necessary, additional fuel from first fuel inlet stream 20 may be added during shut down to consume the oxygen in first inlet air stream 34 in order to provide sufficient reactants (H 2 and CO) within fuel processor 12 . An oxygen sensor 108 is used in the fuel processor 12 as feedback to ensure that excess oxygen is not present. If the pressure within fuel processor 12 is higher than a predetermined level, exhaust valve 104 may be opened to reduce such pressure.
Once the water has been condensed from reformate stream 24 and a high pressure condition has been achieved within fuel processor 12 , fuel processor air mass flow controller 62 is closed to seal the inlet, anode bypass valve 26 remains in the bypass position, and exhaust valve 104 remains closed to seal the exit. Recirculation compressor 32 is then stopped. The resident gases within fuel processor 12 are dry and at an elevated pressure, which is desired for shut down condition, particularly with a CuZn water gas shift catalyst.
During the shut down cycle, the fuel and air are completely consumed (stoichiometric conditions) without water injection and without excessively high reactor temperatures to allow the gases to be dried by condenser 106 .
As is well known in the art, conventional fuel processors suffer from various disadvantages when operating at reduce power and reduced flow, such as auto-ignition in the inlet, reverse water gas shift in the PrOx, cell reversal in the fuel cell stack, and water collection in the fuel cell stack. Furthermore, the transition between power levels are often slow to react due to the time necessary to pressurize or vent reactor volumes so as to achieve steady flow conditions at the new power level.
Within the primary reactor temperatures in the inlet region increase such that there is a limited amount of time before undesirable auto-ignition of the fuel will occur. As the flow through the fuel processor is reduced at low power, the residence time within the inlet is increased. Thus, the rate of reduction in flow and power is limited by the auto-ignition condition in the inlet.
Within the PrOx reactor, after the oxygen is consumed, reformate that is exposed to catalyst will undergo reverse water gas shift reactions, thereby consuming desirable H 2 and creating undesirable CO. At reduced flow, the oxygen is consumed earlier in the PrOx reactor, thereby leaving a larger section of catalyst and a longer residence time for reverse water gas shift reactions to occur.
Within the fuel cell stack, the current flow through each fuel cell is limited by the fuel cell provided the lowest quantity of H 2 . That is, the fuel cell with the lowest H 2 flow limits the current through all of the remaining fuel cells. Therefore, a portion of the available quantity of H 2 (typically 10 to 20%) leaves the fuel cell stack unused. At reduced flows, the portion of H 2 leaving the fuel cell stack needs to be higher for stable operation, which is likely the result of less uniform flow distribution at reduced flows. Also contributing to the minimum flow for stable fuel cell stack operation is the need to clear condensed water to prevent it from collecting in and blocking passages within the gas distribution plates.
In conventional systems, the flow rate through the fuel processor system varies with power level, thus the associated pressure drop necessitates a change in reactor pressure between power levels. However, a change in reactor pressure requires time for flow to fill or vent to the downstream reactors in order to achieve the steady pressure at the new power level. The numerous aforementioned disadvantages are overcome in the present invention by maintaining a higher flow rate, even during low power operation, by recirculating gases through the fuel processor and stack.
Fuel processor system 10 ″, shown in FIG. 3 , illustrates a system having reformate circulation through the fuel processor for startup, means for water condensation and pressurization for shut down, and circulation through the fuel processor and anode for turn down and transients. The fuel processor system 10 ″, shown in FIG. 3 , is the same as that described in reference to FIGS. 1 and 2 , where like reference numerals are used to indicate like components.
More particularly, for startup, anode bypass valve 26 directs reformate stream 24 to anode bypass passage 28 . First fuel inlet stream 20 is introduced into fuel processor 12 . First inlet air stream 34 is delivered to fuel processor 12 by a fuel processor air compressor 202 . FIG. 3 shows first inlet air stream 34 being delivered to three locations in fuel processor 12 in the form of POx air stream 204 , start air stream 206 and PrOx air stream 208 . POx and PrOx air streams 204 , 208 would normally be part of fuel processor 12 . Heat produced by the reactions of fuel inlet stream 20 and inlet air stream 34 warms fuel processor 12 . By staging the inlet air to provide multiple heating locations, the startup time is reduced by improving heat distribution within fuel processor 12 .
To initiate reactions in each of these locations, a spark lit burner or an electrically heated catalyst section (not shown) is used. The overall oxygen to carbon (o/c) ratio (i.e. ratio of first inlet air stream 34 to first fuel inlet stream 20 ) is introduced in proportions slightly rich of stoichiometric to ensure that no excess oxygen is present, which could damage the catalyst within fuel processor 12 . The recirculated reformate 30 acts as a diluent so that all the available first inlet air stream 34 is reacted without excessively high temperatures within fuel processor 12 .
Exhaust reformate passage 36 is employed to exhaust excess reformate to catalytic combustor reactor 16 . Under steady flow, this exhausted reformate in passage 36 is equal to the total mass flow of first fuel inlet stream 20 , first inlet air stream 34 , first water inlet stream 22 and vaporizer steam 38 that passes through fuel processor 12 . This exhausted reformate in passage 36 is reacted with second inlet air stream 40 in catalytic combustor reactor 16 . Second inlet air stream 40 is directed to catalytic combustor reactor 16 via stack air compressor 42 , cathode bypass valve 44 , cathode bypass passage 46 , and exhaust passage 48 . Second inlet air stream 40 is bypassed around fuel cell stack 14 during startup to prevent drying of the membranes within fuel cell stack 14 . Heat from the reaction in catalytic combustor reactor 16 is integrated back into fuel processor 12 by vaporizing second water inlet stream 50 in vaporizer reactor 18 to produce vaporizer steam 38 , which typically is delivered to the PrOx-vaporizer or steam lines within fuel processor 12 . An anode check valve 210 and a cathode check valve 212 are shown to prevent back flow of reformate exhaust 48 into fuel cell stack 14 . Preferably, a reformate check valve 60 is also disposed in exhausted reformate passage 36 to ensure that anode exhaust 56 and cathode exhaust 58 in exhaust passage 48 are not drawn into fuel processor 12 by recirculation compressor 32 .
Once the various reactors within fuel processor 12 are warmed to their operating temperature, anode bypass valve 26 routes reformate stream 24 to fuel cell stack 14 via anode inlet passage 52 . Second inlet air stream 40 is then directed by cathode bypass valve 44 to the cathode side of fuel cell stack 14 via cathode inlet passage 54 . The hydrogen from reformate stream 24 reacts with the oxygen from second air inlet stream 40 across a membrane electrode assembly within fuel cell stack 14 to produce electricity. Anode exhaust or stack effluent 56 from the anode side of fuel cell stack 14 includes a portion of hydrogen that is directed back to catalytic combustor reactor 16 where it is oxidized to provide heat. Cathode exhaust 58 from the cathode side of fuel cell stack 14 includes oxygen which may also be used in catalytic combustor reactor 16 . Anode exhaust 56 and cathode exhaust 58 are combined in exhaust passage 48 and react in catalytic combustor reactor 16 . Vaporizer reactor 18 continues to provide vaporizer steam 38 to fuel processor 12 .
A back pressure regulator 214 is used to set the pressure within fuel processor system 10 ″, while recirculation compressor 32 determines the amount of reformate recirculated. As additional flow from first fuel inlet stream 20 , first inlet air stream 34 , first water inlet stream 22 , and vaporizer steam 38 is added to fuel processor 12 , additional reformate flow will split to exhausted reformate passage 36 to maintain the system pressure. Therefore, at high power, the system 10 ″ operates at a low recirculation ratio, whereby a larger portion of reformate stream 24 is “fresh” having a relatively high H 2 content. At low power, the system 10 ″ operates at a high recirculation ratio, whereby a larger portion of reformate stream 24 is re-circulated and having a relatively low H 2 content. It is important to note that recirculation compressor 32 according to the present embodiment need only overcome the pressure drop through fuel processor 12 and fuel cell stack 14 during normal operation, unlike the system shown in FIG. 2 where the pressure would drop to atmospheric pressure downstream of recirculation valve 102 to allow first inlet air stream 34 to be drawn in. To this end, fuel processor system 10 ″ illustrated in FIG. 3 requires an additional fuel processor air compressor 202 . Alternatively, stack air compressor 42 can be used to deliver air to fuel processor 12 .
As best seen in FIG. 3 , fuel processor system 10 ″ maintains a flow rate that is approximately equal to a fuel processor system operating at an optimum power level. This higher flow rate helps overcome many of the disadvantages described above.
During the shut down cycle of fuel processor system 10 ″, anode bypass valve 26 routes reformate stream 24 to anode bypass passage 28 . Second inlet air stream 40 is then directed by cathode bypass valve 44 through cathode bypass passage 46 to catalytic combustor reactor 16 . This will provide air to catalytic combustor reactor 16 to react with any exhausted reformate in passage 36 from the recirculation loop.
Backpressure regulator 214 is adjusted to indirectly produce the highest possible pressure within the capacity of recirculation compressor 32 . As reformate stream 24 recirculates through fuel processor 12 , water is condensed and separated in condenser 106 .
To further increase the pressure within fuel processor 12 prior to shut down, fuel processor air compressor 202 draws in first inlet air stream 34 . Subsequently, the oxygen within first inlet air stream 34 will react with the hydrogen in circulated reformate 30 within fuel processor 12 to produce additional heat, thereby increasing the pressure within fuel processor 12 . However, if necessary, additional fuel from first fuel inlet stream 20 may be added during shut down to consume the oxygen in first inlet air stream 34 in order to provide sufficient reactants (H 2 and CO) within fuel processor 12 . An O 2 sensor 108 is used in fuel processor 12 as feedback to ensure that excess oxygen is not present.
Once the water has been condensed from reformate stream 24 and a high pressure condition has been achieved within fuel processor 12 , fuel processor air mass flow controllers 216 , 218 , 220 and stack air mass flow controller 64 are closed to seal the inlets, anode bypass valve 26 and cathode bypass valve 44 remain in the bypass position, and back pressure regulator 214 remains closed to seal the exit. Recirculation compressor 32 , fuel processor air compressor 202 , and stack air compressor 42 are stopped. The resident gases within fuel processor 12 are dry and at an elevated pressure, which is desired for shut down condition, particularly with a CuZn water gas shift catalyst.
Yet another alternative system is illustrated in FIG. 4 wherein a compressor may be eliminated from the fuel processor system, generally indicated at 10 ″′. Fuel processor system 10 ″′ is operated at sub-atmospheric pressures such that potential for air ingestion exists. Otherwise, the startup, shut down, turn down and transient operation are similar to fuel processor system 10 ″ illustrated in FIG. 3 . An additional benefit of fuel processor system 10 ″′ is that a recirculated exhaust 302 can be made inert by providing just enough cathode exhaust 58 to catalytic combustor reactor 16 using a combustor air mass flow controller 304 for stoichiometric operation in catalytic combustor reactor 16 .
A cathode back pressure regulator 306 is needed to match the pressure set by a back pressure regulator 308 downstream of catalytic combustor reactor 16 to ensure cathode exhaust 58 can be directed to catalytic combustor reactor 16 . An O 2 sensor 310 may be used in exhaust 312 to ensure stoichiometric operation.
A unique capability of the aforementioned systems is the potential to operate without water addition. This is an advantage for a system that is to be started in ambient temperatures below 0° C., where water is not available. Because the system 10 ″′ operates at a high recirculation, this mode of operation is relatively inefficient at about 62%, however it may be used for short duration.
It should be understood that features of the fuel processor systems illustrated in FIGS. 1-4 can be combined as needed for system requirements. For example, PrOx air 208 may preferably be delivered from stack air compressor 42 . That is, various combinations of the various systems described herein might be made depending upon the specific application.
As should be appreciated from the foregoing discussion, the fuel processor systems of the present invention all include recirculation of fuel processor gases, such as reformate, anode exhaust, or combustor exhaust. This feature provides numerous advantages that are not present in conventional fuel processor systems. For example, the fuel processor systems of the present invention are capable of providing a large mass flow rate through the fuel processor to aid in heating the fuel processor components to the proper operating temperatures during startup. Moreover, during shut down, the fuel processor systems of the present invention enable the fuel processor to run dry and condense water from the reformate to avoid condensation on the catalysts and subsequently be shut down at an elevated pressure to prevent air ingestion upon cooling of the fuel processor. Still further, during turn down, the fuel processor systems of the present invention enable higher flow rates through the fuel processor and fuel cell stack to avoid auto-ignition in the inlet, reverse water gas shift in the PrOx, cell reversal in the fuel cell stack, and water collection in the fuel cell stack, all of which occur at reduced flow rates. During transient response, the fuel processor systems of the present invention, by circulating gases, enables the flow rate and pressure in the fuel processor to remain nearly constant, thereby minimizing the lag in transient response associated with filling or venting volumes in the fuel processor system. The ability to use recirculated gases, which contain water vapor as a product of reaction, enables the fuel processor to run without water injection. The fuel processor systems of the present invention enable rapid thermal start of the fuel processor without the complexity of multiple stages or risk of oxygen exposure.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A fuel processor system capable of circulating fuel processor system gases, such as reformate, anode exhaust, and/or combustor exhaust, through the fuel processor to provide a number of distinct advantages. The fuel processor system having a plurality of fuel cells discharging an H 2 -containing anode effluent and an O 2 -containing cathode effluent. A fuel processor is also provided for converting a hydrogen-containing fuel to H 2 -containing reformate for fueling the plurality of fuel cells. A catalytic combustor is positioned in series downstream from the plurality of fuel cells and a vaporizer reactor is coupled to the catalytic combustor. A bypass passage is finally provided that interconnects an outlet of at least one of the group consisting of the fuel processor, the plurality of fuel cells, the catalytic combustor, and the vaporizer reactor to the inlet of the fuel processor. The bypass passage is operable to circulate a fuel processor system gas to the inlet of the fuel processor. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority and benefit of U.S. Provisional Patent Application Ser. No. 61/289,751 filed Dec. 23, 2009, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to precursor slurry compositions for producing ceramic matrix composite (CMC) articles and a sheet molding compound, and more particularly to slurry compositions utilizing fast curing thermosetting resins.
[0003] CMC materials generally comprise a ceramic fiber reinforcement material embedded in a ceramic matrix material. The reinforcement material serves as the load-bearing constituent of the CMC in the event of a matrix crack, while the ceramic matrix protects the reinforcement material, maintains the orientation of its fibers, and serves to dissipate loads to the reinforcement material. Of particular interest to high-temperature applications are silicon-based composites, such as silicon carbide (SiC) as the matrix and/or reinforcement material. SiC fibers have been used as a reinforcement material for a variety of ceramic matrix materials, including SiC, TiC, Si3N4, and Al2O3.
[0004] One technique for fabricating CMCs involves multiple layers of “prepreg,” often in the form of a tape-like structure, comprising the reinforcement material of the desired CMC impregnated with a precursor of the CMC matrix material. Prepregs may comprise a two-dimensional fiber array comprising a single layer of unidirectionally-aligned tows impregnated with a matrix precursor to create a generally two-dimensional laminate. Multiple plies of the resulting prepregs are stacked and debulked to form a laminate preform, a process referred to as “lay-up.” The prepregs are typically arranged so that fiber tows of the prepreg layers are oriented transverse (e.g., perpendicular) to each other, providing greater strength in the laminate plane of the preform, corresponding to the principal or load-bearing direction of the final CMC component. Following lay-up, the laminate preform will typically undergo debulking and curing while subjected to applied pressure and an elevated temperature, such as in an autoclave.
[0005] The preform may be heated in vacuum or in an inert atmosphere in order to decompose the organic binders, at least one of which pyrolizes during this heat treatment to form a carbon char, and produces a porous preform for melt infiltration. During melt infiltration, molten silicon infiltrates into the porous preform, reacts with the carbon constituent of the matrix to form silicon carbide, and fills the porosity to yield the desired CMC component.
[0006] One process is described in U.S. Pat. Nos. 5,015,540; 5,330,854; and 5,336,550. As described therein, the reinforcing fibers in the preform are coated with a low char yield slurry composition containing polymers that decompose upon heating. The polymers produce little or no char, which means that there is little or no solid material after burnout, resulting in a low strength preform. Thus there is a need for an improved preform with high strength after burn-out.
[0007] In order to address the need for a stronger and tougher preform after burnout, U.S. Pat. No. 6,258,737 describes a process for forming a CMC article using a high char yielding resin slurry composition. Although operable, this disclosed process provides an opportunity for process and product improvement, especially for reduced cycle time and minimized solvent-induced defects.
BRIEF DESCRIPTION OF THE INVENTION
[0008] The above-mentioned need or needs may be met by exemplary embodiments which provide resin systems selected for processibility and green strength. The selected resin systems greatly reduce the need for solvents and therefore solvent processing requirements. Exemplary embodiments employ solvents that are readily removed from the system. Exemplary embodiments utilize increased levels of organic binders or other fillers to provide the desired carbon char levels.
[0009] An exemplary embodiment includes a precursor slurry composition for forming a ceramic matrix composite article. The precursor slurry composition comprises a thermosetting resin, a suitable curing agent, a ceramic component, a carbonaceous solids component, and optionally, a suitable solvent. The thermosetting resin is at least one member selected from a polyester, a vinyl ester, an epoxy resin, a bismaleimide resin, and a polyamide resin. The carbonaceous solids component provides a suitable amount of carbon char upon pyrolization. Exemplary precursor slurry composition may include up to about 70 volume % solids after removal of the solvent, and prior to cure.
[0010] An exemplary embodiment includes a sheet molding compound including first and second outer films comprising a precursor slurry composition; and randomly dispersed reinforcing material being carried between the first and second outer films. The precursor slurry composition comprises a thermosetting resin, a suitable curing agent, a ceramic component, a carbonaceous solids component, and optionally, a suitable solvent. The thermosetting resin is at least one member selected from a polyester, a vinyl ester, an epoxy resin, a bismaleimide resin, and a polyamide resin. The carbonaceous solids component provides a suitable amount of carbon char upon pyrolization. The final char yield comprises the resin char yield and the carbon char attributable to the carbonaceous solids component. Exemplary precursor slurry composition may include up to about 70 volume % solids after removal of the solvent, and prior to cure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding part of the specification. The invention, however, may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
[0012] FIG. 1 is a perspective view of an exemplary CMC component.
[0013] FIG. 2 is a flowchart of an exemplary process for forming a CMC article.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to the drawings, FIG. 1 shows an exemplary ceramic matrix composite component 10 particularly adapted for use in a gas turbine engine assembly. Component 10 includes an airfoil portion 12 against which a flow of gas is directed. The airfoil 10 is mounted to a disk (not shown) by a dovetail 14 that extends downwardly from the airfoil portion 12 and engages a slot of complimentary geometry on the disk. The airfoil has a leading edge section 18 and a trailing edge section 16 . Such a composite airfoil is fabricated by laying up a plurality of plies. Those with skill in the art will readily appreciate that embodiments disclosed herein may be widely adapted to produce other ceramic matrix composite components.
[0015] In an exemplary embodiment, composite component 10 may be formed by exemplary processes disclosed herein and schematically represented in FIG. 2 . In an exemplary embodiment, reinforcing material such as silicon carbide-containing fibers may be provided (Step 100 ), for example, as bundled in tows. The reinforcing material may be formed into complex shapes to form the fiber preform which serves as a base for forming the final CMC article. As is known in the art, the fibers may be provided with boron nitride and/or other coating (e.g., silicon-wetting coatings). In an exemplary embodiment, the fibers may be characterized as “continuous lengths” meaning fiber lengths greater than or equal to 1 centimeter. Other exemplary embodiments may provide reinforcing material as non-continuous or chopped fibers. In other exemplary embodiments fiber tows may be directly laid up on tooling, for example in processes known in the art as filament winding.
[0016] In an exemplary embodiment, the reinforcing material is contacted with an exemplary slurry composition (Step 110 ). In certain exemplary embodiments, the reinforcing material is contacted with the slurry composition prior to shaping into a preform (Step 104 ), for example as a prepreg tape or laminate. In other exemplary embodiments, the reinforcing material may be initially shaped (Step 104 ) and then infused with an exemplary slurry composition. In other words, the reinforcing materials are contacted with an exemplary slurry composition either after being shaped into a preform, as indicated by the dotted line 102 a , or before shaping indicated by dashed line 102 b.
[0017] An exemplary slurry composition includes a fast-cure thermosetting resin system, which, after curing (Step 120 ), provides a cured preform having desired green strength and toughness. Further, the thermosetting resin system may be selected to require minimal solvent additions that must be removed during cure. The thermosetting resin system may be selected to cure very quickly, as compared to other resin systems currently used in forming CMC components. In an exemplary embodiment, the resin system may cure in 7-10 minutes, with substantially all the solvent, if used, being removed before cure. The reduced solvent provides opportunities for improved dimensional control, especially when forming high tolerance components, e.g., turbine blades and shrouds. An additional advantage of the exemplary thermosetting resin systems is the opportunity to use closed die molding techniques due to more constant volume. The quick cure cycles provides fast turn around times on the molding equipment. Additionally, reduced solvent loads result in lower bulk so that during the shaping/molding process there is reduced opportunities for slips or wrinkles, resulting in improved repeatability.
[0018] Exemplary resins are polyesters, vinyl esters, epoxy resins, or other fast-curing thermosetting resins. An exemplary slurry composition includes a polyester resin, a suitable curing agent (e.g., benzoyl peroxide), a ceramic component (e.g., SiC), and a carbonaceous solids component including organic binders or other fillers. The carbon filler loading is generally higher than a level used in the high char resin systems referenced above in order to achieve a comparable carbon yield. For example, carbon-containing fillers in known high char resin systems may be about 27 volume %. In exemplary embodiments disclosed herein, preforms, prior to cure, may include carbon fillers at levels up to about 60-70 volume % by utilizing solvent (e.g., acetone) prior to shaping and removing the solvent prior to cure. Other exemplary embodiments may include the carbonaceous solids component at levels greater than about 30 volume %. Exemplary carbonaceous material may include graphite particles, flakes, whiskers, or fibers of amorphous, single crystal or poly-crystalline carbon, carbonized plant fibers, lamp lack, finely divided coal, charcoal, and carbonized polymer fibers or felt such as rayon poly-acrylonitrile, and polyacetylene. Ideally, the resin(s) provide adequate flow without requiring significant amount of solvent. “Adequate flow” may be determined by the processing requirements such as the flow required to consolidate the resin system during the cure stage. Other processing methods, such as mixing the slurry to a homogenous mixture or winding into a tape may require lower viscosity than consolidation. Those with skill in the art will appreciate the flow requirements for the desired outcomes. Exemplary embodiments may include acetone or other easily removed solvent. Benzoyl peroxide or other agents may be utilized to initiate polymerization of the resin(s).
[0019] Removal of substantially all the solvent, if used, prior to cure, and use of a relatively fast curing thermosetting resin promotes substantially total cure, providing dimensional stability to the preform. The cured preform is pyrolized (Step 130 ) as is known in the art to yield a porous fiber structure for subsequent processing. Pyrolization yields carbon content for subsequent reaction with molten silicon to form the silicon-silicon carbide composite.
[0020] An exemplary melt infiltration process (Step 140 ) is disclosed in U.S. Pat. No. 4,737,328, which is incorporated herein by reference. Sufficient molten silicon infiltrate is infiltrated into the preform to produce the composite component. Specifically, the molten silicon infiltrant is mobile and highly reactive with elemental carbon to form silicon carbide. The period of time required for infiltration may be determined empirically and depends largely on the size of the preform and extent of infiltration required. Thereafter, the resulting infiltrated body is cooled under conditions (atmosphere and cooling rate) to avoid significant deleterious effects. It is envisioned that pyrolization and silicon melt infiltration may be performed in a continuous operation, or in separate operations as understood by those having skill in the art.
[0021] The temperature range for melt infiltration may be from about 1400° C. to about 1800° C., preferably between about 1400° C. and 1450° C. The preform may be placed on a carbon wick that is supported on a boron-nitride coated graphite plate. Silicon (e.g., as 95% Si-5% B alloy) may be placed on the wick in an amount sufficient to completely saturate the wick and fill the preform when molten.
[0022] After cooling, the infiltrated composite body may be removed from the attached carbon wick (largely converted to silicon carbide and silicon) by known techniques such as cutting and grinding with diamond abrasive wheels. Exemplary composite bodies have high density (e.g., not greater than about 3% porosity).
[0023] Thus, there is provided a process for quickly forming a porous preform having sufficient residual carbon char and reinforcement material into which molten Si may be infused to form the SiC matrix. The porous preform may comprise a near net shape incorporating complex features not readily obtainable by prior methods.
[0024] In an alternate embodiment, a sheet molding compound is disclosed. An exemplary sheet molding compound includes reinforcing material of randomly dispersed chopped fibers, for example chopped coated SiC tow bundles typically about 1-5 cm in length, sandwiched between opposing films of the ceramic precursor slurry (i.e., the thermosetting resin system as discussed above). The fast curing thermosetting resin is used to obtain both flow in the mold and green strength after molding but prior to pyrolization. The CMC precursor sheet molding compound can be subsequently processed to suitable green strength, for example, by compression molding. The thicker final form of the CMC sheet molding compound material along with the material's ability to flow and crosslink can reduce CMC component processing time by several hours.
[0025] 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. | A ceramic matrix composite precursor slurry composition includes a thermosetting resin, a suitable curing agent, a ceramic component, a carbonaceous solids component, and optionally, a suitable solvent. The thermosetting resin may be a polyester, a vinyl ester, an epoxy resin, a bismaleimide resin, and/or a polyamide resin. The carbonaceous solids component provides a suitable amount of carbon char upon pyrolization. The precursor slurry composition may comprise up to about 70 volume % solids after removal of the solvent, and prior to cure. A sheet molding compound first and second outer films comprising the precursor slurry composition and randomly dispersed reinforcing material carried between the first and second outer films. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a folded-fin heat sink assembly for use as a cooling solution in micro-electronics and/or telecommunication applications. In particular, the present invention relates to a cost effective method of fabrication of a folded-fin heat sink assembly in which a series of heat sink components comprising the assembly may be fixtured in order to facilitate a low cost post processing joining operation, such as brazing, soldering or thermally conductive epoxy bonding.
BACKGROUND OF THE INVENTION
[0002] Integrated circuit devices are increasingly being used in modern electronic applications such as computers. During normal operation, integrated circuit devices generate significant amounts of heat. If this heat is not continuously removed, the device may overheat resulting in damage to the device and/or a reduction in operating performance. As a general rule, the performance of integrated circuit devices is likely to improve when they are operated at lower temperatures. Hence, heat sink solutions which facilitate a lower integrated circuit operating temperature have an economic value over heat silk solutions offering higher integrated circuit operating temperatures.
[0003] Over the years, there has been a trend toward increases in the number of transistors and therefore capacitance within the integrated circuit; in turn, there has also been a trend towards increased clock frequency speeds of integrated circuit devices. These two trends have resulted in a proportional increase in the power used by the integrated circuit. Consequently, the heat generated by these devices has also increased. In order to adequately cool these high powered integrated circuit devices, heat sinks with greater cooling capacities have evolved.
[0004] Historically within the microprocessor industry, the majority of heat sink solutions have used aluminum extrusions. In aluminum extrusions, surface area aspect ratios are typically limited to a maximum ratio of 12:1.
[0005] In today's marketplace, with microprocessor solutions being offered in the 1.7 GHz clock frequency range, cooling requirements often cannot be met by the technical capabilities offered by aluminum extrusion technology. An increasingly common solution to this problem is folded-fin technology, with its low thickness range (0.004″-0.040″) and tight fin density capabilities which offer heat sink aspect ratios which can approach 40:1 and correspondingly larger surface areas for heat dissipation.
[0006] A typical folded-fin heat sink assembly comprises a base plate and a folded-fin assembly mounted on top of the base plate, the folded-fin assembly having a plurality of joined folded-fins extending upwardly from the base plate. A shroud may also be provided surrounding a substantial portion of the folded-fin assembly. The folded-fin assembly is produced by feeding strip aluminum or copper material through a set of blades which are actuated through cam action to produce its accordion-like structure.
[0007] Typically the base plate and the folded-fin assembly are made of materials which have a high thermal conductivity; materials such as aluminum (approximately 200 W/mK) or copper (approximately 400 W/mK) and, in some cases, these two components comprise the heat sink in its totality.
[0008] The presence of a shroud is desirable for a number of reasons, notable among which is that it can function as:
[0009] i) a device for capturing and supporting other required components of the assembly (e.g. spring clip attachment devices for attaching the heat sink to a support structure),
[0010] ii) a means for securing and supporting other required components (e.g. a cooling fan assembly),
[0011] iii) a means for ducting the heat sink airflow passage, thereby ensuring that the heated air does not rise and leave the heat sink prematurely, thereby decreasing its effectiveness,
[0012] iv) a means for protecting the potentially fragile nature of the folded-fin heat sink from being damaged during handling.
[0013] In these typical applications, the shroud may be made from non-thermally conductive materials such as plastic, and is typically attached to the heat sink in an operation which is downstream of the post-processing joining operation of securing the fins to the base by brazing, soldering, or epoxy bonding. As a general rule, the shroud in these typical applications is not a functional part of the thermal heat sink solution.
[0014] In the above-described typical folded-fin heat sink, special precautions must be taken in order to reduce the tendency of the fins to move or float in a random manner on the liquidus interface between the fins and the base plate, created in the post processing joining operation, which can lead to the problem of individual fins potentially being joined together. This results in an aesthetically displeasing visual component and, more importantly, results in a component which has a significant reduction in its potential thermal performance. Special precautions to avoid such a condition might typically include, for example:
[0015] i) the use of special fixturing during the process step,
[0016] ii) the use of additional and expensive components attached to the heat sink which act as a fixturing/separating device, and
[0017] iii) special upstream operations such as discrete laser welding of individual fins.
[0018] However, such special precautions are often undesirable, for the following reasons:
[0019] (i) they may result in significant additional capital expenditure,
[0020] (ii) they may result in additional component cost and weight,
[0021] (iii) they may result in adding significant unit processing weights through post processing joining operations (i.e. joining the fins to the base plate), which entail heating the overall mass up to a required temperature, and therefore can reduce process throughput significantly, and
[0022] (iv) they may result in additional labor associated with the loading and unloading of components into specialized brazing fixtures or specialized laser welding fixtures.
[0023] It is therefore desirable to provide a low cost, mass-producible folded-fin heat sink assembly which thermally exceeds the capabilities of aluminum extrusion technology, and assists in meeting the present marketplace needs.
SUMMARY OF THE INVENTION
[0024] It is an object of the present invention to provide a folded-fin heat sink assembly solution which obviates or mitigates the disadvantages of known solutions as discussed above.
[0025] In a first aspect, the present invention provides a method of manufacturing a folded-fin heat sink assembly, comprising:
[0026] positioning a folded-fin assembly on a base plate;
[0027] placing a shroud over a substantial portion of the folded-fin assembly with at least part of the shroud engaging the folded-fin assembly;
[0028] urging the shroud towards the base plate to press the folded-fin assembly against the base plate so as to avoid floating of the fins relative to the base plate and relative to each other and securing the shroud to the base plate whilst maintaining the folded-fin assembly under pressure; and
[0029] bonding the folded-fin assembly to the base plate.
[0030] According to a further aspect of the present invention, there is provided a folded-fin heat sink assembly comprising a folded-fin assembly located upon and bonded to a base plate and a shroud located over a substantial portion of the folded-fin assembly and secured to the base plate with at least part of the shroud engaging the folded-fin assembly and maintaining the folded-fin assembly under pressure against the base plate.
[0031] In a presently preferred embodiment, the shroud is formed of a thermally conductive material, such as aluminum, copper or a plastic (including composite materials), which also undergoes the post process joining operation (i.e. brazing, soldering or conductive epoxy bonding) by joining the fins to the shroud, the shroud then acting as an extension of the folded-fin heat sink by providing additional fin surfaces via which heat may be dissipated.
[0032] In a further presently preferred embodiment, the shroud includes at least top and side panels, the side panels being secured to the base plate and the top panel having means extending inwardly therefrom engaging the folded-fin assembly to maintain the folded-fin assembly under pressure against the base plate. Preferably, such means comprises downwardly extending flaps extending transversely over at least a part of the top panel between the side panels.
[0033] In yet a further preferred embodiment, the top panel is provided with opposed edges extending transversely between the side panels and provided with one or more downwardly extending flanges extending therealong and capturing the folded-fin assembly between such flanges to locate the folded-fin assembly on the base plate.
[0034] In yet a further preferred embodiment, the side panels are provided with inwardly extending stop members adapted to engage the base plate and to limit the amount of pressure exerted by the shroud upon the folded-fin assembly by limiting the extent of movement of the shroud towards the base plate.
[0035] In yet a further preferred embodiment, the shroud is a multiple-part construction, at least two of such parts having spaced coplanar side walls, and the heat sink assembly is provided with clip attachment devices for attaching the heat sink assembly to a support structure, such clip attachment devices being supported by and captured between the spaced side walls.
[0036] The invention may be used in conjunction with an integrated fan. Conveniently, the top panel of the shroud has cut-out for passage of air flow from the fins and the fan is mounted on the top panel in registry with the cut-out. In conjunction with the heat sink assembly, the fan provides an active cooling device with impingement airflow primarily, which is especially useful for cooling integrated circuits during operation. Alternatively, the folded-fin heat sink assembly of the invention may be used in conjunction with a detached fin or blower unit, creating a passive cooling device with air flowing parallel to the fin direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
[0038] [0038]FIG. 1 is a front perspective view of an active folded-fin heat sink assembly construction with a singular folded-fin component and a singular shroud.
[0039] [0039]FIG. 2 is the base plate component in FIG. 1 prepared for shroud fixturing prior to the heat sink assembly process.
[0040] [0040]FIG. 3 is the shroud in FIG. 1 prepared for fixturing prior to the heat sink assembly process.
[0041] [0041]FIG. 4 is a front perspective view of an alternate embodiment of an active folded-fin heat sink assembly construction with a two piece folded-fin component and two piece shroud with a clip attachment device incorporated therein.
[0042] [0042]FIG. 5 is a front perspective view of a passive folded-fin hear sink assembly with a singular folded-fin component and a singular shroud construction.
[0043] [0043]FIG. 6 is a front perspective view of an alternate embodiment of a passive folded-fin heat sink assembly construction with a singular folded-fin component and a singular shroud construction; and
[0044] [0044]FIG. 7 is a front perspective view of an alternate embodiment of a passive folded-fin heat sink assembly construction with a dual folded-fin component and a two piece shroud with a captured clip attachment device incorporated.
DETAILED DESCRIPTION OF THE INVENTION
[0045] [0045]FIG. 1 shows a folded-fin heat sink assembly 1 , having folded-fin assembly 2 located on a base plate 3 . The folded-fin assembly 2 is secured to the base plate 3 by brazing, soldering or conductive epoxy bonding. A shroud 5 , and in some instances a thermally conductive intermediate joining material such as a braze shim, a braze clad, a solder shim or a conductive epoxy, the shroud 5 having side walls 5 a and a top wall 5 b is located over the folded-fin assembly 2 . The shroud is secured to the base plate 3 by means of inwardly locking dimples or projections 6 formed in the shroud side walls (see also FIG. 3), which engage with complementary locking holes 4 formed in the opposed edges 3 a of the base plate 3 (see also FIG. 2). An alternate means of joining the shroud and joining material to the base plate may also be through a plurality of laser tack welds along the interface perimeter.
[0046] The base plate 3 typically is constructed from copper or aluminum materials and may subsequently be further processed to incorporate surface treatments such as nickel plating. It is manufactured in a variety of forms which can encompass sawcut extrusions, sawcut plate material or fineblanked stamped components, for example. Some additional post machining processes may be incorporated in order to embody the necessary interface or attachment features, such as the grooves 3 b, that are generally customer specific in nature. In preparation for the shroud attachment, the base plate is drilled in order to create locking holes 4 . Locking dimples or projections 6 engage the locking holes 4 when the shroud is positioned over the folded-fin assembly.
[0047] The shroud 5 is typically constructed from copper or aluminum materials. It is manufactured using a conventional stamping process, or alternately using a combination of a turret press punching operation, and a subsequent bending operation, or by any other desired means. If desired, the shroud top wall 5 b may be provided with an appropriate pattern of cur-outs and holes for fastening ancillary components. In FIG. 3, the top wall 5 b is provided with a cut-out 10 for accommodating a cooling fan 11 as shown in FIG. 1, and holes 12 for accommodating fasteners such as screws or rivers securing the fan to the shroud.
[0048] The heat sink is assembled by placing the folded-fin assembly 2 on the base plate 3 . At this point, no attempt is made to fasten the folded-fin assembly to the base plate. The shroud 5 is then placed over the folded-fin assembly and attached to the base plate by engagement between the holes and dimples 4 , 6 .
[0049] The shroud also has inwardly extending tabs 7 which engage the top surface of the base plate 3 to provide z-coordinate height control for the shroud 5 , and to act as a stop during the shroud attachment step. Downwardly extending flanges 8 located fore and aft of the shroud top wall 5 b provides y-coordinate positional control and location for the captured folded-fin assembly 2 , ensuring its proper relative position in the final heat-sink assembly 1 . Downwardly extending flaps 9 extend across the shroud top wall 5 b and are dimensioned so as to engage and press down upon the top edges of the folded-fin assembly 2 to ensure that a downward force is applied to the individual folded-fins sufficient to prevent undesirable movement such as flotation of the fins, which could result in potential failure of the device to be cooled by the heat sink caused by the fins bonding or wicking together. The flaps also ensure that the first set of fins is spaced appropriately from the shroud during the post process joining operation and that the fins are in contact with the base plate before the post process joining operation.
[0050] Once the shroud is in place upon the base plate, with the folded-fin assembly 2 captured between the shroud and the base plate, the post process joining operation is performed by use of a suitable technique such as brazing, soldering or conductive epoxy bonding. A further joining technique which may be employed is as described in our co-pending application Ser. No. 60/268,414.
[0051] [0051]FIGS. 4 and 7 show alternative embodiments of the invention wherein a two-piece folded-fin assembly comprising pieces 13 a and 13 b and a two-piece shroud comprising pieces 14 a and 14 b are located on a single base plate 3 . Clips 15 for attaching the heat-sink assembly 1 to a suitable support structure (not shown) are captured between the opposed edges of the two-piece shroud 14 a / 14 b.
[0052] [0052]FIGS. 5 and 6 show alternative embodiments of a one-piece folded-fin assembly 2 and a one-piece shroud 5 located on a base plate 3 , the shroud having folded-fin assembly positioning flanges 8 and downwardly extending flaps 9 , to provide a folded-fin heat sink assembly 1 .
[0053] The folded-fin heat sink assembly 1 is readily manufactured by standard mass-production techniques to provide a assembly having excellent joint integrity and a low likelihood of any individual fin being brazed or otherwise in contact with another.
[0054] Referring, for example, to FIG. 5, the folded fin heat sink assembly includes a base plate 3 , a folded-fin assembly 2 mounted to the base plate and a shroud 5 mounted to the base plate. The shroud at least partially covers the folded-fin assembly 2 . The side walls or panels 5 a of the shroud are mounted parallel with the outermost fins of the folded-fin assembly 2 so that each side panel defines, in conjunction with a corresponding outermost fin, an airflow passage for ducting heated air from the base plate toward the top wall or panel 5 b.
[0055] The shroud maintains the folded-fin assembly wider pressure against the base plate by pressing against the folded-fin assembly with downwardly extending flaps or other means. The shroud can be made of a thermally conductive material, such as aluminum or copper, so that it acts as an extension of the folded-fin heat sink and provides additional fin surfaces via which heat can be dissipated.
[0056] While an illustrative and presently preferred embodiment of the invention has been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. | A method of assembling a folded-fin heat sink assembly, the assembly including base plate, a folded fin-assembly and a shroud, includes positioning the folded-fin assembly on a base plate, placing the shroud over the folded-fin assembly, urging the shroud to press the folded-fin assembly against the baze plate and bonding attached to the base plate and a shroud. According to an embodiment, the resulting shroud of the folded-fin assembly acts as extension of the folded-fin heat sink providing additional fin surfaces via which heat can be dissipated. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to an X-ray apparatus having an X-ray beam limiting device assembled with an X-ray tube for stereoradiography.
In medical examinations such as angiography, stereoradiography has the advantage of being able to obtain stereo images. An X ray apparatus for the stereoradiography has used an X-ray tube having a pair of X-ray focal points positioned a certain distance apart. X-rays are alternately irradiated from the one focal point to the other of the X-ray tube to a living body (a subject) through an X-ray beam limiting device, and the X-ray transmitted through the living body are detected by a film or an image intensifier (referred to as "I.I." hereinafter). An observer can obtain a stereo penetrating image, when his right eye sees an image formed according to the transmitted X-rays from the X-ray focal point and his left eye sees an image formed according to the transmitted X-rays from the X-ray focal point.
Japanese Laid-Open No. 60-127698 discloses a example of X-ray beam limiting devices.
The above-mentioned X-ray beam limiting device is placed at irradiation-opening side of an X-ray tube having a pair X-ray focal points for one target. The X-ray beam limiting device comprises: a rectangular limiting means for rectangularly shaping the X-rays; compensating filters for compensating a difference in the X-ray absorptions by heart muscles and lungs and which are situated at the X-ray-focal-point side of the rectangular limiting means; a circular limiting blade having two circular holes for shaping the X-rays from the X-ray focal points into circles according to a circular effective detection area (i.e. an input window) of an I.I.; and inside limiting blades for shaping the rectangular irradiation field defined by the rectangular limiting means into individual squares for the X-ray focal points.
In normal stereoradiography, a subject contacts the effective detection area. In such contact stereoradiography, the X-ray penetrating image of the subject is detected at an enlargement ratio of 1 to 1, and thus the distance between the X-ray focal points and is 63 mm, which is approximately equal to the distance between the eyes.
The blades of the rectangular limiting means and the inside limiting blades are controlled and moved by a stepping motor so that even when the SID (Source-Image Distance) is changed, a square X-ray irradiation field is circumscribed on the circular effective detection area of the I.I.
Each of the circular holes has a maximum diameter according to the minimum SID. Then, when the SID is at minimum, the X-rays are shaped by the circular holes into a cone, resulting in a circular X-ray irradiation field which coincides with the circular effective detection area, not in a square X-ray irradiation field.
However, when the SID is at maximum or relatively long, a circular X-ray irradiation field on the detection surface resulting from the circular holes would be a circle larger than the exterior of the I.I. As a result, the X-ray is shaped into a pyramid, thus resulting in the square X-ray irradiation field. Four corners of the square X-ray irradiation field may go out of the boundary of the exterior of the I.I.
This results in condition in which some of the X-rays are out of the boundary of the exterior of the I.I. and directly leak behind the I.I. Thus, a patient may receive more X-rays than necessary, or other people like an operator may be exposed to the leaked X-rays.
To the contrary, when the SID setting range is limited to avoid the leakage behind the I.I., the device fails to provide sufficient information for diagnoses due to a short SID.
Presently, there is a demand for a magnifying stereoradiographic device which can both perform high-speed serial stereoradiography (:several frames per second in the case of film photography; several tens of frames per second in the case of I.I. photography) and provide magnified images. For example, for a magnifying stereoradiography with magnification of two in which a subject is placed at the middle between the X-ray focal points and the X-ray detection surface, it is required to use an X-ray tube having an interval between the focal points reduced to approximately 35 mm.
As stated above, where the X-ray tube having shorter distances between the focal points is used, the triangular space, in which the X-ray irradiation is not affected, becomes too small to accomodate the conventional horizontally-moving beam limiting means for preventing the above-mentioned x-ray leakage.
SUMMARY OF THE INVENTION
Thus, it is an object of the present invention to provide an X-ray apparatus having an X-ray beam limiting device which prevents the X-ray beams from directly leaking over the detection surface without restricting the SID or the effective detection area.
It is a further object of the present invention to provide an X-ray beam limiting device which prevents the exterior of the detector from increasing its size.
These and other objects can be achieved according to the present invention, in one aspect by providing, an X-ray apparatus comprising: an X-ray tube having a pair of X-ray focal points placed a predetermined distance apart from each other; an X-ray detector having a detection surface in which an circular input window is placed; and a X-ray beam limiting device for limiting an X-ray beam irradiated from each of the X-ray focal points of the X-ray tube onto the circular input window of the X-ray detector, wherein the beam limiting device includes an element for limiting the X-ray beams so that an irradiation field of each one of the X-ray beams onto the detection surface can be formed into shape which is circumscribed on the circular input window.
Preferably, the limiting element comprises a blade unit consisting of a plurality of blades and being capable of limiting each of the X-ray beams to the polygonal shape which enables the X-ray irradiation field onto the detection surface of the X-ray detector to be circumscribed on the input window and to remain within the detection surface, and a control unit for adjusting each position of the plural blades.
The X-ray detector is preferably an image intensifier and the polygonal shape is preferably approximately octagonal.
It is preferred that the blade unit comprises a first set of blades projecting a V-shaped aperture having a base to the detection surface, a second set of blades projecting a V-shaped aperture to the detection surface, and a third set of blades projecting a rectangular aperture to the detection surface. Further, the first set of blades and the second set of blades are placed so that the V-shaped aperture having the base projected by one of the first set of blades and the V-shaped aperture projected by one of the second set of blades are faced each other in a longitudinal direction of the rectangular aperture projected by the third set of blades. The three sets of blades are placed, from one side near to the X-ray tube toward another side near to the X-ray detector, in an order of positioning from the first to the third set of blades.
It is preferred that the first set of blades are individually rotatable round an axis right to a longitudinal direction of the rectangular aperture. Also, it is preferred that the second set of blades are slidable in a transverse direction right to a longitudinal direction of the rectangular aperture, and the third set of blades are slidable in transverse and longitudinal directions of the rectangular aperture.
Further, it is preferred that the control unit is able to adjust each position of the blades in accordance with at least either one of a distance between the X-ray tube and the X-ray detector, and a size of the input window of the X-ray detector.
As a result, the irradiation field of the X-ray beams onto the detection surface of the detector can be formed by the first to third set of blades into an almost octagonal shape, which is circumscribed on the input window. And more, when the distance between the X-ray tube and the X-ray detector is changed, it can be kept that the irradiation field is circumscribed on the input window. Thus, the irradiation field can be rounded along the boundary of the input window as possible as it could be, and remains within the detection surface. This prevents x-ray beams from leaking over the X-ray detector.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention; in which:
FIG. 1 is a perspective view showing an essential portion of an X-ray beam limiting device according to a preferred embodiment of the present invention;
FIG. 2 is a plan view of outside blades and their driving mechanism shown in FIG. 1;
FIG. 3 is a perspective view of inside rotatable blades and their driving mechanism shown in FIG. 1;
FIG. 4 is a side view of the inside rotatable blades and their driving mechanism shown in FIG. 3, when seen along a y-direction;
FIG. 5 is a side view of the inside rotatable blades and their driving mechanism shown in FIG. 3, when seen along an x-direction;
FIG. 6A is a front view of one of an inside rotatable blade;
FIG. 6B is a cross-sectional view of the inside rotatable blade shown in FIG. 6A, taken along a line A--A;
FIG. 7 is a flowchart showing processing in a controller shown in FIG. 1;
FIG. 8 illustrates operation of a combination of the inside rotatable blades and right and left-side limiting blades shown in FIG. 1;
FIG. 9 illustrates an aperture projected onto a detection surface by one of the inside rotatable blades;
FIG. 10 shows an aperture projected onto the detection surface by of the outside blades;
FIG. 11 shows an aperture projected onto the detection surface by the left-side and back and forth-side limiting blades;
FIG. 12 shows an combined aperture of all the blades gathered to make an octagon for a left-side X-ray focal point; and
FIG. 13 represents a rectangular aperture according to a conventional X-ray beam limiting device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of an X-ray apparatus in accordance with the present invention will now be described with reference to FIG. 1 to FIG. 13.
FIG. 1 is a perspective view of an essential portion of an X-ray apparatus having an X-ray beam limiting device 1. The device 1 is assembled with an X-ray tube 2 having a pair of X-ray focal points FR, FL whose interval is 35 mm. An I.I. (Image Intensifier) 3 is placed, apart from the X-ray beam limiting device 1, at a position which faces the device 1. In the FIG. 1, a reference alphabet P represents a patient to be examined.
The I.I. 3 has a detection surface S formed in one side of an cylindrical exterior 3a. The detection surface S includes an input window Se as an effective detection area for X-ray beams. The remaining area excepting the input window Se on the detection surface S forms a torus-like surface, as shown in FIGS. 1 and 9 to 13 and is lead made for absorbing X-ray beams.
The X-ray beam limiting device 1 comprises a rectangular limiting mechanism 10, compensating filters 11, 12 and a polygonal limiting mechanism 13. Those limiting mechanism 10, 13 and filters 11, I2 are assembled inside a box-like casing 14.
The rectangular limiting mechanism 10 has right and left-side limiting blades 21, 22 for limiting X-ray beams in the x-direction, back and forth-side limiting blades 23, 24 for limiting X-ray beams in the y-direction, driving mechanisms 25, 26 for driving the right and left-side blades 21, 22 respectively, and driving mechanisms 27, 28 for driving the back and forth-side limiting blades 23, 24 respectively. For the blade 22 only, a double-plate structure is adopted to gain a wide moving distance in x-direction.
All the blades 21 to 24 are shaped into rectangular plates and made of lead. The right and left-side limiting blades 21, 22, having straight-line edges 21a, 22a for limiting X-ray beams respectively, are placed in parallel at a certain level. The back and forth-side limiting blades 23, 24, also having straight-line edges 23a, 24a for limiting X-ray beams respectively are placed in parallel at a certain horizontal level nearer to the X-ray tube 2, on condition that the blades 23, 24 and 21, 22 cross at a right angle each other.
Each of the above-mentioned driving mechanisms 25 to 28 includes a stepping motor 25a (to 28a), a lead screw 25b (to 28b) attached on the output shaft of the stepping motor 25a (to 28a), a nut 25c (to 28c) engaged with the lead screw 25b (to 28b) and fixed to the blade 25 (to 28), and a photo sensor 25d (to 28d). The output shafts of the motor 25a to 28a are rotatably supported at their both ends on the casing 14. The stepping motors 25a to 28a are driven individually by driving signals supplied from a controller 30. The controller 30 receives sensing signals detected by the photo sensors 25d to 28d to control initial positions of the blades 21 to 24. Then, rotation of the stepping motors 25a to 28a enables the blades 21 to 24 to move in either way of the predetermined x and y-axis directions.
In this X-ray apparatus, an SID sensor 31, which is formed using a potentiometer, is provided for sensing a distance between the X-ray tube 2 and the I.I. 3. Also, there provided is an input and display unit 32 for operation.
The above-mentioned compensating filters 11, 12 are placed in parallel between the rectangular limiting mechanism 10 and the polygonal limiting mechanism 13. And, the filters 11, 12, made of lead, have a heart-shape edges at their face-to-face sides to cut excessive X-rays. The filters 11, 12 can be also slid in predetermined axis directions using stepping motors (not shown in FIG. 1) under control of the controller 30.
The above-mentioned polygonal limiting mechanism 13 is placed at the nearest position to the X-ray tube 2, as shown in FIG. 1. The mechanism 13 comprises: inside rotatable blades 41, 42 for limiting an X-ray irradiation field from the inside thereof; inside-rotatable-blade driving mechanism 43 for driving the inside rotatable blades 41, 42; outside blades 45, 46 for limiting the X-ray irradiation field from the outside thereof; and outside-blade driving mechanism 47 for driving the outside blades 45, 46.
The outside blades 45, 46, made of lead, are each shaped into a thin rectangular plate having a cut 45a (46a) which is open to its one edge, as shown in FIG. 2. Each cut 45a (46a) is made up of two oblique segments 45aa, 45ac (46aa, 46ac) which are cutted in obliquely from the edge, and a parallel segment 45ab (46ab) as a bottom which is parallel to the edge and connected the two oblique segments 45aa, 45ac(46aa, 46ac). The outside blades 45, 46, by the outside-blade driving mechanism 47, are placed in parallel and on condition that the cut 45a, 46a are face-to-face, but are at different levels, enabling them to overlap each other.
The outside-blade driving mechanism 47 includes, as shown in FIG. 2: mounting plates 50, 51 mounting the outside blades 45, 46; nuts 52, 53 each connected to one end of each of the mounting plates 50, 51; a right-handed leading screw 54 screwed through the nut 52; a left-handed leading screw 55 screwed through the nut 53 and integrally connected to the screw 54; a stepping motor 56 for rotating the lead screw 55; and slide bearing mechanisms 57, 58 by which the outside blades 45, 46 smoothly can move translationally in the y direction opposite to each other. The mechanism 47 is also provided with a photo sensor 59 for initialization of the blade positions. For example, when the leading screws 54, 55 are rotated in one direction by the motor 56, the outside blades 45, 46 move away from each other (refer to two-dotted lines), and when the leading screws 54, 55 are rotated in the other direction, the outside blades 45, 46 move closer to each other.
The inside rotatable blades 41, 42 are placed in a triangular space formed by inside boundaries XR1a, XR2a of the x-ray beams XR1, XR2 irradiating from the X-ray focal points FR, FL and a line LN between the focal points FR, FL. The driving mechanism 43 for the blades 41, 42 is symmetrically designed or positioned in FIGS. 3 to 5.
As shown in FIG. 3, each of the blades 41 and 42 has a recess 41a (42a) large enough to cover X-ray XR1 (XR2) irradiating from the focal points FR, FL with a spreading angle θ (refer to FIG. 5) in the y-direction along the side of the device I; and the rotatable shaft 41b (42b) fixed at a first end to the recess 41a (42a). Each one of the recesses 41a, 42a is formed by cutting from one side, or has two oblique-cutted surfaces 41aa, 41ac (42aa, 42ac) cutted obliquely from the side and parallel-cutted surface 41ab (42ab) as a bottom parallel to the side. As shown in FIGS. 6A, 6B, shapes of the recesses 41a, 42a are designed to be a pyramid according to the shape of X-ray beams at the maximum aperture. The inside rotatable blades 41, 42 are also made of lead.
For one inside rotatable blade 41, as shown in FIGS. 3 and 4, the inside-rotatable-blade driving mechanism 43 includes: a stepping motor 60 which is a drive source for the rotation of blade 41 and is fixed to a base 61; a leading screw shaft 62 rotatably connected at both ends thereof by L-shaped metal fixtures 63, 63 to the base 61 and coupled by a coupling 64 to an output shaft 60a of the motor 60; a nut 65 having a pin 66 and screwed onto a leading screw portion 62a of the shaft 62; and a guide plate 67 which has a long hole 67a associated with the pin 66 and is rotatable centered at the rotatable shaft 41b. The blade 41 is fixed to an end portion of the guide plate 67 so as to rotate centered at the rotatable shaft 41b as the guide plate 67 rotates. The mechanism 43 is provided with a photo sensor 68 to initialize the position of the blade 41 (refer to FIG. 4).
For the other inside rotatable blade 42, the mechanism 43 also includes, on the same principle as the blade 41, a stepping motor 70 fixed to a base 71, a leading screw shaft 72 supported rotatably by L-shaped metal fixtures 73, 73 and coupled by a coupling 74 to the motor shaft 70a, a nut 75 having a pin 76 and screwed onto a leading screw portion 72a of the shaft 72, and a guide plate 77 having a long hole 77a associated with the pin 76 and is fixed to the rotatable shaft 42b. The blade 42 is fixed to an end portion of the guide plate 77 so as to rotate centered at the rotatable shaft 42b as the guide plate 77 rotates. The mechanism 43 is also provided with a photo sensor 78 to initialize the position of the blade 42 (refer to FIG. 4).
The rotatable shaft 41b of the blade is placed so that the center line thereof coincides with the center line of the other rotatable shaft 42b of the inside rotatable blade 42, and thus the driving mechanism 43 for the inside rotatable blades 41, 42 is made compact. The rotatable shaft 41b, 42b, at a middle portion thereof, are fitted and fixed to the guide plate 67, 77 respectively, and, at the second end, are supported by a ball bearing 69, 79 respectively so as to rotate smoothly.
The inside rotatable blade 41 adjusts the radiating X-ray XR1 from the inside boundary XR1a. The inside rotatable blade 42 restricts the pyramid-shaped X-ray XR2 from the inside boundary XR2a (refer to FIG. 8).
When the stepping motor 60 rotates, the nut 65 moves along the leading screw portion 62a to a position shown by a two-dot line in FIG. 4; the guide plate 67 rotates on the rotatable shaft 41b to a position shown by a two-dot line; and the blade 41 rotates to a position shown by a two-dot line. The other inside rotatable blade 42 is also rotated to a position in the opposite direction by the other stepping motor 70, thus being able to take a position symmetric to that of the blade 41.
Various signals, including the sensing signals from the photo sensors 25d˜28d, 59, 68, 78, radiography-selection signals (i.e. stereoradiography or monoscopicradiography), and SID signals from the SID sensor 31, are supplied to the controller 30. The controller 30 is provided with a computer to process the input signals according to predetermined procedures shown in FIG. 7 and to calculate driving signals for the stepping motors 25a˜28a, 56, 60, 70. The procedure for X-ray limiting control is designed so that when the SID is changed, the irradiation fields from the two X-ray focal points FL, FR can meet exactly a circular input window Se in the circular detection surface S of the X-ray tube 2.
The operation of the X-ray beam limiting device 1 according to this embodiment as described above will be explained with reference to FIGS. 7 to 12 (FIGS. 8 to 12 show plan views of a concerned portion of the device, illustrating the X-ray irradiation fields projected on the detection surface S).
First, the operation of the controller 30 will now be explained with reference to FIG. 7.
After initiated, at the first Step 100 of the flowchart in FIG. 7, the controller 30 will order initialization of each position of all the blades 11 to 14, 41, 42, 45 and 46 using the sensing signals from the photo sensors 25d to 28d, 59, 68 and 78. The controller 30 drives the stepping motors 25a to 28a, 56, 60 and 70 until sensing light beams will be cut by the blades 11 to 14, 41, 42, 45 and 46 or their related portions. Then, the cutted light beams allow the controller 30 to move all the blades 11 to 14, 41, 42, 45 and 46 individually to their predetermined initial positions by driving the stepping motors 25a to 28a, 56, 60 and 70.
Then, at Step 101, the SID sensing signal from the SID sensor 31 and size information of I.I. 3 will be read in by the controller 30, then, proceeding to Step 102. At the Step 102, the SID sensing signal and I.I. size information are judged whether their values are changed against their previous ones or not. As judgement "YES" (i.e. changed) is made in Step 102, a process of Step 103 will be followed.
At Step 103, each new position and moved direction of all the blades 11 to 14, 41, 42, 45 and 46 according to the newly designated SID or I.I. size is calculated by the controller 30. After this, at Step 104, the controller 30 will supply driving signals corresponding to the calculated values to the stepping motors 25a to 28a, 56, 60 and 70.
Finally, at Step 105, it is judged that the termination of the X-ray limitation control is ordered or not by an operator. If judgement "NO" (i.e. nontermination) is made at Step 105, the processing will be returned to Step 101.
In case judgement "NO" (i.e. unchanged) in Step 102, the processing will be directly jumped to Step 105.
Next, the operation of whole system will be explained, mainly, with focusing on the limitation control of the X-ray beam XR2 from the left-side X-ray focal point FL.
When an operator selects stereoradiography and determines SID, the controller 30 will be initiated to supply driving signals individually to the stepping motors 25a to 28a, 56, 60 and 70 of the mechanisms 10 and 13.
In the inside-rotatable-blade driving mechanism 43, under the control of the controller 30, the stepping motor 60, 70 rotates the inside rotatable blades 41, 42 near the centers of the irradating X-ray beams XR1, XR2, as shown in FIG. 8. These blades 41, 42 form the inside boundaries of the irradiation fields respectivly. Then, the spreading angles of the pyramid-shaped X-ray beams XR1, XR2 from the X-ray focal points FR, FL correspond to an input window (effective detection area) Se shared by the X-ray beams XR1 and XR2 on a detection surface S. That is, projected aperture edges 42aa to 42ac of the inside rotatable blade 42 are circumscribed on the input window (effective detection area) Se of the I.I. 3 as shown in FIG. 9.
The stepping motor 56 of the outside-blade driving mechanism 47 shown in FIG. 2 moves the outside blades 45, 46 under the control of the controller 30, so that projected aperture edges 45aa, 46aa of the outside blades 45, 46 are circumscribed on the input window Se of the I.I. 3 as shown in FIG. 10.
The stepping motor 25a to 28a of the rectangular limiting mechanism 10 rotates the blades 11 to 14, under the control of the controller 30, so that projected aperture edges 21a, 23a, 24a of the blades 21, 23, 24 are circumscribed on the input window Se of the I.I. 3 as shown in FIGS. 5 and 11.
Thus, by the combined operations of the mechanisms 10 and 13, the X-ray beam XR2 from the left-side X-ray focal point FL is limited to form a substantial half regular octagon which is surrounded by the projected aperture edges 21a, 45aa, 23a, 42ac, 42ab, 42aa, 24a and 46aa and circumscribed on the input window Se of the I.I. 3. That is, the irradiation field is rounded along the circular boundary of the input window Se, and remains within the detection surface s. Therefore, the X-ray XR2 will not directly leak behind an exterior 3a of the I.I. 3.
In the same way, the X-ray beam XR1 from the right-side X-ray focal point XR is limited by the operation of the mechanisms 10 and 13, and thus the X-ray beams XR1 and XR2 will not directly leak behind the exterior 3a of the I.I. 3.
If the prior art is adopted, a rectangular aperture IF according to the prior art may be represented as shown in FIG. 13. The four corners (refer to portions painted black) of the rectangular aperture IF in FIG. 13 go out of the boundary of the exterior 3a of the detector 3. Those four corners cause X-ray leaking.
To the contrary, the device 1 according to this embodiment can keep the irradiation field within the detection surface s, and prevent the X-ray beams from directly leaking behind the detection surface s without restricting the SID or the size of the input window.
Even if an X-ray tube having an interval of the X-ray focal points as close as 35 mm is employed, the device still can perform magnifying stereoradiography without restricting the SID or the input window.
The present invention is not restricted by the above embodiment but can be changed or modified within the scope of the invention. For example, the shape of irradiation field on the detection surface S is not restricted to be octagonal, but polygonal shapes having angles more than the octagon may be adopted. By the way, the above-mentioned X-ray beam limiting device 1 is described for use in stereoradiography, but usable as a device for monoscopicradiography. | In order to perform stereoradiography, an X-ray apparatus utilizes an X-ray tube having a pair of X-ray focal points. The X-ray beams are alternately irradiated from the focal points toward an image intensifier through a patient and are limited by an X-ray beam limiting device. The device shapes the irradiated X-ray beams onto a circular detection surface of the image intensifier into a polygon such as octagon. The X-ray irradiation field on the detection surface can be circumscribed to a circular input window (i.e. effective input area), preventing the field from going beyond the detection surface. Thus, direct X-ray leaking over the image intensifier is avoidable. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 61/269,317, filed on Jun. 22, 2009 which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention described herein relates to imaging and object tracking.
2. Background Art
Acquiring and tracking a moving object can be aided by automated processing to improve speed and accuracy. Such processing may include technology that includes computer vision. Computer vision algorithms generally exploit shape and/or appearance features for automated analysis of images and video.
Appearance-based methods are challenged by the changes in an object's appearance. The changes may be due to several factors. These may include a) different illumination sources and conditions, b) variations of the object's orientation with respect to the illumination source and camera, and c) different reflectance properties of objects in the scene. Such variability compromises the performance of many vision systems, including background subtraction methods for motion detection, appearance-based trackers, face recognition algorithms, and change detection.
What are needed, therefore, are systems and methods that provide for the acquisition and tracking of an object where the tracking can be maintained even if changes occur in the illumination sources, object orientation, and appearances of other objects in a scene, or if tracking is momentarily lost.
BRIEF SUMMARY OF THE INVENTION
Identification of an object may be based on its spectral fingerprint. This fingerprint is the object's unique spectral signature based on its molecular composition. This allows two seemingly similar objects to be uniquely distinguished from each other in the presence of other objects. The spectral fingerprint can be either the intrinsic reflectance of an object or the emissivity of an object based on the wavelengths being recorded. Reflectance occurs in the visible, near-infrared, and short wave infrared part of the electromagnetic spectrum and is the ratio of the amount of light striking an object to the amount of light being reflected from an object. Emissivity is a measure of the amount of energy emitted from an object compared to a uniform emitter. By identifying the reflectance or emissivity of an object, a unique spectral fingerprint can be used for surveillance of an object. As will be described in greater detail below, reflectance spectra can be used to perform detection, tracking and association, which are necessary steps for object surveillance.
The detection of an object can exploit its spectral fingerprint by leveraging its unique reflectance signature. Detecting objects in images is often difficult when objects in the scene have similar appearance (e.g., shape and intensity). However if this object's specific spectral signature is known, it can then be unambiguously detected and discriminated from the surrounding objects and background. This is done by examining every image pixel and computing how closely that pixel's spectrum matches a known object spectral signature. Alternatively, if the surrounding background spectral signature is known, it can be used for detecting new and unusual objects.
Tracking an object from one image to another image requires finding the corresponding locations of an object in both images. Stated differently, after various objects have been detected in both images, one needs to find a single match between each object in one image and the next image, a process called association. Association is often difficult when there are many objects in a scene, when objects look similar, or when many of these objects appear and/or disappear from the scene. This problem can be addressed by using spectral information: by looking at the fine spectral signature of each object detected in the first image, this signature can be used to find the closest match in the set of objects detected in the next image. When association is done, physical models can be used to refine each object's spectral signature. This refined spectral signature is then used again for doing future associations.
The use of reflectance spectra for detection, tracking and association of objects allows for the following new capabilities:
Illumination-invariant Tracking
The reflectance spectrum of an object is independent of the illumination and atmospheric conditions under which it is observed. Hence, with the ability to estimate the reflectance spectrum under a wide range of viewing conditions, illumination-invariant tracking can be achieved by using the reflectance spectrum to detect, track, and associate the object across multiple images.
Track Through Gaps in Coverage
Since the reflectance spectrum of an object is consistent over time and independent of illumination conditions, spectral matching algorithms can be used to track and associate the object across spatial and temporal gaps in coverage. For example, if the object leaves the field of view (FOV) of the sensor and re-appears in minutes/hours/days, spectral matching algorithms can be used to determine where and when it has re-appeared in the sensor's FOV.
Tracking in the Presence of Confusers
The performance of many existing tracking algorithms suffers when there are multiple objects with similar appearance/color in the sensor's FOV. The invention described herein addresses this problem by exploiting high-resolution reflectance spectra, which often provides a unique signature/fingerprint that can distinguish the tracked object from others with the same color. For example, when tracking a single white object of interest in a crowd of white objects, the reflectance spectrum of the object of interest can be used to discriminate it from the other white objects, and thus reduce the false alarms that often confuse existing surveillance systems.
A hyperspectral video surveillance system is described herein, which uses a hyperspectral video (HSV) camera. This sensor captures hyperspectral imagery at near-video rates. While standard video cameras capture only three wide-bandwidth color images, the HSV camera collects many narrow-bandwidth images of the scene. For many vision systems, an HSV camera provides several advantages. An HSV camera provides high spatial and temporal resolution to detect and track moving objects. The high spectral resolution allows distinction between objects with similar color. An HSV camera also provides the ability to incorporate radiative transfer theory models to mitigate the effects of illumination variations. Moreover, since a hyperspectral video camera is able to simultaneously capture images with high temporal, spatial, and spectral resolution, it combines the advantages of both video and hyperspectral imagery. HSV cameras are commercially available from vendors such as Surface Optics Corporation of San Diego, Calif.
An HSV camera allows for illumination-invariant vision algorithms for a wide range of problems. Specifically, the measured radiance spectra of the object can be used to estimate its intrinsic reflectance properties that are invariant to a wide range of illumination effects. This is achieved by incorporating radiative transfer theory to compute the mapping between the observed radiance spectra to the object's reflectance spectra.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
FIG. 1 is a block diagram illustrating the overall structure of an embodiment of the invention.
FIG. 2 is a flowchart illustrating the processing of an embodiment of the invention.
FIG. 3 is a flowchart illustrating the tracking process, according to an embodiment of the invention.
FIG. 4 is a flowchart illustrating the prediction process, according to an embodiment of the invention.
FIG. 5 is a flowchart illustrating the correction process, according to an embodiment of the invention.
FIG. 6 is a block diagram illustrating a software or firmware embodiment of the invention.
Further embodiments, features, and advantages of the present invention, as well as the operation of the various embodiments of the present invention, are described below with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the present invention is now described with reference to the figures, where like reference numbers indicate identical or functionally similar elements. Also in the figures, the leftmost digit of each reference number corresponds to the figure in which the reference number is first used. While specific configurations and arrangements are discussed, it should be understood that this is done for illustrative purposes only. A person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the spirit and scope of the invention. It will be apparent to a person skilled in the relevant art that this invention can also be employed in a variety of other systems and applications.
FIG. 1 illustrates the overall system of the invention, according to an embodiment. An object 105 is shown being imaged by a hyperspectral video (HSV) camera 110 . Most modern video cameras provide imagery with high spatial and temporal resolution. This can be somewhat useful for detecting and tracking moving objects. However, their low spectral resolution limits their ability to classify or identify objects based on color alone. Conversely, traditional hyperspectral sensors offer high-resolution spectral and spatial imagery at low temporal resolutions with modest frame rates (up to 0.5 Hz). Hence, they have been utilized extensively for object detection and classification, but only in static, non-dynamic environments, such as geological imaging.
HSV cameras are now available, which are able to capture hyperspectral datacubes at near video rates. The HSV camera offers high spatial, temporal, and spectral resolution imagery. The HSV camera combines the benefits of video and hyperspectral data to allow simultaneously detecting, tracking, and identifying objects using computer vision and hyperspectral image analysis methods.
In an embodiment, the HSV camera is a passive sensor that measures the optical spectra of every pixel from 400-1000 nm (visible and near-IR wavelengths). It acquires datacubes using a line scanning technique. An oscillating mirror scans the scene up to ten times a second, and for each mirror position one horizontal scan line is acquired and its pixels are decomposed by a spectrometer into a full spectral plane. The spectral plane is captured by a charge coupled device (CCD), and is built into a datacube as the mirror completes a vertical scan of the scene. The acquired cube is then either immediately processed in real time or stored, e.g., on a hard drive. Acquisition conditions may be controlled by an operator through an on-board computer. Integration time can also be modified to accommodate low light conditions.
Referring again to FIG. 1 , hyperspectral data 120 is output from HSV 110 in the illustrated embodiment. At 130 , the hyperspectral data 120 is processed to extract the radiance spectra. This is shown as radiance spectra 140 . Note that in an embodiment of the invention, the radiance spectra may have been captured independently of the other data captured by the HSV camera, i.e., spatial and temporal data. In this case, a distinct extraction process for the radiance spectra may not be necessary. At 150 , the radiance spectra 140 is converted to reflectance spectra 160 . The reflectance spectra 160 is then used in a tracking process 170 . Processes 150 and 170 are described in greater detail below.
In an embodiment, processes 130 and 150 may be implemented in a single module 180 . Module 180 may be implemented in software, firmware, hardware, or some combination thereof. Software/firmware implementations may use assembly language or any higher order language, as would be known to a person of ordinary skill in the art. Hardware embodiments may be implemented using application specific integrated circuitry, field programmable gate arrays (FPGA), or any other hardware technology know in the art. In an alternative embodiment (not shown), the tracking process 170 may also be implemented by module 180 .
The overall processing of the invention is shown in FIG. 2 , according to an embodiment. At 210 , hyperspectral data is captured. As discussed above, this data may be captured by an HSV camera in an embodiment of the invention. At 220 , radiance spectra is extracted from the hyperspectral data, as necessary.
At 230 , the radiance spectra is converted to reflectance spectra. In an embodiment of the invention, the reflectance spectra is obtained from the radiance by using a physics modeling system taking into account environmental, weather and atmospheric conditions. One embodiment of this modeling system is MODTRAN.
Generally, in the reflectance domain, there are six main sources of light. The most obvious source is the sun. Light is generated at the sun, passes through the atmosphere, reflects off of the object being imaged, and eventually reaches the sensor. Along the way, the spectral properties of the light are changed as photons are absorbed and scattered through the atmosphere.
Skylight takes a very similar path to sunlight. Once the light reaches the object being imaged, it reflects the same as the sunlight (assuming a diffuse material), and is reflected back through the atmosphere to the sensor along the same path as the sun light. The difference however is that skylight is generated by light scattered in the atmosphere from all directions.
The remaining four sources of light (upwelled radiance, multipath effects, adjacency effects, and trapping effects) are typically orders of magnitude less energetic than sunlight or skylight. Because of this fact, these effects can largely be ignored for short-range, ground-based imaging. However, sometimes multipath and adjacency effects can become noticeable given the unique geometries of ground-based sensing. For example, light reflected from vegetation surrounding an object being imaged can impart part of the vegetative reflectance signature to the object—especially when the object is in full shade conditions where limited skylight is able to reach the object (e.g. dark shadows).
As would be understood by a person of ordinary skill in the art, the full radiometric equation is a sum of the six different sources of light. In an embodiment, the radiometric transfer function can be suitably expressed by using the three most significant terms. The radiometric transfer function for this can therefore be expressed as
L ( x,y, λ)= R ( x,y,λ ){ A (λ)+ F ( x,y ) B (λ)}
where A(λ) represents the radiance due to sunlight, F(x,y) represents the amount of sky light at pixel (x,y) (i.e., in shadow zones the amount of sky not blocked by the object creating the shadow), R(x,y,λ) is the reflectance of the object being imaged, and B(λ) represents the radiance due to sky light. This assumes that the scene is small enough that the source-object-receiver geometry is similar across the image. Also, the terms A(λ) and B(λ) are considered to be independent of pixel location when small areas are imaged (i.e., the sunlight and skylight terms do not vary over the small area being imaged).
Using the radiometric theory described, one can approximate the underlying reflectance signatures in an image. To do this, the image must contain an object with a known reflectance signature. One approach is to identify objects in the scene that have nearly flat reflectance signatures (i.e. constant and independent of wavelength) in full sunlight conditions. Examples of common materials with flat reflectance include concrete and asphalt. The above equation then becomes
L flat (λ)= k{A (λ)+ FB (λ)}
where k now represents an unknown flat reflectance value independent of wavelength. One may also note that the location (x,y) has been removed as there is a need only to identify the flat reflectance object in the scene, not its location. If the entire image is in sunlight, then the reflectance of the image can be calculated as
R ( x , y , λ ) = k L ( x , y , λ ) L flat ( λ )
to within some unknown offset k. To remove the effects of k, each pixel is normalized to have the same energy. The result is an image with fewer illumination differences.
For images that contain shadow zones, the process is slightly more complicated. First, a shadow mask must be estimated. The energy of each pixel, computed using either the L 1 or L 2 norm of its spectra, is thresholded to produce the shadow mask. In this process, very dark objects will be considered in shadow zones independent of their true illumination condition, but the process produces good results in an efficient manner.
Once a shadow mask has been created, a shadow line must be found that crosses across the same material. For the pixels in the full sunlight condition, the previous equation is applied to estimate the reflectance. Using the estimated reflectance, the skylight effects can be estimated such that
kF ( x , y ) B ( λ ) = L ( x , y , λ ) R ( x , y , λ )
for pixels of the same material just inside the shadow zone. Now estimates for both full sun and full shade conditions are available.
Using these estimates and the shadow mask, pixels in full sun can be converted to reflectance. For pixels in shade, their reflectance can be calculated using
R ( x , y , λ ) = L ( x , y , λ ) kF ( x , y ) B ( λ )
Again, the offsets due to k or F(x,y) are not known, but this can be handled by normalizing the resulting reflectance as was done above.
At 240 , the resulting reflectance spectra may be used for locating or tracking an object. This process is illustrated in greater detail in FIG. 3 . At 310 , state data for a current frame or image is received, where the state data includes the reflectance spectra of the object. In an embodiment, the state data may be organized as a formatted state description.
In an embodiment, the state description may take the form of a state vector for example, of the form
X i =[ref1_spectrum, H, W, x, y, {dot over (x)}, {dot over (y)}] T ,
where i denotes the frame, H and W specify the height and width of the bounding box containing the object in the image, x, y are the horizontal and vertical position of the center of the object's bounding box in the image, {dot over (x)},{dot over (y)} are the horizontal and vertical velocities of the object's bounding box in the image, and T denotes transposition. Note that while the example above uses a rectangular bounding box, in general any bounding shape or area (and a specification thereof) may be used.
Embodiments of a state description may include one or more of the following: a spectral vector, spatial descriptors, shape descriptors, spatio-temporal descriptors, temporal descriptors, or kinematic descriptors. Examples of shape descriptors include parametric descriptors such as moment descriptors, Fourier shape descriptors, active contours, active volumes, snakes, dynamic curves, and any combination of these. Kinematic descriptors may include position, velocity, acceleration and any higher order derivative. Appearance descriptors may include feature vectors that are derived from the spectral vectors by using methods such as dimensionality reduction or reprojection or filtering of the spectra. Such methods include PCA, LDA, projection pursuit, wavelet descriptors, and any related method.
Tracking an object includes a prediction process 320 followed by a correction process 330 , as shown in the illustrated embodiment. Given the reflectance spectra from the HSV camera, various processes can be used to track objects in challenging scenarios. Tracking may be based on frame-to-frame matching so as to minimize the need to exploit the kinematics of the object across frames. Since the reflectance spectra are invariant to the imaging conditions, the objects can be tracked by comparing the spectra of every pixel with the spectra of the tracked object. The additional spectral features observed by the HSV camera allow a tracking process to discern between objects of similar colors that would have otherwise not have been separated by a traditional red/green/blue (RGB) camera.
The detection problem may be posed as a one-class hypothesis test in an embodiment. A parametric model for the reflectance spectra of the tracked object may be adopted. Pixels in the HSV sequence that are well-matched to the model are considered to be the tracked object. In an embodiment, a Gaussian model may be assumed for the spectra, which allows use of the Mahalanobis distance classifier.
Specifically, the mean vector m and the covariance matrix Σ of the object's reflectance spectra are estimated to form the Gaussian model N(m, Σ). In each successive HSV frame, the Mahalanobis distance test
m M ( x )=( x−m )Σ −1 ( x−m )≦ T
is computed for every pixel x. The threshold T can be determined by using a constant false alarm rate argument. Pixels whose Mahalanobis distance is below T are considered to be the tracked object. Note that since the process operates on each pixel independently, it can be implemented in parallel for real-time operation in an embodiment. As would be understood by a person of ordinary skill in the art, alternatives to the use of the Mahalanobis distance test and a Gaussian model are available and may be used instead. Rather, the Mahalanobis test and Gaussian model are presented here as examples, and are not meant to limit the scope of the invention.
The prediction process 320 may be performed using a tracking process. A tracking process may include the use of one or more of a Bayes filter, an observer-predictor filter, an alpha-beta filter, a Kalman filter, an extended Kalman filter, an Unscented Kalman filter, an iterated extended Kalman filter, a particle filter, a condensation filter, and any related filter. One embodiment of the particle filter tracker can use importance sampling, sequential importance sampling, factored sampling, or any related sampling.
One embodiment of a prediction process is illustrated in FIG. 4 , according to an embodiment. At 410 , the state vector for the current frame is read. In an embodiment the state vector may have the form X i =[ref1_spectrum, H, W, x, {dot over (y)}, {dot over (x)}] T , as noted above. The prediction step uses the velocity and other dynamic model parameters to predict the value of the state vector at frame k from X k-1 . To do this, a delta description is determined, as shown at 420 . In the illustrated embodiment, the delta description may take the form of a vector. This delta vector may be combined at 430 with the state vector of a preceding frame k−1, shown here as X k-1 . The predicted state may therefore be expressed as the vector {circumflex over (X)} k =X k-1 +[0,ΔH,ΔW,{dot over (x)},{dot over (y)},{umlaut over (x)},ÿ] T +n, where 0 is the zero vector (since the reflectance spectrum is constant for the tracked object), ΔH, ΔW are the expected changes in the height and width of the object, and {umlaut over (x)},ÿ are the horizontal and vertical image accelerations of the tracked object. The vector n is a random Gaussian noise vector that represents uncertainty in the dynamic model.
The correction process is shown in FIG. 5 , according to an embodiment. At 510 , a probability distribution for the next state is calculated. Probabilisitic modeling can be embodied by using a parametric or non-parametric distribution. Embodiments of a non-parametric distribution use a Parzen window PDF estimator, a mixture of Gaussian estimators, mixtures of arbitrary kernels, a support vector PDF estimator, or any related estimator. Embodiments of parametric distribution modeling may use uniform, Gaussian, Cauchy, gamma, beta, exponential, symmetric alpha stable, K, Weibull, Ricean, log normal, Pearson, or Polya modeling, or any variations and/or combinations of the above.
In the illustrated embodiment, the correction process uses a measurement function and the new observation (the hyperspectral video image) to update probabilities of the state vector X k for frame k. In an embodiment, the likelihood or probability of the state vector is given by
p(X k |Z 1:k )∝exp{−(x−y) T Σ −1 (x−y)},
Where in this context x is the average reflectance spectrum of the tracked object, y is the average reflectance spectrum in the part of the image specified by the bounding box X k , and Σ is the spectral covariance matrix of the tracked object.
At 520 , a determination is made for the probability that the predicted state is correct. At 530 , a decision is made as to whether this probability exceeds a predetermined threshold. If so, then at 540 the predicted state is used. Otherwise, at 550 the most likely state is used, as determined by the probability distribution. An optimal estimate for the state vector X k is the one that has the maximum probability or likelihood value.
The processing described above for the conversion of radiance to reflectance spectra, prediction, and correction may be implemented using digital logic in the form of software, firmware, or hardware, or some combination thereof. A hardware implementation may take the form of one or more field programmable gate arrays (FPGAs) for example. Alternatively, a hardware implementation may take the form of one or more application specific integrated circuits (ASICs) or other forms of hardware logic, as would be understood by a person of ordinary skill in the art.
The term software, as used herein, refers to a computer program product including a computer readable medium having computer program logic stored therein to cause a computer system to perform one or more features and/or combinations of features disclosed herein. A software embodiment is illustrated in the context of a computing system 600 in FIG. 6 . System 600 may include a processor 620 and a body of memory 610 that may include one or more computer readable media that may store computer program logic 640 . Memory 610 may be implemented as random access memory (RAM), read-only memory (ROM), or some combination thereof, for example. Processor 620 and memory 610 may be in communication using any of several technologies known to one of ordinary skill in the art, such as a bus. Computer program logic 640 is contained in memory 610 and may be read and executed by processor 620 . One or more I/O ports and/or I/O devices, shown collectively as I/O 930, may also be connected to processor 920 and memory 610 . Computing system may be incorporated in one or both of a transmission node or a receive node.
In the illustrated embodiment, computer program logic 640 includes radiance/reflectance conversion logic 650 . The process for conversion of radiance spectra to reflectance spectra includes receiving radiance spectrum from an HSV camera and transforming the radiance spectrum to reflectance spectra in the manner described above. Computer program logic 640 may also include prediction logic 660 . Prediction logic 660 may be responsible for predicting the location of an object in a succeeding frame, based on observation and parameters derived from a current frame, as described above. Computer program logic 640 may also include correction logic 670 . This latter module may be responsible for determining and applying a correction to a predicted location of the object, as described above.
It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and the appended claims in any way.
The present invention has been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed.
While various embodiments are disclosed herein, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail may be made therein without departing from the spirit and scope of the methods and systems disclosed herein. Thus, the breadth and scope of the claims should not be limited by any of the exemplary embodiments disclosed herein. | Detection and tracking of an object by exploiting its unique reflectance signature. This is done by examining every image pixel and computing how closely that pixel's spectrum matches a known object spectral signature. The measured radiance spectra of the object can be used to estimate its intrinsic reflectance properties that are invariant to a wide range of illumination effects. This is achieved by incorporating radiative transfer theory to compute the mapping between the observed radiance spectra to the object's reflectance spectra. The consistency of the reflectance spectra allows for object tracking through spatial and temporal gaps in coverage. Tracking an object then uses a prediction process followed by a correction process. | 6 |
[0001] This invention was not made under federally sponsored research or development of any kind.
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[0003] Jacobs E N, Ward K E, Pinkerton R M. 1932. The characteristics of 78 related sections from tests in the variable-density wind tunnel. NACA Report. 460.
[0004] National Research Council of the National Academies. 2006. Tires and Passenger Vehicle Fuel Economy: Informing Consumers, Improving Performance. Transportation Research Board Special Report 286.
FIELD OF THE INVENTION
[0005] This invention relates generally to airfoils mounted on wheeled vehicles, including automobiles, vans, buses, recreational vehicles, trucks, and trains. More particularly, this invention has to do with airfoils that may be fixed or adaptively varied to improve the safety, efficiency and performance of such vehicles.
BACKGROUND OF THE INVENTION
[0006] Wheeled vehicle transportation accounts for a major portion of global energy consumption and contributes much of the pollution and greenhouse gases produced by the world. The energy required of the propulsion system of a wheeled vehicle is determined by three factors: aerodynamic drag, rolling resistance, and the energy needed to overcome inertia to accelerate the mass of the vehicle and its contents.
[0007] Demand for increasing fuel efficiency and performance has led to the design of ever more streamlined vehicles, pressing close to the limit of practically achievable reductions in aerodynamic drag. Therefore, if further substantial reductions in the energy requirements of vehicles are to be realized in the design of vehicle bodies, improvements should include reductions in the rolling resistance and inertial mass of vehicles.
[0008] Rolling resistance is very largely due to the energy losses caused by flexing of the wheels and deformation of the surface over which the wheels roll (National Research Council of the National Academies 2006). These energy loses are directly proportional to the force pressing the wheels against the surface. That force is due to the weight of the loaded vehicle, modified by any aerodynamic force pressing upward or downward on the vehicle. Therefore, reduction in vehicle mass would reduce rolling resistance as well as inertia. However, efforts to design lighter vehicles have been limited by handling and safety problems at high speeds because reduction in the weight pressing the wheels against the road results in less traction for accelerating, turning, and braking. An aerodynamic system that would provide constant, well-distributed downward thrust at high speeds could yield some energy savings simply by making it possible to design lighter vehicles without compromising safety, maneuverability, and acceleration at high speeds. The reduced inertial mass of such a vehicle would require less power to achieve acceleration comparable to that of current vehicle designs. However, except at low speeds, rolling resistance would not be reduced. Substantially greater energy savings could be achieved by means of an aerodynamic system that adaptively provides varying amounts of vertical thrust (upward or downward) in response to driving circumstances. Upward thrust could be provided during linear cruising. Downward thrust would be provided during maneuvering, turning, accelerating, and braking. Substantial drag in addition to maximum downward thrust could be provided during strong braking and sharp turns at high speeds. A vehicle fitted with such an adaptive aerodynamic system would attain energy savings while also improving handling, safety and performance.
[0009] At least since the 1920's, some innovative racing cars have employed airfoils, known as “wings,” designed to produce downward thrust to increase traction and improve handling at high speeds. In 1928, the rocket-propelled race cars Opel RAK1 and RAK2 had stubby wings mounted on the sides of the body behind the front wheels. In 1956 Michael May added a large wing above the middle of a Porsche Type 550 car. In 1966 Jim Hall mounted a large wing about a meter above the rear axle of his Chaparral 2E racing car. The angle of attack of the wings of both Michael May and Jim Hall could be controlled manually by the driver. Such manually-controlled wings would be impractical for ordinary (non-racing) vehicles, but might have led to the development of automated airfoil systems that would be practical for ordinary street and highway driving, but for the fact that, after each of the innovations of Michael May and Jim Hall, rules were developed to proscribe such continuously variable wings from racing competition. Large fixed wings are mounted above the front and middle of the relatively high power-to-weight-ratio racing cars known as sprint cars.
[0010] In recent years it has become fashionable to install a kind of “wing” on passenger cars, especially on sports cars. On such vehicles, as a general rule, a single wing, cambered to generate down-thrust, is located above and across the rear edge of the upper surface of the car. In this location, well behind the rear wheels, the wing levers upward on the front wheels, reducing the fraction of the front wheels at high speeds. Because most modern automobiles use the front wheels for propulsion a well as for steering and braking, wings in this location diminish automobile performance as well as safety, handling, and fuel efficiency. Additionally, in this location, wings obstruct somewhat the rear view of the driver, further degrading safety. U.S. Pat. No. 5,419,608 issued May 30, 1995 to Takemoto disclosed the positioning of fixed airfoils on the underside of an automobile, between the wheels. In that location, restricted space and turbulent air flow among the steering, suspension and propulsion mechanisms of the vehicle severely constrain achievement of even the limited purposes of such fixed airfoils. As with that patent, designs disclosed in other patents as well as airfoils actually installed on modern cars are generally fixed or may be adjustable, but are not designed to be under continuous adjustment by the driver or by some automatic system such as the vehicle computer. An exception is an air brake U.S. Pat. No. 6,540,282 B2 issued Apr. 1, 2003 to Pettey. This airbrake provided only one (air braking) of the numerous advantages of the present invention. Another exception is a rear end spoiler incorporating an adjustable wing, disclosed in U.S. Pat. No. 7,226,117 issued Jun. 5, 2007 to Preiss, the sole purpose of which is to reduce drag by controlling air flow at the upper rear edge of vehicles of the station wagon or hatchback type. U.S. Pat. No. 7,264,300 issued Sep. 4, 2007 to Hillgaertner discloses a mechanism for adjusting a rear spoiler wing, but the adjustment comprises only raising (deploying) and lowering (stowing) the spoiler wing without any change in angle of attack or shape. U.S. Pat. No. 7,213,870 issued May 8, 2007 to Williams discloses a mechanism for adjusting both the angle of attack and the extent of surface area of a spoiler. However, in all configurations, this spoiler is designed to exert more or less down-thrust behind the rear wheels of the automobile, entailing all the safety, handling and efficiency problems noted above.
SUMMARY OF THE INVENTION
[0011] The primary purpose of the present invention is to use airfoils to improve the safety, efficiency, handling, and performance of vehicles, rectifying the deficiencies and reversing the dangerous effects of airfoils previously and currently employed on vehicles.
[0012] One or more airfoils are positioned substantially above the vehicle wheelbase. They provide down-thrust, well distributed over the vehicle wheels, increasing traction when additional traction is advantageous, such as during acceleration, braking, and turning. They also increase vehicle stability in crosswinds and turbulence. In preferred embodiments of the invention, the airfoils adaptively and automatically change angle of attack and/or camber, providing airbraking as well as strong down-thrust during strong braking and sharp turns, but alternatively providing lift when the vehicle is driven in a straight line at constant speed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of an automobile mounted with two airfoils having fixed camber but variable angle of attack, adjusted to provide moderately strong down-thrust.
[0014] FIG. 2 shows diagrammatic side views of an automobile with two airfoils having variable-reversible camber as well as variable angle of attack, in various positions: (A) angled and cambered to provide lift to reduce rolling friction while cruising in a straight line, (B) angled and cambered to provide moderate down-thrust for maneuvering in traffic at speed, (C) angled to provide maximum down-thrust and turbulent drag during strong braking, (D) angled to assist in securing luggage carried on the roof of the vehicle and to reduce the aerodynamic drag caused by such luggage, and (E) angled to provide maximum shade over the windshield when the vehicle is parked.
[0015] FIG. 3 shows two perspective views of a van (A) with two airfoils, each subdivided into three segments, each segment having independently and automatically controlled variable-reversible camber as well as variable angle of attack, adjusted to counter the tendency of the vehicle to roll over while turning at high speed, and (B) without airfoils, in accordance with prior art.
[0016] FIG. 4 shows three diagrammatic side views of an airfoil revealing one possible mechanism for varying and reversing camber as well as angle of attack: (A) cambered and positioned to provide lift with minimum drag, (B) cambered and positioned to provide down-thrust with minimum drag, and (C) cambered and positioned to provide strong down-thrust with turbulent drag.
[0017] In FIG. 2 and FIG. 4 , some structures are depicted as semitransparent so that structures behind them may be discerned.
DRAWING REFERENCE NUMERALS
[0018] 1 airfoil apparatus
[0019] 2 forward airfoil
[0020] 3 rear airfoil
[0021] 4 airfoil support structure
[0022] 5 endplate
[0023] 6 axle of airfoil
[0024] 7 pylon
[0025] 8 actuator
[0026] 9 pinion gear
[0027] 10 ring gear
[0028] 11 connecting arm
[0029] 12 drive pin
[0030] 13 forward rib plate
[0031] 14 skin
[0032] 15 attachment of forward rib plate to skin
[0033] 16 leading edge roller
[0034] 17 rear rib plate
[0035] 18 attachment of rear rib plate to skin
[0036] 19 trailing edge member
[0037] 20 forward rib plate linkage pin
[0038] 21 axis of rotation of forward rib plate
[0039] 22 rear rib plate linkage pin
[0040] 23 axis of rotation of rear rib plate
[0041] 24 trailing edge stop
[0042] 25 safety spring
[0043] 26 ligature
[0044] 27 fairing
DETAILED DESCRIPTION
[0045] Most of the safety, performance and efficiency advantages of the present invention can be achieved by mounting a single airfoil (not illustrated) above the upper surface of a vehicle, substantially spanning the width of the vehicle and positioned approximately midway between the front and rear axles of the vehicle, or somewhat closer to the front wheels if the front wheels provide steering and propulsion in addition to braking. In the simplest embodiment of the invention, this airfoil has a fixed camber and angle of attack such that the airfoil exerts down-thrust at speed, making it possible for the vehicle to be constructed of low-density materials, such as aluminum and composites, without compromising safety and performance. Such a vehicle yields gains in efficiency due to reduced weight and therefore lowered rolling resistance at low speeds, and because a vehicle having less mass requires less energy to accelerate.
[0046] Additional improvements in efficiency can be achieved by an embodiment of the invention in which the angle of attack of the airfoil is variable and is controlled automatically by the electronic control module of the vehicle, that is, by the vehicle computer. Depending on driving condition, such an airfoil can provide variable amounts of down-thrust, or even lift, reducing rolling resistance when down-thrust is not needed for maneuvering. Such an airfoil may have a fixed shape, with little or no camber. An example of such an airfoil shape is NACA 0012 (Jacobs et al. 1932) used in the wing of the Lockheed C-5 Galaxy aircraft and the rotor blades of helicopters. To minimize the force required to adjust and maintain the angle of attack, the adjustment of the angle of attack may be made by pivoting the airfoil around its aerodynamic center.
[0047] FIG. 1 shows a perspective view of a sedan-type automobile with two such fixed-camber, variable-angle-of-attack airfoils. In this embodiment of the present invention, the airfoil apparatus 1 comprises a forward airfoil 2 and a rear airfoil 3 supported by an airfoil support structure 4 that can serve the additional function of a roof rack for carrying luggage.
[0048] Further efficiency gains may be achieved if the airfoils are provided with variable camber as well as variable angle of attack. Airfoils in the lift-providing configuration have a convex upper surface and a more flat under surface. To minimize drag while providing down-thrust during acceleration and turning, the shape of the airfoils may be adaptively adjusted. Airfoils may be provided with flexible skin and articulating supporting structure such that, as the control system raises the trailing edge of an airfoil, the upper surface flattens and the under surface becomes more convex (see the example mechanism disclosed below).
[0049] FIG. 2 shows schematic side views of a sedan-type automobile equipped with two such airfoils, having variable camber and variable angle of attack, in various configurations selected automatically by the automobile computer or manually, depending on driving or parking conditions. While the vehicle is driven in a straight line at constant cruising speeds, the airfoils are aligned with the airstream flowing over the surface of the vehicle, and shaped to provide lift ( FIG. 2A ), thereby reducing rolling resistance and increasing fuel efficiency. When the steering wheel is turned, or the accelerator or brake pedal is pressed, the vehicle computer automatically adjusts the airfoil to generate down-thrust ( FIG. 2B ), pressing the vehicle downward against the roadway, thus improving the ability of the vehicle to turn, accelerate, or brake without tire slippage. As the brake pedal is further pressed, the airfoil control system raises the trailing edge of the airfoils, increasing the angle of attack and deflecting the airflow upward. In this configuration, the airfoils not only improve the effectiveness of the existing braking system by increasing down-thrust, and hence tire traction; they also augment the conventional brakes by generating turbulent drag, thereby serving as airbrakes ( FIG. 2C ). The control system also instantly increases the deflection of the airfoils when sensors detect any deviation between the course of motion of the vehicle and the orientation and rotation of the wheels, effectively detecting and counteracting (with increased downward thrust) any tendency for the wheels to slip. Deflection of the airfoils is also triggered when vehicle sensors detect any crosswind or turbulence, such as that generated by a passing large truck. Thus the airfoils not only increase the efficiency of the vehicle, they also improve its handling, performance and especially its safety.
[0050] For safety, strong springs instantly return the airfoils to a default, reverse camber position, pushing the vehicle downward ( FIG. 2B ) whenever there is a loss of power or other fault in the airfoil attitude control system while the vehicle is in motion.
[0051] The airfoils and their support structure may also serve as a roof rack, the airfoils rotating to help secure, as well as provide streamlining for items of luggage stowed on the roof ( FIG. 2D ).
[0052] Airfoils may serve the additional function of providing sun shades for the windshield and windows of the vehicle. When the vehicle is parked, the front airfoil may be rotated automatically (or with manual override) to an inverted position, maximizing the shading of the windshield ( FIG. 2E ).
[0053] Panels of photovoltaic cells (not illustrated) may be incorporated into the surfaces of the airfoils, so that while the vehicle is parked, these panels may be automatically oriented by the airfoil control system to optimize the generation of electricity for charging the vehicle battery system. Such a solar charging system would be particularly useful for electric or hybrid vehicles. Brake lights (not illustrated) may be mounted under transparent skin on the underside of the rear airfoil so that when brakes are activated, automatically tilting the airfoil upward, these lights will be exposed and directed toward following traffic.
[0054] The span of each airfoil may be subdivided into two or more independently controllable sections ( FIG. 3 ), enabling the airfoil system to exert greater down-thrust on one side of the vehicle than the other, thereby counteracting the tendency of the vehicle to roll over when turning. The section (or sections) of airfoil nearest the inside of the turn automatically deflects upwards to a greater extent than the outer section ( FIG. 3A ), thus more strongly pressing downward on the wheels situated on the inside of the turn, which otherwise tend to rise during high-speed turns ( FIG. 3B ).
[0055] Airfoils may be provided with endplates 5 or winglets at the lateral ends for the purpose of reducing induced drag caused by wingtip vortices.
[0056] Various methods may be used to adjust adaptively the shape of the airfoil so that it can vary between exerting down-thrust and lift. Conventional aircraft employ ailerons and elevators to accomplish this purpose, at some cost in aerodynamic drag caused by wing surface discontinuities when the ailerons or elevators are angled substantially. Other methods of adjusting and reversing camber are disclosed in U.S. Pat. No. 4,247,066 issued Jan. 27, 1981 to Frost et al., U.S. Pat. No. 4,530,301 issued Jul. 23, 1985 to Latham, U.S. Pat. No. 6,045,096 issued Apr. 4, 2000 to Rinn et al., and U.S. Pat. No. 7,114,456 B2 issued Oct. 3, 2006 to Sohy. One improved means of minimizing drag while controlling both the shape and angle of attack of a vehicle airfoil is shown in FIG. 4 and described below. Other improved methods may be disclosed in subsequent patents.
[0057] The adaptive airfoil that is illustrated in FIG. 4 pivots on an axle 6 that runs approximately along the aerodynamic center of the airfoil, and which transmits aerodynamic forces exerted on the airfoil to the vehicle via pylon 7 . An actuator 8 (which may be an electric stepper motor or a hydraulic or pneumatic driver) drives a pinion gear 9 that drives a ring gear 10 around the axle. Connecting arms 11 link the ring gear 10 via drive pins 12 to a forward rib plate 13 , which is firmly attached 15 to the airfoil skin 14 only along its forward edge, thus effectively forming a semicylindrical leading edge roller 16 that can roll the skin around the leading edge of the airfoil. The connecting arms 11 also link the ring gear 10 to a rear rib plate 17 , which is firmly attached 18 to the skin 14 near the trailing edge of the airfoil forming a tiltable wedge-shaped trailing edge member 19 . The linkage 20 of the connecting arms 11 to the forward rib plate 13 is farther from the skin and closer to the axis of rotation 21 of the forward rib plate than is the linkage 22 of the connecting arms 11 relative to the skin and the axis of rotation 23 of the rear rib plate 17 . Therefore, rotation of the leading edge roller 16 is relatively amplified, causing the leading edge roller to roll the skin around the leading edge farther than the skin is moved by the trailing edge member 19 as it is tilted by the rotation of the ring gear 10 . This results in tightening and flattening the lower skin and bulging the upper skin ( FIG. 4A ) or visa versa ( FIG. 4B ), depending on the direction of rotation of the ring gear 10 . After rotation of the ring gear maximally flattens the upper surface of the airfoil, further rotation in the same direction tilts the airfoil, raising its trailing edge ( FIG. 4C ), deflecting the airstream upward and increasing turbulent drag as well as downward thrust. Rotation of the ring gear 10 in the opposite direction lowers the trailing edge of the airfoil until it comes down against a trailing edge stop 24 . Further rotation of the ring gear 10 in that direction bulges the upper surface of the airfoil, changing its shape to a lift-generating configuration ( FIG. 4A ). If any fault causes failure of the control system when the airfoil is in the lift configuration ( FIG. 4A ), a strong spring 25 instantly returns the airfoil to a default down-thrust configuration ( FIG. 4B ) for safety.
[0058] A number of additional forward and rear rib plates (not illustrated) are distributed along the length of the airfoil, passively supporting the leading and trailing edges of the airfoil, moving in compliance with the attitude control exerted by the control mechanisms at the ends of the airfoil span or segment. Where the skin is unsupported by rib plates, the skin may be strengthened by a latticework of skin stringers (not illustrated), which assist in transferring upward or downward force from the surface of the airfoil to the vehicle via leading edge roller 16 , trailing edge member 19 , connecting arms 11 , ring gear 10 , and pylon 7 . In areas of the airfoil where the skin is not attached to rib plates, the skin may be supported by a latticework of stringers on the inner surface of the skin. In such areas, ligatures may connect the skin on opposite surfaces of the airfoil, allowing opposite surfaces to move freely in opposite chordwise directions while not moving apart under aerodynamic force. Ligatures may be straps 26 that articulate with stringers or other protrusions from the skin, or ligatures may be strands or span-wise septa that are sufficiently flexible that no articulations are needed. Pylon 7 and actuator 8 are enclosed in a light-weight, streamlined fairing 27 . A control mechanism such as depicted in FIG. 4 may be provided on each of the two lateral ends of the span or central segment of an airfoil. If the airfoil is divided into three separately-articulating segments, as in FIG. 3A , then each pylon may support two actuators, one to control an outboard segment, and one to share (with the other side) in controlling the central segment.
[0059] Although the figures and description above contain many specific details, these merely provide illustrations and examples of some embodiments of this invention. Various other manifestations, variations, and modifications are possible within its scope. For example, in FIG. 4 , for simplicity of illustration, rib plates are shown as solid plates, whereas to save weight, these plates may be perforated by a series of holes. As with this example, the particular arrangements herein disclosed are meant to be illustrative only and are not to be construed as limiting the scope of the invention, which includes any and all applications, variations, modifications and equivalents within the spirit and scope of the appended claims. | One or more airfoils, mounted above the upper surface of an automobile or other vehicle, optionally with variable angle of attack and/or camber, under the continuous automatic control of the vehicle's computer (electronic control module), for the purpose of providing well-distributed vertical thrust with minimum drag, or strong downward thrust with drag, depending on driving circumstances, thereby increasing the safety of the vehicle as well as improving its efficiency and performance. | 1 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority benefit of U.S. Provisional Patent Application Ser. No. 61/806,335, filed on Mar. 28, 2013 and U.S. Provisional Patent Application Ser. No. 61/618,361 filed on Mar. 30, 2012, which are incorporated by reference herein in their entireties for all purposes.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] This invention was made with Government support under Grant No. DA028902, awarded by the National Institutes of Health. The Government has certain rights in this invention.
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] Methamphetamine addicts show profound signs of accelerated aging, but the mechanism underlying this phenomenon is still unknown. The use of the street drug, methamphetamine, has been shown to promote mtDNA deletions and increase oxidative damage, two parameters which have been shown to have an inverse relationship with lifespan in mammals [1-3]. Additional signs of accelerated aging in methamphetamine users include premature myocardial infarctions, atherosclerosis, cardiomyopathy and decline in kidney function [4]. Most practitioners note a much older appearance in patients using methamphetamine after only a few years of use, thus we set out to identify molecular mechanisms that may be involved in methamphetamine induced accelerate aging.
[0005] To treat intoxication by amphetamines, the following drugs are currently used: benzodiazepines, dopamine-receptor antagonists (e.g., roperidol or haloperidol, butyrophenones) and antipsychotics (e.g., olanzapine and risperidone). However, these drugs act mainly on the central nervous system and do not target peripheral tissues that undergo systemic inflammatory syndrome, senescence and multi-organ failure as consequence of amphetamine toxicity. Ceramide has long been implicated as a molecular modulator of aging and longevity [6]. The first evidence of this was seen with the LAG1 mutants and further supported by finding of the role of ceramide in inducing cellular senescence [10]. Here, we report that methamphetamine acts via ceramide to induce cellular senescence and increased chronological aging and that these adverse effects of amphetamines can be treated by manipulation of ceramide metabolism and also apoptosis. Accordingly, this invention provides new methods for treating and diagnosing methamphetamine-induced systemic inflammatory syndrome, senescence and organ failure.
BRIEF SUMMARY OF THE INVENTION
[0006] The invention presented herein provides a method to decrease the toxic effects and morbidity (e.g., accelerated senescence), and prevent complications (e.g., organ failure, multi-organ failure, death) that arise from abuse of amphetamine-type drugs. In this aspect, the present invention discloses the use of inhibitors of de-novo ceramide biosynthesis (e.g., L-cycloserine) or ceramide actions (e.g. thalidomide) as agents for alleviating the systemic toxicity associated with the use of amphetamines/amphetamine-type drugs. Oral, topical, intramuscular or intravenous administration of such inhibitors attenuates injuries induced by amphetamines, reducing their toxic effects (e.g., accelerated senescence) and complications (e.g., multi-organ failure).
[0007] Accordingly, in this first aspect, the invention provides a method of treating an amphetamine-type drug-induced toxicity, said method comprising administering to the subject in need thereof an effective amount of modulator of ceramide metabolism or apoptosis which counters an effect of the drug on ceramide levels or ceramide metabolism or apoptosis. In some embodiments, the treating reduces, prevents or delays the development of an amphetamine-type drug toxicity selected from induced senescence or organ failure in the subject. In still further embodiments of any of the above, the toxicity is mediated by an amphetamine-type drug-induced increased ceramide signaling in apoptosis. The amphetamine-type drug may also be administered to the subject before or after the modulator and at a therapeutically effective time with respect to administering the amphetamine-type drug to the subject. The modulator can be administered for instance from about 15 minutes to about 24 hours before administering the amphetamine-type drug, about 2 to 4 hours before administering the amphetamine-type drug, or at about the same time the amphetamine-type drug. The modulator can be administered well after the amphetamine-type drug and for as long as its adverse effects on health and/or ceramide levels would linger. The modulator can be a ceramide synthesis inhibitor and/or an antisense nucleic acid, a ribozyme, a triplex-forming oligonucleotide, a siRNA, a probe, a primer, an antibody or a combination thereof. In some embodiments, an agent that inhibits ceramide biosynthesis targets at least one ceramide-biosynthetic enzyme selected from the group consisting of a sphingomyelinase, serine palmitoyltransferase, 3-ketosphinganine reductase, ceramide synthase, dihydroceramide desaturase, and combinations thereof. In some further embodiments of the above, the modulator can be FB1, D609, myriocin, cyclosporine, thalidomide, lenalidomide and combinations thereof. In still other embodiments, the modulator is adalimumab, golimumab, infliximab, natalizumab, etanercept, Certolizumab pegol, or Pegsunercept. In other embodiments of any of the above, toxicity is atherosclerosis, cardiomyopathy, cardiac infarction, cardiac insufficiency, or a decline in kidney function. In yet further embodiments of any of the above, the amphetamine-type drug is amphetamine, dextroamphetamine, ephedrine, pseudoephedrine, methamphetamine or a pharmaceutically acceptable salts thereof.
[0008] Further, the invention provides a method for monitoring with ease, low-invasiveness and low-cost peripheral biomarkers of amphetamine-type drug toxicity (i.e., ceramides), which could find potential applications in the following areas: (1) prophylactic and diagnostic screening in a large population of subjects; (2) leading to a more accurate diagnostic tool, especially if used in combination with other clinical parameters; (3) assessing drug response in asymptomatic patients; (4) serving as a secondary outcome measure in clinical trials of symptomatic patients, and (5) deciding if further development of a treatment should be stopped if not likely to be effective; (6) screening compounds for activity in modulating amphetamine toxicity. Further, we disclose a new set of lipid biomarkers ceramide species including, but not limited to, Cer(16:0), Cer(16:1), Cer(18:0), Cer(20:0), Cer(20:1), Cer(24:1); and dihydroceramide species including, but not limited to, DHCer(16:0), DHCer(16:1), DHCer(18:0), DHCer(20:0), DHCer(20:1), DH Cer(24:1) which can be monitored to diagnose and monitor the toxicity induced by amphetamines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 . Lipidome-wide profiles in various tissues of rats self-administering D-meth. (a) Heat-map showing changes in the levels of lipid classes (rows) in rats exposed to methamphetamine for 8 days, compared to control rats receiving saline injections. (b) Heat-map showing changes in the levels of various ceramide species (rows) in rats self-administering methamphetamine relative to control rats; columns show data from individual animals. (c-g) Levels of (c) ceramide, (d) dihydroceramide (DHC), (e) sphingomyelin (SM), (f) dihydrosphingomyelin (DHSM), and (g) mRNAs encoding for enzymes of de novo ceramide biosynthesis in skeletal muscle (vastus lateralis); control (C), open bars; rats self-administering methamphetamine (M), filled bars. DH-, dihydro-; P-, phosphatidyl-; serine palmitoyl transferase, SPT; ceramide synthase, CerS. (h) Dose-dependent effects of involuntary acute administration of methamphetamine on ceramide (d18:1/16:0) levels in rat skeletal muscle.
[0010] FIG. 2 . Effects of methamphetamine on de novo ceramide biosynthesis in primary mouse embryonic fibroblasts (MEF). (a) Concentration dependence of the effect of methamphetamine on ceramide (d18:1/16:0) levels. (b) Effects of vehicle, d-methamphetamine, 1-methamphetamine, d-amphetamine, and cocaine on ceramide (d18:1/16:0) levels. (c) mRNA levels of the genes involved de novo ceramide biosynthesis. (d-f) Lipid analyses of isolated mitochondria from MEF treated with methamphetamine (1 mM). (d) short chain ceramide (d18:1/16:0); (e) long chain ceramide (d18:1/24:0; (f) long chain ceramide d18:1/24:1. (g-i) Effects of ceramide synthesis inhibitors on methamphetamine induced synthesis of ceramides n primary MEF. (g) 50 μM Fumonisin B1 (FB1), a potent inhibitor of CerS; (h) 30 μM L-cycloserine (L-CS) an inhibitor of SPT; (1) 10 μM myrocin.
[0011] FIG. 3 . Effects of methamphetamine on cell senescence in MEF cells. MEFs were treated with methamphetamine (1 mM) for 48 h and senescence associated β-galactosidase (SA-β-gal) levels were measured. (a) Effects of methamphetamine exposure on the number of SA-β-gal positive cells from passage 1 to 5 compared to vehicle-treated cells. (b) Morphological changes typical of senescent phenotype. (c, d) Effects of methamphetamine treatment on measures of replicative capacity. (c) DNA synthesis was evaluated using [ 3 H]-thymidine binding. (d) number of population doublings compared to control cells. (e) Ceramide levels over passages 1 to 5; (f) CerS5 levels over passages 1 to 5. (g, h) Effects of blockage of ceramide synthesis and/or ceramide substitution on methamphetamine induced senescence. MEFs were treated with methamphetamine (1 mM) in the presence of structurally distinct inhibitors of de novo ceramide biosynthesis. Effect of treatments with L-CS (30 μM) or FB1 (50 μM) and/or ceramide analog C8 on (g) SA-β-gal expression and (h) the percent of senescent cells.
[0012] FIG. 4 . (a-d). Effects of methamphetamine on the transcription of inflammatory cytokines and its antagonism by L-CS. (a). IL-6; (b). TNF-alpha; (c) cyclin dependent kinases p21 and (d) p53. (e). Effects of methamphetamine on NF-KB activation. MEFs treated with methamphetamine (1 mM) were harvested 24 hrs later and subjected to chromatin immunoprecipitation assays to assess recruitment of NF-kB subunit p65 to the TNF-α promoter. (f). Effects of methamphetamine and TNF-α treatment on ceramide (d18:1/16:0) levels. (g-i). Effects of three NF-κB inhibitors, (g). thalidomide; (b) 5′-aminosalicyclic acid and (i) JSH-23 on methamphetamine induced de novo ceramide (d18:1/16:0) biosynthesis.
[0013] FIG. 5 . (a-h) Effects of methamphetamine self-administration or acute d-methamphetamine treatment on the transcription of age-related genes. Self-administration: (a) TNF-α, (b) IL-6, (c) p21, and (d) p53. Acute d-methamphetamine treatment (e) TNF-α, (f) IL-6, (g) p21, and (h) p53. (i-k) Effects of blocking ceramide biosynthesis in mice administered methamphetamine alone or methamphetamine in combination with the SPT inhibitor L-CS on (i) ceramide content; (j) the expression of IL-6 mRNA; and (k) the expression of p21 mRNA. (l-o) Effects of L-cycloserine on (l) ceramide levels; (m) IL-6 expression; (n) p21 expression; and (o) body weight in mice self-administering methamphetamine for 8 days with or without a co-treatment with L-cycloserine starting on Day 4 of the self-administration.
[0014] FIG. 6 . Methamphetamine self-administration in rats closely mimics the voluntary component of human drug exposure, and is characterized by high rates of drug intake ( FIG. 1 ). (a) Intake of drug (mg/kg) per session. (b) Number of active hole responses vs. non-active hole responses.
[0015] FIG. 7 . Effect of L-CS (L-cycloserine) on methamphetamine induced increases in ceramide in isolated mitochondria from primary MEF. (a) Cer (d18:1/16:0); (b) Cer (d18:1/24:0); (c) Cer (d18:1/24:1). Values are in pmol/mg of protein.
[0016] FIG. 8 . Effect of L-CS (L-cycloserine) on methamphetamine self-administration. (a) Intake of methamphetamine (mg/kg) per session. (b) Number of active hole responses vs. non-active hole responses.
[0017] FIG. 9 . Role of cytochrome P450 (CYP) in methamphetamine-induced ceramide production. (a,b) Effects of CYP inhibitor clotrimazole (CLO) on (a) cell-associated methamphetamine content and (b) ceramide levels. Primary MEF cultures were treated with methamphetamine (M, 1 mM) for 24 h and rinsed before extraction and quantification of methamphetamine by LC/MS. (e) Effects of CYP inhibitors on ceramide levels: SKF-525A (SKF, 10 μM), cimetidine (CIM, 10 μM), quinidine (QUI, 10 μM) and HET-0016 (HET, 10 μM). (d-e) Time-course of the effects of (d) methamphetamine (mM) and (e) 4-hydroxy-D-methamphetamine (4-OH, 1 mM) on ROS production. (f-g) Effects of (f) clotrimazole and (g) SKF-525A, cimetidine, quinidine and HET-0016 on ROS production. Values are expressed as mean±s.e.m. of three separate experiments, each performed in triplicate. ANOVA followed by Bonferroni post hoc test: ***P<0.001 vs vehicle; s P<0.05, SSS P<0.001 vs methamphetamine.
[0018] FIG. 10 . Time-course of hydrogen peroxideproduction in primary MEF cultures treated with D-methamphetamine or L-methamphetamine (each at 1 mM). ***P<0.01, two-tailed Student's t test.
[0019] FIG. 11 . Effects of methamphetamine self-administration, L-cycloserine (L-CS) treatment or combination of methamphetamine plus L-CS on food intake. *P<0.05, **P<0.01, ***P<0.001, ANOVA followed by Bonferroni post hoc test.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In the present study, we used an unbiased lipidomic approach to identify the mechanism behind amphetamine-type drugs (e.g., methamphetamine)-induced aging and senescence. Our results have implicated that alterations in ceramide biosynthesis are responsible for the evolution of many pathologies attributed to amphetamine-type drug use (e.g., methamphetamine use) and provide the rational for development of novel therapeutic interventions. More specifically we found that alterations in de novo ceramide metabolism, caused by methamphetamine, lead to drug-induced senescence. Although, the aging consequences of methamphetamine addiction in people were phenotypically obvious, not much was known about the molecular mechanisms responsible for this process. We have shown that methamphetamine can accelerate aging in vivo and in vitro by increasing the rate at which cells senescence and by inducing a state of chronic systemic inflammation two robust markers of aging. Of even more significance is the fact that the induction of senescence and inflammation induced peripherally by methamphetamine use is dependent on increased cellular ceramide contents and that by blocking the induction of ceramide biosynthesis with L-CS we are able to ameliorate the premature aging consequences of amphetamine-type drug use (e.g., methamphetamine use).
[0021] Accordingly, this invention provides for the use of modulators of ceramide biosynthesis or ceramide action, to ameliorate the toxicity and systemic inflammation associated with abuse (acute or chronic) or other uses (acute or chronic) of amphetamine-type drugs. Pharmacological modulation of drug-induced toxicity and systemic inflammation is a highly desirable therapeutic intervention. Furthermore, we describe a set of biological measurements from easily accessible human tissues (e.g. blood), which are strong indicators or predictors of systemic toxicity associated with abuse of amphetamine-type drugs. Early detection of amphetamine-type drug-induced toxicity is highly desirable to monitor the progression of the amphetamine-type drug toxicity, to assess responses to drug treatments and improve therapeutic intervention.
[0022] We identified select lipid species that are altered in the dorsal striatum of male Sprague-Dawley rats treated with a dose of methamphetamine (2×10 mg/kg; intraperitoneal injection), which produces neurotoxicity in rats. These alterations reveal previously unknown and potentially important effects of methamphetamine on the rat brain lipid interactome. Most notably, we found that methamphetamine administration is followed by a marked increase in the striatal levels of various ceramide species, which are known to be involved in cell aging and apoptotic cell death. RT-PCR analyses showed that the expression of mRNA transcripts encoding for ceramide synthases isoforms were markedly and selectively elevated in the dorsal striatum of methamphetamine-treated rats, compared to saline-treated controls. These results indicate that methamphetamine enhances de novo ceramide biosynthesis in the dorsal striatum, a brain region that is highly sensitive to methamphetamine toxicity. Although drug addiction is conceptualized as a chronic disease of the brain, exposure to drugs can also affect a variety of extra-neural tissues. In particular, amphetamine-derived stimulant drugs such as methamphetamine are known to induce disruptive effects on mitochondrial function, which are also evident in the liver. These data suggest that peripheral tissues might provide a source of biomarkers for exposure to amphetamines. No information is currently available, however, about the possible association of amphetamine use with peripheral lipid dysfunction. Encouraged by the results obtained in the brain, we conducted lipidomic analyses of liver tissue from rats exposed to methamphetamine (2×10 mg/kg; intraperitoneal injection). The analyses revealed marked increases in ceramide levels in various peripheral tissues including plasma, skeletal muscle, heart, liver and skin. Our choice of tissues is based on two criteria: (i) existence of metabolic links with lipid pools of the brain; and (ii) ease of access for potential biomarker collection. Thus, we found that exposure to a toxic dose of methamphetamine alters lipid profiles not only in the brain, but also in peripheral tissues that are vulnerable to the toxic effects of this drug. Notably, low doses (i.e., non-toxic) of methamphetamine did not induce any changes in ceramide species. Our data suggest that peripheral tissues provide a source of biomarkers for abuse of amphetamines and consequent toxicity. Additionally, our data revealed that the inhibition of the de-novo ceramide biosynthesis (e.g.; by L-cycloserine) or ceramide actions (e.g., thalidomide) is able to block the toxic effects induced by amphetamine. In particular, these drugs prevent amphetamine-induced inflammation and senescence (measured by beta-galactosidase assay, crystal violet morphology, and gene expression of pro-inflammatory and pro-senescence genes). This evidence corroborates the use of the de-novo ceramide biosynthesis (e.g., by L-cycloserine) or actions (e.g., thalidomide) to decrease amphetamine toxicity.
[0023] Oral, topical, intramuscular or intravenous administration of inhibitors of de-novo ceramide biosynthesis or inhibitors of ceramide action attenuates injuries induced by amphetamine-type drugs, reducing the toxic effects and morbidity and prevent complications (e.g., multi-organ failure).
Amphetamine-Type Drugs
[0024] Amphetamine-type drugs act as central nervous system stimulants and have many therapeutic uses as wells as much potential for abuse. These drugs generally possess an phenyethylamine core. Amphetamine-type drugs according to the invention include amphetamine, its dextro and levo racemates, dextroamphetamine, ephedrine, pseudoephedrine, methamphetamine, methylphenidate and their salts (e.g., amphetamine sulphate, dextroamphetamine and methamphetamine). These drugs may also be co-formulated in the pharmaceutical compositions according to the invention.
[0000]
Amphetamine-Type Drug Induced Toxicity
[0025] Amphetamine-type drug induced toxicities include adverse effects in the Central and Peripheral Nervous Systems, and non-nervous system organs such as the heart, kidneys, circulatory system, skin, pancreas, and lungs. Adverse effects include, but are not limited to, early cell death and loss of function for the affected organs. Adverse effects include, but are not limited to, cardiac insufficiency, cardiomyopathy, heart failure, atherosclerosis, reduced kidney function or kidney failure, inflammation, and type 2 diabetes. Adverse effects are dose-related, increase with increasing dose, and can result from acute and/or chronic administration of the amphetamine drug(s).
Modulators/Agents/Compounds for Use in Treating Amphetamine-Type Drug Induced Toxicity According to the Invention.
[0026] Ceramide acts as a second messenger in the apoptotic cascade. Diverse cytokine receptors and environmental stresses utilize ceramide to signal activation of apoptosis. (see, Haimovitz-Friedman et al., British Medical Bulletin 53(3):539-553 (1997); and see also, Bikman et al., Journal of Clinical Investigation 121(11):4222-4230 (2011), each of which is incorporated by reference with respect to the modulators which reduce ceramide levels, functional elements of the apoptotic cascade which comprise a ceramide moiety, modulators which reduce the apoptotic cascade, and/or favor anabolism over catabolism as disclosed therein). Accordingly, reducing ceramide levels and/or other elements of the apoptotic cascade is contemplated to treat amphetamine-type drug (e.g., methamphetamine)-induced senescence and aging.
[0027] Modulators of apoptosis for use according to the invention further include the TNF alpha inhibitors adalimumab, golimumab, infliximab, natalizumab, etanercept, Certolizumab pegol, and Pegsunercept.
[0028] Modulators of ceramide metabolism for use according to the present invention also include those agents disclosed in U.S. Patent pplication No. 20030096022, published May 22, 2003, corresponding to U.S. patent application Ser. No. 10/029,372 filed on Dec. 21, 2001 and incorporated herein by reference in its entirety with respect to such agents and their use in reducing ceramide levels or apoptosis. These include inhibitors of reactions that yield metabolic precursors of ceramide, which is a metabolic precursor of SPH and S-1-P. Enzymes that catalyze such reactions include but are not limited to serine palmitoyl transferase (SPT) which catalyzes the production of 3-ketosphinganine, a precursor in ceramide synthesis (see, Methods in Enzymology, 311:1-9, 1999). Inhibitors of serine palmitoyl transferase include but are not limited to viridiofungins (e.g., Australifungin, Viridiofungins, Rustmicin, and Khafrefungin) (see, Mandala et al., J. Antibiot. (Tokyo) 50:339-343, 1997; and Mandala et al., Methods in Enzymology, 311:335-348, 1999), lipoxamycin (Mandala et al., J. Antibiot. (Tokyo) 47:376-379, 1994), and sphingofungins E and F (Horn et al., J. Antibiot. (Tokyo) 45:1692-1696, 1992). Other SPT inhibitors are disclosed by Hanada et al., Biochemical Pharmacology, 59:1211-1216, 2000; Zweerink et al., The Journal of Biological Chemistry, 267:25032-25038, 1992; and Riley ct al., Methods in Enzymology, 311:348-361, 1999). 3-Ketosphiganine Reductase catalyzes the production of sphinganine (dihydrosphingosine), a precursor in ceramide synthesis. See Beeler et al., The Journal of Biological Chemistry, 273:30688-30694, 1998. Dihydroceramide synthase catalyzes the acetylation of dihydrosphingosine to produce dihydroceramide, a direct precursor of ceramide. Inhibitors of ceramide synthase include, but are not limited to, Fumonisin B1 (a fungal toxin) (Merrill et al., J. Lipid Res. 26:215-234A, 1993; Wang et al., Adv. Lipid Res. 26:215-234, 1993; Tsunoda et al., J. Biochem. Mol. Toxicol. 12:281-289, 1998); derivatives of fumonisin (Humpf et al., J. Biol. Chem. 273:19060-19064, 1998); alternaria toxins (Mandala et al., J. Antibiot. 48:349-356, 1995); viridiofungins (Merrill et al., J. Lipid Res. 26:215-234A, 1993); astralifungins (Mandala et al., J. Antibiot. 48:349-356, 1995; Furneisen et al., Biochim. Biophys. Acta. 1484:71-82, 2000); and D-erythro-N-myristoyl 2-amino-1-phenylpropanol (Hunnan, Science 274:1855-1859, 1996). Agents which stimulate the destruction of metabolic precursors of ceramide are also contemplated for use according to the present invention. Enzymes that catalyze such reactions include but are not limited, sphingomyelin deacylase which catalyzes the production of sphingoylphosphorylcholine from sphingomyelin.
[0029] Additional modulators of ceramide levels for use according to the present invention are disclosed in U.S. Patent Publication No. 20050182020, published on Aug. 18, 2005, corresponding to U.S. patent application Ser. No. 10/712,684, filed on Nov. 14, 2003 and which is incorporated herein by reference with respect to such modulators (a) myriocin; (b) cycloserine; (c) Fumonisin B1; (d) PPMP; (e) compound D609; (f) methylthiodihydroceramide; (g) propanolol; and (h) resvaratrol. Additional deoxynojirimycin derivative modulators for use according to the invention are disclosed in U.S. Patent Publication No. 20070135487, published on Jun. 14, 2007, and corresponding to U.S. patent application Ser. No. 10/595,584, filed on Oct. 29, 2004, and incorporated herein by reference with respect to such derivatives disclosed therein and their methods of administration. Suitable deoxynojirimycin derivatives for use according to the present invention are disclosed in EP 947, EP 193770, U.S. Pat. No. 4,940,705, EP 481950, WO 95/22975, WO 00/33843, WO 01/07078 which are each hereby incorporated by reference with respect to such subject matter.
[0030] As taught in U.S. Patent Publication No. 20080241121, published Oct. 2, 2008, and corresponding to U.S. patent application Ser. No. 11/695,519, filed Apr. 2, 2007, and incorporated by reference in its entirety with respect to the ceramide modulating agents disclosed therein, a number of other agents can be used to reduce ceramide levels. By way of example inhibitors of SPT include, but are not limited to, the sphingo-fungins, lipoxamycin, myriocin, L-cycloserine and β-chloro-L-alanine, as well as the class of Viridiofungins. Ceramide synthase acylates the amino group of sphingosine, sphinganine and other sphingoid bases using acyl CoA esters. Inhibitors of this enzyme include, for example, the Fumonisins, the related AAL-toxin, and australifungins. The Fumonisins family of inhibitors are produced by Fusarium verticillioides and includes Fumonisin B1 (FB1). The N-acylated forms of FB1 are potent ceramide synthase inhibitors as the O-deacylated form is less potent. Of the N-acylated forms of FB1, the erythro-, threo-2-amino-3-hydroxy-, and stereoisomers of 2-amino-3,5-dihydroxyoctadecanes are contemplated. Australifungins from the organism Sporomiella australlis are also contemplated for use according to the invention as they inhibit ceramide synthase as well. Contemplated inhibitors of dihydroceramide desaturase include but are not limited to the cyclopropene-containing sphingolipid GT11, as well as a-ketoamide (GT85, GT98, GT99), urea (GT55) and thiourea (GT77) analogs of this molecule. Sphingomyelin pathway inhibitors are also contemplated for use according to the invention. Sphingomyelin is hydrolyzed by sphingomyelinase to yield phosphorylcholine and ceramide. The physiological inhibitors of sphingomyelinase are also contemplated for use according to the invention and include L-alpha-phosphatidyl-D-myo-inositol-3,5-bisphosphate, L-alpha-phosphatidyl-D-myo-inositol-3,4,5-triphosphate. Ceramide-1-phosphate and sphingosine-1-phosphate are also so contemplated. Glutathione is another agent for use according to the methods of the invention. Compounds, which are structurally unrelated to sphingomyelin, but function as sphingomyelinase inhibitors can also be used according to the invention. These compounds include desipramine, imipramine, SR33557, (3-carbazol-9-yl-propyl)-[2-(3,4-dimethoxy-phenyl)-ethyl)-methyl-amine (NB6), Hexanoic acid (2-cyclo-pent-1-enyl-2-hydroxy-1-hydroxy-methyl-ethyl)-amide (NB12) C11AG and GW4869. Compound SR33557 is a specific acid sphingomyelinase inhibitor. Other inhibitors for use according to the invention which are derived from natural sources include Scyphostatin, Macquarimicin A, and Alutenusin, Chlorogentisylquinone, and Manumycin A, and alpha-Mangostin. Scyphostatin analogs can also be used according to the invention (e.g., spiroepoxide 1, Scyphostatin and Manumycin A sphingolactones). Sphingomyelin analogs with inhibitory proprieties are also contemplated for use according to the invention (e.g., 3-O-methylsphingomyelin, and 3-O-ethylsphingomyelin).
[0031] The following compounds which have been shown to reduce ceramide by inhibition can also be used according to the invention: [3 (10,11-Dihydro-dibenzo[b,f]azepin-5-yl)-N-propyl]-[2 (3,4-dimethoxyphenyl)-ethyl]methylamin, [3 (10,11-Dihydro-dibenzo[b,f]azepin-5-yl)-N-propyl]-[2 (4-methoxyphenyl)-ethyl]methylamin, [2 (3,4-Dimethoxyphenyl)-ethyl]-[3 (2-chlorphenothiazin-10-yl)-N-propyl]-methylamin, [2 (4-Methoxyphenyl)-ethyl]-[3 (2-chlorphenothiazin-10-yl)-N-propyl]-methylamin, [3 (Carbazol-9-yl)-N-propyl]-[2 (3,4-dimethoxyphenyl)-ethyl]methylamin, [3 (Carbazol-9-yl)-N-propyl]-[2 (4-methoxyphenyl)-ethyl]methylamin, [2 (3,4-Dimethoxyphenyl)-ethyl]-[2 (phenothiazin-10-yl)-N-ethyl]-methylamin, [2 (4-Methoxyphenyl)-ethyl]-[2 (phenothiazin-10-yl)-N-ethyl]-methylamin, [(3,4-Dimethoxyphenyl)-acetyl]-[3 (2-chlorphenothiazin-10-yl)-N-propyl]-methylamin, n (1-naphthyl)-N′[2 (3,4-dimethoxyphenyl)-ethyl]-ethyl diamine, n (1-naphthyl)-N[2 (4-methoxyphenyl)-ethyl]-ethyl diamine, n [2 (3,4-Dimethoxyphenyl)-ethyl]-n [1-naphthylmethyl]amine, n [2 (4-Methoxyphenyl)-ethyl]-n [1-naphthylmethyl]amine, [3 (10.11-Dihydro dibenzo[b,f]azepin-5-yl)-N-propyl]-[(4-methoxyphenyl)-acetyl]-methylamin, [2 (10,11-Dihydro-dibenzo[b, f]azepin-5-yl)-N-ethyl]-[2 (3,4-dimethoxyphenyl)-ethyl]methylamin, [2 (10,11-Dihydro-dibenzo[b,f]azepin-5-yl)-N-ethyl]-[2 (4-methoxyphenyl)-ethyl]-methylamin, [2 (10,11-Dihydro-dibenzo[b,f]azepin-5-yl)-N-ethyl]-[(4-methoxyphenyl)-acety-1]-methylamin, n [2 (Carbazol-9-yl)-N-ethyl]-N′[2 (4-methoxyphenyl)-ethyl]piperazin, 1 [2 (Carbazol-9-yl)-N-ethyl]-4[2 (4-methoxyphenyl)-ethyl]-3,5-dimethylpiperazin, [2 (4-Methoxyphenyl)-ethyl]-[3 (phenoxazin-10-yl)-N-propyl]-methylamin, [3 (5,6,11,12-Tetrahydrodibenzo[b,f]azocin)-N-propyl]-[3 (4-methoxyphenyl)-propyl]methylamin, n (5H-Dibenzo [A, D]cycloheptan-5-yl)-N′[2 (4-methoxyphenyl)-ethyl]-propylene diamine and [2 (Carbazol-9-yl)-N-ethyl]-[2(4-methoyphenyl)-methoxyphenyl)-ethyl]methylamine, as described in WO2000 EP04738 20000524 herein incorporated by reference. L-carnitine id also contemplated for use according to the invention (see, U.S. Pat. No. 6,114,385, herein incorporated by reference). Other suitable compounds include silymarin, 1-phenyl-2-decanoylaminon-3-morpholino-1-propanol, 1-phenyl-2-hexadecanoylaminon-3-pyrrolidino-1-propanol, Scyphostatin, L-carnitine, glutathione, and human milk bile salt-stimulated lipase (see, U.S. Pat. No. 6,663,850 herein incorporated by reference).
[0032] In some preferred embodiments, ceramide levels may be reduced by myriocin, cycloserine, Fumonisin B tyclodecan-9-xanthogenate (D609), PPMP, methylthiodihydroceramide, propanolol, resveratrol and other agents as described in U.S. Patent Application Publication No. 20050182020 or U.S. Patent Application Publication No. 20100086543, published on Apr. 8, 2010, or U.S. Patent Application Publication No. 20100204162, published on Aug. 12, 2010, all of which are herein incorporated by reference particularly with respect to the ceramide modulators of various kinds (including nucleic acids, anti-sense nucleic acids, ribozymes, anti-sense RNAs, and siRNAs, antibodies which target enzymes involved in ceramide biosynthesis) disclosed therein. Agents comprised of polypeptides sequences have also been shown to reduce ceramide levels as described in U.S. Pat. No. 7,037,700 and herein incorporated by reference.
[0033] Other ceramide modulators for use according to the invention can also include the following SPT inhibitors:
[0000]
[0000] As well as the following compounds:
[0000]
[0034] Also contemplated for use according to the present invention are deoxy-sphingolipid blockers. These compounds are compounds or substances capable of inhibiting SPT or capable of competing with the natural reactants leading to deoxy-sphingolipids in the SPT pathway (e.g., L-alanine and glycine). (See, PCT Patent Application Publication No. WO2011/104298 which is incorporated herein by reference in its entirety and particularly with respect to such agents). Blockers for use according to the invention, for instance, are L- and D-serine, D-alanine and analogues thereof (see, Kayoko Kanda et al. (Journal of General Microbiology (1988), 134, 2747-2755), Woese Cr. et al (J Bacteriol. 1958 December 76(6): 578-88) and Yasuda Y. et al (Microbiol. Immunol. 1985; 29(3): 229-41). Accordingly, blockers for use according to the invention include L-serine, D-serine, D-alanine, D-threonine, O-methyl-DL-sehne, sphingofungin B, cycloserine, myriocin, β-chloroalanine, lipoxamycin and viridofungin A, and combinations thereof. Additionally, nucleic acids, anti-sense nucleic acids, ribozymes, anti-sense RNAs, and siRNAs, antibodies which target enzymes involved in ceramide biosynthesis are also contemplated as modulators. 3. The composition of claim 1 comprising at least one first substance capable of competing with L-alanine and glycine in the reaction catalysed by SPT and at least one second substance capable of inhibiting serine-palmitoyltransferase (SPT).
[0035] This list is non-exhaustive. One of ordinary skill in the art would appreciate that analogs or fragments of the inhibitors included herein would similarly be inhibitory. In addition to the agents described herein are agents that decrease ceramide pathway metabolic enzymes, or increase ceramide catabolic enzymes, including but not limited to agents, which modify, or regulate transcriptional or translational activity or which otherwise degrade, inactivate, or protect theses enzymes.
[0036] The “subject” to be treated includes any animal, including, but not limited to, mammals (e.g., rat, mouse, cat, dog) including humans to which a treatment is to be given. “Mammal” includes humans and non-human mammals (e.g., dogs, cats, rabbits, cattle, horses, sheep, goats, swine, rats, mice, and primates).
[0037] The term “effective amount” means a dosage sufficient to produce a given result with respect to the indicated disorder or condition. In the case of therapeutic methods, the result may comprise a subjective or objective improvement in the recipient of the dosage.
[0038] The terms “treatment”, “therapy” and the like include, but are not limited to, methods and manipulations to produce beneficial changes in a recipient's health status or reduce or prevent a pathology induced by an amphetamine drug such as methamphetamine and mediated by increased ceramide levels and/or apoptosis. Preventing or reducing the deterioration of a recipient's status is also included by the term. Therapeutic benefit includes any of a number of subjective or objective factors indicating a beneficial response or improvement of the toxicity being treated as discussed herein.
[0039] Pharmaceutical compositions are also provided by the invention. A pharmaceutical composition comprising a therapeutically effective amount of an amphetamine drug; and one or more of a therapeutically effective amounts of an agent for use according to the invention. In some embodiments, the agent is an inhibitor of ceramide biosynthesis or apoptosis; and a pharmaceutically acceptable carrier. For example, the agent can be a compound (nucleic acid, antibody, small or large molecule) that inhibits ceramide biosynthesis by targeting at least one ceramide-biosynthetic enzyme selected from the group consisting of a sphingomyelinase, serine palmitoyltransferase, 3-ketosphinganine reductase, ceramide synthase, dihydroceramide desaturase, and combinations thereof. In other embodiments, the agent that inhibits ceramide biosynthesis comprises a compound selected from the group consisting of Fumonisin B1 (FB1), tyclodecan-9-xanthogenate (D609), myriocin and combinations thereof.
[0040] Pharmaceutically acceptable carriers to be used in formulating a compound for use according to the invention are determined in part by the particular compound being administered, as well as by the particular method used to administer the composition. Accordingly, there are a wide variety of suitable formulations of pharmaceutical compositions of the present invention (see, e.g., Remington's Pharmaceutical Sciences, 20 th ed., 2003, supra).
[0041] Formulations suitable for oral administration can consist of (a) liquid solutions, such as an effective amount of the packaged nucleic acid suspended in diluents, such as water, saline or PEG 400; (b) capsules, sachets or tablets, each containing a predetermined amount of the active ingredient, as liquids, solids, granules or gelatin; (c) suspensions in an appropriate liquid; and (d) suitable emulsions. Tablet forms can include one or more of lactose, sucrose, mannitol, sorbitol, calcium phosphates, corn starch, potato starch, microcrystalline cellulose, gelatin, colloidal silicon dioxide, talc, magnesium stearate, stearic acid, and other excipients, colorants, fillers, binders, diluents, buffering agents, moistening agents, preservatives, flavoring agents, dyes, disintegrating agents, and pharmaceutically compatible carriers. Lozenge forms can comprise the active ingredient in a flavor, e.g., sucrose, as well as pastilles comprising the active ingredient in an inert base, such as gelatin and glycerin or sucrose and acacia emulsions, gels, and the like containing, in addition to the active ingredient, carriers known in the art.
[0042] The compound, alone or in combination with other suitable components, can be made into aerosol formulations (i.e., they can be “nebulized”) to be administered via inhalation. Aerosol formulations can be placed into pressurized acceptable propellants, such as dichlorodifluoromethane, propane, nitrogen, and the like.
[0043] Suitable formulations for rectal administration include, for example, suppositories, which consist of the packaged nucleic acid with a suppository base. Suitable suppository bases include natural or synthetic triglycerides or paraffin hydrocarbons. In addition, it is also possible to use gelatin rectal capsules which consist of a combination of the compound of choice with a base, including, for example, liquid triglycerides, polyethylene glycols, and paraffin hydrocarbons.
[0044] Formulations suitable for parenteral administration, such as, for example, by intraarticular (in the joints), intravenous, intramuscular, intratumoral, intradermal, intraperitoneal, and subcutaneous routes, include aqueous and non-aqueous, isotonic sterile injection solutions, which can contain antioxidants, buffers, bacteriostats, and solutes that render the formulation isotonic with the blood of the intended recipient, and aqueous and non-aqueous sterile suspensions that can include suspending agents, solubilizers, thickening agents, stabilizers, and preservatives. In the practice of this invention, compositions can be administered, for example, by intravenous infusion, orally, topically, intraperitoneally, intravesically or intrathecally. Parenteral administration, oral administration, and intravenous administration are the preferred methods of administration. The formulations of compounds can be presented in unit-dose or multi-dose sealed containers, such as ampules and vials.
[0045] Injection solutions and suspensions can be prepared from sterile powders, granules, and tablets of the kind previously described. Cells transduced by nucleic acids for ex vive therapy can also be administered intravenously or parenterally as described above.
[0046] The pharmaceutical preparation is preferably in unit dosage form. In such form the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form. The composition can, if desired, also contain other compatible therapeutic agents.
[0047] Preferred pharmaceutical preparations deliver one or more compounds for use according to the invention, optionally in combination with one or more other agents (e.g., an amphetamine drug). Sustained release formulations of compounds for use according to the invention are also contemplated.
[0048] In therapeutic use for the treatment of amphetamine drug induced toxicity, the compounds utilized in the pharmaceutical method of the invention are administered at the initial dosage of about 0.001 mg/kg to about 1000 mg/kg daily. A daily dose range of about 0.01 mg/kg to about 500 mg/kg, or about 0.1 mg/kg to about 200 mg/kg, or about 1 mg/kg to about 100 mg/kg, or about 10 mg/kg to about 50 mg/kg, can be used. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. For example, dosages can be empirically determined considering the particular patient. The dose administered to a patient, in the context of the present invention should be sufficient to effect a beneficial therapeutic response in the patient over time. Determination of the proper dosage for a particular situation is within the skill of the practitioner. Generally, treatment can be initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day, if desired.
[0049] The pharmaceutical preparations are typically delivered to a mammal, including humans and non-human mammals.
Methods for Testing Compounds for Use According to the Invention
[0050] The invention also provides methods of testing a compound for use according to the invention comprising the steps of: (a) contacting in vivo or in vitro a mammalian cell(s) with an amphetamine drug and the compound to be tested and determining whether the contacting reduces the formation of a deoxy-sphingolipid, a ceramide, or reduces apoptosis in the cell(s) as compared to a control mammalian cell(s) contacted with the amphetamine drug and not the test compound. Ceramide species to monitor include, but are not limited to, Cer(16:0), Cer(16:1), Cer(18:0), Cer(20:0), Cer(20:1), Cer(24:1); and dihydroceramide species including, but not limited to, DHCer(16:0), DHCer(16:1), DHCer(18:0), DHCer(20:0), DHCer(20:1), DH Cer(24:1). The invention also provides methods of testing a compound for use according to the invention comprising the steps of: (a) administering the test compound to a mammal also treated or to be treated with an amphetamine drug dose which increases ceramide levels (e.g., a toxic dose of the amphetamine drug) in the mammal and determining whether the administered test compound reduces the formation of a deoxy-sphingolipid, a ceramide, or reduces apoptosis, and/or reduces an adverse health effect in the mammal as compared to a control mammal treated with the amphetamine drug and not the test compound. Ceramide species to monitor include, but are not limited to, Cer(16:0), Cer(16:1), Cer(18:0), Cer(20:0), Cer(20:1), Cer(24:1); and dihydroceramide species including, but not limited to, DHCer(16:0), DHCer(16:1), DHCer(18:0), DHCer(20:0), DHCer(20:1), DH Cer(24:1). In some in such methods, the adverse effect is on an affected organ as described above for amphetamine drug-induced toxicities. In some embodiments, the subject is as described above (e.g., a human, a primate, or a rodent (rat, mouse). In some embodiments, samples from the test and control subject are taken and analyzed for levels of a lipid of the ceramide pathway whose levels are affected by the methamphetamine treatment. The sample can be a tissue sample taken from one or more of an affected organ, blood, or urine.
Monitoring for Amphetamine Drug Toxicity and Amphetamine Drug Administration.
[0051] In a further aspect, a new set of lipid biomarkers (e.g., ceramides, Cer(16:0), Cer(16:1), Cer(18:0), Cer(20:0), Cer(20:1), Cer(24:1); and dihydroceramide species including, but not limited to, DHCer(16:0), DHCer(16:1), DHCer(18:0), DHCer(20:0), DHCer(20:1), DH Cer(24:1)) for use in assessing, diagnosing and monitoring for any toxicity induced by amphetamine drug is provided. Accordingly, the invention provides a method for monitoring with ease, low-invasiveness and low-cost peripheral biomarkers of amphetamine toxicity (i.e., ceramides), which find applications in the following areas: (1) prophylactic and diagnostic screening in a large population of subjects; (2) leading to a more accurate diagnostic tool, especially if used in combination with other clinical parameters; (3) assessing drug response in asymptomatic patients; (4) serving as a secondary outcome measure in clinical trials of symptomatic patients, and (5) deciding if further development of a treatment should be stopped if not likely to be effective. In this aspect, samples of tissue are taken from a subject having been administered an amphetamine drug or suspected of having been administered an amphetamine drug and the samples are then analyzed for the amount of one or more lipids of the ceramide pathway. The amount of the analyzed lipid is then compared to that for a control or reference population not having been exposed to the amphetamine drug. Alternatively, or in addition, the levels of the analyzed lipid can be tracked over time by repeated sampling of the individual subject, and the trend of the lipid levels over time compared. Elevated levels of the analyzed lipid compared to controls levels being indicative of an amphetamine toxicity and/or likely use or continued use of amphetamine by the subject. The sample can be a tissue sample taken from one or more of an affected organ, blood, saliva, or urine. In some embodiments, the monitoring is repeated over time to track the health status or continued use of an amphetamine drug by the subject. In some further embodiments, the subject (e.g., an amphetamine-type drug user, a person suspected of same) identified to have an elevated ceramide lipid levels as shown by the above assessing, diagnosing or monitoring is further treated with a modulator of ceramide metabolism or apoptosis according to the methods of the invention. In still some further embodiments of same the modulator dosing is adjusted or ended according to the results of monitoring the ceramide lipid levels over time. In some additional embodiments of any of the above, the same or additional samples from the subject are also tested for the presence of an amphetamine-type drug or its metabolites.
[0052] The following examples are provided for illustrative purposes, and are not intended to limit the scope of the invention as claimed herein. Any variations in the exemplified articles and/or methods which occur to the skilled artisan are intended to fall within the scope of the present invention.
EXAMPLE
Targeting Ceramide in Amphetamine Toxicity
Elevated Ceramide Levels in Rats Self-Administering Methamphetamine
[0053] Methamphetamine self-administration in rats closely mimics the voluntary component of human drug exposure, and is characterized by high rates of drug intake ( FIG. 6 ) [11]. To examine whether high methamphetamine intake is accompanied by abnormality in lipid profile, we conducted an unbiased lipidomic analysis of various tissues obtained from rats that self-administered methamphetamine and compared these to controls. Lipids were extracted and analyzed by LC/MS n for the major lipid classes. To facilitate visual inspection of broad regions of interest in the lipidome, LC/MS n data were processed statistically using heat-maps. This survey revealed that multiple ceramide species were substantially increased in methamphetamine-exposed rats, compared to controls ( FIG. 1 a ). The largest increase in ceramide levels were seen in the skeletal muscle, heart and liver ( FIG. 1 b ). To investigate whether the elevation in ceramide levels in rats self-administering methamphetamine resulted from a stimulation of ceramide biosynthesis we conducted a focused lipidomic analysis on skeletal muscle. Methamphetamine self-administration was associated with a 4-fold increase in ceramide (d18:1/16:0) ( FIG. 1 c ) and dihydroceramide (d18:1/16:0) ( FIG. 1 d ). By contrast the levels of sphingomyelin (d18:1/16:0) ( FIG. 1 e ) and dihydrosphingomyelin (d18:1/16:0) ( FIG. 1 f ), which generate ceramide through the degradative pathway, were unchanged. This increase in ceramide was accompanied by increased serine palmitoyltransferase (SPT) and ceramide synthase (CerS) gene expression ( FIG. 1 g ) and increased CerS activity (data not shown). These results indicate that methamphetamine self-administration in rats increased de novo ceramide biosynthesis in skeletal muscle.
[0054] As prolonged methamphetamine self-administration exerts negative health effects we tested the acute effects of methamphetamine in rats. Intraperitoneal administration of methamphetamine (3, 10, and 20 mg/kg) caused a dose-dependent increase in d18:1/16:0 ceramide levels in rat skeletal muscle ( FIG. 1 h ), and other peripheral tissues (data not shown). As seen with methamphetamine self-administration, non-contingent methamphetamine administration increased CerS6 gene expression, one of the main enzymes responsible for generating d18:1/16:0 ceramide [12], (data not shown) and increased CerS activity (data not shown).
D-Methamphetamine Enhances De Novo Ceramide Biosynthesis in Primary Mouse Embryonic Fibroblasts
[0055] As a further test for the ability of methamphetamine to alter ceramide production we used primary mouse embryonic fibroblasts (MEF). Incubation of MEF with methamphetamine increased ceramide (d18:1/16:0) in a dose-dependent manner ( FIG. 2 a ). The effect of methamphetamine was stereospecific; the non-toxic enantiomer 1-methamphetamine has no such effect ( FIG. 2 b ). Interestingly, d-amphetamine also produced a modest but statistically significant (p<0.014) increase in ceramide content ( FIG. 2 b ). The increased ceramide levels induced by methamphetamine were accompanied by increased mRNA levels of the genes involved de novo ceramide biosynthesis ( FIG. 2 c ). The main sight of de novo ceramide biosynthesis is the endoplasmic reticulum; however recent work has identified CerS enzymes in the mitochondria, indicating that some de novo ceramide biosynthesis also occurs in the mitochondria. Lipid analysis of isolated mitochondria from MEF treated with methamphetamine (1 mM) showed a unique pattern of ceramide increase in which in addition to increases in short chain ceramide (d18:1/16:0) ( FIG. 2 d ) we also found a mitochondrial specific increase in long chain ceramides (d18:1/24:0 and d18:1/24:1) ( FIG. 2 e, f ). The increase in long chain ceramides specifically in the mitochondria can result in increased mitochondrial dysfunction and the production of excess reactive oxygen species. Further, 30 μM L-cycloserine (L-CS), an inhibitor of SPT [13], was able to block methamphetamine induced increases in ceramide in primary MEF ( FIG. 2 h, i ) and in isolated mitochondria from primary MEF ( FIG. 7 ). Similar results were obtained using 50 μM Fumonisin B1 (FB1), a potent inhibitor of CerS and 10 μM myrocin, a structurally distinct SPT inhibitor [14]( FIG. 2 g ). Overall, these findings indicate that methamphetamine treatment induced a stereospecific activation of the de novo biosynthetic pathway in MEF cells.
Methamphetamine Accelerates Senescence in Primary Mouse Embryonic Fibroblasts
[0056] Primary cells in culture exhibit a finite proliferative lifespan with a limited capacity to undergo population doubling before they stop dividing [13, 14]. Limitations in proliferative capacity correlate with the age of the organism and the life expectancy of the species from which the cells are obtained from; such that the older the age or the shorter the lifespan, the lesser the ability of the cells to undergo population doubling [15]. Cells which can no longer replicate are said to be senescent, a state where normal somatic cells lose their replicative capacity resulting in an irreversible growth arrest. We treated MEFs with methamphetamine (1 mM) for 48 h and measured expression of the well-established histochemical marker of senescence, senescence associated β-galactosidase (SA-β-gal). Methamphetamine exposure increased the number of SA-β-gal positive cells from passage 1 to 4 compared to vehicle-treated cells ( FIG. 3 a ). At passage 5, when MEF cells begin to reach the end of their replicative capacity, methamphetamine did not further increase the number of SA-β-gal positive cells ( FIG. 3 a ). The largest methamphetamine induced elevation in the number of SA-β-gal positive cells was seen at passage 3, with a greater than 4-fold increase versus non-treated cells. Senescent cells also display an enlarged and flattened morphology as compared to actively replicating cells. Following a 48 h methamphetamine treatment (I mM) at passage 2 MEF display morphological changes typical of senescent phenotype ( FIG. 3 b ). Consistent with the SA-β-gal data, at passage 5 both treated and untreated cells displayed a senescent morphology as the MEF naturally reached the end of their replicative lifespan. We then examined the effect of methamphetamine treatment on replicative capacity. DNA synthesis, measured using [ 3 H]-thymidine binding, decreased following 48 h of methamphetamine treatment (1 mM) ( FIG. 3 c ), as did the number of population doublings compared to control cells ( FIG. 3 d ). To validate that ceramide might be mediating the induction of senescence we looked at the levels of ceramide from passage 1 to 5 and found a steady increase in ceramide levels ( FIG. 3 e ) as well as in increase in CerS5 ( FIG. 3 f ). Given that methamphetamine increased ceramide levels and that ceramide plays a large role in the induction of senescence, we hypothesized that the blockage of ceramide biosynthesis would ameliorate methamphetamine induced senescence. To test this hypothesis we treated MEFs with methamphetamine (1 mM) in the presence of structurally distinct inhibitors of de novo ceramide biosynthesis, L-cycloserine (L-CS) and fumonisin B1 (FB1). Treatment with L-CS (30 μM) or FB1 (50 μM) suppressed SA-β-gal expression induced by methamphetamine ( FIG. 3 g,h ). In contrast, neither L-CS nor FB1 blocked the expression of SA-β-gal by the cell-permeable ceramide analog C8 ( FIG. 3 g,h ). The results suggest that methamphetamine accelerates cell senescence and that blocking ceramide biosynthesis can decrease senescence induced by methamphetamine.
Methamphetamine Activates Pro-Inflammatory and Pro-Senescent Genes Through an NF-κB Dependent Mechanism
[0057] To understand how methamphetamine induces senescence in MEF we analyzed the gene expression of well-known markers of aging which contribute to inflammation and senescence. In addition to morphological and histochemical changes, senescent cells display changes in many cell cycle-regulating genes such as p15, p16, p23, and p53 [16, 17]. Additionally, studies on the biomarkers of aging have shown that IL-6, TNF-α and other inflammatory cytokines are the most reliable aging parameters [18]. We found that methamphetamine treatment resulted in the elevation of the transcription of inflammatory cytokines, IL-6 and TNF-alpha, as well as an increase in the cyclin dependent kinases p21 and p53 ( FIGS. 4 a - d ). The increase in the transcription of these genes was dependent on increased cellular ceramide contents, as this increase was blocked with the co-administration of the SPT inhibitor L-CS. The activation of these genes following treatment pointed to a possible NF-κB dependent activation following methamphetamine treatment. MEFs treated with methamphetamine (1 mM) were harvested 24 hrs later and subjected to chromatin immunoprecipitation assays. We found recruitment of NF-kB subunit p65 to the TNF-α promoter ( FIG. 4 e ) indicating that methamphetamine treatment activated NF-kB's transcriptional activity. Additionally, we were also able to mimic the effects of methamphetamine on cellular ceramide content by activating NF-κB with TNF-α treatment, suggesting that NF-kB activation is a necessary step in ceramide biosynthesis ( FIG. 4 f ). To further test if NF-κB activation was essential for increased cellular ceramide content following methamphetamine treatment we treated cells with three distinctly different NF-κB inhibitors, JSH-23, 5′-aminosalicyclic acid and thalidomide in an attempt to block the effects of methamphetamine on de novo ceramide biosynthesis. We found that all three inhibitors of NF-κB were able to inhibit the effect of methamphetamine on MEF cells indicating that methamphetamine is dependent on the activation of this pathway ( FIG. 4 g - i ). These data indicate that the succession of events which lead to the activation of de novo ceramide biosynthesis following methamphetamine treatment is dependent on the activation of NF-κB.
Methamphetamine Increases the Expression of Inflammatory and Senescent Genes In Vivo
[0058] We next tested whether increased ceramide content was also leading to an accelerated aging phenotype in self-administering rats and rats treated acutely with methamphetamine. Methamphetamine self-administration resulted in elevated levels of transcription of age-related genes TNF-α, IL-6, p21, and p53 ( FIG. 5 a - d ). Acute methamphetamine treatment resulted in increased transcription of IL-6 and p21, but not TNF-α and p53 ( FIG. 5 e - h ). Although the cyclin-dependent kinase inhibitor p21 is usually induced by p53 dependent mechanisms, it can also be induced by p53 independent mechanisms following stress, in both cases elevated p21 transcript leads to cell cycle arrest [19]. To determine whether blockage of ceramide biosynthesis in vivo could also prevent the premature aging effects of methamphetamine we conducted an acute experiment in mice in which they were administered methamphetamine alone or methamphetamine in combination with the SPT inhibitor L-CS. We found that acute treatment with methamphetamine increased ceramide content and the expression of IL-6 and p21 mRNA ( FIG. 5 i - k ). These methamphetamine-induced changes are as a direct result of increased ceramide content as we were able to block the increase of ceramide with the administration of L-CS and thus block the increase of IL-6 and p21 mRNA ( FIG. 5 i - k ). To gain more insight into the possible therapeutic use of L-CS for methamphetamine addicts we investigated whether L-CS treatment could rescue methamphetamine self-administering animals from the deleterious effects of ceramide accumulation. To test this, we allowed rats to self-administer methamphetamine for a period of 8 days, and treated them with L-CS 4 days into the self-administration study. Inhibition of de novo ceramide synthesis using L-CS blocked methamphetamine induced increases in ceramide content and transcription of age-related genes IL-6 and p21 ( FIG. 5 l - n ). As an overall marker of the health of the animal we monitored weight, and found that L-CS treatment was able to rescue the wasting phenotype see in methamphetamine self-administering animals ( FIG. 5 p ). However, L-CS treatment had no effect on methamphetamine self-administration ( FIG. 9 ), nor any influence on meth induced changes in body temperature ( FIG. 5 o ) validating that we are specifically targeting ceramide mediated effects on methamphetamine use with L-CS treatment. Together these data provide strong evidence for the possibility of treating the progeric effects of methamphetamine by inhibiting de novo ceramide biosynthesis.
Methamphetamine Metabolism Via CYP2D6 Triggers Ceramide Biosynthesis
[0059] Methamphetamine is metabolized in humans and rodents by cytochrome P450 (CYP)-2D6, a widely distributed CYP isoform that catalyzes the oxidation of methamphetamine into D-amphetamine and 4-hydroxy-D-methamphetamine (Wu, D., et al. Biochem Pharmacol 53, 1605-1612 (1997); Lin et al. Drug Metab Dispos 25, 1059-1064 (1997)). A by-product of this reaction is the formation of reactive oxygen species (ROS) Riddle, E. L., et al., AAPS J 8, E413-418 (2006)), which are known to activate NF-KB-dependent stress-response signals that can lead to ceramide formation (Dbaibo, G. S., et al., J Biol Chem 268, 17762-17766 (1993). To determine whether CYP2D6 metabolism might be involved in methamphetamine-induced ceramide production, we blocked CYP activity in primary MEF cultures using a panel of five chemically distinct agents: clotrimazole, SKF-525A and cimetidine (three pan-CYP inhibitors), quinidine (selective for CYP2D6) and HET-0016 (selective for CYP4A). LC/MS analyses showed that incubation of MEF in the presence of clotrimazole (1-10 μM) increased the levels of non-metabolized methamphetamine ( FIG. 9 a ) and concurrently decreased methamphetamine-induced ceramide accumulation ( FIG. 9 b ), while exerting no effect on baseline ceramide content (in pmol-mg −1 protein, control: 52.9±5; clotrimazole 10 μM: 49.2±3; n=3). Similarly to clotrimazole, SKF-525A, cimetidine and quinidine (each at 10 μM) normalized ceramide formation in D-meth-treated cells, whereas HET-0016 (10 μM) was ineffective ( FIG. 9 c ).
[0060] As a further test of the role of CYP2D6 in methamphetamine-induced ceramide production, we determined whether exposure to methamphetamine stimulates ROS generation in MEF. As anticipated from previous studies, methamphetamine caused a concentration-dependent increase in ROS formation ( FIG. 9 ), whereas L-methamphetamine (a less preferred CYP2D6 substrate) and 4-hydroxy-D-methamphetamine (a product of methamphetamine metabolism via CYP2D6) had little or no effect ( FIG. 9 e and FIG. 10 ). The release of ROS evoked by methamphetamine was prevented by the pan-CYP inhibitors—clotrimazole ( FIG. 9 f ), SKF-525A and cimetidine ( FIG. 9 g )—and the CYP2D6 inhibitor, quinidine ( FIG. 9 g ), but not by the CYP4A inhibitor, HET-0016 ( 9 g ).
[0061] An early cellular response to ROS formation is the recruitment of NF-KB (Gloire, G., et al., Biochem Pharmacol 72, 1493-1505 (2006); Schreck, R., et al., EMBO J 10, 2247-2258 (1991)), which can also be induced by methamphetamine (Asanuma, M. et al. Brain Res Mol Brain Res 60, 305-309 (1998); Lee, Y. W., et al., J Neurosci Res 66, 583-591 (2001)). Accordingly, our findings indicate that the oxidative metabolism of methamphetamine via CYP2D6 stimulates ceramide biosynthesis, most likely through induction of ROS formation and subsequent engagement of NF-KB.
[0062] L-CS did not alter key centrally mediated actions of methamphetamine—including its ability to maintain self-administration ( FIG. 8 ), increase body temperature (data not shown) and reduce food intake ( FIG. 11 ). Nevertheless, the SPT inhibitor corrected the abnormalities in body weight.
Discussion
[0063] Ceramide has long been implicated as a molecular modulator of aging and longevity [6]. The first evidence of this was seen with the LAG1 mutants and further supported by finding of the role of ceramide in inducing cellular senescence [10]. Our work further supports the known roles of ceramide in aging as we have found that it is not only involved in the progression of normal chronological aging, but that manipulation of its metabolism can accelerate aging. More specifically we found that alterations in de novo ceramide metabolism, caused by methamphetamine, can lead to drug-induced senescence. Although, the aging consequences of methamphetamine addiction in people were phenotypically obvious, not much was known about the molecular mechanisms responsible for this process. We have shown that methamphetamine can accelerate aging in vivo and in vitro by increasing the rate at which cells senescence and by inducing a state of chronic systemic inflammation two robust markers of aging. Of even more significance is the fact that the induction of senescence and inflammation induced peripherally by methamphetamine use is dependent on increased cellular ceramide contents and that by blocking the induction of ceramide biosynthesis with L-CS we are able to ameliorate the premature aging consequences of methamphetamine use. This may one day lead to the production of pharmacological therapies which may prolong the life of addicts in order to facilitate their recovery form methamphetamine addiction.
Materials and Methods
Chemicals
[0064] D-Methamphetamine hydrochloride (=amphetamine), L-methamphetamine hydrochloride, L-cycloserine and myriocin were purchased from Sigma Aldrich (St. Louis, Mo., USA). Fumonisin B 1 and C8 ceramide were purchased from Cayman Chemicals (Ann Arbor, Mich., USA). NF-κB inhibitors were purchased from Santa Cruz Biotechnology (Santa Crux, Calif., USA).
Methamphetamine Self-Administration
[0065] Subjects.
[0066] Male Sprague-Dawley rats (Charles River, Wilmington, Mass.), weighing approximately 360-440 g at the beginning of the self-administration experiment, were individually housed in a temperature- and humidity-controlled environment under a reversed lighting 12-h light/dark cycle (lights on at 7:00 p.m.). The rats were allowed free access to food (NIH07 biscuits) in their home cage throughout the study. Water was available ad libitum in the home cage and in the testing chamber. Rats were tested in the light phase. They were experimentally and drug naïve at the beginning of this study.
[0067] Animals were maintained in facilities fully accredited by the American Association for the Accreditation of Laboratory Animals and all experiments were conducted in accordance with the guidelines of the Institutional Care and Use Committee of the Intramural Research Program, NIDA, NIH, and the Guidelines for the Care and Use of Mammals in Neuroscience and Behavioral Research (National Research Council 2003).
[0068] Apparatus.
[0069] Each of eighteen standard operant-conditioning chambers (Coulbourn Instruments, Lehigh Valley, Pa.) contained a white house light and two holes with nose-poke operanda on either side of a food trough. Upon activation, each nose poke produced a brief feedback tone. One hole was defined as active (left in nine chambers, right in remaining nine) and the other hole as inactive. methamphetamine or saline were delivered through Tygon tubing, protected by a metal spring and suspended through the ceiling of the experimental chamber from a single-channel fluid swivel. The tubing was attached to a syringe pump (Harvard Apparatus, South Natick, Mass.), which was programmed to deliver 2-s injections. The injected volume was adjusted for every animal to deliver a methamphetamine dose of 0.1 mg/kg/injection. Experimental events were controlled by microcomputers using MED Associates interfaces and software (Med Associates Inc., East Fairfield, Vt.).
[0070] Silastic catheter was implanted into the external jugular vein under anesthesia with a mixture of ketamine and xylazine (60 and 10 mg/kg i.p., respectively). Catheter exited the skin behind the ear. After catheter implantation, a nylon bolt glued to an acrylic mesh was implanted subcutaneously in the midscapular region. The nylon bolt served as a tether, preventing the catheter from being pulled out during self-administration sessions. Following surgery, the IV catheter was flushed daily during the first week with 0.2-0.3 ml of solution containing cephalosporin (100 mg/ml; Cefazolin For Injection, USP; Hospira Inc., Lake Forest, Ill., USA) and then flushed before and after each daily session with saline to maintain its patency) and then flushed after each daily session with saline to maintain its patency.
[0071] Procedure.
[0072] Each experimental group was divided into two subgroups that were tested simultaneously. One subgroup served as yoked controls and passively received an injection of saline (which was not contingent on responding) each time a response-contingent injection of 0.1 mg/kg methamphetamine was actively self-administered by the first subgroup of rats. Nose-poke responses by the yoked control rats were recorded, but had no programmed consequences. The first experimental groups consisted of 12 rats self-administering methamphetamine and 6 yoked control rats. The second experimental group consisted of 9 rats self-administering methamphetamine and 9 yoked control rats. The third experimental group consisted of 16 rats self-administering methamphetamine and 8 yoked control rats. In this third experimental group, half of the animals (8 methamphetamine and 4 yoked) received i.v. pretreatment with L-cycloserine (L-CS) that started before session 4. The pretreatment with L-CS was always given immediately before and after each session and the catheter was flushed with 0.5 ml of saline afterwards. Before and after sessions 4 and 5 animals received dose 10 mg/kg of L-CS and before and after sessions 6, 7, and 8 they received dose 20 mg/kg of L-CS. The animals received total dose 160 mg/kg of L-CS during the experiment. In this group, we also measured three times the rectal temperature. The first measurement was done one the day before the experiment began at 2 pm, the second measurement was done at 2 pm before the eighth session, and the third measurement immediately after the eighth session.
[0073] Eight consecutive 15-hour sessions were conducted between 4 p.m. and 8 a.m. Rats and the food in the feeders were weighed before the start of each session. At the start of each session, a white house light was turned on and a priming injection of 0.1 mg/kg methamphetamine (or saline for yoked group), sufficient to fill the “dead” space of the IV catheter, was automatically delivered. Rats learned to self-administer methamphetamine under one-response, fixed ratio schedule (FRI) of i.v. methamphetamine injection with 30-s time-out duration. Each nose-poke response in the active hole (FRI) produced a delivery of an i.v. injection of 0.1 mg/kg of methamphetamine followed by 30-s timeout period, during which the chamber was dark and responses in either hole had no programmed consequences. Nose-poke responses in the “inactive” hole were recorded but had no programmed consequences.
[0074] Tissue Collection.
[0075] The rats were always euthanized 2 hrs after the eighth session ended. The first experimental group of rats was euthanized by decapitation and brain, liver, heart, kidney (left), spleen, pancreas, testis, epididymal fat, skeletal muscle (vastus lateralis muscle), and skin (hind paw) were harvested from each rat. All tissues were rinsed in the mix of RNase-free water with DEPC-treated phosphate-buffered saline (PBS) and dried with sterile gauze. Brains and livers were snap-frozen in isopentane. The rest of the tissues were snap-frozen in liquid nitrogen. All tissues were double wrapped in aluminum foil and stored in −80° C.
[0076] The second experimental group was euthanized as follows. Five yoked pairs were euthanized by decapitation and tissues were harvested and handled as described above. Four yoked pairs were anaesthetized with Equithesin (9.72 mg/ml pentobarbital and 44.4 mg/ml chloral hydrate, 3 ml/kg i.p.) and perfused intracardially with 0.1M PBS followed by 4% paraformaldehyde dissolved in 0.1M PBS. Animals were then decapitated and brains removed and fixed in 4% paraformaldehyde in 0.1M PBS for 2 h and then immersed in 20% sucrose/0.1 M PBS solution for 48 h at 4° C. The brains were subsequently rapidly frozen in dry ice and stored at −80° C.
[0077] The third experimental group was euthanized by decapitation (see the first group for details) and brain, liver, heart, spleen, left kidney, skeletal muscle and skin were collected from each rat. The tissues were handled as described for the first group.
[0078] Drugs.
[0079] S(+)-methylamphetamine HCl (methamphetamine) was purchased from Sigma Aldrich (St. Louis, Mo., USA) and dissolved in saline. L-cycloserine (Sigma Aldrich, St. Louis, Mo., USA) was dissolved in saline and administered i.v. in volume 1 ml/kg.
Acute Methamphetamine Administration in Rats
[0080] Subjects.
[0081] Forty-six male Sprague-Dawley rats (Charles River, Wilmington, Mass.), weighing approximately 360-420 g were used in these experiments. Other details as described in methamphetamine self-administration section.
[0082] Procedure.
[0083] Three groups of rats were used for these experiments. Group 1: On the day of the experiment, rats received two i.p. injections of methamphetamine, 10 mg/kg (n=6), or saline (n=6) every 2 h. Two hours after the last administration of methamphetamine or saline, rats were euthanized by decapitation. Brain, liver, kidney (left), heart, skin (hind paw), skeletal muscle (vastus lateralis muscle) were harvested. Brains and livers were snap-frozen in isopentane and other tissues were snap-frozen in liquid nitrogen and stored at −80° C. Group 2: On the day of the experiment, rats received two i.p. injections of methamphetamine, 1.5 mg/kg (n=6), or saline (n=6) every 2 h. Other details are the same as for group 1. Group 3: On the day of the experiment, five rats received two i.p. injections of 1.5 mg/kg methamphetamine every 2 h; five rats received two i.p. injections of 5 mg/kg methamphetamine every 2 h; six rats received two i.p. injections of 10 mg/kg D-methamphetamine every 2 h, and six rats received two i.p. injections of saline every 2 h. Two hours after the last injection, blood was collected by cardiac puncture under isoflurane anesthesia and immediately afterwards brain, skeletal muscle and skin were harvested and handled as described for group 1.
[0084] Drugs.
[0085] S(+)-methylamphetamine HCl (methamphetamine) was purchased from Sigma Aldrich (St. Louis, Mo., USA) and dissolved in saline.
[0000] Lipid Extractions from Tissues
[0086] Lipid extractions were conducted as previously described [20]. Briefly, frozen brain samples were weighed and homogenized in cold methanol containing appropriate internal standards (listed below). Lipids were extracted by adding chloroform and water (2/1, vol/vol) and fractionated through open-bed silica gel columns by progressive elution with chloroform/methanol mixtures. Fractions eluted from the columns were dried under nitrogen, reconstituted in chloroform/methanol (1:4, vol/vol; 0.1 ml) and subjected to LC/MS.
[0000] Lipid Extractions from Cells in Cultures
[0087] Cells were washed with ice-cold phosphate-buffered saline (PBS) and scraped into 0.5 ml of methanol/water (1:1, vol:vol) containing the internal standards listed below. Protein concentrations were measured using the BCA protein assay (Pierce, Rockford, Ill., USA). Lipids were extracted with chloroform/methanol (2:1, vol:vol; 1.0 mL). The organic phases were collected, dried under nitrogen and dissolved in methanol for LC/MS analyses.
Lipidomic Analyses.
[0088] Lipid molecular species were quantified by normalizing the individual molecular ion peak intensity with an internal standard for each lipid class. A mixture of non-endogenous molecules was used as internal standards and added before the extraction process to allow lipid levels to be normalized for both extraction efficiency and instrument response.
[0089] Fatty Acids.
[0090] Fatty acids were quantified with an Agilent 1100 liquid chromatograph coupled to a 1946D mass detector equipped with an ESI interface (Agilent Technologies, Palo Alto, Calif.). A reversed-phase XDB Eclipse C18 column (50×4.6 mm i.d., 1.8 μm, Zorbax, Agilent Technologies) was eluted with a linear gradient from 90% to 100% of A in B for 2.5 min at a flow rate of 1.5 ml/min with column temperature at 40° C. Mobile phase A consisted of methanol containing 0.25% acetic acid and 5 mM ammonium acetate; mobile phase B consisted of water containing 0.25% acetic acid and 5 mM ammonium acetate. Column temperature was kept at 40° C. Mass detection was in the negative ionization mode, capillary voltage was set at −4.0 kV and fragmentor voltage was 120 V. Nitrogen was used as drying gas at a flow rate of 13 liters/min and a temperature of 350° C. Nebulizer pressure was set at 60 pounds per square inch. For quantification purposes, the deprotonated pseudo-molecular ions [M−H] − of the fatty acids were monitored in the selected ion-monitoring mode (SIM), using d 8 -arachidonic acid (Cayman Chemical, Ann Arbor, Mich.) as internal standard (m/z=311.3) as previously reported (ref) Commercially available fatty acids (Nu-Chek Prep, Elysian, Minn., Cayman Chemical or Sigma-Aldrich, St Louis, Mo.) were used as references.
[0091] Monoacylglycerols (AGs).
[0092] We used an Agilent 1100-LC system (Agilent Technologies, Palo Alto, Calif.) coupled to a 1946D-MS detector equipped with an ESI interface (Agilent Technologies). MGs were separated on a XDB Eclipse C18 column (50×4.6 mm i.d., 1.8 ρm; Zorbax; Agilent Technologies). They were eluted with a gradient of methanol in water (from 85% to 90% methanol in 2.0 min and 90% to 100% in 3.0 min) at a flow rate of 1.5 ml/min. Column temperature was kept at 40° C. MS detection was in the positive ionization mode, capillary voltage was set at 3 kV, and fragmentor voltage was 120 V. Nitrogen was used as drying gas at a flow rate of 13 liters/min and a temperature of 350° C. Nebulizer pressure was set at 60 psi. Commercial MGs were used as reference standards. For quantification purposes, we monitored the Na+ adducts of the molecular ions [M+Na]+ in SIM mode, using HDG (m/z 367) as an internal standard.
[0093] Diacylglycerols (DGs).
[0094] We used an Agilent 1100-LC system coupled to a MS detector Ion-Trap XCT interfaced with ESI (Agilent Technologies). DG species were separated using a XDB Eclipse C18 column (50×4.6 mm i.d., 1.8 μm, Zorbax), eluted by a gradient of methanol in water (from 85% to 90% methanol in 2.5 min) at a flow rate of 1.5 ml/min. Column temperature was kept at 40° C. The capillary voltage was set at 4.0 kV and skimmer voltage at 40 V. N itrogen was used as drying gas at a flow rate of 12 liters/min, temperature at 350° C., and nebulizer pressure at 80 psi. Helium was used as collision gas, and fragmentation amplitude was set at 1.2 V. DG were identified in the positive ionization mode based on their retention times and MS 3 properties, using synthetic standards as references. Multiple reaction monitoring was used to acquire full-scan tandem MS spectra of selected DG ions. Extracted ion chromatograms were used to quantify isobaric DG species and dinonadecadienoin (m/z 667.8>367.5), which was used as an internal standard.
[0095] Triacylglycerols (TGs).
[0096] We used an Agilent 1100-LC system coupled to a MS detector Ion-Trap XCT interfaced with atmospheric pressure chemical ionization (Agilent Technologies). Lipids were separated on a Poroshell 300SB C18 column (2.1×75 mm i.d., 5 μm, Agilent Technologies) at 50° C. A linear gradient of methanol in water containing 5 mM ammonium acetate and 0.25% acetic acid (from 85% to 100% of methanol in 4 min) was applied at a flow rate of 1 ml/min. MS detection was set in positive mode. Corona discharge needle voltage set at 4 kV. Capillary voltage was 4.0 kV, skim1 40 V, and capillary exit at 118 V. Nitrogen was used as drying gas at a flow rate of 10 liters/min, temperature of 350° C., nebulizer pressure of 50 PSI and vaporization temperature at 400° C. Helium was used as collision gas. Total TGs were quantified by integrating the area of the total ion current (m/z 700-900) at a selected interval of retention time (from 4 to 5 min), using TG 19:1/19:1/19:1 (m/z 944.8, Nu-Chek Prep) as an internal standard.
[0097] Glycerophospholipids.
[0098] Phospholipids molecular species were analyzed by tandem mass spectrometry, using an Agilent 1100 liquid chromatograph coupled to an ESI-ion-trap XCT mass detector. A reversed-phase Poroshell 300SB C18 column (2.1×75 mm i.d., 5 μm, Agilent) was eluted with a linear gradient from 85% to 100% of mobile phase A in B in 5 min at a flow rate of 1.0 ml/min with column temperature at 50° C. Mobile phase composition was as described above. The capillary voltage was set at 4.0 kV and skimmer voltage at −40 V. Nitrogen was utilized as drying gas at a flow rate of 10 liters/min, temperature at 350° C. and nebulizer pressure at 60 pounds per square inch. Helium was the collision gas and fragmentation amplitude was set at 1.2 V. Mass detection was in the negative ionization mode and was controlled by the Agilent/Bruker Daltonics software version 5.2. Synthetic 1,2-diheptadecanoyl-sn-glycero-3-phosphoethanolamine, 1,2-diheptadecanoyl-sn-glycero-3-phosphocholine, 1,2-diheptadecanoyl-sn-glycero-3-phosphoglycerol, 1,2-diheptadecanoyl-sn-glycero-3-phosphoserine, 1,2-diheptadecanoyl-sn-glycero-3-phosphoinositol (Avanti Polar Lipids, Alabaster, Ala.) were used as internal standards.
[0099] Sphingolipids.
[0100] Sphingolipid molecular species were analyzed by tandem mass spectrometry, using an Agilent 1100 liquid chromatography coupled to an ESI-ion-trap XCT mass detector. Dihydroceramides and ceramides were separated on a Poroshell 300 SB C18 column (2.1×75 mm i.d., 5 μm; Agilent Technologies) maintained at 30° C. A linear gradient of methanol in water containing 5 mM ammonium acetate and 0.25% acetic acid (from 80% to 100% of methanol in 3 min) was applied at a flow rate of 1 ml/min. Detection was in the positive mode, capillary voltage was 4.5 kV, skim1 −40 V, and capillary exit −151 V. Nitrogen was used as drying gas at a flow rate of 12 L/min, temperature of 350° C., and nebulizer pressure of 80 psi. Helium was used as collision gas. Ceramide species were identified by comparison of its LC retention time and MS n fragmentation pattern with that of authentic standards (Avanti Polar Lipids). Extracted ion chromatograms were used to quantify the following ceramides: d18:1/16:0 [M+H] + (m/z=538.5>520.5>264.3), d18:0/16:0 [M+H] + (m/z=540.5>522.5), d18:1/18:0 [M+H] + (m/z=566.5>548.5>264.3), d18:0/18:0 [M+H] + (m/z=568.5>550.5), d18:1/24:0 [M+H] + (m/z=650.6>632.8>2643), d18:0/24:0 [M+H] + (m/z=652.6>634.8), d18:1/24:1 [M+H] + (m/z=648.6>630.8>264.3), d18:0/24:1 [M+H] + (m/z=650.6>632.8), using d18:1/12:0 [M+H] + (m/z=482.5>464.5>264.3) as an internal standard. Sphingomyelin species were separated using a reversed-phase Poroshell 300SB C18 column (2.1×75 mm i.d., 5 μm, Agilent) and eluted with a linear gradient from 85% to 100% of mobile phase A in B in 5 min at a flow rate of 1.0 ml/min with column temperature at 50° C. Mobile phase composition was as described above. The capillary voltage was set at −4.0 kV and skimmer voltage at −40 V. Nitrogen was utilized as drying gas at a flow rate of 10 liters/min, temperature at 350° C. and nebulizer pressure at 60 pounds per square inch. Helium was the collision gas and fragmentation amplitude was set at 1.2 V. Mass detection was set in either positive or negative ionization mode and was controlled by the Agilent/Bruker Daltonics software version 5.2. Sphingomyelin species were identified by LC-MS n using reference standards (Avanti Polar Lipids) and quantified using sphingomyelin d18:1/12:0 [M]+(m/z=647.8>588.8) as an internal standard. Sphingomyelin species were monitored using the following multiple-ion reactions: d18:1/16:0 [M] + (m/z=703.8>644.8), d18:1/18:0 [M] + (m/z=731.8>672.8), d18:1/24:0 [M] + (m/z=815.8>756.8), d18:1/24:1 [M] + (m/z=813.8>754.8).
Gene Expression.
[0101] Total RNA was extracted from frozen tissues using TRIzol reagent (Invitrogen, Carlsbad, Calif.) and was purified with the RNeasy mini kit (Qiagen, Valencia, Calif.). First-strand complementary DNAs were synthesized using SuperScript II RNaseH reverse transcriptase (Invitrogen). Reverse transcription of total RNA (2 μg) was carried out using oligo(dT)12-18 primers for 50 min at 42° C. mRNA levels were measured by quantitative real-time polymerase chain reaction (RT-PCR) with a Mx 3000P system (Stratagene, La Jolla, Calif.). The following list of primers and fluorogenic probes purchased from Applied Biosystems (TaqMan Gene Expression Assays, Foster City, Calif.): Ceramide Synthase 1 (Rn01420081_m1), Ceramide Synthase 2 (Rn01762789_m1), Ceramide Synthase 4 (Rn01767402_m1), Ceramide Synthase 5 (Rn01532864_m1), Ceramide Synthase 6 (Rn01270930_m1), Interleukin-6 (Rn01410330_m1). mRNA levels were normalized using beta actin, 18S ribosomal protein or glyceraldehyde-3-phosphate dehydrogenase as internal standards. Additional PCR primers were designed using Primer 3 (https://www.Frodo.wit.mit.edu), and the sequences are shown in S.Table XXX.
Enzymatic Activities
[0102] Fresh rat tissues were collected in 1 ml of homogenization buffer (25 mM HEPES, pH 7.4, containing 5 mM EGTA, 50 mM NaF, and complete mini EDTA-free protease inhibitor). Tissues were disrupted using pulse homogenizer, and centrifuged at 800×g for 5 min. The postnuclear supernatant was centrifuged at 250,000×g for 30 min at 4° C. in ultracentrifuge. The microsomal membrane pellet was resuspended in 250-500 μl of homogenization buffer. Protein concentration was measured using the BCA protein assay (Pierce, Rockford, Ill.).
(Dibydro)Ceramide Synthase Activity
[0103] Ceramide synthase activity was measured at 37° C. for 1 hr in HEPES buffer (20 mM, pH 7.4) containing 2 mM MgCl 2 , fatty acid-free bovine serum albumin (20 μmol) membrane proteins (0.05-0.1 mg), using dihydrosphingosine (sphinganine d17:0, 20 μmol) and palmitoyl-coenzyme A (70 μmol) as substrates. The reactions were stopped by adding chloroform-methanol (2:1, v/v) containing C12:0 ceramide (d18:1/12:0) as an internal standard. Lipid extracts were dried under nitrogen and reconstituted in chloroform-methanol (1:3, v/v; 0.1 ml) for LC-MS analyses. Products of reaction were measured using an Agilent 1100-LC system coupled to ion-trap XCT and interfaced with ESI (Agilent Technologies). The mobile phase A was methanol containing 0.25% acetic acid and 5 mM ammonium acetate; mobile phase B was water containing 0.25% acetic acid and 5 mM ammonium acetate. Lipids were separated using a reversed-phase Poroshell 300SB C-18 column (2.1×75 mm i.d., coating layer of 0.25 μm on total particle diameter of 5 μm, 300 Å of porous diameter, Agilent Technologies) and identified based on their retention times. A linear gradient was applied from 50% A to 100% B in 6 min at a flow rate of 1.0 ml/min with column temperature set at 50° C. The capillary voltage was set at 4.5 kV and skimmer voltage at 40V. Nitrogen was used as drying gas at a flow rate of 10 liters/min, temperature at 350° C. and nebulizer pressure at 60 psi. Helium was used as collision gas. For quantification purposes, we monitored the ions at m/z 526.5>508.5 for C17:0 dihydroceramide (d17:0/16:0) and m/z 482.5>464.5>264.3 for C12:0 ceramide (d18:1/12:0).
Primary Fibroblast Culture
[0104] Mouse embryonic fibroblasts (MEFs) were prepared from mice embryo as previously reported [21]. Briefly, pregnant mice at day 13 post coitum were sacrificed and the uteri were dissected out. Each embryo was separated from the placenta and the head and visceral tissues were removed. The remaining body was minced in PBS and incubated with 0.1 mM trypsin/1 mM EDTA at 37° C. for 15 min. Two volumes of Dulbecco's Modified Eagle Medium (DMEM) containing 10% fetal bovine serum (FBS) was added and stood for 5 minutes to settle down large pieces of unbroken tissues. The supernatant was then removed and centrifuged at 200×g for 5 min and suspended in fresh DMEM containing 10% FBS. Cells were cultured at 37° C. with 5% CO 2.
Mitochondrial Isolation
Senescence-Associated β-Galactosidase (β-Gal) Staining.
[0105] Detection of senescence-associated β-galactosidase staining was performed as previously reported [22]. Briefly, we plated MEFs on Lab-Tek chamber slides at a density of 5×10 4 cells per chamber. Next day, cells were treated with the indicated dose of drug for 48 hours. Cells were washed twice with PBS and fixed in 2% formaldehyde/0.2% glutaraldehyde for five minutes at room temperature. After two PBS washes the slides were incubated with fresh β-galactosidase stain solution (1 mg/mL 5-bromo-4-chloro-3-indoyl β-D-galactoside (X-Gal) 40 mM sodium phosphate, pH 6.0, 5 mM potassium ferrocyanide, 5 mM potassium ferricyanide, 150 mM NaCl, and 2 mM MgCl 2 ) at 37° C. for 12-16 hours. Slides were washed with PBS and mounted with DAPI containing media. Images were taken for the β-gal staining and overlapped with fluorescent images taken of the same region to count the number of cells staining positive for β-gal (Nikon Eclipse E600). More than 200 cells from 5 different regions of a slide were counted in a blind fashion.
DNA Replication Assay
[0106] Cells were seeded in 12-well plates (5×10 4 per well) and treated with 1 mM methamphetamine for 48 hours. The medium was then replaced with fresh media containing 2.5 μCi/mL of [ 3 H]thymidine (6.7 Ci/mmol, MPBio). After 24 hours, cells were rinsed twice with ice-cold PBS and genomic DNA was isolated using the DNeasy Kit (Qiagen). Radioactivity from the genomic DNA was measured in a liquid scintillation counter LS-6500 (Beckman Instruments, Fullerton, Calif.).
Crystal Violet Staining
[0107] To study cell morphology, cells were plated and treated in 6-well plates. After fixation, with 4% paraformaldehyde cells were stained with crystal violet (0.5% crystal violet in methanol:PBS, 1:1, v/v). After thorough wash in tap water, images were taken using a Westover Scientific Series 8 microscope.
Population Doubling
[0108] We plated 1×10 6 cells on a 60 mm dishes and treated them with 1 mM methamphetamine. Cells were trypsinized and re-plated at the same density (1×10 6 cells/dish) every 3 days for 6 passages. Population doublings were calculated according to the formula log (final cell number/plated cell number/log 2).
Statistical Analyses
[0109] Lipid-level data were analyzed using restricted maximum likelihood estimation (Proc Mixed; SAS Institute, Cary, N.C.), which can handle data sets in which some points are missing “at random” (e.g., due to technical problems) and which does not require homoscedasticity between conditions. Methamphetamine exposure was a between-subjects factor, and lipid species (or lipid family) was a within-subjects factor. Residuals under this mixed model were found to be normally distributed. P values from Proc Mixed were used to perform paired comparisons between the methamphetamine and control group for each lipid species (or family), maintaining an overall false discovery rate (Benjamini and Hochberg, 1995) of 0.05 for the entire experiment. For graphic presentation of group results, heatmaps were generated using the Studentized value for each comparison, such that each cell represents the size of the difference between the means of the methamphetamine and control groups, divided by the pooled standard error. Red cells indicate increased lipid levels in the methamphetamine group, and green cells represent decreased levels. For graphic presentation of individual-subject results, heatmaps were generated by normalizing the data for each lipid species relative to the mean and standard error of the control group, such that the color of each subject's cell indicates the number of standard errors above (red cells) or below (green cells) the mean of the control group. Descriptive statistics are presented as means±SD. The differences between unadjusted mean values were determined by two-tailed t-test. All confidence intervals correspond to a 95% confidence level.
[0110] U.S. Provisional Patent Application Ser. No. 61/806,335, filed on Mar. 28, 2013, is incorporated herein by reference in its entirety and particularly with respect to its updated and more comprehensively described research methods and results and discussion of their therapeutic utility.
ROS Production
[0111] Production of ROS was measured using the fluorescent probe CM-H2DCFDA (Invitrogen). This carboxy derivative of fluorescein carries additional negative charges that improve its retention compared to noncarboxylated forms. For these experiments, MEFs were grown in DMEM without phenol red, for which anti-oxidative properties have been reported. Cells were plated to subconfluence in 12-well plates, washed 3 times with pre-warmed PBS and loaded for 30 min at 37° C./5% CO 2 with 5 mM CM-H2DCFDA in DMEM without phenol red (loading medium). Then the loading medium was removed and pre-warmed fresh medium containing the different CYP450 inhibitors in presence or absence of methamphetamine was added. Fluorescence (excitation at 485 nm, emission at 530 nm) was analyzed immediately, cells were incubated at 37° C./5% CO 2 , and fluorescence was analyzed at the indicated time points. ROS rate versus control (%) was calculated subtracting the percentage of ROS increasing from time zero in the methamphetamine-treated samples to the percentage of ROS increasing from time zero in vehicle-treated samples.
REFERENCES
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[0134] Unless otherwise stated, the following terms used in the specification and claims are defined for the purposes of this Application and have the following meanings. It is noted here that as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise.
[0135] Each publication, patent application, patent, and other reference cited in any part of the specification is incorporated by reference in its entirety. With regard to any inconsistencies in usage, the present disclosure will dominate. Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be readily apparent to those of ordinary skill in the art in light of the teachings of this invention that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims. | Methamphetamine is a highly addictive psychostimulant that causes profound damage to the brain and other body organs. Post mortem studies of human tissues have linked the use of this drug to diseases associated with aging, such as coronary atherosclerosis, but the molecular mechanism underlying these findings remains unknown. We report now that methamphetamine accelerates cellular senescence in vitro and activates transcription of genes involved in cell-cycle control and inflammation in vivo by stimulating production of the sphingolipid messenger ceramide. This pathogenic cascade is triggered by reactive oxygen species, generated through methamphetamine metabolism via cytochrome P 450 -2D6, which recruit nuclear factor (NF)-KB to induce expression of enzymes in the de novo pathway of ceramide biosynthesis. Inhibitors of ceramide formation prevent methamphetamine-induced senescence and attenuate systemic inflammation and health deterioration in rats self-administering the drug. The results support therapeutic approaches to reduce the adverse consequences of methamphetamine abuse and improve effectiveness of treatments. | 0 |
BACKGROUND OF INVENTION
[0001] An embodiment relates generally to controller area network systems within a vehicle.
[0002] A controller-area network (CAN) is a vehicle bus standard intended to allow electronic control units (ECUs) and other devices to communicate with one another without a central or host computer. Vehicle systems and subsystems have numerous ECUs that control actuators or receive vehicle operation data from sensing devices. The CAN system is an asynchronous broadcast serial bus which communicates messages serially. Therefore, only one message is communicated on a communication-bus at one instance of time. When a message is ready to be transmitted onto the communication bus, the bus controller controls the message transfer on the bus. If more than one message transmission is initiated simultaneously by multiple transmitters, the more dominant message is transmitted. This is known as an arbitration process. A message with a highest priority will dominate the arbitration and a message transmitting at the lower priority will sense this and wait.
[0003] In various scenarios, messages relating to vehicle operation may be processed by different nodes in succession within a CAN system. In such a scenario, the messages are provided to a first node and the messages are processed at different instances of time. When the processing for a first message is completed at a respective node, it is transmitted along the communication bus to a next node for additional processing. Meanwhile, the next message is processed in the first node, and is thereafter successively transmitted along the communication bus to the next node for additional processing. This process continues for successive messages. Due to inherent delays in processing messages, or contention in the communication bus, messages may be lost in the communication process since there is no central or host computer to assure that each of the messages are maintained and not dropped. In such an instance, the lost message may be overwritten by another message. Therefore, there is a need to assure that each message that may be lost to due to jitter, asynchronous clocks, and finite bus controller buffer sizes, are properly maintained and processed within the CAN system.
SUMMARY OF INVENTION
[0004] An advantage of an embodiment is the reduction of message loss due to contention on the communication bus in a CAN system. Sender buffers are added in each node that store messages that are generated for transmission, but cannot be transferred to the bus controller due to the current message already occupying the memory of the bus controller. Receiving buffers are added in each node for storing message received from the communication bus where application components within a node for which the message is directed is not available to receive and process the received message. Therefore, messages that are delayed in transmission in the CAN system due to jitter, finite CAN controller buffer size, and asynchronous clocks can be stored in a buffer until the bus controller is available or the application component is ready to process the message.
[0005] An embodiment contemplates a distributed embedded real-time controller area network system for a vehicle. A communication bus transmits messages within the controller area network system. A plurality of nodes forms a plurality of communication endpoints that are communicably coupled by the communication bus. Each node comprises at least one application component for generating vehicle operation data and an electronic control unit that is in communication with the at least one application component. The electronic control unit generates a message containing the vehicle operation data. The electronic control unit functions in an event-triggered mode to initiate a transmission of the message to the communication bus. The electronic control unit includes a sending buffer for storing the generated message. A bus controller interfaces with the electronic control unit. The bus controller manages the transfer of messages to and from the communication bus. The transfer of messages onto the communication bus is executed by the bus controller on a periodic basis. The bus controller is unavailable to receive a message from the electronic control unit when a previous message stored within a memory of the bus controller is awaiting transmission on the communication bus. The bus controller is available to receive a message from the electronic control unit when the memory is empty. Messages are stored in the sender buffer when the bus controller is unavailable. A respective message within the sender buffer is transferred to the bus controller when the bus controller is available.
[0006] An embodiment contemplates a method of communicating messages between nodes within a distributed embedded real-time controller area network system of a vehicle. The controller area network system includes a communication bus and a bus controller for controlling a transmission of messages on the communication bus where the transfer of messages onto the communication bus is executed by the bus controller on a periodic basis. The controller area network system further includes a plurality of nodes forming a plurality of communication endpoints that are communicably coupled by the communication bus. Each node includes at least one application component, an electronic control unit, a sender buffer, and a receiver buffer. The method comprises the steps of the electronic control unit receiving vehicle operation data from the at least one application component and generating a message that includes the vehicle operation data for transmission on the communication bus. The electronic control unit functioning in an event-triggered mode for initiating the transmission of the message on the communication bus to a next respective mode. The message is stored in the sender buffer in response to the bus controller indicating that the communication bus is unavailable. A respective message is transferred from the sender buffer when the bus controller is available to receive a next message. The bus controller is unavailable to receive the next message from the electronic control unit when a previous message stored within a memory of the bus controller is awaiting transmission on the communication bus. The bus controller is available to receive a message from the electronic control unit when the memory is empty. The respective message is transmitted on the communication bus.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 is a schematic illustration of a controller area network system.
[0008] FIG. 2 is a timeline illustrating data message processing in the controller area network system.
[0009] FIG. 3 is a timeline illustrating a buffering technique for the controller area network system.
[0010] FIG. 4 is a flowchart of a buffering technique for a sender buffer according to an embodiment of the invention.
[0011] FIG. 5 is a flowchart for an enqueuing task for the sender buffer according to an embodiment of the invention.
[0012] FIG. 6 is a flowchart for a dequeuing task for the sender buffer according to an embodiment of the invention.
[0013] FIG. 7 is a flowchart of a buffering technique for a receiver buffer according to an embodiment of the invention.
[0014] FIG. 8 is a flowchart for an enqueuing task for the receiver buffer according to an embodiment of the invention.
[0015] FIG. 9 is a flowchart for a dequeuing task for the receiver buffer according to an embodiment of the invention.
DETAILED DESCRIPTION
[0016] There is shown in FIG. 1 a controller area network (CAN) system 10 . The CAN system 10 includes a plurality of electronic control units (ECUs) 12 - 18 coupled to a communication bus 20 which allows the ECUs to communicate with one another. Each of the plurality of ECUs 12 - 18 are coupled to one or more sensors, actuators, or control devices (the group hereinafter referred to as application components) and are generally represented by 20 - 26 , respectively. The application components are not directly connected to the communication bus 20 , but are coupled through the respective ECUs. The application components could also be software components in ECUs. A single control feature may span across multiple application components, and involve control messages from source to destination ECU via one or more intermediate processing/control ECUs attached to the same communication bus. For the purposes of this invention, it is understood that CAN systems are known in the art and that ECUs, application devices, CAN controllers, and transceivers are referred to as nodes and the details of their composition will not be discussed in detail herein.
[0017] In FIG. 1 , messages are serially communicated over the communication bus 20 to each ECU 12 - 18 as shown. Each node N 1 , N 2 , N 3 , and N 4 processes each message prior to transmitting each message to a next respective node. The five messages d 1 -d 5 are illustrated in FIG. 2 . Messages d 1 -d 5 are each transmitted sequentially to the first node N 1 . At the first node N 1 , each message is processed on a periodic basis and then is respectively transmitted to the second node N 2 for additional processing. Timeline 30 represents respective times when the messages d 1 -d 5 are input to the first node N 1 . Timeline 32 represents respective times when the messages d 1 -d 5 are provided to a controller area network controller (hereinafter referred to as a bus controller) for transmission to the second node N 2 via the communication bus.
[0018] Due to contention on the communication bus, a message may not be immediately added to the bus controller. If contention is present, then the message could be lost.
[0019] An example of message loss is illustrated in FIG. 2 . The first message d 1 is processed in the first node N 1 and then is transmitted on the communication bus to the second node N 2 . Timeline 34 illustrates the time when the message d 1 is received at the second node N 2 . Message d 1 is processed in the second node N 2 and is then is provided to the bus controller for transmission on the communication bus. The second message d 2 is processed in the first node N 1 as illustrated on timeline 30 .
[0020] Message d 2 is successfully transmitted on the communication bus and received by the second node N 2 as illustrated on timeline 32 . Before the arrival of message d 2 at node N 2 , the second execution of the application component on node N 2 needs the input, shown at 38 , in which case the first message d 1 is reused, as shown by the dotted line 36 in FIG. 2 . Between the second execution and the third execution of the application component on node N 2 on line 34 , two input messages d 2 and d 3 arrive at node N 2 as shown on line 32 in FIG. 2 . Since the typical buffer size for each node can only accommodate one message, message d 2 will be overwritten by message d 3 before it could be used by the application component on node N 2 . As a result, the third execution of the application component on node N 2 will use message d 3 and message d 2 will get lost.
[0021] FIG. 2 further shows that messages d 3 and d 4 are also lost due to message overwritten and message d 1 is repeatedly reused. The processed messages output from the fourth node N 4 include messages d 1 -d 1 -d 1 -d 1 -d 5 . Data messages d 2 , d 3 , d 4 are lost due message overwritten which may be the direct result of jitter, finite buffers, or asynchronous clocks.
[0022] To reduce message loss due to contention at the bus controller or on the communication bus, software based sender buffers and receiver buffers are utilized in each node. CAN Controller hardware contains hardware buffer cells (CAN mailboxes) used for data transmission and receiving. Therefore, the embodiments described herein are directed at a software based buffering strategy without any impacts to the actual CAN Controller hardware buffer usage. A respective ECU within a node will include a sender buffer and a receiver buffer that are shared by all application components on the respective node. For example, for nodes N 1 -N 4 as described in FIG. 2 , a common sender buffer and a common receiver buffer is utilized for all application components in N 1 , a common sender buffer and a common receiver buffer is utilized for all application components in N 2 , a common sender buffer and a common receiver buffer is utilized for all application components in N 3 , and a common sender buffer and a common receiver buffer is utilized for all application components in N 4 .
[0023] FIG. 3 illustrates the utilization of a sender buffer and a receiver buffer for preventing message loss. As shown in FIG. 3 , messages d 1 -d 5 are transmitted to the first node N 1 at periodic instances of time as shown on timeline 40 . Timeline 41 represents the time when the messages are transmitted out to the bus controller. Timeline 42 represents the time when the messages are transmitted out on the communication bus. Timeline 43 represents the time when the messages are received by the second node N 2 .
[0024] A sender buffer 44 is integrated within the ECU in the first node N 1 and is shared by all application components on the first node N 1 . The sender buffer 44 temporarily stores messages until the bus controller is ready to accept a next message for transmission on the communication bus.
[0025] A receiver buffer 45 is integrated within the ECU in the second node N 2 and is shared by all application components on the second node N 2 . The receiver buffer 45 temporarily stores messages received on the communication bus until the message is ready to be transferred to an application component.
[0026] As illustrated in FIG. 3 , all messages are input to the first node N 1 at periodic instances of time as shown on timeline 40 . In timeline 41 , messages may be prevented from being immediately placed in the bus controller due to message rewriting or another message occupying the bus controller. This is illustrated by message d 3 . Message d 2 shown on timeline 40 occupies the memory of the bus controller awaiting transmission on the communication bus. Typically, the bus controller has available memory for only a single message, and if a message such as d 2 is already occupying the bus controller, then message d 3 cannot be transferred to the bus controller. Under prior art conditions, message d 3 would be lost.
[0027] In a preferred embodiment as illustrated in FIG. 3 , if the bus controller is not ready to accept message d 3 , then data message d 3 is temporarily stored in the sender buffer 44 . The message d 3 is prioritized in a sender message link list where it waits until the bus controller is available. Various rules may be used to determine how a respective message is prioritized in the message link list as will be discussed in detail later. When the bus controller is empty and message d 3 is the highest ordered message in the sender buffer 44 , then message d 3 is transferred to the bus controller as shown on timeline 41 and is thereafter transmitted on the communication bus as shown on timeline 42 .
[0028] The receiver buffer 45 is a memory device integrated with an ECU of the second node N 2 . Application components receive messages from the receiver buffer 45 when the application is ready to process a message. If the application component is unable to accept the message received from the communication bus, then the message may be lost if not retrieved immediately. To reduce message loss, the receiver buffer 45 stores a respective message received in the bus controller until the application component is ready to accept the message. The message stored in the receiver buffer 45 is added to the end of a receiver message link list and awaits message retrieval by a respective application component. As shown in FIG. 3 , the receiver buffer 45 is shared by all application components in the second node N 2 . The receiver buffer 45 may be segregated into buffer cells and each buffer cell is maintained in the receiver message link list according a respective ordering scheme.
[0029] The process for buffering messages received from the communication bus is controlled by two software task modules that are used in cooperation with the sender buffer and the receiver buffer. A first task module is an enqueuing task module. The second task module is a dequeuing task module.
[0030] For each sender buffer, there is an enqueuing task module and a dequeuing task module. The enqueuing task is executed when the ECU cannot transmit a message to the bus controller due to the memory of the bus controller being occupied. The enqueuing task module provides a routine for adding the message to a respective cell of the sender buffer when the bus controller is unavailable.
[0031] The sender buffer includes a plurality of buffer cells. Each buffer cell within the sender buffer is treated as an individual memory block and the messages in different buffer cells are ordered in a sender message link list. The sender message link list prioritizes the order of the buffer cells. The enqueuing task module of the ECU maintains a binary flag for each buffer cell. When a corresponding buffer cell is empty, the binary flag is set to 1. When a corresponding buffer cell is occupied, the binary flag is set to 0.
[0032] When the enqueuing task module needs to add a new message to the buffer, a status of the binary flag in each buffer cell is first checked. If the binary flag indicates that there is an empty buffer cell (i.e., binary flag set to 1), then the new message will be entered into the buffer cell and the respective buffer cell is added to the end of the sender message link list. The flag of the respective buffer cell is changed from 1 to 0. In the event that there is no empty buffer cell available, then different deletion policies can be adopted to accommodate the new message such as the oldest message deleted first or the lowest priority message deleted first.
[0033] The second software task, the dequeuing task, is used to orderly transfer messages from the sender buffer to the bus controller. The dequeuing task could be triggered by different methods such as periodic triggering, or after the execution of enqueuing task module, or upon the confirmation of the successful transmission of the last message by the bus controller. When the dequeuing task is executed, a message is transferred from the sender buffer to the bus controller. If the transfer is successful, such that the bus controller is available to accept the message, then the message will be transferred and the respective message will be deleted in the sender buffer; otherwise, the message will remain in the sender buffer and the dequeuing task terminates. The dequeuing task will be executed again after the confirmation of the successful transmission of the last message by the bus controller, which indicates that the bus controller currently is available to receive a message. Various dequeuing policies may be used for determining which message in the sender buffer is selected for transfer to the communication controller. Dequeuing policies may include the oldest message transmitted first or highest priority message transmitted first.
[0034] For the receiver buffer, there is also an enqueuing task module and a dequeuing task module for transitioning messages from the communication bus to the application components. The enqueuing task module is utilized when a message needs to be retrieved from the communication bus. The enqueuing task module is triggered whenever a new message is received by the bus controller. Each cell of the receiver buffer is treated as an individual memory block and the messages in different buffer cells are organized as a receiver message link list. The enqueuing task module of the ECU maintains a binary empty-flag for each buffer cell (i.e., the binary flag is 1) when the corresponding cell is empty; otherwise the binary flag is 0. When the enqueuing task module needs to add a new message to the receiver buffer, it first checks whether there is an empty buffer cell. If there is an empty buffer cell, then the new message will be stored in the empty buffer cell and the buffer cell is added to the end of the receiver message link list. The binary flag of the buffer cell is changed from 1 to 0. In the event that there is no empty cell currently available in the receiver buffer, then different deletion policies may be adopted such as the oldest message is deleted first or the lowest priority message is deleted first.
[0035] The dequeuing task module is utilized for transferring messages from the receiver buffer to a respective application component. The dequeuing task could be triggered by an application component when an input message is needed or may be triggered periodically. Upon a successful removal of the message from the receiver buffer, the message will be removed from the receiver buffer and transferred to the application component or other local storage device associated with the application component. The dequeuing task would always remove the oldest message from the receiver buffer for each application component.
[0036] FIG. 4 illustrates a broad overview of a flow diagram for a sender buffer management technique for transferring messages from an application component of a respective node to the bus controller.
[0037] In block 50 , the application component processes the data and is transferred to the ECU within the node for generating and transmitting a message on the communication bus. In block 51 , the sender buffer enqueuing task is initiated. In block 52 , the respective message is stored in a respective cell of the sender buffer. In block 53 , the sender buffer dequeuing task is initiated. In block 54 , the message is transferred to the bus controller for transmission on the communication bus.
[0038] FIG. 5 illustrates a detailed process of the sender buffer enqueuing task module initiated as indicated in block 51 of FIG. 4 . In block 60 , the sender buffer enqueuing algorithm is initiated. In block 61 , a determination is made as to whether an empty buffer cell is available in the sender buffer. This determination is based on whether any buffer cell has a binary flag indicating an empty cell status. If the determination is made that a buffer cell is empty, then the routine proceeds to step 63 . If the determination is made that an empty buffer cell is not available in the sender buffer, then a currently stored message is deleted in the sender buffer cell, in step 62 , according to the deletion policy (e.g., oldest message deleted first or lowest priority message deleted first). In step 63 , the new message is stored in the empty buffer cell. The binary flag of the buffer cell is set to 1, and the buffer cell is added to the sender message link list. In step 64 , the enqueuing algorithm ends for this respective transfer task.
[0039] FIG. 6 illustrates a detailed process of the sender buffer dequeuing task initiated as indicated in block 53 of FIG. 4 . In block 70 , the sender buffer dequeuing algorithm is initiated. In block 71 , a determination is made as to whether the bus controller is available to accept a message. If the determination is made that the bus controller is not available, then the routine proceeds to step 73 . If the determination is made that the bus controller buffer is available to accept a message, then the message is removed from the sender buffer to the bus controller buffer according to the dequeuing process policy in step 72 , (e.g., oldest message is dequeued first or highest priority message is dequeued first). In step 73 , the dequeuing algorithm ends for the respective transfer task.
[0040] FIG. 7 illustrates a broad overview of a flow diagram for a receiver buffer management technique for transferring messages from a bus controller to an application component of a respective node. In block 80 , the application bus controller transmits a message on the communication bus and the message is received at a respective node. In block 81 , the enqueuing task for the receiver buffer is initiated. In block 82 , the respective message is stored in an empty cell of the receiver buffer. In block 83 , the receiver buffer dequeuing task is initiated. In block 84 , a respective message is transferred to a respective application component.
[0041] FIG. 8 illustrates a detailed process of the receiver buffer enqueuing task module as indicated in block 81 of FIG. 7 . In block 90 , the receiver buffer enqueuing algorithm is initiated. In block 91 , a determination is made as to whether an empty buffer cell is available in the receiver buffer by determining whether any receiver buffer cell has a binary flag indicating an empty cell status. If the determination is made that a receiver buffer cell has an empty cell status, then the routine proceeds to step 93 . If the determination is made that an empty buffer cell is not available in the receiver buffer, then a message is deleted in the receiver buffer cell according to the deletion policy (e.g., oldest message deleted first or lowest priority message deleted first). In step 93 , the received message is stored in the empty buffer cell. The binary flag of the respective receiver buffer cell is set to 1, and the respective receiver buffer cell is added to the end of the message link list. In step 94 , the enqueuing algorithm ends for this respective message task.
[0042] FIG. 9 illustrates a detailed process of the receiver buffer dequeuing task initiated as indicated in block 83 of FIG. 7 . In block 100 , the receiver buffer dequeuing algorithm is initiated. In block 101 , the oldest message stored in the receiver buffer is removed from the receiver buffer and is provided to the respective application component. In block 102 , the routine ends for this respective task.
[0043] While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. | A vehicular distributed embedded real-time controller area network system includes ECUs functioning in an event-triggered mode for initiating transmission of a message to a communication bus. Each ECU includes a sending buffer for storing message. A bus controller interfaces with the ECUs and manages the transfer of messages to and from the communication bus. The transfer of messages onto the communication bus is executed by the bus controller on a periodic basis. The bus controller is unavailable to receive a message from an ECU when a previous message stored within a memory of the bus controller is awaiting transmission on the communication bus. The bus controller is available to receive a message from an ECU when the memory is empty. Messages are stored in the sender buffer when the bus controller is unavailable. A respective message within the sender buffer is transferred to the bus controller when the bus controller is available. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to an oil-sealed vacuum pump which includes an oil circuit for supplying bearings and the pump chamber with oil as well as a valve arranged in the oil circuit for shutting off the oil supply to the pump chamber when the pump is at a standstill.
A vacuum pump of the above-outlined type is disclosed in British Pat. No. 875,444. The oil pump of the oil circuit of the vacuum pump disclosed in the British patent draws oil from a sump situated in the pump housing and drives the oil to a check valve-type arrangement whose closure member is biased by a very weak spring so that the oil pressure in the oil circuit is only slightly above atmospheric pressure. From the valve which opens when the pressure of the closing spring is overcome, the oil delivered in excess by the oil pump passes through the bearings of the pump shaft into the pump chamber and therefrom is reintroduced into the sump by a discharge valve.
It is a disadvantage of the above-outlined vacuum pump structure that the oil cannot be admitted to the bearings with a pressure which is significantly above the atmospheric pressure although such a higher oil pressure would be desirable for a reliable and continuous lubrication of the bearings. It would be thinkable to select a stronger spring for the check valve to cause an increase of the oil pressure in the oil circuit. This, however, would mean that the oil serving as a seal for the rotary piston is injected into the pump chamber with a continuous high pressure. The disadvantage of such an arrangement resides in the fact that at high suction pressures unnecessarily large oil quantities would be injected into the gases delivered in large quantities. This not only unnecessarily increases the oil consumption during the operation of a pump working at high suction pressures but also would mean an increased environmental pollution because of the high oil content in the gases expelled by the pump.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved oil-sealed vacuum pump of the above-outlined type in which a reliable bearing lubrication with pressurized oil is achieved and yet, a pump operation up to 1000 millibar suction pressure is ensured without unnecessarily charging the delivered gases with oil vapors.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the oil circuit which supplies the bearings of the pump chamber with oil has a pressure reducer for decreasing the overpressure, generated by the oil pump, to the atmospheric pressure and further, the conduit branches leading to the bearings are situated upstream of the pressure reducer, whereas the conduit branch leading to the pump chamber and to the shutoff valve are situated downstream of the pressure reducer as viewed in the direction of the oil flow.
In a vacuum pump structured as outlined above, with the aid of the oil pump and the pressure reducer a relatively high pressure may be maintained in that part of the oil circuit which supplies the bearings with lubricating oil. The pump chamber is supplied with depressurized oil so that the pump operates as a self-drawing pump. Such a pump draws little oil at high suction pressures while during operation at final pressures it draws a large quantity of oil. The increased oil consumption and the pollution of the environment at high suction pressures are thus significantly reduced with a pump structured according to the invention.
Further, an oil supply of the bearings by an oil circuit of relatively high pressure makes possible the use of an oil filter in this part of the oil line. Due to a relatively high pressure difference across the oil filter, only purified oil will be admitted to the bearings. It is further feasible to monitor the pump by means of the oil pressure which is an unequivocal indicator of the operational condition of the pump.
Further, supplying the pump chamber with oil by the subsequent, depressurized part of the oil circuit has the advantage that the pump chamber too, receives solely purified oil.
The shutoff valve ensures that when the pump is stopped, the oil quantities which are inside the pump chamber are reliably limited. This is of decisive advantage in the cold start of the pump and thus has a direct effect on the dimensioning of the pump motor. An undesirable oil increase in the pump and in the suction nipple during an accidental reverse run of the pump is also reliably prevented.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic elevational view of an oil circuit associated with a vacuum pump, according to a preferred embodiment of the invention.
FIG. 2 shows a preferred embodiment of a vacuum pump according to the invention, illustrated partially in section and partially as viewed in the direction of the front side of the pump body.
FIG. 3 is a sectional view taken along line III--III of FIG. 2.
FIG. 4 is a sectional view taken along line IV--IV of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, there are shown, in essence, those components of a vacuum pump which are deemed to aid in understanding the invention. Thus, the pump comprises an outer housing 1 including an oil sump 1a which is partially filled with oil 2. There is further shown a suction nipple 3 and a suction nipple valve 4, the latter being formed by a plate-like valve seat 5 provided with an opening 6 and a movable valve disc 7. The valve disc 7 is connected with a piston 8 which is displaceable in a cylinder 9.
The oil circuit of the vacuum pump comprises a suction conduit 11 through which, by means of an oil pump 12, oil is drawn from the sump 1a and driven into a pressure conduit 13. In the zone of the outlet opening 14 of the pressure conduit 13 there is arranged a throttle (pressure reducer) 15 which maintains the desired oil pressure (between 1.5 and 2 bar, preferably 1.7 bar) and by means of which the pressure of the oil is reduced to the pressure prevailing in the oil sump 1a. The bearings of the vacuum pump are supplied with pressurized oil by means of branch conduits 16, 17 and 18 of the oil circuit. Three oil supply conduits (16, 17 and 18) are required in case of a two-stage pump in which two end bearings and one intermediate bearing of the two rotors have to be supplied with oil. In case of a one-stage pump, two branch conduits are sufficient. After the pressurized oil supplied by the branch conduits 16, 17 and 18 has passed through the bearings, it returns to the oil sump 1a.
In the pressure conduit 13, immediately downstream of the oil pump 12, there is arranged an oil filter 19 to ensure that exclusively purified oil flows in the pressure conduit 13 and the branch conduits downstream of the oil filter 19.
A further branch conduit 21 extends from the pressure conduit 13 and opens into a control cylinder 22 which accommodates a control piston 23. An oil conduit 24 opens, at 25, into the control cylinder 22 at that side of the control piston 23 which is oriented away from the inlet of the conduit 21. The other end of the conduit 24 opens into the cylinder 9 adjacent that face of the piston 8 which is oriented away from the valve disc 7. The inlet opening 25 of the conduit 24 receives a plug 26 surrounded by a sealing grommet 27 to form a valve seat. The closing member of this valve is an end face 28 of a cylindrical extension 29 of the control piston 23. The extension 29 has a smaller diameter than that of the control piston 23. The control piston 23 is biased open by a spring 31 which is arranged between a shoulder of the control piston 23 and a cylinder end wall 32 which contains the inlet opening 25 of the conduit 24. The cylindrical extension 29 is threadedly engaged in the control piston 23 by means of a thread 33 so that the force of the spring 31 which acts when the control valve 27, 28 is in a closed position, may be varied.
A small-volume, open-top oil storage vessel 35 communicates with the control cylinder 22 by means of a conduit 34. The inlet opening of the conduit 34 in the cylinder 22 is adjacent that end face of the control piston 23 which is oriented away from the inlet of the conduit 21.
During operation of a vacuum pump constructed as described above, the oil pump 12 delivers oil from the oil sump 1a into the pressure conduit 13. The oil pump 12 may be a rotary vane pump or a gear pump and may be coupled to the vacuum pump shaft for being driven thereby, as described, for example, in British Pat. No. 875,444. The delivery characteristics of the oil pump 12 and the size of the throttle 15 are so designed that after the start of the vacuum pump the desired oil pressure is built up and maintained in the pressure conduit 13. The pressure in the conduit 13 exerts a force on the piston 23 and overcomes the force of the spring 31, so that the inlet opening 25 of the oil conduit 24 is closed. The suction nipple valve 4 is, under these conditions, in its open position so that the vessel coupled to the nipple 3 is evacuated.
During the above-outlined operational conditions predetermined oil quantities, designated at Q 1 , Q 2 and Q 3 flow through the pressure conduit 13. The piston 23 defines, with the wall of the cylinder 22, a relatively wide clearance 36 so that the chamber of the cylinder 22 underneath the piston 23 and the oil storage vessel 35 are filled with oil. By virtue of the clearance 36 a steady oil flow of a quantity Q 4 is maintained through the conduit 21. Excess oil is returned by overflow from the oil storage vessel 35 to the sump 1a. The oil pump 12 is so dimensioned that the entire oil circuit is operated with excess oil, that is, at all times more oil flows in the circuit than required by the vacuum pump.
When the vacuum pump is shut off, the oil quantities delivered by the oil pump simultaneously decrease so that the oil pressure in the pressure conduit 13 is reduced. When the pressure in the conduit 13 falls below a predetermined value, the force of the spring 31 lifts the piston 23 off the opening 25, so that by virtue of the atmospheric pressure prevailing at the upper surface of the oil in the oil reservoir 35, oil is forced into the conduit 24 and is introduced underneath the piston 8 into the cylinder 9. The oil quantity underneath the piston 23 and in the oil reservoir 35 is so small that the oil introduced into the cylinder 9 serves essentially only for sealing the piston 8 against the cylinder wall in which it slides. The pressure medium proper for actuating the piston 8 is air which is introduced into the conduit 24 behind the oil through the oil reservoir 35. The entire oil quantity in the cylinder 22 and in the oil storage vessel 35 amounts to a few cm 3 . This oil quantity should be so small that it serves essentially only as a seal for the clearance situated between the piston 8 and the cylinder 9. These occurrences ensure a closing of the suction nipple valve 4 without an undesirable intake of air. After the suction nipple valve 4 is closed and the air entering behind the oil has displaced the oil situated between the piston 8 and the cylinder wall 9, an airing of the pump chamber occurs. The operation of the suction nipple valve control is independent from the presence of the oil filter 19, that is, even in an oil circuit without an oil filter (as symbolized by the broken-line bypass 20), the suction nipple valve 4 and its control operate in a satisfactory manner.
A particular advantage of the construction of the suction nipple valve 4 and its control operating as a function of the oil pressure resides in that both cylinder and piston arrangements 8, 9 and 22, 23 are, because of the desired clearance between respective piston and cylinder not subject to strict manufacturing tolerances and therefore are inexpensive to make. By appropriate choice of the oil quantities Q 1 and Q 4 and by a corresponding adaptation of the force of the spring 31, the control arrangement may be adjusted such that even at relatively small pressure drops in the oil circuit (for example, a decrease of the desired pressure from approximately 1.7 bar to 1.5 bar) the inlet opening 25 of the conduit 24 is opened. The delay of response of the suction nipple valve 4 is, due to the hydro-pneumatic actuation, so short that it is ensured that even before standstill (that is, during inertia runout) of the vacuum pump the suction nipple valve 4 is closed. In general, the actuation of the suction nipple valve by means of the oil pressure in an oil circuit which is supplied by a vacuum pump shaft-driven oil pump has the advantage of a rapid and reliable operation, since the operational condition of the vacuum pump is unequivocally indicated by the oil pressure in the oil circuit.
With the outlet opening 14 of the pressure conduit 13 there is associated a spring biased closure 41 which, together with a particularly structured wall 42 in the zone of the outlet opening 14 performs several functions. The outlet opening 14 is surrounded by a groove 43 which is provided in the wall 42 and which is concentric with the outlet opening 14. The groove 43 extends to a bore 44 through which oil passes for supplying the pump chamber. The bore 44 is provided with a throttle 45 whose size is adapted to the suction power of the vacuum pump. The resilient closure 41 which is preferably an elastic steel strip, covers both the outlet opening 14 of the oil pressure conduit 13 and the bore 44. The spring force of the resilient closure 41 and the distance of its mounting points 46, 47 on the wall 42 from the oil ports 14 and 44 are so selected that they effect only a negligible pressure drop for the oil exiting the outlet opening 14. Thus, for all practical purposes, the oil is discharged through the outlet opening 14 with the pressure prevailing in the sump 1a. Further, at this location of the oil circuit too, the circulation is effected by means of excess oil, that is, even at the final pressure run of the vacuum pump, more oil is discharged through the outlet opening 14 than drawn by the pump through the throttle 45 arranged in the bore 44.
During operation of the vacuum pump, oil under pressure is, by virtue of the throttle 15, depressurized to the pressure prevailing in the oil sump 1a. The depressurized oil first flows into the groove 43 surrounding the outlet opening 14. From the groove 43 which communicates with the bore 44, one part of the oil flows, by virtue of the suction effect of the pump chamber, through the throttle 45 of the bore 44. Excess oil is reintroduced into the oil sump 1a. The resilient closure 41 ensures that only oil which has left the outlet opening 14 flows through the bore 44 and the throttle 45. Therefore, exclusively oil which has flown through the oil filter 19 is introduced into the vacuum pump chamber and consequently, the pump chamber cannot be endangered by soiled oil. Nevertheless, the vacuum pump operates as a self-drawing pump, that is, it determines itself the oil quantities it requires. In high pressure ranges, for example, small oil quantities flow through the throttle 45, so that undesirably high oil vapor components are no longer present in the gas removed by the vacuum pump. It is independently ensured that the vacuum pump bearings are supplied with pressurized lubricating oil.
Further, the resilient closure 41 and the groove 43 effect an oil shutoff during standstill of the vacuum pump. In such an operational condition the vacuum prevailing in the pump chamber causes, through the bore 44, the resilient closure 41 to be tightly pressed against the wall 42. In this manner, the closure 41 completely seals the bore 44 so that no oil supply to the vacuum pump can take place. This solution yields a further advantage: in general, it has been a problem that during an accidental reverse run of the pump (because of an erroneous switching) an undesired oil increase in the suction nipple 3 could occur. With the above-described arrangement, however, such oil increase is reliably prevented.
Turning now to FIG. 2, there is illustrated in section a rotary vane-type vacuum pump. During the operation of the pump the delivered gases, after they flow through the suction nipple 3, the open suction nipple valve 4 and a suction channel (designated by an arrow 51) are admitted into the pump chamber 52 which accommodates a rotor 53 with the vanes 54. The compressed gases are introduced through the outlet channel 55 into the oil sump 1a which is filled with oil up to the line 56 so that the resilient closure 41 is situated underneath the oil surface. The exhaust nipple proper is not shown.
The end wall 42 of the pump block 57 arranged in the oil sump 1a of the pump housing 1 is shown in elevation at its lower portion. Sections III--III and IV--IV taken through the frontal wall are illustrated in FIGS. 3 and 4. The pressure conduit 13 with the throttle 15 terminates in the front wall 42. Prior to the depressurization of the oil to the pressure prevailing in the oil sump 1a by virtue of the throttle 15, there is effected a lubrication of the bearing of the vacuum pump shaft (not shown) supported in the front wall 42. For this purpose oil is supplied in a branch conduit (port) 17. The port 17 is blocked outwardly by a plug 58.
The resilient closure 41 (shown in broken lines in FIG. 2) is secured to the front wall 42 by means of screws 46 and 47. The closure 41 covers the two openings 14 and 44 as well as the groove 43 surrounding the opening 14. The throttle 15 is formed by a bilateral piercing of the front wall 42. The throttle 45 is threadedly engaged in the front wall 42 by means of a thread 59 so that, dependent upon the suction power of the vacuum pump, different throttles 45 may be used.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | An oil-sealed vacuum pump comprises an oil circuit for supplying a pump chamber and bearings of the vacuum pump with oil. The oil circuit includes first and second branch conduits leading to the bearings and the pump chamber, respectively. The vacuum pump further has an oil pump coupled to the oil circuit for driving oil therethrough, a valve assembly coupled to the oil circuit for shutting off oil supply to the pump chamber during standstill of the vacuum pump, and a pressure reducer coupled to the oil circuit for reducing the oil pressure to environmental pressure. The first branch conduit leading to the bearings is situated upstream of, and the second branch conduit leading to the pump chamber and the valve assembly are situated downstream of the pressure reducer as viewed in the direction of oil flow in the oil circuit. | 5 |
This application claims the benefit of Provisional Application No. 60/341,640, filed Dec. 18, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the disposal of CHF 3 .
2. Description of Related Art
Fluoroform (CHF 3 , HFC-23) is a by-product of the reaction of HF with trichloromethane to form chlorodifluoromethane (CHF 2 Cl, HCFC-22), which is the primary source of perfluoroolefin, such as tetrafluoroethylene (TFE). The fluoroform by-product constitutes less than about 3 wt % of the HCFC-22 formed, but because annual production of HCFC-22 is large worldwide, the amount of fluoroform by-product made amounts to several millions of pounds per year. The fluoroform by-product either has to be used or has to be subject to disposal.
U.S. Pat. No. 3,009,966 discloses that fluoroform is thermally inert (col. 1, I. 13-14), but nevertheless finds a use for the fluoroform as a source of TFE and hexafluoropropylene (HFP) by pyrolysis of the fluoroform at temperatures of 700-1090° C., with temperatures of 1000° C. and higher being required to obtain conversions of at least 50% for the fluoroform at contact (pyrolysis times) of 0.1-0.12 sec. (Tables 1 and 2). The higher yields of HFP are accompanied by increasing amounts of perfluoroisobutylene (PFIB), which is toxic. Even at lower pyrolysis temperatures, the yields of PFIB can be quite high. U.S. Pat. No. 6,025,532 discloses the pyrolysis of fluoroform to a mixture of HF, TFE and HFP at a temperature of at least 700° C., but actually at 1000° C. at a contact time of 32 milliseconds (Examples), followed by contacting the mixture with a fluorination catalyst to obtain HFC-125 (CF 3 CHF 2 ) and/or HFC-227ea (CF 3 CHFCF 3 ). The high temperature required for pyrolyzing fluoroform at short contact times has limited the use of fluoroform by-product, whereby excess fluoroform has been available, which to avoid venting to the atmosphere has been disposed of by incineration.
Several references disclose the use of fluoroform in an auxiliary pyrolysis role. WO 96/29296 discloses the co-pyrolysis of HCFC-22 with fluoroalkane to form primarily large molecule fluoroalkanes. In particular, the reference discloses this reaction being carried out wherein the fluoroalkane co-reactant is fluoroform and the pyrolysis temperature is 700° C. and the contact time is 10 seconds, to obtain 100% conversion of the HCFC-22, with the result being a 60% yield of pentafluoroethane (Example 1). The disadvantage of this process, besides the extraordinarily long contact time, is that 40% of the yield is apparently not useful product. It is impractical to attempt to dispose of HFC-23 by consuming it in a process which produces such a high yield of by-product which itself needs disposal. Example 1 also reports that perfluoropropene is formed, without quantifying its amount, which is characteristic of reporting trace amounts detectable in the gas phase chromatography analysis used. The Examples of this reference are conducted with an aqueous alkaline wash of the pyrolysis reaction mixture to eliminate the HCl co-produced. The washing could also limit the ultimate reaction product to saturated HFC compounds. In the Examples the reactor is quartz. Quartz reacts with hydrogen fluoride, a probable intermediate in the pyrolysis reaction of HFC-23 and HCFC-22. The elements of hydrogen fluoride are part of the process according to the present invention and its consumption in side reactions, as with quartz, would lead to a reduction in the production of saturated hydrofluorocarbons.
Another reference disclosing the auxiliary use of fluoroform in a pyrolysis reaction is U.S. patent application Ser. No. 09/878,540, filed Jun. 11, 2001 (U.S. patent application Publication Ser. No. 2002/0032356-A), which discloses the pyrolysis of HCFC-22 in a gold-lined reactor to direct the synthesis reaction to the formation of the fluoroolefins TFE and HFP, without forming significant amounts of PFIB. The Examples disclose the co-pyrolysis of HCFC-22 and HCFC-124 (CF 3 CHFCl) to favor the formation of HFP over TFE. The possibility of fluoroform (CHF 3 ) being present with the HCFC-22 is also disclosed as a recycle gas in the reactor system, the fluoroform thereby being the major component fed to the reactor, indicating that the fluoroform is acting as an inert carrier in the pyrolysis process, as would be expected from the relatively low pyrolysis temperatures and short contact times disclosed. Such use of fluoroform is not an effective way to dispose of fluoroform.
The problem remains of finding an economically acceptable use for the fluoroform by-product so that it does not have to be incinerated.
BRIEF SUMMARY OF THE INVENTION
The present invention solves this problem by consuming fluoroform (HFC-23) to economically produce useful product by co-pyrolyzing the fluoroform with chlorodifluoromethane (HCFC-22) at a temperature in the range of about 625-800° C., preferably about 690-775° C. and contact time of less than two seconds, and obtaining as a result thereof a product mixture of useful saturated and unsaturated compounds, i.e. at least three compounds selected from the group consisting of pentafluoroethane (CF 3 CHF 2 , HFC-125), heptafluoropropane (CF 3 CHFCF 3 , HFC-227ea), TFE, and HFP, respectively. The process can be carried out by feeding the mixture of reactants (HCFC-22 and HFC-23) through a reaction zone, the surface of which is metal, preferably gold, to minimize the formation of perfluoroisobutylene by-product in the pyrolysis reaction.
Unexpectedly, the HFC-23 pyrolyzes at the relatively low temperature of the co-pyrolysis reaction in short contact times to produce a high yield, e.g. at least 80%, of the above-mentioned useful products and little to no detectable PFIB. Apparently, the presence of the HCFC-22 in the pyrolysis reaction reduces the reaction (decomposition) temperature of the HFC-23 so that the latter is consumed in the pyrolysis reaction. Typically at least 4 parts by weight of HFC-23 is consumed for each 100 parts by weight of HCFC-22 such that the amount of HFC-23 consumed is greater than the amount produced as by product during the manufacture of HCFC-22.
The function of the fluoroform in the present invention is to increase the amount of useful saturated two- and three-carbon atom compounds, CF 3 CHF 2 (HFC-125) and CF 3 CHFCF 3 (HFC-227ea), along with production of TFE and HFP.
DETAILED DESCRIPTION OF THE INVENTION
The pyrolysis reaction in the present invention is carried out by continuous feeding of the co-reactants to a pyrolysis reactor and continuously withdrawing the resultant mixture of reaction products and unreacted reactants from the reactor. Pyrolysis reactors generally comprise three zones: a) a preheat zone, in which reactants are brought close to the reaction temperature; b) a reaction zone, in which reactants reach reaction temperature and are at least partially pyrolyzed, and products and any by-products form; c) a quench zone, in which the stream exiting the reaction zone is cooled to stop the pyrolysis reaction, preferably to 500° C. or lower, to reduce coking or polymerization downstream of the reaction zone. “Coke” is solid carbonaceous material that accumulates in, and on the surface of, the reactor. The resulting fouling is undesirable because it interferes with heat transfer and fluid flow. Quenching may be accomplished by interior cooling or exterior cooling, or both.
The reactor can be tubular, wherein the pyrolysis reaction occurs in the interior of the tube, and the tube can have a variety of cross-sectional shapes, such as circular, oval (elliptical) or polygonal, said shapes being of the interior or of the exterior surfaces of the tube, or both. The tubular reactor will typically have an inner diameter in the case of circular cross-section of at least about 0.125 in (0.32 cm), preferably about 0.125 in (0.32 cm) to about 3 meters, more preferably about 0.5 in (1.27 cm) to about 2 m, and most preferably about 0.7 in (1.8 cm) to about 1 m. The ratio of volume to surface area of a tubular reactor of unit length and of interior radius R can be determined by dividing the surface area A (A=2 πR) into the volume V (V=π·R2). If R is in centimeters, V/A=(R/2) cm3/cm2. In this way it can be stated that the volume to surface ratio is at least about 0.08 cm3/cm2, preferably about 0.08 cm3/cm2 to about 75 cm3/cm2, more preferably about 0.32 cm3/cm2 to about 50 cm3/cm2, and most preferably about 0.64 cm3/cm2 to about 25 cm3/cm2.
The reactor is made of metal, such as nickel or nickel alloy. The exposed surface of the reaction zone in particular is of a metal that resists corrosion at the pyrolysis temperatures of reaction of HCFC-22 and HFC-23. Nickel or nickel alloys such as Inconel® or Hastelloy® are preferred, Inconel® is more preferred. Most preferred is gold, because gold is more resistant to the corrosive action of hydrogen halides and the formation of coke than are nickel-based materials. Gold has the further advantage of suppressing PFIB formation. Whereas the process of this invention with a nickel or nickel alloy reactor generates less than about 5% PFIB based on the combined weight of TFE, HFP, HFC-125 and HFC-227ea, in a gold reactor less than about 2% PFIB is formed on the same basis. “Exposed surface” refers to the surface that is exposed to the reactants and/or reaction products in the reaction zone. Apart from using gold as the material of the surface of the reaction zone and optionally of the exposed surface of the quench zone, the reactor can be of conventional design.
The gold on the interior surface of the reaction zone must be supported by a heat-resistant, thermally conductive material of construction, such as a metal which has a melting temperature of at least about 1100° C. and which gives structural integrity to the reactor. Inconel® and Hastelloy® are nickel alloys suitable for use as supporting materials for the gold lining of the reactors (see for example U.S. Pat. No. 5,516,947). Other thermally conductive supporting materials can be used. Thermal conductivity enables the reactor to be externally heated to provide the interior temperature necessary for the pyrolysis reaction. It is desirable that the supporting material be metallurgically bonded to the gold lining for the best heat transfer. By a metallurgical bond is meant a bond in which atoms of the metals in the supporting material and the gold lining interdiffuse, that is, diffuse among each other about the bonded interface. U.S. patent application Publication Ser. No. 2001/0046610 (Nov. 29, 2001) discloses a method for making a gold-lined tube in which the gold lining is metallurgically bonded to the supporting material.
Normally a plurality of the tubular reactors will be positioned within a shell, and a heating medium will be flowed between the interior wall of the shell and the exterior walls of the tubular reactors bundled therein to provide the heating for the pyrolysis reaction. Alternatively, the shell can be exteriorly heated or fired by means such as electrical means to provide the interior heating. The combination of the shell and the tubular reactors positioned therein forms the pyrolysis furnace. Alternatively, the reactor may consist of a single reaction vessel, where the required heat for the reaction is other means such as hot inert gas mixed with the reactants. Use of hot inert gas to supply some or all of the heat needed for the reaction reduces or eliminates the heat that must be supplied through the reactor wall. Supplying heat through the reactor wall requires that the wall be hotter than the contents of the reaction space. This condition can lead to undesirable reactions and to decomposition of reactants, intermediates, or products at the wall. The greater the reactor cross-section, the higher wall temperatures must be to supply the necessary heat. Therefore, heating by means of hot inert gas becomes more attractive as the reactor cross-section increases. Examples of hot inert gases which can be used include helium and tetrafluoromethane.
Preferably, the residence time (contact time) in the reaction zone is less than about 1.5 seconds, and more preferably the residence time is about 0.01 to about 1 seconds and even more preferably, from about 0.05 to about 0.8 seconds. Residence time is determined by dividing the net volume of the reaction zone by the volume feed rate in seconds of the gaseous feed to the reactor at reaction temperature and pressure.
The gas temperature within the reaction zone is considered to be the pyrolysis reaction temperature and is measured using a thermocouple in the gas phase in the reaction zone. The reaction zone is heated to a temperature sufficient for the pyrolysis reaction to occur, preferably within the reaction time of less than 1.5 seconds.
Preferably, the HCFC-22 and HFC-23 are preheated to temperatures approaching but not reaching the temperatures at which their respective pyrolyses begin. Preheating reduces the amount of heat that must be provided in the reaction zone and thereby reduces the temperature difference between the walls of the reaction zone and the gas feed. The closer the wall and the gas temperatures are to the desired reaction temperature, the fewer will be side reactions generating undesirable products and reactor fouling. HCFC-22 and HFC-23 may be mixed and preheated together. The preferred preheating temperature when the two gases are fed together is between about 500° C. and 600° C., and most preferably between about 550° C. and 600° C. If the gases are preheated separately the HCFC-22 is preheated to about 300° C. to 450° C., and the HFC-23 is preheated to about 500° C. to 600° C.
In another embodiment in which HFC-23 and HCFC-22 are preheated separately, the HFC-23 is preheated to at least about 850° C., and the HCFC-22 is preheated to about 300° C. to 550° C. This embodiment is preferred for adiabatic reaction of HFC-23 and HCFC-22 or to reduce the amount of heat that must be supplied to the reaction by heating the reaction vessel. It takes advantage of the thermal stability of HFC-23 to heat it to less than its decomposition temperature (e.g. conversion of no more than 3%) in the absence of HCFC-22. The heat in the HFC-23 supplies some or all of the heat necessary for the reaction of HFC-23 with HCFC-22 and reduces or eliminates the need for heat to be provided to the reaction vessel. The quantity of heat provided will depend upon the amount of HFC-23 in relation to the amount of HCFC-22.
Depending upon contact times and reaction zone temperatures as well as feed ratios, HFC-23 and HCFC-22 may not be consumed completely in a single pass through the reactor. In continuous processes it is often most efficient to operate at less than 100% conversion so as to maximize production of desired products and minimize undesirable products and fouling. When conversion is less than 100% in the process of this invention, the stream exiting the reactor is treated by conventional methods such as distillation to separate products from unreacted reactants, and the unreacted reactants are mixed with fresh HFC-23 and HCFC-22 to bring the resulting mixture to the desired composition, and the mixture is fed back into the reactor. It may also be desirable to recycle some of the products. For example, CF 3 CFHCl (HCFC-124), CF 2 ClCF 2 H (HCFC-124a), and octafluorocyclobutane ((CF 2 ) 4 , c318) if formed, can be separated from other products such as HFC-125, HFC-227ea, TFE, and HFP, and added to the reactor feed mixture. Pyrolysis of HCFC-124 and HCFC-124a in the presence of HCFC-22 and HFC-23 contributes to the production of HFP. c318 contributes to TFE production. Through recycling, more HFC-23 can be consumed than is produced in the original manufacture of HCFC-22.
In another embodiment, the flow of the feed through the reactor is partially obstructed to cause back-mixing, i.e. turbulence, and thereby promote mixing of reactants and good heat transfer, further reducing the necessary residence time of the feed in the reactor, e.g. to less than about one-half second. This partial obstruction can be conveniently obtained by using perforated baffles or packing. Increased back-mixing can also be accomplished by increasing the feed rate so as to cause turbulent flow through the reactor.
The volume ratios of HFC-23:HCFC-22 are preferably about 1:10 to 5:1. One preferred ratio is about 2:1 to 5:1, more preferred being about 2:1 to 4:1. Another preferred ratio is no greater than 1:1, such as 1:10 to 1:1. Unreacted HFC-23, is recovered and recycled along with the unconverted HCFC-22. Enough fresh HFC-23 and HCFC-22 are added to this recycle stream to make up for the material converted in the reactor. Preferably the residence time in the reaction zone (contact time), and the relative proportions of HCFC-22 and HFC-23, are such that overall conversion is at least about 10% and yield to useful products is at least about 90%.
HFC-125 finds use as a refrigerant and HFC-227ea finds use as a propellant and fire extinguishant.
The reactor is operated at a temperature, residence time and HFC-23:HCFC-22 ratio such that at least 3 parts of the HFC-23 is converted relative to 100 parts of HCFC-22 converted in order that the amount of HFC-23 consumed is greater than the amount of HFC-23 produced as a by-product during the manufacture of HCFC-22 and which HFC-23 is usually less than about 3 wt %.
EXAMPLES
The reactor used herein is a ¾ inch (1.9 cm) inner diameter (ID) gold-lined reactor. The reactor outer tube material is a 16 inch (40.6 cm) length Inconel® 600 (nickel alloy) tube with a wall thickness of 0.113 inch (0.29 cm) and an outer diameter (OD) of 1.046 inch (2.7 cm). The inner tube material is gold, metallurgically bonded to the Inconel® as described in Example 1 of U.S. patent application Publication Ser. No. 2001/0046610 (Nov. 29, 2001). The wall thickness of the gold tube is 0.039 inch (0.1 cm) and the tube ID is 0.742 inch (1.9 cm). Prior to using this tube, an 8 inch (20.3 cm) portion (centered in the 16 inch (40 cm) length) is milled to an OD of {fraction (15/16)} inch (2.4 cm) so that 1 inch (2.5 cm) ID clamp-on heaters fit snugly with enough room to position thermocouples that control and monitor temperatures. The preheat zone is 5 inch (13 cm) long and the reaction zone is 2 inch (5 cm) long. They are heated by a ceramic-type band heaters. Temperatures are controlled using thermocouples positioned at the center of each section on the outside wall of the tube. They are held securely in place by the heaters themselves. In addition, the corresponding gas temperature inside the reaction zone is also measured. Gas feeds to the reactor are controlled using calibrated mass flowmeters. The reactor is operated at about 1-2 psig (108-115 kPa) back-pressure to get flow through the analytical system.
A small portion of the product stream from the reactor is analyzed using an on-line GC/MS (gas chromatograph/mass spectrometer) equipped with a 20 foot (6.1 m)×0.125 inch (3.2 mm) steel column packed with 5% Krytox® 143AC perfluoroether on 60/80 mesh (0.25/0.18 mm) Carbopak BHT. GC programming conditions are set for a start temperature of 60° C. which is held for 3 minutes. It is then heated to 200° C. at the rate of 5° C./minute and held at 200° C. for 5 minutes. The analytical results are reported in mole %. In the examples, product analysis shows less than 2 wt % PFIB based on the total weight of TFE, HFP, HFC-125, and HFC-227ea unless otherwise stated.
The identification and structure of fluorocarbons disclosed herein are listed below.
HCFC-22 =
CHF 2 Cl
HFC-23 =
CHF 3
HFC-125 =
CF 3 CF 2 H
HFC-227ea =
CF 3 CHFCF 3
HFC-227ca =
CF 3 CF 2 CF 2 H
TFE =
CF 2 ═CF 2
c318 =
cyclo(CF 2 ) 4
HFP =
CF 2 ═CFCF 3
HCFC-124 =
CF 3 CFHCl
HCFC-124a =
CF 2 ClCF 2 H
HCFC-226cb =
CF 2 ClCF 2 CF 2 H
FC-1318 =
C 4 F 8 isomer
PFIB =
(CF 3 ) 2 C═CF 2
not PFIB
Example 1
Through the reactor maintained at an operating control temperature setting of 775° C. and a preheater temperature setting of 600° C., a stream of HFC-23 is passed at flowrates of 800, 400, 200, and 100 cc/min at standard temperature and pressure (sccm). At the operating flowrates of 400, 200, and 100 sccm, the conversion of HFC-23 to TFE is about 0.2, 0.4, and 0.6% respectively. Only traces of HFP, HFC-125 and HFC-227ea are observed. The gc detection limit is about 1000 ppm.
Conclusion: When HFC-23 is the sole feed to the reactor at 775° C., >99 mole % of HFC-23 is unreacted, and only TFE is formed in measurable quantities in the little reaction that does occur. Other small amounts of byproducts produced were less than 0.2 mole % of the total.
Example 2
Through the reactor maintained at a control temperature setting of 850° C. and a preheater setting of 600° C., a stream of HFC-23 is passed at flowrates of 400, 200 and 100 sccm. The conversion of HFC-23 to TFE is 0.9, 2.0 and 3.0% respectively. Also observed are 0.2 and 0.6% HFP at HFC-23 flowrates of 200 and 100 sccm. At the HFC-23 operating flowrate of 100 sccm, 0.15% HFC-125 is obtained which corresponds to less than 5% of the total of TFE and HFC-125. Perfluoroisobutylene (0.08%) is also identified by GC/MS at this low-flow condition.
Conclusion: Even at a reactor control temperature setting of 850° C., when HFC-23 is the sole feed to the reactor, conversion is only from about 1 to 5 mole % and 95% of the product that forms is TFE and HFP. HFC-125 production is <5% of the product and HFC-227ea is less than 1%.
Examples 3-6
Through the reactor, operating at a control temperature setting between 775° C. and 850° C. and a preheat temperature of 600° C. is passed an equimolar flow of HFC-23 and HCFC-22 at the rates indicated in Table 1. The major products of the reaction, and the combined unconverted HCFC-22 and HFC-23 starting materials are shown in Table 1. Contact time for these Examples is about 1 second.
TABLE 1
Example Number
3
4
5
6
Reactor control temp. setting
775
825
850
850
(° C.)
Reactor gas temperature (° C.)
697
735
751
747
HCFC-22 feed (cc/min)
100
100
100
200
HFC-23 feed (cc/min)
100
100
100
200
Results (mole %)
TFE
9.80
5.51
5.05
11.80
HFC-125
0.68
2.89
3.86
1.45
HFP
1.94
4.88
6.08
3.11
HFC-227ea
ND
1.80
2.25
0.80
HCFC-124a
3.16
4.21
3.75
3.45
HCFC-124
0.29
0.75
0.80
0.52
c318
2.99
2.02
1.33
2.57
PFIB
0.05
0.18
0.26
0.10
FC-1318
0.07
0.25
0.40
0.14
HCFC-226cb
0.67
0.49
0.33
0.45
HFC-23 + HCFC-22
79.5
75.3
73.6
74.6
125/(125 + TFE) × 100
6.5
34.4
43.3
10.9
227ea/(227ea + HFP) × 100
—
26.9
27.0
20.5
ND = Less than 100 ppm by total volume.
Conclusion: Compared to the pyrolysis of HFC-23 alone in Examples 1 (reactor control temperature setting 725° C.) and 2 (reactor control temperature setting 850° C.), pyrolysis in the presence of HCFC-22 gives 0.7% HFC-125 at reactor control temperature setting 725° C. (reactor gas temperature 697° C.), where none was detectable in Example 1, and 3.9% HFC-125 at 850° C. (reactor gas temperature 750° C.), compared to 0.15% in Example 2. The presence of HCFC-22 promotes the pyrolysis of HFC-23 and the formation of HFC-125 and HFC-227ea. If necessary or desired, the HCFC-124, HCFC-124a, and c318 can be recovered as products or recycled back to the reactor to produce additional quantities of TFE and HFP.
Examples 7-14
In these examples, the ratio of HFC-23:HCFC-22 is varied in addition to the reactor control temperature. The preheater setting is 600° C.?. The results summarized in Table 2 show the reaction products obtained. Contact time for these Examples is about 0.5 second.
TABLE 2
Example Number
7
8
9
10
11
12
13
14
Reactor Control
775
775
825
825
825
850
850
850
temperature
Setting (° C.)
Reactor gas
692
694
729
729
731
746
750
746
temperature (° C.)
HFC-23 feed (cc/min)
300
350
250
300
350
250
300
350
HCFC-22 feed
100
50
150
100
50
150
100
50
(cc/min)
Results (mole %)
TFE
7.71
2.77
9.31
6.47
2.71
8.46
6.01
2.87
HFC-125
0.35
0.16
1.06
0.86
0.31
1.52
1.44
0.45
HFP
0.62
0.17
1.93
1.17
0.30
2.45
1.71
0.41
HFC-227ea
0.15
0.09
0.58
0.48
0.16
0.84
0.79
0.22
HCFC-124a
0.45
0.03
1.04
0.71
0.03
1.99
0.82
0.03
HCFC-124
0.05
0.01
0.09
0.12
0.02
0.34
0.17
0.02
c318
0.66
0.10
1.72
0.89
0.15
1.63
0.89
0.18
HFC-23 + HCFC-22
90.0
96.7
84.3
89.3
96.3
82.8
88.2
95.8
125/(TFE + 125) × 100
4.3
5.4
10.2
11.7
10.3
15.2
19.3
13.6
227ea/(HFP + 227ea) ×
19.4
34.6
23.1
29.1
34.8
25.5
31.6
32.8
100
Conclusion: Increasing the ratio of HFC-23 to HCFC-22 in the feed from 1:1 (see Example 6 in Table 1) through 5:3 favors formation of HFC-125 and HFC-227ea over TFE and HFP. Conversion declines at the expense of the fluoroolefins until, at 7:1, conversion to HFC-125 and HFC-227ea declines also although the amount of HFC-125 and HFC-227ea, relative to TFE and HFP respectively increases.
Examination of the data summarized in Table 2 and comparison with Table 1 shows that at a given operating temperature, the amount of HFC-125 and HFC-227ea that can be coproduced can be varied by varying the HCFC-22:HFC-23 ratio. Again, comparison of the results with that obtained with Example 2 shows that the yields of HFC-125 and HFC-227ea relative to TFE and HFP respectively are higher when HCFC-22 is present in the feed along with HFC-23.
Examples 15-18
Examples are run in a gold-lined quartz TGA (thermogravimetric analyzer) type flow reactor (a 1 in (2.54 cm) diameter quartz tube lined with gold foil) packed with prefluorinated 2 mm gamma alumina spheres. The selective preheat of the reactants fed the HFC-23 is preheated to 600° C. and HCFC-22 to 400° C. The ratio of HCFC-22:HFC-23 is varied and so is the total flow rate and the wall temperature. The contact time for these Examples is less than 0.5 seconds. The results in Table 3 describe the reaction products. The remainder is essentially unreacted HCFC-22 and HFC-23.
TABLE 3
Example Number
15
16
17
18
Reactor wall temp. (° C.)
775
775
850
850
Reactor gas temperature (° C.)
704
693
768
753
HCFC-22 feed (cc/min)
106
250
106
250
HFC-23 feed (cc/min)
519
750
519
750
Results (mole %)
TFE
20.2
19.5
17.9
24.6
HFC-125
0.9
0.3
3.1
1
HFP
2.3
1.2
8.1
3.6
HFC-227
2.1
1.4
3.4
2
HCFC-124a
0.6
0.3
0.7
0.4
c318
ND
ND
0.1
0.05
PFIB
ND
ND
0.07
0.35
HFC-23 + HCFC-22
71.5
76.8
61.3
64.5
125/(125 + TFE) × 100
4.3
1.5
14.8
3.9
227/(227 + HFP) × 100
47.7
53.8
38.6
46.3
Conversion of HCFC-22
82.9
59.6
92.9
81.6
Conversion of HFC-23
17.4
11.1
27.6
20.1
ND = less than 100 ppm. HFC-227 is a combination of the isomers HFC-227ea and HFC-227ca.
Under these conditions, the yield of the saturated compounds are high and the yield of HFC-227 is much higher than the yield of HFC-125. | The present invention relates to the co-pyrolysis of fluoroform and chlorodifluoromethane to form a mixture of useful fluoroolefin and saturated HFCs, notably, tetrafluoroethylene and hexafluoropropylene and CF 3 CHF 2 and CF 3 CHFCF 3 , respectively. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a non-provisional patent application claiming the benefit of the filing date of U.S. Provisional Application No. 60/613,889, filed Sep. 28, 2004, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention pertains to a valve assembly and method for increasing efficiency thereof, in the neutral mode of operation, without impairing the performance in non-neutral operating modes. The present invention further relates to a hydraulic system that includes the noted valve assembly and an improved method of operation. Specifically, a separate charge pump relief valve is eliminated and the valve bypass orifices utilize increased cross-sectional areas to permit the passage of substantially the full flow of the charge pump at a low restriction to flow through these orifices.
[0004] 2. Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
[0005] Hydrostatic transmissions have many uses, including the propelling of vehicles, such as grass mowing machines, and offer a stepless control of the machine's speed. A typical hydrostatic transmission system includes a variable displacement main pump coupled in a closed hydraulic circuit with a fixed displacement hydraulic motor. For most applications, the main pump is driven by a prime mover, at a predetermined speed, in a given direction. Changing the displacement of the main pump will change its output flow rate, which controls the speed of the coupled motor. Main pump outflow can be reversed, thus reversing the directional rotation of the motor. In a vehicle, the motor is connected directly, or via suitable gearing, to the vehicle's wheels or tracks. Both acceleration and deceleration of the transmission are controlled by varying the displacement of the main pump from its neutral position. A charge pump is added to the hydraulic circuit in order to charge the closed circuit with hydraulic fluid, through check valves, thus making up for possible lost fluid due to internal leakage. Additional valves, such as high pressure relief valves, bypass valves and hot oil shuttle valves, for example, are also often utilized, in a manner well known in the art. The present invention relates specifically to the hydraulic main pump and motor combination having improved integrated valves for providing smoother operation, particularly during the acceleration phase of the transmission, near its neutral position.
[0006] In hydrostatic transmission applications, an over-center variable displacement main pump is normally utilized, with a control handle enabling the operator to control the direction and amount of flow from the main pump. By pushing the handle in one direction, the main pump delivers flow in one direction of motor operation. By pulling the handle in the opposite direction, the main pump delivers flow for the opposite direction. In order to avoid a rough, jerky start of the motor, the prior art has utilized an orifice with a fixed diameter that is added to the closed-loop circuit to increase the width of the dead band of the hydrostatic transmission. The dead band of a hydrostatic transmission refers to the non-response range of the transmission, near its neutral position, where the motor will not turn over due to internal cross-port leakage across the bypass orifice.
[0007] Prior art U.S. Pat. No. 6,837,047 B2, also assigned to the assignee of the present invention, and which will be more fully discussed in the “Detailed Description of the Invention”, sets forth a hydraulic valve assembly, as well as a hydraulic system that utilizes this valve assembly, together with a method for increasing the width of the transmission dead band, wherein the bypass orifices are enabled in the neutral position, but are substantially disabled in non-neutral positions. While this has improved transmission performance, the present invention represents an improvement over these prior art constructions by eliminating the previously-required prior art charge pump relief valve and modifying the hot oil shuttle valve by increasing the sizes of the bypass orifices so as to allow the passage of substantially the full flow of the charge pump, at a low pressure drop, i.e., at a low restriction to flow through these bypass orifices, thus resulting in a less costly and more efficient hydrostatic transmission that also operates at a lower working temperature.
[0008] The patent literature sets forth a large number of hydrostatic transmission pump/motor systems, including, for example: U.S. Pat. No. 2,961,829 to Weisenbach; U.S. Pat. No. U.S. Pat. No. 3,326,049 to Reinke; U.S. Pat. No. 3,734,225 to Kobald et al.; U.S. Pat. No. 5,211,015 to Schroeder, and U.S. Pat. No. 6,263,670 B1 to Gluck et al. However, none of these prior art structures pertains to the specific structure, system, and method of operation of the present invention.
BRIEF SUMMARY OF THE INVENTION
[0009] Accordingly, in order to overcome the deficiencies of the prior art devices and methods, the present invention provides an improved hydraulic valve assembly that eliminates the previously-required charge pump relief valve and utilizes a modified hot oil shuttle valve, having increased cross-sectional area bypass orifices that allow the passage of substantially the full flow of the charge pump, at low pressure drop, i.e., at a low restriction to flow through these orifices. This results in a less costly and more efficient hydrostatic transmission that also operates at a lower working temperature.
[0010] Specifically, in terms of structure, a feature of the present invention is to provide a hydraulic system for use with a hydrostatic transmission, comprising in combination: a variable displacement main pump; a hydraulic motor; a closed loop hydraulic circuit, including low and high pressure leg portions, operatively interconnecting the main pump and motor; a charge pump, within the circuit, having an outlet line only to the circuit; a valve block within the circuit, for controlling fluid transfer between a first, second and third line, within the hydraulic circuit, wherein two of the first, second and third lines define first and second pressure lines and are located at substantially similar longitudinal distances from the remaining one of the first, second and third lines, the remaining line being rotationally displaced relative to the first and second pressure lines, the valve block comprising:
i. a valve body defining a first port for connection to the remaining line, a second port for connection to one of the first and second pressure lines, and a third port for connection to the other of the first and second pressure lines, the valve body further including a spool bore in fluid communication with the first, second and third lines; ii. a valve spool adapted for sealing reciprocation within the spool bore, having a first end portion, a second end portion, a connecting portion having a cross-sectional area smaller than the cross-sectional areas of the first and second end portions, a first bypass orifice within the valve spool extending between the first end portion and the connecting portion, and a second bypass orifice within the valve spool extending between the second end portion and the connecting portion, the valve spool being movable from a neutral position, in which the valve spool is longitudinally centered within the spool bore and where the pressure forces in the first and second pressure lines are substantially similar, to a first position, occurring when the pressure forces in the first pressure line are greater than the pressure forces in the second pressure line, or to a second position, occurring when the pressure forces within the first pressure line are less than the pressure forces in the second pressure line, with the connecting portion being in fluid communication with at least a portion of the first port at each of the positions of the valve spool, wherein: while in the neutral valve spool position, the first bypass orifice is aligned with the first pressure line for fluid communication with the remaining line and the second bypass orifice is aligned with the second pressure line for fluid communication with the remaining line; while in the first valve spool position, the first and second bypass orifices are at least substantially disabled and the connecting portion is in fluid communication with one of the first and second pressure lines; while in the second valve spool position, the first and second bypass orifices are at least substantially disabled and the connecting portion is in fluid communication with the other of the first and second pressure lines; iii. dampers located at both ends of the valve spool, for centering the valve spool, relative to the remaining line, in the neutral valve position; and iv. wherein the bypass orifice cross-sectional areas are of a size to allow the passage of substantially the full flow of the charge pump at a low restriction to flow through the bypass orifices; and one of a relief orifice and a low pressure forward/reverse charge pressure relief valve interconnected with the valve block and the hydraulic circuit low pressure leg portion, the bypass orifices exposing both of the hydraulic circuit low and high pressure leg portions to the one of a relief orifice and relief valve when the main pump is substantially centered to stop rotation of the hydraulic motor.
[0014] In one version thereof, the one of the relief orifice and relief valve is a relief orifice, while in another version thereof, the one of the relief orifice and the relief valve is a relief valve.
[0015] In a further version, the only fluid that needs to be passed through the bypass orifices is the fluid that is produced as a result of any undesired slight inclination of the angle of an internal swashplate of the main pump, when the main pump is placed in the neutral position by an operator.
[0016] In a differing version, the first and second bypass orifices have a cross-sectional area sufficient to permit equalization of the fluid pressure between the hydraulic circuit low and high pressure leg portions. In one application, the valve block functions as a hot oil shuttle valve.
[0017] A further embodiment of this invention pertains to a hydraulic valve assembly for use in a hydrostatic transmission, the transmission including a variable displacement main pump, an interconnected charge pump, an interconnected hydraulic motor, and an interconnecting closed loop hydraulic circuit having low and high pressure leg portions, the hydraulic valve assembly controlling fluid transfer between a first, a second and a third line, within the hydraulic circuit, wherein two of the first, second and third lines define first and second pressure lines and are located at substantially similar longitudinal distances from the remaining one of the first, second and third lines, the remaining line being rotationally displaced relative to the first and second pressure lines, the valve assembly comprising in combination: a valve body defining a first port for connection to the remaining line, a second port for connection to one of the first and second pressure lines, and a third port for connection to the other of the first and second pressure lines, the valve body further including a spool bore in fluid communication with the first, second and third lines; a valve spool adapted for sealing reciprocation within the spool bore, having a first end portion, a second end portion, a connecting portion having a cross-sectional area smaller than the cross-sectional area of the first and second end portions, a first bypass orifice within the valve spool extending between the first end portion and the connecting portion, and a second bypass orifice within the valve spool extending between the second end portion and the connecting portion, the valve spool being movable from a neutral position, in which the valve spool is longitudinally centered within the spool bore and where the pressure forces in the first and second pressure lines are substantially similar, to a first position, occurring when the pressure forces in the first pressure line are greater than the pressure forces in the second pressure line, or to a second position, occurring when the pressure forces in the first pressure line are less than the pressure forces in the second pressure line, with the connecting portion being in fluid communication with at least a portion of the first port at each of the positions of the valve spool, wherein: while in the neutral valve spool position, the first bypass orifice is aligned with the first pressure line for fluid communication with the remaining line and the second bypass orifice is aligned with the second pressure line for communication with the remaining line; while in the first valve spool position, the first and second bypass orifices are at least substantially disabled and the connecting portion is in fluid communication with one of the first and second pressure lines; while in the second valve spool position, the first and second bypass orifices are at least substantially disabled and the connecting portion is in fluid communication with the other of the first and second pressure lines; dampers, located at both ends of the valve spool, for centering the valve spool, relative to the remaining line, in the neutral valve position; and wherein the first and second bypass orifices have a cross-sectional area sufficient to permit the equalization of the fluid pressure between the hydraulic circuit low and high pressure leg portions.
[0018] In a variation thereof, the only fluid that needs to be passed through the bypass orifices is the fluid that is produced as a result of any undesired slight inclination of the angle of an internal swashplate of the main pump, when the main pump is placed in the neutral position by an operator.
[0019] In a differing variation, the bypass orifice cross-sectional areas are of a size to allow the passage of substantially the full flow of the charge pump at a low restriction to flow through the bypass orifices. In one version, the only fluid that needs to be passed through the bypass orifices is the fluid that is produced as a result of any undesired slight inclination of the angle of an internal swashplate of the main pump, when the main pump is placed in the neutral position by an operator. The valve assembly can function as a hot oil shuttle valve.
[0020] Another feature of the present invention includes a method for increasing the efficiency of a hydrostatic transmission, in a neutral mode of operation, without impairing the performance in non-neutral modes of operation, wherein the hydrostatic transmission includes: a variable displacement main pump; a hydraulic motor; a closed loop hydraulic circuit operatively interconnecting the main pump and motor; a charge pump having an outlet line operatively interconnected only to the circuit; a valve block within the circuit, for controlling fluid transfer between a first, second and third line, within the hydraulic circuit, wherein two of the first, second and third lines define first and second pressure lines, the remaining line defining an outlet line; the valve block comprising a valve body defining a first port for connection to the remaining line, a second port for connection to one of the first and second pressure lines, and a third line for connection to the other of the first and second pressure lines, the valve body further including a spool bore in communication with the first, second and third lines; a valve spool adapted for sealing reciprocation within the spool bore, having a first end portion, a second end portion and a connecting portion having a cross-sectional area smaller than the cross-sectional areas of the first and second end portions; and dampers for centering the valve spool in a neutral mode of operation, the method comprising: a. including a first bypass orifice, within the valve spool, extending between the first end portion and the connecting portion; b. also including a second bypass orifice, within the valve spool, extending between the second end portion and the connecting portion; c. sizing the cross-sectional areas of the first and second bypass orifices to allow the passage of substantially the full flow of the charge pump, at a low restriction to flow, through the bypass orifices; d. keeping the connecting portion in fluid communication with the first port at all times; e. permitting substantially equal fluid flows from the second and third ports, via the first and second bypass orifices, respectively, to the first port, in the neutral mode of operation when fluid forces acting on the first and second end portions are about equal; and f. shifting the valve spool from the neutral mode of operation to non-neutral modes of operation during which the fluid forces acting on the first and second end portions are unequal, to thereby at least substantially disable the fluid flows via the first and second bypass orifices while simultaneously permitting fluid flows from one of the pressure lines to the outlet port.
[0021] The noted method also includes that the only fluid passing through the bypass orifices is the fluid that is produced as a result of any undesired slight inclination of the angle of an internal swashplate of the main pump, when the main pump is placed in the neutral position by an operator.
[0022] The noted method further includes that the recited sizing step alternatively includes keeping the cross-sectional areas of the first and second bypass orifices of a sufficient size to permit equalization of the fluid pressure between the hydraulic circuit low and high pressure leg portions.
[0023] Finally, the noted method includes that the recited sizing step alternatively includes keeping the cross-sectional areas of the first and second bypass orifices of a sufficient size to allow the passage of substantially the full flow of the charge pump at a low restriction through the orifices.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0024] FIG. 1 is a hydraulic schematic of a typical prior art hydrostatic transmission closed loop circuit, similar to that of FIG. 9 of U.S. Pat. No. 6,837,047 B2;
[0025] FIG. 2 is an elliptical cross-sectional view of the actual design of the hot oil shuttle valve schematically illustrated in prior art FIG. 1 , showing the hot oil shuttle valve with integrated orifices and springs on both ends of the valve in a neutral position;
[0026] FIG. 2 a is a view, similar to that of FIG. 2 , but showing the position of the prior art shuttle valve when the fluid pressure in line 23 is greater than the fluid pressure in line 24 ;
[0027] FIG. 2 b is a view, similar to that of FIG. 2 , but showing the position of the prior art shuttle valve when the fluid pressure in line 24 is greater than the fluid pressure in line 23 ;
[0028] FIG. 3 is a hydraulic schematic of the present invention showing a hydrostatic transmission closed loop circuit, without the charge pump relief valve of FIG. 1 , together with a modified hot oil shuttle valve.;
[0029] FIG. 4 is a schematic of the hot oil shuttle valve in the circuit of FIG. 2 ;
[0030] FIG. 5 is a view, similar to that of FIG. 2 , showing the hot oil shuttle valve of this invention with modified integrated orifices in a neutral position;
[0031] FIG. 5 a is a view, similar to that of FIG. 5 , but showing the shuttle valve when the fluid pressure in line 23 a is greater than the fluid pressure in line 24 a; and
[0032] FIG. 5 b is a view, similar to that of FIG. 5 , but showing the position of the shuttle valve when the fluid pressure in line 24 a is greater than the fluid pressure in line 23 a.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Referring first to the several prior art drawings, FIG. 1 shows a schematic diagram of a typical prior art hydrostatic transmission closed-loop circuit or loop 10 , similar to that of FIG. 9 of U.S. Pat. No. 6,837,047 B2, consisting of a variable displacement main radial piston pump 12 and a hydraulic motor 14 , such as a fixed displacement motor, connected to each other by lines 23 and 24 of circuit 10 . Pump 12 can be an over-center axial piston pump or a bent-axis piston pump. With an over-center variable displacement axial piston pump, the displacement of the pump is determined by the size and number of pistons, as well as the stroke length. An input shaft 11 for pump 12 is driven by a prime mover (not shown), such as an internal combustion engine or an electrical motor, at a predetermined speed, in predetermined direction. Although the size and number of pistons are fixed, changing the piston stroke length can change the displacement of the pump. The stroke length is determined by the angle of the swashplate of pump 12 , which can be tilted by any corresponding stroke controlling device, for example a trunnion shaft (not shown). The trunnion shaft is connected to a control handle through a linkage installed in the machine. When an operator pushes the handle forward, pump 12 delivers flow for one direction of motor 14 operation. Changing the displacement of pump 12 will change its output flow rate, which controls the speed of motor 14 . Moving the swashplate or yoke (not shown) of pump 12 overcenter will automatically reverse the flow out of pump 12 , thus reversing the direction of motor 14 . Depending upon the direction of the overcenter movement of pump swashplate or yoke, line 23 (or line 24 ) of circuit or loop 10 can be a high pressure supply line or a low pressure return line.
[0034] A charge pump 16 , also driven via input shaft 11 , supplies additional hydraulic fluid to closed-loop circuit 10 at the rate of approximately 10-30% of the flow rate that main pump 12 can deliver. Charge pump 16 draws fluid from a reservoir 13 which can be passed through a filter 15 and supplies this fluid into closed-loop circuit 10 through a conduit line 17 by way of one-way check valves 18 and 19 to compensate for any possible flow loss due to internal leakage. A charge pump relief valve 22 is used to provide a relief path to reservoir 13 when more than the required flow from charge pump 16 cannot enter closed loop circuit 10 , and also regulates the pressure of the low pressure side of circuit 10 . Relief valves 26 and 27 are positioned between lines 23 and 24 and protect each line from pressure overload during operation. Valve 26 provides relief for line 23 and valve 27 provides relief for line 24 .
[0035] In certain applications, closed-loop circuit 10 will also have a bypass valve 29 positioned between lines 23 and 24 in order to transfer oil from one line to the other. The use of bypass valve 29 will enable motor 14 to turn over with little resistance when it is desirable, for example, to move a machine for a short distance without operating the transmission. Again, in certain applications, a hot oil shuttle valve 73 is provided to reduce loop temperature by connecting the low pressure side of closed-loop circuit 10 to a drain line. This valve allows a certain percentage of the hot oil being discharged from motor 14 to flow back to reservoir 13 for cooling and filtering, and replaces the discharged hot oil with cooled, filtered oil from charge pump 16 . Line 32 connects a forward/reverse charge pressure relief valve 33 with hot oil shuttle valve 73 to provide a lower resistance on the low pressure side of closed-loop circuit 10 . Relief valve 33 maintains a certain amount of fluid pressure on the low pressure side of closed-loop circuit 10 . Since charge pump relief valve 22 is in parallel with relief valve 33 , charge pump relief valve 22 should be set at a pressure higher than that of relief valve 33 . When the transmission is in neutral and hot oil shuttle valve 73 is centered, charge pump flow is relieved over relief valve 22 .
[0036] As best seen in prior art FIG. 2 , prior art hot oil shuttle valve 73 utilizes both lines 23 and 24 for inlet flows while line 32 comprises the single outlet conduit, or exhaust line, connected with relief valve 33 . Lines 23 and 24 are connected to inlet ports 87 and 88 , respectively, in the valve body, while line 32 is connected to an outlet port 89 in the valve body. Position 80 shows the actual construction and orientation of valve 73 during low fluid flow from charge pump 16 when the fluid pressures in lines 23 and 24 are approximately equal. Valve spool 61 is centered so that the receiving or inlet ends of orifices 75 and 76 are substantially aligned with lines 23 and 24 , respectively.
[0037] Referring now to prior art FIG. 2 a, when the operator activates the stroke controlling device in one direction in order to initiate turning of motor 14 , main pump 12 will pump fluid into the corresponding side of the loop, either line 23 or 24 . When the increased fluid pressure reaches a predetermined or set value sufficient to turn motor 14 , valve 73 will shift as shown in non-neutral position 81 , so that orifices 75 and 76 are disabled, or shut-off in a juxtaposed position against the wall of valve bore 61 ′, and fluid can flow through low pressure line 24 . Charge pump 16 then continuously charges the closed-loop on the low pressure side through line 24 . Fluid flowing through low pressure line 24 ensures that cavitation does not occur in the hydrostatic transmission system. The distance from the inlet end of orifice 76 to a mid-portion 77 in valve 73 is substantially the same as the diameter of port 88 . Therefore, there is no interruption of fluid flow from line 24 when valve 73 shifts in this direction. Fluid will flow from line 24 to orifice 76 , then to mid-portion 77 during this transition.
[0038] Turning now to prior art FIG. 2 b, when the operator changes the direction of movement of the control handle, main pump 12 will alter the direction of the fluid flow. When the pressure differential between lines 23 and 24 reaches a predetermined value, valve 73 will move to position 82 . In position 82 , the fluid pressure in line 24 is greater than the fluid pressure in line 23 , thus biasing spool 61 towards low pressure line 23 . As in position 81 ( FIG. 2 a ), both orifices 75 and 76 are disabled in juxtaposed position against valve bore 61 ′ and pressurized fluid can only reach line 32 through low pressure line 23 . The distance from the inlet end of orifice 75 to mid-portion 77 in valve 73 is substantially the same as the diameter of port 87 . Therefore, there is no interruption of fluid flow from line 23 when valve 73 shifts in this direction. Fluid will flow from line 23 to orifice 75 , then to mid-portion 77 during this transition.
[0039] In recapitulation, when the transmission is in operation, hot oil shuttle valve 73 senses which leg 23 or 24 of circuit or loop 10 is at high pressure and shifts to expose relief valve 33 to the low pressure side of loop 10 . Charge pump relief valve 22 is now in parallel with relief valve 33 which is set to relieve hydraulic pressure at a lower setting than charge pump relief valve 22 so that valve 22 does not open. Hot, contaminated hydraulic working fluid exits from the outlet of hydraulic motor 14 via hot oil shuttle valve 73 and across relief valve 33 with the hot, contaminated hydraulic fluid going back to reservoir 13 through the case of main pump 12 , either through the case of hydraulic motor 14 , as shown, or directly into the case of main pump 12 , bypassing hydraulic motor 14 . Relief valves 33 and 22 can take the form of either relief valves or orifices (not shown per se). The full flow of cool, filtered hydraulic working fluid provided by charge pump 16 enters loop 10 since it cannot exit across relief valve 22 . A volume of hot, hydraulic working fluid, equal to the flow of charge pump 16 , exits loop 10 across hot oil shuttle valve 73 and relief valve 33 . When main pump 13 is centered, so as to provide no flow of hydraulic working fluid, and stops the rotation of hydraulic motor 14 , there is no pressure differential across hot oil shuttle valve 73 and it centers. Relief valve 33 is now out of circuit 10 and the flow from charge pump 16 exits across charge pump relief valve 22 at a higher pressure than the pressure that was experienced when relief valve 33 controlled the pressure from charge pump 16 . This noted higher pressure builds heat and inefficiency within circuit 10 .
[0040] As described in previously noted prior art U.S. Pat. No. 6,837,047 B2, when it is desired to stop rotation of hydraulic motor 14 , the swashplate of main pump 12 is centered by the operator. If it does not center exactly and is at a slight unintended angle, pressure will build up in one of the legs 23 or 24 of circuit 10 , thus causing hydraulic motor 14 to slowly rotate and the machine to creep. Orifices 75 or 76 are designed to allow the transfer of a small amount of hydraulic working fluid from leg 23 or 24 to the opposite leg, thus equalizing the pressure across hydraulic motor 14 and eliminating its tendency to slowly rotate.
[0041] Proceeding now to FIG. 3 , illustrated therein is a hydraulic schematic diagram of the present invention, showing a hydrostatic transmission closed loop circuit 10 a, without the charge pump relief valve 22 of previously-described prior art closed loop circuit 10 of FIG. 1 . In addition, hot oil shuttle valve 73 a is modified in a manner to be described hereinafter. The schematic diagram of FIG. 3 is quite similar to that of prior art FIG. 1 and like parts are identified with like numerals with the addition of the suffix “a”. Specifically, as noted, prior art charge pump relief valve 22 is eliminated and, very importantly, hot oil shuttle valve 73 a is modified by increasing the sizes of orifices 75 a, 76 a, to allow the passage of substantially the full flow of charge pump 16 a, at a low pressure drop, i.e., at a low restriction to flow through orifices 75 a, 76 a. These orifices need only to be large enough to permit equalization of the fluid pressures between circuit legs 23 and 24 . The only fluid that needs to be passed is the fluid that is produced by any undesired slight inclination angle of the swashplate when the pump is placed in its neutral position by the operator. The noted orifice modification exposes both legs 23 a, 24 a of loop 10 a to low pressure relief valve 33 a when main pump 12 a is substantially centered to stop the rotation of hydraulic motor 14 a. The benefits of new circuit 10 a include the elimination of the cost of the previously-required prior art charge pump relief valve 22 and allows lower hydraulic working fluid pressure, via charge pump 16 a, when main pump 12 a is centered and hydraulic motor 14 a is at rest. The result is a less costly and more efficient transmission that also operates at a lower working temperature.
[0042] In terms of operation, hydrostatic transmission circuit 10 a, except as noted directly above, operates very similar to that of previously-described prior art circuit 10 .
[0043] FIG. 4 is basically a schematic diagram of hot oil shuttle valve 73 a, showing both lines 23 a and 24 a for inlet flows while line 32 a comprises the single outlet or exhaust line. Similarly, FIG. 5 is similar to that of prior art FIG. 2 in showing hot oil shuttle valve 73 a in physical position 80 a during low working fluid flow from charge pump 16 a (not shown here) when the fluid pressures in lines 23 a and 24 a are approximately equal. Valve spool 61 a is substantially centered so that the receiving inlet ends of orifices 75 a and 76 a are substantially aligned with inlet lines 23 a and 24 a, respectively.
[0044] Turning now to FIG. 5 a, which is similar to that of prior art FIG. 2 a, shows hot oil shuttle valve 73 a in non-neutral physical position 81 a, wherein both orifices 75 a and 76 a are disabled or shut-off in a juxtaposed position against the wall of valve bore 61 ′ a and fluid in low pressure line 24 a can only reach line 32 a through valve spool 61 a.
[0045] Finally, turning to FIG. 5 b, which is similar to that of prior art FIG. 2 b, shows hot oil shuttle valve 73 a in position 82 a, wherein the working fluid pressure in line 24 a is greater than the working fluid pressure in line 23 a, thus biasing spool 61 a towards low pressure line 23 a. As is the case in position 81 a ( FIG. 5 a ), both orifices 75 a and 76 a are disabled in juxtaposed position against valve bore 61 ′ a and fluid in low pressure line 23 a can only reach line 32 a through valve spool 61 a.
[0046] At this point it should be well understood that in circuit 10 a, prior art charge pump relief valve 22 is eliminated and hot oil shuttle valve 73 a is modified, by increasing the sizes of orifices 75 a, 76 a to allow the passage of substantially the full flow of charge pump 16 a, at a low pressure drop. Thus, both legs 23 a and 24 a of loop 10 a are exposed to low pressure relief valve 33 a when main pump 12 a is centered to stop the rotation of hydraulic motor 14 . The result is a less expensive but more efficient transmission.
[0047] It is deemed that one of ordinary skill in the art will readily recognize that the present invention fills remaining needs in this art and will be able to affect various changes, substitutions of equivalents and various other aspects of the invention as described herein. Thus, it is intended that the protection granted hereon be limited only by the scope of the appended claims and their equivalents. | Improvement in a hydrostatic valve assembly for use in a hydrostatic transmission, for controlling fluid transfer between a first, second and third line, wherein two of the lines define first and second pressure lines within a closed loop circuit. The valve assembly comprises a valve body having ports in communication with the three lines; a spool bore and valve spool reciprocating therewithin, having first and second end portions joined by a connecting portion, and first and second bypass orifices within the valve spool; and dampers for centering the valve spool in a neutral position. The bypass orifices utilize increased cross-sectional areas that permit the passage of substantially the full flow of the charge pump, without using a charge pump relief valve, at a low pressure drop. A hydraulic system utilizing this valve assembly and a method for increasing the transmission efficiency, in the neutral mode, are also set forth. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of a Non-Provisional Application entitled “AMMUNITION FEED SYSTEM FOR FIREARM” being filed concurrently herewith on May 24, 2010, which claims the benefit of U.S. Provisional Application No. 61/280,810, filed Nov. 9, 2009. The disclosures of both applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention is directly related to firearms, and the feeding of non-linked cartridges in semi-automatic and automatic small arms. More particularly, the invention expands on the capacity of cartridges that can be fed into a firearm without having to change magazines as frequently.
BACKGROUND OF THE INVENTION
[0003] Since the discovery of gunpowder in the ninth century, and the invention of firearms in the tenth century, firearms have made significant advancements. Single shot, single barreled, muzzle loading flintlock musket firearms of the late 1700's and early 1800's were a great advancement in the history of firearms, but they did not offer the marksman with a quick subsequent shot(s). If the target was missed and the marksman wanted to reload, a time consuming process of reloading involved pouring gunpowder down the barrel, and ramming a projectile on top of the powder, followed by priming the breach before being able to fire once again. In a life or death situation, the time to reload was unacceptable.
[0004] The quest for a faster second shot or in reality a faster reload for any number of shots, was found to be a feature that is extremely desirable. In approximately 1860, a single barreled “repeating rifle” (a rifle in which could be reloaded by operating a lever as fast as a marksman could actuate it) using a cartridge was patented. This was the beginning of the multiple cartridge magazine and fast loading/reloading firearms.
[0005] Today, many modern firearms use box magazines containing many cartridges. Most box type magazines stack cartridges that lay horizontal relative to the barrel of the firearm in a rectangular magazine, but in a vertical stack. That is to say that the cartridges are laying on their sides, one stacked on top of another, and feed upward in a channel within a somewhat rectangular-shaped magazine in the position in which they are fed into the chamber of the firearm.
[0006] However, the capacity of box type magazines are limited because they have the physical characteristic of extending significantly below the firearm. Additionally, drum type magazines in some cases offer a higher cartridge capacity in a shallower area below a firearm, but normally offer only one method of loading. Also many drum type magazines become jammed and fail to feed, and it is difficult to correct the jammed drum type cartridges.
[0007] A deviation of the standard box magazine is a “banana” shaped box magazine which does help limit some of the protrusion of the magazine below the firearm, and provides a greater cartridge capacity. The curvature of this type of magazine is generally towards the muzzle of the firearm.
[0008] Additionally, many of these conventional box magazines or drum magazines include one or more springs for applying tension to the cartridges to ensure that the cartridges load transfer from the magazine to the firearm properly. As with a conventional box magazines or drum magazines, when a magazine is stored with cartridges loaded into the magazine, the spring becomes weakened because of the constant tension being placed on the follower spring for long periods of time. The spring has a tendency to take a “set” and become less powerful.
[0009] Accordingly there exists a need for a magazine for use with various types of firearms which overcome the current drawbacks of conventional magazines.
SUMMARY OF THE INVENTION
[0010] The present invention is a firearm cartridge feeding system that feeds non-linked cartridges to semi-automatic and automatic small arms. It is designed to replace the boxed-type magazine and the drum-type magazine in firearms designed to accept boxed-type and drum-type magazines.
[0011] The outward appearance of the feeding system of the present invention is round or somewhat circular in appearance. However, it is within the scope of the invention that the feeding system may be shaped differently to other shapes to meet fastener and other equipment requirements.
[0012] The firearm cartridge feeding system of the present invention is adaptable to any weapon that receives a box or drum type magazine. In one embodiment, the body of the invention has two distinct compartments. One compartment is designed to house the power spring, sometimes called a clock spring, and the second compartment sits behind the spring compartment and is separated by a firewall, which holds the cartridges in a spiral channel. In one embodiment of the present invention, the spiral channel is of the single stack type, and in other embodiments, the spiral channel is a double stack type.
[0013] The firearm cartridge feeding system, when inserted into a weapon with the magazine well opening at the bottom of the firearm, feeds cartridges from the spiral channel into a chamber positioning channel, and then to the feed lips. With the cartridges positioned as to feed into the chamber of a firearm, the cartridges are stripped from the feed lips by the firearm's loading mechanism.
[0014] The firearm cartridge feeding system of the present invention stores cartridges in a spiral channel or groove within a housing that is optionally offset in an angular direction tangent to the magazine well. This is to compact a greater number of cartridges in an area which is not obstructive or less obstructive to the operation of a firearm, compared to the number of cartridges available in a conventional box magazine or a conventional drum-type magazine.
[0015] In one embodiment of the feeding system of the invention, cartridges are easily loaded into the firearm cartridge feeding system by inserting cartridges at the feed lips, and/or the firearm cartridges are loaded by placing cartridges directly into the spiral channel after removing the spiral cover of the housing.
[0016] Loading the firearm cartridge feeding system by removing the spiral cover of the housing for loading the spiral channel provides a distinct advantage over prior art designs. With some designs of the firearm cartridge feeding system of the present invention, a number of cartridges can be “dumped” into a formed loading bowl (raised lip around the spiral to retain cartridges) around the spiral and then shaken by the user to quickly orientate the cartridges in the spiral. Because of the physical design and shape of some cartridges, they fall into the spiral correctly orientated for use.
[0017] The firearm cartridge feeding system of the present invention includes a cam stop winding knob which allows the user to only wind the power spring in one direction. The winding knob also acts as a pawl to prevent the power spring from unwinding before the user desires the spring tension to be released. This is accomplished by using a set of cam stop bearings disposed in a set of cam bearing pockets formed as part of a cam stop winding knob power spring pocket retainer.
[0018] The spring tension on the spiral following cartridge drive arm, which drives the cartridges through the spiral, is relieved by pressing a clutch release push button, which in turn disengages the power spring drive shaft from the encapsulated spring clutch mechanism.
[0019] The present invention also includes a power spring drive shaft assembly which is incorporated into the encapsulated spring clutch mechanism. When the clutch release push-button is pressed, it disengages a power spring primary drive shaft pin from a set of encapsulated spring clutch mechanism castle cover locking notches, and allows spring tension to be released from the spiral follow cartridge drive arm.
[0020] Once the firearm cartridge feeding system has been loaded and spring tension has been put on the cartridges to feed through the spiral by winding the cam stop winding knob with power spring pocket, the firearm cartridge feeding system is easily unloaded using one of two methods. One method that is used to remove the cartridges is to push the first cartridge exposed at the feed lips in a forward direction as if the cartridge were being stripped from the feed lips by a firearm. A second more expeditious method of unloading the firearm cartridge feeding system is to relieve spring tension on the spiral following cartridge drive arm by pressing the clutch release push button, removing the spiral cover and underlying drive components, and dump the cartridges from the spiral.
[0021] Another advantage of the present invention is that the firearm cartridge feeding system is able to be loaded with cartridges and stored for long periods of time without damaging the power spring because it can be stored with little or no tension on the power spring. The user needs only to wind the cam stop winding knob to place tension on the power spring and to make the firearm cartridge feeding system ready for use. This provides for tension to be applied to the power spring only when necessary, extending the life of the power spring.
[0022] The firearm cartridge feeding system is primarily constructed from composite materials which aid in contributing to the lightweight, weather resistant, and natural lubricity of the space age materials. However, some components such as the springs are made of metals. The metal components are made of materials that resist rust and corrosion.
[0023] 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 Figure only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0025] FIG. 1 is a first perspective view of a body portion for a firearm ammunition feeding system, according to the present invention;
[0026] FIG. 2 is a second perspective view a body portion with an encapsulated spring clutch mechanism installed to full depth in the center of the body portion, used in a firearm ammunition feeding system, according to the present invention;
[0027] FIG. 3 is a third perspective view of a body portion used in a firearm ammunition feeding system, according to the present invention;
[0028] FIG. 4 is a fourth perspective view of a body portion used in a firearm ammunition feeding system, according to the present invention;
[0029] FIG. 5 is a perspective view of an encapsulated spring clutch mechanism secondary drive shaft used for a firearm ammunition feeding system, according to the present invention;
[0030] FIG. 6 is a perspective view of a body portion of a firearm ammunition feeding system with a spiral following cartridge drive arm in a fully extended position, according to the present invention;
[0031] FIG. 7 is a perspective view of a body portion of a firearm ammunition feeding system with a spiral following cartridge drive arm in a fully retracted position, according to the present invention;
[0032] FIG. 8 is a perspective view of a body portion of a firearm ammunition feeding system with a spiral following cartridge drive arm in a fully retracted position and a cartridge cover plate assembled to the body portion, according to the present invention;
[0033] FIG. 9A is a first perspective view of a spiral following cartridge drive arm used in a firearm ammunition feeding system, according to the present invention;
[0034] FIG. 9B is a second perspective view of a spiral following cartridge drive arm used in a firearm ammunition feeding system, according to the present invention;
[0035] FIG. 10 is a top view of a cartridge cover plate used in a firearm ammunition feeding system, according to the present invention;
[0036] FIG. 11 is a perspective view of a spiral cover attached to a body portion used in a firearm ammunition feeding system, according to the present invention;
[0037] FIG. 12 is a first perspective view of a body portion having a cam stop winding knob attached to the body portion, used in a firearm ammunition feeding system, according to the present invention;
[0038] FIG. 13 is a second perspective view of a body portion having a cam stop winding knob attached to the body portion, used in a firearm ammunition feeding system, according to the present invention
[0039] FIG. 14 is a first perspective view of the inner surface of a cam stop winding knob used in a firearm ammunition feeding system, according to the present invention;
[0040] FIG. 15 is an enlarged perspective view of a cam stop winding knob and a cam stop bearing disposed in a cam bearing pocket used in a firearm ammunition feeding system, according to the present invention;
[0041] FIG. 16 is a second perspective view of the inner surface of a cam stop winding knob, with cam stop bearings disposed in respective cam stop bearing pockets used in a firearm ammunition feeding system, according to the present invention;
[0042] FIG. 17 is a first perspective view of an encapsulated spring clutch mechanism assembly used in a firearm ammunition feeding system, according to the present invention;
[0043] FIG. 18 is a perspective view of an encapsulated spring clutch mechanism, used in a firearm ammunition feeding system, according to the present invention;
[0044] FIG. 19 is a perspective view of a power spring drive shaft and an encapsulated spring clutch mechanism compression spring assembled to an encapsulated spring clutch mechanism castle cover which are part of an encapsulated spring clutch mechanism, used in a firearm ammunition feeding system, according to the present invention;
[0045] FIG. 20 is a perspective view of a encapsulated spring clutch mechanism castle cover which is part of an encapsulated spring clutch mechanism used in a firearm ammunition feeding system, according to the present invention;
[0046] FIG. 21 is a first perspective view of a power spring primary drive shaft, which is a part of an encapsulated spring clutch mechanism used in a firearm ammunition feeding system, according to the present invention;
[0047] FIG. 22 is a front view of a body portion having several firearm cartridges loaded in a spiral channel used in a firearm ammunition feeding system, according to the present invention;
[0048] FIG. 23A is a first perspective view of cartridges being removed from a spiral channel formed as part of a body portion of a firearm cartridge feeding system, according to the present invention;
[0049] FIG. 23B is a second perspective view of cartridges being removed from a spiral channel formed as part of a body portion of a firearm cartridge feeding system, according to the present invention;
[0050] FIG. 24 is a perspective view of an ammunition feeding system in an assembled state, according to the present invention;
[0051] FIG. 25 is a perspective view of an ammunition feeding system with the fastener for the clutch release push button removed, according to the present invention;
[0052] FIG. 26 is a perspective view of an ammunition feeding system with the clutch release push button removed and the clutch release push button return spring exposed, according to the present invention;
[0053] FIG. 27 is a perspective view of an ammunition feeding system with the clutch release push button and clutch release push button return spring removed, according to the present invention;
[0054] FIG. 28 is a bottom view of a cam stop winding knob used for an ammunition feeding system, according to the present invention;
[0055] FIG. 29 is a top view of a cam stop winding knob removed from an ammunition feeding system, according to the present invention
[0056] FIG. 30 is a second perspective view of an encapsulated spring clutch mechanism used for a firearm ammunition feeding system, according to the present invention;
[0057] FIG. 31 is a second perspective view of a power spring primary drive shaft, which is a part of the encapsulated spring clutch mechanism used in a firearm ammunition feeding system, according to the present invention;
[0058] FIG. 32 is an enlarged top view of a clutch release push button used in a firearm ammunition feeding system, according to the present invention;
[0059] FIG. 33 in an enlarged side view of a clutch release push button used in a firearm ammunition feeding system, according to the present invention;
[0060] FIG. 34 is a perspective bottom view of a clutch release push button used in a firearm ammunition feeding system, according to the present invention;
[0061] FIG. 35 is a first perspective view of an alternate embodiment of an encapsulated spring clutch mechanism cup which is part of an encapsulated spring clutch mechanism used in a firearm ammunition feeding system, according to the present invention;
[0062] FIG. 36 is a second perspective view of an alternate embodiment of an encapsulated spring clutch mechanism cup which is part of an encapsulated spring clutch mechanism used in a firearm ammunition feeding system, according to the present invention;
[0063] FIG. 37 is a third perspective view of an alternate embodiment of an encapsulated spring clutch mechanism cup which is part of an encapsulated spring clutch mechanism used in a firearm ammunition feeding system, according to the present invention; and
[0064] FIG. 38 is a perspective view of an alternate embodiment of a housing used in a firearm ammunition feeding system, according to the present invention;
[0065] FIG. 39 is a first perspective view of a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0066] FIG. 40 is a second perspective view of a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0067] FIG. 41 is a first exploded view of a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0068] FIG. 42 is a second exploded view of a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0069] FIG. 43A is a perspective view of a clutch-drive assembly used in a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0070] FIG. 43B is an exploded view of a clutch-drive assembly used in a second alternate embodiment of a firearm ammunition feeding system used in, according to the present invention;
[0071] FIG. 44A is a perspective view of a feedneck extension used in a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0072] FIG. 44B is an exploded view of a feedneck extension used in a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0073] FIG. 45A is a sectional view taken along lines 45 A shown in FIG. 45B ;
[0074] FIG. 45B is a perspective view of a feedneck extension and a double lock latch attached to a body used in a firearm ammunition feeding system, with the feedneck extension inserted into a section of a magazine well, according to the present invention;
[0075] FIG. 46 is a sectional view taken along lines FIG. 46 of FIG. 40 ;
[0076] FIG. 47 is an enlarged sectional view of the circled portion shown in FIG. 46 ;
[0077] FIG. 48 is a side view of a feedneck extension and a double lock latch attached to a body used in a second alternate embodiment of a firearm ammunition feeding system, with the feedneck extension inserted into a magazine well, according to the present invention;
[0078] FIG. 49A is a perspective view of a cartridge follower assembly used in a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0079] FIG. 49B is a first exploded view of a lead follower, a shell follower, and a bolt stop actuator follower used in a cartridge follower assembly for a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0080] FIG. 49C is a second exploded view of a lead follower, a shell follower, and a bolt stop actuator follower used in a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0081] FIG. 49D is a sectional view taken along lines 49 D of FIG. 49C ;
[0082] FIG. 50A is a side view of another alternate embodiment of a firearm ammunition feeding system having a feedneck extension which configures the body to be at an angle of ten degrees relative to the feedneck extension, according to the present invention;
[0083] FIG. 50B is a side view of a second alternate embodiment of a firearm ammunition feeding system, according to the present invention;
[0084] FIG. 51A is a first perspective view of a ten-degree angled feedneck extension connected to a body portion according to the embodiment shown in FIG. 50A ;
[0085] FIG. 51B is the ten-degree angled feedneck extension shown in FIG. 51A removed from the body portion;
[0086] FIG. 51C is a sectional side view taken along lines 51 C of FIG. 51B ;
[0087] FIG. 52A is a third perspective view of a second alternate embodiment of a housing used in a firearm ammunition feeding system, according to the present invention;
[0088] FIG. 52B is a perspective view of another alternate embodiment of a firearm ammunition feeding system having a feedneck extension which configures the body to be at an angle of forty-five degrees relative to the feedneck extension, according to the present invention; and
[0089] FIG. 52C is a perspective view of yet another alternate embodiment of a firearm ammunition feeding system having a feedneck extension which configures the body to be at an angle of ninety degrees relative to the feedneck extension, according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0090] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0091] An ammunition feed system is shown in the Figures according to the present invention, generally at 10 . The basic housing or body 12 of the system includes feed lips 14 installed at a neck 16 of the body 12 . Also included is a larger opening or pocket, shown generally at 18 , in the center of the body 12 which is for the insertion of an encapsulated spring clutch mechanism, generally shown at 20 . Also shown in the Figures is a spiral channel 22 which is used to contain a plurality of firearm cartridges, generally shown at 24 . On the outside of the body 12 are projections 26 having threaded apertures 27 used to fasten a spiral cover 28 to the housing 12 . In alternate embodiments, the projections 26 are of different shapes and forms, depending upon the fasteners used. A firewall 30 (best seen in FIGS. 1-7 ), separates the spiral channel 22 from a power spring drive shaft compartment 48 , and is located opposite spiral channel 22 . The spiral channel 22 does not penetrate the firewall 30 ; however, in alternate embodiments there are penetrations or apertures in the firewall 30 in selected locations to allow fluid draining if the system 10 becomes contaminated with a fluid. In still another embodiment, drain holes are placed in the spiral compartment and housing or body 12 to drain fluid.
[0092] While the housing or body 12 is shown in the Figures, in an alternate embodiment, a slightly raised lip to form a bowl is placed around the spiral channel 22 to prevent cartridges 24 from rolling off of the spiral area when loading the cartridges 24 . Firearm cartridges 24 are loaded directly into the spiral channel 22 with the spiral channel 22 oriented spiral side up and horizontal to the ground, or the cartridges 24 are removed from the spiral channel 22 when the body 12 is placed spiral side down and in a horizontal position. In another alternate embodiment, the system 10 is manufactured with a shortened feed neck 216 to accept multiple feed neck extensions with unique feed lips to mate to different firearms when the caliber of the firearm is in common.
[0093] Also shown in the center of the encapsulated spring clutch mechanism 20 is an opening 32 which receives an encapsulated spring clutch mechanism secondary drive shaft 34 . The secondary drive shaft 34 inserts into this opening 32 and in turn drives a spiral following cartridge drive arm 36 . The secondary drive shaft 34 includes a hex end 52 which mates or inserts into the encapsulated spring clutch mechanism hex drive opening 32 , while a double flat key end 56 extends through an elongated aperture 114 formed as part of the drive arm 36 , and turns the spiral following cartridge drive arm 36 when assembled. The hex drive opening 32 is part of an encapsulated spring clutch mechanism cup 98 . In an alternate embodiment, the encapsulated spring clutch mechanism secondary drive shaft 34 is integral to the encapsulated spring clutch mechanism cup 98 , instead of being separate, as shown in FIG. 5 .
[0094] FIGS. 3 and 4 shows the opposite side of the body 12 in relation to the spiral channel 22 . This side of the body 12 houses the power spring assembly 64 , a cam stop winding knob 38 with power spring pocket 40 , a plurality of cam stop bearings 42 , and a power spring drive shaft 50 which protrudes through a power spring drive shaft opening 46 centered in the power spring compartment 48 . The firewall 30 forms part of the power spring compartment 48 .
[0095] Referring to FIGS. 6 and 7 , the encapsulated spring clutch mechanism 20 , the encapsulated spring clutch mechanism secondary drive shaft 34 , the spiral following cartridge drive arm 36 , and the spiral following cartridge drive arm pin 58 are shown assembled to the body 12 . The feed system 10 also includes a cartridge cover plate 60 (shown in FIGS. 8 and 10 ), which has been omitted in FIG. 6 so that the relationship of the encapsulated spring clutch mechanism 20 to the spiral following cartridge drive arm 36 is better understood. FIG. 6 shows the spiral following cartridge drive arm 36 fully extended and at the end of it's travel when pushing cartridges 24 out of the system 10 . FIG. 7 shows the firearm ammunition feeding system 10 having the spiral following cartridge drive arm 36 and spiral following cartridge drive arm pin 58 in the fully retracted position (this position is normal when the system 10 is fully loaded with firearm cartridges 24 or ready to be loaded with firearm cartridges 24 ).
[0096] It should also be noted that in FIG. 7 the encapsulated spring clutch mechanism 20 is slightly elevated to be seen more clearly, however the normal position for the encapsulated spring clutch mechanism 20 is fully seated in the encapsulated spring clutch mechanism pocket 18 .
[0097] It can be seen in FIG. 8 that the cartridge cover plate 60 is installed in the correct position under the spiral following cartridge drive arm 36 . Referring again to the Figures generally, the plate 60 includes a cartridge cover plate secondary drive shaft center or central aperture 116 through which the secondary drive shaft 34 extends, and an elongated aperture 118 which the spiral following cartridge drive arm pin 58 extends through when the plate 60 is installed. In this embodiment, the aperture 116 is of the same shape as the cross-section as the hex end 52 of the shaft 34 such that the plate 60 rotates with the shaft 34 . However, in alternate embodiments, the cartridge cover plate secondary drive shaft center 116 is of any desired shape, and does not have to be driven by the encapsulated spring clutch mechanism secondary drive shaft 34 .
[0098] The plate 60 retains firearm cartridges 24 in the spiral channel 22 of the body 12 , while allowing the spiral following cartridge drive arm pin 58 to protrude through the elongated aperture 118 into the spiral channel 22 for pushing firearm cartridges 24 through the spiral channel 22 . The aperture 118 of the drive arm 36 has two bearing surfaces 62 left and right of the longitudinal axis (longitudinally slotted). When placed on and driven by the encapsulated spring clutch mechanism secondary drive shaft 34 , the arm 36 travels outwardly or inwardly (depending on clockwise or counterclockwise rotation) when guided by the spiral following cartridge drive arm pin 58 , as the pin 58 moves in the spiral channel 22 of the spiral housing 12 .
[0099] As previously discussed, a spiral cover 28 is attached to the body 12 . The spiral cover 28 retains the firearm cartridges 24 , the cartridge cover plate 60 , the spiral following cartridge drive arm 36 , the spiral following cartridge drive arm pin 58 , the encapsulated spring clutch mechanism secondary drive shaft 34 , the encapsulated spring clutch mechanism 20 , and feed lips 14 attached and assembled correctly to the housing 12 . The secondary drive shaft 34 is of a length where the shaft 34 contacts with the inner surface of the spiral cover 28 when the system 10 is completely assembled. However, the inner surface of the spiral cover 28 only functions to provide a bearing surface against the double flat key end 56 , and is located to permit free rotation of the shaft 34 , and preventing any binding of the shaft 34 .
[0100] The spiral cover 28 attaches to the housing 12 through the use of a set of fasteners 130 , which in this embodiment are screws 130 , which extend through the spiral cover 28 as shown in FIG. 11 and into the threaded apertures 27 formed as part of the projections 26 . There are also threaded apertures 132 formed as part of the neck 16 , and more screws 130 are inserted through apertures 134 formed in the spiral cover 28 and into the threaded apertures 132 to further secure the spiral cover 28 to the body 12 . While the spiral cover 28 is shown as a single piece, in an alternate embodiment the cover 28 is split into any number of pieces for functionality or mounting to the housing or body 12 .
[0101] A clutch release push-button 66 is installed in the clutch release push-button pocket 68 , and the clutch release push-button pocket 68 is integral to the cam stop winding knob 38 . The cam stop winding knob 38 is characterized by a knob-like protrusion and is centrally located, so that an operator of the firearm ammunition feeding system 10 easily winds a biasable member or power spring 64 for system 10 use. The depth 122 of the cam stop winding knob 38 being the cam stop winding knob power spring pocket ceiling 72 and the inside circumference being the cam stop winding knob power spring pocket retainer 74 . When the spring mechanism or power spring 64 is installed into the power spring drive compartment 48 , the power spring 64 is captured between the cam stop winding knob power spring pocket ceiling 72 and the firewall 30 of the power spring drive compartment 48 . The spring 64 is contained laterally by the cam stop winding knob power spring pocket retainer 74 . The firewall 30 separates the power spring drive compartment 48 from the portion of the body 12 having the spiral channel 22 .
[0102] In alternate embodiments, the cam stop winding knob power spring pocket retainer 74 is of different sizes to allow power springs 64 of different sizes to be used. In this embodiment, the cam stop winding knob power spring pocket retainer 74 is substantially round in shape and the thickness of the cam stop winding knob power spring pocket retainer 74 is less than the depth 122 of the power spring pocket 40 . The cam stop winding knob power spring pocket retainer 74 includes a slot 140 for receiving a first end or hook end 142 of the spring 64 ; the slot 140 and hook end 142 provide an anchor for the spring 64 . Cam stop winding knob power spring pocket retainers 74 of various sizes along with various power springs 64 of different spring constants are used, depending upon the caliber of the firearm. Alternatively, if a large power spring 64 is used, the slot 140 may be integrally formed as part of the inner wall of the power spring pocket 40 , and there is no need for a cam stop winding knob power spring pocket retainer 74 .
[0103] The power spring 64 also includes a looped portion 144 which during assembly, moves through a groove 146 formed as part of the power spring drive shaft 50 . When assembled, the looped portion 144 abuts and is anchored by a notch 148 , which increases the tension in the spring 64 as the cam stop winding knob 38 is rotated.
[0104] When the cam stop winding knob 38 is inserted into the power spring drive compartment 48 and assembled with the cam stop bearings 42 , the cam stop winding knob 38 turns only in one direction and locks if turned in the opposite direction. This cam configuration acts as a linear, noiseless pawl. The slightly raised narrow race midway between the cam stop winding knob power spring pocket retainer 74 and the outer circumference 76 of the cam stop winding knob power spring pocket 40 is the cam stop friction race 78 . The purpose of the race 78 is to minimize the amount of contact surface between the cam stop winding knob 38 and the firewall 30 of the power spring drive compartment 48 , thereby reducing operating friction. While the race 78 shown in the figures is shown as a continuous race, in alternate embodiments friction may be further reduced by changing the race 78 to a few short intermittent points.
[0105] FIG. 16 shows the cam stop bearings 42 located in a correct position of a respective cam stop bearing pocket 80 formed on an outer wall 81 of the power spring pocket 40 . While one cam stop bearing 42 may be used to create the pawl action, in this embodiment multiple cam stop bearings 42 which are evenly spaced function to distribute forces placed on an inner wall 83 along the diameter 82 of the power spring compartment 48 . In other embodiments, any number of cam stop bearing pockets 80 and cam stop bearings 42 are used. Also shown in FIG. 16 is the cam stop winding knob outer lip 84 . The lip 84 contacts the body 12 when the system 10 is assembled, and serves as a barrier to prevent large particles and debris from obstruction of the cam stop winding knob 38 , as well as preventing the collection of particles of debris in the power spring compartment 48 .
[0106] In this embodiment, there are three cam stop bearing pockets 80 with three cam stop bearings 42 correctly located on the outer circumference of the cam stop winding knob power spring pocket 40 . The cam stop winding knob 38 also includes a power spring drive shaft push-button opening 86 , which receives the power spring drive shaft 50 when the system 10 is assembled. When the cam stop winding knob 38 is correctly assembled to the housing or body 12 of the power spring compartment 48 side of the system 10 , the power spring primary drive shaft push-button end 88 is seen in the cam stop winding knob push-button pocket 90 .
[0107] The clutch release push-button 66 attaches directly to the power spring primary drive shaft push-button end 88 , with a clutch release push-button return spring 92 directly under the clutch release push-button 66 . The power spring drive shaft 50 includes a first set of flats 150 which are in contact with a second set of flats 152 formed as part of a small diameter portion 154 of the clutch release push-button 66 . The small diameter portion 154 includes a hollowed portion, generally shown at 156 , which is of a corresponding shape to the power spring primary drive shaft push-button end 88 , including having the second set of flats 152 . The small diameter portion 154 also has a bottom surface 158 which is part of a large diameter portion 160 . The bottom surface 158 includes an aperture 162 which extends through the large diameter portion 160 , and when the push button 66 is assembled, the aperture 162 is in substantial alignment with a threaded aperture 164 formed as part of the power spring primary drive shaft push-button end 88 . To attach the push button 66 to the shaft 50 , the button 66 is slid onto the push-button end 88 such that the first set of flats 150 are in sliding contact with the second set of flats 152 , the bottom surface 170 of the small diameter portion 154 contact a set of shoulders 172 , and the push-button end 88 is disposed in the hollowed portion 156 . A fastener in the form of a screw 166 is then inserted through the aperture 162 and into the threaded aperture 164 of the shaft 50 , securing the push-button 66 to the shaft 50 .
[0108] When the clutch release push-button 66 is attached to the shaft 50 , the clutch release push-button return spring 92 is disposed between and is in contact with a lower surface 168 formed as part of the large diameter portion 160 and a contact surface 174 formed as part of the clutch release push-button pocket 68 . When the screw 166 is tightened, the clutch release push-button 66 is disposed in the clutch release push-button pocket 68 . The cam stop winding knob 38 is held attached to the body 12 by the fastener 166 attaching the clutch release push button 66 to the shaft 50 . The return spring 92 then applies a force to the contact surface 174 of the push button pocket 68 , thereby maintaining the assembly of the cam stop winding knob 38 to the body 12 .
[0109] The encapsulated spring clutch mechanism 20 transfers energy from the power spring assembly 94 , or more specifically, the power spring 64 , to the encapsulated spring clutch mechanism secondary drive shaft 34 , which turns the spiral following cartridge drive arm 36 . The encapsulated spring clutch mechanism 20 is shown assembled in FIGS. 17 and 30 , and disassembled in FIGS. 18-21 . The encapsulated spring clutch mechanism 20 includes the power spring primary drive shaft 50 having the power spring primary drive shaft push-button end 88 , an encapsulated spring clutch mechanism castle cover 96 , and the encapsulated spring clutch mechanism cup 98 . When assembled, the power spring primary drive shaft 50 extends through a central aperture 176 formed as part of the castle cover 96 .
[0110] Also included are encapsulated spring clutch mechanism castle cover ear notches 100 which are formed on adjacent sides of the cup 98 , and there are corresponding castle cover ears 124 formed on adjacent sides of the encapsulated spring clutch mechanism castle cover 96 . Also shown in FIG. 18 , the encapsulated spring clutch mechanism hex drive opening 32 is located approximately in the center of the encapsulated spring clutch mechanism cup floor 102 . As seen in FIG. 19 , the power spring primary drive shaft 50 , the encapsulated spring clutch mechanism castle cover 96 , and the encapsulated spring clutch mechanism compression spring 70 are shown in the assembled state, and the cup 98 is removed.
[0111] The encapsulated spring clutch mechanism castle cover 96 mates to the encapsulated spring clutch mechanism cup 98 . The castle cover ears 124 are selectively received into the ear notches 100 , and screw fasteners extend into apertures 126 formed as part of the cup 98 and threaded apertures 128 formed as part of the castle cover 96 . The encapsulated spring clutch mechanism castle cover locking notches 104 are internal to the encapsulated spring clutch mechanism cup 98 when assembled.
[0112] In an alternate embodiment, the encapsulated spring clutch mechanism castle cover notches 104 are placed in the floor 102 of the encapsulated spring clutch mechanism cup 98 . Also, there are many methods of attaching the encapsulated spring clutch drive mechanism castle cover 96 to the encapsulated spring clutch mechanism cup 98 . An alternate embodiment includes the encapsulated spring clutch mechanism castle cover 96 assembled to the encapsulated spring clutch mechanism cup 98 by any means that do not interfere with the intended rotation of the encapsulated spring clutch mechanism cup 98 or clutch action of the encapsulated spring clutch mechanism 20 . The alternate embodiments include a stab lock, glue, pinning, welding, etc in place of a fastener used with the apertures 126 , 128 .
[0113] The power spring primary drive shaft 50 when assembled into the encapsulated spring clutch mechanism 20 engages the encapsulated spring clutch mechanism castle cover locking notches 104 through the use of a power spring primary drive shaft castle pin 106 , and is held in an engaged position by the encapsulated spring clutch mechanism compression spring 70 . When the clutch release push-button 66 is pressed, the power spring primary drive shaft 50 moves to disengage or remove the power spring primary drive shaft castle pin 106 from the encapsulated spring clutch mechanism castle cover locking notches 104 . The compression spring 70 is disposed between the encapsulated spring clutch mechanism cup floor 102 and the encapsulated spring clutch mechanism castle cover 96 .
[0114] In operation, when it is desired to load and use the system 10 and the system 10 is in an assembled state, the user simply removes the fasteners 130 from the spiral cover 28 , and then removes the spiral cover 28 from the body 12 . The spiral following cartridge drive arm 36 and the cartridge cover plate 60 are removed as well. Firearm cartridges 24 are placed into the spiral channel 22 after the removal of the spiral cover 28 , the spiral following cartridge drive arm 36 , the encapsulated spring clutch mechanism secondary drive shaft 34 , and the cartridge cover plate 60 . While some firearm cartridges 34 self-locate in the spiral channel 22 , other firearm cartridges are easily located in the spiral channel 22 by the user. After completely filling the spiral channel 22 partially or completely with firearm cartridges 24 , the various components are reassembled and the spiral cover 28 attaches to the housing or body 12 .
[0115] Once the feeding system 10 of the present invention has been loaded with cartridges 24 , the cam stop winding knob 38 is rotated. Rotational force is transferred through the cam stop winding knob 38 to the power spring 64 and then to the drive shaft 50 . However, the drive shaft 50 is prevented from rotating because the spiral following cartridge drive arm pin 58 receives a reactionary force from the cartridges 24 , which is transferred through the spiral following cartridge drive arm pin 58 , the spiral following cartridge drive arm 36 , the secondary drive shaft 34 , the encapsulated spring clutch mechanism 20 , and the power spring drive shaft 50 . The power spring drive shaft 50 does not rotate as the cam stop winding knob 38 is rotated, and therefore tension builds in the power spring 64 . The rotation of the cam stop winding knob 38 applies a rotational force to the hook end 142 of the power spring 64 because of the hook end 142 being located in the slot 140 , and the looped portion 144 being adjacent the notch 148 on the power spring drive shaft 50 . As the cam stop winding knob 38 is rotated, it is prevented from rotating in the opposite direction due to the pawl action generated by the cam stop bearings 42 and cam bearing pockets 80 described above.
[0116] Once the user has rotated the cam stop winding knob 38 to generate the desired amount of tension in the power spring 64 , the cam stop winding knob 38 does not move, and the firearm is ready for use. As the user fires the firearm, the cartridges 24 are discharged one at a time, and a new cartridge 24 is fed through the feed lips 14 into the firearm. The cartridges 24 are fed into the firearm because of the tension in the power spring 64 . The tension in the power spring 64 causes the power spring drive shaft 50 to rotate because of rotational force applied to the shaft 50 from the spring 64 . This rotational force is transferred to the power spring primary drive shaft castle pin 26 , to the encapsulated spring clutch mechanism castle cover 96 , the castle cover ears 124 , the castle cover ear notches 100 , the encapsulated spring mechanism cup 98 , the encapsulated spring mechanism cup floor 102 , the hex drive opening 32 , the hex end 52 of the secondary drive shaft 34 , the secondary drive shaft 34 , the spiral following cartridge drive arm 36 , spiral following cartridge drive arm pin 58 , and then to the cartridges 24 . This causes the remaining cartridges 24 to move in the spiral channel 22 as the cartridges 24 moved from the feed lips 14 into the firearm are discharged from the firearm.
[0117] If the user decides to stop using the firearm, but wishes to have the cartridges 24 remain in the feed system 10 for future uses, the user simply presses the clutch release push button 66 . Pushing the clutch release push button 66 also applies a force to the power spring drive shaft 50 . The user must press the push button 66 with enough force to overcome the force of the clutch release push button return spring 92 and the encapsulated spring clutch mechanism compression spring 70 . As force is applied to the power spring drive shaft 50 from the push button 66 , the power spring primary drive shaft castle pin 106 is removed from the encapsulated spring clutch mechanism castle cover locking notches 104 . This allows the clutch release push button 66 , the power spring drive shaft 50 , and the compression spring 70 to rotate relative to the encapsulated spring clutch mechanism castle cover 96 and the encapsulated spring clutch mechanism cup 98 . The remaining tension in the power spring 64 causes the power spring drive shaft 50 to rotate and relieve the tension in the power spring 64 . This prevents the power spring 64 from permanently deforming, or developing a “set,” improving the life of the power spring 64 .
[0118] If the user decides to use the firearm again, the cam stop winding knob 38 is wound to generate tension in the power spring 64 as described above. If the castle pin 106 is not disposed in one of the notches 104 , there are multiple notches 104 that the pin 106 can be received into such that when the cam stop winding knob 38 is rotated, if the pin 106 is not disposed in one of the notches 104 , then as the cam stop winding knob 38 is rotated, the rotational force applied to the power spring 64 by the cam stop winding knob 38 as described above causes the power spring 64 to rotate the power spring drive shaft 50 until the castle pin 106 is in alignment with one of the notches 104 . The castle pin 106 then slides into the respective notch 104 ; rotational force is then transferred through the various components as described above to build tension in the power spring 64 .
[0119] After the firearm cartridge feeding system 10 has been loaded, and if it is desired to remove the cartridges 24 from the system 10 (for the purpose of long term storage, for example), the system 10 is easily unloaded by removing the spiral cover 28 , the spiral following cartridge drive arm 36 , the encapsulated spring clutch mechanism secondary drive shaft 34 , and the cartridge cover plate 60 . Once the components have been removed from the system 10 , the firearm cartridges 24 are spilled out, best shown in FIGS. 23A and 23B .
[0120] Another embodiment of the encapsulated spring clutch mechanism cup 98 is shown in FIGS. 35-37 , with like numbers referring to like elements. In this embodiment, the encapsulated spring clutch mechanism cup, generally shown at 180 , is integral with the secondary drive shaft 34 . More specifically, the secondary drive shaft 34 is formed as part of the encapsulated spring clutch mechanism cup floor 182 . The cup 180 also includes a plurality of cam bearing pockets 184 formed as part of the cup 180 , instead of being formed as part of the cam stop winding knob 38 , as discussed with regard to the previous embodiment. There are also cam stop bearings (not shown) which are received into the cam bearing pockets 184 and operate in substantially the same manner as the cam stop bearings 42 described in the previous embodiment.
[0121] Another embodiment of the housing 12 is shown in FIG. 38 , with like numbers referring to like elements. This embodiment is similar to the housing 12 shown in the other Figures, with the exception that unneeded material has been removed surrounding the spiral groove 22 to make the housing 12 lighter, thereby reducing the overall weight of the ammunition feeding system 10 .
[0122] It should be noted that the various components of the ammunition feeding system 10 are made of various types of polymers to reduce friction between the various components, as well as prevent any deterioration from exposure to moisture due to various weather conditions. The ammunition feeding system 10 is completely submersible in a liquid, such as water, and is completely operational after being removed from the liquid. The components that are made of the various polymers are the housing 12 , the cam stop winding knob 38 , and the encapsulated spring clutch mechanism cup 98 .
[0123] Another embodiment of an ammunition feed system according to the present invention is shown in FIGS. 39-52C generally at 186 , with like numbers referring to like elements. This embodiment includes a body 188 , which is generally similar to the body 12 described in the previous embodiments, but also includes some distinguishable features. The body 188 also includes a spiral channel 190 , and a clutch pocket, generally shown at 192 . This embodiment does not have an encapsulated spring clutch mechanism 20 , but rather includes a clutch assembly, generally shown at 194 , the function of which will be described later.
[0124] The body 188 also includes a sidewall 196 which protrudes outwardly from the sides of the spiral channel 190 , and functions as a loading bowl to facilitate the loading of the cartridges 24 into the spiral channel 190 . Connected to the sidewall 196 is a plurality of pedestal stops 198 . Each of the pedestal stops 198 includes a ledge 200 used for supporting the cartridge cover plate 60 when the ammunition feed system of the present invention is assembled. The cartridge cover plate 60 is substantially the same as described in the previous embodiments, but as shown in FIGS. 41-42 , 46 - 47 , and 51 C, also includes a pair of tabs 202 , and the spiral following clutch drive arm 36 is disposed between the tabs 202 when the ammunition feed system 186 is assembled. In this embodiment, the cartridge cover plate 60 is not only driven for rotation by the spiral following clutch drive arm pin 58 , as with the previous embodiment, but is also driven for rotation by the spiral following clutch drive arm 36 applying rotational force to the tabs 202 . The spiral following clutch drive arm pin 58 still extends through the elongated aperture 118 and into the spiral channel 190 , and the elongated aperture 114 is in substantial alignment with the cartridge cover plate secondary drive shaft center 116 .
[0125] This embodiment also includes a spiral cover plate 204 which has an upper flange 206 and a pair of upper locking tabs 208 , each of the upper locking tabs 208 having a tapered surface 210 which is adjacent a shoulder 212 . When connected to the body 188 , each of the upper locking tabs 208 are received into a respective slot 214 formed as part of a shortened neck portion, shown generally at 216 , and the shortened neck portion 216 is formed as part of the body 188 . The upper locking tabs 208 are substantially rigid, but are also biasable in that during assembly, the upper locking tabs 208 are initially inserted into the slots 214 , and as the tabs 208 are pushed further into the slots 214 , the tapered surfaces 210 are in contact with and move along the respective outer surfaces 217 of the slots 214 , and the outer surfaces 217 bias the tabs 208 inwardly until the tabs 208 are pushed far enough into the slots 214 that that tapered surfaces 210 have completely moved through the slots 214 . The bias on the tabs 208 is then relieved, and the tabs 208 return to their initial position, causing the shoulders 212 to be in contact with a ledge 215 adjacent the slot 214 , preventing the removal of the tabs 208 from the slots 214 . Each of the slots 214 is formed as part of a protrusion 218 , with the protrusion 218 being part of the shortened neck portion 216 .
[0126] To remove the tabs 208 from the slots 214 , the user simply applies pressure to the tapered surfaces 210 , thereby moving the tabs 208 in a direction toward one another, to allow the tabs 208 to move back through the slots 214 , the user then pulls on the cover plate 204 . This causes the tabs 208 to move back through the slots 214 in the opposite direction.
[0127] The spiral cover plate 204 also includes a spiral cover retaining strap slot 220 which is able to receive a first portion 222 of a spiral cover retaining strap, generally shown at 224 . The strap 224 also includes a second portion 226 operable for extending into a bottom slot 228 formed as part of the body 188 . The first portion 222 includes a tapered surface 230 which terminates into a shoulder 232 . During assembly, the first portion 222 is pushed through the slot 220 , and the tapered surface 230 contacts the inside of the slot 220 , causing the first portion 222 to deflect. When the first portion 222 is pushed through the slot 220 far enough that the tapered portion 210 of the first portion 222 is completely through the slot 220 , the tapered surface 210 is no longer in contact with the inner surface of the slot 220 , and the first portion 222 returns to its original position. When assembled, the first portion 222 extends through the slot 220 until the shoulder 232 is adjacent and in contact with a ledge 234 to prevent the first portion 222 from being pulled out of the slot 220 . To remove the first portion 222 from the slot 220 , force is applied to the tapered surface 230 such that the first portion 222 moves toward the cover plate 204 until the shoulder 232 is no longer in contact with the ledge 234 , allowing the first portion 222 to be pulled from the slot 220 .
[0128] The second portion 226 also includes a folded portion 236 which terminates into a shoulder 238 . When assembled, the second portion 226 is inserted through the bottom slot 228 until the folded portion 236 is completely through the slot 228 , this allows the shoulder 238 to contact a ledge 240 of the bottom slot 228 . The folded portion 236 does not have a tapered surface as described above with reference to the other tabs 208 or the first portion 222 , and is intended to provide a permanent connection between the strap 224 and the body 12 .
[0129] To further secure the spiral cover plate 204 to the body 188 , the spiral cover plate 204 includes a lower fastening tab 233 which when assembled extends into a bottom fastening tab slot 235 .
[0130] The spiral cover plate 204 also includes a recessed portion 242 which receives at least part of the tabs 202 protruding from the cartridge cover plate 60 , preventing any interference between the rotation of the tabs 202 and the spiral cover plate 204 as the cartridge cover plate 60 rotates. As previously mentioned, the spiral following clutch drive arm 36 and the spiral following clutch drive arm pin 58 transfer rotational force to the tabs 202 and the slot 118 , respectively. The spiral following clutch drive arm pin 58 receives rotational force from the clutch assembly 194 . More particularly, the clutch assembly 194 includes a drive shaft 244 which combines features of both the secondary drive shaft 34 and the power spring drive shaft 50 of the previous embodiments. The drive shaft 244 (similarly to the secondary drive shaft 34 of the previous embodiment) has a double flat key end 246 which extends through the cartridge cover plate secondary drive shaft center 116 , through the elongated aperture 114 , and is in contact with the bearing surfaces 62 for transferring rotational force to the spiral following clutch drive arm 36 . Additionally, the arm 36 , and therefore the pin 58 , travels outwardly (toward the outer diameter of the cartridge cover plate 60 ) or inwardly (toward the cartridge cover plate secondary drive shaft center 116 ), depending on whether there is clockwise or counterclockwise rotation, as the pin 58 moves in the spiral channel 190 of the body 188 . This causes the arm 36 to move across the double flat key end 246 of the shaft 244 , while still receiving rotational force from the shaft 244 .
[0131] The drive shaft 244 also includes a power spring primary drive shaft push-button end, generally shown at 248 (similar to the power spring drive shaft push button end 88 as described in the first embodiment), having a first set of flats 250 which are in contact with the second set of flats 152 formed on the small diameter portion 154 of the clutch release push button 66 . The push-button end 248 also includes a threaded aperture 252 . To attach the push button 66 to the push-button end 248 , the button 66 is slid onto the push-button end 248 such that the push-button end 248 is disposed in the hollowed portion 156 , the first set of flats 250 contact the second set of flats 152 , and the bottom surface 170 of the small diameter portion 154 contacts a set of shoulders 254 . The screw 166 is then inserted through the aperture 252 and into the threaded aperture 164 of the shaft 244 , securing the push button 66 to the shaft 244 .
[0132] The shaft 244 also includes an aperture 256 which receives a drive pin 258 . The drive pin 258 is positioned in the aperture 256 such that a substantially equal amount of the drive pin 258 protrudes out of the aperture 256 on each side of the drive shaft 244 , best shown in FIGS. 43 A and 46 - 47 . When assembled, the drive pin 258 is selectively received into one or more of a plurality of locking notches 260 formed as part of a castle end 262 of a power spring drive sleeve, shown generally at 264 . The castle end 262 is part of a larger diameter portion 266 , and part of the larger diameter portion 266 is adjacent an outer lip 268 . The power spring drive sleeve 264 also includes a small diameter portion 270 , and a power spring eyelet notch 272 . This embodiment also incorporates the same power spring 64 used with the previously described embodiments, and the power spring eyelet notch 272 is used for anchoring the looped portion 144 of the power spring 64 in a similar manner as compared to the notch 148 of the previously described embodiments.
[0133] As best shown in FIGS. 46-47 , a portion of the drive shaft 244 extends through the drive shaft opening 274 of the body 188 into the pocket 192 such that the double flat key end 246 , the pin 258 , and the castle end 262 are disposed in the pocket 192 , and the drive pin 258 is selectively in contact with a bottom surface 276 of the pocket 192 . The maximum depth 278 of each of the locking notches 260 is in substantial alignment with the bottom surface 276 of the pocket 192 when the feed system 186 is assembled. The large diameter portion 266 of the drive sleeve 264 is selectively in contact with the drive shaft opening 274 because the large diameter portion 266 is of a smaller diameter compared to the drive shaft opening 274 . The large diameter portion 266 is of a size to allow the drive shaft sleeve 264 to rotate as freely as possible within the drive shaft opening 274 , while still maintaining the proper position of the drive shaft sleeve 264 within the opening 274 . This rotation is further facilitated by the small diameter portion 270 . Because the small diameter portion 270 is not in contact with the opening 274 , there is less overall friction between the drive sleeve 264 and the drive shaft opening 274 . The inner surface 280 of the lip 268 is also in contact with the bottom surface 282 of a recess 284 formed in the power spring drive shaft compartment, shown generally at 286 .
[0134] The power spring drive shaft compartment 286 also includes a firewall 288 and a sidewall 290 . The firewall 288 separates the compartment 286 from the spiral channel 190 , essentially performing the same function as the firewall 30 described in the previous embodiments. This embodiment of the invention also includes a cam stop winding knob, shown generally at 292 . The cam stop winding knob 292 of this embodiment is substantially similar to the cam stop winding knob 38 of the previous embodiment, but also has several different features as well. The cam stop winding knob 292 includes the same cam stop bearings 42 , cam stop bearing pockets 80 , outer lip 84 , power spring pocket 40 , and clutch release push button pocket 68 . Also similar to the previous embodiment, the clutch release push button pocket 68 includes the power spring drive shaft push-button opening 86 and the contact surface 174 .
[0135] However, in this embodiment, the cam stop friction race 78 has several hollowed sections 294 where material has been removed, reducing the weight of the cam stop winding knob 292 , and therefore reducing the overall weight of the ammunition feeding system 186 . Also included is a lever portion 296 which provides the user with leverage for rotating the cam stop winding knob 292 . The power spring drive shaft push-button opening 86 also includes a recessed portion 298 having an inner surface 300 . When assembled, part of the large diameter portion 266 of the drive sleeve 264 is disposed in the recessed portion 298 and is adjacent the inner surface 300 . This embodiment also uses the same power spring 64 used for the previous embodiments, but the cam stop winding knob 292 in this embodiment also includes a slot 302 formed as part of the inner wall 305 of the power spring pocket 40 (which in this embodiment performs the same function as the slot 140 and the cam stop winding knob power spring pocket retainer 74 of the previous embodiments). The slot 302 receives the hook end 142 of the power spring 64 , and the looped portion 144 selectively contacts the power spring eyelet notch 272 of the drive sleeve 264 .
[0136] When assembled, the drive sleeve 264 is pushed through the recess 284 of the drive shaft opening 274 until the castle end 262 protrudes out of the pocket 192 . The drive shaft 244 is then inserted through the drive sleeve 264 until the drive pin 258 is positioned in two of the locking notches 260 as shown in FIGS. 43 A and 46 - 47 . The drive pin 258 prevents the drive shaft 244 from being pushed through the sleeve 264 any further. The cam stop winding knob 292 is then assembled to the body 188 , and part of the large diameter portion 266 of the drive sleeve 264 is disposed in the recessed portion 298 and is adjacent the inner surface 300 , best shown in FIG. 47 . The power spring primary drive shaft push-button end 248 protrudes out of the drive sleeve 264 , through the power spring drive shaft push-button opening 86 , and into the clutch release push button pocket 68 , also shown in FIG. 47 . The clutch release push button return spring 92 is positioned in the pocket 68 and contacts the contact surface 174 . The clutch release push button 66 is then placed on the push-button end 248 of the shaft 244 such that the first set of flats 250 are in contact with the second set of flats 152 , the bottom surface 170 is in contact with the shoulders 254 , and the clutch button return spring 92 is positioned between the contact surface 174 and the lower surface 168 of the clutch release push button 66 . The screw 166 is then inserted through the aperture 162 of the clutch release push button 66 and into the threaded aperture 252 of the drive shaft 244 , securing the clutch release push button 66 to the drive shaft 244 . The first set of flats 250 and second set of flats 152 to prevent relative rotation between the drive shaft 244 and the clutch release push button 66 .
[0137] When the cam stop winding knob 292 is assembled to the body 188 , the outer lip 84 is in contact with the outer periphery of the sidewall 290 , and the outer wall 81 is adjacent the sidewall 290 , best seen in FIG. 46 . When the power spring 64 is installed into the power spring drive compartment 286 , the power spring 64 is captured between the cam stop winding knob power spring pocket ceiling 72 and the firewall 288 of the power spring drive compartment 286 . The spring 64 is contained laterally by the inner wall 305 .
[0138] As stated above, the body 188 has a shortened neck portion 216 , instead of being shaped like the neck 16 described in the previous embodiments. The slots 214 , ledges 215 , and protrusions 218 are all formed as part of the shortened neck portion 216 . Adjacent each of the protrusions 218 is a recessed portion 304 , which is where the portion of the locking tabs 208 having the tapered surfaces 210 are located respectively, when the spiral cover plate 204 is attached to the body 188 . The spiral channel 190 is connected to a cartridge channel 306 , which is also formed as part of the neck portion 216 . When in operation, the cartridges 24 are fed from the spiral channel 190 through the cartridge channel 306 , and through a feed neck extension, shown generally at 308 .
[0139] The feed neck extension 308 has a body portion 310 which is correspondingly shaped to be received into a magazine well, shown generally at 312 . Connected to the body portion 310 is a rear flange 314 . Also connected to the body portion 310 and substantially perpendicular to the rear flange 314 is a first side flange 316 and a second side flange 318 . Each of the side flanges 316 , 318 includes a diagonal portion 320 which positions the side flanges 316 , 318 at a wider location relative to the body portion 310 . Also connected to the body portion 310 and the side flanges 316 , 318 is a front flange 322 , and connected to the front flange 322 is a darted feed neck latch, shown generally at 324 . The darted feed neck latch 324 is selectively inserted through an aperture 326 formed as part of a front wall 328 .
[0140] The neck portion 216 includes a first sidewall 330 and a second sidewall 332 . Each sidewall 330 , 332 includes a slot 214 , a recessed portion 304 , and a protrusion 218 . Formed on the inside of the first sidewall 330 is a first feed neck extension channel 334 , and formed on the inside of the second sidewall 332 is a second feed neck extension channel 336 . The first feed neck extension channel 334 is complementary in shape to the first side flange 316 , and the second feed neck extension channel 336 is complementary in shape to the second side flange 318 such that the feed neck extension 308 is operable to be connected to the neck portion 216 . When the feed neck extension 308 is connected to the neck portion 216 , there are a pair of angled surfaces 338 which are in contact with the diagonal portions 320 , best seen in FIG. 45A , preventing the feed neck extension 308 from becoming detached from the neck portion 216 when assembled together.
[0141] The feed neck extension 308 is also held in place by the upper flange 206 when the spiral cover plate 204 is attached to the body 188 . When assembled, the upper flange 206 is in contact with a feed neck extension guide rail 340 formed as part of the feed neck extension 308 . The feed neck extension guide rail 340 helps to properly position the feed neck extension 308 when connecting the feed neck extension 308 to the firearm, and includes a slot 342 and an aperture 344 which receives a roll pin 346 . The feed neck extension 308 also includes a channel 348 which extends along an outer sidewall 350 . The channel 348 is offset from the center of the slot 342 , and there is a bolt stop actuator 352 having a first flat portion 354 , a second flat portion 356 , and a third flat portion 358 . The first flat portion 354 is connected to the third flat portion 358 , and the second flat portion 356 is also connected to the third flat portion 358 , with the third flat portion 358 being substantially perpendicular to both the first flat portion 354 and the second flat portion 356 . The first flat portion 354 is disposed in the slot 342 and the third flat portion 358 extends through the channel 348 . The second flat portion 356 is positioned along the inner surface of the sidewall 350 .
[0142] When assembled, a portion of the roll pin 346 is disposed in the aperture 344 , and a portion of the roll pin 346 extends into the slot 342 . The portion of the roll pin 346 that extends into the slot 342 also extends into an elongated aperture 360 formed as part of the first flat portion 354 . This limits the range of movement of the bolt stop actuator 352 in the slot 342 to movement between a retracted position (when the actuator 352 is completely disposed in the slot 342 ) and an extended position (when a portion of the actuator 352 protrudes out of the slot 342 ), the function of which will be descried later. The range of motion is determined by the length of the elongated aperture 360 , which may be different lengths if desired.
[0143] Also formed as part of one of the sidewalls 362 of the feed neck extension 308 is a release aperture 364 which, when the feed neck extension 308 is correctly inserted into the magazine well 312 , is substantially aligned with the magazine catch channel 366 of the magazine well 312 . The magazine catch channel 366 has a lower ledge 368 which is selectively in contact with a corresponding shoulder surface 370 of a double lock latch hook 372 .
[0144] The double lock latch hook 372 is part of a double lock latch 374 . The double lock latch 374 also has a double latch retainer hook 376 , and the double latch retainer hook 376 is located in a lower channel 378 formed as part of the second sidewall 332 . The double lock latch 374 also has a lower flange 380 in contact with the upper surface of the second sidewall 332 as shown in FIGS. 45A , 48 , and 51 A. There is also a double lock latch disassembly opening 382 formed as part of the lower channel 378 . The double latch retainer hook 376 also includes a shoulder surface 384 in contact with an upper surface 386 of the double lock latch disassembly opening 382 , preventing the removal of the double lock latch 374 from the double lock latch disassembly opening 382 . The distance between the lower flange 380 and the shoulder surface 384 provides for a close fit with the upper surface 386 and the upper surface of the second sidewall 332 .
[0145] In order to remove the double lock latch 374 , the feed neck extension 308 must be removed from the magazine well 312 . The end of a screw driver is inserted into the double lock latch disassembly opening 382 , and a force is applied to the portion of the double latch retainer hook 376 exposed in the double lock latch disassembly opening 382 . Then, the double lock latch 374 is moved to the left when looking at FIG. 45A such that the shoulder surface 384 is no longer in contact with the upper surface 386 , and the lower flange 380 is no longer in contact with the upper surface of the second sidewall 332 , allowing the double latch retainer hook 376 to be pulled upwardly through the lower channel 378 , and therefore allowing the double lock latch 374 to be removed from the neck portion 216 , if desired.
[0146] The magazine well 312 has an elongated sliding mechanism 388 which is disposed in magazine catch channel 366 , and is selectively in contact with the double lock latch hook 372 . The elongated sliding mechanism 388 is connected to the release mechanism associated with the firearm for releasing a typical magazine from the magazine well 312 . When the body portion 310 of the feed neck extension 308 is disposed in the magazine well 312 , the double lock latch hook 372 provides additional support for preventing the feed neck extension 308 from becoming dislodged from the magazine well 312 . When it is desired to remove the feed neck extension 308 from the magazine well, the release mechanism of the firearm is actuated, the elongated sliding mechanism 388 moves from left to right when looking at FIG. 45A , and therefore moves in the magazine catch channel 366 , but also applies a force to the double lock latch hook 372 , causing the double lock latch 374 to deflect, and the shoulder surface 370 to no longer be in contact with the lower ledge 368 . The feed neck extension 308 is then removable from the magazine well 312 .
[0147] The elongated sliding mechanism 388 is a commonly known part used with most conventional firearms. The ammunition feeding system 186 of the present embodiment expands on the use of the elongated sliding mechanism 388 by using the elongating sliding mechanism 388 to actuate and release the double lock latch 374 as described above. The use of the double lock latch 374 helps to additionally secure the feed neck extension 308 to the magazine well 312 , but since the double lock latch 374 does not require any additional actuation (other than using the release mechanism), the user of the firearm still uses the release mechanism of the firearm in a known manner.
[0148] The body portion 310 also includes another sidewall 392 which is substantially parallel to the sidewall 350 having the slot 342 and channel 348 , and yet another sidewall 394 which is substantially parallel to the sidewall 362 having the release aperture 364 . The sidewall 394 also includes a pocket, generally shown at 396 , in which is located a cartridge stop assembly, generally shown at 398 . The pocket 396 includes an angled ledge 400 which terminates into an angled wall portion 402 . Adjacent and connected to the angled ledge 400 and the angled wall portion 402 are a pair of pocket sidewalls 404 , each of which has a sidewall lip 406 . There is also an upper gap, shown generally at 408 , and a lower gap, shown generally at 410 . Below the lower gap 410 is a sidewall ledge 412 formed as part of the sidewall 394 , and the sidewall ledge 412 has a lipped portion 414 .
[0149] When looking at FIG. 45A , to the right of the upper gap 408 is a back wall 416 , and to the left of the upper gap 408 is a beam portion 418 having an inner surface 420 . The back wall 416 is also formed as part of a cartridge stop guide section or feed lip 422 having a first cartridge stop guide surface 424 and an angled cartridge stop surface 426 . The first cartridge stop guide surface 424 is substantially parallel to a second cartridge stop guide surface 428 formed as part of the angled wall portion 402 .
[0150] The cartridge stop assembly 398 includes a stop cover 430 , a biasable member, which in this embodiment is a flat spring 432 , and a cartridge stop 434 . The stop cover 430 has an outer surface 436 which is substantially parallel to the sidewall 394 when the cartridge stop assembly 398 is assembled in the pocket 396 . The stop cover 430 also has an inner surface 438 , and formed as part of the inner surface is a stop cover guide section 440 , which has a spring guide surface 442 . An upper tab 444 is also formed as part of the stop cover 430 , and is substantially parallel to and offset from the inner surface 438 . A lower tab 446 is formed as part of the stop cover 430 and is substantially perpendicular to the inner surface 438 . The lower tab 446 includes a shoulder 448 having a tapered surface 450 and a contact surface 452 .
[0151] The cartridge stop 434 includes a stop ledge 454 which is selectively in contact with the cartridge stop surface 426 when the cartridge stop 434 is in an extended position. The stop ledge 454 is adjacent an outer guide surface 456 , and the outer guide surface 456 is in sliding contact with the first cartridge stop guide surface 424 . The cartridge stop 434 also includes an outer guide surface 458 in sliding contact with the second cartridge stop guide surface 428 , and a biasing surface 460 which is in contact with the flat spring 432 . The flat spring 432 is also disposed in the pocket 396 , and is located between the second cartridge stop guide surface 428 and the spring guide surface 442 . The flat spring 432 is also located on the angled ledge 400 , and the angled ledge 400 is substantially perpendicular to the spring guide surface 442 and the cartridge stop guide surfaces 424 , 428 .
[0152] The cartridge stop 434 is designed to be a width that allows the cartridge stop 434 to fit between the pocket sidewalls 404 . The cartridge stop 434 is shown in the extended position in FIGS. 39 , 45 A- 45 B, and 51 B, and when in the extended position, the cartridge stop 434 is designed to prevent the removal of the cartridges 24 from the feed neck extension 308 (other than through the use of the forward stripping action of a firearm slide, bolt, or feeding method; cartridges 24 may also be manually stripped from the lips by the user). The cartridge stop 434 also includes an outer contact surface 462 which is angled in relation to the biasing surface 460 . The outer contact surface 462 is also adjacent an angled outer contact surface 464 formed as part of the cartridge stop guide section 422 .
[0153] To assemble the cartridge stop assembly 398 , the cartridge stop 434 is placed between the cartridge stop guide surfaces 424 , 428 , and the flat spring 432 is positioned in the pocket 396 underneath the cartridge stop 434 such that the flat spring 432 is located between the cartridge stop 434 and the angled ledge 400 . The first cartridge stop guide surface 424 is in contact with the inner guide surface 456 , and the outer guide surface 458 is in contact with the second cartridge stop guide surface 428 .
[0154] To assemble the stop cover 430 to the body portion 310 , initially the upper tab 444 is inserted into the upper gap 408 such that the upper tab 444 is disposed between the back wall 416 and the inner surface 420 of the beam portion 418 , and the stop cover 430 is then pushed towards the pocket 396 such that the tapered surface 450 slides along the sidewall ledge 412 and the lower tab 446 moves into the lower gap 410 . The contact between the tapered surface 540 and the sidewall ledge 412 causes the lower tab 446 to deflect, generating a tension in the lower tab 446 . Once the lower tab 446 has moved far enough into the lower gap 410 , and the tapered surface 540 is no longer in contact with the sidewall ledge 412 , the tension in the lower tab 446 is released, and the lower tab 446 returns to its normal position, causing the shoulder 448 to be in contact with the contact surface 452 of the lipped portion 414 , thereby preventing the removal of the stop cover 430 from the pocket 396 . The lower tab 446 having the shoulder 448 being used in combination with the lower gap 410 and the lipped portion 414 provides for a “snap fit” connection.
[0155] Formed as part of the sidewall 362 having the release aperture 364 is a feed lip or curved section 466 . Cartridges 24 may optionally be loaded into the spiral channel 190 through the feed neck extension 308 by placing the cartridges 24 (one at a time) on the contact surfaces 462 , 464 and in contact with the outer edge 468 of the curved section 466 . Force is applied to the cartridge 24 by pressing on the cartridge 24 in the direction of the arrow 470 , and this force is transferred to the cartridge stop 434 . Once enough force is applied to the cartridge 24 , the force applied to the cartridge stop 434 by the flat spring 432 is overcome, and the cartridge stop 434 retracts and moves in a direction towards the angled ledge 400 . Once the cartridge stop 434 has retracted enough, the cartridge 24 moves down into the feed neck extension 308 and follows the path indicated by the arrow 472 . Once inside the feed neck extension 308 , each cartridge 24 is supported by a cartridge follower assembly, shown generally at 474 .
[0156] The cartridge follower assembly 474 is operable for movement through the spiral channel 190 , the cartridge channel 306 , and portions of the cartridge follower assembly 474 are able to move through the feed neck extension 308 . The cartridge follower assembly 474 has a lead follower 476 , a plurality of shell followers 478 , and a bolt stop actuator follower 480 . While it is shown in the drawings that the cartridge follower assembly 474 has ten shell followers 478 , it is within the scope of the invention that more or less shell followers 478 may be used.
[0157] The lead follower 476 is made up of a lead follower top 482 having a follower top aperture 484 which receives a portion of a lead follower dowel 486 . Another portion of the lead follower dowel 486 is received into a follower bottom aperture 488 formed as part of a lead follower bottom 490 . The lead follower bottom 490 also has a tapered section 492 .
[0158] Each of the shell followers 478 has a shell follower top 494 having a shell follower top aperture 496 which receives a portion of a shell follower dowel 498 . The shell follower dowel 498 is also partially received into a shell follower bottom aperture 500 formed as part of a shell follower bottom 502 . In an alternate embodiment, the construction of the shell followers 478 may be simplified by integrating the shell follower dowel 498 with the shell follower top 494 , and manufacturing them as a single component.
[0159] The bolt stop actuator follower 480 includes an actuator follower top 504 and an actuator follower top aperture 506 . The actuator follower top aperture 506 receives part of an actuator follower dowel 508 , and part of the actuator follower dowel 508 is received into an actuator follower bottom aperture 510 formed as part of an actuator follower bottom 512 . Also received into the actuator follower bottom aperture 510 is a dowel spring 514 and a plunger 516 . The plunger 516 includes a stopper portion or enlarged diameter portion 518 and a shaft portion 520 . The actuator follower bottom aperture 510 also includes a large diameter portion 522 and a small diameter portion 524 , which terminates into a retainer surface 526 . During assembly, the plunger 516 is inserted into the actuator follower bottom aperture 510 , followed by the dowel spring 514 . The actuator follower dowel 508 is then inserted into the aperture 510 , and the spring 514 is therefore positioned between the actuator follower dowel 508 and the enlarged diameter portion 518 . The plunger 516 is movable within the aperture 510 between a retracted position (where the shaft portion 520 is completely retracted into the small diameter portion 524 , and the enlarged diameter portion 518 is not in contact with the retainer surface 526 ) and an extended position (where the spring 514 biases the plunger 516 outwardly, the shaft portion 520 protrudes out of the small diameter portion 524 , and the enlarged diameter portion 518 is in contact with the retainer surface 526 ).
[0160] The followers 476 , 478 , 480 are connected together through the use of a plurality of follower links 528 , each having a first dowel aperture 530 and a second dowel aperture 532 . The follower links 528 are positioned in a staggered fashion, best shown in FIGS. 41-42 , and 49 A. During assembly, the lead follower dowel 486 is inserted through the first dowel aperture 530 of the first of the plurality of links 528 prior to the lead follower dowel 486 being inserted into one of the apertures 484 , 488 . The shell follower dowel 498 is then inserted through the second dowel aperture 532 as well as the first dowel aperture 530 of a subsequent link 528 prior to being inserted into one of the apertures 496 , 500 . This process is repeated for each of the shell followers 478 and the bolt stop actuator follower 480 until the cartridge follower assembly 474 is assembled as shown in FIGS. 41-42 and 49 A.
[0161] In operation, and referring generally again to FIGS. 39-52C , when it is desired to load and use the system 186 of the present invention, and the system 186 is in an assembled state as shown in FIGS. 39-40 , 46 - 47 , 50 A- 50 B, and 52 A- 52 C, the user simply applies a force to the tapered surfaces 210 of each of the locking tabs 208 to remove each shoulder 212 from the respective ledges 215 , allowing the tabs 208 to move through the slots 214 as the user pulls on the cover plate 204 . Because of the strap 224 , the cover plate 204 may be folded away from the body 188 , without being completely disconnected from the body 188 , which helps prevent the cover plate 204 from becoming lost or misplaced. However, if it is desired to completely remove the cover plate 204 from the body 188 , the user simply applies a force to the tapered surface 230 of the first portion 222 of the strap 224 , to allow the first portion 222 to be pulled through the slot 220 . Once the tabs 208 have been pulled through the slots 214 and the first portion 222 of the strap 224 has been pulled through the slot 220 , the cover plate 204 is completely detached from the body 188 .
[0162] Once the cover plate 204 is removed, the spiral following cartridge drive arm 36 and the cartridge cover plate 60 are removed as well. This allows the user to place the cartridges 24 in the spiral channel 190 individually. The cartridge cover plate 60 , spiral following cartridge drive arm 36 , and cover plate 204 are then reassembled to the body 188 . Alternatively, the cartridges 24 may be dumped into the body 188 and surrounded by the sidewall 196 . The cartridge cover plate 60 , spiral following cartridge drive arm 36 , and cover plate 204 are then reassembled to the body 188 ; the body 188 is then shaken, and the cartridges 24 self-locate into the spiral channel 190 . To fully load the spiral channel 190 with cartridges 24 , the cartridge follower assembly 474 and the spiral following cartridge drive arm pin 58 are optimally placed at the centermost part of the spiral channel 190 , which is substantially adjacent to the pocket 192 . Additional cartridges 24 may be loaded into the feed neck extension 308 as described above.
[0163] Once the spiral channel 190 is loaded with cartridges 24 , and the cartridge cover plate 60 , spiral following cartridge drive arm 36 , and cover plate 204 are then reassembled to the body 188 , the cam stop winding knob 292 is rotated using the lever 296 , generating tension in the power spring 64 . As the cam stop winding knob 292 is rotated, the cam stop winding knob 292 is prevented from rotating in the opposite direction because of the cam stop bearings 42 and the cam bearing pockets 80 generating the pawl action in the same manner as described with reference to the previous embodiments. Rotational force is transferred from the cam stop winding knob 292 to the slot 302 formed as part of the cam stop winding knob power spring pocket retainer 305 , the hook end 142 of the power spring 64 , the power spring 64 , the looped portion 144 of the power spring 64 , and then to the power spring eyelet notch 272 of the drive sleeve 264 .
[0164] However, the drive sleeve 264 does not rotate, thereby generating the aforementioned tension in the power spring 64 . The drive sleeve 264 receives a reactionary force from the drive pin 258 . The cartridges 24 are prevented from exiting the feed neck extension 308 by the cartridge stop 434 and the feed lip 466 . This generates the reactionary force that is transferred through the cartridges 24 , the cartridge follower assembly 474 , the spiral following cartridge drive arm pin 58 , the spiral following cartridge drive arm 36 , the double flat key end 246 of the drive shaft 244 , the drive shaft 244 , the drive pin 258 , the locking notches 260 formed as part of the castle end 262 of the drive sleeve 264 , and the drive sleeve 264 . Therefore, the drive sleeve 264 does not rotate when the cam stop winding knob 292 is rotated, and tension builds in the power spring 64 .
[0165] Once the user has rotated the cam stop winding knob 292 to generate the desired amount of tension in the power spring 64 , the cam stop winding knob 292 does not move, and the firearm is ready for use. As the user fires the firearm, the cartridges 24 are discharged one at a time, and the remaining cartridges 24 are sequentially fed through the feed neck extension 308 into the firearm. The cartridges 24 are fed into the firearm by the tension in the power spring 64 because as each cartridge 24 is discharged from the firearm, there is space left in the feed neck extension 308 for the remaining cartridges 24 to move. The tension in the power spring 64 causes the drive sleeve 264 to rotate because of the rotational force applied to the power spring eyelet notch 272 from the spring 64 . This rotational force is transferred to from the castle end 262 of the drive sleeve 264 to the drive pin 258 , the drive shaft 244 , the double flat key end 246 of the drive shaft 244 , the spiral following cartridge drive arm 36 , the spiral following cartridge drive arm pin 258 , the cartridge follower assembly 474 , and then to the cartridges 24 . This causes each of the remaining cartridges 24 to move in the spiral channel 190 as the cartridges 24 moved from the feed neck extension 308 into the firearm by the bolt stop are discharged from the firearm.
[0166] Once all of the cartridges 24 are discharged, at least a portion of the cartridge follower assembly 474 moves into the feed neck extension 308 . However, as the cartridge follower assembly 474 moves into the feed neck extension 308 , the bolt stop actuator follower 480 moves into the feed neck extension 308 as well. The plunger 516 is biased by the dowel spring 514 to move away from the actuator follower dowel 508 , but the plunger 516 is held inside the actuator follower bottom aperture 510 by the cartridge cover plate 60 , a portion of the spiral cover plate 204 near the shortened neck portion 216 , and the sidewall 350 of the feed neck extension 308 . Once the bolt stop actuator follower 480 moves into the feed neck extension 308 , and the small diameter portion 524 of the actuator follower bottom aperture 510 is in alignment with the channel 348 , the shaft portion 520 of the plunger 516 moves into the channel 348 underneath the bolt stop actuator 352 because of the biasing force generated by the dowel spring 514 .
[0167] Once the shaft portion 520 of the plunger 516 is located in the channel 348 , and is underneath the first flat portion 354 of the bolt stop actuator 352 , the shaft portion 520 moves the bolt stop actuator 352 upwardly as the cartridge follower assembly 474 moves upwardly in the feed neck extension 308 . The bolt stop actuator 352 moves upwardly, but is limited in its upward movement by the roll pin 346 contacting the bottom of the elongated aperture 360 . There are also two shell followers 478 between the bolt stop actuator follower 480 and the lead follower 476 . The spacing created by the shell followers 478 between the bolt stop actuator follower 480 and the lead follower 476 is designed as such that when the bolt stop actuator follower 480 is located inside the feed neck extension 308 and the shaft portion 520 of the plunger 516 has moved the bolt stop actuator 352 to it upmost position, the lead follower 476 is positioned against the cartridge stop 434 and the feed lip 466 . The bolt stop (not shown) of the firearm is then only allowed to move until the bolt stop contacts the bolt stop actuator 352 . The limited movement of the bolt stop provides an indication to the user that all of the cartridges 24 have been discharged from the firearm, and the feed system 186 needs to be reloaded.
[0168] If the user decides to stop using the firearm, and there are still cartridges 24 in the system 186 , but wishes to have the cartridges 24 remain in the feed system 186 , the user simply pushes the clutch release push button 66 in the same manner as described in the previous embodiment. However, in this embodiment, the clutch release push button 66 is used to actuate the clutch assembly 194 , instead of the encapsulated spring clutch mechanism 20 , as with the previous embodiment. The user pushes the clutch release push button 66 to overcome the force applied to the clutch release push button return spring 92 in the clutch release push button pocket 68 formed as part of the cam stop winding knob 292 . As the clutch release push button 66 is pressed, the force applied to the clutch release push button 66 is transferred to the drive shaft 244 , and moves the drive shaft 244 axially within the drive sleeve 264 towards the spiral cover plate 204 . The recessed portion 242 formed in the cover plate 204 provides room for the drive shaft 244 to move axially without contacting the cover plate 204 .
[0169] As the drive shaft 244 is moved axially from the force applied to the clutch release push button 66 , the drive pin 258 is moved out of the locking notches 260 . Once the drive pin 258 is moved out of the locking notches 260 , the drive sleeve 264 is allowed to rotate relative to the drive shaft 244 . The tension in the power spring 64 causes the drive sleeve 264 to rotate, and as a result, the tension in the power spring 64 is relieved. As with the previous embodiment, this prevents the power spring 64 from permanently deforming, or developing a “set,” improving the life of the power spring 64 .
[0170] If the user decides to use the firearm again, the cam stop winding knob 292 is rotated to generate tension in the power spring 64 as previously described. However, if the drive pin 258 is not located in one of the locking notches 260 , there are multiple locking notches 260 that the drive pin 258 may be received into. Therefore, when the cam stop winding knob 292 is rotated, if the drive pin 258 is not disposed in one of the locking notches 260 , then as the cam stop winding knob 292 is rotated, the rotational force applied to the power spring 64 also rotates the drive sleeve 264 . The drive sleeve 264 continues to rotate as the cam stop winding knob 292 is rotated until two of the locking notches 260 are in alignment with the drive pin 258 . The clutch release button return spring 92 biases the clutch release push button 66 , and therefore the drive shaft 244 , away from the spiral cover plate 204 ; the drive pin 258 is consequently biased towards the castle end 262 of the drive sleeve 264 . This causes the drive pin 258 to move into whichever of the locking notches 260 come into alignment with the drive pin 258 as the drive sleeve 264 is rotated. Once the drive pin 258 has moved into a pair of the locking notches 260 , the drive sleeve 264 is prevented from rotating, and tension is generated in the power spring 64 as the cam stop winding knob 292 is rotated as described above.
[0171] It should be noted that if the spiral channel 190 were not completely full of cartridges 24 when the cartridges 24 are loaded, when the cam stop winding knob 292 is rotated, the rotational force is transferred through the various components as described above, but the drive sleeve 264 , drive shaft 244 , spiral following cartridge drive arm 36 , and the cartridge cover plate 60 also rotate, and the spiral following cartridge drive arm pin 58 moves the cartridge follower assembly 474 and the cartridges 24 in the spiral channel 190 until the one of the cartridges 24 contacts the cartridge stop 434 and the feed lip 466 . Once a cartridge 24 contacts the cartridge stop 434 and feed lip 466 , the cartridges 24 are prevented from further movement unless the firearm is fired, and therefore, the reactionary force is generated, and tension is generated in the power spring 64 as described above.
[0172] After the feed system 186 has been loaded, if it is desired to remove the cartridge 24 from the system 186 , the system 186 is easily unloaded by removing the spiral cover plate 204 , the spiral following cartridge drive arm 36 , and the cartridge cover plate 60 in the manner previously described. Once these components have been detached from the system 186 , the firearm cartridges 24 are spilled out.
[0173] While it has been shown that the feed neck extension 308 is substantially straight, FIGS. 50 A and 51 A- 52 C show alternate embodiments of the feed neck extension 308 having the sidewalls 350 , 362 , 392 , 394 as well as the rear flange 314 , the side flanges 316 , 318 , and the front flange 322 shaped differently such that when the feed neck extension 308 is connected to the body 188 , the body 188 is angled relative to the feed neck extension 308 . There are some applications where it is preferable for a firearm to be of a reduced height, and when the body 188 of the ammunition feed system 186 is angled as shown in FIGS. 50 A and 51 A- 52 C, the overall height of the firearm is reduced, making the firearm more compact. For example, in FIGS. 50 A and 51 A- 51 B, the body 188 is located at an angle 534 of ten degrees from vertical. In FIG. 52B , the body 188 is located at an angle 536 of forty-five degrees from vertical, and in FIG. 52C , the body 188 is located at an angle 538 of ninety-degrees from vertical. It is also within the scope of the invention that the feed neck extension 308 may be manufactured in a manner to position the body 188 at any desired angle relative to the firearm.
[0174] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the essence of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | The present invention is a firearm cartridge feeding system to automatically feed firearm cartridges in a successive order one diameter of a firearm cartridge at a time, to the chamber of a bolt action, semi-automatic, or fully automatic firearm until all firearm cartridges in the system are expended. The firearm cartridges are stored in a tight spiral channel side by side to maximize the use of the peripheral space surrounding the area of a magazine well or feed point of a firearm. The housing or body of the firearm feeding system consists of a multiple segment body or housing. The housing contains a spiral channel, clutch mechanism pocket and a spring drive compartment which supports the storage of firearm cartridges and the arrangement of a drive system for feeding the firearm cartridges to the feed lips. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 USC §119 to Finnish Patent Application No. 20021214 filed on Jun. 20, 2002.
FIELD OF THE INVENTION
The present invention relates to a method for evaluating the reliability of a program in an electronic device with at least a processing memory for processing of software, said program being stored in a storage memory, in which method the program is loaded in said processing memory for processing. The invention also relates to a system for evaluating the reliability of a program in an electronic device with at least a processing memory for processing of programs, and means for loading the program in said processing memory for processing, and which system comprises means for storing the program in a storage memory. Furthermore, the invention relates to an electronic device comprising means for evaluating the reliability of the program, a processing memory for the processing of programs, and means for loading the program in said processing memory for processing, and a program corresponding to the program to be checked being stored in the storage memory. The invention also relates to a storage means containing program commands to be processed in the electronic device, to evaluate the reliability of the program loaded in the processing memory of the electronic device, said program being stored in the storage memory, and which electronic device comprises means for loading the program in said processing memory for processing.
BACKGROUND OF THE INVENTION
A variety of electronic devices apply programmable control means, such as microprocessors, microcontrollers, programmable logics, and/or application-specific programmable integrated circuits. Such electronic devices contain stored software consisting of one or more programs containing e.g. program commands required for the operation of the electronic device. In the storage of such software, a memory is used, of which at least a part is a non-volatile memory, i.e. the content of the memory is retained even if the operating voltage of the memory is cut off. These memories include for example a read-only memory (ROM), a programmable ROM (PROM) and an electrically erasable PROM (EEPROM). At least a part of the memory is normally integrated in the electronic device, but in addition, the memory can be increased in many applications by means of, for example, a memory expansion board, or by using a storage means outside the device, such as a data network or the like. One such memory expansion board is the so-called Flash memory card. The Flash memory is a kind of EEPROM type memory whose content can be changed by electrical programming. The contents of the Flash memory will be retained even after the cutting off of the operating voltages. By means of such an expansion memory, it is easy to provide the electronic device with new software, memory capacity for storing, for example, photographs in a digital camera, for setting access rights e.g. in a mobile station, etc. The installation of software in an electronic device can also be performed, in a way known as such, by using other storage means, such as a diskette, a CD-ROM, or a DVD, or possibly directly from a data network.
To run a program, it is typically loaded in the memory of the electronic device, after which the processor of the electronic device starts to run the program code, preferably under control by the operating system. In multi-run operating systems, the operating system alternates the processing of different programs being run, wherein each program being run is typically processed for a given time, after which another program is in turn for processing. The processing time allocated for different programs may vary. If there are several processors, it is possible to process several processing threads in parallel.
The programs may consist of one or more program blocks which are preferably stored as files of their own in a permanent memory, for example on a diskette, a fixed disk, a Flash memory, a data network, or the like. Furthermore, so-called library programs are known, to which several different programs or only one program can have access, wherein the program code may comprise a call to a library program. During the running of a program, the processing is, for a moment, shifted to the library program, after which the processing is continued from the program, which is called the library program. Such library programs typically include programs of general use to implement, for example, the displaying of data on the display of the electronic device. Thus, the compiler of the program does not need to compile the commands needed for controlling the display in the program, but it is possible to define a call to a library program in the program and, in connection with the call, to determine the parameters possibly needed by the library program.
Some electronic devices, such as computers and wireless communication devices, are used more than before to perform such operations, in which the programs used must be reliable. Such operations include, for example, the attending of bank errands, such as the payment of bills, the subscription of products and/or services, the transmission of confidential data in encrypted form, signing, etc. In this context, reliability means, for example, that the programs must not contain an unreliable program code, such as so-called viruses, which might alter the running of the program. A virus or another unreliable program may change the processing of the program without the user noticing anything different from the normal. Thus, for example in a situation, in which the user wants to make a payment, for example to pay the licence of a music piece subscribed via the network, the user starts a program intended for making payments in the electronic device. The program or a library program used by the program may be affected by a virus, wherein the operation of the program no longer corresponds to the original. On the other hand, there are virus programs which may affect the operation of other programs to be run in electronic devices without altering a part in the program related to the payment event or the library program. The virus may thus be activated somewhere in a program being processed in the so-called background, such as in a calendar application. In said payment event, the virus program may, for example, wait until the payment program writes the sum to be paid on the display of the electronic device, and upon detecting this, reduces the sum to be displayed, changes the recipient of the payment, or the like. However, the amount of the original sum is debited from the user's account, although the user believes that the charge was lower and was forwarded to the correct recipient of the payment.
A solution has been developed to the above-presented problem, where known signs of virus programs, or so-called fingerprints, are searched for in the memory of the electronic device. These fingerprints are a kind of parts of the program code, which are typical for a given virus program or a virus program type. However, the number of virus programs is already so large that it is almost impossible to search for all virus programs on the basis of such fingerprint identification. Furthermore, the method requires that the fingerprint data are updated in the electronic device as often as possible, even several times a day, to keep the data as up-to-date as possible.
Another solution is that for each program to be installed in the electronic device, a check digit is computed by a suitable algorithm, such as a cryptographically strong hash algorithm. In the computing of such a hash algorithm, the program code of the program is used. The check digit is stored in the electronic device in connection with the installation of the program. The storing must take place in such a way that it is made sure that the check digit cannot be changed. In connection with the starting of the program, the check digit is compared with a reference digit computed for the program in a corresponding way. If the check digit and the reference digit are the same, it is assumed that the program is reliable, and the program is loaded in the memory of the electronic device and the running of the program is started. However, in practice, there will be situations in which the checking performed at the stage of loading the program will not be sufficient. For example, even several months may have passed since the loading of the program before the checking is made. Thus, the reliability of the software loaded in the memory also should be checked. This checking is necessary in connection with starting of e.g. a payment program or another such program, for whose reliable operation it is absolutely important that there are no unreliable programs in the memory of the electronic device. To check the reliability of a program loaded in the memory, it is usually not possible to use said computing of the reference digit. This is due to the fact that the program normally contains such parts of the program code whose content must be changed in connection with the loading according to the part of the memory where the program is loaded at the time. Such variable parts include, for example, the memory addresses, the absolute jump addresses and links in the program. Thus, the computation of the reference digit will no longer give the same result, so that even though the program was not changed to be unreliable, the comparison between the check digit and the reference digit will not give the same result.
SUMMARY OF THE INVENTION
It is an aim of the present invention to provide an improved method for evaluating the reliability of programs loaded in the memory of an electronic device. The invention is based on the idea that a first reference digit is computed for the program to be checked and loaded in the memory; a second reference digit is computed for a program corresponding to the memory loaded in the memory and stored in the storage memory, by using in the computation for the program the loading address where the program is stored in the memory, and making a comparison between said first and second reference digits. Thus, for an unchanged program, the same value is obtained for both the first and the second reference digit. When computing the second reference digit, the program is not loaded in a memory, but only the parts of the program code, which are dependent on the loading address, are set to correspond to the loading address where the program is actually stored in the memory. To put it more precisely, the method according to the present invention is primarily characterized in that the method comprises at least the following steps:
a first determining step to determine data about the loading address of said program to be checked in the processing memory, a modification step to search for a program corresponding to said program to be checked in the storage memory, wherein if the searched program is found, the program code of the searched program is modified to correspond to the loading of the program in the loading address determined in the first determining step, and an examining step to examine the conformity of the program loaded in the processing memory and the modified program, wherein the result of the examining step is used in the evaluation of the reliability of the program to be checked.
The system according to the present invention is primarily characterized in that the system comprises:
means for determining data about the loading address of said program to be checked in the processing memory, means for searching for a program corresponding to said program to be checked, in the storage memory, and for modifying the program code of the searched program to correspond to the loading of the program in the loading address determined in the first determining step, and examining means for examining the conformity of the program loaded in the processing memory and the modified program, wherein the result of the examining step is arranged to be used in the evaluation of the reliability of the program to be checked.
The electronic device according to the present invention is primarily characterized in that the electronic device comprises:
means for determining data about the loading address of said program to be checked in the processing memory, means for searching for a program corresponding to said program to be checked, in the storage memory, and for modifying the program code of the searched program to correspond to the loading of the program in the loading address determined in the first determining step, and examining means for examining the conformity of the program loaded in the processing memory and the modified program, wherein the result of the examining step is arranged to be used in the evaluation of the reliability of the program to be checked.
Furthermore, the storage means according to the present invention is primarily characterized in that the storage means comprises program commands for taking the following steps:
a first determining step to determine data about the loading address of said program to be checked in the processing memory, a modifying step, in which a search for a program corresponding to said program to be checked is made in the storage memory, wherein if the searched program is found, the program code of the searched program is modified to correspond to the loading of the program in the loading address determined in the first determining step, and an examining step, in which the conformity of the program loaded in the processing memory and the modified program is examined, wherein the result of the examining step is used in the evaluation of the reliability of the program to be checked.
The present invention shows remarkable advantages over solutions of prior art. In the method according to the invention, it is possible to check the reliability of a program loaded in a memory, because in the method, the program stored in the memory is compared with a reliable program stored in a storage memory so that the program in the storage memory is subjected to a modification of addresses similar to that made when the program was loaded in the memory. Thus, the points of the program code, which are dependent on the loading address of the program, are taken into account in the computation of the reference digits. Thus, the loading address of the program is not significant as such. By the method of the invention, it is possible to detect even such changes affecting the reliability of the program, which have been entered in the program code after it has been loaded in the memory of the electronic device. Consequently, the use of the electronic device for performing operations, which require reliable software, is safer than the use of solutions of prior art.
DESCRIPTION OF THE DRAWINGS
In the following, the invention will be described in more detail with reference to the appended drawings, in which
FIG. 1 shows an electronic device according to a preferred embodiment of the invention in a reduced block chart,
FIG. 2 shows the method according to a preferred embodiment of the invention in a simplified flow chart,
FIG. 3 shows a system, in which the invention can be applied,
FIG. 4 shows the memory space of the memory of the electronic device in an example situation, and
FIG. 5 shows a known principle on forming a digital signature.
DETAILED DESCRIPTION OF THE INVENTION
The following is a description on the operation of an electronic device 1 according to an advantageous embodiment of the invention in connection with the method of the invention. The electronic device 1 used can be any electronic device, which contains means 2 for running programs, such as a processor 2 a . Advantageously, the electronic device 1 comprises operating system software or the like, by which the essential functions of the electronic device are controlled and by which the running of other programs (applications) can be controlled in the electronic device 1 . Some non-restrictive examples of such electronic devices 1 to be mentioned in this context include a wireless communication device, such as Nokia 9210i Communicator, and a computer.
The electronic device 1 according to an advantageous embodiment of the invention, shown in FIG. 1 , comprises a control block 2 containing at least one processor 2 a (CPU) for running programs. Furthermore, the control block preferably comprises a digital signal processor 2 b (DSP).
In addition, the control block 2 preferably comprises logic functions 2 c , in which it is possible to implement, for example, at least part of the logic functions of the electronic device. In practical applications, the control block 2 can be implemented by using, for example, an application specific integrated circuit (ASIC). Furthermore, the electronic device 1 comprises memory means 3 , which preferably contain at least a read only memory 3 a (ROM) and a random access memory 3 b (RAM). At least part of the read only memory can be an electrically erasable programmable read only memory 3 c (EEPROM). It is also possible to connect a memory expansion to the electronic device 1 of FIG. 1 , by placing a memory expansion block 4 in memory connection means 5 . The memory expansion block 4 is, for example, a Flash memory card, but also other memory expansion means can be applied in connection with the invention, such as a data network 10 , a fixed disk, or another storage means. Advantageously, the electronic device 1 is also provided with a user interface UI which preferably comprises a display 6 , a keyboard 7 , and audio means 8 , such as an earpiece/a speaker and a microphone. The electronic device 1 according to an advantageous embodiment of the invention, shown in FIG. 1 , also comprises communication means 9 , such as means for performing mobile station functions, for example a GSM mobile station and/or a UMTS mobile station.
In the following, it will be assumed that the random access memory 3 b of the electronic device is used as a place for loading software, for the running of programs. The loadable software can be stored in the read only memory 3 a , in the electrically erasable programmable read only memory 3 c , in the memory expansion block 4 , or the loading can be preferably performed by means of the communication means 9 and e.g. a mobile communication network 11 from an external data network 10 ( FIG. 3 ), such as the Internet data network, or from a local data network, such as WLAN or Bluetooth™. Said memory 3 b arranged for the processing of programs can, in this context, be also called the software processing memory, and in a corresponding manner, the memory in which the programs are stored for loading can be called the software storage memory. However, it will be obvious that in practical applications, the storage memory and the processing memory are not necessarily separate memories, but they can also be implemented at least partly in the same memory. It is also possible that the program is not actually loaded in the processing memory, but the storage memory is used as the processing memory; in other words, the program is processed directly from the storage memory.
The security method according to an advantageous embodiment of the present invention functions in the following way. The operation is illustrated in the flow chart of FIG. 2 , and an example system is illustrated in the reduced block chart of FIG. 3 . Let us assume that the user wants to use a so-called trusted program, whose use requires that one has information, as reliable as possible, that the memory 3 b used for the processing of the software of the electronic device 1 does not contain unreliable programs, i.e. virus programs or other programs which might have a harmful effect on the running of said program. The checking operations can be performed, for example, in such a way that the trusted program is provided with a program code used to perform checking operations of the method according to the invention, or the trusted program includes a call, for example, to a checking program stored in the read only memory 3 a of the electronic device 1 , in which the operations of the method according to the invention are performed. It is also possible to implement the performing of the checking operations by means of a system call or a service possibly implemented in the operating system, by means of a library program, or the like, wherein the trusted program includes a corresponding system call or a call to such a service or library program at the point where the checking operations must be performed. When a library program is used, one should, in one way or another, make sure that the library program itself is reliable.
At the stage when the checking operations are performed, it is examined which programs are loaded in the software processing memory 3 b of the electronic device 1 . This information can be obtained, for example, from the operating system. Furthermore, the loading address of the programs loaded in the processing memory 3 b is determined, which in this context means the memory address from which on the program code of the program is in the memory. However, it is obvious that the program is not necessarily loaded as one block in the memory but it can be loaded in several memory addresses. However, the means for loading the program, such as the operating system, is capable of determining all the memory spaces in which the program code is loaded. For clarity, however, it will be assumed hereinbelow that one program is loaded as one block, starting from a memory address (loading address). At different times of using the programs, however, this loading address may vary, for example because the same programs are not necessarily always loaded in the electronic device 1 and the loading of the programs is not necessarily always performed in the same order. Normally, the operating system places the program to be loaded in a memory area with a sufficient free memory space for loading the program at the moment of the loading. FIG. 4 shows the memory space of the software loading memory 3 b in an example situation. Three programs 401 , 402 , 403 are loaded in the software loading memory 3 b.
In the memory according to the invention, a suitable algorithm, such as a cryptographically strong hash function, is used for computing the first and the second reference digits. Such a hash function modifies an input m and returns a character string of fixed length, which is called the hash value h. Thus, mathematically h=H(m). The length of the character string returned by the function is independent of the length of the input m. In this application, the program code is used as the input. One feature of the cryptographically strong hash function is that it can be considered as a unidirectional function, i.e., on the basis of the computed result it is, in practice, very difficult or even impossible to determine the input used in the computation. Furthermore, one of the properties of the hash function is that the probability that two different inputs would give the same character string as the result, is as low as possible. However, it is obvious that, instead of the hash function, it is possible to apply another method with corresponding properties in view of the input and the character string to be formed.
The steps of the method are preferably processed in a program specific way, wherein the examining is started from one program loaded in the memory, for example from the first program 401 in the situation of FIG. 4 . The processor 2 a preferably starts a security program stored in the read only memory 31 (block 201 in the flow chart of FIG. 2 ). This security program is provided with information about the loading address as well as the name or another identification of the program to be checked (block 202 ). After this, the check digits are computed. The first check digit is computed on the basis of the program code of the program stored in the memory (block 203 ). The second check digit is preferably computed in the following way. The checking program determines the name or other identifier of the program loaded in the memory, and retrieves the corresponding program from the storage memory, such as the memory expansion block 4 (block 204 ). It is also possible that the program is retrieved from an external data network 10 to the electronic device 1 . After the program has been found, the modification of the program code is started, to modify it to correspond to the loading address of the program loaded in the memory (block 205 ). Consequently, in this modification step, the necessary memory addresses, jump addresses, links and the like are set to such values which they receive when the program is loaded to a given loading address. If the loading address varies, the above-mentioned values can be different, wherein it is not worthwhile to compute the second reference digit for such a program code, which is identical with the program code stored in the storage memory. Preferably, in connection with making the program code modifications, the second reference digit is computed by using the same algorithm as in the computation of the first reference digit (block 206 ). After the whole program code has been gone through, the second reference digit has also been formed.
By the above-described arrangement, it is possible to make the changes, which correspond to the loading of the program in the processing memory 3 b , in the program code of the program stored in the storage memory. However, in this modification step, the program code is not loaded in said loading address. Also, the actual program stored in the storage memory, is not changed, but in this context, the changes to be made in the program code refer to temporary changes, which are necessary for applying the method. These temporary changes can, if necessary, be stored e.g. in the random access memory. However, it will be obvious that for making the changes and for computing the reference digit, the modification step can be taken, for example, as a parallel operation by modifying the program code and by always computing the second reference digit for a small memory area at a time. Thus, the need for memory capacity will be very small. After computing the reference digits, they are compared (block 207 ). If the comparison shows that the first and the second reference digits are identical, it is very probable that the checked program loaded in the memory corresponds to the same program stored in the memory means and the program can be trusted, if the origin of the program is known and it can be considered sufficiently reliable. However, if the comparison shows that the reference digits are not identical, it is possible that the software processing memory 3 b of the electronic device 1 contains a program, which may be harmful, such as a virus program. Thus, measures are taken to prevent any damage possibly caused by the program, which is evaluated to be unreliable (block 208 ). For example, this checked program is stopped and deleted from the software processing memory 3 b . The above-identified operations are iterated (block 209 ) until preferably all the programs 401 , 402 , 403 stored in the processing memory 3 b have been checked.
It will be obvious that the mutual computing order of said first and second reference digits is of no significance, wherein either one of them can be computed first, or they can be computed in parallel. Also, the comparison of the reference digits can be performed in connection with the computation of the reference digits, wherein if a difference is possibly found between the first and the second reference digits, the computation and the comparison do not need to be completed.
The above-described steps of computing the first and the second reference digits are not necessarily needed, wherein in the method according to another preferred embodiment of the invention, the comparison is made directly on the basis of the program codes. Consequently, the program code stored in the processing memory is compared with the program code modified at the modification step. If the comparison shows that the program codes are identical, it can be assumed that the program in the processing memory has not been changed.
In a method according to a preferred embodiment of the invention, such a program loaded in the processing memory 3 b is stopped and, for example, deleted from the processing memory or its running is interrupted for the time of the running of a trusted program, if no corresponding program stored in the storage memory is found for such a program loaded in the processing memory 3 b . Furthermore, such programs loaded in the processing memory 3 b are stopped or deleted from the processing memory 3 b , which can be found to be possibly unreliable even without the security method according to the invention.
After all the necessary checking operations have been completed and the programs found to be unreliable have been deleted, it is possible to continue the processing of the trusted program in the normal way. If necessary, however, it is possible to display, for example on the display 6 of the electronic device, information if unreliable programs have been found in the processing memory 3 b , wherein the user can take the necessary measures to examine such programs in more detail and possibly delete them from the electronic device 1 .
In this context, it should be mentioned that in the above-described method, it is also possible, if necessary, to check that the program stored in the storage memory is reliable, before computing the second reference digit. This can be done, for example, by examining the authenticity and origin of a digital signature possibly stored in connection with the program. The purpose of this is to secure that the origin of the program stored in the storage memory is not other than that notified in connection with the program, provided that the secret key used in the generation of the digital signature is not known by others than the program manufacturer.
Another method for verifying the program stored in the storage memory is the following. At the stage of installing the program, for example the hash value is computed from the program and stored in a safe way, that is, in such a way that the hash value cannot be easily changed. In this, it is possible to use, for example, the digital signature, wherein the public key can be used at the stage of checking the program stored in the storage memory to verify the digital signature. In addition to verifying the digital signature, the reference digit is computed on the basis of the program code of the program stored in the storage memory, and the computed reference digit is compared with the safely stored reference digit. If these match, it can be assumed at a very high probability that the program stored in the storage means has not been changed after the installation step and it can be used for verifying the program stored in the processing memory.
For digital signatures, several systems have been developed, such as the RSA, DSA (Digital Signatures Algorithm), and ECC (Elliptic Curve Cryptography). These systems use algorithms, which compress the information to be signed, including SHA-1 (Secure Hash Algorithm) and MD 5 (Message Digest 5 ) to be mentioned in this context. FIG. 5 shows, in a principle view, the processing of a digital signature, which is prior art known as such by a person skilled in the art. The data 501 to be signed, for example the program code of the program stored in the storage memory, is led to a block 502 performing a hash function (compressing function). After this, the hash data formed by the hash function is signed 503 with a secret key SK. The signature 504 is connected to the data 501 to be signed. At the stage of verifying the signed data, the data confirmed with the signature is led to a block 505 performing the hash function, for producing hash data 506 . The signature is verified 507 by using a public key PK corresponding to the signatory's secret key, after which the hash data 506 is compared 508 with the data formed in the verification 507 of the signature. If the data match, the signed data can be relied on with a high probability.
The different steps of the method according to the present invention can be largely implemented by software, for example as program commands of the processor 2 a . The method can thus be implemented as a program and stored on a suitable storage means, such as a Flash memory, a DVD, a CDROM, a data network 10 , or the like. The program can be installed in the electronic device from said storage means.
It is obvious that the present invention is not limited solely to the above-presented embodiments but it can be modified within the scope of the appended claims. | A method and associated system and electronic device for evaluating the reliability of a program ( 401 ) stored in a storage memory of an electronic device ( 1 ) having a processing memory ( 3 b ) for processing programs, wherein the program ( 401 ) is loaded into the processing memory ( 3 b ) for processing, wherein a first determining step determines data about the loading address of the program ( 401 ), a modification step searches for a program corresponding to the program ( 401 ) in the storage memory ( 4, 10 ), wherein if the searched program is found, the program code of the searched program is modified to correspond to the loading of the program in the loading address determined in the first determining step. An examining step examines the conformity of the program loaded in the processing memory and the modified program, wherein the result of the examining step is used in the evaluation of the reliability of the program ( 401 ) to be verified. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Stage Application of International Application No. PCT/EP2010/060193 filed Jul. 15, 2010, which designates the United States of America, and claims priority to German Application No. 10 2009 034 207.9 filed Jul. 22, 2009, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to methods and systems for allocating transmission signals to transmission channels of a radio transmission system, in which the transmission bandwidths of the transmission channels can overlap.
BACKGROUND
[0003] In a large number of vehicles, in particular motor vehicles, nowadays a large number of functions are triggered or controlled by means of mobile radio transmitters which are carried by users on their person. Such a radio transmitter can also have a reception part for radio signals here, with the result that radio communication with a transceiver for radio signals, which is mounted in or on the vehicle, can also take place in a bidirectional fashion. During the radio communication between a radio transmitter, which may be, for example, a mobile identification signal generator for controlling functions of a vehicle, and a corresponding receiver which is arranged in or on a vehicle, large ranges are desired. This may apply, in particular, to comfort functions such as, for example, the activation of a stationary heating system from a relatively large distance. Furthermore, it is also possible to provide alarm functions in which, for example, a status of a vehicle is checked independently and cyclically and transmitted to the mobile identification signal generator (vehicle key). In this context, the authorization of the respective identification signal generator should also be verified.
[0004] Due to the large transmission and reception ranges of such a system it can be expected that a system may receive signals from other systems with, for example, the same method of functioning and/or similar channel parameters of the radio transmission, which may be disadvantageous. For example, this can lead to undesired effects or interference on the respective radio transmission. Furthermore, given such a high traffic density as occurs, for example, in built-up areas, a radio receiver in a vehicle can continuously receive signals which, despite the lack of authorization, have to be checked to determine whether they are associated with and authorized for the corresponding vehicle. As a result, for example the power consumption of such a radio receiver may be undesirably increased by up to a factor of 10.
SUMMARY
[0005] According to various embodiments, a method is provided for allocating transmission signals to transmission channels of a radio transmission system and for verifying said signals.
[0006] According to an embodiment, a method may be provided for allocating a transmission signal to a transmission channel having a transmission bandwidth and a nominal center frequency and which is established between a radio transmitter and a radio receiver The method may include emitting the transmission signal at the radio transmitter with an actual transmission frequency; receiving the transmission signal in the radio receiver; determining the frequency of the transmission signal in the radio receiver; and deciding on the allocation of the transmission signal to the one transmission channel if the frequency which is determined by the radio receiver is in a predefined frequency range.
[0007] According to a further embodiment, the predefined frequency range may depend on the transmission bandwidth and the nominal center frequency of the one transmission channel. The radio transmitter may have a first tolerance of its actual transmission frequency with respect to the nominal center frequency of the transmission channel, and the radio receiver has a second tolerance with respect to the nominal center frequency of the transmission channel, wherein the predefined frequency range depends on the maximum values of the two tolerances. According to a further embodiment, the allocation of the transmission signal to the transmission channel may take place when a passage difference between the radio transmitter and the radio receiver is not greater than the sum of the maximum permissible tolerance of the radio transmitter and of the maximum permissible tolerance of the radio receiver.
[0008] According to a further embodiment, a plurality of radio transmitters which transmit transmission signals and radio receivers which receive transmission signals may be provided, between which there are transmission channels each having a transmission bandwidth and a nominal center frequency, wherein the channel spacings which are related to the respective center frequencies are such that the transmission channels overlap. According to a further embodiment, the nominal center frequencies of the transmission channels of two radio receivers which are adjacent with respect to the center frequencies, and their associated radio transmitters may be spaced apart in such a way that the distance is at least the larger of two channel separation values, wherein one channel separation value for one radio receiver in each case may correspond precisely to the sum of the respective maximum permissible tolerances of the frequencies of the transmission signals which are allocated to the two adjacent radio transmitters and of twice the maximum permissible tolerance of the center frequency of the respective radio receiver. According to a further embodiment, the predefined transmission bandwidth and/or channel spacings may be equal for all the transmission channels.
[0009] According to a further embodiment, the distance between the nominal center frequencies of the transmission channels of two radio receivers which are adjacent with respect to the center frequencies may be selected such that said distance corresponds precisely to the sum of the respective maximum permissible tolerances of the frequencies of the transmission signals which are allocated to the two adjacent radio transmitters and of twice the maximum permissible tolerance of the center frequency of the respective radio receiver. According to a further embodiment, the radio transmitter and the radio receiver may be part of an access monitoring and/or control system of a vehicle, wherein the radio transmitter is a mobile identification signal generator and the radio receiver is a quasi-fixed radio receiver which is mounted in or on the vehicle and has the purpose of verifying the identification signal generator, and wherein functions of the access monitoring and/or control system are triggered by a verified identification signal generator. According to a further embodiment, the radio transmitter may transmit a data packet which has a wake-up preamble in a first part and an unambiguous identification code in a second part, wherein when the vehicle is not operating, the radio receiver is in a power-saving state of rest and is activated cyclically in order to receive signals, and during the reception of a wake-up preamble, the radio receiver determines the current frequency of the transmission signal, wherein after reception of the wake-up preamble and determination of the frequency of the transmission signal the radio receiver does not return to the power-saving state of rest, and subsequently check the identification code in the second part of the data packet if the current frequency of the transmission signal specifies a transmission signal which is associated with the channel of the radio receiver. According to a further embodiment, the wake-up preamble has an unambiguously encoded signal component which is compared with a predefined unambiguous pattern by the radio receiver.
[0010] According to a further embodiment, the radio receiver may evaluate the reception field strength and/or the modulation parameters and/or the data rate of the wake-up preamble and/or the line coding in order to verify the unambiguous allocation of a transmission signal, received from the radio receiver, to this radio receiver during the reception of the wake-up preamble. According to a further embodiment, a bidirectional radio communication may be provided in the access monitoring and/or control and/or information system. According to a further embodiment, bidirectional radio communication may take place in such a way that on the forward path and the return path of the radio communication are implemented by means of different transmission channels. According to a further embodiment, the predefined frequency range may depend on the channel spacing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Example embodiments will be explained in more detail below with reference to figures, in which:
[0012] FIG. 1 is a diagram showing by way of example the frequency tolerances of the transmission and reception characteristics of a radio channel;
[0013] FIG. 2 a is a diagram showing the guard band of a radio channel;
[0014] FIG. 2 b is a diagram showing the definition of an adjacent channel, of adjacent channel suppression, of a common mode channel as well as the required selection curve of a radio channel according to conventional techniques;
[0015] FIG. 3 is a diagram showing the minimum possible channel spacing according to the method according to certain embodiments;
[0016] FIG. 4 is a diagram showing the change in the interference probability and blocking probability when the method is applied to channel overlap;
[0017] FIG. 5 a is a diagram showing a conventional wake-up preamble (WUP);
[0018] FIG. 5 b is a diagram showing a wake-up preamble (WUP) which has encoded information;
[0019] FIGS. 6 a - 6 b show an example of radio communication in which different channels are used for the forward path and return path of the radio communication;
[0020] FIGS. 7 a - 7 c show a diagram showing examples of the arrangement of paired radio channels for redundant signal transmission; and
[0021] FIG. 8 is a diagram showing the minimum possible channel spacing according to certain embodiments of the method for adjacent channels with different frequency tolerances.
DETAILED DESCRIPTION
[0022] As already mentioned, long ranges are desired for radio communication between a mobile identification signal generator for controlling functions of a vehicle and a corresponding receiver which is arranged in or on a vehicle, wherein alarm functions in which a vehicle status is checked and transmitted to the mobile identification signal generator (vehicle key) are also included. In such a context, the authorization of the respective identification signal generator for the radio receiver and therefore the corresponding vehicle must also be verified in every case.
[0023] Owing to the necessary long transmission and reception ranges of the radio communication it is to be expected that a system also receives signals from other systems which have identical or similar functionalities and therefore have identical or similar channel parameters for the radio communication. This may lead to undesired effects or interference on the radio communication. A first example of this is interference of a receiver by the signals of other systems. Interference may be so strong in such a case that the desired communication between a specific radio transmitter and a specific radio receiver fails.
[0024] An example of undesired interference on a radio channel by signals of another adjacent system which is located in the range of the receiver is actual blocking by the signals of the adjacent system. In such a case, the signals of the adjacent system are received and firstly accepted as valid (because, for example, the transmission frequency matches the radio channel used) and processed. In such a context, it is only during the processing of the transmission signal (during the verification of an unambiguous code in the transmission signal, for example) that it is detected that this signal is not valid for the corresponding receiver.
[0025] This may lead to an increased utility factor of a vehicle-side receiver and therefore, for example, also to an undesirably increased power demand. In addition, this blocking also results in the increased risk of a radio telegram of the actually allocated system being missed or not being detected. The telegram structure applied according to certain conventional systems provides a signal with two components here. What is referred to as a wake-up preamble (WUP) is therefore transmitted before the actual data packet (frame) which carries the information in a radio telegram. The vehicle-mounted receiver in a vehicle which is not being operated and which is, for example, parked, is in what is referred to as the state of rest or “polling mode” in which said receiver is activated cyclically and checks received signals for wake-up criteria, such as, for example, reception field strength, modulation parameters or simple bit patterns.
[0026] Various systems generally use identical or similar WUP structures here. Therefore, even in the case of signals of an adjacent system a receiver must firstly assume that there is a valid signal and it cannot return immediately to the state of rest. Only the checking (verification) of an unambiguous code makes it possible to check which system a transmission signal or the emitting radio transmitter is actually associated with and whether said signal or transmitter is authorized. However, according to conventional techniques this unambiguous code is arranged in the data packet of the signal, that is to say after the WUP in terms of timing.
[0027] Considering typical transmission times of radio telegrams makes the extent of additionally occurring active operating states of a receiver clear. A WUP usually has a length of approximately 150 ms, and the frame (the data packet) usually has a length of approximately 100 ms. This means that the receiver has to remain on reception for up to 250 ms until it can be detected that the signal does not belong to the system in question. The existence of a large number of spatially adjacent systems leads accordingly to an increase in the activity of the receiver and therefore to an increased power demand.
[0028] Furthermore, as stated, there is an increased risk that the receiver will miss telegrams of the system in question because, during the reception (of checking) of the signal of an adjacent system, it is not possible to react to signals of the system in question. The subsequent exemplary calculation for a German built-up area clarifies the above-mentioned problem. While the population of Germany is 82.244 million, the number of registered vehicles is 48.1 million (as at 2007). The statistical number of vehicles per inhabitant is therefore 0.58. In a city such as Munich with 1.294 million inhabitants, this results in 647,000 vehicles in the municipal area. Assuming that 10% of the vehicles are equipped with radio communication systems such as those described above and are active, there are therefore 64,700 such systems in the municipal area of Munich. Given a size of the municipal area of 310 km 2 , this leads statistically to 209 radio communication systems per km 2 .
[0029] If a density of 200 systems per km 2 and a system range of, on average, 1 km is then assumed, 628 such systems can influence one another. This results in a number of several hundred or even thousand transmitted or received WUPs per hour given customary user profiles or for certain scenarios (a parking garage). Given 100 WUPs/h, an increase in the power consumption of a receiver of approximately 10% is to be expected. Given 500 WUPs per hour, this increase in power consumption is approximately 40%, and given 1000 WUPs per hour an increase in the power consumption of approximately 80% is to be expected. Given approximately 10,000 WUPs per hour, a receiver will receive the signal of another system at any time. A polling mode is therefore no longer possible and the power consumption is increased approximately by the factor of 10. Furthermore, interference with the communication is very probable.
[0030] Certain previous approaches to a solution to this problem comprise, for example, one or more of the following measures:
Allocation of different channels (frequency diversity) for various vehicles or groups of vehicles. The disadvantage here is that a good channel selection is necessary, which limits the number of channels. Repetition of the radio telegram—cyclically or only in the event of a fault. The disadvantages here are relatively high power consumption in, for example, the mobile radio transmitter and therefore a shorter service life of the power supply (for example battery). In addition it is disadvantageous that although the system performance is improved in terms of interference, the situation in terms of receiver blocking is made worse. Reduction in the receiver bandwidth and consequently the channel bandwidth. It is disadvantageous that for certain functions relatively high data rates are advantageous (for example PASE, optimization of the quiescent current, reaction time) and therefore a sufficient reduction in the receiver bandwidth is not possible for all applications.
[0034] Both a transmitter and a receiver in a radio transmission system which cover a channel with a nominal frequency have a tolerance with regard to the actual transmission and reception frequencies. This is illustrated by way of example with respect to the definition of terms in FIG. 1 . FIG. 1 shows a transmitter 1 and a receiver 2 as well as the bandwidth 3 which is respectively occupied by the transmitter 1 and the receiver 2 and which is allocated symmetrically about the nominal frequency of the channel. A customary transmitter such as the transmitter 1 has, with respect to its current frequency, certain, for example fabrication-conditioned or temperature-dependent frequency tolerances 4 in the negative and positive directions, which tolerances together define the entire tolerance range. The same applies to the receiver 2 , which has frequency tolerances 5 .
[0035] In the present example, these tolerances 4 and 5 are assumed to be symmetrical, that is to say to have the same deviations of the frequency in the positive and negative directions. Given an occupied bandwidth 3 of, for example, 20 kHz, these positive and negative frequency tolerances 4 , 5 can be, for example, 5 kHz in the positive and negative directions, but they can also each respectively have different sizes for the transmitter and the receiver. Two extreme cases for the maximum deviations from the nominal frequency around which the occupied bandwidth 3 is respectively arranged can be derived therefrom. This leads finally to the entire bandwidth 6 of the transmitter 1 taking into account the above tolerances. In an analogous fashion, this applies to the bandwidth 7 of the receiver 2 , as also illustrated in FIG. 1 . Since the positive and negative transmitter and receiver tolerances 4 , 5 are added together in the extreme cases, the minimum necessary transmission bandwidth of the receiver 2 is therefore calculated as
[0000] 2 ·F TS +2 ·F TE +B B
[0000] where F TS stands for the frequency tolerance 4 of the transmitter 1 , F TE2 stands for the frequency tolerance 5 of the receiver 2 and BB stands for the occupied bandwidth 3 .
[0036] FIG. 2 a illustrates the relationship between the frequency tolerances 4 , 5 which are to be taken into account and the margin 8 which is to be additionally taken into account according to conventional techniques and which is necessary since the reception filter has a finite gradient (represented as a dashed line in FIG. 2 a ). The 3-dB cut-off frequencies of the reception filter, which is usually embodied as a bandpass filter, are usually used to determine the size of the receiver bandwidth 14 . The sum of the transmitter tolerance 4 , receiver tolerance 5 and the margin 8 with respect to the frequency is generally taken into account as what is referred to as a guard band 9 in the channel definition according to conventional techniques. The entire channel bandwidth 10 is therefore equal to the sum of the occupied bandwidth 3 and twice the guard band 9 .
[0037] FIG. 2 b shows a known arrangement of adjacent transmission channels n−1, n and n+1 each with a channel bandwidth which corresponds to the sum of the occupied bandwidth 3 and twice the guard band 9 . The profile of the reception filter of the channel n is represented as a dashed line, wherein there is an adjacent channel suppression 11 with respect to the channel n+1.
[0038] In order to permit rapid and reliable allocation or differentiation (associated signal, non-associated signal) even at the start of reception of a radio telegram, according to certain embodiments the frequency tolerances of the transmitter and receiver may now be taken into account. The respective actual carrier frequency of the received transmission signal is measured in the receiver during the WUP reception. The measurement can be carried out, for example, using an AFC method (AFC=automatic frequency control) or by means of FFT demodulation (FFT=fast Fourier transformation). By using the previously defined (permissible) frequency error, a decision is made as to whether the received signal (radio telegram) can or cannot originate from an associated transmitter.
[0039] In this context, there must be no possibility of simultaneous, interference-free signal transmission in adjacent channels. This means that even channel spacings which result in a frequency overlap not only of directly adjacent channels but also of further indirectly adjacent channels with respect to the directly adjacent channels of adjacent channels.
[0040] FIG. 3 shows the derivation of the minimum possible channel spacing 13 with a method according to certain embodiments for simultaneous signal transmission in adjacent channels having equal bandwidths and tolerances, which signal transmission permits unambiguous channel allocation. For this purpose, the worst case is assumed in which the transmission signal and the center frequency have the maximum frequency deviations (tolerances) in different directions. In such a case, the maximum frequency tolerance 4 of a transmitter and the maximum frequency tolerance 5 of a receiver of the channel n with respect to the maximum frequency error 12 are added together.
[0041] Furthermore, allowance is made for the fact that an adjacent channel n+1 also has the worst case with respect to the allocation of a transmission signal to one of the channels n or n+1. This means that the center frequency of the adjacent channel n+1 is shifted in the direction of the channel n by the maximum possible value of the frequency tolerance 5 . In the present example, it is assumed that adjacent channels of a radio system have equal bandwidths and equal symmetrical frequency tolerances, as is the case, for example, in a radio system for controlling functions of a vehicle.
[0042] On this basis, it is possible to determine the minimum possible channel spacing 13 (=KA) which is necessary to reliably allocate the frequency of a received transmission signal (radio telegram) to the associated channel. This minimum possible channel spacing 13 must meet the following condition here:
[0000] KA≧ 2 ·F TS +2 ·F TE
[0043] In contrast, the necessary channel spacing according to conventional techniques is calculated according to FIG. 2 as:
[0000] KA=B B +2 ·S D =B B +2 ·F TS +2 ·F TE +2 ·M,
[0000] where M is a margin 8 and SD is the guard band 9 .
[0044] According to certain embodiments, the necessary channel spacing is therefore reduced by the value obtained from B B +2·M. In this way, the selection criterion “frequency error” or “frequency tolerance” permits reliable differentiation of the channels with which a transmission signal is associated. Under these conditions, the channels can be arranged more closely to one another on the frequency axis. With respect to the definition of the channel spacing according to conventional techniques, overlaps of adjacent channels are therefore also possible. The number of channels which are possible in a predefined frequency band is therefore increased.
[0045] This will be clarified below with reference to a comparative computational example. In this context, an available frequency band with a width of 300 kHz is assumed. The occupied bandwidth of the radio channels is 20 kHz both in conventional techniques and in the method according to certain embodiments, and the frequency tolerances of the transmitters and of the receivers are assumed to be +/−5 kHz.
[0046] Taking these values as a basis, the minimum guard band for transmission channels which are arranged adjacently in a frequency band according to conventional techniques (frequency diversity) is calculated as
[0000] S Dmin =0.125 ·B B +1.25· F TS +1.25· F TE =2.5 kHz+6.25 kHz+6.25 kHz=15 kHz.
[0047] The receiver bandwidth 14 (see FIG. 2 a ) is calculated as
[0000] B B +2· F TS +2· F TE =20 kHz+2·10 kHz=40 kHz.
[0048] The channel bandwidth 10 (see FIG. 2 a ) is calculated as
[0000] KA min =B B 2· SD= 20 kHz+2.15 kHz=50 kHz.
[0049] This results in a minimum channel spacing KA min of 50 kHz and a number of 6 channels in the predefined frequency band of 300 kHz.
[0050] For the method according to certain embodiments, the receiver bandwidth 14 is likewise calculated as:
[0000] B B +2· F TS +2· F TE =20 kHz+2·10 kHz=40 kHz.
[0051] The minimum channel spacing is however calculated as
[0000] 2· F TS +2· F TE =2·5 kHz+2·5 kHz=20 kHz.
[0052] This means that channels which are adjacent at the frequency can overlap with respect to their receiver bandwidth 14 by up to 20 kHz (see for example FIG. 7 b and FIG. 7 c ) and at the same time, according to certain embodiments of the method, reliable allocation of transmission signals to transmission channels can still be achieved. For this reason, a maximum total of N K =14 adjacent channels can then be arranged in the available frequency band with a width of 300 kHz, where F VB stands for the available frequency band:
[0000] N K =( F VB i−B B +2· F TS +2· F TE )/ KA min −1=(300 kHz−20 kHz+2·10 kHz)/20 kHz−1=14.
[0053] In certain embodiments of the method which is presented it is also advantageous that the determination of the frequency of the transmission signal and the allocation to a transmission channel can already be carried out during the reception of the wake-up preamble of the radio telegram. The radio telegram (data packet) has here the wake-up preamble (WUP) in a first part and an unambiguous identification code in a second part. The radio receiver is usually in a power-saving state of rest and is activated cyclically in order to receive any signals.
[0054] In this context, in certain embodiments of the method, the receiver of the radio telegram does not return after the reception of the wake-up preamble and determination of the frequency of the transmission signal to a power-saving state of rest and subsequently verify the identification code in the second part of the data packet only if the current frequency of the transmission signal indicates a transmission signal which is associated with the channel of the radio receiver. This ensures that the active operation of the receiver is reduced for each radio telegram which is received and not assigned to the latter, with the result that a corresponding power saving can be achieved during the operation of the receiver.
[0055] The change in the probability of interference and blocking when the method of certain embodiments is applied to the channel overlap will be considered below. The distance between the center frequencies of two adjacent channels in the conventional channel grid according to conventional techniques will be referred to as Δ f CS , and the distance in the channel grid according to certain embodiments using the channel overlap is referred to as Δ f CO . The receiver bandwidth is equal to Δ f CS . The B ges is the entire available transmission bandwidth which can also comprise a plurality of channels. N CS channel and N CO channel are the number of users (transmission systems) per channel with the conventional channel grid and with the channel grid with channel overlap. The change in the probability of blocking or interference with the conventional channel grid (CS) or with the channel grid with channel overlap (CO) can be summarized with the following expressions:
[0000]
P
Block
CO
P
Block
CS
=
Δ
f
CO
Δ
f
CS
·
(
1
1
+
Δ
f
CS
B
ges
(
Δ
f
C
0
Δ
f
CS
-
1
)
)
-
1
N
Channel
CS
1
-
1
N
Channel
CS
P
Interf
CO
P
Interf
CS
=
(
1
1
+
Δ
f
CS
B
ges
(
Δ
f
C
0
Δ
f
CS
-
1
)
)
-
1
N
Channel
CS
1
-
1
N
Channel
CS
[0056] FIG. 4 shows the profiles for the ratios of:
[0000]
P
Block
CO
P
Block
CS
and
P
Interf
CO
P
Interf
CS
[0000] as a function of the number of users per channel in the conventional channel grid (CS). According to the example illustrated further above with 6 channels in the conventional channel grid (CS) and with 14 channels in the channel grid with channel overlap (CO) it is apparent that for many users the probability of blocking per conventional channel can be significantly reduced approximately according to the ratio
[0000]
Δ
f
CO
Δ
f
CS
[0000] while the probability of interference becomes only moderately worse. If it is also taken into account that in order to calculate the above curves the occupied bandwidth has been set equal to the receiver bandwidth and to the channel spacing in the conventional channel grid (CS), it becomes clear that the ratios shown can in reality behave even better since frequency ranges which are not used in the calculation have been considered as being used.
[0057] FIG. 5 a shows the structure of a customary radio telegram such as is used according to conventional techniques in radio systems for controlling vehicle systems. The radio telegram 34 (data packet) is divided into a first part 15 and a second part 16 . The first part 15 constitutes what is referred to as the wake-up preamble (WUP), and the second part represents what is referred to as the useful data, which may have, for example, a unique code for identifying and verifying the transmitter of the radio telegram. The vehicle-side receiver is located in a vehicle which is not operating, for example parked, in what is referred to as a state of rest or “polling mode” in which it is cyclically actuated and checks received signals for “wake-up” criteria such as, for example, reception field strength, modulation parameters or simple bit patterns. Various systems generally use identical or similar WUP structures here.
[0058] FIG. 5 b shows the structure of a radio telegram with a WUP code according to certain embodiments. In this context, a simple pattern is inserted into the WUP 15 of a radio telegram 34 , which pattern can be used to detect the association with a vehicle or with a vehicle group as soon as the WUP 15 is received.
[0059] In this way, as soon as WUP is detected, a rapid decision can be made as to whether a signal which is extraneous to the system is present or whether the received radio telegram 34 is associated with the receiver. The WUP detection can be implemented cost-effectively by, for example, a simple correlator.
[0060] A simple pattern (for example a restriction to 8 bits) is advantageous here since otherwise necessary time of the receiver in the active operating state (power consumption) for arriving at the decision increases. For this reason, various vehicles could also have the same WUP code. The objective is primarily to reduce the adjacent systems which are possible or present for blocking. Systems according to the present state of the art frequently use patterns within the WUP with simple level changes (for example: low-high-low-high) in order to permit simple and rapid detectability of the WUP. In contrast, certain embodiments use a specific code within the WUP.
[0061] According to certain embodiments, configuration possibilities of the method are that the radio receiver evaluates the reception field strength and/or the modulation parameters and/or the data rate of the wake-up preamble (WUP) and/or the line coding in order already to verify the unambiguous allocation of a transmission signal, received from the radio receiver, to this radio receiver during the reception of the wake-up preamble.
[0062] FIG. 6 a shows an example embodiment of the method in which different channels are used for the forward path and return path 17 , 18 of a bidirectional radio communication. For this purpose, radio transmitters 23 , 24 (for example identification signal generators for a vehicle) also each have a radio receiver 1 a or 1 b , respectively, and radio receivers 19 , 20 also each have a radio transmitter 2 a or 2 b , respectively. FIG. 6 a shows two vehicles 17 and 18 , respectively, each with a radio receiver 19 and 20 , respectively, and a radio receiver 1 a and 1 b , respectively, as well as two mobile identification signal generators and respectively radio transmitters 23 and 24 which each also include radio receivers 2 a and 2 b . For what is referred to as the uplink 22 , that is to say the radio link from the identification signal generator 23 , 24 to the vehicle 17 , 18 , a different frequency channel is available than for what is referred to as the downlink 21 , that is to say the radio link from the vehicle 17 , 18 to the identification signal generator 23 , 24 .
[0063] In this way, the probability of interference in situations with a high vehicle density (for example on a large car park) can be reduced. Vehicles which transmit in the downlink do not disrupt the uplink of adjacent vehicles when this method is applied. If, for example, the vehicle 17 transmits an alarm, this leads to a frequent periodic emission of the downlink radio telegrams. A user would like to open the adjacent vehicle 18 in which he transmits an uplink radio telegram via the identification signal generator 24 . When the same channel is used for uplink and downlink there would then be a high probability that the uplink telegrams for vehicle 18 would experience interference from the downlink telegrams of vehicle 17 . This is avoided by the use of different frequency channels for the uplink and downlink. FIG. 5 b shows by way of example the arrangement of the different channels over the frequency f for an uplink channel 25 and a downlink channel 26 .
[0064] In a further embodiment, the possibility of overlapping adjacently arranged channels as described further above can be used to configure the largest possible number of channel allocations with particularly good selection properties. The objective is firstly to reduce the susceptibility to interference from interference signals using the configuration of a plurality of channels which are used in parallel with redundant signal transmission. The further apart the frequencies of the channels which are used in parallel and allocated to one another are, the greater the degree of achievable interference suppression through the parallel use of channels. In the following FIG. 7 , for example in each case two channels which are used in parallel for redundant signal transmission are represented for the sake of better clarity, wherein more than two channels can also be used in order to improve the susceptibility to interference.
[0065] FIG. 7 a illustrates by way of example 3 equidistant channel pairs 27 a , 27 b ; 28 a , 28 b ; and 29 a , 29 b which are arranged in a predefined frequency range and whose receiver bandwidths or channels do not overlap (e.g., according to conventional techniques). An unused frequency range 32 and a frequency spacing of channels 33 which are respectively allocated to one another results from the shown arrangement of the channel pairs 27 a , 27 b ; 28 a , 28 b ; and 29 a , 29 b.
[0066] The channel overlap which is described further above can then be applied to increase the number of channel pairs in the predefined frequency range with constant selection properties (susceptibility to interference). An example of this is illustrated in FIG. 7 b . In this context, the receiver bandwidths, frequency tolerances and minimum required channel spacings of the exemplary calculation given further above are applied so that the illustrated channels have a transmission bandwidth of 40 kHz and a channel overlap of 20 kHz. From FIG. 7 b it is apparent that the number of three channel pairs accommodated in the predefined frequency band (see FIG. 7 a ) is increased to five ( 27 a , 27 b and 28 a , 28 b and 29 a , 29 b and 30 a , 30 b as well as 31 a , 31 b ), wherein the size of the unused frequency range 32 and the frequency spacing 33 of channels which are respectively allocated to one another remains constant.
[0067] Furthermore, the channel overlap can be applied to increase the frequency spacing 33 of channels which are respectively allocated to one another in the predefined frequency range with a constant number of channel pairings (three). This leads to an improvement in the selection properties and to a reduction in the susceptibility of the redundant signal transmission to interference. An example of this can be seen in FIG. 7 c . Here, the frequency spacing 33 of channels which are respectively allocated to one another is increased by 20 kHz.
[0068] FIG. 8 shows additionally the derivation of the minimum possible channel spacing in a method according to various embodiments for a simultaneous signal transmission in adjacent channels n and n+1 which are to be unambiguously allocated and which have different tolerances 4 n and 4 n+1 for the frequency of the transmission signal and different tolerances 5 n and 5 n+1 for the center frequency of the transmission channel compared to FIG. 3 . The minimum channel spacing is calculated here as MAX[(2*5 n +4 n +4 n+1 ), (2*5 n+1 +4 n +4 n+1 )]. Consequently, the problem arises that on many transmission paths (radio transmitter/radio receiver) transmission occurs in a limited frequency range which does not permit appropriate division of a conventional channel grid. The radio receivers are therefore frequently woken up in order to carry out an identification procedure. According to certain embodiments, the transmission paths then operate at offset frequencies and the receivers test the transmission frequency before the identification procedure and carry this out only at a suitable frequency. The allocation of a transmission signal to a transmission channel provides here for the emission of the transmission signal by the radio transmitter within a transmission channel. The actual transmission frequency does deviate here from the nominal transmission frequency, i.e. the center frequency of the transmission channel owing to tolerances in the transmitter, wherein the maximum possible deviation is known. After the reception of the transmission signal by the radio receiver, the frequency of the transmission signal is determined within the radio receiver. Determination of the “current frequency” of a transmission signal is always only possible with the finite accuracy of the frequency normal or time normal within the measuring device. In the case of radio transmitters and radio receivers, the deviations from this normal are of the same order of magnitude. For this reason it is more appropriate to speak of the determination of a passage difference between the transmitter and receiver since a measuring error which is approximately of the same size in terms of absolute value occurs during the determination of the frequency error of the transmission signal.
[0069] Accordingly, the allocation of the transmission signal to the transmission channel which is being sought occurs if the specific frequency of the transmission signal does not exceed a threshold value. The frequency band corresponds here to a type of “threshold value” to the effect that a decision has to be made on the basis of a specific criterion and this criterion is the frequency location of the received signal with respect to the desired or permissible frequency range. When there are a plurality of transmitters and receivers and/or in the case of bidirectional communication, the transmission paths operate at offset frequencies, that is to say are divided into various channels. The transmission channels can then be spaced apart in such a way that their channel bandwidths overlap one another, specifically in a directly adjacent fashion and an indirectly adjacent fashion, that is also to say the neighbor of the neighbor. According to certain embodiments, channel spacings (for example half transmission channel bandwidth) which permit superimposition of frequency components of (directly and indirectly) adjacent channels are sufficient. The channel arrangement may therefore be advantageously defined in such a way that larger channel spacings than are necessary on the basis of the channel allocations are not selected and therefore as many channels as possible can be provided.
LIST OF REFERENCE NUMBERS
[0000]
1 Transmitter
1 a Transmitter
1 b Transmitter
2 Receiver
2 a Receiver
2 b Receiver
3 Occupied bandwidth
4 Frequency tolerance
5 Frequency tolerance
6 Bandwidth
7 Bandwidth
8 Margin
9 Guard band
10 Channel bandwidth
11 Adjacent channel suppression
12 Frequency error
13 Channel spacing
14 Receiver bandwidth
15 First part of radio telegram
16 Second part of radio telegram
17 Vehicle
18 Vehicle
19 Transceiver
20 Transceiver
21 Downlink
22 Uplink
23 Identification signal generator
24 Identification signal generator
25 Uplink channel
26 Downlink channel
27 a Channel
27 b Channel
28 a Channel
28 b Channel
29 a Channel
29 b Channel
30 a Channel
30 b Channel
31 a Channel
31 b Channel
32 Frequency range
33 Frequency spacing
34 Radio telegram | A method for allocating a transmission signal to a transmission channel which has a transmission bandwidth ( 14 ) and a rated center frequency and which is established between a radio transmitter ( 1 ) and a radio receiver ( 2 ) has the steps: emitting the transmission signal on the radio transmitter ( 1 ) end with an actual transmitter frequency; receiving the transmission signal in the radio receiver ( 2 ); determining the frequency of the transmission signal in the radio receiver ( 2 ); and deciding on the allocation of the transmission signal to a transmission channel if the frequency determined by the radio receiver ( 2 ) lies in a predetermined frequency range. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None.
REFERENCE TO A MICRO-FICHE APPENDIX
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an inter-form concrete mold supporting system and method for constructing concrete foundations or floors through the use of the inter-form system, and more particularly to a height-adjustable, inter-truss as a featured component of the inter-form system and a method for easily constructing monolithic concrete slab-on-grade floors and foundations in situ with enhanced cost-effectiveness.
2. Description of the Related Art
A search of the prior art located the following United States patents which are believed to be representative of the present state of the prior art: U.S. Pat. No. 6,397,535 B1, issued June 2002, U.S. Pat. No. 6,367,764 B1, issued April 2002, U.S. Pat. No. 5,830,378 issued November 1998, U.S. Pat. No. 6,231,025 B1, issued May 2001, U.S. Pat. No. 5,419,055, issued May 1995, U.S. Pat. No. 5,174,083, issued December 1992, U.S. Pat. No. 4,817,353, issued April 1989, U.S. Pat. No. 5,399,050, issued March 1995, U.S. Pat. No. 1,972,913 issued September 1934, U.S. Pat. No. 4,498,707, issued February 1985, U.S. Pat. No. 3,963,210, issued June 1976, U.S. Pat. No. 3,785,606 issued January 1974, U.S. Pat. No. 3,288,042, issued November 1966, and U.S. Pat. No. 2,635,320, issued April 1953.
BRIEF SUMMARY OF THE INVENTION
The inter-form system and method provide the use of an inter-truss form to eliminate formwork members cast in concrete foundations. The inter-form system and method also eliminate steel or wood stake voids and possible corrosion to structural concrete reinforcements from intrusion of moisture from earthen substrate.
It is therefore an object of the inter-form system and method to provide an easily configured and adjustable concrete mold supporting system and method for constructing concrete floors and foundations.
Specifically, it is an object of the inter-form system and method to provide a novel system and method for cost effective concrete floor and foundation construction by use of low cost components and elimination of labor costs as well as the costs associated with traditional forming brackets which require storage, transportation and maintenance.
Another object of the inter-form system and method is to provide a system to eliminate formwork members cast in concrete foundations.
It is also an object of the inter-form system and method to provide a novel system which eliminates steel or wood stake voids and further eliminates early corrosion to structural concrete re-enforcement is due to earth moisture intrusion.
A preferred embodiment of the inter-form system and method discloses a combination of four central components. A steel base plate coated in plastic to prevent the steel having contact with the earth receives a piece of Rebar which is set into vertical position by the base plate sleeve. The Rebar held by the base plate acts as the support member or leg of the system. The length of the support member or leg is determined by depth of footing and is field cut. The central piece of the system, the inter-truss is positioned over the top of the support member and is set to elevation with a set nut. It is then determined where the holes are to be drilled in the form boards. After determining the hole locations, a piece of half-inch, inner rod having threaded ends is sized between forms and inserted into the truss. Angle brackets are installed to the truss using threaded taper bolts threaded on to the inner rod threaded ends. The angle bracket is installed above top of the form and lumber is nailed in to hold the top of the form to the desired width and above to allow finishing under support. The dimension between each of these members is determined by height and width of designed form. The final step is to align all set and placed forms with wood or steel stakes secured into the earth outside the foundation limits.
In an embodiment of the inter-form system and method under light forming conditions the inner rod, taper bolts, and angle brackets can be replaced by a special made snap tie and wedge to hold form boards on each side.
Other features, advantages, and objects of the inter-form system and method will become apparent with reference to the following description read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a front elevation view of an embodiment of the inter-form concrete mold supporting system.
FIG. 2 is a top planar view of the base plate element of FIG. 1 .
FIG. 2A is a front elevation view of FIG. 2 .
FIG. 3 is a front elevation view of the inter-truss element of FIG. 1 .
FIG. 3A is a left side view of FIG. 3 .
FIG. 3B is a top planar view of FIG. 3 .
FIG. 4 is a side view of the angle bracket element of FIG. 1 .
FIG. 5 is a side view of the taper bold element of FIG. 1 .
FIG. 5A is an end view of FIG. 5 .
FIG. 6 is a elevation end view of an embodiment of the present invention for inter-form concrete mold supporting system.
FIG. 7 is a perspective view of the wedge element of FIG. 6 .
FIG. 8 is a side elevation view of the snap-tie element of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawing figures, an embodiment of the inter-form concrete framing system includes: a base plate 20 ; a support member 30 having a top end and a bottom end, wherein the support member 30 bottom end is supported in a vertical position by the base plate 20 ; an inter-truss member 40 having a predetermined length and two ends, the inter-truss member 40 positioned perpendicular to the support member 30 and adjustably attached to the support member 30 top end; and an attachment assembly on each truss member end whereby vertical angle brackets 50 are fixedly attached perpendicularly to the second tubing member 46 of the inter-truss member 40 .
The inter-truss member 40 further comprises a stabilization member 42 connected to first 44 and second 46 tubing members of predetermined length, FIGS. 3-3B . Each tubing member 44 and 46 comprises two ends and an exterior side. The first tubing member 44 is sized to receive and secure the support member 30 top end to define top and bottom first tubing member 44 ends. The first 44 and second 46 tubing members are fixedly attached to the stabilization member 42 such that the top end of the first tubing member 44 is transverse to the second tubing member 46 .
In an embodiment of the present invention, the inter-truss member 40 further comprises an inner rod 60 sized to reside within and extend beyond the second tubing 46 length. This inner rod 60 comprises two threaded ends to receive a threaded attachment assembly.
In an embodiment of the present invention, the base plate 20 comprises a centered sleeve 22 having a centered opening of predetermined diameter extending vertically from the plate and sized to receive and hold the vertical member 30 . The base plate 20 comprises steel coated with plastic. The base plate further comprises at least four openings 24 to secure the plate to a ground substrate.
The attachment assembly of an embodiment of the present invention comprises two threaded taper bolts 70 each sized to fit and attach over the inter-truss 40 inner rod 60 threaded end thus securing an angle bracket 50 .
The attachment assembly of an alternate embodiment of the present invention comprises snap tie 80 and wedge 90 assembly wherein the snap tie 80 is sized to be fixedly inserted through at least one wedge 90 and into each second tubing member 46 end thus securing formwork 100 .
The preferred embodiment 10 of inter-form concrete framing system, FIGS. 1-5 , comprises a steel base plate base 20 coated with plastic comprising at least four openings 24 to secure the base plate 20 to a ground substrate and further comprising a center sleeve 22 having a centered opening of predetermined diameter extending vertically from the plate sized to receive and hold a support member 30 . The preferred embodiment 10 support member 30 is a predetermined length of Rebar having a top end and a bottom end. The rebar bottom end is insertably attached into to the base plate sleeve 22 , whereby the rebar support member 30 is held in a fixed vertical position. The preferred embodiment 10 of the present invention further comprises an inter-truss member 40 comprising a stabilization member 42 and first 44 and second 46 tubing members of predetermined length. Each tubing member 44 and 46 comprises two ends and exterior sides, FIGS. 3 , 3 A and 3 B. The inter-truss member 40 further comprises a rod 60 sized to reside within and extend beyond the second tubing member 46 . The rod 60 comprises two threaded ends. The first tubing member 44 is sized to receive and secure the support member 30 top end and thereby define top and bottom first tubing member 44 ends. The tubing members 44 and 46 are fixedly attached in transverse alignment with the stabilization member 42 such that the top end of the first tubing member 44 is in tangential communication with the transverse second tubing member 46 . Threaded taper bolts 70 sized to fit and attach each rod 60 threaded end to an angle bracket 50 whereby vertical angle brackets 50 are fixedly attached perpendicularly to the inter-truss second tubing member 46 .
The foregoing assembly and inter-form system can be used for ready-mixed concrete inter-form method characterized by the following steps: 1) arranging, at a predetermined interval, at least two inter-form systems 10 or 12 according to the foregoing specification (i.e., FIGS. 1 and 6 ); 2) setting the elevation of each inter-truss member 40 on its corresponding vertical support member 30 ; 3) mounting opposed formworks 100 on the vertical angle brackets 50 so as to locate the inter-form system in a space formed between opposed formwork 100 and define an upper end surface; 4) mounting formwork 200 to opposed formwork 100 upper ends; 5) aligning all set and placed formwork with staking secured into the ground substrate beyond the foundation limits (not depicted); 6) filling ready mix concrete in the space provided between opposed formwork 100 up to top formwork 200 ; 7) allowing the concrete to cure; and 8) removing formwork 100 and 200 . When the concrete has been applied to the space defined within formwork 100 and 200 , the inventive inter-form system is buried into the concrete floor or foundation with only the upper surface of formwork 200 and the exterior surfaces of formwork 100 exposed to the outside.
Support member 30 is determined by depth of footing and is field cut. After the inter-truss 40 is positioned over the top of the support member 30 , the inter-truss 40 is set to elevation with on the support member 30 by a set nut 48 through the first tubing member 44 and locking against the support member 30 , FIG. 3 . At this point, it is then determined where the holes are to be drilled in the formwork 100 . After determining formwork 100 hole locations, a piece of one-half inch end-threaded or all-thread inner rod 60 that is cut or purchased to proper length, preferably to a length two inches less than formwork width and centered between the formwork 100 . Next, angle brackets 50 , FIGS. 1 and 4 , typically comprising a piece of two inch angle with pre-drilled large holes 54 for each taper bolt 60 and smaller holes 52 for #8 or #16 duplex nails, FIG. 4 , are installed. Each angle bracket 50 is held in place and each taper bolt 60 , FIGS. 1 and 5 , is slid through a corresponding angle bracket 50 large hole 54 and formwork 100 and threaded on to the threaded ends of inner rod 60 . The angle bracket 50 is installed above formwork 100 and additional formwork 200 is nailed in to hold formwork to the desired width to allow finishing under support. The dimension between each of these members is determined by height and width of the desired form. All set and placed formwork is aligned and set with wood or steel stakes secured into the earth substrate outside foundation limits (not depicted).
In an embodiment of the invention 12 under light forming conditions the inner rod 60 , taper bolts 70 and angle bracket 50 can be replaced by a special made snap tie 80 and wedge 90 to hold the formwork 100 to the inter-truss 40 , FIGS. 6-8 .
In accordance with the preceding explanation, variations and adaptations of the inter-form concrete mold supporting system and method invention will suggest themselves to a practitioner of the construction equipment arts. Thus, in accordance with these and other possible variations and adaptations of the present invention, the scope of the invention should be determined in accordance with the following claims, only, and not solely in accordance with that embodiment within which the invention has been taught. | Disclosed are a height-adjustable inter-form concrete mold supporting system and method for in situ concrete construction. The system has a support member detachably disposed on a base plate. An inter-form truss is adjustably attached to the support member and holds formwork brackets to define concrete pour width. A plurality of like assemblages and attached formwork define concrete pour length and height of the monolithic concrete slab-on-grade foundations or flooring in situ. | 4 |
[0001] This invention relates to optimization of engine operating performance and more particularly to optimization of diesel engine performance and even more particularly to optimization of diesel engine performance in vehicles, such as over-the-highway vehicles and construction vehicles.
BACKGROUND
[0002] An internal combustion engine does not exhibit a constant high level of efficiency throughout its operating range. Each engine, and particularly each diesel engine, has an area in its torque vs. speed map where it operates most efficiently. This area can be called the “sweet spot”. For heavy vehicles, such as over-the-highway tractors and trucks, the driving habits that result in operating the engine with maximum or near-maximum efficiency, in the sweet spot, are not readily apparent to the driver. Parameters affecting engine efficiency include but are not limited to engine speed, engine load, engine temperature, ambient temperature, and ambient air pressure.
[0003] Some systems provide drivers with information on vehicle performance and optimum operating point, but these systems typically may indicate only that the engine is in the sweet spot and do not indicate the changes needed to get to this favorable operating range. Without such feedback, drivers have to rely on experience and “feel”, which inevitably results in less than optimal operating efficiency.
[0004] WO 03/76788 A1 by Edwards discloses a gas substitution system for a dual-fuel (diesel/liquefied petroleum gas) diesel engine that monitors load and RPM and the operational state of the engine and vehicle, including throttle displacement, cruise control, idle, wheel and engine braking, and manual control. Data is collected to establish parameters such as fuel consumption and exhaust emissions for load/RPM pair values and used to create a table of optimum gas substitution values at each load/RPM pair within the range of operational states within which substitution is viable. This arrangement does not interact with and provide feedback to the driver in real time.
[0005] WO 82/02576 describes using a microprocessor to monitor a number of vehicle operating parameters that can be displayed, for example on a light-emitting diode (LED). A keypad may be used to input other vehicle-related parameters. In addition to presenting torque, RPM, speed, etc. values, the display can change color to indicate a recommended gear change to the driver. Nevertheless, this is just a method of realizing variable compression ratio and is not a driving aid.
[0006] EP 0 919 419 A1 by Trepp discloses a remote cooperative engine control system with remote data processing in which recommended control signals may be communicated to drivers of many vehicles, either from the engine control systems or from a remote location. A display for standard vehicle data (speed, mileage, fuel) may be used for this purpose. Engine operating characteristics may be altered, for example, based upon ambient conditions (temperature, level of oxides, etc).
[0007] U.S. Pat. No. 4,383,514 to Fiala describes an arrangement for fuel supply to the combustion chambers of an engine. Fuel economy can be improved by isolating (i.e., not fueling) certain combustion chambers based upon the load on the engine. For example, fuel may be supplied to four combustion chambers under heavy load, to only two chambers under reduced load, and to no chambers under braking.
[0008] U.S. Pat. No. 4,559,599 to Habu et al. describes a shift indication apparatus, including a shift up/down indicator, based on a stored torque data map and a stored fuel consumption rate data map of an engine. Economical running of the vehicle may be realized by obeying the shift indicator.
[0009] U.S. Pat. No. 5,017,916 to Londt et al. discloses a shift prompter/information display system for indicating gear shift timing and other related data to a driver. A section of the display can indicate a target value for fuel economy when the vehicle is in a cruising mode. A target gear to which the transmission should be shifted is displayed when the engine speed is equal to the synchronous meshing speed of the target gear.
[0010] U.S. Pat. No. 6,067,847 to Staerzl discloses a running quality evaluator for an engine that allows a technician to monitor the running engine on a display and to make corrections for optimizing the engine function. Engine operating parameters such as spark timing can be adjusted to improve quality. The arrangement quantifies the running performance and outputs a signal that can be interpreted as an indicator of performance quality.
[0011] U.S. Pat. No. 6,178,373 to Davis et al. describes an engine control method that involves generating optimized control set points for fuel flow, airflow, exhaust gas recirculation, and spark ignition timing to balance emissions and fuel economy.
[0012] U.S. Pat. No. 6,356,831 to Michelini et al. relates to optimizing gear shifting performance in a manual transmission of an internal combustion engine and more particularly to optimizing gear shifting performance with a lean-capable engine that can operate in multiple combustion modes. An operator is given “shift up” and “shift down” indications on a shift schedule based on lowest cost value for fuel economy and vehicle emissions as a function of different engine combustion modes.
[0013] These devices and systems do not provide enough feedback to drivers, which forces drivers to rely on experience and “feel”. Drivers also have no benchmark from which operating performance can be improved.
SUMMARY
[0014] Compared with the documents described above, Applicants' invention provides a driver with feedback on vehicle performance and the optimum operating point and on the throttle, transmission, and possibly other adjustments needed to attain the optimum operating point, or “sweet spot”. In particular, an interface between the engine and the operator is provided that displays actions that must be taken to maintain the engine in its best performance, e.g., most fuel-efficient, operating region. In addition, the distance or time over which an engine or vehicle is operated or driven in the optimum performance range may be recorded, enabling comparison of operating intervals under different operator conditions and habits and provision of operator incentives for maintaining the engine or vehicle in the most efficient operating range. Thus, a driver can be rewarded, for example by increasing a vehicle's maximum road speed limit, for achieving operational performance targets that can be predefined. For a driver who is paid by distance traveled, this reward translates into additional income. Another advantage of Applicants' invention is that the percentage of operating distance or time spent in the engine's sweet spot during a defined measurement period, or running interval, is viewable and verifiable, for example within a vehicle's instrument cluster, on a per-driver basis if desired. Thus, a fleet manager can verify that drivers' performances have met expectations and can provide rewards like monetary bonuses. Further, sweet-spot data may be downloaded from a vehicle through a communication link, such as a satellite or cellular phone, to a “back office” application, thereby enabling a fleet owner or manager to view the efficiency of a driver in “real time”.
[0015] In accordance with an aspect of the invention, there is provided a system for providing information to an operator of an engine such that the engine operates with optimal performance. The system includes a plurality of sensors adapted to measure operating parameters of the engine; an engine management system adapted to receive measured operating parameters from the sensors and to generate signals indicative of a current operating performance of the engine and signals indicative of performance-increasing adjustments to current operating parameters; and a display adapted to present symbols in response to signals from the engine management system. The symbols guide the operator to increase or maintain engine performance.
[0016] In accordance with another aspect of the invention, there is provided a method of providing information to an operator of an engine such that engine performance can be optimized. The method includes determining at least one current operating parameter of the engine; generating at least one signal indicative of at least one performance-increasing adjustment to the at least one current operating parameter; and presenting at least one symbol to the operator based on the at least one signal. The symbol guides the operator to increase or maintain engine performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The several features, objects, and advantages of Applicants′ invention will be understood by reading this description in conjunction with the drawings, in which:
[0018] FIG. 1 is a block diagram of an engine sweet spot indicator;
[0019] FIG. 2 is a diagram of an instrument cluster having a display connected through a data bus to an engine management system;
[0020] FIG. 3 is an example of an engine speed-torque map;
[0021] FIG. 4 is a flow chart of a method of engine sweet spot indication; and
[0022] FIG. 5 is a plot depicting running intervals and operating performance over distance.
DETAILED DESCRIPTION
[0023] Applicants′ Engine Sweet Spot Indicator (ESSI) is a system that provides an engine operator such as a vehicle driver with the feedback needed to maintain high engine operating performance, e.g., fuel efficiency, communicating the engine's most efficient operating area, or sweet spot, to the driver under any operating condition. The ESSI interacts with the driver and provides instructions for controlling the engine in the most efficient manner, thereby giving the driver a tool that can minimize the operating cost of the vehicle or other engine-powered machine.
[0024] The ESSI is an aid that advises the operator when the engine is being operated most efficiently. FIG. 1 is a block diagram of an exemplary ESSI 100 . One or more suitable sensors 102 measure operating parameters of the engine, such as engine speed (RPM), intake charge air pressure and temperature, engine coolant and oil temperature, turbine boost pressure and temperature, fuel flow, ignition timing, etc., and send measured data to an engine management system (EMS) 104 . For example, engine speed can be measured by sensors that determine camshaft and/or flywheel rotational speed and that provide measurement data about 100 times per second. A typical EMS 104 for a modern engine includes a processor 106 that executes programmed instructions for controlling the operation of the engine. These instructions are stored in a memory 108 with other information needed for operating the engine as desired, including for example the measured data from the sensors 102 that are passed to the memory 108 and processor 106 by suitable input/output (I/O) conditioning circuitry 110 . As indicated by the double-headed arrows, information may flow bi-directionally among the processor, memory, and I/O circuitry, but it will be appreciated that there are many suitable arrangements of devices within an EMS.
[0025] As shown in FIG. 1 , information from the sensors 102 and EMS 104 can flow through the I/O devices 110 to a number of other devices and displays provided in the vehicle or in association with the engine controlled by the EMS 104 . In a vehicle like an over-the-highway truck, these other devices may include an instrument cluster 112 and a satellite unit 114 that can be conveniently connected in parallel to a suitable data bus 116 that may transport information in serial, parallel, or other suitable form. FIG. 1 also indicates that one or more off-board diagnostic tools and devices 118 may be connected to the data bus as desired. It will be appreciated that the sensors 102 also may pass their information through the data bus 116 rather than directly to the I/O circuitry 110 as shown.
[0026] The instrument cluster 112 typically includes a number of gauges and displays that indicate selected operating conditions to an operator. An instrument cluster in a vehicle, for example, typically includes a speedometer and fuel-remaining gauge, as well as other gauges and devices, such as a keypad, touchscreen, or other device that an operator can use to enter information. A display device included in the instrument cluster 112 can serve as part of the human-machine interface (HMI) of the ESSI 100 , but it will be appreciated that other visual and/or audio displays can be used. A suitable display device is a liquid crystal display (LCD) or other display device that is capable of presenting alphanumeric and icon characters in response to signals from an electronic processor or other circuit. Such an arrangement is depicted in FIG. 2 , which shows an instrument cluster 112 having a display 120 that, with other devices as appropriate, is connected through the data bus 116 to the EMS 104 .
[0027] One or more status icons or other characters displayed, for example in a status icon bar, of the instrument cluster 112 can be used to guide the driver into the engine's “sweet spot” by appropriately adjusting engine speed and/or another operating parameter. In one embodiment, the guidance includes icons indicating throttle position and/or gear selection, e.g., “increase throttle” or “shift up”. For a vehicle having a manual transmission, the number of the optimum gear can be presented on the display 120 . In addition, associated audible indications may be presented for these conditions, guiding the vehicle operator to the action required to get the engine into the sweet spot even without looking at the instrument cluster 112 . The EMS 104 may be programmed to enable the audible and/or visible indications to be turned off and on according to driver preference that would be indicated, for example, by corresponding selections via keypad from a set-up menu presented on the display 120 . While the “sweet spot” is attained, the display 120 presents a suitable status icon or character that indicates this. As described in more detail below, achieving this target for a sufficient distance or time period can give the driver a performance bonus, such as an increased speed limit.
[0028] In general, a two-dimensional engine torque-speed map can define the sweet spot area in which the engine operates with maximum or near-maximum fuel efficiency, i.e., minimal brake specific fuel consumption (BSFC). BSFC is a parameter that indicates an engine's efficiency in terms of fuel usage and is the ratio of fuel flow in mass per unit time divided by horsepower. FIG. 3 is an example of such a torque-speed map, with engine speeds between 500 RPM and 2300 RPM indicated on the horizontal axis and engine torques between 500 pound-feet (lb-ft) (about 370 newton-meters (Nm)) and 2000 lb-ft (about 1480 Nm) indicated on the left-most vertical axis. The right-most vertical axis indicates horsepower. It will be appreciated that different engines have different torque-speed maps, which are readily determined in a number of ways, for example by running the engines on a dynamometer.
[0029] Several contours of constant BSFC are shown in FIG. 3 , as is the sweet spot area of substantially minimal BSFC for engine speeds between about 1350 RPM and about 1550 RPM and engine torques between about 900 lb-ft (666 Nm) and about 1300 lb-ft (962 Nm). In general, operating conditions to the left of the sweet spot can be improved by increasing the throttle and/or gear-shifting down and operating conditions to the right of the sweet spot can be improved by decreasing the throttle and/or gear-shifting up. As indicated by FIG. 3 , this guidance can be presented to an operator by up/down arrows in the display 120 .
[0030] Optimization of engine performance by controlling engine torque and speed to minimize BSFC is currently important for applications of this invention in management of diesel engines such as those used in vehicle fleets, but it should be understood that these are not the only parameters that may be used. For example, it may be advantageous to control an engine, such as an engine in a stationary application like a power plant, so as to minimize exhaust emissions rather than BSFC. Moreover, FIG. 3 is only two-dimensional but this is not required; it will be appreciated that Applicants' invention can be used to optimize engine operation in higher-dimensional spaces, for example, spaces determined by torque and speed, as well as engine load, temperature, or pressure.
[0031] Experimentally determined torque-speed data may be stored as a look-up table in the memory 108 or may be reduced to one or more mathematical equations that are computed by the processor 106 . During operation, the EMS 104 carries out a method that is illustrated by the flow chart of FIG. 4 . In step 402 , the EMS 104 periodically determines the operating conditions of engine torque and engine speed, logs that data (step 404 ), and compares those data to the stored torque-speed table or to values produced by suitable equations corresponding to such a table (step 406 ), thereby periodically determining locations in the torque-speed map. Engine speed is advantageously measured directly by a sensor 102 as described above while engine torque is computed by the processor 106 from fuel consumption and engine friction losses that are mathematically related to engine torque in a known way. Engine friction losses are typically determined experimentally by off-line dynamometer testing. In-operation fuel flow or consumption can be measured in several ways, for example by straight-forward computation using fuel pressure and injector stroke measurements.
[0032] Data representing the current location in the torque-speed map, after suitable conditioning, if necessary, is provided through the data bus 116 to the instrument cluster 112 . The information from the EMS 104 is interpreted if necessary by the instrument cluster 112 and presented on the display 120 as symbols that inform the driver how to act, e.g., increase throttle, shift up, etc., to obtain an engine operating condition in or near the sweet spot area (step 408 ). It will be appreciated that the data rate of the EMS for running the engine may be different from, and usually higher than, the rate at which sweet spot indicators are presented and refreshed on the display 120 . As described above, engine speed may be measured about 100 times per second, and for example sweet spot indicators may be updated about 1 time per second. Of course, other rates can be used.
[0033] It will be appreciated that the look-up table or equation(s) defining the torque-speed map may be stored in a memory associated with a processor in the instrument cluster or in another location, even a remote location, rather than in the EMS 104 . If so, the EMS 104 need only provide engine operating data to such a processor, for example through the data bus 116 to a processor on the vehicle or-through a communication link, such as a satellite or cellular telephone or other wireless communication device, to a remote processor. As described in more detail below, the EMS 104 may determine and then present symbols indicating Sweet Spot Target and Sweet Spot Attained percentages.
[0034] The sweet spot data, i.e., the engine's torque-speed conditions, are advantageously logged by the EMS 104 , for example by storing the data in the memory 108 , possibly in association with an indication of the respective driver's or operator's identity. The stored data can be accessed, for example by the off-board diagnostics tools 118 . Data such as the percentage of operating distance or time in the sweet spot can be retrieved from the vehicle memory 108 by a vehicle fleet manager to determine how efficiently the fleet's drivers are operating. This enables fleet operations management, and even an operator of a single vehicle, to recover measured individual vehicle and driver performance. It will be appreciated that the indicators presented to a vehicle operator can be readily adjusted through the software executed by the processor 106 if desired, subjecting a driver's perceived sweet spot to software control. Thus, a fleet operator may adjust a sweet spot target as drivers become more proficient with the ESSI or as it is determined that a target is out of reasonable reach of the drivers. The target value can be altered in a number of ways, for example by an off-board tool 118 that can write suitable data into the memory 108 .
[0035] For an engine in a typical over-the-highway truck, sweet spot indicator data is advantageously broadcast by the EMS 104 and displayed by the instrument cluster 112 when a vehicle is moving at speeds greater than about 30 kilometers per hour (KPH) (about 20 miles per hour (MPH)), and may not be broadcast when the vehicle speed is less than the 30 KPH threshold. Even so, performance data can be logged and available for later retrieval as described above.
[0036] Referring again to FIG. 2 , the display 120 can advantageously display a “% Sweet Spot Target” value, e.g., 50%, which is a selectable goal for operating distance or time spent in the sweet spot in comparison to total operating distance or time, and a “% Sweet Spot Attained” value, which is a measured ratio of operating distance or time spent in the sweet spot to total operating distance or time. The % Sweet Spot Attained value is updated periodically, e.g., every few seconds, so that a driver can see where his or her performance stands with respect to the target. This typically increases the amount of engine run-time that is spent in the efficient region.
[0037] The ESSI 100 may further include a performance award or bonus feature such that a driver is rewarded, e.g., with a higher speed limit and/or money or other value. The reward may be earned when a selected efficiency is achieved. As described above, a driver can input identity information to the ESSI, and data representing the percentage of running distance or time that the driver actually spent in the engine's sweet spot area during the preceding running interval are stored in the EMS 104 , which can compare such stored actual data with a target percentage. The storage capacity needed for such data in a memory 108 is easily provided by currently available memory circuits. The target percentage may be defined by fleet management. The result of the comparison is a reward, or even a penalty, according to whether the actual sweet spot percentage is greater or less than the target percentage.
[0038] It will be understood that the performance bonus feature of the ESSI 100 can be used in many ways to assist a vehicle or fleet manager to achieve a wide variety of performance goals. For example, actual vs. target sweet spot percentage can be considered by itself in deciding whether to award a performance bonus, or the actual vs. target percentage can be considered along with other factors, such as a comparison of actual fuel economy with a target fuel economy and/or a comparison of actual idling time with a target idling time.
[0039] Instead of periodically completely resetting the sweet spot trip data, it can be more advantageous to accumulate data in a sliding window that represents a particular distance interval. The size of the window or running interval (in miles or kilometers) may be specified through an off-board diagnostic tool, such as a dealer communication system. Sweet spot trip data accumulated during the running interval, which may be 100 miles, may then be viewed as desired at different odometer readings. Each read-out of trip data preferably includes the percentage of running interval that the driver has spent in the sweet spot area during the previous running interval. It will be appreciated, of course, that the running interval may be a time period rather than a distance, or even another parameter, such as a fuel quantity, that is of interest to the operator, vehicle, or fleet manager.
[0040] The running interval and target are preferably programmable parameters, thereby enabling adjustment of the dynamics of the sweet spot indicators and performance bonus features. The dynamics alter the ease and difficulty of attaining a sweet spot target percentage and getting or losing any performance bonus reward. The running interval is in effect a “rolling mileage buffer” as illustrated in FIG. 5 , which is a plot of operating performance, as measured by the inverse of BSFC, versus distance. The sweet spot area is indicated in FIG. 5 by BSFC's lower than the dashed line, which corresponds to the central BSFC contour shown in FIG. 3 .
[0041] When the running interval is a distance, the distance(s) through which the vehicle is operated in the sweet spot area are summed over a running interval and then converted to a percentage of the running interval. For example in FIG. 5 , the distances 1 and 2 summed over the running interval 3 are more than 50% of the running interval, and so if the % Sweet Spot Target is set at 50%, the driver has attained the target, and might be entitled to a performance bonus award. Seeing the trip totals, e.g., the % Sweet Spot Attained, in the instrument cluster message display provides the operator with a status report on his or her driving habits. From there, the operator knows how near or far he or she is from achieving the sweet spot target. If this were not a running window, the farther an operator drove a vehicle, the less likely the driver might be to earn a reward because more and more distance would have to be spent in the sweet spot area. Thus, the running interval can be considered as a sliding window, with the % Sweet Spot Attained being computed at substantially non-overlapping positions of the window, i.e., for non-overlapping running intervals.
[0042] It will be appreciated that procedures described above may be carried out repetitively as necessary to control a vehicle. To facilitate understanding, many aspects of the invention are described in terms of sequences of actions that can be performed by, for example, elements of a programmable computer system. It will be recognized that the various actions could be performed by specialized circuits (e.g., discrete logic gates interconnected to perform a specialized function or application-specific integrated circuits), by program instructions executed by one or more processors, or by a combination of both.
[0043] Moreover, the invention can additionally be considered to be embodied entirely within any form of computer-readable storage medium having stored therein an appropriate set of instructions for use by or in connection with an instruction-execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch instructions from a medium and execute the instructions. As used here, a “computer-readable medium” can be any means that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction-execution system, apparatus, or device. The computer-readable medium can 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 include 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, EEPROM, or Flash memory), an optical fiber, and a portable compact disc read-only memory (CD-ROM).
[0044] Thus, the invention may be embodied in many different forms, not all of which are described above, and all such forms are contemplated to be within the scope of the invention. For each of the various aspects of the invention, any such form may be referred to as “logic configured to” perform a described action, or alternatively as “logic that” performs a described action.
[0045] It is emphasized that the terms “comprises” and “comprising”, when used in this application, specify the presence of stated features, integers, steps, or components and do not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof.
[0046] The particular embodiments described above are merely illustrative and should not be considered restrictive in any way. The scope of the invention is determined by the following claims, and all variations and equivalents that fall within the range of the claims are intended to be embraced therein. | System and methods provide information to an operator of an engine such that the engine operates with optimal performance, such as maximal fuel efficiency. Such a system may include a plurality of sensors adapted to measure operating parameters of the engine; an engine management system adapted to receive measured operating parameters from the sensors and to generate signals indicative of a current operating performance of the engine and signals indicative of performance-increasing adjustments to current operating parameters; and a display adapted to present symbols in response to signals from the engine management system. The symbols guide the operator to increase or maintain engine performance. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of U.S. patent application Ser. No. 14/070,132, filed Nov. 1, 2013 and U.S. patent application Ser. No. 13/311,731 filed on Dec. 6, 2011 which are continuations of U.S. Pat. No. 8,614,008 issued on Dec. 24, 2013, which is a national stage application of PCT/FR2007/00536 filed on Mar. 29, 2007 which claims the benefit of PCT/FR2006/000898 filed on Apr. 19, 2006, the entire disclosures of which are hereby incorporated by reference herein.
The invention concerns the fabrication of plates or blanks of coated steel intended to be welded and then heat treated to obtain parts having good mechanical characteristics and good corrosion resistance.
BACKGROUND
Some applications require steel parts combining high mechanical strength, high impact resistance and good corrosion resistance. This type of combination is particularly desirable in the automotive industry which requires a significant reduction in vehicle weight and excellent capacity to absorb energy in the event of a collision. This can be achieved in particular by using steel with very good mechanical characteristics having a martensitic or bainitic-martensitic microstructure: anti-intrusion, structural or safety components of automotive vehicles such as bumpers, door reinforcements, B-pillar reinforcements or roof reinforcements, for example, require the above qualities.
Patent EP 0971044 discloses a fabrication method in which hot- or cold-rolled steel plate coated with aluminum of aluminum alloy is the starting material. After shaping to produce a part, and before heat treatment at a temperature above A c1 , the coating is heated to form a surface alloy by interdiffusion between the steel and the aluminum coating. This alloy prevents decarburization of the metal and oxidation during heat treatment in a furnace. It therefore eliminates the necessity for furnaces containing a special atmosphere. The presence of this alloy also obviates certain surface operations on the treated parts, such as shot blasting, which operations are necessary for plates having no coating. The parts are then cooled under conditions adapted to confer a tensile strength that can exceed 1500 MPa.
With the aim of reducing vehicle weights, parts have been developed consisting of steel blanks of different compositions or different thicknesses continuously butt-welded together. These welded parts are known as “butt-welded blanks” Laser beam welding is a preferred method of assembling such blanks, exploiting the flexibility, quality and productivity characteristics of the process. After these welded blanks have been cold-pressed, parts are obtained having mechanical strength, pressability, impact absorption properties that vary within the parts themselves. It is therefore possible to provide the required properties at the appropriate location without imposing an unnecessary or costly penalty on all of the parts.
The fabrication method described in patent EP 0971044 can be applied to butt-welded blanks in the following manner: starting from steel plate, possibly of different compositions or thicknesses, and having a metal pre-coating, butt-welded blanks are obtained by a welding process. These welded blanks then undergo heat treatment to form a surface alloy and are then hot-pressed and quenched. This produces quenched parts with thicknesses and intrinsic mechanical characteristics that vary and represent an ideal response to local loading requirements.
SUMMARY OF THE INVENTION
However, this fabrication method runs into considerable difficulties: when welding coated steel blanks, a portion of the initial surface pre-coating is transferred into the molten area created by the welding operation. These exogenous metal elements are concentrated in particular by strong convection currents in the liquid metal. These elements are segregated in particular in the interdendritic spaces in which the liquid fraction having the greatest concentration of dissolved elements is located. If austenizing follows with a view to quenching the welded blanks, these enriched areas become alloyed through interdiffusion with the iron or other elements of the matrix and form intermetallic areas. On subsequent mechanical loading, these intermetallic areas tend to be the site of onset of rupture under static or dynamic conditions. The overall deformability of the welded joints after heat treatment is therefore significantly reduced by the presence of these intermetallic areas resulting from welding and subsequent alloying and austenizing.
It is therefore desirable to eliminate the source of these intermetallic areas, namely the initial surface metal coating liable to be melted during butt-welding. However, eliminating this source itself gives rise to a serious problem: the precoated area on either side of the future welded joint can be eliminated, for example by a mechanical process. The width of this area from which the pre-coating is removed must be at least equal to that of the future area melted by welding so as not to encourage subsequent formation of intermetallic areas. In practice, it must be much more than this, to allow for fluctuations in the width of the molten area during the assembly operation. Thus there exist after the welding operation areas on either side of the welded joint that no longer have any surface metal pre-coating. During further alloying and austenizing heat treatment, scale formation and decarburizing occur within these areas located next to the weld. These are areas that tend to corrode when the parts go into service because they are not protected by any coating.
There is therefore a need for a fabrication process that prevents the formation of intermetallic areas within welded assemblies, which are sources of the onset of rupture.
There is also a need for a fabrication process such that the welded and heat treated parts have good corrosion resistance.
There is also a need for an economic fabrication process that can be integrated without difficulty into existing welding lines and that is compatible with subsequent pressing or heat treatment phases.
There is also a need for a product on which operations of butt-welding, then of heat treatment, pressing and quenching, lead to the fabrication of a part having satisfactory ductility and good corrosion resistance. One particular requirement is for a total elongation across the welded joint greater than or equal to 4%.
An object of the present invention is to solve the needs referred to above.
The present invention therefore provides a plate consisting of a steel substrate and a precoat consisting of a layer of intermetallic alloy in contact with the substrate, topped by a layer of metal alloy. On at least one precoated face of the plate, an area situated at the periphery of the plate has the metal alloy layer removed.
The precoat is preferably an alloy of aluminum or based on aluminum.
The metal alloy layer of the precoat preferably comprises, by weight, from 8 to 11% of silicon, from 2 to 4% of iron, the remainder of the compound being aluminum and inevitable impurities.
The width of the area from which the metal alloy layer has been removed is preferably between 0.2 and 2.2 mm.
The width of the area from which the metal layer has been removed preferably varies.
The thickness of the intermetallic alloy layer is preferably between 3 and 10 micrometers.
The area from which the metal alloy has been removed is preferably produced by partly eliminating the metal alloy layer on at least one precoated face of the plate by brushing.
The area from which the metal alloy has been removed can be produced by partially eliminating the alloy layer on at least one precoated face of the plate by means of a laser beam.
The present invention also provides a welded blank obtained by butt-welding at least two plates according to a preferred embodiment of the present invention, the welded joint being produced on the edge contiguous with the area from which the metal alloy has been removed.
The present invention further provides a part obtained by heat treatment and deformation of a welded blank according to a preferred embodiment of the present invention, the precoat being converted throughout its thickness by the heat treatment into an intermetallic alloy compound providing protection against corrosion and decarburization of the steel substrate.
The present invention even further provides a plate, blank or part according to a preferred embodiment, the composition of the steel comprising, by weight: 0.10%≦C≦0.5%, 0.5%≦Mn≦3%, 0.1%≦Si≦1%, 0.01%≦Cr≦1%, Ti≦0.2%, Al≦0.1%, S≦0.05%, P≦0.1%, 0.0005%≦B≦0.010%, the remainder consisting of iron and inevitable impurities resulting from the production process.
The composition of the steel preferably comprises, by weight: 0.15%≦C≦0.25%, 0.8%≦Mn≦1.8%, 0.1%≦Si≦0.35%, 0.01%≦Cr≦0.5%, Ti≦0.1%, Al≦0.1%, 5≦0.05%, P≦0.1%, 0.002%≦B≦0.005%, the remainder consisting of iron and inevitable impurities produced by the production process.
The present invention additionally provides a part according to a preferred embodiment wherein the microstructure of the steel is martensitic, bainitic or bainitic-martensitic.
The present invention also provides a method that includes the steps of coating a steel plate to obtain a precoat including an intermetallic alloy layer topped by a metal alloy layer and, then, on at least one face of the plate, removing the metal alloy layer in an area at the periphery of the plate.
The width of the area may be preferably between 0.2 and 2.2 mm.
The invention further provides a method of fabricating a precoated steel plate that includes of coating a steel plate to obtain a precoat having an intermetallic alloy layer topped by a metal alloy layer, on at least one face of the plate, removing the metal alloy layer in an area not totally contiguous with the periphery of the plate and cutting the plate in a plane so that the area from which the metal alloy has been removed is at the periphery of the cut plate.
The width of the area from which the metal alloy has been removed and which is not totally contiguous with the periphery of the plate may be preferably between 0.4 and 30 mm.
The precoating is preferably effected by dip coating with aluminum.
The layer is preferably removed by brushing.
In a preferred embodiment the layer is removed by the impact of a laser beam on the precoat.
The invention also provides a method according to any one of the above embodiments in which the emissivity or reflectivity of the area over which the metal alloy layer is removed is measured, the measured value is compared with a reference value characteristic of the emissivity or reflectivity of the metal alloy layer, and the removal operation is stopped when the difference between the measured value and the reference value is above a critical value.
The present invention also provides a method wherein the layer is removed by means of a laser beam, characterized in that the intensity or wavelength of the radiation emitted at the point of impact of the laser beam is measured, the measured value is compared with a reference value characteristic of the emissivity of the metal alloy layer, and the removal operation is stopped when the difference between the measured value and the reference value is above a critical value.
The invention also provides a method wherein at least two plates fabricated according to any one of the above embodiments are butt-welded, the welded joint being produced on the edge contiguous with the area from which the metal alloy layer has been removed.
The width before welding of the area from which the metal layer has been removed at the periphery of the plate is preferably 20 to 40% greater than half the width of the weld.
The width of the area from which the metal alloy has been removed and which is not totally contiguous with the periphery of the plate is preferably 20 to 40% greater than the width of a weld.
The present invention also provides a part fabrication method wherein a welded blank fabricated according to a preferred embodiment of the present invention is heated to form, by alloying between the steel substrate and the coating, an intermetallic alloy compound, and so as to confer a partially or totally austenitic structure on the steel, then the blank is hot deformed to obtain a part. The part is cooled at a rate adapted to confer the target mechanical characteristics.
The rate of cooling is preferably above the critical rate for martensitic quenching.
In a preferred embodiment the welding is effected by a laser beam.
The welding is even more preferably effected by an electrical arc.
The present invention also provides a use of a plate, blank or part according to any one of the above embodiments for the fabrication of structural or safety parts for motorized terrestrial automotive vehicles.
BRIEF DESCRIPTION OF THE FIGURES
Other features and advantages of the invention will become apparent in the course of the description given hereinafter by way of example and with reference to the following appended figures.
FIG. 1 is a diagram showing one embodiment of plate according to the present invention before welding;
FIG. 2 is a diagram of a second embodiment of plate according to the present invention;
FIG. 3 is a diagram of an example of a butt-welded joint of the present invention;
FIG. 4 is a macrograph of a welded joint of the present invention after austenizing and alloying heat treatment;
FIG. 5 is a macrograph of a reference welded joint showing the appearance of harmful intermetallic areas within the molten metal; and
FIG. 6 is a macrograph of plate according to the present invention before welding, from which plate the metal alloy has been removed locally using a laser beam.
DETAILED DESCRIPTION
As explained above, total elimination of the metal coating on either side of the joint before welding has led to localized corrosion problems. The inventors have surprisingly shown that eliminating a precise portion of the coating solves the problems referred to above.
To explain the present invention, there are explained first certain characteristics of coated strip or plate usually produced by immersion in baths of molten zinc or aluminum or zinc or aluminum alloys.
These continuous, so-called “dip” methods yield the following general morphology of the coatings:
At the surface of the steel substrate of the plate an intermetallic alloy a few micrometers thick is precipitated, formed by a very fast reaction on immersion in the molten bath. These intermetallic alloys being relatively fragile, inhibitors are added to the molten bath in an attempt to limit the growth of this layer. In the case of zinc or aluminum alloy coatings, the alloys constituting this layer are often of the Fe x Al y type, in particular Fe 2 Al 5 . In the case of zinc alloy coatings, the presence of this aluminum-rich intermetallic layer is explained by the fact that the zinc baths often contain a small quantity of aluminum that plays an inhibitor role.
This layer of intermetallic alloys can sometimes be of a complex nature, for example divided into two intermetallic sub-layers, the sub-layer in contact with the substrate being richer in iron.
This layer of intermetallic alloys is topped by a metal alloy layer the composition of which is very close to that of the bath. A thicker or thinner metal layer is entrained by the plate as it leaves the molten bath, and this thickness can be controlled by means of jets of air or nitrogen.
The inventors have shown that it is necessary to eliminate this layer locally to solve the problems referred to above, which is particularly advantageous.
Consider more particularly FIG. 1 , showing a plate of the present invention. The term plate is to be understood in a broad sense and denotes in particular any strip or object obtained by cutting a strip, a coil or a sheet. In this particular example the plate has two faces and four edges. The present invention is not limited to this rectangular geometry, of course. FIG. 1 shows:
A steel substrate 1 . This substrate can be of plate that is hot-rolled or cold-rolled, as a function of the required thickness, or of any other appropriate form. Superposed on the substrate, and in contact therewith, a pre-coating 2 is present on the two faces of the part. This pre-coating itself consists of:
a layer of intermetallic alloy 3 in contact with the substrate 1 . As already explained, this layer is formed by reaction between the substrate and the molten metal of the bath.
The precoat is advantageously an aluminum alloy or aluminum-based. This type of precoat is particularly suitable for subsequent heat treatment that forms an intermetallic compound by interdiffusion with the substrate 1 and (see below) localized removal of the surface layer. In particular, the metal alloy of the precoat can contain 8 to 11% by weight of silicon and 2 to 4% of iron, the remainder consisting of aluminum and inevitable impurities. Adding silicon enables reduction of the thickness of the intermetallic layer 3 .
The periphery 5 of the plate is also shown. According to the invention, a portion 6 of the periphery does not carry the metal alloy layer 4 but retains the intermetallic alloy layer 3 . This portion 6 is intended to be placed in contact with another plate and then to be butt-welded in a plane defined by the edge 11 to form a blank.
In a first embodiment, the layer 4 is advantageously removed by means of a brushing operation effected at the periphery 5 : the material removed by the brush is essentially the surface layer, which has the lowest hardness, i.e. the metal alloy layer 4 . The harder layer 3 will remain in place as the brush passes over it. Using an aluminum or aluminum-based precoat is particularly advantageous as the difference in hardness between the intermetallic alloy layer 3 and the metal layer 4 is very large.
The person skilled in the art will know how to adapt the various parameters specific to the brushing operation, such as the choice of the kind of brush, the speed of rotation and of relative movement in translation, the pressure perpendicular to the surface, to carry out the removal as completely and quickly as possible, adapting them to the particular nature of the precoat. For example, a wire brush mounted on a rotary shaft driven in translation parallel to the edge of the part 6 could be used.
In a second embodiment, the layer 4 is removed by a laser beam directed toward the periphery of the plate: interaction between this high energy density beam and the precoat causes vaporization and expulsion of the surface of the precoat. Given the different thermal and physical properties of the metal alloy layer 4 and the intermetallic layer 3 , the inventors have shown that a succession of short laser pulses with appropriate parameters leads to selective ablation of the metal layer 4 , leaving the layer 3 in place. The interaction of a pulsed laser beam directed toward the periphery of a coated plate and moved in translation relative to that plate therefore removes the peripheral metal layer 4 . The person skilled in the art will know how to adapt the various parameters, such as the choice of laser beam, the incident energy, the pulse duration, the speed of relative movement in translation between the beam and the plate, and the focusing of the beam onto the surface to carry out the ablation as quickly and completely as possible, adapting them to the particular nature of the precoat. For example, a Q-switch laser could be used, having a nominal power of a few hundred watts and delivering pulses with a duration of the order of 50 nanoseconds. The width of the removal area 6 can naturally be varied by means of successive contiguous ablations.
The width of the area 6 from which the metal layer has been removed must be adjusted to enable:
welding with no introduction of any element of the precoat into the molten area, sufficient corrosion resistance of the welded assembly after subsequent alloying and austenizing heat treatment.
The inventors have shown that the above conditions are satisfied if the width of the area 6 is 20% to 40% greater than half the width of the molten area created when butt-welding blanks.
The minimum value of 20% ensures that the precoat is not introduced into the molten metal during welding, and the value of 40% ensures satisfactory corrosion resistance.
Given the welding conditions for plate from 1 to 3 mm thick, the width of the area 6 is between 0.2 and 2.2 mm.
This situation is represented in FIG. 3 , which shows diagrammatically in section after welding plate comprising a precoat 2 formed of an intermetallic alloy layer 3 and a metal layer 4 . The molten area 10 has its axial plane 9 in the welding direction. The dashed lines show the initial extent of an area 6 melted by the welding operation.
FIG. 3 illustrates the situation in which the weld is globally symmetrically on the two opposite faces of the plate. Under these conditions, the width of the area 6 is exactly the same on both faces. However, as a function of the welding process used and the parameters of that process, the weld can have an asymmetrical appearance. According to the invention, the width of the area 6 can then be coordinated to this asymmetry so that this width is slightly greater than half the width of the molten area 10 on each of the respective two faces. Under these conditions, the width of the area 6 differs from that of the area 6 ′ shown in FIG. 3 .
If welding conditions evolve during an assembly operation, for example to take account of local modification of geometry or thickness, the width of the area 6 can also be coordinated with the corresponding variation of the width of the molten area along the welded periphery of the plate. The width of the area 6 naturally increases if local conditions lead to the formation of a wider weld.
In the case of welding two coated plates of different thickness, the width of the area 6 can also be different on the welded peripheral portion of each of the two plates.
In a variant of the invention shown in FIG. 2 , the layer 4 is removed over an area 7 of a coated plate that is not totally contiguous with the periphery 5 of the plate. The plate is then cut in an axial plane 8 perpendicular thereto, for example by a slitting process. A plate as shown in FIG. 1 is then obtained. The width removed is 20% to 40% greater than the width of the molten area that would be produced by a welding operation in the axial plane 8 .
In one variant of the invention, the width removed is between 0.4 and 30 mm. The minimum value corresponds to a width such that cutting in the axial plane 8 produces two plates having a very narrow removal area 0.2 mm wide on each of the two plates. The maximum value of 30 mm corresponds to a removal width well suited to industrial tools for performing such removal. A subsequent cutting operation can be effected, not on the axial plane 8 situated in the middle of the removal area, but at a location adapted to produce a plate whose removal width is slightly greater than half the width of the molten area produced by a welding operation, defined by the conditions of the invention.
As explained above, the removed widths ensure that the metal coating is not introduced into the molten metal during subsequent welding of the plate and also that the welded blank is corrosion resistant after heat treatment.
Removal of the metal layer 4 can be monitored by means of micrographic examination. However, it has also been shown that the efficiency of the removal operation can be checked very quickly by optical inspection: there is a difference in appearance between the metal layer 4 and the underlying intermetallic layer 3 , which is darker. The removal operation must therefore continue and be stopped when there is seen in the area 6 a significant change of tone relative to the surface coating. It is therefore possible to monitor removal by spectrometer reflectivity or emissivity measurement: the area 6 is illuminated by a light source, one or more optical sensors being directed towards this area. The measured value corresponds to the reflected energy. That value is compared with a reference value corresponding to the emissivity or reflectivity of the metal layer 4 or with a value measured by another sensor directed toward the metal layer. It is also possible to measure the variation of the reflected energy as a function of time. If the layer 6 is flush with the surface, the energy collected is lower than that corresponding to the metal alloy layer 4 . The precise moment at which the removal operation reaches the layer 3 can therefore be determined by previous calibration.
In the case of coating removal by laser ablation, it is also possible to analyze the intensity or the wavelength of the radiation emitted at the point of impact of the laser beam on the precoated plate. The intensity and the wavelength are modified when the layer 4 has been eliminated and the laser beam impacts on the layer 3 . The thickness of the layer removed can therefore be monitored in the following manner: the intensity or the wavelength of the radiation emitted at the point of impact of the laser beam is measured, that measured value is compared with a reference value characteristic of the emissivity of the metal alloy layer 4 , and the removal operation is stopped when the difference between the measured value and the reference value is above a predetermined critical value.
Depending on specific constraints, this step of removing the metal alloy layer can be carried out at various stages of the production process, and in particular:
either after unwinding coils fabricated on continuous rolling mill trains, before cutting to form a smaller format plate, or before welding the cut plate.
In the method of the invention, a hot- or cold-rolled steel plate with the following composition by weight is the starting material: carbon content between 0.10 and 0.5%, and preferably between 0.15 and 0.25% by weight. This element impacts greatly on the quenchability and on the mechanical strength obtained after cooling that follows the alloying and austenizing of the welded blanks. Below a content of 0.10% by weight, the quenchability is too low and the strength properties are insufficient. In contrast, beyond a content of 0.5% by weight, the risk of defects appearing during quenching is increased, especially for the thickest parts. A carbon content between 0.15 and 0.25% produces a tensile strength between about 1250 and 1650 MPa.
Apart from its role as a deoxidant, manganese also has a significant effect on quenchability, in particular if its concentration by weight is at least 0.5% and preferably 0.8%. However, too great a quantity (3% by weight, or preferably 1.8%) leads to risks of excessive segregation.
The silicon content of the steel must be between 0.1 and 1% by weight, and preferably between 0.1 and 0.35%. Apart from its role of deoxidizing the liquid steel, this element contributes to hardening. Its content must nevertheless be limited to avoid excessive formation of oxides and to encourage coatability.
Beyond a content above 0.01%, chromium increases quenchability and contributes to obtaining high strength after the hot forming operation, in the various portions of the part after cooling following the austenizing and alloying heat treatment. Above a content equal to 1% (preferably 0.5%), the contribution of chromium to obtaining homogeneous mechanical properties reaches saturation.
Aluminum favors deoxidation and precipitation of nitrogen. In amounts above 0.1% by weight, coarse aluminates form during production, which is an incentive to limit the content to this value.
Excessive quantities of sulfur and phosphorus lead to increased weakness. For this reason it is preferable to limit their respective contents to 0.05 and 0.1% by weight.
Boron, the content of which must be between 0.0005 and 0.010% by weight, and preferably between 0.002 and 0.005% by weight, has a large impact on quenchability. Below a content of 0.0005%, insufficient effect is achieved vis à vis quenchability. The full effect is obtained for a content of 0.002%. The maximum boron content must be less than 0.010%, and preferably 0.005%, in order not to degrade toughness.
Titanium has a high affinity for nitrogen and therefore contributes to protecting the boron so that this element is found in free form to have its full effect on quenchability. Above 0.2%, and more particularly 0.1%, there is however a risk of forming coarse titanium nitrides in the liquid steel, which have a harmful effect on toughness.
After preparation of the plate according to any of the methods described above, they are assembled by welding to obtain a welded blank. More than two plates can naturally be assembled to fabricate complex finished parts. The plates can be of different thickness or composition to provide the required properties locally.
Welding is effected after placing the plates edge-to-edge, the areas with no metal alloy layer being in contact with each other. Welding is therefore effected along the edge contiguous with the areas 6 where the metal alloy layer has been removed.
In the context of the invention, any continuous welding means can be used appropriate to the thicknesses and to the productivity and quality conditions required for the welded joints, and in particular:
laser beam welding, electric arc welding, and in particular the GTAW (Gas Tungsten Arc Welding), plasma, MIG (Metal Inert Gas) or MAG (Metal Active Gas) processes.
Under the conditions of the invention, the welding operation does not lead to remelting of a portion of the metal coating 4 , elements whereof would thereafter be found in the molten area. Only a minimal quantity of the intermetallic alloy layer 3 is remelted by this operation into the molten area. As the following example shows, this very limited quantity has no influence on the metallurgical quality or the mechanical properties of the welded joint after alloying and austenizing heat treatment.
The welded blank is then heated to bring about conjointly:
A surface alloying treatment in which elements of the steel substrate, in particular iron, manganese and silicon, diffuse into the precoat. This forms a surface intermetallic alloy compound the melting point of which is significantly higher than that of the metal alloy layer 4 . The presence of this compound during heat treatment prevents oxidation and decarburization of the underlying steel. Austenizing of the base steel, either partial or total. The heating is advantageously effected in a furnace so that the part reaches a temperature between Ac1 and Ac3+100° C. Ac1 and Ac3 are respectively the start and end temperatures of the austenitic transformation that occurs on heating. According to the invention, this temperature is maintained for a time greater than or equal to 20 s so as to render uniform the temperature and microstructure at the various points of the part.
Under the conditions of the present invention, during this heating phase, no brittle intermetallic areas are formed within the molten metal, which would be harmful to the mechanical properties of the part.
This is followed by hot deformation of the blank to its final shape as a part, this step being favored by the reduction of the creep limit and the increase of the ductility of the steel with temperature. Starting from a structure that is partly or totally austenitic at high temperature, the part is then cooled under appropriate conditions to confer the target mechanical characteristics: in particular, the part can be held in a tooling during cooling, and the tooling can itself be cooled to encourage the evacuation of heat. To obtain good mechanical properties, it is preferable to produce martensitic, bainitic or bainitic-martensitic microstructures.
In the area 6 on either side of the welded joint, the intermetallic layer 3 , which is between 3 and 10 micrometers thick before heat treatment, is alloyed with the steel substrate and produces good corrosion resistance.
EXAMPLE
The following embodiments show by way of example other advantages conferred by the present invention. They concern a cold-rolled steel strip 1.5 mm thick, with the following composition by weight:
TABLE 1
Composition of the steel (% by weight)
C
Mn
Si
S
P
Al
Cr
Ti
B
0.224
1.160
0.226
0.005
0.013
0.044
0.189
0.041
0.0031
The steel strip was precoated by dipping it in a molten bath of an aluminum alloy containing 9.3% of silicon and 2.8% of iron, the remainder consisting of aluminum and inevitable impurities. The strip was then cut into plates with a format of 300×500 mm 2 . These have on each face a precoat comprising a layer of intermetallic alloy comprising mostly Fe 2 Al 3 , Fe 2 Al 5 and Fe x Al y Si z . This 5 micrometers thick layer in contact with the steel substrate has a 20 micrometers thick layer of Al—Si metal alloy on top of it.
Before laser beam welding, four different preparation methods were used:
Method I (according to the present invention): the Al—Si metal alloy layer was removed by longitudinal brushing over a width of 1.1 mm from the edge of the plate, on the 500 mm long side. Brushing was effected in exactly the same way on both faces using an 80 mm diameter “Spiraband” wire brush mounted on an angled rotary system, guided in movement in translation on a counterweight bench. The brushing force is approximately 35 N at the point of brush/blank contact, and the speed of movement of the brush 10 m/min. This brushing eliminates the metal alloy layer, leaving only the 5 micrometer intermetallic alloy layer in the brushed area. Method II (according to the present invention): the Al—Si metal alloy layer was removed by laser ablation over a width of 0.9 mm from the edge of the plate. The laser ablation was carried out in exactly the same way on both faces using a Q-switch laser with a nominal energy of 450 W delivering 70 ns pulses. The pulse energy is 42 mJ. The constant speed of movement in translation of the laser beam relative to the plate is 20 m/min. FIG. 6 shows that this laser ablation eliminates the metal alloy layer 4 leaving only the 5 micrometer intermetallic alloy layer 3 in the treated area. Method R1 (not according to the invention): all of the precoat, comprising the metal alloy layer and the intermetallic alloy, was mechanically removed over a width of 1.1 mm, and therefore identical to that of method 1, by means of a carbide plate type tool for fast machining, in longitudinal translation. As a result, subsequent welding is carried out in an area with all of the precoat removed on either side of the joint. Method R2 (not according to the invention): laser welding was effected on precoated plate with no particular preparation of the periphery.
The above plates were laser beam welded under the following conditions: nominal power: 6 kW, welding speed: 4 m/minute. Given the width of the weld, in method I, there is found the presence of an area with no metal alloy over a width of approximately 0.3 mm following production of the welded joints.
The welded blanks were subjected to alloying and austenizing heat treatment including heating to a temperature of 920° C., which was maintained for 7 minutes. These conditions lead to complete austenitic transformation of the steel of the substrate. During this heating and constant temperature phase, it is found that the aluminum-silicon-based precoat forms an intermetallic compound throughout its thickness by alloying with the base steel. This alloy coating has a high melting point and a high hardness, features high corrosion resistance, and prevents oxidation and decarburization of the underlying base steel during and after the heating phase.
After the phase of heating to 920° C., the parts were hot-deformed and cooled.
Subsequent cooling between jigs yielded a martensitic structure. The tensile R m of the steel substrate obtained after such treatment is above 1450 MPa.
The following techniques were then used to characterize the welded joints in the parts obtained in this way:
Micrographic sections show the presence of any intermetallic areas within the welded joints. Mechanical tension tests across welded joints in samples 12.5×50 mm 2 determines the tensile strength R m and the total elongation.
Accelerated corrosion tests were carried out according to the DIN 50021, 50017, and 50014 standards. These tests include, following salt mist spraying, cycles alternating dry phases at 23° C. and wet phases at 40° C.
Table 2 sets out the results of these characterizations:
TABLE 2
Welded joint characteristics after heat treatment
Fragile
intermetallic
areas within
Rm
Corrosion
Method
welded joints
(MPa)
A(%)
resistance
I (according to the
None
>1450
≧4
∘
present invention)
II (according to the
None
>1450
≧4
∘
present invention)
R1 (not according to
None
>1450
≧4
●
the invention)
R2 (not according to
Present
1230
≦1
∘
the invention)
∘: Satisfactory
●: not satisfactory
Under the quenching conditions required after heat treatment, the microstructure of the base metal and the molten area during welding is totally martensitic with the above four methods.
In the case of method I of the invention, the melted area contains no intermetallic area, as FIG. 4 shows.
On the other hand, in the method R2, note the presence of intermetallic areas (see FIG. 5 ), in particular towards the periphery of the melted area where the elements of the precoat were concentrated by spontaneous convection currents in the liquid bath caused by a Marangoni effect. These large intermetallic areas, which can be oriented substantially perpendicularly to the mechanical load, act as stress concentration and onset of rupture effects. Elongation in the crosswise direction is in particular reduced by the presence of these intermetallic areas: in the absence of these areas, the elongation is above 4%. It drops to below 1% when they are present.
No significant difference in mechanical characteristics (strength and elongation) is noted between the method I of the invention and the method R1. This indicates that the thin layer of intermetallic alloy left in place by brushing and remelted by welding does not lead to the formation of brittle areas within the molten metal, as FIG. 4 shows.
In the case of the method R1, corrosion resistance is reduced: the steel is totally bared on either side of the welded joint by the total removal of the precoat. Lacking corrosion protection, red rust is then seen to appear in the heat-affected areas on either side of the weld.
Thus the method of the invention simultaneously achieves good ductility of the welded joint after treatment and good corrosion resistance.
Depending on the composition of the steel, in particular its carbon content and its manganese, chromium and boron content, the maximum strength of the parts can be adapted to the target use. Such parts will be used with profit for the fabrication of safety parts, and in particular anti-intrusion or underbody parts, reinforcing bars, B-pillars, for the construction of automotive vehicles. | A method of forming a steel part is provided. The method includes the steps of coating a first steel plate to obtain a first precoat upon the first steel plate so as to define a first base, a first intermetallic alloy layer on the first base and a first metal alloy layer on the first intermetallic alloy layer. On a first face of the first steel plate the first metal alloy layer is removed in a first area of the first steel plate, while at least part of the first intermetallic alloy layer in the first area remains. A second steel plate is coated to obtain a second precoat upon the second steel plate so as to define a second base, a second intermetallic alloy layer on the second base and a second metal alloy layer on the second intermetallic alloy layer. On a second face of the second steel plate, the second metal alloy layer is removed in a second area of the second metal plate, while at least part of the second intermetallic alloy layer in the second area remains. After removal of the first and second metal alloy layers, the first steel plate is butt-welded to the second steel plate at the first and second areas to form a welded blank. A heat treatment is performed on the welded blank. The welded blank is shaped after the heat treatment into the steel part. A steel part is also provided. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority from U.S. Provisional Application 60/605,434 having a filing date of Aug. 30, 2004 the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to fibrous insulation for paneled or wrapped disposition in at least partial surrounding relation to an interior chamber of a heat-generating appliance. More particularly, the invention relates to an insulating material formed from a blend of cotton and polymeric fibers held together in a cohesive structure by fusion bonding between the fiber constituents and wherein the cotton fibers are pretreated with a flame retardant composition prior to blending with the polymeric fibers such that flame retardant treated cotton fibers are disposed substantially throughout the insulating material.
BACKGROUND OF THE INVENTION
[0003] In a number of appliance environments a heated interior chamber is used to hold articles being treated by heat. By way of example only, such appliance environments include clothes dryers, dish washers and the like. In such environments it is desirable to provide a degree of insulation between the interior chamber and the exterior surrounding cabinet so as to reduce energy consumption and to reduce the possibility of the exterior cabinet becoming overheated. It is also desirable to provide a degree of sound insulation to reduce operational noise. Insulating materials such as fiberglass and the like may function well to contain heat but may have limited sound dampening capacity unless a substantial thickness is used. Moreover such materials are often irritating to the skin and thus may undesirable during the manufacturing process. Cotton-based materials are generally non-irritating to users but they may have limited resistance to flammability. Flame resistance may be important if the interior or associated component such as an electric motor, bearing or the like becomes overheated.
SUMMARY OF THE INVENTION
[0004] This invention provides advantages and alternatives over the prior art by providing insulating materials suitable for heat-generating appliances. The insulating materials contain substantial percentages of cotton fiber while retaining substantial flammability resistance. The insulating materials provide exceptional heat blocking and sound damping characteristics.
[0005] According to a potentially preferred feature, the cotton fibers may be treated with a flame retardant composition and dried prior to blending with other fiber constituents.
[0006] According to another potentially preferred feature, the cotton fibers may be blended with a polymeric fiber including a relative low melting point constituent and subjected to a heat treatment to fusion bond the fibers together at bonding points across the thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention will now be described by way of example only with reference to the accompanying drawings which constitute a portion of the specification herein and in which:
[0008] FIG. 1 is a schematic illustration of a processing line for forming a fibrous insulating material for a heat-generating appliance;
[0009] FIG. 2 is a cross-section of a representative fibrous insulating material formed by the processing line in FIG. 1 ;
[0010] FIG. 3 is a partial cut-away view of a clothes dryer incorporating an insulating panel of fibrous insulating material formed by the processing line in FIG. 1 ; and
[0011] FIG. 4 is a schematic illustration of an alternative processing line for forming a fibrous insulating material for a heat-generating appliance.
[0012] While the present invention has been illustrated and generally described above and will hereinafter be described in connection with certain potentially preferred embodiments, procedures, and practices, it is to be understood that in no case is the invention to be limited to such illustrated and described embodiments, procedures, and practices. On the contrary, it is intended that the present invention shall extend to all alternatives, modifications, and equivalents as may embrace the principals of the present invention within the true scope and spirit thereof.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0013] Reference will now be made to the drawings, wherein to the extent possible, like reference numerals are utilized to designate like components throughout the various views. In FIG. 1 there is illustrated a processing line for formation of a fibrous insulation material 10 as will be described more fully hereinafter. Of course, it is to be understood that the illustration is highly schematic and that the process may be the subject of any number of alternative arrangements as will be recognized as being suitable to those of skill in the art upon reference to this specification.
[0014] As illustrated, in the formation process, a collection of blended fibers 12 is deposited upon a carrier belt 14 for transport to a leveling belt 16 disposed in opposing relation to the carrier belt 14 such that a space of controlled thickness is established between the carrier belt 14 and the leveling belt 16 . The fibers 12 are preferably a blend of cotton fibers intermixed with polymeric fibers. A blend of cotton fibers and polyester fibers may be particularly preferred although other polymeric fibers such as polypropylene, nylon and the like are also contemplated. By way of example only, a blend of about 20% to 80% cotton, more preferably about 40% to 60% cotton and most preferably about 50% cotton with the remainder being polyester may be particularly desirable.
[0015] The blend of fibers 12 preferably includes some percentage of a relatively low melting point constituent so as to permit the heat activated point bonding of fibers to one another upon application of heat. According to one contemplated practice, the blend of fibers 12 is made up of cotton within the ranges specified above in combination with polyester fibers with different melting point constituents. According to such practice, it is contemplated that about 5% to about 75% of the polyester fibers may be so called “bi-component” polyester fibers incorporating a sheath of low melting point CO-PET polyester around a standard PET polyester core. As will be appreciated, upon the application of heat, the sheath material undergoes preferential flow and bonding to surrounding fiber constituents. Of course, other forms of low melting point material such as discrete fibers of low melting point material may also be utilized.
[0016] As illustrated, after being deposited on the carrier belt 14 , the blend of fibers 12 is conveyed to a leveling belt 16 disposed in spaced opposing relation to the carrier belt 14 . The fibers are thus forced into a space of defined thickness between the carrier belt 14 and the leveling belt 16 . According to the illustrated practice, while the fibers 12 are constrained between the carrier belt 14 and the leveling belt 16 they are subjected to a heating operation at an oven 20 so as to facilitate the heat fusion of fibers to one another by the melting and resolidification of the low melting point constituent. The resultant fibrous insulation material 10 is thus formed from a blend of cotton fibers that are point bonded to polyester or other polymeric fibers by heat activated thermoplastic material. The bonding also fixes the height to a level substantially corresponding to the height between the carrier belt 14 and the leveling belt 16 . The fibrous insulation material 10 is preferably characterized by a mass per unit area of about 1.3 ounces per square foot to about 20 ounces per square foot. One potentially preferred construction is characterized by a mass per unit area of about 4 ounces per square foot with a thickness of about 1 inch.
[0017] As previously noted, the fibrous insulation material 10 is preferably characterized by substantial flammability resistance. According to one contemplated practice, such flammability resistance is imparted by treatment of the cotton constituent fibers with a flame resistant chemical composition prior to blending with the polymeric constituent fibers. By way of example only, and not limitation, the cotton constituent fibers may be treated with flame resistant chemicals such as di-ammonium phosphate or the like and then be allowed to dry prior to being blended with the polyester or other polymeric fiber constituent. Thus, the treated cotton fibers will be distributed throughout the blend and the finished fibrous insulation material 10 . This provides enhanced uniformity in fire resistance thoughout the formed structure.
[0018] As further noted above, the fibrous insulation material 10 also provides a substantial level of sound dampening. In order to promote such sound dampening it is contemplated that the cotton and polymeric fibers preferably have relatively low linear density ratings in the range of about 4 denier or less, more preferably about 3 denier or less and most preferably about 1 to 3 denier. Of course, higher or lower denier ratings may also be utilized if desired.
[0019] Depending upon the level of low melting point material included within the blend of fibers, the fibrous insulation material 10 may be characterized by differing levels of flexibility ranging from stiff to substantially pliable. By varying the stiffness level the fibrous insulation material 10 may be adapted for insulation of numerous different appliances. By way of example, a relatively pliable costruction may be desirable to wrap around the interior of a dishwasher while a more rigid panel structure may be desirable for use as insulation panels at the interior of a clothes dryer cabinet. By way of example only, and not limitation, in FIG. 3 there is illustrated a clothes dryer 30 having a heated interior chamber 32 surrounded by a cabinet 34 . As illustrated, panels of the fibrous insulation material 10 may be disposed within the cabinet 34 so as to provide a flame barrier at least partially surrounding the interior chamber 32 .
[0020] It is also contemplated that insulation materials of increased density and rigidity may be produced by alternative processing techniques. By way of example only, and not limitation, FIG. 4 illustrates a process for forming a stiffened panel 110 wherein the leveling belt and oven are replaced by a pair of cooperating heated calendering roll stations 140 , 142 . As will be appreciated, at such stations a pressure applying heated roll presses down on the fibers 112 blended as previously described and deposited on the belt 114 . This heat and pressure activates low melting point constituents within the fiber blend thereby causing the desired point bonding fusion between the fibers. In addition, the heated rolls provide an ironing effect to the surface of the panel 110 , thereby smoothing the surface which may be desirable in some environments of use. While double sided calendering is illustrated, it is likewise contemplated that calendering may be performed across only a single side if desired.
[0021] It is to be understood that while the present invention has been illustrated and described in relation to several potentially preferred embodiments, constructions, and procedures that such embodiments, constructions, and procedures are illustrative and exemplary only and that the present invention is in no event to be limited thereto. Rather it is contemplated that modifications and variations embodying the principles of the present invention will no doubt occur to those of ordinary skill in the art. It is therefore contemplated and intended that the present invention shall extend to all such modifications and variations as may incorporate the broad aspects of the present invention within the true scope and spirit thereof. | An appliance insulating panel of fibrous construction. The insulating panel incorporates substantial percentages of cotton fiber while retaining substantial flammability resistance. The insulating panel construction provides exceptional heat blocking and sound damping characteristics. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/461,482, filed Aug. 12, 2009, which claims priority to U.S. Provisional Patent Application No. 61/188,727, filed Aug. 12, 2008.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a location-based recovery device and risk management system for portable computing devices and data.
[0004] 2. Related Art
[0005] With the advent of telecommunications, it has become useful and desirable for enterprises and individuals to employ various forms of sensors and communications devices to monitor the condition and location of certain assets such as portable computing devices. Advances in digital, electronic and wireless communication devices have extended the range and convenience of portable asset monitoring. Global Positioning Satellites (GPS) such as Inmarstat, Iridium, Globalstar, or Msat now increase the accuracy of portable asset location and movement. Such technologies are significant in improving efficiency and economic management of portable assets. Such devices and business practices are well known in the prior art.
[0006] There are approximately a dozen disclosures describing GPS features that relate to portable device theft and recovery that constitutes the known prior art relating to the present invention. The present invention provides novel and useful improvements, methods and processes for reducing economic and property losses related to the theft or loss of portable computing devices which, without limitation, is distinguished from the prior art in the following discussion.
[0007] In U.S. Patent Publication No. 2006/0007039, a method and system are disclosed for expanding law enforcement recovery efforts for missing vehicles using VHF enabled networks and concealed GPS receivers. The present invention application is distinguished in that its hardware elements are novel and unique to the small dimensions of a portable computing device. A further limitation of the prior art is that it substantially provides only passive tracking capabilities. An improvement of this invention over the prior art is the novel enablement of the tracking device to receive and initiate certain limited and useful operations of the stolen or missing computing assets to prevent unauthorized use of its digital content.
[0008] U.S. Patent Publication No. 2004/0198309 discloses a stolen vehicle tracking and recovering method that utilizes cellular telecommunication networks for providing location guidance information to improve vehicle recovery. An improvement of the present invention over the prior art is its use of an implanted GPS device within a portable computing device that communicates directly with a global positioning satellite network and independently of the operating system of the portable computing device.
[0009] In U.S. Patent Publication No. 2003/0005316, the prior art teaches a mobile system that is provided with a theft recovery mechanism comprising a host chipset and a locator subsystem connected to the host chipset that is arranged to determine a current location of the mobile system; and a main storage connected to the host chipset and arranged to store an operating system (OS) and contain an OS-Present application and/or a Pre-OS application configured to enforce security policies during user authentication and determine whether the mobile system may have been stolen or used inappropriately to based on the security policies. A novel improvement of the present invention is its use of an implanted autonomous device that coordinates theft and tracking functions separate from an existing computing operating system. This improvement provides a measure of security from programming interference or compromise by software viruses that can attack and compromise mobile device operating systems.
[0010] In U.S. Pat. No. 5,793,283, titled “Pager Vehicle Theft Prevention and Recovery System”, the prior art teaches a theft prevention and recovery system using pager network for vehicles, which transmits a designated electronic alarm signal via free space through an electronic transceiver when a remote alarm activation signal is received. The user instructs the transceiver to transmit a continuous pager signal containing longitudinal and latitudinal coordinates generated by the GPS. The longitudinal and latitudinal coordinates allow the car to be traced and recovered. The present invention is distinguished from this prior art because its mode of operation configures to the unique parameters of a personal computing system, which contains data files. In the event of a loss or theft of the personal computing system, a novel improvement of the present invention is that it can determine and activate procedures on the data files if such data files must be cordoned off, destroyed, encrypted or transmitted to a remote and secure location.
[0011] Other prior art is disclosed in U.S. Patent Publication No. 2007/0180207, which involves secure radio frequency identification (RFID) backup/restore for computing/pervasive devices. This prior art uses an automated RFID based data backup and recovery system for a computing device to invoke logic to initiate physical copying and transmission of digital storage device content to remote storage device. The present invention is distinguished by its separate universal GPS device that is installed in a portable computing device. Further the present invention requires positive activation by the user and can trigger disablement of the host computing device to prevent economic loss related to a potential disclosure breach of proprietary, personal or commercial data.
[0012] In U.S. Patent Publication No. 2006/0033616, titled “Smart Container Gateway”, the prior art comprises a smart container gateway that provides communication with global and local networks, container and cargo security sensors and cargo identification tags. The smart container gateway communicates with one or more networks by means of an integrated structural RF antenna, power generator and radio control subsystem. The present invention is distinguished in that its application requires insertion of a compact and covert device into the interior space of the portable computing device and requires external power from the host device and external activation prior to performing or activating to perform any function.
[0013] In U.S. Patent Publication No. 2005/0017900, titled “Tracking Unit”, the prior art describes a tracking unit for assisting in the recovery of stolen monies or other property includes a housing containing a GPS receiver for receiving GPS signals from overhead satellites, a cellular phone transceiver, a microprocessor, and a battery. Following a theft, the microprocessor activates the cellular phone transceiver to dial the telephone number of a central monitoring station. The present invention is distinguished in that it is directly installed into the theft risk (i.e. the portable computing device) in which it is installed.
[0014] In U.S. Patent Publication No. 2004/0075539, titled “Vehicle Monitoring System”, the prior art discloses “remote theft monitoring for vehicle by sensing vehicle displacement, engine operation and key entry.” When a possible theft condition is determined, the service provider server will generate a message to alert a security agency. The present invention disclosure is distinguished by its use in portable computing devices and its requirement for active external activation by an owner to operate its novel features and benefits.
[0015] In U.S. Pat. No. 6,049,269, titled “Wide Area Wireless System for Access Into Vehicles and Fleets for Control, Security, Messaging, Reporting and Tracking”, the prior art invention uses a paging signal initiated by owner if his or her vehicle is stolen, on-board paging receiver, decoder, controller, alarm and ultimate disablement of vehicle. The present invention is an improvement in its use of a novel software based method that employs au insertable GPS device into portable computing devices. In the present invention, a novel software based method computes a GPS system purchase price related to the savings from economic loss by recovery or by cash compensation in the event of an unrecoverable loss of said portable computing device.
[0016] Notwithstanding the prior art discussed herein, the invention is novel because none of the prior disclosures either alone or in combination are sufficient to disclose the invention set forth in this application. As a result, the present invention offers numerous advantages over the prior art, including, without limitation:
[0017] a) The claimed invention discloses a novel and useful GPS device and antennae system that may be covertly and efficiently installed into a portable computing device.
[0018] b) The invention is a novel means to employ software in the GPS device that may instruct the portable computing device to transmit, alter or destroy data files in the portable computing device to prevent loss of economic value or personal privacy.
[0019] c) The invention is a novel software based method and financial system to acquire and install such a GPS device and software and to provide an insurance product to compensate for loss by the theft of or accidental loss of portable computing devices.
[0020] From the discussion that follows, it will become apparent that the present invention addresses the deficiencies associated with the prior art while providing numerous additional advantages and benefits not contemplated or possible with prior art constructions.
SUMMARY OF THE INVENTION
[0021] A location-based recovery device and risk management system for portable computing devices and data is disclosed herein. The location-based recovery device and risk management system both protects data stored on portable computing devices and assists in the location and recovery of portable computing devices that have been stolen or otherwise lost. The stored data may be overwritten or encrypted for later decryption when the portable computing device is recovered. In this manner, such data is protected even when the portable computing device is lost.
[0022] Various embodiments of the location-based recovery device and risk management system are disclosed herein. For instance, in one exemplary embodiment, the location-based recovery device and risk management system may be a portable computing device comprising a power source configured to allow operation of the portable computing device without being connected to an electrical outlet, a data storage assembly configured to store one or more data files on the portable computing device, and a wireless communication assembly.
[0023] The wireless communication assembly may be configured to receive one or more wireless signals to determine a geographic location of the portable computing device, receive input indicating the theft or loss of the portable computing device, and transmit the geographic location of the portable computing device after receiving the input indicating the theft or loss of the portable computing device.
[0024] Upon receiving one or more particular wireless transmissions, the data storage assembly modifies the data files utilizing a random binary fill or encryption that is capable of decryption if the portable computing device is recovered. This protects the data files on the portable computing device. It is contemplated that the particular wireless transmissions may only be transmitted by an authorized user of the portable computing device.
[0025] It is noted that the wireless communication assembly may have various configurations. For example, the wireless communication assembly may comprise a GPS device, a cellular data transceiver, a Wi-Fi data transceiver, or various combinations thereof in one or more embodiments.
[0026] In another exemplary embodiment, the location-based recovery device and risk management system may be a data protection and recovery system for a portable computing device (e.g., a laptop, tablet, or smartphone). Such system may comprise one or more communication devices configured to send one or more transmissions to the portable computing device indicating the theft or loss of the portable computing device, wherein the portable computing device is configured to, upon receipt of one or more is particular transmissions, modify data stored thereon utilizing a random binary fill or encryption that is capable of decryption if the portable computing device is recovered. The communication devices will typically also be configured to receive a response from the portable computing device indicating the geographic location of the portable computing device.
[0027] A user interface of the system may query a user whether to activate data file management on the portable computing device. Upon receiving user input activating data file management, the communication devices transmit the particular transmissions thereby causing the portable computing device to modify the data stored thereon utilizing a random binary fill or encryption that is capable of decryption if the portable computing device is recovered. The particular transmissions may be received wirelessly by the portable computing device. It is noted that the communication devices may be further configured to transmit one or more instructions to the portable computing device to decrypt encrypted data store thereon.
[0028] The user interface may be further configured to query the user whether to activate file management comprising the random binary fill or encryption that is capable of decryption if the portable computing device is recovered. In addition, it is contemplated that the user must be an authorized user of the data protection and recovery system in order to utilize the system's capabilities.
[0029] Various methods for data protection and recovery for a portable device are disclosed herein as part of the location-based recovery device and risk management system as well. For instance, in one exemplary embodiment, a method for data protection and recovery for a portable device may comprise providing a data storage device configured to store data on the portable device and to modify the stored data utilizing a random binary fill or encryption that is capable of decryption and data recovery if the portable device is recovered, and wirelessly receiving input indicating the theft or loss of the portable computing device via a signal reception and transmission. assembly of the portable computing device. Upon receiving the particular wireless transmissions, a geographic location of the portable computing device is determined and reported to a user via the signal reception and transmission assembly.
[0030] In the method, modification of the stored data utilizing a random binary fill or encryption that is capable of decryption and data recovery if the portable device is recovered is conditioned upon receipt of one or more particular wireless transmissions by the signal reception and transmission assembly.
[0031] It is noted that the method may further comprise installing a GPS device, cellular data transceiver, Wi-Fi data transceiver, or various combinations thereof in the portable device as part of the signal reception and transmission assembly. Similar to above, it is contemplated that the particular wireless transmissions may only be transmitted by an authorized user of the portable device.
[0032] Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description, It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
[0034] FIGS. 1A-1C are exemplary schematics illustrating the elements of the invention device in various view planes that demonstrate the composition of electrical and structural elements necessary for installation into a portable computing device.
[0035] FIG. 1A is a frontal plane view of said exemplary device.
[0036] FIG. 1B is a back plane view of said exemplary device.
[0037] FIG. 1C is a side view of said exemplary device.
[0038] FIG. 2 is an exemplary process and software block flow diagram for use of the installed exemplary device of FIGS. 1A-C in the event of theft or loss of the portable computing device to which the device is covertly affixed.
[0039] FIG. 3 is a block diagram illustrating a preferred embodiment of the method and system disclosed by the present invention which respects to, purchase, registration, signal generation, tracking and control of the installed exemplary device of FIGS. 1A-1C .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] In the following description, numerous specific details are set forth in order to provide a more thorough description of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known features have not been described in detail so as not to obscure the invention.
[0041] Due to the growth of the Information Technology (IT) infrastructure and general decrease in costs and sizes of GPS device components, there has been a growing demand for GPS implementation within portable assets, such as portable computing devices. As individuals and enterprises expand the use of portable computing devices such as with laptop, tablet, and handheld computers (e.g., smartphones), there has been an increasing recognition of the vulnerability such devices have for theft or loss and the corresponding increase in economic value and corresponding loss when theft or loss occurs. For example, of the more than 10,000 laptops that go missing every month at Chicago O'Hare Airport, approximately only 22% are ever recovered.
[0042] A problem in the prior art has been an inability to configure and fabricate GPS devices that were compact enough to conveniently install on portable computing devices. A further problem is the inability to configure an embedded antennae configuration with such a compact GPS device that will reliably transmit such signals usable by a GPS tracking network for device recovery in the event of theft or loss. A still further problem has been a lack of means to configure such GPS devices for simple, rapid and covert installation into existing portable computing devices that will be both efficacious yet difficult to detect and disable by thieves. A still further problem in the prior art is the lack of an enabling system to instruct the installed GPS device in a portable computing device to instruct the computing device to transmit, alter or destroy stored data files to prevent economic loss or breach of privacy rights. A still further problem is the lack of a suitable business method and process to price, acquire and install such GPS devices, concurrent with a method to price and provide a risk management financial instrument to compensate a purchaser for potential the risk of toss and impairments occasioned by the irrecoverable or partial recovery of portable computing devices and data therein installed.
[0043] Currently, GPS is a fast-growing field. For instance, cell phones currently have the ability to have GPS on them, as do automobiles, thereby giving GPS products off-the-shelf availability. However, in the present invention, the device's solutions and implementation, and the size of the unit make it unique. In addition, the present invention includes a novel, computationally based recovery replacement program that utilizes a generated insurance service to mitigate the risks and costs associated with theft and loss of portable computing devices.
[0044] Therefore, a first object of the present invention is to disclose a novel and useful GPS device and antennae system that may be covertly and efficiently installed into a portable computing device through the memory slots on the motherboard.
[0045] A second further object of the invention is to disclose a novel means to employ specific software (referred to herein as “Silver Bullet software”) in the GPS device that may independently instruct the portable computing device to transmit, alter or destroy data files in the portable computing device to prevent loss of economic value or personal privacy through the unique coding of the Silver Bullet software application.
[0046] A third further object of the present invention is to disclose a novel computerized and enabled method to acquire and install such a GPS device and software and to provide a computer generated insurance product to compensate for accidental loss or theft of such portable computing devices.
[0047] The present invention is embedded into the portable computing device via au open card slot on the motherboard of said portable computing device, which is respectively illustrated in the diagrams of FIGS. 1A , 1 B, and 1 C. In a preferred embodiment, the device is always powered on, even when the portable computing device is not plugged in. The power drain is minimal due to the fact the device is in “sleep mode” and allows for a SMS message to be sent to the device on demand and therefore locating the portable computing device with accuracy within 5 meters.
[0048] Unlike prior art products that are required to be connected to the Internet, the present invention can be located on demand regardless of whether or not the portable computing device is plugged in or connected to the Internet. A SMS text message is sent to the device and it responds with longitude/latitude parameters of its locations. These parameters are entered into a mapping software system and locate the device and display its location on a map of the area within 5 meters of accuracy.
[0049] In contrast, prior art devices are typically embedded into the systems BIOS and can only be located from Internet “hotspots” such as Starbucks coffee, bookstores and other wired locations, etc. This means the portable computing device can only be located from an internet connection in which it is connected therefore no on demand capability exist with the prior art products and, therefore, are less accurate.
[0050] The present invention incorporates other novel features as well. For example, if desired by the owner, a transmitted message to the Silver Bullet software can be sent to and through the present invention to destroy the data contained on the hard drive rendering the portable computing device useless. The Silver Bullet software function will issue a command to the present invention that will activate a binary overwrite command that will fill the entire hard drive with 1's and 0's rendering the portable computing device useless and even unable to boot up since the operating system will also be overwritten. Prior art products do not offer or anticipate this capability.
[0051] Furthermore, in the unlikely event the portable computing device is not recovered within a definite time (e.g., 15 calendar days), the risk management process of the present invention will electronically commence an order, payment and shipment process to replace the portable computing device with a comparable product of like, kind and quality or better. Additionally the risk management process can also electronically provide compensation to the owner for the lost economic value of the data files stored on the unrecovered portable computing device.
[0052] It will be obvious to one skilled in the art that the invention may take numerous forms of device and system configurations that will accommodate a diversity of covert GPS tracking devices, portable computing devices, and electronically implemented, software-based insurance and purchase business systems. What follows is a preferred embodiment of the useful novelties of the present invention. However, for one skilled in the art it will be obvious that the novel features disclosed herein may be employed with equal utility to alternate configurations of the invention elements.
[0053] The disclosed invention is the GPS personal tracking and recovery device used inside of laptops and other types of portable computing devices. In a preferred embodiment with this type of system, a battery or power source is required. If the device is charged using its internal battery it typically has four hours of run time and three days of standby time. However, if the invention device is charged using the laptop power source in which the invention device was installed, that device can operate efficiently using inside power as long as that power is available. In some cases, people will disconnect the power and/or repackage. However, when it becomes time to re-engage power, the invention device will begin transmitting again and has been set on a protocol that allows the user to continue to transmit immediately. If somebody attempts to change the exterior of the portable computing device, the invention's embedded chip will still react.
[0054] Referring now to FIG. 1A , the exemplary invention is shown in frontal plane view. At 100 the flexible antenna for GMS transmission is displayed. At 102 , a GPS antenna is displayed. A telephone modern 104 provides for reception and transmission of software enabled data and instructions between the invention device and a remote invention user. A GPS transmitter 106 enables the invention device to transmit and obtain location signals from a GPS/GSM array. A SIMM card housing and apparatus 108 together with the modem 104 , antennae 102 , 100 and the GPS transmitter 106 are affixed and communicate with a circuit board 110 . In the present embodiment, the circuit board 100 is in signal communication with the computing element of portable computing device through a connector rail 112 , The circuit board 110 has an electric power connection with the portable computing device at 114 .
[0055] Referring now to FIG. 1B is a back plane “through view” of the exemplary invention which was previously referenced in FIG. 1A . The invention illustrated in FIG. 1B maintains the same orientation as FIG. 1A and the observer views the back plane view through the front plane orientation. The conspicuous feature of FIG. 1B is a rechargeable battery element 118 , affixed to the circuit board 110 , which communicates with external recharging power through the battery recharge port at 114 .
[0056] Referring now to FIG. 1C is an alternative side view of the invention device illustrating an alternative positioning of some of the invention device elements. More specifically, the circuit board 110 is shown housing various communication circuit elements 120 within the circuit board 110 itself. The flexible antenna 100 is mechanically affixed to the rechargeable battery 118 . The connector rail 112 and battery recharge port elements are deliberately omitted in the plane view to highlight other invention elements. However, for one skilled in the art such alternate assemblies are well understood and frequently used to minimize overall device size and/or connection compatibility to the portable computing device. Further, flexibility in the invention device element assembly lends itself to covert design in either imitation of other circuit elements or compact size. Either option is novel and useful in preventing invention device tampering or detection.
[0057] For this exemplary application, the invention tracking device will be used inside of a laptop computing device, deriving its power source directly from said computer's battery source as shown at 114 in FIGS. 1A and 1B respectively. The invention device allows the laptop owner to use either a desktop computer, a third party tracking service and/or a cellular phone for immediate tracking capability. Additionally, once the invention device registers the laptop as missing, an owner has the ability to initiate regular monitoring whereby, for example, the installed device can transmit a location, based upon plain sight, every two minutes up to every 24 hours.
[0058] This invention's tracking device is useful because of the fact that there is a high theft and low recovery rate of laptops, An additional novel benefit is that this invention device can be used in almost any type of device which utilizes an AC/DC power source to and which can be converted to the 12-volt standard typically required, The usefulness of this device is self-evident with the ability to recover misplaced or stolen products through the ability to have immediate real-time access based upon GPS satellite transmission.
[0059] FIG. 2 is a block diagram indicating an exemplary software enabled process utilizing the tracking device. Such a process starts 200 with physical installation of the device at a step 205 , referenced in FIGS. 1A-C . Concurrently at step 205 , the software components are installed in the invention device and a covert tracker device 225 such as a desktop computer, cellular phone or a telecommunications service provider system. The enabled covert tracking device system remains dormant at a step 210 until activation by a transmitted request from the owner or authorized user to an operational covert tracker device. An activation of the installed device at a step 215 results in a query at a decision step 220 on whether to activate the tracking program routine. A “no” response at decision step 220 returns the installed device to a dormant mode at step 210 . A “yes” at decision step 220 requires manual activation of the software elements to activate tracking operations at a step 225 through transmission and detection of GPS location coordinates at a step 230 . Upon activation, the owner or authorized user is queried as to whether to commence data file management via the installed tracker device at a decision step 235 . A “no” at decision step 235 returns either to the decision step 220 tracker query option or to automated tracking at step 225 that continues periodic detection and transmission of GPS location coordinates. A “yes” at decision step 235 is indicative of a threat that data on the portable computing device is at risk of unauthorized use or unacceptable loss. A “yes” at decision step 235 thus queries the owner or authorized user to encrypt or destroy portable computing device data files at a decision step 240 . If the “destroy” option is authorized, the invention initiates its Silver Bullet software routine to overwrite and destroy portable computing device data files. It will be obvious to one skilled in the art that the Silver Bullet software may also be used to uninstall or disable stored software programs, protocols or operating systems deemed proprietary and a cause of economic loss in the event of loss or imminent unauthorized use of the portable computing device. If the encrypt option is selected at decision step 240 then the owner/authorized user is queried whether to transmit such data files at a decision step 245 . If a “yes” occurs at decision step 245 then the installed tracking device uploads and sends such files to the activation location at a step 250 . If an owner successfully recovers the portable computing device at a decision step 260 , the tracking routine ends and the system is returned to its initial settings of the dormant state at step 210 . If the laptop or data are not recovered within a definite time at decision step 260 , the owner then electronically files an insurance claim at a step 265 , which makes compensation to the owner for loss. Upon replacement of the lost hardware, the user process returns to step 205 for installation and protection of the replacement device.
[0060] Referring now to FIG. 3 , a preferred embodiment of the method of the present invention is shown. A laptop computer owner 360 who will own or owns a portable laptop 330 will procure the covert GPS device 320 in connection with a purchase agreement that incorporates an insurance policy related to a future event involving theft or loss of laptop 330 . The policy will be produced using a novels series of software algorithms that utilize, without limitation, a plurality of data inputs; the cost of GPS in device 320 , the cost of installation of GPS device, the cost of monitoring service 340 , the cost of communications from monitoring service to GPS satellite array 310 , the cost of communication of the UPS satellite with covert GPS device 320 , a future time based value of information and data maintained or to be maintained on laptop 330 for which owner 360 will be compensated in the event of theft or loss of laptop. The payments is made by laptop owner 360 to insurer 350 may be a lump sum or a series of fixed or variable payments. The covert GPS device 320 will be installed by a certified contractor and will place the covert device into laptop 330 in a manner that makes it difficult to recognize the covert device as other than the normal hardware of laptop. The contractor will also connect the covert device power receptacle to the power system of laptop 330 . The contactor will enable an anti tampering feature of covert GPS device 320 to trigger an alarm or automatic transmission signal as part of the security protection features of the invention. The covert GPS device 320 will be electronically enabled using embedded software algorithms that may also be encrypted to provide security to the owner 360 and an identifier code for monitoring service 340 and GPS satellite array 310 . In the event of a theft or loss of laptop 330 , owner 360 will communicate the event to insurer 350 . Insurer 350 will communicate with service 340 to initiate a tracking algorithm to locate laptop 330 . Alternately, the owner 360 call report will be automatically forwarded to monitoring service 340 . GPS device 320 will receive an enabling transmission from GPS Satellite 310 and commence periodic GPS location emissions using power derived from laptop 330 power source.
[0061] In a further variation of the invention, the monitoring service 340 will manually or automatically transmit to the GPS satellite array 310 an authorization for covert device 320 to initiate a wireless data transmission of files stored on laptop 330 to secure files managed by the monitoring service 340 . These files will be forwarded under secure transmission or recorded on to a suitable data storage medium for physical delivery of such data files stored on laptop 330 to owner 360 . In a still further variation of the invention the instructions regarding data stored on laptop 330 may instruct the laptop to alter or eradicate such stored files.
[0062] In summary and without limitation, the invention is comprised of the following elements:
[0063] A first element consisting of fabricating an installed covert tracking device further comprised of circuit, electronic and power elements as shown in FIGS. 1A , 1 B, and 1 C that is compatible with the portable computing device into which it is installed;
[0064] A second element where said covert tracking device is acquired in conjunction with a software generated insurance policy and tracking system to mitigate the risk of loss of a portable computing device into which said covert tracking device is installed;
[0065] A third element of installing the covert tracking device covertly inside the portable computing device and further attaching it to the power source and/or battery of said portable computing device where said tracking device itself does not rely on any functions from the portable computing device and is stand-alone other than the power source;
[0066] A fourth element where, once the tracking device is installed in the portable computing device, and in the event for whatever reason the portable computing device is misplaced and or stolen, an owner of the lost portable computing device will have the ability to telecommunicate to activate a recovery protocol utilizing the tracking features of the covert tracking device;
[0067] A fifth element where recovery of all portable computing devices using this tracking device invention is based upon real-time GPS locations and, in the event recovery is not immediate, the tracking device itself receives a communication that allows the tracking device to power on and regularly source and transmit GPS location data until actual recovery or determination of an unrecoverable loss of said portable computing device.
[0068] A sixth element where a portable computing device being misplaced or stolen, a certain minimum time must lapse (e.g., 5 days) before it is deemed unrecoverable. If the portable computing device is not recovered within the lapsed period, a risk management underwriter will be obligated, through said insurance policy, to replace the unrecovered portable computing device together with a compensable sum for the economic loss of proprietary data files.
[0069] It will be obvious to one skilled in the art that this invention device, method and process apply to numerous other types of portable computing devices. The immediate invention opportunity appears to be with laptops, as there is apparently a unique and unmet need to mitigate sensitive and valuable data storage and restriction issues in the event of loss or theft of the portable computing device.
[0070] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. In addition, the various features, elements, and embodiments described herein may be claimed or combined in any combination or arrangement. | A device and software utilizing Global Positioning Satellite (GPS) technologies for monitoring and recovering portable computing devices and, a method and system for acquiring such devices, protecting data on such devices, and for compensating owners of devices. A GPS mechanism of the invention provides real time tracking of missing devices that may be coordinated with security agencies to intercept and recover missing computing devices. When a stolen device is unrecoverable, the invention may receive a signal to initiate data recovery where a wireless network is available to recover data for the owner. Alternatively, the GPS mechanism instructs the device to encrypt or destroy stored data files to prevent commercial espionage or privacy violations. The invention discloses a software system and method for computing a purchase price of the GPS mechanism, computing compensation for loss of the device and lost data. | 6 |
[0001] CROSS REFERENCE TO RELATED PATENT APPLICATIONS
[0002] This patent application claims priority from U.S. Provisional Patent Application Ser. No. 61/771,826, filed on Mar. 2, 2013, titled: “PERSONAL COMPUTER WITH STORAGE COMPARTMENT”, the disclosure of which is hereby incorporated by reference for all purposes.
BACKGROUND
[0003] Personal computer systems (“PCs”) are widely known and used in homes, places of work, data centers, etc. A sample PC in the prior art is now described,
[0004] Referring to FIG. 1 , components of a conventional personal computer system are described. The components include a housing 110 , which contains at least a processor 120 , such as a microprocessor. A memory 122 is also typically provided in housing 110 . Memory 122 may store programs for execution by processor 120 . A reboot switch 130 is typically also provided on housing 110 , which may be used to restart processor 120 manually.
[0005] Moreover, a port 140 may be coupled to housing 110 . Port 140 may be intended for use during the regular operation of the PC. Port 140 may be a USB port, a CD ROM drive, a DVD drive, a plug for plugging in an accessory for the personal computer system, a cable port, and so on. Port 140 may receive an other device 142 according to an arrow 144 . When other device 142 is so received, port 140 enables other device 142 to exchange data with processor 120 via port 140 . Other device 142 may be a thumb drive, a CD ROM with a software product, a DVD with a product, a cable, etc. PCs are typically additionally provided with more ports, a screen, a keyboard, speakers, a power cord, etc.
[0006] PCs are further provided with a number of additional associated objects, such as object 150 . Object 150 is associated with other components of the PC, as indicated by arrow 151 . Object 150 might be of the type that is used rarely, such as an instruction manual, a warranty card, one or more memory devices that store software products that are stored in memory 122 , cards showing product key codes, and so on. Object 150 may be provided by the manufacturer, or be purchased later. And, in some embodiments, object 150 may operate as other device 142 .
[0007] A problem is that, after installation of the PC, associated objects such as object 150 often become stored elsewhere, and then forgotten about. If, however, years later, the owner is to make a service call, these objects become necessary. Those responding to the service call may first ask for these objects and for the product code numbers they indicate, so as to prove ownership of the software products in the PC. They may also need the memory device to reinstall its software product.
BRIEF SUMMARY
[0008] The present description gives instances of personal computer systems and methods, the use of which may help overcome problems and limitations of the prior art.
[0009] In one embodiment, a personal computer system (“PC”) is provided with a housing that includes a storage compartment. One or more objects associated with the PC can be stored in the storage compartment, such as a user manual, a warranty card, a memory device that stores a software package downloaded to the PC, a card or other object showing a software product key code, and so on.
[0010] An advantage over the prior art is that such objects are more reliably retrieved, when time comes for a service call about the PC, or receiving a discount for an upgrade. This may be helpful for users of PCs, for Information Technology (IT) departments that manage PCs for other users, for data centers, and so on.
[0011] These and other features and advantages of this description will become more readily apparent from the following Detailed Description, which proceeds with reference to the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a diagram of components of a conventional personal computer system.
[0013] FIG. 2 is a diagram of components of a personal computer system made according to embodiments of the invention.
[0014] FIG. 3 is a diagram of components of a personal computer system, according to embodiments in which the main storage compartment is provided at the top of the housing, and with an optional door.
[0015] FIG. 4 is a diagram of components of a personal computer system, according to embodiments in which the compartment is provided at a side wall of the housing, and with an optional door.
[0016] FIGS. 5A and 5B are diagrams of components of a personal computer system according to embodiments, showing respectively the compartment door open and closed.
[0017] FIG. 6 is a flowchart for illustrating methods according to embodiments.
DETAILED DESCRIPTION
[0018] As has been mentioned, the present description is about personal computer systems. Embodiments are now described in more detail.
[0019] FIG. 2 is a diagram of components of a personal computer system (PC) 200 , which is made according to embodiments of the invention. PC 200 includes a housing 210 , which contains at least a processor 220 , such as a microprocessor. A memory 222 is also typically provided in housing 210 . Memory 222 may store programs for execution by processor 220 . A reboot switch 230 is typically also provided on housing 210 , which may be used to restart processor 220 manually. Reboot switch 230 can also be a power-on switch.
[0020] Moreover, a port 240 may be coupled to housing 210 . Port 240 may be intended for use during the regular operation of the PC. Port 240 may be a USS port, a CD ROM drive, a DVD drive, a plug for plugging in an accessory for the PC, a cable port, and so on. Port 240 may receive a first device 242 according to arrow 244 . When first device 242 is so received, port 240 enables first device 242 to exchange data with processor 220 via port 240 . Other device 242 may be a thumb drive, a CD ROM with a software product, a DVD with a product, a cable, etc. PC 200 may be further provided with more ports, a screen, a keyboard, speakers, a power cord, etc.
[0021] PC 200 is further provided with at least one associated object 250 . Object 250 may be provided by the manufacturer, or be purchased later. And, in some embodiments, object 250 could be first device 242 . Object 250 might be of the type that is used rarely, such as an instruction manual for the use of PC 200 , a warranty card, one or more memory devices that store software products that are stored in memory 222 , cards showing product key codes, and so on. In case object 250 is associated with software, the software could be the operating system that PC 200 is sold with or other software that is added on at purchasing time, or later. If object 250 is an instruction manual, then it could be a booklet or folded paper. If object 250 is a warranty card, then it could be a postcard. Object 250 is shown in the general shape of a pentagon, to indicate that it could have the shape of any one of these embodiments.
[0022] In some embodiments, a software product is stored in memory 222 , and object 250 is associated with the software product, such as an operating system, an application, and so on. For example, object 250 can have printed on it a key code for downloading the software product to the personal computer system, or enabling it to be run indefinitely. Object 250 can be a CD-ROM, a DVD, a box for a CD-ROM or a DVD, a postcard, and so on. In some embodiments, object 250 may operate as first device 242 .
[0023] Housing 210 also includes an opening 277 . More particularly, in the example of FIG. 2 , housing 210 generally defines a plane at that location, and opening 277 is an opening at that location, and within that plane. A different example will be described later.
[0024] Moreover, housing 210 includes a main storage compartment 270 . Compartment 270 may be accessible from outside housing 210 via opening 277 . Compartment 270 may be used for storing object 250 removably, which means that object 250 may be stored in compartment 270 , and then removed from there. As such, object 250 can be retained in compartment 270 , together with PC 200 , for the long term, until it is needed for a service call.
[0025] In some embodiments, object 250 is stored within main storage compartment 270 . For example, that is where a user or IT department may store object 250 . In other embodiments, object 270 may be shipped to a reseller or a customer in a box along with housing 210 , but not within compartment 270 . It could be up to the user to store object 250 in compartment 270 .
[0026] In FIG. 3 , main storage compartment 270 is of a generic shape, to indicate that main storage compartment 270 could have any shape. In preferred embodiments, care is taken to give main storage compartment 270 a shape that is suitable for receiving and storing object 250 . As such, the shape of compartment 270 may be determined by the shape of object 250 , which is often substantially flat. Another consideration is for main storage compartment 270 to have a shape that does not interfere with other components inside housing 210 , or with the airflow of a fan that could be cooling processor 220 .
[0027] In some embodiments, object 250 measures at least 2″ (5 cm) in a width dimension, by at least 2′ (5 cm) in a height dimension, by at least 0.04″ (0.1 cm) in a depth dimension. In addition, main storage compartment 270 may be shaped and large enough so that object 250 can be stored therein without being bent, and without protruding through opening 277 .
[0028] Another consideration is to decide on which wall of housing 210 to place opening 277 . It should be considered that object 250 is typically thin and flat and, as such, a large surface may be sought in which to create opening 277 . In some embodiments, the housing includes a wall that stands vertically when the PC is operated, and the opening is at the wall. This is suitable for embodiments such as that of FIG. 2 , where housing 210 is in the upright “tower” configuration, and the vertical walls are large. That need not be always the case, however. Another example is now described.
[0029] FIG. 3 is a diagram of components of a personal computer system 300 , which is made according to embodiments. PC 300 includes a housing 310 , which contains at least a processor 320 similar to processor 220 . A memory 322 is provided in housing 310 , and a reboot switch 330 is provided on housing 310 , similar to reboot switch 230 . A port 340 , similar to port 240 , may be coupled to housing 310 , In addition, PC 300 is provided with at least one object 350 similar to object 250 .
[0030] Moreover, housing 310 includes a main storage compartment 370 . Compartment 370 may be accessible from outside housing 310 via opening 377 . Compartment 370 may be used for storing object 350 removably, in the example of FIG. 3 , object 350 is shown stored in main storage compartment 370 .
[0031] In the example of FIG. 3 , main storage compartment 370 is at the top of housing 310 . Housing 310 includes an opening 377 , which is also an opening of compartment 370 . Unlike the example of FIG. 2 , however, opening 377 is not an opening within a larger plane of housing 310 .
[0032] Optionally, in a PC made according to embodiments, the housing further includes a door for the main storage compartment. In the example of FIG. 3 , housing 310 includes a door 378 that opens upwards. Door 378 is implemented so that it can be opened to substantially permit access to main storage compartment 370 via opening 377 , and closed to substantially limit access to main storage compartment 370 via opening 377 . When closed, access may be limited completely, or only partially. If partially, for example, the door may leave a slit through which materials can be inserted in compartment 370 , but not easily removed without opening door 378 . Door 378 may have further a handle for being opened and closed.
[0033] In this example, door 378 is supported on a hinge, and opens and closes by rotating around the hinge. Other embodiments can also be implemented. For example, the door could open and dose by sliding. The door can be made from any suitable material, such as the material used for housing 310 . Alternately the door could be transparent, from plastic, and so on. Making the door able to slide may present concerns as to its structural integrity, but it maybe preferred if not enough space is expected to be provided between PCs, for opening a door by swinging it on a hinge.
[0034] FIG. 4 is a diagram of components of a personal computer system 400 , which is made according to embodiments. PC 400 includes a housing 410 , which contains at least a processor 420 similar to processor 220 . A memory 422 is provided in housing 420 , and a reboot switch 430 is provided on housing 410 , similar to reboot switch 230 . A port 440 , similar to port 240 , may be coupled to housing 410 . In addition PC 400 is provided with at least one object 450 similar to object 250 .
[0035] Moreover, housing 410 includes a main storage compartment 470 . Compartment 470 may be accessible from outside housing 410 via opening 477 .
[0036] Compartment 470 may be used for storing object 450 removably. In the example of FIG. 4 object 450 is shown stored in main storage compartment 470 .
[0037] In the example of FIG. 4 , storage compartment 470 is at a vertical side wall of housing 410 . An opening 477 is an opening of housing 410 , and also of compartment 470 . Moreover, a door 478 is optionally provided which, in this example, opens upwards. Door 478 may have further a handle for being opened and closed.
[0038] Furthermore, in the embodiment of FIG. 4 , door 478 include a latch 479 , for remaining closed. Since a latch can be opened by anyone, embodiments with a latch are useful in environments where trust is high, such as within a home or a data center and, worrying about a key is more of a problem and a liability than a benefit.
[0039] FIGS. 5A and 5B are diagrams of components of a personal computer system 500 , which is made according to embodiments. PC 500 includes a housing 510 , which contains at least a processor and a memory (not shown). A reboot switch 530 is provided on housing 510 , similar to reboot switch 230 . A port 540 , similar to port 240 , may be coupled to housing 510 .
[0040] Referring particularly to FIG. 5A , a door 578 is open which permits access to main storage compartment 570 . PC 500 is provided with a DVD 550 , which stores software that is also stored on the processor of PC 500 . As such, DVD 550 could be an embodiment of objects 250 , 350 , 450 described above. DVD 550 is stored in compartment 570 . Additionally, door 578 optionally includes a lock 581 .
[0041] Referring to FIG. 5B , door 578 is closed, which limits access to compartment 570 . In the example of FIGS. 5A and 5B , lock 581 can be unlocked by a key 582 , which is visible only in FIG. 5B . Key 582 may be retained by the user, or by a company's IT department. When key 582 is provided, it may avoid the need for door 578 to have a handle.
[0042] It will be observed that key 562 protrudes from the basic plane of housing 510 . In some embodiments, the housing includes an auxiliary storage compartment that is distinct from the main storage compartment. The auxiliary storage compartment is accessible from outside the housing, and the key can be stored in the auxiliary storage compartment. This way, the key will not protrude. Again, in environments with trust is high, the key might never be used.
[0043] Keys according to embodiments need not be physical keys like key 582 . For example, a PC typically receives electrical power from a power outlet at the housing, for its operational needs. In some embodiments, the housing includes a keypad that is powered by the received electrical power. In such embodiments, the lock can be unlocked by dialing a code in the keypad.
[0044] FIG. 6 shows a flowchart 600 for describing methods according to embodiments. The methods of flowchart 600 may also be practiced by using embodiments described above. For example what can be used is a personal computer system that includes a housing that has an opening and a main storage compartment that is accessible from outside the housing via the opening, and a memory within the housing. A number of operations of flowchart 600 were already described above.
[0045] According to an operation 610 , an object can be procured, which is associated with a software product.
[0046] According to another operation 620 , the object can be used to install the software product in the memory. For example, the personal computer system could further include a port, the object could include a memory device on which the software product is stored, and the software could be installed by inserting the memory device in the port. For another example, the object could have a product key code written thereon, and the software product could be installed by accessing a communications network via an interface, and entering the product key code in the interface. The communications network could include the internet.
[0047] According to one more operation 630 , the object can be stored in the main storage compartment.
[0048] According to an optional operation 640 , in embodiments where the housing also includes a door, the door is closed while the object is stored in the main storage compartment. Closing the door substantially limits access to the main storage compartment. In some embodiments, the door includes a latch and, once closed, the door is maintained closed due to the latch. Later, the door may be reopened, and the object may be removed from the main storage compartment.
[0049] According to an optional operation 650 occurring after operation 640 , the door is locked after being closed. The door may later be unlocked. If locking is performed by a key, the housing could also include an auxiliary storage compartment, and the key could be stored in the auxiliary storage compartment.
[0050] According to an optional next operation 660 , the personal computer system is then shipped to a reseller or to a customer.
[0051] In the above, the order of operations is not constrained to what is shown, and different orders may be possible according to different embodiments. In addition, in certain embodiments, new operations may be added, or individual operations may be modified or deleted.
[0052] This description includes one or more examples, but that does not limit how the invention may be practiced. Indeed, examples or embodiments of the invention may be practiced according to what is described, or yet differently, and also in conjunction with other present or future technologies.
[0053] A person skilled in the art will be able to practice the present invention in view of this description, which is to be taken as a whole. Details have been included to provide a thorough understanding. In other instances, well-known aspects have not been described, in order to not obscure unnecessarily the present invention.
[0054] Other embodiments include combinations and sub-combinations of features described herein, including for example, embodiments that are equivalent to: providing or applying a feature in a different order than in a described embodiment, extracting an individual feature from one embodiment and inserting such feature into another embodiment; removing one or more features from an embodiment; or both removing a feature from an embodiment and adding a feature extracted from another embodiment, while providing the advantages of the features incorporated in such combinations and sub-combinations.
[0055] The following claims define certain combinations and subcombinations of elements, features and steps or operations, which are regarded as novel and non-obvious. Additional claims for other such combinations and subcombinations may be presented in this or a related document. | A personal computer system (“PC”) is provided with a housing that includes a storage compartment. One or more objects associated with the PC can be stored in the storage compartment, such as a user manual, a warranty card, a memory device that stores as software package downloaded to the a card or other object showing a software product key code, and so on, Such objects are more reliably retrieved, when time comes for a service call about the PC, or receiving a discount for an upgrade. This may be helpful for users of PCs, for Information Technology (IT) departments that manage PCs for other users, for data centers, and so on. | 6 |
Device, such as a carding machine, for processing fibres The present invention relates to a carding machine comprising a cylinder provided with a lining, and at least two carding segments which are arranged one after the other in the direction of rotation at least over an area of the circumference of said cylinder and which are each provided with a toothed lining, toothed linings of said carding segments being designed differently.
BACKGROUND OF THE INVENTION
Such a carding machine is known e.g. from German-Offenlegungsschrift 2 226 914. The carding segments described there have different tooth densities per unit area.
Such devices serve to clean, open and parallelize raw fibres, e.g. cotton. The starting material (in the form of flocks) is supplied via an opening cylinder unit to a cylinder (e.g. a main cylinder) provided with a lining, and entrained by the circumference of said cylinder in the direction of rotation. For this purpose, the cylinder is provided with a large number of sawteeth. Normally, this toothed lining is formed by producing a sawtooth wire which is then wound onto the outer circumference of the cylinder. The tooth shapes can be designed differently for a great variety of different applications. The tips of the teeth, however, point mainly in the direction of rotation.
Carding segments are arranged at least over part of the circumference of the cylinder so that the fibres are not only entrained by the cylinder provided with a lining but also subjected to processing. Normally, a carding segment will extend over the whole width of the cylinder. The lower surface of a carding segment has an arcuate shape, whereby it is adapted to the outer circumference of the cylinder provided with a lining, and it is also equipped with a toothed lining. In many cases, the teeth are arranged in rows of teeth one behind the other and are also produced by insertion of a sawtooth wire. The tooth shape is similar to the shape of the teeth on the cylinder provided with a lining, the tips of the teeth pointing in a direction opposite to the direction of rotation of the cylinder provided with a lining. The carding segments are moved so close to the cylinder that the fibres are subjected to an opening, combing and parallelization process.
Between the carding segments, cleaning stations can be arranged, which are provided with suction means for removing dirt particles and fibre fragments. This means that the carding segments may also be arranged at a certain distance from one another. This kind of device for treating fibre material has already been known for a long time and has proved very successful. It goes without saying that, nevertheless, efforts are being made to improve these devices. In particular, attempts are made to improve the efficiency of fibre parallelization. Moreover, different fibres sometimes necessitate different processing methods.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a fibre-processing device, such as a carding machine, of the type mentioned at the start, which executes more effective fibre parallelization.
According to the present invention, this object is achieved in that the teeth of the toothed linings are provided with a rake angle which, on average at least, is larger in an upstream carding segment than in a downstream carding segment so that, when the fibres are engaged by the toothed lining of the carding segment constituting the upstream carding segment in the direction of rotation, the resultant influence on an individual fibre entrained by the circumference of the cylinder will exceed the influence exerted when the fibres are engaged by the toothed lining of a carding segment constituting a downstream carding segment in the direction of rotation.
This has the effect that, in the direction of rotation of the cylinder, the engagement of the toothed linings of the carding segments with the fibres will change from more intensive at the beginning towards a kind of engagement in which careful processing of the fibres is effected. Influence or mechanical influence on an individual fibre entrained by the circumference of the cylinders means here the intensity or aggressiveness with which the respective toothed lining comes into contact with a fibre moved past the carding segments. The fibres which are supplied in the form of flocks at the beginning of the carding operation and which have not yet been opened are immediately subjected to intensive processing by the geometry of the first toothed lining, whereupon, in dependence upon the degree of opening of the fibres, the toothed linings can be adapted to said degree of opening so that the desired effect will be achieved. Surprisingly enough, the opposite course of action has always been taken in the prior art up to now. At the beginning of the carding operation, the still closed fibres were, as far as possible, subjected to processing which was less intensive than that of the fibres which had already been opened to an increasing extent. Presumably, efforts were made to subject the fibres to more intensive processing precisely at the point where they had already been opened to an increasing extent.
The decisive aspect of the present invention is that the toothed linings of the carding segments cause different processing effects from intensive to less intensive without any necessity of influencing other parameters. Due to the dependence on simple geometric connections, optimum carding segments can be provided for a great variety of different kinds of fibres in a very uncomplicated and inexpensive manner. Hence, a plurality of completely different tooth shapes can be used on one and the same device, i.e. carding machine. It turned out that, on the basis of this structural design, the fibres can be processed very effectively at comparatively high speeds and with a very good result. The present invention particularly aims at reducing the tendency of the toothed lining towards drawing fibres away from the cylinder, due to the tooth geometry, so that optimum transport of the fibres in the processing gap between the carding segment and the cylinder is effected. A sign indicating that a toothed lining is optimally adapted to the degree of opening of the fibres is a uniform wear of the processing height of the teeth.
A very simple variant for further developing the present invention is implemented such that the teeth of the toothed linings are provided with a rake angle α which, on average at least, is larger in an upstream carding segment than in a downstream carding segment. Depending on the respective structural design, the toothed linings are often provided with hundreds of teeth. In most cases an individual comparison between a tooth of a toothed lining of a carding segment and a tooth of a toothed lining of a subsequent carding segment would suffice, but, as far as the effect produced is concerned, it will be fully sufficient when the upstream carding segment effects, on average, a more aggressive engagement than the respective downstream carding segment. Insofar, an average rake angle α is taken as a reference value. When the tooth of the toothed lining is considered to be a part where the angles are described by the normal designations used in the case of a wedge shape, the rake angle α is defined between the cutting face, i.e. here the fibre processing face of the tooth and an imaginary line extending from the tip of the tooth to the centre of the cylinder. This means that the front carding segments act on the fibres with a more acute angle, whereas in the case of the downstream carding segments the processing faces of the teeth become increasingly steeper relative to the fibre.
Due to the change of the rake angle α, the toothed lining of the first carding segment plucks, pulls or tugs more strongly at the fibres than the downstream carding segments. The angle α, which becomes smaller and smaller, then has the effect that the fibres will no longer enter the toothed area of the toothed lining with the same intensity, i.e. depth. On the contrary, the tooth shape, which becomes increasingly obtuse, has the effect that the fibres will show a reduced tendency towards entering the processing area of the toothed lining of the carding segments. Experiments have shown that this will also result in a better distribution of the fibres over the entire height of the processing area of the teeth; this finds especially expression in the wear characteristics. The teeth wear substantially uniformly over the whole height of the processing zone. Neither the tip nor the root area of the processing zone are subjected to increased wear.
Another possibility of influencing the desired carding effect via the shape of the teeth is that the teeth of the toothed linings comprise an area, which is defined between the outer cutting area contour line comprising the cutting face and an imaginary connecting line intersecting the cylinder axis and the tip of the tooth at right angles and which, on average at least, is larger in an upstream carding segment than in a downstream carding segment. This means that the area below the processing face of the tooth is larger at the beginning of the carding process than in a later stage of said process so that the amount of fibres which is able to enter the processing area of the toothed lining of the carding segments will presumably be larger in the upstream carding segments than in the downstream carding segments. Assuming that all the tips of the teeth of the carding segments are spaced equally from the lining of the cylinder, the fibres will—due to the geometry of the tooth shapes of the carding segments—be forced more and more in the direction of the cylinder as the degree of opening increases. The fibres are thus, on average, transported optimally in the carding gap between the respective carding segment and the cylinder. Due to this geometrical adaptation, the influence exerted on the fibres by the teeth of the carding segment will normally be less intensive in downstream areas.
Another design measure is to be seen in that the teeth of the toothed linings have a cutting area and a root area and that the width of the root area is larger in an upstream carding segment than in a downstream carding segment. This variant can, on the one hand, be used for arranging the teeth of the various carding segments behind one another and displaced relative to one another. On the other hand, it is also possible to provide the downstream carding segment with much closer spaced teeth. These teeth can then have an appropriately smaller size so as to effect a less aggressive engagement.
Another measure for realizing the present invention can be so conceived that a tooth spacing of the teeth of the toothed linings is larger in an upstream carding segment than in a downstream carding segment. The term tooth spacing means in the present case the distance from one tip of a tooth to the next tip of a tooth in the carding direction. This means that in downstream carding segments, the teeth are arranged closer to one another.
In addition, the teeth of the toothed linings can have a height which, on average at least, is higher in an upstream carding segment than in a downstream carding segment. Also in this case, it is essentially the average height of the teeth of a toothed lining that is of importance. The lower height in the downstream carding segments automatically guarantees a less aggressive engagement, when e.g. the carding segments are adjusted such that they are located on the same level relative to the cylinder.
It is, however, also possible to maintain the overall height of the teeth in the case of all carding segments and to implement one variant such that the cutting areas of the teeth of the toothed linings have a height which, on average at least, is higher in an upstream carding segment than in a downstream carding segment. The engagement of the individual teeth will then be less intensive not because of the overall height of the teeth, but because of the lower height of the cutting areas. Hence, the tips of the teeth can be arranged at the same distance from the cylinder in all carding segments and still produce this positive effect,
Another improvement of fibre parallelization and processing can be achieved in that the teeth of the toothed lining of an upstream carding segment, or rows of said teeth extending in the direction of rotation, are laterally displaced relative to the teeth of the toothed lining of the downstream carding segment, or relative to rows of said teeth extending in the direction of rotation. The teeth of a single carding segment can be arranged one after the other in a row when seen in the carding direction or direction of rotation of the cylinder. The teeth of the following carding segment should, however, be positioned such that they are displaced relative to said row so that the fibres can be processed over the whole width independently of the paths predetermined by the respective carding segments.
When the width of a tooth of the toothed lining of an upstream carding segment is divided by the width of a tooth of the toothed lining of the respective downstream carding segment the result can preferably be unequal to an integer. This will automatically guarantee that it is impossible to arrange the teeth of an upstream carding segment and a downstream carding segment such that they are disposed one behind the other. Due to the uneven division they will inevitably always be displaced relative to one another.
Another embodiment is designed in such a way that the teeth of a carding segment, which are arranged one after the other in the direction of rotation, are arranged such that they are displaced relative to one another. It is thus possible to achieve also within a single carding segment the best possible large-area processing over the whole width of the cylinder with a correspondingly enhanced parallelization effect.
In addition, dirt separation means can be arranged between at least some of said carding segments. These dirt separation means can be designed e.g. in accordance with DE 19852562. Normally, these means consist of a vertically adjustable guide strip and a subsequent separation blade which acts on the fibre at a specific angle and which removes dirt particles due to the impact effect.
According to a advantageous embodiment, suction means or a suction device are additionally provided, said suction means removing fibre fragments and dirt particles from the carding area. The prior art discloses a sufficient number of design possibilities for this kind of means.
A preferred embodiment of the present invention is implemented in such a way that in the toothed linings of the carding segments of the cover the distance between the shoulder and the tips of the teeth is smaller than the distance between the shoulder and the associated tips of the toothed lining of the main cylinder. Due to the resultant smaller passage height in the cover linings, the fibres are caused to return more rapidly from the covers to the main cylinder. At first glance this does not seem to make sense, since the more aggressive tooth engagement in the case of the first carding segments has, apparently, precisely the opposite effect, viz. that, when the fibre flocks reach the carding element, they are drawn away from the carding zone of the main cylinder into the cover and that the individual fibres are removed from the cover one after the other and parallelized. Due to the lower passage height in the cover linings this effect is maintained, but the covers are not filled with an excessive amount of fibres. This has, in total, the consequence that the dwell time of the fibres in the cover linings will be reduced, whereby the output per hour of the carding machine will, of course, be increased.
The present invention additionally relates to a carding segment for a device, such as a carding machine, for processing fibres, said carding segment being provided with a toothed lining. The carding segment is characterized by the features that the tooth geometry of the toothed lining varies in the processing direction, and that, when the fibres are engaged by an area of the toothed lining constituting an upstream area in the processing direction, the resultant influence on an individual fibre to be processed will be equal to or more intensive than the influence exerted when the fibres are engaged by an area of the toothed lining constituting a downstream area in the processing direction. By means of such a carding segment, the desired effect can also be achieved within the processing area of the carding segment itself. In this respect, it would especially be imaginable to use comparatively large carding segments which could produce the desired effect as a whole. The tooth geometry within this carding segment can change in a way corresponding to the preceding changes which take place from one carding segment to the next. Changes of the angle, the height, etc. within a single carding segment are therefore possible.
Furthermore, the present invention also relates to a method of opening, combing and parallelizing fibres by means of a cylinder provided with a lining and by means of at least two carding segments which are arranged one after the other in the direction of rotation at least over an area of the circumference of said cylinder, each of said carding segments being provided with a toothed lining. The method is characterized in that, as the degree of opening of the fibres increases, the tooth geometry of the toothed linings of the carding segments varies in dependence upon said degree of opening of the fibres so that the fibres will be in engagement with the teeth of the toothed linings of the carding segments in a substantially uniform manner over the entire height of the processing areas of said teeth. In contrast to the carding methods that have been used up to now, the method according to the present invention effects the change of the tooth geometry of the toothed linings of the carding segments as a function in dependence upon the degree of opening of the fibres and in dependence upon the wear occurring at the toothed linings. This will in particular also have the effect that the fibres are optimally conveyed and processed in the processing gap between the carding segments and the cylinder. Experiments have shown that very good results can be achieved in this way and that the wear characteristics can be improved. The question why the opposite course of action has always been adopted in the prior art up to now and why the fibres have been processed such that the influence thereon and the processing aggressiveness increased as the degree of opening increased, can, retrospectively, only be answered by assuming that a misinterpretation existed quite obviously.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, embodiments of the present invention will be explained in detail making reference to a drawing, in which
FIG. 1 shows, in a schematic side view, a carding device provided with a plurality of carding segments which are arranged one after the other,
FIG. 2 shows a detail from a toothed lining of a carding segment in an enlarged side view,
FIG. 3 shows a view of a tooth of the lining according to FIG. 2 cut along the line III—III in FIG. 2 ,
FIG. 4 shows a detail from a toothed lining of a carding segment in an enlarged side view for explaining the relationship between respective areas,
FIG. 5 shows the lower surfaces of two successively arranged carding segments, only part of the toothed lining being shown schematically,
FIG. 6 shows a schematic representation for illustrating the displacement between the teeth of an upstream carding segment and those of a downstream carding segment,
FIG. 7 shows a schematic representation of the lower surface of a carding segment having rows of teeth which extend at an oblique angle,
FIG. 8 shows a schematic representation of the toothed lining of an individual carding segment, said toothed lining changing in the direction of processing, and
FIG. 9 shows, in a schematic representation, a sectional view through a sawtooth wire of the main cylinder lining with a saw tooth wire of a cover lining arranged above said main cylinder lining.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a schematic representation of a carding device 1 in a plane perpendicular to an axis of rotation A of a carding cylinder or main cylinder 2 . The circumferential surface 3 of the main cylinder 2 is provided with a lining 4 for processing fibre material. The lining 4 consists of a wound-on toothed wire, the individual tips of said teeth pointing in the direction of rotation and carding direction B. The structural design of such linings 4 is known very well in the prior art and will not be described in detail in the present connection. From arrow B it can be seen that the main cylinder 2 rotates clockwise. On the left hand side, an opening cylinder 5 is schematically shown, said opening cylinder 5 supplying the fibres to the main cylinder 2 . Also for this purpose, known opening cylinder devices can be used. The prior art discloses a sufficient number of examples. On the opposite side, a doffer cylinder 6 is provided; this doffer cylinder 6 schematically represents the doffer device which removes the carded fibres from the main cylinder 2 and carries them off for further processing. Also as far as these doffer devices 6 are concerned, the prior art discloses a sufficient number of examples which need not be discussed in detail.
On the outer circumference, at least in the upper area thereof (in the portion between the opening cylinder 5 and the doffer cylinder 6 ), a plurality of fixed carding segments 7 to 10 is provided, the carding segments being arranged one after the other. Each of these carding segments 7 to 10 is arranged at a certain distance above the circumferential surface 3 of the main cylinder 2 . In addition, the segments are also adapted to the contour of the main cylinder 2 and have therefore an arcuate shape, the lower surfaces of said segments being arranged always at the same distance from said circumferential surface 3 as far as possible. These carding segments 7 to 10 are provided with toothed linings 12 to 15 on the lower surfaces 11 thereof. Similar to the lining 4 of the main cylinder 2 , these toothed linings consist of juxtaposed toothed wire sections. The fundamental structural design and arrangement of such linings on carding elements is also known in the prior art.
The device according to FIG. 1 is essentially new and inventive insofar as the toothed linings 12 to 15 process the fibres with decreasing aggressiveness in the sequence mentioned here. In the present case, this means that four different steps of aggressiveness exist. It would, of course, also be possible that two successively arranged carding segments process the fibres with the same aggressiveness and that the subsequent carding segments are then, in turn, less aggressive. Moreover, only the carding segments 7 to 10 are shown in this variant in order to make things easier. Normally, it would be possible to arrange also other processing devices on the circumference of the main cylinder 2 . In particular when the opening cylinder 5 and the doffer cylinder 6 are arranged further down on the circumference of the main cylinder 2 , a larger operating area will be available, which permits further carding segments or other processing devices to be arranged in addition.
Every carding segment 7 to 10 can be regarded as a kind of cover piece, which is arranged such that it hovers over the main cylinder 2 at a small distance therefrom and which, in contrast to the main cylinder 2 , stands still. It follows that a processing gap 16 for carding the fibres, which are not shown, exists between the toothed lining 4 of the main cylinder 2 and the toothed linings 12 to 15 of the carding segments 7 to 10 .
Each of the respective carding segments 7 to 10 have provided between them a separation channel 17 for removing dirt and fibre fragments. At the end of the respective carding segments 7 , 8 and 9 an L-shaped, striplike hold-down device 18 is provided by means of which the fibres emerging from the processing gap 16 are slightly pressed down so that, subsequently, they will expand outwards in an explosion like movement and come into contact with a separation blade 19 . The separation blade 19 may occupy a great variety of angular positions so that the separation can be executed with different cutting angles. The height of the separation blade 19 above the toothed lining of the main cylinder 2 can be adjusted as well, and it is also possible to adjust the height of the hold-down device 18 in accordance with the main cylinder 2 for varying the distance. The dirt particles and the fibre fragments are then discharged through the gap between the hold-down device 18 and the separation blade 19 . A separate suction device can be arranged above each separation channel 17 . It is, however, definitely also possible to arrange a suction hood over the whole unit. The prior art discloses, also in this respect, various design possibilities which can be used for these purposes.
In the following, the geometry of the teeth of the carding segments 7 to 10 will now be explained in detail making reference to FIGS. 2 and 3 .
FIG. 2 shows an enlarged representation of a small detail of the toothed lining of the carding segment 7 . The toothed lining 12 has been turned upside down for this purpose. For the sake of simplicity, only one row of teeth is shown. The individual teeth 20 of the toothed lining 12 are produced from a common steel wire, at least as long as said teeth are arranged in one row. In the prior art, a great variety of such carding teeth as well as a great variety of production methods are known. All of them should be applicable in the present case. In FIG. 2 , teeth 20 in the form of a sawtooth profile are shown. For the sake of simplicity, the designations of angles and the angular relationships, which are normally used in the case of cutting tools, will also be used in the present context for describing the toothed lining 12 .
Accordingly, each tooth 20 has a wedge angle β and a rake angle α. The rake angle α is defined between a tangent on the cutting or processing face 21 and a line 22 whose course is defined by the shortest connection between the tip 23 of the tooth and the axis A of the main cylinder 2 . These are, of course, the conditions existing when the carding segment 7 has been installed. The wedge angle β is normally smaller than 45° so that the resultant teeth 20 are comparatively pointed. The distance t between a tip 23 of a tooth to the next tip 23 of another tooth of a row of teeth is referred to as tooth spacing in the present case. In most cases, hundreds of said teeth 20 are attached to the lower surface 11 of a carding element 7 to 10 .
FIG. 3 shows a section along line III—III in FIG. 2 through a toothed wire 24 . In the present case, the whole structure shown in FIG. 3 and having the height h is considered to be a tooth 20 . This tooth 20 is subdivided into an upper cutting area 25 having the height h s and a lower root area 26 . The root area 26 is broader than the cutting area 25 so that, when toothed wires 24 are arranged side by side, the cutting areas 25 will be laterally spaced from one another. The cutting area 25 extends along one side of the toothed wire 24 up to the tip 23 of the tooth and merges essentially smoothly with the root area 26 , whereas on the other side the transition to the root area 26 takes place in the form of a step 27 . The root area 26 has a width F st . This root width F st provides, in the final analysis, also the distance between the cutting areas 25 of a toothed lining. The root area 26 serves to firmly secure the toothed wires to the lower surface of the carding segments 7 to 10 .
From the schematic representation according to FIG. 1 , it can be seen that the angle α of carding segment 7 is larger than that of carding segment 8 , and that the angle α of carding segment 8 is larger that of carding segment 9 as well as that the angle α of carding segment 9 is larger than that of carding segment 10 . This means that the processing face 21 of the tooth 20 approaches the imaginary connecting line 22 more and more. In this context, larger means not only the magnitude but also negative signs so that, according to the definition of FIG. 2 , negative angular values also have to be regarded as smaller angles.
In addition, also the tooth spacing t decreases from one carding segment to the next in direction B. This means that the tooth spacing t of carding segment 7 is larger than that of carding segment 8 , and that the tooth spacing t of carding segment 8 is larger that of carding segment 9 as well as that the tooth spacing t of carding segment 9 is larger than that of carding segment 10 . It follows that the distance between the teeth 20 decreases from one carding segment to the next.
Furthermore, also the height h s of the cutting area 25 decreases in the carding direction B from one carding segment to the next. This means in detail that the height h s in the case of carding segment 7 is higher than that in the case of carding segment 8 , that the height h s in the case of carding segment 8 is higher than that in the case of carding segment 9 , and that the height h s in the case of carding segment 9 is higher than that in the case of carding segment 10 . This also has the effect that the overall height h of the teeth 20 decreases from one carding segment to the next.
In an embodiment, which is not shown, it would also be possible to maintain the overall height h and to reduce only the height h s of the cutting area 25 .
The above-mentioned reductions of the dimensions for the angle α, the tooth spacing t, the root width F st and the cutting area height h s are, related to the respective carding segments 7 to 10 , averaged values. The aim to be achieved by these reductions is that the aggressiveness with which the fibres are processed decreases from one carding segment to the next. Hence, carding segment 7 works more aggressively than carding segment 8 , carding segment 8 works more aggressively than carding segment 9 and carding segment 9 works more aggressively than carding segment 10 . Aggressiveness means here the intensity with the fibres are acted upon by the carding segments. Preferably, all these measures are used in combination. It is, however, definitely also possible to change only one of these dimensions.
On the basis of FIG. 4 , it is explained that, when seen in a side view, the processing face 21 spans a contour line, which starts at the tip 23 of the tooth and which is concave in the root area of the tooth 20 . An imaginary connecting line 22 , which intersects the axis A of the cylinder at right angles and which extends precisely through the tip 23 of the tooth 20 , encloses in the area of its extension together with the contour line of the tooth 20 an area F. This area F can be determined for each tooth of the toothed linings 12 , 13 , 14 and 15 . If the angle α is changed and also if other parameters are changed according to the teaching of the present invention, this area F will always be smaller in the case of a subsequent carding segment than in the case of a preceding carding segment. In this connection, an averaged size of the area F per carding segment 7 , 8 , 9 or 10 can again be taken as a reference value. When the thickness of the teeth 20 is included in these considerations as well, also the volume below the processing face 21 will become smaller so that, when the size of the area F decreases, the number of fibres which can be accommodated in this region will be reduced. With fibres that become more and more open, this will lead to a more uniform distribution along the processing face 21 and to a more uniform wear.
In the following, the mode of operation of the above embodiment will be explained in detail.
Fibres are supplied to the main cylinder 2 via the opening cylinder 5 and entrained by the toothed lining 4 on the circumferential surface 3 of said main cylinder 2 in the direction of rotation B. When the fibres enter the gap 16 between the carding segment 7 and the main cylinder 2 , a combing operation for parallelizing the fibres takes place. This is done due to the fact that the tooth tips 23 of the toothed lining 12 of the carding segment 7 point in a direction opposite to the direction of the toothed lining 4 of the main cylinder 2 . Due to the subsequent separation of dirt in the separation channel 17 , first fibre fragments and dirt particles are removed.
Subsequently, the fibre material additionally passes through the working gaps 16 defined between the respective carding segments 8 , 9 , 10 and the main cylinder 2 , the fibres being carded and parallelized in the respective working gaps with decreasing intensity. The intensity decreases due to the above-described structural design of the toothed linings 12 to 15 on the carding segments 7 to 10 . Subsequently, the parallelized and entrained fibres are removed from the main cylinder 2 via the doffer cylinder 6 and carried away for further processing.
Making reference to FIGS. 5 to 7 , further embodiments of the carding segments are explained in detail.
In FIG. 5 the lower surfaces of two successively arranged carding segments 7 and 8 are shown. For the sake of simplicity, only a part of the toothed linings 12 and 13 is shown. In the present case, toothed wires comprising a plurality of teeth 20 are used, said teeth 20 extending substantially parallel to a plane intersecting the axis A at right angles. According to the representation shown in FIG. 5 , the tips of the teeth 20 point to the left. The rows of teeth of carding segment 7 are arranged such that they are displaced relative to the rows of teeth of carding segment 8 . This is shown on the basis of FIG. 6 by means of a schematic front view of the teeth. The two front teeth 20 symbolize two juxtaposed rows of teeth of the carding segment 7 and the tooth 20 lying between and behind these front teeth symbolizes a row of teeth of the carding segment 8 located therebehind. It can easily be seen that the cutting areas of these teeth 20 are displaced relative to one another so that also different areas of the fibres will be processed by the carding segments 7 and 8 . This displacement can also be achieved in that the root width F t of the preceding carding segment 7 divided by the root width F t of the following carding segment 8 does not result in an integer (F stn /F stn+1 ≠integer). FIG. 5 also shows that the height h s of the cutting area 25 of the teeth of the rear carding segment 8 is smaller than the height h s of the teeth 20 of the carding segment 7 arranged in front of said carding segment 8 .
FIG. 7 shows a further embodiment of a carding segment. In this embodiment the rows of teeth of the toothed linings are arranged at an oblique angle so that processing within a carding segment 7 to 10 will automatically extend over the whole width of the main cylinder 2 . An orientation relative to a subsequent carding segment 8 , 9 or 10 is not absolutely necessary.
Also in the case of the variants according to FIGS. 5 to 7 , all the dimensions described in the first embodiment can be changed so as to influence the intensity of the carding effect from one carding segment to the next.
In FIG. 8 a special embodiment of a carding segment 30 is described. This carding segment 30 is provided with a toothed lining 31 which changes in the direction of processing B. In FIG. 8 it is schematically shown that the teeth 20 representing the front teeth in the direction of processing have a rake angle α 1 which is larger than that of the following teeth. The rake angle α 1 is therefore larger than the rake angle α 2 , and the rake angle α 2 is larger than the rake angle α 3 . In view of the fact that the rake angle α 4 is negative, also the rake angle α 3 is larger than the rake angle α 4 . FIG. 8 only shows a schematic representation, and, consequently, the variation of the tooth shape could also take place over a larger area and less rapidly. Also all the other changes of tooth geometry for achieving the same effect could be carried out in such a carding segment 30 similar to the above-described changes. However, the best results can presumably be achieved by changing the respective angles. It would definitely be imaginable to arrange a single carding segment 30 having this kind of structural design on a cylinder 4 .
From FIG. 9 it can be seen that in the toothed linings of the carding segments the distance h between the shoulder 40 and the associated tips 41 of the teeth is chosen such that it is smaller than the distance H between the shoulder 42 and the associated tips 43 of the teeth of the toothed lining of the main cylinder. The resultant smaller passage height h formed in the covers has the effect that, in spite of the cutting edges which act more aggressively on the fibres in the case of the first carding segments and which draw the fibre bundles from the carding zone between the tips of the teeth into the passages of the cover, the fibre volume contained in the covers is kept small and that, in addition, also the dwell time of the fibres in the carding segments of the cover is reduced. | The present invention relates to a device, such as a carding machine, for processing fibers, said device comprising a cylinder, which is provided with a lining, and at least two carding segments which are arranged one after the other in the direction of rotation at least over an area of the circumference of said cylinder, each of said carding segments being provided with a toothed lining. The present invention aims at improving the efficiency of such a device especially in terms of fiber parallelization. In order to achieve this, the toothed linings of the carding segments are designed differently; when the fibers are engaged by the toothed lining of the carding segment constituting the upstream carding segment in the direction of rotation, the resultant influence on an individual fiber entrained by the circumference of the cylinder will be equal to or more intensive than the influence exerted when the fibers are engaged by the toothed lining of a carding segment constituting a downstream carding segment in the direction of rotation. | 3 |
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 09/850,505, filed May 7, 2001, which is a continuation of U.S. patent application Ser. No. 09/510,955, filed Feb. 22, 2000, which is a continuation of U.S. Pat. No. 6,064,373, which is a continuation of U.S. Pat. No. 5,668,570, which is a continuation-in-part of U.S. patent application Ser. No. 08/084,811, filed Jun. 29, 1993, now abandoned. Each of the related applications is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] This invention relates to desktop or portable computers with flat panel displays. In particular it relates to personal computers that will lie on a desk or table, which a human operator will use to: (1) enter keyboard data, pen or voice data/information; (2) view displayed information and/or (3) hear audio/voice information.
[0004] 2. Related Art
[0005] Heretofore, portable computers with flat panel displays were embodied in a “clamshell” type design. When these prior art computers are ready for use, the display panel is unfolded to a roughly vertical orientation. The attached keyboard and computer enclosure form the bottom half of the clamshell. For portable transport, the flat panel display is folded down over the keyboard and computer enclosure. This prior art configuration has several shortcomings. First, since the unit sits on a desk or table, the screen is always at a lower elevation than the eye level of the person sitting and operating the computer. Thus the person must continually look down to the display. Over long periods of time, this will cause neck and back strain on the user. Secondly, if a pen/stylus input means is added to the display screen, the roughly vertical operating orientation is inconvenient and ergonomically incorrect when the user is handwriting or sketching. If the user tries to hold his/her arm up to write on a vertical screen, the users arm will tire. Over long periods of writing on a vertical screen, this awkward position will cause strain on one's wrist. Even if the user is willing to hold his/her hand up to write on the vertical screen, it may not be physically secure for the user's hand pressure. Thirdly, the prior art clamshell design does not provide elevation adjustment or azimuth angle adjustment means. This restricts the ergonomic usability of the prior art computer and display units.
[0006] For example, U.S. Pat. No. 4,859,092 of Makita discloses a portable typewriter and display unit. However, a single pair of pivoting arms connect the display unit to the main body. When its display unit is raised to its highest elevation, the distance from the user's eyes to the display screen is large. Therefore, middle aged users who are near sighted, will have difficulty in viewing the screen. No pen/stylus input mean is disclosed, but even if one is added, the display unit would not provide a physically secure writing surface. The Makita does not provide a means of placing equal and opposite restraining force onto the display unit. U.S. Pat. No. 4,624,434 of Lake discloses a tiltable display terminal, but no display unit elevation adjustment is taught. Again no pen input means is disclosed, and if one is added, the unit would not be physically stable for normal hand/arm forces applied by the user. U.S. Pat. No. 5,115,374 of Hongoh teaches a laptop portable computer with a facsimile function. Hongoh discloses a touch panel screen, but no pen input means, and no vertical elevation adjustment of its display unit is taught. In order to provide a horizontal display orientation, the display unit must be detached from the main body and set back, in reverse orientation, to the connector sockets on the main body, which is a severe disadvantage.
[0007] Several prior art pen computer units exit. However, their display screens are fixed to their enclosure to form a flat tablet. They are designed for the mobile user market. This limits their use for desktop pen/stylus computing environments. No prior art has solved the problem of a personal computer for the office environment, capable of standard computing, pen computing, and voice telephone communications.
[0008] The invention disclosed herein solves the above problems by providing an ergonomic designed desktop system that is capable of several important computer and communications functions. It provides a display panel assembly, pen/stylus input unit, multiple support arms, and a main unit in a roughly wedge shape. The display panel assembly can be adjusted in inclination angle, azimuth angle and elevation. Thus invention overcomes the problems of the prior art. For example, the display panel of the invention can be easily adjusted by hand in elevation to a height roughly of the user's eye level. The user does not have to look down to see the screen when in normal PC-keyboard operation. If the unit is used as a pen/stylus computer, the display panel can be folded by hand to a physically secure position, at an inclination angle that is ergonomically correct for handwriting and sketching. Finally, the display screen can be physically adjusted in many orientation combinations, including azimuth angles, inclination angles and elevation translations. Thus the invention can be used in a wide range on office desktop positions and by a wide range of users and orientations.
SUMMARY
[0009] The disclosed invention overcomes the shortcomings of the prior art by providing display screen adjusting means for desktop computers and terminals, such that the entire apparatus is sufficiently small to be portable or transportable. The invention disclosed herein provides an easy to use desktop workstation, to which the human user can adjust its screen for many screen positions. In addition, the workstation can fold down for transport. The workstation may also include external communication means such as voice/data modem and/or telephone means.
[0010] Accordingly an object of the invention is to provide small compact workstation for the office, having an array of useful functions and capabilities at the finger tips of the human user sitting at his/her desk. Functions may include pen/stylus input means, computer means, display device(s), mass memory devices, keyboard, mouse, speaker phone, network interface and modem.
[0011] Another object of the invention is to give the user a voice and data communications capability at the desktop, capable of standard text/graphics computing, as well as voice/video/pen communication to others individuals or computers, via modem or network (LAN/WAN) interfaces.
[0012] Still another object of invention is to provide the user with an ergonomic workstation that can be adjusted to a wide range of positions and orientations, such that there will be a reduction or elimination of body stress and fatigue by the user, over long periods of use.
[0013] Still another object of the invention is to provide a modular desktop workstation such that the user can configure the workstation to how he/she works, or to their choice at a particular time. For example, the user will have the choice of using a detached keyboard, pen/stylus input, mouse, trackball, handset telephone, or speaker telephone, depending on his/her wishes for accomplishing a particular task.
[0014] Still another object of the invention is to provide a unit that is small and light enough for the user to easily transport it to other locations. Other objects of the invention will become evident by reading the following invention descriptions and inspection of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The details of the present invention, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:
[0016] [0016]FIG. 1A is a side view of the desktop workstation with the display panel assembly oriented vertically and somewhat raised from its lowest position;
[0017] [0017]FIG. 1B is a side view of the desktop with the display panel assembly folded to its lowest inclined position, with a stylus/pen input means;
[0018] [0018]FIG. 2 is exploded perspective view of the desktop workstation with a telephone means placed on one side;
[0019] [0019]FIG. 3 is a general block diagram of the electrical elements of the invention;
[0020] [0020]FIG. 4 is a general flow diagram of the software that may execute on the workstation's digital computing means;
[0021] [0021]FIG. 5 is a perspective view of a display monitor associated apparatus; and
[0022] FIGS. 6 A- 6 B are front views of display monitors with two different screen roll angles.
DETAILED DESCRIPTION
[0023] The invention can be described with reference to FIG. 1A and 1B shows a desktop workstation from the side in two different display screen orientations and modes of operation. The term desktop workstation is defined to be an interactive man-machine or man-computer interface, in which a human being can enter and view data/information. The workstation or interface may or may not include a digital computing means. A display panel assembly 2 is attached to a support structure 4 via a hinge pin 5 . The support structure 4 is connected to a support arm 12 via a hinge means 14 . The display panel assembly 2 includes a relatively thin display device further defining a viewing screen. Examples of the possible display technologies are Liquid Crystal Displays (LCD), electro-luminescent, plasma panel, and field emission displays. They may be monochrome or color, and they could be light modulator or light emitter types of displays. LCD's are most commercially available flat panel display devices, available in a wide variety of sizes, shapes, resolutions and other characteristics.
[0024] Typical of these LCD's is the Sharp Electronics Corporation's LM64P90 and LM64K90 monochrome LCD's. They have a 640×480 display pixel format, a viewing area of 196×148 mm, a dot pitch of 0.30×0.03 mm, and cold cathode fluorescent backlight. The former has 150 ms rise plus fall response time, a transmissive viewing mode, 50 Nits brightness, and 13:1 contrast ratio. The latter has a 250 ms rise plus fall response time, a transflective viewing mode, 35 Nits brightness, and 10:1 contrast ratio. For many applications, color LCD's are required. Sharp Electronics Corp. makes several direct-view color Thin Film Transistor (TFT) LCD modules. Typical specifications for their LQ10DH11 product are a 640 (×3)×480 display pixel format, 211×158 mm viewing area, a 0.33(0.11×3)×0.33 mm dot pitch, a hot cathode fluorescent backlight.
[0025] The display panel assembly 2 is free to rotate through large inclination angles (at least 90 degrees), represented by rotation A, about the hinge axis of hinge means 14 . Support arms 12 and 8 in turn connect the display panel to the workstation a main unit 6 . The main unit may include an enclosure or housing for control electronics including a digital computer, microprocessor or other control means. The display panel assembly 2 may be electrically connected to electronics located in the main unit 6 , via an electrical cable routed inside the support structure 4 and support arms 12 and 8 , or via a cable routed externally to the main unit. The size of main unit 6 should be small, so as to not present a large “foot print” on the desk or table. The unit should be easily carried by one person. The invention may powered by light weight batteries or it may be an AC powered workstation.
[0026] The support arm 8 is attached to support arm 12 by a hinge means 16 , such that the latter arm can be rotated though rotation C about the axis of the hinge means, as shown in FIG. 1A. Support arm 8 is attached to the main unit 6 by hinge means 20 , such that the arm can rotate though large angles as shown in rotation B about the axis of the hinge means. Thus the above mechanical elements can work in combination, and the user is can adjust the orientation of the display panel assembly 2 in both inclination angle and elevation. The friction of each hinge is such that the user can adjust the orientation by hand, and its position is either self-locking or can adjusted to lock in position. The lengths of the support arms 8 and 12 should be selected to provide the desired display screen elevation and forward viewing positions. Many different combinations of lengths may be embodied.
[0027] Several methods can be implemented to give the user the capability to adjust the screen in azimuth angle. One technique is to rotationally attach the display panel assembly 2 to a support structure 4 via a cylindrical hinge pin 5 , so that the display can rotate through azimuth angles. The hinge pin 5 can be made hollow so that electrical conductors can be routed through it to the support structure 4 . Another method would be to place the main unit on stationary base structure via a lazy-susan structure. Rubber feet may be placed under the main unit, as shown in the figure. The weight of the display panel assembly 2 should be as low as possible, and the mass of the main unit and its electronics should be large enough so that if the display assembly is adjusted in the extreme forward position, the unit will remain physically and gravitationally stable. A computer keyboard unit 7 is shown connected to the main unit 6 via an electrical cable 9 . The computer keyboard unit 7 may be attached or detached. If it is a detached keyboard, the electrical signals may be transmitted to the computer via wires or electromagnetic radiation means.
[0028] [0028]FIG. 1B shows the workstation of in FIG. 1A, except the display panel is folded down to its lowest inclined position and a stylus input means 22 is included. The stylus input means is defined to be a stylus or pen position encoding device that encodes, in two or three dimensions, the position of a handheld stylus, as the user moves it over an active area corresponding to the display screen. The screen of the display panel is facing upward and at a convenient inclined angle for user hand writing, drawing and sketching with the stylus or pen. An electrical wire/cable 23 may be used to connect the pen/stylus to the control electronics in the main unit. A natural inclined angle of the screen for stylus/pen data input is roughly 30 degrees from the horizontal. However, the display panel assembly may be locked into position at a multiplicity of orientations.
[0029] Another embodiment is shown in FIG. 2, which presents a perspective view of another embodiment of the invention, where several elements are shown in exploded view, for clarity. A display panel assembly 2 including its display screen 3 is rotationally connected to the support structure 4 via the cylindrical hinge pin 5 . The display panel assembly is then free to rotate through wide azimuth angles D as shown. The support structure 4 is connected to support arm pairs 12 A and 12 B via hinge means 14 A and 14 B. The cylindrical shafts of hinges 14 A and 14 B, which may be threaded, fit in the round holes of the support arm pairs 12 A and 12 B. Support arm pair 8 A and 8 B is attached to the previous arm pair at hinge elements 16 A, 16 B and 16 C, where element 16 B is a long shaft, the ends of which may be threaded. The other ends of support arm pair 8 A and 8 B are attached to the main unit 6 via hinges 20 A and 20 B. The friction of each hinge means may be adjusted by a threaded shaft or screw 19 and a standard nut 17 or a finger tightened nut/knob 17 A. The friction should be sufficient to support the display panel assembly under the gravitational and normal hand writing/sketching forces.
[0030] As shown in FIG. 2, a telephone unit may be added or integrated into the desktop workstation. A telephone handset 26 and cord 32 may located either side of the workstation. A telephone keypad 28 should be placed in a convenient location of the user. For a hands-free telephone operation, a microphone 30 and speaker 36 may be included. The telephone unit may be attached or detached from the main unit. The telephone may function during workstation operation and/or independently of the workstation operation. A computer keyboard, mouse or trackball devices may be included, in addition to the stylus/pen input means. All controls should be designed to be simple and easy to use.
[0031] [0031]FIG. 3 shows a block diagram of the basic electrical elements of the computer workstation. The pen/stylus input means' electronics 36 can be interfaced directly to flat panel display device electronics 38 . Examples of available products that have combined these functions are the Super-K™ display tablet from SuperScript Inc. Video Tablet from Kurta© Corporation, and the PL-100 Integrated Tablet for Wacom Technology Corp. Typically, these products are connected to a controller card in the computer's I/O bus, via a cable. Specifications for such display-tablet include: active area 7.56 by 5.67 inches, accuracy ±0.02 inch, resolution 1016 PPI, data transfer rate 270 coordinate pairs/sec., pen slew rate up to 135 IPS without significant distortion, and stylus/pen weight 15 grams.
[0032] As shown in the figure the flat panel display is electrically connected to the workstation microcomputer/controller 44 . The microcomputer may be any one of several commercially available products, such as the Intel™ 86286, 86386 or 86486 processors, Motorola Corporation's 68030 or 68040 processors, as well as several others. If the workstation is to be battery powered, then low voltage (3V) low-power microprocessors should be used. The microcomputer/controller 44 may be embodied by several means.
[0033] One available microcomputer system that may be used, is the Moby Brick product manufactured by Ergo Computing of Peabody Mass.. The Moby Brick product consists of a 386/486 CPU, with 4 to 32MB RAM, hard disk s from 170MB to 1GB, built in video controller, a 3.5 inch 1.44MB floppy drive, two serial ports, one parallel port and one ISA 16 bit half length card slot. All the above is built into a 7.9×11.3×3.3 inch module that weighs 8.7 lbs. The CPU required by the invention may be a 20 MHz 386SX, 33/40 MHz 386DX, or the 33 MHz 486DX. Either internal or external modems may be embodied in to the system. An optional expansion chassis may be added to the system with four slots for ISA cards.
[0034] [0034]FIG. 4 shows a general flow diagram of typical stored program software that may execute in the microcomputer or processor 44 . Many commercial available operating systems, window environment and application software are available to run in the microcomputer. Typical operating systems that could be used include Microsoft Corporation's MS-DOS™, IBM's OS/2™, Go Corporation's Pen Point or various companies' UNIX products. Possible windowing environments include Microsoft's Windows™ 3.x and Windows for Pen™, Hewlett Packard's New Wave™, or X-Windows from various companies. Software may be pen centric like Pen Point™ software or it may be just pen/mouse aware. As shown in FIG. 4, after a standard power up and the system diagnostics and checkout is completed the operating system is loaded. Depending on the desired configuration a number of device driver, TSR's, communication programs and pen/stylus control programs may be loaded. The workstation should be capable of either run in windows or non-windows environments.
[0035] The microcomputer/controller 44 of FIG. 3 includes associated support electronics, I-O devices and power supply. All the above should be compact in size, so that the size of the overall desktop workstation is as small as practical. The advantage of small size is that it provides a smallest footprint of the desk. This is important in office environments, where desk space is at a premium. The main unit's footprint dimensions, on the desktop, could be in the range of 15 by 13 inches, depending of the size of the screen and whether of telephone handset is included.
[0036] The keyboard function 42 may be electrically connected to the microcomputer/controller 44 . A standard mouse/trackball unit 46 may be connected to the microcomputer via an I-O card or serial port in the standard manner. Both the pen and mouse/trackball interfaces may be desirable in certain applications. An external communication means 46 is connected to the microprocessor. The communications means could be embodied by a communications I-O card, internal/external modem or other communication means. However embodied, the workstation shall have the capability to communicate data (text, graphics, video, and voice) interactively on either Wide Area Networks (WAN) 50 or Local Area Networks (LAN) 52 . The WAN in its simplest form may consist for two workstations connected to each other via internal/external modems over standard or hi-speed telephone lines.
[0037] Either an external or internal (built-in) telephone/speaker phone 48 may be connected to the microprocessor/controller. It may integrated into the workstation or embodied as a stand alone device, depending on the user's requirements. The telephone/speaker phone may also be connected to ordinary telephones lines 54 or wireless/cellular networks 56 . The primary purpose of the external communication means of the workstation is to provide two way interactive text, graphics (including pen/stylus), video and voice/audio communication to: (1) other users operating similar workstations (at the same time or unattended), and/or (2) one or more computers on a network of computers or terminals. Other standard computing and communication components may be added to the invention that are obvious to those skilled in the art.
[0038] In another embodiment, the microprocessor and support electronics 44 can be located at the display panel assembly 2 , instead of the main unit 6 . For example, they may be located on one or more printed circuit boards surrounding and behind the display screen. Such an implementation with battery power is well known to those skilled in the art. The display panel and computer assembly can then be removed from the support structure 4 and hinge pin 5 , as shown in FIG. 1A by a typical removal direction E. This can be accomplished by a simple plug and socket arrangement at the bottom of the display panel assembly. An advantage of this implementation is that two modes of user operation are then possible. One is the desktop operation as described above. The other is a portable mobile display-tablet operation. The user has the option to remove the display-computer unit from the socket, and use it as notebook computer or display-tablet.
[0039] A rechargeable battery pack and power management circuitry should be included in the assembly. The battery pack may be removable via a slot on the side of the display panel assembly 2 . The main battery pack typically consists of NiCd or newer Nickel Hydride type batteries. A backup battery may also be embodied. The mass memory components, of these hand held display panel assemblies, may consist of a small magnetic 2.5 or 3.5 inch disk hard drives or semiconductor Flash Memory modules. Mass memory of at least 80 megabytes are typically required. If removable, the battery pack and flash memory modules should conform to the PCMCIA Standards. These standards are important for interchangeability among different manufactures. Because of the high level of LSI accomplished today, relatively thin, 1-2 inch thick, display panel assemblies can be realized containing a flat panel display, drive circuitry, microcomputer card, support circuitry and battery pack, within a light weight enclosure. The display panel and computer assembly can then be removed from the support structure 4 and hinge pin 5 , as shown in FIG. 1A by a typical removal direction E. This can be accomplished by a simple plug and socket arrangement at the bottom of the display panel assembly. An advantage of this implementation is that two modes of user operation are then possible. One is the desktop operation as described above. The other is a portable mobile display-tablet operation. The user has the option to remove the display-computer unit from the socket, and use it as notebook computer or display-tablet.
[0040] [0040]FIG. 5 shows alternate embodiment of the desktop workstation system consisting primarily of a base unit 6 A, display panel assembly 2 , pen/stylus input means 22 , keyboard unit 7 , a telephone base unit 6 B and a telephone handset 26 . The computer or workstation is designed for desktop computing and data communications for typical office, home or factory use. All the major functions for computing, communications, and conferencing are made available to user in this desktop arrangement. The base unit 6 A, which is similar to the main unit of FIG. 1 and 2 , is embodied as a somewhat smaller wedge shape enclosure, which does not take up much desk space and provides an inclined position for pen input. The telephone base unit 6 B and keyboard unit 7 are shown here as separate units, so that they can be pushed aside to make room on the desktop. Electrical cables 58 and 9 connect the handset and keyboard to the base unit 6 A where most of the computer and electronic components are located. The stylus/pen 22 is connected to the computer in the base unit via an electrical cable 23 .
[0041] The display panel assembly 2 is physically connected to the base unit 6 A via a universal hinge arrangement 4 and an actuator assist means 8 . This connection is shown in an exploded view in the figure. The universal hinge means may be embodied in many ways, such as a ball and socket joint arrangement. Thus, the display panel assembly 2 with its display screen 3 , is position adjustable in a multiplicity of orientations. A Cartesian coordinate system diagram, defining the axes for translations and rotations, is shown in the figure. The panel can be rotated in Inclination angle I, Azimuth angle D, and Roll angle R. Further position adjustment means are added, to provide elevation adjustment along axis y, as shown in double arrow B.
[0042] The display panel assembly 2 may be electrically connected to the electronics in the base unit by running a cable through the hinge pin 5 and through the actuator assist means 8 attached to the hinge pin. Sufficient slack in the cable must be provided for the full height of the adjustment range. A slack take-up means should be provided, so that when the panel is in its lower elevation positions, the cable does not bind. The vertical force of actuator assist means should be roughly equal to the weight of the display panel assembly 2 . The actuator assist means 8 could be embodied by several alternative devices, including an air spring, a mechanical spring, pneumatic, hydraulic, or electromechanical actuator means. One or more actuators could be included. A means for locking and unlocking the actuator position should be provided within the assist means 4 . Such actuators and locking mechanisms are well known to those in the art.
[0043] Even though flat panel display assemblies typically weigh only a few ounces, there are several reasons why an actuator assist means may be desirable. If an actuator is not implemented, and the user desires to raise the panel vertically by hand, the user would have to grab one edge of the panel and pull up. If the base unit is not secured to the table or it is not sufficiently heavy, the entire unit may lift off the table. The user would have to place one hand on the base unit and the other on the display panel and pull. Both of the above user actions are undesirable. Using two hands for a simple position adjustment, takes more time to accomplish, and the user may lose his/her's concentration during a computing task. Making the base unit heavy enough so that its weight is larger than the force applied by one's hand is also undesirable. Therefore, a telescoping actuator means 8 should be embodied with a force roughly equivalent to the weight of the display assembly 2 , so that the user can easily adjust the position of the display panel by hand. The actuator means may include a locking and unlocking means for temporarily holding the display assembly in the desired position.
[0044] An alternate embodiment is shown is FIG. 6A and 6B, showing front views of a desktop unit with a universal ball and socket type support and hinge means 4 attached to the display panel assembly 2 , as well as other components. The support and hinge means consist of an L-shaped support member 4 C, such that the display panel, when supported near the front of the base unit 6 A, can be rotated about the z-axis (shown in FIG. 5) and miss the front edge of the base. The L-shaped member 4 C, as shown is FIG. 6A and 6B, is foreshortened (i.e., one side of the L is pointing out of the paper). FIG. 6B shows a front view of the display panel, where the panel is rotated 90 degrees to the typical portrait display orientation. The locking and unlocking part 4 A can be a hand knob for applying a force to a hinge means. In this embodiment, the locking knob is facing forward, toward the front of the desktop unit. Other locking/unlocking knob positions are possible. A support post 5 A is fixed to the actuator assist means 8 at one end and is attached to the support and hinge means 4 at the other. The assist actuator means 8 may consist of several telescoping arm and post members, in order to provide for greater elevation travel. The actuator means should be capable of collapsing into a unit with relatively small height dimension. This later feature is important because the height dimension of front portion base unit is relatively small. As above, the support post can be hollow to allow the electrical cable to be routed through it. An advantage of the FIG. 6A and 6B embodiment is that it provides for both landscape and portrait screen orientations in the same desktop unit, which the user can easily change by hand.
[0045] The embodiments of FIG. 5 and FIG. 6 results in a relatively integrated desktop computer and telecommunication system, designed to used by a person at his/her desk. The system is designed to replace the user's exiting telephone and desktop computer, with a general purpose integrated telephony and computing system. An unique aspect of this invention is that the wedge shaped base unit 6 A, telephone handset enclosure 6 B and the keyboard unit 9 are made to be small separate units, but the display panel assembly 2 can be quite large. The telephone handset and enclosure combination can be slide under the display panel assembly, to save desktop space. This embodiment allows the user to move these separate units out of the way when not in use, and pulled into position, when required.
[0046] The scope of the invention disclosed here should be determined by the appended claims and their legal equivalents, rather than by the examples given above. | A relatively small transportable desktop computer/workstation with a display panel assembly ( 2 ) in combination with a microprocessor or controller ( 44 ) is made display screen position adjustable, in inclination angle, azimuth angle and elevation translation movements. The workstation can have a pen or stylus touch screen input function ( 36 ) added, so that a user or operator can write, draw and sketch directly onto the screen in a natural manner. The workstation can be placed on top of a desk or table providing an ergonomic man-machine interface for information communications between individual users via a communications network. A keyboard ( 7, 42 ), voice/speaker telephone ( 48 ), mouse or trackball input unit ( 46 ), and communications modem ( 42 ) may be added to the workstation. The flat panel display, pen input device and microprocessor can be combined into an assembly, which can be removed from the main body for portable mobile computing operation. | 8 |
RELATED APPLICATIONS
[0001] The present application is being filed as a non-provisional patent application claiming priority under 35 U.S.C. §119(e) from, and any other benefit of, U.S. Provisional Patent Application No. 62/172,283 filed on Jun. 8, 2015, the entire disclosure of which is herein incorporated by reference.
FIELD
[0002] The invention generally relates to handbags, shoulder bags, sack packs, and tote bags and, more particularly, to bags designed to prevent theft by enabling the contents to be locked inside and the bag to be locked to a fixed object.
BACKGROUND
[0003] Bags of all types have been used by people to carry their belongings for thousands of years. Over the years, bags have taken on a seemingly infinite number of shapes, sizes, and styles. Bags are designed for style/fashion, comfort, and utility (durability and the ability to hold and protect objects). Typically, bags are made out of a textile that enables them to be attractive, flexible, durable, pleasant to the touch, and functionally able to adapt to a wide range of contents. Some bags are made so that they can be closed to prevent the contents from falling out, and some bags can be locked closed to prevent tampering with the contents.
[0004] Furthermore, it is known that even bags that lock closed do not truly protect the contents from tampering, as the textile construction leaves them susceptible to being cut or torn open by someone wishing to tamper with the contents. This vulnerability causes undesirable conditions for the user including but not limited to: a false sense of security for some users; ongoing concern over tampering or theft since the contents are really not secure; damage to the bag if tampering or theft is attempted; and reduced utility for the bag since it is not secure due to its construction, even though it locks.
[0005] Furthermore, bags that lock are typically constructed of a heavy woven canvas or nylon textile that is very stiff, rough, and abrasive, and not considered to be fashionable or comfortable to carry. For those reasons, locking bags have traditionally been limited to business and security uses, and not everyday consumer and fashion use.
[0006] Furthermore, even bags that lock closed are vulnerable to theft, as some thieves may choose to take the entire bag rather than just forcibly open it to access its contents. Therefore, even the most secure bag made from the most impenetrable material and locking mechanism still leaves the contents vulnerable to theft.
SUMMARY
[0007] In view of the above, a bag is provided that is made from a textile that is highly resistant to cutting, tearing, or abrasion. The material is extremely difficult to penetrate by thieves. This design reduces the risk of a thief easily “breaking in” through the bag to access its contents. Additionally, the textile is soft, flexible, attractive, and is considered highly desirable by consumers from a fashion and comfort standpoint.
[0008] The bag also uses a novel strap, which can be used both to lock the bag closed and to secure the bag to a fixed object. The strap is made from a tubular textile material that is soft to the touch and has a high degree of tensile strength. Inside the tubular strap is an assembly made from wire rope (braided steel cable). The combination of the tubular textile surrounding the wire rope creates a strap that is soft, flexible, attractive, and resistant to cutting, stretching, or breaking.
[0009] The bag also uses a novel compartment to hide the strap. This compartment keeps the bag aesthetically pleasing by hiding the strap such that it is not visible when it is not being used to lock or secure the bag.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:
[0011] FIG. 1 is a front elevational view of a locking bag, according to an exemplary embodiment.
[0012] FIG. 2 is a transparent view illustrating internal features of the bag of FIG. 1 .
[0013] FIG. 3 is a diagram showing manipulation of a locking strap of the bag of FIG. 1 .
[0014] FIG. 4 is another diagram showing manipulation of the locking strap of the bag of FIG. 1 .
[0015] FIG. 5 is a diagram showing engagement of a locking device with the locking strap of the bag of FIG. 1 .
[0016] FIG. 6 is a diagram showing the bag of FIG. 1 being secured to a fixed object.
[0017] FIG. 7 is a diagram showing the bag of FIG. 1 secured to a fixed object.
[0018] FIG. 8 is a diagram showing a fastening device, according to an exemplary embodiment, in a fastened state within the bag of FIG. 1 .
[0019] FIG. 9 is a diagram showing a fastening device, according to an exemplary embodiment, in an unfastened state within the bag of FIG. 1 .
[0020] FIG. 10 is a diagram of an internal member of the locking strap of the bag of FIG. 1 .
DETAILED DESCRIPTION
[0021] While the general inventive concepts are susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered merely as an exemplification of the general inventive concepts. Accordingly, the general inventive concepts are not intended to be limited to the specific embodiments illustrated herein.
[0022] A locking, cut-resistant bag 100 , according to an exemplary embodiment, will be described with reference to FIGS. 1-10 . The bag 100 is formed from a material that exhibits superior cut, tear, and abrasion resistance as compared to conventional materials used to make such bags (e.g., handbags, shoulder bags, sack packs, tote bags). In some embodiments, the cut-resistant fabric is the Cut-Tex® PRO material provided by the PPSS Group (United Kingdom). Cut-Tex® PRO is a cut-resistant fabric made out of a combination of ultra-high molecular weight polyethylene (UHMWPE) and other fibers weaved by special high-density knitting machines. The Cut-Tex® PRO material is generally five (5) times more cut resistant than Kevlar®, a material known for its use in bulletproof vests. The Cut-Tex® PRO material meets other current standards, as shown in Table 1.
[0000]
TABLE 1
ISO 13997: 1999 Blade Cut Resistance Level 5
>27
Newton
EN 388: 2003 Blade Cut Resistance Level 5
Highest level
EN 388: 2003 Tear Resistance Level 4
>398
Newton
EN 388: 2003 Abrasion Resistance Level 4
>8,000
cycles
[0023] In general, the material is not readily compromised by traditional cutting implements such as scissors, knives, etc. Instead, cutting of the material may require specialized equipment such as a rotary cutting machine, a CNC router, etc. In some embodiments, the material used to form the bag 100 may have other properties, for example, being flame retardant. Typically, the material is relatively supple and has characteristics (e.g., look, feel) that would render it aesthetically pleasing to many users.
[0024] The bag 100 can be formed from one or more layers, plies, or the like of the material, which are joined in any suitable manner. In some embodiments, layers of the material are sewn together. In some embodiments, the thread used to sew the material together is also durable and/or cut resistant to avoid introducing a potential “vulnerability” to the bag.
[0025] In some embodiments, the material is formed as a tube so that the bag 100 can be fashioned by closing (e.g., sewing) an end of the tube shut. In some embodiments, the end of the tube to be closed is folded inward and then sewn together, whereby the stitching is neither visible nor accessible from outside the bag 100 . In this manner, the bag 100 is formed and includes a tubular body 102 extending between a closed end 104 and an open end 106 .
[0026] The inside of the bag 100 defines a cavity capable of storing items. The dimensions of the cavity are not limited by the general inventive concepts. However, the bag 100 will typically be sized so as to be readily worn on the body of or otherwise carried by a single person. In one exemplary embodiment, the bag 100 has a height h of approximately 18 inches (45.7 centimeters) and a width w of approximately 14 inches (35.6 centimeters). In one exemplary embodiment, the bag 100 weighs approximately 22.25 ounces (630.8 grams).
[0027] The bag 100 includes two primary states: an open state and a closed state. In the open state, the cavity is generally accessible through the open end 106 of the bag 100 such that items can be placed into and removed from the bag 100 . In the closed state, the cavity is generally not accessible. From the closed state, the bag 100 can also be locked to secure items within the cavity of the bag 100 (see FIG. 5 ). Furthermore, from the closed state, the bag can also be locked to a fixed object to secure the bag 100 at a specific location (see FIG. 7 ).
[0028] As shown in FIG. 1 , the bag 100 is in the open state. The bag 100 includes structure that facilitates transition from this open state to the closed state. For example, the bag 100 includes a first drawstring 110 , a second drawstring 112 , and a locking strap 150 .
[0029] The first drawstring 110 is primarily situated on a first side 114 of the bag 100 . The first drawstring 110 is formed by a pair of ropes 118 or rope-like members. In some embodiments, the first drawstring 110 is formed from a pair of nylon ropes. An end of each of the ropes 118 is anchored at a point 122 on the bag 100 near the first side 114 and the closed end 104 . In some embodiments, an end of each of the ropes 118 is passed through an opening in the bag 100 at the point 122 and then knotted to one another so as to not be removable through the opening. The opposite ends of the ropes 118 are feed through an opening in the bag 100 near the first side 114 and the open end 106 and into a first channel 130 , passage, or the like that extends around a circumference of the open end 106 of the bag 100 . In particular, one of the ropes 118 extends around one half of the circumference of the open end 106 and the other one of the ropes 118 extends around the other half of the circumference of the open end 106 . The ends of the two ropes 118 are fixed to the bag 100 at a point 134 within the first channel 130 near the second side 116 .
[0030] The second drawstring 112 is primarily situated on a second side 116 of the bag 100 . The second drawstring 112 is formed by a pair of ropes 120 or rope-like members. In some embodiments, the second drawstring 112 is formed from a pair of nylon ropes. An end of each of the ropes 120 is anchored at a point 124 on the bag 100 near the second side 116 and the closed end 104 . In some embodiments, an end of each of the ropes 120 is passed through an opening in the bag 100 at the point 124 and then knotted to one another so as to not be removable through the opening. The opposite ends of the ropes 120 are feed through an opening in the bag 100 near the second side 116 and the open end 106 and into a second channel 132 , passage, or the like that extends around a circumference of the open end 106 of the bag 100 . In particular, one of the ropes 120 extends around one half of the circumference of the open end 106 and the other one of the ropes 120 extends around the other half of the circumference of the open end 106 . The ends of the two ropes 120 are fixed to the bag 100 at a point 136 within the second channel 132 near the first side 114 .
[0031] The ropes 118 , 120 function as carrying handles, shoulder straps, or the like for the bag 100 . Given the aforementioned configuration of the ropes 118 , 120 , pulling on the first drawstring 110 and/or the second drawstring 112 results in the open end 106 of the bag 100 being mostly cinched closed.
[0032] The locking strap 150 is formed by surrounding a reinforcing member 200 (see FIG. 10 ) with a material that is both strong and aesthetically pleasing. In some embodiments, the material is nylon. In some embodiments, the material used to form the locking strap 150 is the same as the material used to form the bag 100 . In some embodiments, a color of the material forming the locking strap 150 is selected to complement a color of the material forming the bag 100 .
[0033] In some embodiments, the material is a tubular nylon strap that surrounds the reinforcing member 200 . The tubular nylon covering provides a soft consistent outer feel, a visually appealing look, a high-degree of tensile strength, and adds to the overall cut resistance of the locking strap 150 .
[0034] With reference to FIG. 10 , the reinforcing member 200 is formed from a material that is highly resistant to cutting, tearing, or abrasion. In some embodiments, the reinforcing member 200 is made from metal cable or wire. In some embodiments, the reinforcing member 200 is made from steel cable.
[0035] In one exemplary embodiment, the reinforcing member 200 is made from three pieces 202 , 204 , 206 of 1/16-inch (0.159-centimeter) stainless steel cable. The general inventive concepts contemplate that thinner or thicker cables could be used. The pieces 202 , 204 , 206 are joined to one another to form a continuous loop. In particular, as shown in FIG. 10 , the pieces 202 and 204 are joined to one another by a fastener 210 . The pieces 202 and 206 extend around opposite sides of a spool member 220 and are then joined to one another on both sides of the spool member 220 by a pair of fasteners 212 . The fasteners 212 not only secure the pieces 202 and 206 to one another, but also keep the spool member 220 fixed therebetween. In some embodiments, an outer surface of the spool member 220 includes a groove or the like that is sized to accommodate at least a portion of the pieces 202 , 206 therein. Likewise, the pieces 204 and 206 extend around opposite sides of a spool member 222 and are then joined to one another on both sides of the spool member 222 by a pair of fasteners 214 . The fasteners 214 not only secure the pieces 204 and 206 to one another, but also keep the spool member 222 fixed therebetween. In some embodiments, an outer surface of the spool member 222 includes a groove or the like that is sized to accommodate at least a portion of the pieces 204 , 206 therein. In some embodiments, the fasteners 210 , 212 , 214 are identical.
[0036] Notwithstanding the embodiment illustrated in FIG. 10 , any type of fastener or other joining technology could be used. For example, in some embodiments, the pieces 202 , 204 , 206 could be welded to one another.
[0037] As noted above, the locking strap 150 is formed by surrounding the reinforcing member 200 with a tubular nylon strap to form a continuous loop. A pair of grommets 160 are positioned in the locking strap 150 to correspond to the spool members 220 , 222 of the reinforcing member 200 . Often, the grommets 160 will only negligibly increase a thickness of the locking strap 150 . Prior to closing the loop, the locking strap 150 is inserted through an opening 154 in the bag 100 and into a third channel 156 , passage, or the like that extends around a circumference of the open end 106 of the bag 100 . Because it is housed in the third channel 156 , most of the locking strap 150 remains hidden from sight when the bag 100 is in the open state, which contributes to the overall aesthetics of the bag 100 . The opening 154 in the bag 100 is situated between the first side 114 and the second side 116 (and, preferably, equidistant between the two sides 114 , 116 ). In some embodiments, a portion of the locking strap 150 (such as a portion near fastener 210 ) is anchored at a point (not shown) within the third channel 156 that is opposite the opening 154 .
[0038] Prior to closing the loop, the locking strap 150 is also placed through a locking ring 152 . In this manner, the locking ring 152 can freely traverse the locking strap 150 .
[0039] In some embodiments, the first channel 130 and the second channel 132 are the same channel. In this case, the drawstrings 110 , 112 can be attached (e.g., stitched) or otherwise anchored within the channel to prevent undesired displacement or unbalancing of the drawstrings 110 , 112 . In some embodiments, the first channel 130 , the second channel 132 , and the third channel 156 are all the same channel. In this case, the drawstrings 110 , 112 and the locking strap 150 can be attached (e.g., stitched) or otherwise anchored within the channel to prevent undesired displacement or unbalancing of the drawstrings 110 , 112 and the locking strap 150 . In some embodiments, the third channel 156 is situated below the first channel 130 and the second channel 132 (i.e., furthest from the open end 106 of the bag 100 ).
[0040] An interior of the bag 100 (i.e., the cavity formed therein) can include additional structure to increase the storage options available to a user thereof. For example, the bag 100 can include one or more internal storage compartments or devices. As shown in FIG. 2 , the bag 100 includes an internal storage pocket 140 having a zipper closure 142 . The storage pocket 140 can be made from or otherwise lined with a shielding (e.g., RF shielding) material, which can protect against unauthorized scanning of the contents within the storage pocket 140 . As another example, the bag 100 includes a clasp 144 for removably attaching one or more keys thereto. Typically, the grommets 160 are relatively flush with the surface of the locking strap 150 .
[0041] The interior of the bag 100 can also include structure that increases the security of the bag 100 . In particular, the bag 100 can include internal structure that prevents or otherwise increases the difficulty of unauthorized opening of the bag 100 . For example, the bag 100 can include structure that is readily opened when the bag 100 is in the open state and virtually impossible to open when the bag 100 is in the closed state.
[0042] As one example, the bag 100 can include a unidirectional fastener. As used herein, the term “unidirectional fastener” refers to a snap or other type fastener that can be fastened and unfastened in only one direction. That is, given the four cardinal directions, the unidirectional fastener can be fastened and unfastened by force exerted in a specific one of the directions but not by force exerted in the other three directions. As another example, the bag 100 can include a bidirectional fastener. As used herein, the term “bidirectional fastener” refers to a snap or other type fastener (e.g., zipper) that can be fastened and unfastened through force exerted along one axis but not by force exerted along any other axis.
[0043] For example, as shown in FIGS. 8-9 , the bag 100 includes an internal unidirectional fastener 170 . One such suitable unidirectional fastener is a Pull-the-DOT® snap provided by Scovill Fasteners of Clarkesville, Ga. The unidirectional fastener 170 includes a socket 172 and a stud 174 that can be fastened (see FIG. 8 ) and unfastened (see FIG. 9 ) in only one direction, as described above. By choosing the direction in which the unidirectional fastener 170 operates to be substantially parallel to the open end 106 of the bag 100 , it is virtually impossible to operate the unidirectional fastener 170 when the bag is in the closed state. Accordingly, the unidirectional fastener 170 provides an additional layer of protection for the contents of the bag 100 .
[0044] In some embodiments, the bag 100 includes a plurality of unidirectional and/or bidirectional fasteners.
[0045] The process of transitioning the bag 100 from the open state to the closed state will now be described.
[0046] First, any internal fasteners (e.g., the unidirectional fastener 170 ) should be fastened.
[0047] Next, the first drawstring 110 should be pulled in a direction away from (and preferably substantially perpendicular to) the first side 114 of the bag 100 . Simultaneously, the second drawstring 112 should be pulled in a direction away from (and preferably substantially perpendicular to) the second side 116 of the bag 100 . By pulling the drawstrings 110 , 112 tight, the open end 106 of the bag 100 is cinched closed.
[0048] After the open end 106 is cinched closed, the locking strap 150 should be pulled out through the opening 154 in the bag 100 . Pulling of the locking strap 150 can be done by pulling on the locking strap 150 itself (see FIG. 3 ) or by pulling on the locking ring 152 surrounding the locking strap 150 (see FIG. 4 ). The locking strap 150 should be pulled through the opening 154 until both grommets 160 are outside of the third channel 156 (i.e., are accessible outside of the bag 100 ). Once the locking strap 150 has been pulled out to this degree, the open end 106 of the bag 100 is considered fully cinched shut.
[0049] Next, a locking device 300 is used to lock the bag 100 , thereby maintaining the fully cinched shut state of the open end 106 of the bag 100 . The locking device 300 can be any conventional lock or similar device capable of being locked and unlocked only by an authorized user.
[0050] As shown in FIGS. 5-6 , the locking device 300 is a combination lock having a body 302 and a curved post 304 . When the proper combination is input to the locking device 300 (i.e., via dials on the body 302 ), the post 304 is released from the body 302 and the locking device 300 is unlocked. Conversely, when a wrong combination is input to the locking device 300 , the post 304 remains trapped in the body 302 and the locking device 300 stays locked.
[0051] As shown in FIG. 1 , the bag 100 can include an external pocket 180 for housing or otherwise hiding the locking device 300 when the locking device 300 is not being used. Alternatively, when not being used, the locking device 300 could simply be secured to the locking ring 152 or placed in the internal pocket 140 to prevent loss thereof.
[0052] To lock the bag 100 , the curved post 304 is released from the body 302 and inserted through both grommets 160 in the locking strap 150 . Then, the post 304 is returned to the body 302 and the locking device 300 locked. Because the locking device 300 is too large to fit through the opening 154 , the locking strap 150 is prevented from traveling back into the third channel 156 of the bag 100 . Consequently, the bag 100 is locked in the closed state (see FIG. 5 ).
[0053] It is also possible to secure the bag 100 in the closed state to a fixed object. The term “fixed object,” as used herein, is not intended to mean only objects that are absolutely fixed. Instead, the term encompasses any item not intended to be readily move by an unauthorized person. Typically, the fixed object will not be readily portable by a single person. Thus, fixed objects could include, for example, a beach chair, a bike rack, an automobile steering column, etc.
[0054] To secure the bag 100 to a fixed object 400 , the locking strap 150 is pulled out of the bag 100 , as described above. With the locking ring 152 moved to the end of the locking strap 150 , the locking strap 150 is wrapped around the fixed object 400 such that the locking ring is substantially aligned with the grommets 160 (see FIG. 6 ). In this manner, the curved post 304 of the locking device 300 can be inserted through both grommets 160 and the locking ring 152 of the locking strap 150 . Then, the post 304 is returned to the body 302 and the locking device 300 locked. Because the locking strap is secured around the fixed object 400 , the bag 100 is effectively secured to the fixed object 400 in the closed state (see FIG. 7 ).
[0055] The above description of specific embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. For example, although the illustrative embodiments disclosed herein utilize grommets 160 in the locking strap 150 as the primary locking means, it is contemplated that other designs and/or configurations of holes or openings in the locking strap 150 could also be used. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as defined by the appended claims and equivalents thereof. | An improved tote bag with a locking mechanism is disclosed. The bag provides a high degree of security yet still remains soft, unstructured, and fashionable. | 0 |
FIELD OF INVENTION
This invention relates to protective covers for exposed steel reinforcing bars used in reinforced concrete.
BACKGROUND OF INVENTION
Steel reinforcing bars (“rebar”) are used in reinforced concrete in building structures. During the construction of buildings, the ends of the rebar are often exposed and extend upwardly from recently poured concrete sections or walls. Exposed ends are sharp and present a hazard to workmen, particularly to workmen working overhead. Many workmen have sustained puncture injuries, and in a significant number of cases have been killed, due to accidentally falling or stepping onto the exposed ends of the rebar.
Various protective safety covers have been proposed and used to protect workmen from this hazard. Bush U.S. Pat. No. 4,202,378 and Bush Design Pat. No. 262,093 refer to a protective safety cover for use on the free projecting ends of rebar comprising a hollow cylindrical body of a deformable plastic material, the body being closed at one end and open at the other. A plurality of inwardly extending projections are formed within the open end of the cylindrical body to secure the protective cover to the rebar. The closed end of the body has a flat circular head which extends radially outwardly from the body to present an enlarged flat impact surface. Other plastic protective covers for rebar are discussed in Schimmelpfenning U.S. Pat. No. 5,884,443 and Don De Cristo Concrete Accessories Inc. Catalog “Plastic Rebar Guard”, p. 43. Lunn U.S. Pat. No. 4,833,850 proposed a protective cover for rebar in the form of a metal support adapted to hold a impact absorbing spherical cushion.
When it was realized that these all plastic protective covers were subject to penetration upon severe impact, such as a workman falling from a height, it was proposed to insert a separate piece of rebar through lateral holes near the closed end of the cylindrical body to provide for a steel stop as discussed in WO91/14839 and Underwood U.S. Pat. No. 5,363,618. This approach is not self-contained, is inconvenient, and subject to not being consistently practiced.
Consequently, protective covers having a built in metal plate or “seat” in the bottom of the closed end of the body were developed. Protective covers of this type are discussed in Schnepf U.S. Pat. No. 5,313,757, Workman U.S. Pat. Nos. 5,447,290 and 5,613,336, Deslauriers Impalement Protective “Safety Cap DISC System”, Buffalo American Allsafe Company “BarGard”, Mutual Industries Inc. OSHA Rebar Cups Part Numbers 14640-4 and 14640-5, Dunn U.S. Design Pat. No. 408,268, and Kassardjian et al U.S. Pat. Nos. 5,381,636, 5,523,043, 5,568,708, 5,824,253, 5,943,836, 5,946,871 and Design No. 363,657. Protective covers with metal plates or seats passed the original Cal OSHA drop test.
However, after an investigation of job site injuries, Cal OSHA subsequently declared that the existing protective covers with metal plate or seat were inadequate, primarily due to being subject to penetration through the side of the cylindrical body upon impact on the head, resulting in serious puncture injuries to workmen falling onto the rebar.
Cal OSHA since established a new and more stringent drop test which all new rebar protective covers are required to meet. Kassardjian et al U.S. Pat. No. 5,729,941 relates to a rebar cover having a preformed metal stamping in the form of a bowl-shaped metal seat which is incorporated in the closed inner end of the cylindrical body. The bowl-shaped metal seat is said to be of a composition and thickness to prevent penetration of the rebar through the seat and thereby preclude penetration of the rebar through the side of the cover body upon impact.
The use of a preformed bowl-shaped metal stamping as the seat adds to the expense of the rebar protective cover.
Subsequently, a rebar protective cover having a hollow cylindrical body and impact head of a thickness and integrally formed of a plastic material was developed which was found to provide a protective cover which passes the current Cal OSHA drop test. This rebar protective cover is disclosed in applicant's co-pending U.S. patent application Ser. No. 09/569,826, filed May 12, 2000, the disclosure of which is incorporated herein by reference.
SUMMARY OF THE INVENTION
Briefly, this invention comprises a rebar protective cover for use on the projecting free end of a concrete reinforcing bar to prevent impact injuries comprising:
(a) a hollow cylindrical collar, having an open end and a closed end, (b) an overhanging impact head of substantial extent projecting laterally outwardly beyond the closed end of said collar, (c) a bowl-shaped shaping member having the concave surface facing the open end of the collar, (d) a solid cementitious member occupying the space between said closed end of the collar and the underside of said shaping member, said cementitious member having a surface abutting the underside of said shaping member complementary to said shaping member and adapted to resist impact penetration,
said protective cover preventing penetration of the cover by rebar when the cover is subjected to the Cal OSHA drop test.
The invention further comprises the combination of a rebar used to reinforce concrete wherein the rebar has an exposed free end and a safety protective cover disposed on said exposed, said protective cover comprising:
(a) a hollow cylindrical collar, having an open end and a closed end, (b) a flat overhanging impact head of substantial extent projecting laterally outwardly beyond the closed end of the collar, (c) a bowl-shaped shaping member having the concave surface facing the open end of the collar, (d) a solid cementitious member occupying the space between said closed end of the collar and the underside of said shaping member, said cementitious member having a surface abutting the underside of said shaping member complementary to said shaping member and adapted to resist impact penetration.
said protective cover preventing penetration of the cover by rebar when the cover is subjected to the Cal OSHA drop test.
DESCRIPTION OF PREFERRED EMBODIMENTS
Turning to the drawings:
FIG. 1 is an exploded perspective view of the plastic parts of the protective cover of this invention.
FIG. 2 is a sectional view of the assembled protective cover of this invention.
FIG. 3 is a sectional, exploded view taken vertically through the parts shown in FIG. 2 , but taken prior to assembly with the cement still in the unhardened state.
FIG. 4 is a side view of the assembled protective cover of this invention when in place over a rebar.
FIG. 5 is a side view in partial breakaway of the assembled protective cover of FIG. 2 positioned over rebar.
FIG. 6 shows the positioning of the assembled protective cover on the rebar at the maximum possible angle, as required by the current Cal OSHA drop test. The free end of the rebar abuts the inside of the shaping member which is separated from the closed end of the cylindrical body portion by cementitious member.
FIG. 7 is similar to FIG. 2 with the addition of the dimensions in one preferred embodiment.
FIG. 8 shows three perspective views of the complete rebar protective cover of this invention.
The hollow cylindrical collar 2 is closed at one end 6 and is open at the other 7 . The flat impact head 1 is formed so that when joined to the cylindrical collar 2 , the impact head extends beyond and overhangs the collar 2 .
The separately formed impact head 1 as shown is preferably circular and has an area of about 16 square inches as required by Cal OSHA. The impact head can also be square.
Four web-like buttresses 8 , spaced at a 90° interval, help support the periphery of the impact head 1 around its underside.
The fin holder 5 has the inside flanges 9 serve to keep the protective cover longitudinally aligned with the rebar 10 by gripping the sides of the rebar.
The fin holder 5 , the shaping member 4 , the collar 2 and the impact head 1 are first individually formed by injection molding of the polyolefins described herein.
Then the putty-like cement is poured into the collar 2 in an amount sufficient so that when the shaping member 4 is inserted, the cement rises to about mid-level inside the collar 2 as shown in FIG. 2 . The collar walls 11 are preferably thickened in this area. The shaping member 4 itself is not capable of absorbing high impact and serves to shape the surface of the cementitious material 3 to a bowl shape as the concrete hardens. This concrete bowl shaped surface abutting the underside of shaping member 4 acts as the high impact absorbing seat.
The fin holder 5 is then placed in the collar 2 and the impact head 1 positioned against the closed end 6 of the collar 2 . The assembly is heated to cause the fin holder 5 to adhere to the inside of the collar 2 and the impact head 1 to adhere to the closed end 6 of the collar 2 . This assembly can be performed before or after the cement 3 has hardened. Complete hardening of the cementitious material 3 takes about 24 hours. The shaping member 4 becomes adhered to the surface of the hardened cement 3 .
In the completed protective cover, the shaping member 4 is preferably positioned such that the top of the shaping member is about midway between the closed end 6 of the collar 2 and open end of the collar and the concave bottom surface of the shaping member 4 is about one third the distance from the closed end 6 of the collar to the open end of the collar 2 . A preferred example of these dimensions is shown in FIG. 7 .
The plastic parts of the protective cover of this invention are integrally molded, in standard plastic injection molding equipment, using a high molecular weight polyolefin polymers. The plastic can contain a small amount (about 0.04%) of an orange colorant such as anti-UV red, a small amount of orange pigment (about 0.032%) and a small amount of filler such as calcium chloride (about 1% to 3%), all based on the total weight of polymers. These additives are desirable, but not essential.
In my preferred embodiment, the plastic parts of the protective cover are injection molded of a homogenous mixture of two very high molecular weight polyethylene polymers as follows:
Molecular Weight
Density
Percentage
Polymer
Distribution
gTcm 3
By Weight
Extra High
about 2.5 × 10 5 to
about 0.945
about 95%
Molecular
about 15 × 10 5
Weight High
Density
Polyethylene
Ultra High
essentially all
about 0.97
about 5%
Molecular
over about
Weight High
15 × 10 5
Density
Polyethylene
The upper limit of the molecular weight of the ultra high molecular weight high density polyethylene is not critical. Such polymers currently available are believed to be only slightly above 15×10 5 but could be higher such as 20 or 25×10 5 .
The two polymers are premixed and colorant, pigment and filler are added. A homogenous blend forms in the molten state which is then injected into the cavity of the mold. Injection molding equipment is used to form the protective cover to the desired shape.
The cementitious portion of the protective cover is a high strength concrete mixed with carborundum/ceramic grain.
The cementitious portion 3 of the protective cover is prepared by mixing:
Carborundum:
70%-80%
Cement:
29%-19% and
Ceramic powder or quartzite:
1%
These ingredients are mixed with water. Various well known cement additives can also be added in minor amounts. Those skilled in the art can modify the ingredients and proportions.
The following are preferred ingredients:
1. The carborundum particles size: about 8-20 mesh
2. The quartzite particles size: about 40-50 mesh
3. Ceramic powder: composition is Al 2 O 3 , SIO 2 and MgO
4. Ceramic powder particle size: 40-50 mesh.
The upper surface of the impact head 1 of the protective cover is preferably flat as shown in the Figures. However, a domed or mushroom shaped upper surface is also acceptable.
The original Cal OSHA drop test required the protective cover be capable of withstanding at least the impact of a 250 pound weight dropped from a height of 10 feet without penetration failure of the cover. This drop test was based on the rebar being aligned with the longitudinal dimension of the cylindrical body portion.
The problem is that many prior protective covers in actual use, upon impact, allowed the rebar to penetrate and pierce the side of the cylindrical body at or around its junction with the impact head. Failures of this kind have resulted in serious industrial accidents.
Since it was found upon severe impact that the interior flanges 9 would break or give way, allowing the protective cover to become cocked at an angle to the rebar, the latest Cal OSHA drop test requires that it be conducted with the protective cover positioned over the rebar as shown in FIG. 6 .
The following test results demonstrated the efficacy of the rebar safety protective cover of this invention.
A rebar protective cover was assembled using as the cementitious material a mixture of carborundum about 75%, cement about 24% and quartzite about 1%, all of weight.
Cal OSHA DROP TEST
Test Procedure:
The drop test was conducted in accordance with the latest Cal OSHA procedure. The rebar protective cover of FIG. 7 was attached to the sheared end of a 6 inch long #4 rebar mounted on a support. The rebar was rigidly held in a vertical position during impact. A test weight was suspended above the test item at the specified drop height of 10 feet, as measured from the bottom of the test weight to the top of the test item. The test weight consisted of 250 pounds of dry sand in a Kevlar bag having a circumference of 41 inches. The test weight was slowly raised to the specified drop height. When the test weight reached the specified drop height, the test weight was quickly released by cutting the support wire cable. The test weight then impacted the test item. The test rebar protective cover was then visually inspected for evidence of physical damage. Three (3) drops were conducted: The first drop was conducted with the plastic rebar protective cover of this invention installed squarely on the rebar so that the impact head 1 is at a right angle to the lengthwise dimension of the exposed rebar. The second and third drops were performed with the plastic stabilizer flanges 9 removed from the rebar protective cover of this invention prior to the test. This allowed the rebar protective cover to sit on the rebar with the impact head, at maximum angle out of level (out of square). A drawing of this set-up may be seen in FIG. 6 . The free end of the rebar abutted the inside of the shaping member 4 at its lateral extremity, as shown.
Test Data:
Test Weight: 250 pounds Drop Height: 10 feet
Test Results:
The rebar caps completed the drop tests with no evidence of cracking and/or splitting of the cementitious material.
As used herein, the term “Cal OSHA drop test” refers to the above described test.
These results indicate that the rebar protective cover of this invention is likely to be more effective in preventing serious puncture injuries to workmen accidentally falling on the end of exposed rebar. | Briefly, this invention comprises a rebar protective cover for use on the projecting free end of a concrete reinforcing bar to prevent impact injuries comprising:
(a) a hollow cylindrical collar, having an open end and a closed end, (b) an overhanging impact head of substantial extent projecting laterally outwardly beyond the closed end of said collar, (c) a bowl-shaped shaping member having the concave surface facing the open end of the collar, (d) a solid cementitious member occupying the space between said closed end of the collar and the underside of said shaping member, said cementitious member having a surface abutting the underside of said shaping member complementary to said shaping member and adapted to resist impact penetration,
said protective cover preventing penetration of the cover by rebar. | 4 |
BACKGROUND OF THE INVENTION
Wall-to-wall carpeting is usually installed with an underlay or padding to provide comfortable walking. It is somewhat difficult to install such carpeting over a normal underlay because of the need to stretch the carpeting toward the wall over an underlay that tends to cling to the carpeting. This causes uneveness in the underlay and the carpeting. Contrary to other carpet and underlay structures, in this instance it would be desirable for the face of the underlay which contacts the carpeting to be of low friction so the carpet can slide easily over the underlay during installation. Relative sliding after installation is not a problem since both the carpeting and the underlay are fixed around the entire perimeter.
The general structure of the overlay described in my U.S. Pat. Nos. 4,504,537 and 4,504,538 is admirably suited for the purposes of the present invention except for the central stiffening lattice and the upper layer which contacts the carpeting. That upper layer has been modified to provide the properties needed for purposes of this invention.
It is an object of this invention to provide a novel rug underlay having characteristics suitable for use with wall-to-wall carpeting. It is another object of this invention to provide a rug underlay of fibrous material having a uniform consistence, no unpleasant odor, and a clean appearance. It is still another object of this invention to provide a rug underlay having a carpet contacting surface that has low friction and will permit carpeting to slide over it easily. Still other objects will be apparent from a more detailed description of this invention which follows.
BRIEF DESCRIPTION OF THIS INVENTION
This invention provides a rug underlay comprising a central needle punched fiber batting, a lower outer corrugated surface of partially heat fused fibers produced by heat fusing and corrugating the lower surface of said central layer and an upper outer thin layer of a low friction spun woven polyester scrim. In preferred embodiments of this invention the fiber batting comprises a mixture of a majority of polypropylene fibers and a minority of nylon fibers, polyester fibers, and cotton fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features 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 schematic illustration in perspective indicating how a mass of fiber batting is needle punched into a compressed fibrous central layer;
FIG. 2 is a cross section through the rug underlay of this invention; and
FIG. 3 is a plan view of the top layer of the rug underlay with a portion thereof folded so as to show the lower outside layer of the underlay.
DETAILED DESCRIPTION OF THE INVENTION
The central core 10 of the rug underlay of this invention comprises a mass of fibrous material compressed into a layer about 1/4 to 1/2 inch thick. This central core 10 can be made in any of several ways but it has been found most desirable to perform it by a needle punching operation which is depicted in FIG. 1. A mass of fiber batting 11 is subjected to a needle punching operation in a press in which a plurality of closely spaced, barbed needles 12 are punched through batting 11 enough times to compress the batting 11 to a very thin dense layer of intertwined fibers. It is preferable to subject a mass of fibers to a carding operation to produce fiber batting 11 with most of the fibers in the batting generally parallel with each other. Such a carded fiber batting produces a more desirable structure for this invention than a batting that has not been carded. Needle punching is a common operation employed in the fiber industry to intertwine fibers and filaments into a felt-like layer of material. In general a mass of fiber batting is needle punched to a thin layer which is then turned over and another mass of batting is applied to the opposite surface and needle punched again. These operations are repeated with new layers of batting applied to opposite sides of the needle punched layer until a central core 10 has been produced of the desired thickness, preferably about 5/16 inch. The fibers in the batting may be any type of natural or synthetic fibers, although snythetic are preferred such as polyprolefin, nylon, polyester, acrylic polymer, etc. Preferably, the fibers are polypropylene of mixtures of a majority of polypropylene, and a minority of nylon, polyester and cotton.
The central layer 10, as described above, is then treated to produce a lower layer 14 which will cling to any lower underlay or to the floor on which it is laid. Lower layer 14 is a surface of partially fused fibers having a stiff hard feeling as compared to the compressed fibers of the central core. Lower layer 14 also has some fiber ends projecting upwardly which can be sensed by rubbing this surface with one's fingers or by looking at the surface through a microscope. These fiber ends produce a good frictional contact with wooden or masonry flooring or with an underlay covering the floor. A preferred method of producing surface 14 is by applying sufficient heat to partially fuse the fibers at one of the outside surfaces of central layer 10 of needle punched fibers described previously. The corrugated appearance of lower layer 14 may be achieved by passing the underlay under a heated roller having a pattern of raised ridges. The roller is heated to a sufficiently high surface temperature to cause partial fusing of the fibers at the outer portion of layer 10 as they pass under the roller. This action produces a semistiff corrugated surface having a pattern of depression 15 that provides an excellent grip for flooring or another underlay.
It is not critical that corrugated depressions 15 be in any particular design to provide the proper contact between the underlay and the flooring below the underlay. The design may be parallel ridges and grooves, a geometric design such as squares, triangles, etc.; or any other design of ridges and valleys which will provide a good grip on the adjoining surface and, at the same time provide a good cushioning effect. A particularly preferred design is a simple pattern of parallel depressions 15 about 1/4-1/2 inch apart. Each depression 15 being about 1/16 inch wide and 1/16 inch deep.
Upper layer 16 is a thin layer of low friction fibrous material bonded to the upper surface of the central core 10 of needle punched fibers so as to provide a slightly slippery contact with the underside of a carpet lying on that surface. This layer may be made of any suitable type of fiber, preferably, a polyester in a spun woven pattern. Such a layer need not be more than about 0.001 inch thick. Layer 16 may be attached to central layer 10 by any of a variety of means. For example, layer 16 may be lightly needle punched onto the outside surface of central layer 10. An adhesive may be applied to the surface of central layer 10 and layer 16 pressed thereon. Still another procedure is to press layer 16 onto layer 10 and apply sufficient heat to cause a partial melting of the fibers at the interface, which upon cooling will be firmly intertwined with each other.
FIG. 3 shows the general appearance of the underlay with corrugated surface of parallel depressions or grooves 15 on lower layer 14 and with the spun woven fibrous upper layer 16. An appropriately prepared underlay of the construction described above may have a thickness of about 5/16 inch for a weight of approximately 30 ounces or a thicker structure of about 1/2 inch for a weight of about 48-52 ounces. Thicknesses and weights between these extremes are also readily prepared as may be understood by those skilled in the art.
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 rug underlay comprising a centered layer of needle punched fiber batting, an upper outer corrugated layer of heat fused fibers, and a lower outer thin layer of a low friction spun woven polyester scrim. This article is used as a padding or an underlay for wall-to-wall carpeting. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority of U.S. Provisional Patent Application No. 60/098,078, filed Aug. 27, 1998.
BACKGROUND OF THE INVENTION
The present invention relates generally to networks, and more particularly, to a method for detecting devices connected to such a network.
Networks, such as computerized Local Area Networks (LANs) are commonly used to interconnect many different devices, such as computers. There is an increasing requirement to provide communication between these devices. This is because of the number of devices that are to be connected together, and the increases in the amount of information that is to be communicated between them. As a result, a number of networking technologies have been developed, and many standards have been developed around these technologies.
One example of such a technology includes a token ring network in which many devices are connected in either a physical or logical ring, and a token is transmitted around the ring from device to device. When a device requires access to the ring to transmit information, it waits to receive the token and then holds the token while transmitting data on the network. Other devices are prevented from receiving the token while information is being transmitted by the token holder.
Another networking technology is Ethernet. Ethernet is a commonly used LAN scheme in which multiple devices are connected together. In some cases, only one device can transmit data at a time. A device transmits data in the form of a packet that includes a destination address. The packet propagates throughout the network, and is received by all other devices connected to the network. The destination device may copy the entire packet. The other devices may reject the packet after determining that it is addressed to the destination device.
Because of the large number of users and devices associated with a LAN, management of the LAN is quite complex and can be handled by a system administrator or a centralized management system. The system administrator or central management system is an entity that a user of a device typically contacts when the user encounters a problem related to the network. The increasing growth and complexity of LANs makes it more difficult for a user to contact the system administrator. For example, the identity and/or location of the system administrator may not be known to many users. In addition, reliance on these centralized management systems can cause congestion in the LAN due to the number of packets destined to the system administrator. Further, a centralized management system increases the risk of network failure because of the excessive reliance on the system administrator.
SUMMARY OF THE INVENTION
In general, in one aspect, the present invention is directed to a method for detecting characteristics of a plurality of peer devices connected to a network that includes generating. an identification frame by one of the peer devices. The identification frame may be propagated to only the other peer devices in the network.
Implementations of the invention include one or more of the following. The identification frame may include a network address or a group address. An error or a predefined MAC address may be introduced into the frame to cause the peer device to recognize the frame. The network may be a token ring or an Ethernet network. The error may be a corruption of the cyclic redundancy control (CRC) check bit or a predefined combination of the padding bits of the identification frame.
In another aspect, the present invention is directed to a computer network that includes a plurality of peer devices connected to the network by a plurality of links and switches. An identification frame is propagated from one peer device to the other peer devices to enable a plurality of features of the peer devices receiving the identification frame.
Implementations of the invention may include one or more of the following. The identification frame may be a MAC frame. The identification frame may be exchanged in a management information format. Each of the switches may have a media access controller connected between the selected device and a transceiver circuit. The transceiver circuit may include a controller for recognizing an error or a predefined MAC address in the identification frame.
In yet another aspect, the present invention is directed to a network including a plurality of peer devices that includes a plurality of switches connected to the devices. The switches may include computer software residing on a computer readable medium at each switch to recognize an identification frame from one of the peer devices. The switch may propagate the identification frame only to other ones of the peer devices in the network.
Other advantages will become apparent from the following description including the drawings and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary network.
FIG. 2 illustrates a block diagram of a switch that can be implemented in the network of FIG. 1 .
FIG. 3 illustrates an identification frame transmitted among a plurality of devices connected to the network of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A system administrator is responsible for managing a network. The system administrator's responsibilities may include configuring a device that is added to the network. Thus, the system administrator is responsible for the central management of the network. This means that the system administrator must enable certain functionalities of the devices, the network, and other attached peripherals. This requirement of centralized management of the system by the administrator increases the risk in a network that a network failure may occur at the system administrator. As a result, the entire network may be inoperable during the time that the network failure is being remedied. Further, a network failure at the system administrator may also cause other network failures throughout the network that initiate at the system administrator. For example, the system administrator is responsible for detecting the presence of a failed link and notifying the devices of the failure. However, if the administrator is unable to notify the devices, the devices may not receive important data. This means that the device may not be able to execute or continue a process running on its system.
Accordingly, the present inventor has discovered a method in which a device connected to a network may obtain characteristic information about other similarly connected devices without notifying or relying on the system administrator. In the preferred method, the characteristic of information is distributed using an identification frame that is propagated to various devices connected to the network to cause these devices to perform various functions.
FIG. 1 illustrates an example network, such as a local area network (LAN) 1 . The network 1 may be an Ethernet medium that has a bus-type architecture. Alternatively, the network 1 may be a token-ring medium having a ring-type architecture. The network 1 may be a heterogeneous system including several connected devices, such as computers or peripherals, to which the devices can share access. Alternatively, the network may be a homogeneous network in which every connected device uses the same protocol.
FIG. 1 shows that a device 2 is connected to the network 1 by a switch 8 via links 9 . Similarly, a device 3 is connected to the network 1 by a switch 7 via links 5 , and a device 4 is connected to the network 1 by a switch 13 via links 15 . Each of the switches 7 , 8 , and 13 may include ports (not shown) for propagating data to or from an attached device. Each of the switches 7 , 8 , and 13 may include multiple ports for connecting multiple devices to the network 1 . A switch is a network device that operates at a data link layer of the Open Systems Interconnection (OSI) reference model. The switches 7 , 8 , and 13 may be bridges, routers, or other similar devices for propagating frames of data throughout the network 1 . The devices 2 , 3 , and 4 may include a personal computer (PC), a file server, a printer, or other suitable devices that may interface with the network 1 . A system administrator 25 may also be connected to the network 1 . The network 1 may also include a hub 6 that can be used to connect the devices 2 , 3 , and 4 of network 1 to other networks including other devices. For example, network 1 may be connected to an Ethernet or token ring network.
FIG. 2 illustrates an example block diagram of a suitable configuration for the switches, 7 , 8 , and 13 . The switch includes a transceiver circuit 10 connected to a media access control (MAC) 15 . The MAC 15 is an interface between a physical layer device, such as a transceiver circuit 10 , and the attached device. The MAC 15 generally may perform a plurality of functions. For example, during the transmission of data, the MAC assembles the data to be transmitted into a frame of data with address and error detection fields. Conversely, during the reception of the frame of data, the MAC disassembles the frame and performs address checking and error detection. Further, the MAC may perform preamble generation/removal.
The switches 7 , 8 , and 13 may also have different configurations to support different topologies or protocols. Further, each of the switches 7 , 8 , and 13 may be configured to perform different functions. For example, the controller may be programmed to cause only switch 7 to process frames of data received from a device located on a specific link of the network 1 .
The transceiver circuit 10 includes an encoder/decoder circuit 17 , a controller 19 , and 20 a memory 21 connected to the controller 19 . The transceiver circuit 10 is a physical layer device that takes data from the MAC 15 , encodes it, and serializes it for transmission on one of the attached links. This process is reversed for data propagating towards the attached device. The controller 19 may perform a variety of functions including an auto-negotiation process. An auto-negotiation process may be stored in the memory 21 . The controller may execute the auto-negotiation process between the switch and the attached device. An example of an auto-negotiation process is set forth in Clause 28 of the IEEE 802.3 Standard. The auto-negotiation process exchanges information about each device, determines the common capabilities of the device, and selects the highest performance common capabilities between the switch and the device.
As discussed above, in the preferred method, an identification frame is transmitted between devices in the network to enable certain functionalities of the devices. Preferably, the identification frame is only transmitted to “peer” devices in the network. A peer device is a device that can be configured to process or identify the identification frame from other frames in the network. The device may be configured explicitly. This means that a process, such as software residing on a computer, can identify the identification frame. Alternatively, the switch connected to the device can be configured to recognize the identification frame. In this configuration, a frame arriving at the switch that is recognized as an identification frame that is to be passed to an attached device will be propagated to that device. If the switch does not recognize the frame, the frame is not processed.
Preferably, the identification frame may include characteristic information about the sending device. For example, the identification frame 40 may include information to determine whether a peer device is from a specific group, such as a particular corporation. Further, the identification frame can include the network address of the sending device or information about other peer devices. This identification information may be exchanged in the form of sysObjectId object in the management information base (MIB) MIB-II MIB format.
The identification frame may also include information that can be used to enable certain functionalities of the device that sends or receives the identification frame. For example, information between devices may be obtained to determine the specifications about a device such as the processor speed of a device. The preferred method may be used to control adaptive packet sizes by enabling large frame or jumbo frames in an Ethernet. The preferred method may also be used to provide secured data transmissions between peer devices. For example, a device can transmit a password in the identification frame associated with particular data to a peer device that can be used to access the data.
An example of transmitting identification frames in accordance with the preferred method is shown in FIG. 3 . Assume that the identification frame 40 is configured with a predefined MAC address “M”, switch. 8 is configured to identify the MAC address, and the frame 40 is transmitted from the device 3 . The frame may also include other information, such as source and destination address information. The frame 40 is then received at switch 7 . At this stage, the identification frame 40 may be passed to the other switches 8 and 13 . The frame is received and processed by switch 8 because the switch is configured to recognize that the identification frame. As a result, the frame 40 will be passed to device 2 .
Conversely, the switch 13 in this example is not configured to recognize the predefined MAC address M. Accordingly, the switch will discard the frame 40 . This means that device 4 is identified as a non-peer device, and thus, does not receive the identification frame 40 .
In one operating regime, the identification frame can be inhibited from forwarding to non-peer devices by introducing an error in the identification frame to cause the non-peer devices or the switches connected to those devices to reject the frame. For example, the controller 19 of MAC 15 can be configured to recognize the error to identify the identification frame. The error may be a corruption of the cyclic redundancy control check (CRC) or a predefined combination of the padding bites. Padding bites may include any unused or additional bites of the identification frame.
In another operating regime, the identification frame may be inhibited from forwarding to non-peer devices using a modified MAC address. For example, the controller 19 may be configured to cause the MAC 15 to identify the identification frames. This means that a peer device can be configured to process the frame when the MAC address is identified by the MAC 15 . This means that non-peer devices that are not configured to recognize the MAC address will drop the frame or forward it to an unknown address.
FIG. 3 also illustrates that the device 2 returns an identification frame 60 to device 3 that includes similar characteristic information found in identification frame 40 . The identification frame 60 can also be used to transmit information to device 3 . Additionally, identification frame 60 can include an “Ack” field to acknowledge that the connection between the devices 2 and 3 has been properly established. The identification frame 60 can be processed by the peer devices or the switches connected to the peer devices substantially the same as the identification frame 40 .
The preferred method allows devices to communicate independent of a system administrator in a network, such as a LAN. This limits the reliance by the devices on the system administrator. For example, a device can be added or deleted from a device. When this occurs, the device can send an identification frame to notify other peer devices. This means that the system administrator does not have to take responsibility for this information. Further, the preferred method reduces the risk of system failure at the system administrator because large amount of data can be transmitted between devices. As a result, the responsibilities on the system administrator are substantially reduced.
Further, this means that such a system failure may not cause a system-wide failure throughout the network. Further, the devices can enable specific functions of attached peer devices.
The methods and mechanisms described here are not limited to any particular hardware or software configuration, or to any particular communications modality, but rather they may find applicability in any communications or computer network environment.
The techniques described here may be implemented in hardware or software, or a combination of the two. Preferably, the techniques are implemented in computer programs executing one or more programmable computers that each includes a processor, a storage medium readable by the processor (including volatile and non-volatile memory and/or storage elements), and suitable input and output devices. The programmable computers may be either general-purpose computers or special-purpose, embedded systems. In either case, program code is applied to data entered with or received from an input device to perform the functions described and to generate output information. The output information is applied to one or more output devices.
Each program is preferably implemented in a high level procedural or object-oriented programming language to communicate with a computer system. However, the programs can be implemented in assembly or machine language, if desired. In any case, the language may be a compiled or interpreted language.
Each such computer program is preferably stored on a storage medium or device (e.g., CD-ROM, hard disk, magnetic diskette, or memory chip) that is readable by a general or special purpose programmable computer for configuring and operating the computer when the storage medium or device is read by the computer to perform the procedures described. The system also may be implemented as a computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner.
A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims. For example, the identification frame may include characteristic information to cause the peer devices to make optimal use of bandwidth in the network. | A method is disclosed for permitting devices connected to a network to identify characteristics of other devices connected to a network. The devices may automatically obtain information about the other devices in the network in a distributed manner without required a centralized management entity. This means that functions, such as device configuration, can be performed without a system administrator. This reduces the risk of system failure at the system administrator by reducing the reliance on the administrator. The disclosed method may be used in a network employing Ethernet or token-ring frame formats. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a process for calcining green coke obtained from a delayed coking process. More specifically, the present invention contemplates producing high-grade coke efficiently by carrying out unit process stages for calcining green coke in respectively separate heating furnaces.
Preparation of green coke from heavy oils of petroleum or coal origin such as residue oils of catalytic cracking and thermal cracking, straight run residue oils and tar of thermal cracking, coal tar pitch or mixtures thereof by a delayed coking process which comprises heat treatment at a temperature of 400° to 550° C. for 60 minutes to 50 hours is known. The green coke produced by this process still contains a significant quantity of moisture and volatile matter. Accordingly, there is also known a process for calcining the produced green coke in order to remove the water content and volatile matter from the green coke and to densify it, thereby producing a carbon material having a high density and a low coefficient of thermal expansion which is suitable for use as an electrode material for steel-making, aluminum smelting or the like or a carbon material for other shaped articles.
Calcining of such green coke is carried out in heating furnaces such as a rotary kiln, a rotary hearth, and a shaft kiln. That is, the raw material green coke introduced into the furnace through its inlet is dried, heated and calcined by heat of combustion resulting from the combustion of fuels, the volatile matter produced from the coke and part of the calcined coke during the time the coke is transferred to its outlet and the calcined coke is then removed from the furnace. In addition, it is well known that the calcining temperature, the rate of heating, and the furnace atmosphere in a series of calcining stages have an influence on the quality of the calcined coke. Accordingly, various types of improved processes for calcining green coke have been proposed.
One of these processes comprises pre-drying green coke in a separate apparatus by utilizing the heat of a hot gas leaving a rotary kiln before the coke is introduced into the rotary kiln (as disclosed in Japanese Patent Laid-open Publication No. 33201/1975). Another process comprises calcining green coke in a rotary kiln by supplying air through more than one opening at an intermediate part of the kiln in order to ensure complete vaporization and combustion of the volatile matter contained in the green coke which have a great influence on the quality of the calcined coke (as disclosed in Japanese Patent Laid-open Publication No. 16031/1975).
Of the above described improved processes, the former is said to be characteristic in that drying of green coke can be carried out at a low cost of operation and with good control of the process operation. However, it cannot be said that controlling of the drying process only is a substantial improvement in a calcining process for obtaining high-grade coke.
On the other hand, the latter is said to be advantageous in that the combustion of the volatile matter contained in green coke is promoted, in that the heat of combustion is utilized, and in that useless combustion of completely calcined coke is avoided. However, this process entails the following problems. A rapid temperature rise due to the combustion of the volatile matter which occurs at an air blowing place has a great influence on the quality of the resulting coke, and it is difficult to independently control the optimal temperature of the final stage of the calcining which has a great influence on the quality of the resulting coke because the calcining temperature of the final stage is greatly affected by the combustion control of the volatile matter.
Accordingly, it can be said that the above described known processes are still not fully satisfactory as processes for calcining green coke. According to the knowledge of the inventors, it is considered that the difficulties accompanying the known processes are attributable to the fact that control factors are too few as compared with the number of the unit stages included in the calcination of green coke. That is, as stated above, the calcination of green coke involves three unit stages: water removing and drying stage, volatile matter removing and combusting stage, and final calcining stage. It is preferable that these unit stages be controlled independently from each other. The reasons for this are as follows.
(1) Green coke ordinarily contains 7 to 10% by weight of water and 6 to 10% by weight of volatile matter and in the calcining process, the water is evaporated at about 100° C. and the volatile matter begins to evaporate at an increased temperature of the order of 450° C. That is, the respective evaporation temperatures are different from each other and the evaporated volatile matter burns and serves as a source of heat. Therefore, in order to ensure the stabilization of temperature distribution throughout the total calcining process when a raw material having different contents of water and volatile matter is used, the water removing stage and the volatile matter removing and burning stage are preferably controlled independently from each other.
(2) Green coke ordinarily contains a volatile matter content of 6 to 10% by weight or as high as 20% by weight depending upon the operation conditions of a delayed coker (the volatile matter substances are these which are defined according JIS M 8812). When this volatile matter is heated to a temperature of 450° to 600° C. in a heating furnace, it is evaporated, and a part thereof is melted. The melt functions as a binder forming carbonaceous adhesive matter such as ring-shaped adhesive matter (coke ring) in a rotary kiln, thereby preventing a normal flow of coke. However, if an adequate oxidizing atmosphere is maintained in the furnace, fusible volatile matter is rendered infusible in the course of temperature rise, whereby the formation of such carbonaceous materials can be prevented.
Such maintenance of an adequate oxidizing atmosphere in the volatile matter removing stage not only makes the volatile matters infusible but also improves the combustion condition thereof, which in turn affords an efficient recovery of heat. However, in the prior system wherein the volatile matter removal and the final calcining are carried out in one furnace, maintaining of a sufficiently oxidizing atmosphere so as to effectively carry out the removal and combustion of the volatile matter in the volatile matter removal stage leads to the combustion of the product coke in the final calcining stage, and this is therefore unfavorable. Thus, according to the prior system, the loss of coke is as high as about 10% by weight.
(3) Since the conditions of the final calcining stage particularly have an influence on the property of the product coke, it is preferable that the final calcining stage be controllable independently of the preceding water removing stage and volatile matter removing and burning stage.
SUMMARY OF THE INVENTION
On the basis of the above considerations, the present invention aims at providing an improved process for calcining green coke wherein, by adopting a system in which the respective stages of the calcining of green coke can be independently controlled, high-graded coke is obtained in a high yield while an effective utilization of heat is maintained, and such problems as the adhesion of carbonaceous materials are eliminated.
Accordingly, the process for calcining green coke according to the present invention is a process for calcining green coke obtained by a delayed coking process in heating furnaces of three or more stages connected in series, in which the control of temperature and the adjustment of atmosphere in the respective furnaces can be independently carried out, which process comprises carrying out the following steps in the respective furnaces in the indicated order:
(a) evaporating the water contained in the green coke, and drying and preheating the coke;
(b) distilling off and burning the volatile matter in the dried coke; and
(c) heating and calcining the coke from the step (b).
The present invention will be further described with respect to the following examples with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a flow chart illustrating one example of the process of the present invention using rotary kilns as heating furnaces; and
FIG. 2 is a partial side view illustrating an arrangement of a raw material feeder 1 provided in a kiln 2.
DETAILED DESCRIPTION
The numerical values set forth hereinafter are only typical ones, and, in particular, the temperature and retention time values indicate standard ranges. Of course, these values can be appropriately varied depending on the properties of green coke and the properties of the calcined coke desired.
Referring to FIG. 1, the green coke obtained by a delayed coking process is dressed into the desired particle size distribution, for example, such that about 25% is not greater than 3 mesh, about 75% is above 3 mesh, and the maximum particle diameter is not greater than 70 mm. Then, the coke is introduced into a drying and pre-heating kiln 2 through a raw material feeder 1.
The raw material feeder may be of a type wherein a hopper is directly inserted into the kiln 2 from the upper end thereof. In order to ensure a better airtightness, as is shown in FIG. 2, it is preferable that the feeder be of such a type that raw material coke is introduced into an annular raw material reservoir 1c having a diameter greater than that of the kiln, which reservoir is attached to the side of the kiln body 2b in the neighbourhood of the upper end 2a of the kiln, through a conveyor 1a and a hopper chute 1b, and a trough 1d communicating with the kiln body 2b is provided, for example, at four portions within the reservoir 1c. The raw material is charged into the kiln through the troughs.
The green coke typically has a water content of 7 to 10% (by weight, as in all percentages hereinafter), a volatile matter content of 6 to 10% (according to JIS M 8812), and an apparent density of 0.80 to 0.95 g/cm 3 . The green coke in the kiln 2 is heated to a temperature of 350° to 400° C. by a hot gas (which is at a temperature between about 1,100° to 1,300° C.), introduced into the kiln 2 through a duct 5 from a burning kiln 3 and a final calcining kiln 4 as hereinafter described. As a result, pre-heating of the coke is carried out with evaporation of the water.
The inclination angle of the kiln 2 is of the order of 1.2 to 3.0 degrees and the inner diameter, the total length, and rotational speed of the kiln are selected so as to ensure a retention time of 10 to 30 minutes. By way of example, an inner diameter of 2.3 m, a total length of 20 m, and a rotational speed of 0.5 to 1.0 rpm are adopted for a green coke charge of 10 tons/hr.
The hot gas leaving the kiln 2 is still at a temperature of about 500° to 700° C., which gas is introduced into an air pre-heater 7 through a duct 6 where the gas undergoes a heat-exchange with air, and the gas itself is cooled to a temperature of about 200° to 400° C. and then discharged outside of the system through a chimney 8, while the air is pre-heated to a temperature of 300° to 500° C. The pre-heated air is introduced into the burning kiln 3 and the combustion chamber 10 of the final calcining kiln 4 through a piping 9 (9a, 9b). Further, an air inlet (not shown) is provided at the base of the chimney 8 so as to control the quantity of air introduced and to adjust the pressure in the chimney, for example, to -20 mm H 2 O.
The coke pre-heated to a temperature of 350° to 400° C. in the drying and pre-heating kiln 2 is introduced into the burning kiln 3 through a coke feeding device 11 where the volatile matter contained in the coke is distilled off and burned by the pre-heated air from the piping 9a, and the coke is heated to a temperature of about 800° to 980° C.
The coke feeding device 11 is of almost the same type as the raw material feeder 1. Ordinarily, the inlet end of the kiln 3 is positioned immediately below the outlet end of the kiln 2, and the pre-heated coke from the kiln 2 is directly dropped by gravity into an annular material reservoir 11c (not shown, corresponding to the reservoir 1c of FIG. 2) of the coke feeding device 11 of the kiln 3 through a conduit. If such an arrangement is not appropriate, the transportation between the kilns may be carried out by means of a steel belt conveyor or a moving hopper.
At the start of the operation, the coke bed is heated to a temperature (about 600° C.) at which the volatile matter begins to be distilled off and burned by heat due to a burner 12. After this, the burner 12 may be turned off. The inclination of the kiln 3 is about 1.2° to 3.0°, and the retention time is between 30 to 60 minutes. For a coke charge rate of 10 tons/hr, an example of this kiln 3 has an inner diameter of 3.0 m, a length of 20 m, and a rotational speed of 0.5 to 1.0 rpm.
As stated above, the pre-heated air is introduced into the kiln 3, and an adequate oxidizing atmosphere is maintained within the kiln 3. Accordingly, it is possible to burn the volatile matter completely, whereby high-grade coke is obtained, and, at the same time, saving of fuel is achieved. In addition, as the volatile matter may also be rendered infusible, it is possible to prevent completely the formation of ring-shaped adhesive materials in the drying zone.
In the case where the possibility of coke ring-formation is low, judging from the quantity and properties of the volatile matter contained in green coke or for the convenience of the process operation, the pre-heated air is not always introduced in a parallel flow with the flow direction of the coke as shown in FIG. 1, but it may be introduced in a counter flow. However, in order to maintain a high oxygen concentration in the low-temperature drying zone of the kiln 3 and to promote the infusibilization of the volatile matter and to prevent the formation of coke ring, a parallel flow is preferable.
Then, the coke heated to a temperature of about 800° to 980° C. in the burning kiln 3 is introduced into the final calcining kiln 4 through a coke feeding device 13, where the coke is heated to a calcining temperature of 1,200° to 1,500° C. and thus calcined. The coke feeding device 13 may be of the same type as the coke feeding device 11. The coke is maintained at the calcining temperature for about 10 to 30 minutes in the calcining kiln 4, and the total retention time within the calcining kiln 4 is between about 30 to 60 minutes. In one example of practice, this kiln 4 has an inner diameter of 2.3 m, a length of 20 m, and a rotational speed of 0.5 to 1 rpm for a green coke charge rate of 10 tons/hr.
The calcining kiln 4 may be provided, for example, with the combustion chamber 10 for fuel at the opposite end of the inlet for introducing coke wherein fuel is burned by a burner 14, and the combustion gas is utilized to heat the coke, or an air-premixing type burner which ejects a short flame may be utilized to heat the coke without the burning chamber. Since the quantity of the pre-heated air introduced can be optionally adjusted according to this heating method, it is possible to control the useless combustion of the calcined coke which cannot be avoided in conventional processes, whereby the quality of the calcined coke is improved, and a high yield is obtained.
The burning chamber 10 has a construction in which the discharge opening for the combustion gas is directly connected to the outlet of the kiln. As a short flame burner, use is made of a pre-mixing type gas burner wherein a fuel gas and air for combustion are uniformly mixed, and the mixture is injected through a nozzle for combustion thereof. Particularly, a partial pre-mixing type burner wherein primary air only is mixed with the fuel gas is preferable. By adjusting the quantity of the primary air, it is possible to shorten the flame to a length not greater than 1.0 or 1.5 m.
The calcined coke is removed as a product from a withdrawal chute 15 positioned before the combustion chamber 10. Ordinarily, the withdrawn coke is introduced into a cooler of rotary kiln type which is provided with a spray nozzle for a cooling water therein and water is sprayed directly on the coke. However, if necessary, the coke may be cooled by a gas. According to the present invention, it is possible to control the combustion loss of the calcined coke within 1%.
The flow rate and temperature distribution at the respective parts per 1 ton of green coke are shown in the following table.
______________________________________Position TemperatureNo. Flowing material (° C.) quantity______________________________________ 1 Green coke Ambient 1 ton temperature11 Pre-heated coke 400 0.92 "13 Volatile matter-free 850 0.82 " coke15 Calcined coke 1,350 0.81 " 9 Pre-heated air 360 1,330 Nm.sup.3 9a Pre-heated air " 930 " 9b Pre-heated air " 400 "16 Combustion gas of 1,000 410 " fuel17 Combustion gas of 1,200 1,000 " volatile matter 5 Combustion gas of 1,140 1,410 " volatile matter and fuel 6 Combuston gas of 570 1,520 " volatile matter and fuel14 Fuel -- 52 kg (calorific value 7,400 kcal/kg)______________________________________
The calcined coke thus obtained has the typical properties shown below and is suitable as an electrode material for steel-making and for other applications.
______________________________________Apparent density 1.42 g/cm.sup.3True specific gravity 2.110 g/cm.sup.3Coefficient of thermal expansion* 1.2×10.sup.-6 /°C.(calcined at 1,000° C.)Coefficient of thermal expansion* 0.8×10.sup.-6 /°C.(graphitized at 2,600° C.)______________________________________ *The coefficient of linear thermal expansion was determined as follows.
The calcined coke was pulverized and 92% of the particles having a particle size of above 200 mesh and 8% of the particles having a particle size below 200 mesh were mixed. 100 parts of this mixture was mixed with 25 parts of coal tar binder pitch (of a softening point of 90.3° C., a benzene insoluble content of 19.8%, a quinoline insoluble content of 4.4%, a volatile matter content of 62.7%, and a fixed carbon content of 53.2%), and the mixture was heated, kneaded and mold-shaped. Then, the shaped article was calcined at a temperature of 1,000° C. Another shaped article was graphitized at a temperature of 2,600° C. Test pieces (rods 5 mm in diameter and about 50 mm in length) were made from the calcined article and the graphitized article, respectively. These test pieces were tested over a temperature range of 30° to 100° C.
In the above described example, a rotary kiln was used for each of the three heating furnaces. However, a part or all of these rotary kilns may also be substituted by a rotary hearth, a retort, or a shaft kiln. However, a rotary kiln is preferable for the reasons that the rapid combustion of the volatile matter can be avoided in the volatile matter removing and burning furnace and the final calcining furnace, and a uniform calcination of coke can be carried out under the optimal temperature rising rate, temperature condition, and atmosphere, whereby high-grade calcined coke is obtained.
In addition, it is most preferable to use three heating furnaces from the standpoint of apparatus economy while the independent controllability of the respective furnaces is maintained. However, if necessary, the respective stages or steps can be, of course, further divided into stages or steps in a plurality of furnaces.
As is apparent from the foregoing, the process for calcining coke according to the present invention has the following advantages.
(1) By using three or more heating furnaces, the respective stages of the coke calcination can be controlled independently from each other and the optimum conditions for producing high-grade coke can be realized.
(2) By ensuring complete control of the combustion condition of the volatile matter contained in green coke, it is possible to produce high-grade coke having a high density, and, at the same time, it is possible to eliminate the formation of ring-shaped adhesive materials in the volatile matter evaporating and burning zone, which is encountered in a process for calcining green coke using one rotary kiln. In addition, as the volatile matter can be completely burned, a more efficient recovery of heat can be attained as compared with the prior process.
(3) By suppressing the useless combustion of the calcined coke, it is possible to improve the quality and yield of the coke. The combustion loss of the calcined coke is reduced to about 1% or less, that is, one tenth or below of the entailed in the prior process.
(4) By controlling the different stages of the green coke calcination independently and combining the respective stages, the efficiency of utilization of heat can be improved. When rotary kilns of the same capacity are used, the calcination can be carried out with a converted quantity of fuel used (the quantity of pure fuel used+the quantity of burned coke calculated in terms of the fuel) which is about 30% or less of that required by the prior process. | A process for calcining green coke containing water and combustible volatile matter and obtained by a delayed coking process in three or more stages of heating furnaces which are connected in series, and the control of the temperature and the adjustment of the atmosphere in the respective furnaces can be independently carried out, which process comprises carrying out, in respective furnaces in the indicated order, the steps of:
(a) evaporating the water contained in the green coke, and drying and pre-heating the coke;
(b) distilling off and burning the volatile matter from the dried coke; and
(c) heating and calcining the coke from the step (b).
Because each furnace can be controlled independently from the other furnaces in the above described process, it is possible to produce high-grade coke without process difficulties such as the loss of the coke by combustion and the formation of coke ring. | 2 |
This application is a division of application Ser. No. 211,537, filed 6/27/88, now U.S. Pat. No. 4,893,908 issued Jan. 16, 1990.
BACKGROUND OF THE INVENTION
This invention relates to the use of a conductive polymer material to selectively control light transmission through a transparent or semitransparent panel or film, and more particularly to the use of a conductive polymer material to provide a window shade of adjustable transmittance. Such a device may be embodied as a flexible adhesive-backed laminated plastic sheet, or as an integral part of a multiple-pane thermal insulating window panel.
Thermal-pane windows conventionally make use of spaced multiple (two or more) panes to provide a thermal barrier restricting heat conduction between the outside and the inside of a building and therefore tending to reduce heating and cooling costs. To further reduce cooling costs, window shades or blinds are used to block out intense, direct rays of sunlight, since conventional windows, insulating or otherwise, have little effect on radiative heating. However, in using a conventional shade to eliminate solar glare, the view to the outside is blocked, which may be considered a visually unattractive result. U.S. Pat. No. 4,268,126 discloses a multi-pane window unit that uses an electrooptical shade as an integral part of a thermal pane window. Such a device relys on diffuse reflection of light rays to provide mainly privacy. The effectiveness of such a window to control radiative heating (solar energy) is limited by the ability of the window device to reduce transmitted radiation by mainly diffuse scattering and not by optical absorption. Devices listed in U.S. Pat. No. 4,268,126 typically reduce solar radiative heating by up to 15%.
Thus, there exists a need for a window unit which includes an electrooptical device as an integral part of a thermopane window that provides a broad adjustable range of coherent light transmittance in both the visible and near-IR region of the electromagnetic spectrum. Such a window device which relies on absorption rather than diffuse reflectance can be used to control glare and the degree of radiative heating from sun rays while not blocking or obscuring the view from the outside.
The present invention makes use of conductive polymer material to provide adjustable control of the intensity of light transmission through a multi-pane thermal window unit or in automobile or aircraft windows or mirrors where adjustable light transmission is desired. The room occupant may select the degree of light transmittance of the shade, thus eliminating glare and the adverse effect on cooling requirements from direct rays of the sun, while not blocking the view to the outside.
Conjugated backbone polymers, e.g., polyacetylene, polyphenylene, polyacenes, polythiophene, poly(phenylene vinylene), poly(thienylene vinylene), poly(furylene vinylene), polyazulene, poly(phenylene sulfide), poly(phenylene oxide), polythianthrene, poly(isothianaphthene), poly(phenylquinoline), polyaniline, and polypyrrole, and the like have been suggested for use in a variety of electronic applications based upon their characteristic of becoming conductive when oxidized or reduced either chemically or electrochemically. Electrodes composed of such polymers can, according to the method of MacDiarmid et al. in U.S. Pat. No. 4,321,114, be reversibly electrochemically reduced to an n-type conductive state (the polymer being inserted by cations) or reversibly oxidized to a p-type conductive state (the polymer being inserted by anions).
The electrochemical oxidation or reduction process is generally recognized to be accompanied by sharp changes in the color of the polymer as well as its optical absorption coefficient (its ability to transmit light). Electrochromic devices based on conductive polymers have been described for example by F. Garnier et al. in J. Electroanal. Chem. 148, 299 (1983), by K. Kaneto et al. Japan J. Appl. Phys 22, L412 (1983), and by T. Kobayashi et al., J. Electroanal. Chem. 161, 419 (1984).
SUMMARY OF THE INVENTION
The present invention provides an electro-optical shade of adjustable light transmittance as an integral part of a multi-pane thermal window unit or as a free standing flexible plastic laminate which may be applied within laminated sheets of glass for automotive and other applications, or which may be applied to the surface of an existing window or mirror.
Advantageously, the thermal window unit is resistant to radiative heating and conductive heat transfer between the exterior and interior. Preferably, it consists of substantially parallel, spaced window panes, mounted in a window frame, a first of the panes having affixed thereto the first wall of an electro-optical conductive polymer cell providing a selected light transmittance, and a second of said panes delimiting, with a second wall of said cell a space providing a thermal break. When the device is included as an integral part of a glass laminate, the advantage of an adjustable tint is obtained from varying the amount and polarity of direct current applied. The transmission of both visible and near-infrared radiation can be adjusted.
The term "electro-optical conductive polymer cell" as used hereinafter is intended to means a device consisting of two electrodes with an electrolyte in between, and at least one of such electrodes comprising an electrochromic conductive polymer. The conductive polymer material being electro-optically responsive to an applied voltage between the electrodes, such that light transmittance through the conductive polymer material is selectable depending upon the polarity of the applied potential and the charge passed through the cell. Additionally, the "electro-optical conductive polymer cell" can contain transparent or semitransparent electrically conductive layers in contact with the electrodes, sealant or adhesive layers, support layers comprised, in one embodiment of the invention, of a plurality of walls of transparent film having sufficient supporting strength to maintain the structural integrity of the cell; binders; and polarizer elements, as discussed hereinafter in more detail.
As used herein the term "pane" means a transparent or semitransparent, inorganic or organic material having mechanical rigidity and a thickness greater than about 24 microns.
The term "electrically conductive layer" as used herein means a layer or sequence of layers containing an electrically conductive material which is chemically inert during the operation of the cell. The electrically conductive layer can consist of a thin semitransparent conductive film of uniform or of nonuniform thickness or of a sheet-like array of substantially parallel or antiparallel wires.
The window unit may further comprise a window frame means for securing the mutual orientation of a plurality of transparent, nonintersecting or, preferably, substantially parallel, sequentially spaced panes and for sealing and isolating a space therebetween; a first transparent pane mounted in the window frame means in a position toward an interior facing side of said frame means; a second transparent pane, nonintersecting with and, preferably, substantially parallel to and spaced from said first pane, mounted in said frame means in a position toward an interior facing side of said frame means; a conductive polymer cell comprising in a preferred configuration a first wall composed of a semitransparent electrically conductive layer in contact with an electrode, a second wall composed of a transparent or semitransparent electrode and an electrolyte disposed between opposing faces of said first and second walls, at least one of said electrodes being electro-optically responsive. Said first wall of said cell being affixed to one of the opposing faces of said first and second panes and said second wall of said cell being affixed to the second pane or for a thermal window delimiting with the other opposing face of said first and second panes a space providing a thermal break; and an electrical means for applying a potential between said conductive layers and said electrodes of a selected strength at least sufficient to change the optical transmission of said conductive polymer material.
The invention further provides a method for decreasing radiative heating and conductive heat transfer between the exterior and the interior of the building, comprising the steps of: mounting within a window frame a plurality of spaced window panes, a first and second of said panes having opposing faces; affixing to one of the opposing faces a first wall of a conductive polymer cell, said first wall being composed of a transparent electrically conductive layer coated with an electro-optically responsive polymer and cooperating with a second wall composed of a transparent electrically conductive layer and, optionally, coated with an electroactive material such as an electro-optically responsive polymer, to form a cavity containing an ion conducting electrolyte in contact with opposing faces of the first and second walls; applying a potential between said first and second walls to provide a selected light transmittance upon passage of a current therebetween; and, optionally, delimiting between said second wall of said cell and the other of said opposing faces of said panes a space providing a thermal break.
Advantageous structural features are provided by the method and means of this invention. The conductive polymer cell may be readily produced as film on rolls for application to the sizeable area provided by either opposing face of the panes. Once applied, a thermal break is achieved without need for more than two panes of glass. The size, weight, and the cost of the window unit is markedly reduced, manufacturing procedures are simplified and the reliability and operating efficiency of the unit are increased.
The panes may be light polarizing to further reduce glare from direct sunlight or to increase the efficiency of the polymer cell where the electrochromic polymer can be also polarized and oriented horizontally to limit glare or at 90° with respect to an additional polarizing element to provide enhanced optical absorption characteristics. An inert gas may be injected into the space delimited between the second wall of the cell and an opposing face of a pane, or the space may be evacuated to the extent practical to enhance thermal conductivity break characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood and further advantages will become apparent when reference is made to the following detailed description of the preferred embodiment of the invention and the accompanying drawings in which:
FIG. 1 is a perspective view of a multi-paned window of the present invention in a typical frame; and
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1, showing a thermal barrier space between a wall of the electro-optical conductive polymer cell and an opposing face of a pane;
FIG. 3 is a sectional view showing the details of the electro-optical conductive polymer cell.
DETAILED DESCRIPTION OF THE INVENTION
Referring specifically to the drawings, in FIG. 1 there is shown a window unit 1 having two non-intersecting and, preferably, substantially parallel, spaced transparent panes 6 and 8 mounted in a conventional frame 5. A cross-sectional view taken along the line 2--2 in the direction indicated by the arrows is shown in FIG. 2.
Transparent panes 6 and 8 are mounted in channels 4 of frame 5 with a conventional semi-rigid sealant 9, such as butyl rubber, so that the panes are non-intersecting and, preferably substantially parallel and spaced. The sealant aids in securing the mutual orientation of the panes. The window unit is mounted in a window opening of a wall structure so that the pane 6 is the outside pane and pane 8 is the inside pane. Panes 6 and 8 and the space 10 constitute the thermalpane portion of the embodiment wherein space 10 provides a thermal barrier significantly restricting the conduction of heat through the window. Frame 5 is shown as being hollow, by way of example, to restrict peripheral heat conduction and may be an extruded aluminum alloy. To enhance the thermal barrier effect, space 10 may be evacuated to the extent practical, or filled with an inert gas selected from the group consisting of argon, nitrogen, dry air, neon and mixtures thereof. Use of an inert gas, such as argon, inside of the thermal pane can be usefully employed to prevent corrosion or oxidative degradation of the conductive polymer cell, polarizer elements, and adhesive window components.
Affixed to one of the opposing faces of panes 6 and 8 by means of a suitable adhesive is a first wall 11 of an electro-optical conductive polymer cell. A variety of adhesives can be conveniently utilized. Preferably the adhesive should thoroughly wet and evenly coat the surface of the pane and the opposing face of the polymer cell, so as to ensure proper bonding and the elimination of spurious void spaces which can scatter light and interfere with sound mechanical adhesion. Also, the set adhesive is preferably colorless and either amorphous or microcrystalline with a crystallite size much smaller than the wavelength of light, so that negligible light scattering or absorption of light occurs at the adhesive interface. Adhesives found especially suitable for this purpose are certain polyvinylacetate adhesives, or cyanoacrylate adhesives and the like. Wall 11 is composed of a transparent, electrically conductive film, such as tin oxide deposited on a transparent film composed of glass or plastic such as polymethylmethacrylate, polycarbonates and the like. Wall 11 is coated with a thin layer of electro-optical responsive polymer 16 and cooperates with a second wall 7 composed of transparent, electrically conductive film having the composition of wall 11 and, optionally, coated with an electro active material 17 such as an electro-optically responsive polymer, a transition metal oxide or the like, to form a cavity containing a liquid or solid electrolyte material 14. Electrical leads 13 connect the first and second walls 11 and 7 (which constitute electrodes) to a variable d.c. current supply 15. The electrolyte material 14 fills substantially the entire volume of the cavity. Typically, the distance between opposing faces of walls 11 and 7 is about 1-20 mil (25-500.0 microns).
Conductive polymers are intended for use as the primary electrochromic substance of which one or both electrodes are comprised. These polymers may be either anion inserting (p-type) or cation inserting (n-type). Oxidized (p-type) conductive polymers are preferred.
Suitable anion inserting (p-type) polymers include oxidized polyacetylene, poly(p-phenylene), polyacene, polyperinaphthalene, poly(phenylene vinylene), poly(thienylene vinylene), poly(furylene vinylene) polyazulene, polynaphthalene, poly(phenylene sulfide), poly(phenylene oxide), polyphenothiazine, polyaniline, polypyrrole, polythiophene, polythianthrene, polyisothianaphthene and substituted versions of the above. Such polymers may be coated by reaction, when oxidized, with pyrroles, thiophenes, azulenes, oxiranes, anilines or furans, as described in commonly-assigned U.S. Pat. No. 4,472,987, the disclosure of which is incorporated herein by reference.
Among the above listed polymers, those which are substantially transparent and colorless in either their oxidized or neutral states (but not both) are preferred. These preferred polymers include polyaniline in the form referred to as poly(phenylene amine) and polypyrrole which are transparent in their neutral state, and poly(alkoxythienylene vinylene) and polyisothianaphthene which are substantially transparent in their oxidized state. Most preferred are poly(phenylene amine) and poly(alkoxythienylene vinylene).
Suitable cation inserting (n-type) polymers include poly(p-phenylene), polyacetylene, poly(p-phenylene vinylene), and poly(phenylquinoline) which are preferred. Most preferred is poly(phenylquinoline) and its substituted derivatives.
Polymers suitable for this invention may also contain electrochromic substituent groups such as viologens and the like to enhance the intensity of the changes in optical and infrared absorption.
Since it is critical that the device of this invention be capable of a large number of cycles between states of varying transmissiveness, the device must be provided with two electrodes at which fully reversible electrochemical reactions occur. These electrodes must be separated by a solid or liquid electrolyte which is ionically conductive but electrically insulating. The components of this electrolyte must in general be electrochemically inert but there may be certain embodiments that contain species which undergo reversible reactions at one or both electrodes.
While only one of the two electrodes of the electro-optical cell need be composed of an electrochromic material, advantage in contrast and efficiency is obtained if both electrodes operate in tandem. In this case, a given polarity of the voltage applied to the cell causes both electrodes to become simultaneously deeply colored or absorbing in the visible or infrared or both. The opposite polarity applied to the cell causes both electrodes to become optically transmissive in the visible or infrared or both. The efficiency of the device is further improved by orienting the polymers 16 and 17 on their supports (11, and 7 in FIGS. 2,3) such that the polymer chain orientation of opposing electrodes differs by 90°. Cross-polarization then further limits the transmission of light when the polymers are in their absorbing state. The polymers can be oriented to achieve a polarization of light by drawing of the substrate (for a polymer substrate) after the conductive polymer is deposited, by grooving the substrate prior to deposition, by imposing a shear during electrochemical polymerization or by other chain orientation methods.
We can arbitrarily classify materials for the electro-optical cell as anode or cathode materials based on their becoming transmissive during an anodic or cathodic process, respectively. That is, an anode material is defined as a material that becomes transmissive during an oxidation process and becomes optically absorbing during a reduction process. The reverse would apply for a cathode material.
Tables 1 and 2 list a number of anode and cathode materials useful for the construction of the electro-optical cell of this invention. In a preferred embodiment, one electrode would be composed of a material from Table 1 and the opposing electrode would be composed of a material from Table 2. In these preferred embodiments, the device in its visibly transmissive state would be substantially colorless (with very light blue, green or yellow tint). Other polymers included in the broad description of useful polymers could be employed for devices designed to provide distinct color transformations such as blue to red or green to red along with changes of transmitted light intensity.
TABLE 1______________________________________Materials for Use as the Anode.sup.(a) Film Preparation Redox State ofMaterials Method.sup.(b) Colored Form______________________________________poly(alkoxythienylene SC neutralvinylene)polyisothianaphthene E neutralTungsten bronze (WO.sub.3) CVD reduced (cation- inserted)Molybdenum bronze (MoO.sub.3) CVD reduced (cation- inserted)poly(phenylquinoline) SC reduced (cation- inserted)poly(p-phenylene) E reduced (cation- inserted)polyacetylene P neutral______________________________________ .sup.(a) Materials which become transmissive during an anodic process (oxidation) .sup.(b) E = electrochemical polymerization SC = solution cast CVD = chemical vapor deposition p = direct chemical polymerization onto substrate
TABLE 2______________________________________Materials for use as the Cathode.sup.(a) Film Preparation Redox State ofMaterial Method.sup.(b) Colored Form______________________________________poly(phenylene amine) E,SC oxidized (anion- inserted)polypyrrole E oxidized (anion- inserted)poly(p-phenylene SC oxidized (anion-vinylene) inserted)polyacetylene P neutral polymer______________________________________ .sup.(a) Materials which become transmissive during a cathodic process (reduction). .sup.(b) Eelectrochemical polymerization SC = solution cast P = direct polymerization onto substrate
It is also possible to construct an electro-optical cell using only one of the materials from either Table 1 or Table 2. One of the electrodes would then be composed of a continuous film of a conductive polymer and the opposing electrode would either be composed of narrow strips of the same polymer or of a largely transparent conductive material which does not appreciably change its optical absorption characteristics but which provides a substrate for, or itself undergoes a reversible electrochemistry. In this embodiment, an electroactive species might be included in the electrolyte. Such species include FeSO 4 . When such an electroactive species is included in the electrolyte a semipermeable or selective diffusion barrier might be provided between the two electrodes to improve the stability.
The solvents which may be included in the electrolyte of the electro-optical cells of the present invention may vary widely and can be organic solvents or aqueous solvents normally used for electrochemical oxidations or reductions. Preferably, these solvents should be electrochemically inert to oxidation and reduction during use while simultaneously being capable of dissolving the desired salt at a concentration of preferably about 0.1M and more preferably about 1M, capable of wetting the polymer, and providing an ionic conductivity about equal to or in excess of about 10 -5 S/cm, preferably about equal to or greater than about 10 -4 S/cm more preferably about 10 -3 S/cm. Examples of such useful solvents include propylene carbonate, ethylene carbonate, sulfolane, methylsulfolane, butrolactone, dimethylsulfolane, 3-methyl-2-oxazolidone, alkane sultones, e.g., propane sultone, butane sultone, dimethyl sulfoxide (DMSO), dimethyl sulfite, acetonitrile, benzonitrile, methyl formate, methyltetrahydrofurfuryl ether, tetrahydrofuran (THF), 2-methyltetrahydrofuran (2-MTHF), dioxane, dioxolane, 1,2-dimethoxyethane (DME), dimethoxymethane, diglyme and glymes, and water. Mixtures of such available organic solvents may also be used, such as mixtures of sulfolane and dimethoxyethane, or mixtures of propylene carbonate and dimethoxyethane, or mixtures of water and acetonitrile, benzonitrile and aqueous perchloric acid, acetone and water, and the like.
The solvents chosen for use in any particular situation will, of course, depend upon many factors such as the precise electrolyte composition used and the voltage range desired as well as the choice of electrodes and other components.
In a preferred embodiment, the solvent may also be replaced by a polymer which is capable of conducting ions. Such polymers include those in which an acid, base, or salt may be dissolved to form an ion conducting medium. These polymers include but are not restricted to poly(vinyl alcohol), poly(ethylene oxide), poly(propylene oxide), polysiloxane, poly(alkoxyphosphazines), and mixtures thereof.
Also included are polymers which form gels with or may be swollen by aqueous or nonaqueous solvents. Such polymers may vary widely and include polyacetates, poly(vinylalcohal) polydiacetylenes, polyethylene, and the like, and copolymers or terpolymers such as ethylene-propylene-diene terpolymer (EPDM).
Salts for use in the electro-optical device of this invention may vary widely but must be ionizable in the solvent chosen and must provide suitable counterions for the oxidized or reduced conductive polymers employed as electrochromic materials.
In the case of oxidized (p-type) conductive polymers the anion of the salt must be capable of insertion into the polymer during oxidation without decomposition. Suitable anionic species include I - , I - 3 , Br - , Cl - , ClO 4 - , PF 6 - , BF 4 - , AlCl 4 - , FeCl 4 - , HF 2 - fluorinated organoborates, and organofluoroborates, such as B(p--FC 6 H 4 )-- 4 and B(C 6 F 4 ) 4 - , sulfonates, such as CF 3 SO - 3 , CF 3 (C 6 H 4 )SO 3 - , C 6 H 5 SO 3 - and CH 3 (C 6 H 4 )SO 3 - , POF 4 - , CN - , SCN - , CF 3 CO 2 - (trifluoroacetate), C 6 H 5 CO 2 - (benzoate), HSO 4 - and the like.
In the case of reduced (n-type) conductive polymers the cation of the salt must be capable of insertion into the polymer during reduction without decomposition. Suitable cationic species include Li + , Na + , K + , Rb + , Cs + , alkylammoniums such as (CH 3 ) 4 N + , (C 2 H 5 ) 4 N + , (C 3 H 7 ) 4 N + , (C 4 H 9 ) 4 N + , (CH 3 )(C 3 H 7 ) 3 N + , as well as sulfonium and phosphonium analogs and the like, and cyclic ions such as pyridinium, imidazolium, and the like. Particularly preferred are the alkali-metal ions.
For devices which contain only p-type or only n-type polymers, the ion that remains in solution and which is not inserted must be inert to oxidation and reduction, respectively. Preferred anions for use in the presence of reduced polymers are PF 6 - , alkylborates and arylborates (U.S. Pat. No. 4,522,901), and halides. Preferred cations for use in the presence of oxidized conductive polymers are the alkali-metal ions, protons, and silver ions.
Room-temperature molten salts may also be useful as electrolytes in the present invention. Such salts include alkylimidazolium tetracholoraluminates (the use of which for the oxidation and reduction of conductive polymers is described in U.S. Pat. Nos. 4,463,071 and 4,463,072), alkylpyridinium tetrachloroaluminates, and mixtures of the above with alkali-metal halides.
A variety of transparent conductors, such as SnO 2 , InO 3 and Cd 2 SnO 4 and the like, can be used for the conductive surface on walls 7 and 11 (see FIGS. 2 and 3). Examples of commercial compositions for such conductors are transparent metal oxides made by Deposition Technology and Sierracin/Intrex using sputtering techniques involving reactive gases in combination with metal targets. Leybold-Heraeus also offers commercially a metal/metal oxide coating called TCC 2000 which is sufficiently transparent and conductive for the present application.
EXAMPLES OF THE INVENTION
Example 1
Poly(phenylene amine) electrodes were fabricated by electrochemically oxidizing acidic aqueous solutions of aniline. A solution containing 0.5M aniline, 0.5M NaHSO 4 , and 0.6M H 2 SO 4 was found to be preferred over solutions containing Cl - or CH 3 SO 3 - anions in place of HSO 4 - . Galvanostatic deposition of the polymeric film on ITO conducting glass (a glass, D, coated with an indium-tin oxide conductive layer, E, in FIG. 1) was accomplished by imposing a constant current of 0.35 mA/cm 2 between the ITO electrode and a nickel screen counter electrode until a total charge of 70 mC/cm 2 had passed. This procedure produced a very uniform, adherent film of electrooptic polyphenylene amine on the ITO glass.
Example 2
A window containing an electro-optical cell was assembled as in FIG. 1 from an electrode with a poly(phenylene amine) deposit as described in Example 1 and a second piece of ITO conducting glass separated by a spacer of an inert material, teflon, with the intervening space being filled with a liquid electrolyte solution of 1.0M H 2 SO 4 . When a cathodic current was applied to the electrode with the poly(phenylene amine) deposit the window become highly transmissive. When an anodic current was applied to the electrode with the polymeric deposit the window became highly absorbing with a dark green-blue coloration.
Example 3
A window containing an electro-optical cell was assembled as in Example 2 except that the electrolyte was a gel consisting of a 20 wt % aqueous solution of poly(vinyl alcohol) and 1.1M H 3 PO 4 . When a cathodic current was applied to the electrode with a poly(phenylene amine) deposit the window became transmissive. When an anodic current was applied to the electrode with the polymeric deposit the window became highly absorbing. Repeated cycling, however, caused a brownish discoloration of the window which was found to be caused by the lack of a reversible couple at the electrode composed only of ITO glass.
Example 4
A window was assembled as in Example 3 except that the gel electrolyte contained ferrous sulfate (1 mM) and ferric sulfate (1 mM), an electrochemically reversible couple which moderated the cell voltage and served as a substrate to take up and release charge as the polymeric electrode was being charged. When a cathodic current was applied to the electrode with the poly(phenylene amine) deposit, the window became transmissive. When an anodic current was applied to the electrode with the polymeric deposit the window became highly absorbing. Repeated cycling was achieved without the discoloration observed in Example 3.
Example 5
A window was assembled as in Example 3 except that the electrolyte was a solid transparent film made by applying a 20 wt. % aqueous solution of poly(vinyl alcohol) and 1.1M H 3 PO 4 to the electrode having the polymeric deposit of poly(phenylene amine) and evaporating the water at 35° C. for 24 hours. When a cathodic current was applied to the electrode with the poly(phenylene amine) deposit the window become transmissive. When an anodic current was applied to the electrode with the polymeric deposit the window became highly absorbing. | A method is provided for decreasing radiative heat transfer and adjustably limiting visible light and near infrared radiation transfer and glare through a window. The method comprises the steps of: (a) mounting within a frame of the window a plurality of spaced window panes, a first and second of the panes having opposing faces; (b) assembling between the opposing faces a conductive polymer cell, the cell having a first wall composed of a transparent conductive layer affixed to the first pane and having deposited thereupon an electroactive electro-optically responsive conductive polymer, and a second wall comprised of a transparent conductive layer coated on the second pane, the layer being optionally coated with a second electro-optically responsive polymer, the first and second walls delimiting a cavity containing an ion-conducting electrolyte which contacts opposing surfaces of the first and second walls, and (c) applying a potential between the first and second walls to provide a selected light transmittance upon passage of current therebetween. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a divisional of copending application Ser. No. 504,447 filed Apr. 3, 1990 which is a divisional of copending application Ser. No. 348,543 filed on May 2, 1989.
SUMMARY OF THE INVENTION
This invention relates to a class of novel compounds which are useful as comonomers to tint contact lens materials. These compounds are represented by the general formula ##STR2## where X denotes a polymerizable, unsaturated organic radical; and R denotes an organic diradical with 2 to 12 carbon atoms. The invention also relates to copolymers of the above compounds which are useful as materials in biomechanical applications.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a novel class of compounds which are particularly useful as comonomers to impart a blue color in biomechanical devices. Specifically, the present invention relates to compounds represented by the foregoing general formula wherein R and X are defined as follows: R is a divalent organic radical with 2 to 12 carbon atoms and X is a polymerizable, unsaturated radical, such as a methacrylate, acrylate, vinyl carbonyl, or vinyl carbamate functional moieties. Compounds wherein R is a divalent phenyl alkyl radical have been found to be especially useful polymerizable dyes.
The general synthetic scheme for producing the comonomers of the present invention is illustrated below. ##STR3##
The comonomers produced by the General Synthetic Scheme outlined above have several characteristics which distinguish them over dye comonomers used in biomechanical devices previously. For instance, the present invention dye monomers are compatible with many monomers used to produce biomechanical materials. This allows the dye to be mixed with the bulk monomer prior to the polymerization of that comonomer.
Furthermore, the functionality of the present dye comonomers allows them to be more completely polymerized with the bulk monomers used to produce state of the art biomechanical materials. This ensures that the present invention dye comonomers become integral parts of the copolymer's matrix and cannot be leached out of that matrix by conditions (e.g., physiological conditions) that are encountered by hydrogel materials, especially biomechanical materials such as contact lenses.
Furthermore, due to the solution compatibility of these dye comonomers with other comonomers, they can be used in various concentration ranges which allows them to be used as tinting (or coloring) agents. This result is a particularly important characteristic in contact lens materials and has heretofore been unavailable in the art.
The comonomer dyes of the present invention can be used to produce biomechanical materials in conjunction with known monomers while maintaining all of the advantageous characteristics of polymers produced from the known monomers. This allows for the production of copolymers which are tinted or colored and which still maintain the beneficial physiological characteristics required for biomechanical materials.
The monomers which the present invention can be copolymerized with include both hydrophilic and hydrophobic monomers. Biomechanical materials, of course, include copolymeric mixtures. The compounds of the present invention are used as an additional agent in the prepolymer mixtures disclosed in the art. The dye compound of this invention is added in amounts sufficient to impart the desired color intensity. The upper limit of comonomer dye concentration may be restricted by the amount of crosslinking effected by the difunctional dye molecule. Typically the dye concentration will not exceed 5% of the total monomer mixture. More typically the dye concentration will range from about 0.001 to about 2 weight percent of the total monomer mixture. The concentration will of course determine the color intensity of the resulting copolymer.
The polymerizable dye of this invention is particularly useful to color hydrogel materials. Hydrogel materials (i.e., water-containing polymers) are prepared from a wide variety of copolymeric mixtures characterized by the presence of hydrophilic monomers. Examples of hydrophilic monomers are 2-hydroxyethylmethacrylate, N-vinyl pyrrolidone, and methacrylic acid. Copolymeric mixtures used to prepare hydrogels may also include polymers such as polyvinyl alcohol and polyethylene glycol. Hydrogels for contact lenses are generally made by the polymerization of hydrophilic monomers (e.g., 2-hydroxyethylmethacrylate or N-vinyl pyrrolidone) with a crosslinking agent. Useful hydrogels are also obtained by the copolymerization and crosslinking of hydrophilic and hydrophobic monomers to obtain the desired level of water absorption in the gel. Suitable hydrogels are further exemplified by the materials described in U.S. Pat. Nos. 27,401; 3,532,679; and 3,937,680.
The monomers of the present invention can also be used in conjunction with rigid gas permeable contact lens formulations known in the art as exemplified in U.S. Pat. Nos. Re. 31,406, 4,424,328, 4,139,548, 4,433,111, 4,152,508, 4,450,264, 4,153,641, 4,540,761, 4,372,203, and 3,950,315.
The invention compounds may also be used as comonomers with silicone based systems. Silicones are also well known in the art and are exemplified by the following U.S. Pat. Nos.: 4,136,250, 3,518,324, and 4,138,382.
The following examples are not intended to exemplify the full scope of the present invention. They are meant to illustrate certain specific examples of the present invention to those skilled in the art and to provide sufficient basis for those skilled in the art to practice their invention.
EXAMPLES
EXAMPLE 1a
Synthesis of 1,4-Bis(2-methacrylamidoethylamino)anthraquinone(I)
Into a 250 ml 2 neck round bottom flask equipped with a thermometer was placed 6.0 g of leucoquinizarin and a stir bar, and the flask was flushed with nitrogen. To this was added 75 ml of ethylene diamine through which nitrogene had been bubbled of 15 minutes. While keeping the reactants under nitrogen, the solution was heated to 50° C. for one hour during which the solution turned green. The nitrogen blanket was then removed and air was bubbled through the solution for one hour, keeping the temperature at 50° C., causing the solution to turn blue. Water, 250 ml, was added and the intermediate product was isolated by filtration, washed with water and air dried. The intermediate was recrystallized from acetonitrile. The final isolated yield was 37%. A solution of 1.0 g of the intermediate in 250 ml of methanol was cooled to <3° C. using an ice bath. To this was added 5.0 ml of triethylamine and 3.5 ml of methacryloyl chloride. After one hour the reaction was complete. The product was precipitated by the addition of 500 ml of water, isolated by filtration, washed with 1:1 methanol:water and then water, and air dried giving an isolated yield of 80%.
According to the above procedure, the following compounds were prepared:
1,4-bis(2-acrylamidoethylamino)anthraquinone, 1,4-bis(3-methacrylamidopropylamino)anthraquinone (II), 1,4-bis(3-methacrylamido-2,2-dimethylpropylamino) anthraquinone (III), 1,4-bis(2-acrylamidocyclohexylamino)anthraquinone, and 1,4-bis(2-methacrylamidocyclohexylamino)anthraquinone (IV).
EXAMPLE 1b
Synthesis of 1,4-Bis(3-methacryloxypropylamino)anthraquinone(V)
The intermediate was prepared as before using 8.0 g of leucoquinizarin and 50 ml of 3-aminopropanol giving a recrystallized yield of 23%. To a solution of 1.0 g of the intermediate in 200 ml of acetonitrile was added 3.0 ml of triethylamine and 1.5 ml of methacryloyl chloride at room temperature. The reaction was complete after 1/2 hour. The solution was diluted to 1 liter with water and 1.0 g of NaOH was added. The gummy solids were isolated on fluted filter paper, redissolved in 200 ml of acetone and reprecipitated by the addition of 200 ml of water. The product was isolated by filtration on a fritted filter, washed with 1:1 acetone:water, water and air dried. The isolated yield was 20%.
EXAMPLE 1c
Synthesis of 1,4-Bis(1-methacryloxy-2-butylamino)anthraquinone(VI)
A mixture of 15 g of quinizarin, 75 ml of (±)-2-amino-1-butanol and 100 ml of water was heated under nitrogen at 90° C. for 7.5 hours and then diluted to 500 ml to precipitate the product. The intermediate was isolated by filtration, washed with water and air dried. Recrystallization from toluene gave a yield of 52%. To a solution of 2 g of the intermediate in 100 ml of dry acetonitrile was added 4.0 ml of triethylamine and 3.0 ml of methacryloyl chloride. After 1/2 hour, 300 ml of ethylene glycol was added and 10 minutes later the solution was diluted to 1 liter with water. The tacky product was filtered out of the solution, redissolved in 200 ml of acetone and precipitated by the addition of 500 ml of water. The wet product was redissolved in 200 ml of acetone a second time and precipitated by the addition of 300 ml of water, isolated by filtration, washed with water and air dried. The isolated yield was 52%. The TLC showed the expected two spots for both the intermediate and the final product.
EXAMPLE 1d
Synthesis of 1,4-Bis(1-methacryloxy-2-pentylamino)anthraquinone(VII)
A deoxygenated solution of 3.0 g of leucoquinizarin, 10.0 g of (±)-2-amino-1-pentanol and 50 ml of triethylamine was heated at 60° C. under nitrogen overnight. Air was then bubbled through the solution at 55° C. for 3 hours. The resulting oil was diluted with 250 ml of methanol and then with 250 ml of water to precipitate the intermediate, which was isolated by filtration, washed with 2:1 water:methanol and the water, and air dried. The isolated yield was 75%. To a solution of 2.0 g of the intermediate in 50 ml of dry acetonitrile was added 4.0 ml of triethylamine and 2.0 ml of methacryloyl chloride. After 30 minutes at room temperature, the reaction was completed. The solution was diluted with 50 ml of ethylene glycol followed by 400 ml of water 15 minutes later. After vigorous stirring for one hour, most of the gummy product was sticking to the sides of the flask. The solution was filtered and the solids were dissolved in 500 ml of methanol. The product was reprecipitated by the addition of 500 ml of water, isolated by filtration, washed with 1:1 water:methanol followed by water and air dried. Isolated yield was 34%.
EXAMPLE 1e
Synthesis of 1,4-Bis(4-methacryloxycyclohexylamino)anthraquinone(VIII)
A deoxygenated solution of 10.0 g of trans-4-aminocyclohexanol hydrochloride, 2.76 g of NaOH, 25 ml of water and 45 ml of triethylamine was added to a nitrogen filled flask containing 2.0 g of leucoquinizarin and the mixture was heated at 55° C. for two hours. Air was then bubbled through the solution overnight at 55° C. to form the crude intermediate. The slurry was diluted to 250 ml with water and the solids were isolated by filtration. Unoxidized product was removed by placing the solids in 500 ml of boiling 2-propanol for one hour, cooling and filtering. The purified intermediate was washed with methanol and air dried. The isolated yield was 61%. To a slurry of 1.5 g of the intermediate in 10o ml of toluene was added 5.0 ml of pyridine and 1.4 ml of methacyloyl chloride. After boiling for 10 minutes, the product was formed and the solvent was removed on a rotovap. The solids were dissolved in 500 ml of acetone and the product was precipitated by the addition of 500 ml of water. The fine precipitate was isolated on fluted filter paper, redissolved in acetone, precipitated with water and the product was isolated by filtration. After washing with water, the product was air dried. The yield was 60%.
EXAMPLE 1f
Synthesis of 1,4-Bis(2-methacryloxycyclohexylamino)anthraquinone(IX)
A deoxygenated solution of 10.9 g of 2-aminocyclohexanol hydrochloride, 2.58 g of NaOH, 50 ml of water and 100 ml of triethylamine was added to a nitrogen filled flask containing 2.0 g of leucoquinizarin and the mixture was heated at 55° C. for four hours. Air was then bubbled through the solution overnight with the temperature reaching 80° C. After diluting with water, the solids were filtered out. The solids were slurried and washed with acetone until the filtrate was light blue. The yield of the air dried product was 42%. Over a 1/2 hour period of time, a total of 2.6 ml of methacryloyl chloride, 4.0 ml of triethylamine and 2.0 ml of pyridine was added to a slurry of 1.0 g of the intermediate in 100 ml of dry acetonitrile. Product was formed by boiling the mixture for one hour. Water, 25 ml, was added and the solvents were rotovaped off. The solids were slurried in 1 liter of water containing 0.5 g of NaOH for 1/2 hour and the product was isolated from the highly colored solution by filtration. The product was dissolved in 300 ml of acetone, precipitated by the addition of 600 ml of water and isolated by filtration several times until the filtrated was light blue. The yield of the air dried product was 20%.
EXAMPLE 1g
Synthesis of 1,4-Bis(2-methacryloxy-1-phenylethylamino)-anthraquinone(X)
In an oxygen free solution, 3.0 g of leucoquinizarin and 10.0 g of L-2-phenylglycinol in 150 ml of triethylamine were reacted overnight at 55° C. Air was then bubbled through the solution for 3 hours at 55° C. and the mixture was reduced to dryness on a rotovap. The solids were dissolved in acetone and the intermediate was precipitated by the addition water containing NaOH. The product was isolated from the highly colored solution by filtration, washed and air dried. The yield of the intermediate was 45%. Two grams of the intermediate was dissolved in 100 ml of dry acetonitrile to which was added 4.0 ml of triethylamine and 2.5 ml of methacyoyl chloride. After 1/2 hour the reaction was complete. Methanol, 25 ml, was added and the solvents were rotovaped off. The product was dissolved in 250 ml of water and isolated by filtration several times until the filtrate was light blue. The yield of the air dried product was 33%.
EXAMPLE 1h
Synthesis of
1,4-Bis(1-methacryloxy-3-methyl-2-pentylamino) anthraquinone(XI)
A 1.5 g sample of leucoquinizarin was reacted with 5.0 g of L-isoleucinol in 50 ml of triethylamine under nitrogen for 6 hours at 55° C. Air was then bubbled through the solution for 8 hours with the temperature reaching 80-° C. at one point. The mixture was diluted with 1:1 methanol:water and filtered to isolate the intermediate. The intermediate was washed with the same solvent mixture until the filtrate was light blue. The yield of the air dried intermediate was 87%. TLC showed that the intermediate still contained unoxidized and mono-substituted impurities. To a solution of 1.23 g of the impure intermediate in 50 ml of dry acetonitrile was added 3.0 ml of triethylamine and 1.5 ml of methacyloyl chloride. The reaction was complete after 15 minutes at room temperature. Methanol, 50 ml, was added and the solution was evaporated to dryness. The crude product was purified by column chromatography over silica gel using 1:1 toluene:chloroform as the eluent. When the solvent was evaporated, it was found that the product was tacky. Repeated dissolving in methanol and stripping resulted in a dry product. The yield was 63%.
EXAMPLE 1i
Synthesis of 1,4-Bis(4-(2-methacryloxyethyl) phenylamino-anthraquinone (XII)
A 3.0 g sample of leuquinizarin was heated with 10.0 g of 4-aminophenethyl alcohol (mp 113° C.) under nitrogen at reflux (˜150° C.) for 5 hours. TLC showed no further changes occurring. Ethylene glycol, 25 ml, was added and air was bubbled through the hot solution for 3 hours. After cooling, the resulting solid cake was broken up and the solids were dissolved in 1 liter of acetone, the solution filtered and the intermediate was precipitated by the addition of 1 liter of NaOH in water. The intermediate was isolated by filtration, washed with water and air dried. The yield was 38%. To a slurry of 1.6 g of the intermediate in 30 ml of dry acetonitrile was added 3.2 ml of triethylamine and 1.6 ml of methacrylol chloride at room temperature. After 30 minutes the reaction was complete and 15 ml of ethylene glycol was added. After 15 minutes, the product was precipitated by diluting the solution to 1 liter with water and isolated by filtration. The product was purified by dissolving 800 ml of acetone and precipitated by the addition of 400 ml of water. The product was isolated from the deep rust colored solution by filtration, washed with 1:1 acetone:water and air dried. The isolated yield was 57%.
EXAMPLE 2
Preparation of Tinted Copolymeric Contact Lens Materials
A monomer mix was prepared from the following formulation:
______________________________________2-hydroxymethacrylate (HEMA) 99.49 wt %Ethylene Glycol Dimethacrylate (EGDMA) 0.34 wt %Benzoin Methyl Ether Catalyst (NVP) 0.17 wt %monomer I 200 ppm______________________________________
Monomer (I) is the dye molecule synthesized in Example 1(a). The monomer mixture was polymerized between silicone treated glass plates using a fluorescent UV source. Similar pHEMA films were cast using 200 ppm of the various monomers synthesized in Example 1.
EXAMPLE 3
Discs were cut from the film prepared from monomer I (as described in Example 2). These untinted discs were tinted by a state of the art method using Procian blue (Procian Blue discs). The visible spectra of the film discs of example 2 and the Procian Blue discs were compared. The discs were then subjected to accelerated hydrolysis testing and the resultant visible spectra were again compared. Both types of discs showed about the same loss of color intensity. However, the loss of the color intensity in the Procian disc was from loss of dye from the disc whereas loss of color intensity in the monomer I disc was due to the hydrolysis of the amine functionality rather than actual monomer loss.
EXAMPLE 4
pHEMA films were made with 200 ppm of each of the monomers I, II, III, and IV. Incorporation of the bismethacrylamide monomers into the pHEMA was tested with the following results:
______________________________________Monomer Bridge (R) % Incorporation______________________________________I --(CH.sub.2).sub.2 -- 92II --(CH.sub.2).sub.3 -- 90III --CH.sub.2 C(CH.sub.3).sub.2 --CH.sub.2 -- 82IV 1,2-cyclohexylene 82______________________________________
The hydrolytic stability of the final polymeric material was tested by boiling the samples in buffered saline solution. After 4 weeks the loss of color intensity was as follows:
______________________________________ % LossMonomer at 600 nm at 640 nm______________________________________I 18 26II 16 28III 14 26IV 5 7______________________________________
The monomer with the largest R radical produced the most stable copolymeric material.
EXAMPLE 5
The dimetheyacrylate ester monomers were tested for incorporation in to a pHEMA material and for stability. Incorporation was as follows:
______________________________________Monomer Bridge (R) Precursor % Incorporation______________________________________V 3-aminopropanol 100VI 2-aminobutanol 98VII 2-aminopentanol 98VIII 4-aminocyclohexanol 98XI 2-aminocyclohexanol 95X 2-amino-2-phenylethanol 97XI 2-amino-3-methylpentanol 97XII 2-(4-aminophenyl)ethanol 99______________________________________
The hydrolytic stability of the pHEMA films were tested as described in Example 4. After 4 weeks, the loss of color intensity was as follows:
______________________________________ % of LossMonomer at 600 nm at 640 nm______________________________________V 49 53VI 14 27VII 16 28VIII 25 38IX (3 weeks) 11 25X 15 24XI 14 29XII 6 6______________________________________
EXAMPLE 6
Films were cast from a monomer mix as described in Example 2 except that the mix contained 150 ppm of monomer XII. The control was untinted film cast from the same lot of monomer mix.
Film properties were measured with the following results:
______________________________________ Monomer XII ControlTest Film Film______________________________________modulus (g/mm.sup.2) 57 59tensile 66 71% elongation 280 290initial teat 6.8 6.7propagation tear 4.9 5.0% H.sub.2 O 37.3 37.9O.sub.2 permeability 8.9 × 10.sup.-11 9.2 × 10.sup.-11(cm.sup.3 × cm/sec × cm.sup.2 × @35 C)______________________________________
The results show that the monomer does not affect the physical characteristics of standard contact lens materials.
EXAMPLE 7
A monomer mix was prepared from the following formulation:
______________________________________Methyl methacrylate 36.4 gramsNVP 88.2 gramsEGDMA 0.033 gramsAllyl methacrylate 0.24 gramsVAZO-64 Catalyst 0.12 gramsMonomer XII 450 ppm______________________________________
The monomer mix was heat cured into rods from which buttons were cut and discs were lathed. The buttons and discs were blue-green. | Dye monomers of the general chemical formula ##STR1## where X denotes an unsaturated polymerizable organic radical; and
R is an organic diradical with 2 to 12 carbon atoms. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. application Ser. No. 11/910,575 filed Jun. 16, 2008, the teachings of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to a thermally bonded nonwoven fabric having improved thermal and chemical stability. The invention further relates to uses of this nonwoven fabric.
PRIOR ART
[0003] Melt-bondable fibers and nonwoven fabrics produced therefrom are known from EP 0 340 982 B1. Melt-bondable fibers are dual-component fibers composed of a first, at least partially crystalline, polymer component and a second component, adhering to the surface of the first component, containing a compatible blend of polymers comprising at least one amorphous polymer and at least one polymer which is at least partially crystalline. The melting temperature of the second component is at least 30° C. below that of the first component, but is at least equal to or greater than 130° C. In addition, the weight ratio of the amorphous polymer of the second component to the at least partially crystalline polymer of the second component is in the range of 15:85 and 90:10, and has a value such that binding of dual-component fibers to a similar dual-component fiber is prevented, and the first component forms the core and the second component forms the sheath for a dual-component fiber spun in the form of a sheath-core configuration. This dual-component fiber is mixed with conventional polyester fibers and thermally bonded to produce a nonwoven fabric, which is processed into an abrasive fleece by application of abrasive particles.
[0004] Heat-bondable conjugate fibers are known from JP 07-034326 which have a sheath-core configuration, and have a core made of a polyester containing polyethylene terephthalate (PET) as the main component, and have a sheath that is produced from a copolymerized polyester or a side-by-side conjugate fiber composed of polyethylene terephthalate and a copolymerized polyester. The copolymerized polyester represents the lower-melting component, and contains butylene terephthalate units and butylene isophthalate units as repeating structural units. A nonwoven fabric produced from these dual-component fibers is designed to have excellent thermal resistance and fatigue resistance against pressure stress, so that it may be used as an alternative material for polyurethane seat coverings, primarily in the automotive sector.
[0005] Thermally bonded nonwoven fabrics may also be produced from a mixture of drawn and undrawn PET fibers. However, these nonwoven fabrics require bonding under heat and pressure in a calendar. The bonding capability of the undrawn amorphous PET fibers is based not on a melting process, but, rather, on the crystallization process for PET, which begins above 90° C. provided that crystallizable fractions are still present. Such nonwoven fabrics have high chemical and thermal stability. However, the production process permits little flexibility. Thus, for undrawn PET fibers, for example, it is not possible to activate the bonding capability multiple times, since this requires a process that is irreversible below the melting temperature. In addition, bonding of nonwoven fabrics having weights per unit area >150 g/m 2 with undrawn PET fibers is difficult, since in the calendaring process the external heat cannot penetrate sufficiently into the nonwoven web. A more or less pronounced gradient always occurs.
DESCRIPTION OF THE INVENTION
[0006] The object of the invention is to provide a thermally bonded nonwoven fabric having improved thermal stability properties, in particular the shrinkage tendency of the nonwoven fabrics obtained. In addition, the chemical stability is increased compared to fibers containing copolymers of monomer mixtures such as isophthalic acid/terephthalic acid.
[0007] The object is achieved according to the invention by use of a thermoplastically bonded nonwoven fabric containing a low-shrinkage dual-component core-sheath fiber. The low-shrinkage dual-component core-sheath fiber is composed of a crystalline polyester core and a crystalline polyester sheath which has a melting point at least 10° C. lower than the core, and has a hot-air shrinkage of less than 10%, preferably less than 5%, at 170° C. At temperature stresses of 150° C. (1 h), a corresponding nonwoven fabric exhibits a thermal dimensional change (shrinkage and curl) of less than 2%. In the context of the invention, the term “crystalline” means a polyester polymer having a heat of fusion (DSC) of >40 joule/g and a width of the melting peak (DSC) preferably occurring at <40° C. at 10° C./min.
[0008] The sheath of the low-shrinkage dual-component fiber is preferably composed of a homogeneous polyester polymer, produced from a monomer pair, of which greater than 95% is formed from a single polymer pair. In the case of the polyester described in the claims, this means that >95% of the polymer is composed of a single dicarboxylic acid and a single dialcohol.
[0009] The mass ratio of the core-sheath component is typically 50:50, but for specialty applications may vary between 90:10 and 10:90.
[0010] A nonwoven fabric is particularly preferred in which the sheath of the dual-component core-sheath fiber is composed of polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), or polyethylene terephthalate (PET).
[0011] Further preferred is a nonwoven fabric in which the core of the low-shrinkage dual-component core-sheath fiber is composed of polyethylene terephthalate or polyethylene naphthalate (PEN).
[0012] The nonwoven fabric according to the invention may contain additional fibers besides the low-shrinkage dual-component core-sheath fiber, depending on the particular use. It is preferred to use 0 to 90% by weight of monofil standard polyester fibers, for example, together with the low-shrinkage dual-component fiber.
[0013] The nonwoven fabric according to the invention is preferably composed of low-shrinkage dual-component core-sheath fibers having a titer in the range between 0.1 and 15 dtex. The nonwoven fabric according to the invention has a weight per unit area between 20 and 500 g/m 2 . For a weight per unit area of 150-190 g/m 2 , for example, the nonwoven fabric according to the invention achieves a bending stiffness of greater than 1 Nmm transverse to the machine direction, as determined in accordance with ISO 2493.
[0014] The method for producing the thermally bonded nonwoven fabric is characterized in that the fibers are laid out to produce a nonwoven fabric, thermally bonded, and immediately compressed if necessary. In the method, the fibers of the nonwoven fabric according to the invention are placed in a thermal fusion oven which allows uniform temperature equilibration of the binding fibers. The low-shrinkage dual-component core-sheath fibers are preferably laid out wet in a paper layout process and dried, or laid out dry using a carding or airlaid process and then bonded at temperatures of 200 to 270° C., and optionally compressed using a calendar or press tool at rolling temperatures below the melting point of the sheath polymer, preferably <170° C. This compression is preferably carried out immediately after the bonding process in the dryer, when the fibers are still hot. However, the structure of the fibers also allows subsequent heat treatment, since the bonding process may be activated multiple times.
[0015] The thermally bonded nonwoven fabrics obtained have shrinkage and curl values in the range of <2%, preferably <1%.
[0016] The nonwoven fabrics according to the invention are suitable as a liquid filter medium, membrane support fleece, gas filter medium, battery separator, or nonwoven fabric for the surface of composite materials on account of their high thermal stability, low shrinkage tendency, and stability with regard to chemical aging. This is particularly true for use as an oil filter medium in motor vehicle engines.
[0017] The invention is explained in greater detail below with reference to the figures, which show the following:
[0018] FIG. 1 shows a diagram illustrating the maximum tensile forces for nonwoven fabrics A and B in the form of an index, after storage in air and in oil, relative to the respective new state (DIN 53508 and DIN 53521);
[0019] FIG. 2 shows a diagram illustrating the maximum tensile force elongation for nonwoven fabrics A and B after storage at 150° C. in air and in oil, relative to the respective new state (DIN 53508 and DIN 53521);
[0020] FIG. 3 shows a diagram illustrating the maximum tensile forces for nonwoven fabrics A and B at various temperatures in the form of an index, relative to the respective new state (DIN EN 29073-03);
[0021] FIG. 4 shows an electromicrograph of a membrane support fleece bonded with undrawn polyester fibers (nonwoven fabric E; comparative example);
[0022] FIG. 5 shows an electromicrograph of a membrane support fleece which according to the invention is composed of 100% low-shrinkage PET/PBT dual-component fiber (nonwoven fabric F);
[0023] FIG. 6 shows a DSC curve for a dual-component fiber A containing crystalline sheath polymer (in this case PET/PBT; according to the invention); and
[0024] FIG. 7 shows a DSC curve for a dual-component fiber B containing amorphous sheath polymer (in this case PET/coPET; prior art).
TEST METHODS
Bending Stiffness
[0025] The bending stiffness was determined in Nmm in accordance with ISO 2493.
Thermal Dimensional Change (Shrinkage)
[0026] The sample (DIN A4-size sample) was provided with marks 200 mm apart in the longitudinal and transverse directions. The samples were stored for 1 hour at 150° C. in a circulating air oven and then cooled for 20 minutes at room temperature, after which the dimensional change was determined. This value was expressed as a percentage of the starting value for the longitudinal and transverse directions. The algebraic signs preceding the percentage value indicate whether the dimensional change is positive (+) or negative (−). The mean value was determined from at least six individual values (measurements).
Thermal Dimensional Change (Curl)
[0027] The sample (DIN A4-size sample) was provided with marks at which the thickness was determined in accordance with ISO 9073/2. The samples were stored for 1 hour at 150° C. in a circulating air oven and then cooled for 20 minutes at room temperature, after which the thickness was predetermined at the marks (ISO 9073/2). The curl (B), expressed as a percentage, was calculated as follows:
[0000] B (%)=(Thickness after storage×100/Thickness before storage)−100
[0028] The mean value was determined from at least six individual values (measurements).
Testing of Hot-Air Shrinkage
[0029] Twenty individual fibers were tested. The fiber was provided with a pretensioning weight as described below. The free end of the fiber was placed in the clamp of a clamping plate. The length of the clamped fiber was determined (L 1 ). The fiber, freely suspended without weight, was then temperature-equilibrated for 10 minutes at 17° C. in a circulating air drying oven. After cooling for at least 20 minutes at room temperature the same weight from the determination of L 1 was suspended from the fiber again, and the new length (L 2 ) after the shrinkage process was determined.
[0030] The percentage of hot-air shrinkage was calculated from the following expression:
[0000] HS (%)=(Σ L 1 −L 2 )*100/Σ L 1
[0000] TABLE 1 Size of pretensioning weight Pretensioning Titer (dtex) weight (mg) ≦1.20 100 >1.20 100 ≦1.60 >1.60 150 ≦2.40 >2.40 200 ≦3.60 >3.60 250 ≦5.40 >5.40 350 ≦8.00 >8.00 500 ≦12.00 >12.00 700 ≦16.00 >16.00 1000 ≦24.00 >24.00 1500 ≦36.00
In the freely suspended state the fiber should have an uncurled appearance. If the curl was too great, the next heavier weight was selected.
Heat of Fusion (DSC)
[0031] The sample was weighed in a DSC apparatus from Mettler Toledo and heated from 0° C. to 300° C. using a temperature program of 10° C./min. The area beneath the endothermic melting peak obtained, in conjunction with the original fiber weight and the associated masses of the sheath or core component, represents the heat of fusion of the respective component in J/g.
Example 1
[0032] Nonwoven fabric A represents a dry-laid, carded, and thermally bonded nonwoven fabric having a weight per unit area of 190 g/m 2 . This nonwoven fabric was composed of 75% low-shrinkage PET/PBT dual-component fiber having a sheath melting point of 225° C. and a core-to-sheath ratio of 50:50, and up to 25% conventional PET fibers. The thickness was 0.9 mm, and the air permeability was 850 L/m 2 s at 200 Pa. 140 g/m 2 of the fibers were carded by combing using a cross-layer, and the remaining 50 g/m 2 were carded in a longitudinal layout. The nonwoven fabric was bonded in a thermal fusion oven at approximately 240° C., and was calibrated to the target thickness using an outlet press tool.
Comparative Example
[0033] Nonwoven fabric B was produced analogously as for nonwoven fabric A. The differences consisted in use of conventional PET/CoPET dual-component fibers having a sheath melting point of approximately 200° C., and reduction of the oven temperature to 230° C. The resulting weight per unit area, thickness, and air permeability were comparable.
[0034] The advantages of nonwoven fabric A according to the invention compared to nonwoven fabric B are as follows:
[0000] The width of the nonwoven fabric after the dryer decreased by only about 9% for nonwoven fabric A, whereas a loss in width of approximately 21% occurred for nonwoven fabric B.
The transverse bending stiffness for nonwoven fabric was 15% greater.
The increase in thickness after storage at 150° C. (thermal dimensional change) for nonwoven fabric A was 1.5%, and for nonwoven fabric B, 4.7%.
The thermal and chemical stability for storage at 150° C. in air and in oil was much better for nonwoven fabric A ( FIGS. 1 and 2 ). The diagrams clearly show greater destruction of nonwoven fabric B when stored in motor oil. In particular, the brittleness in FIG. 3 indicates a problem with the chemical stability of nonwoven fabric B in oil.
The maximum tensile forces at various temperatures show a much more favorable progression for nonwoven fabric A ( FIG. 3 ).
Example 2
[0035] Nonwoven fabrics C and D represent wet-laid, dried, and thermally bonded nonwoven fabrics having a weight per unit area of 198 g/m 2 and 182 g/m 2 , respectively. These nonwoven fabrics were composed of 72% low-shrinkage PET/PBT dual-component fiber having a sheath melting point of 225° C. and a core-to-sheath ratio of 50:50, and up to 28% conventional PET fibers. The fibers were present as dispersible short-cut fibers. The fibers were deposited on a screen belt in the paper-laying process, dried, and thermally bonded in a second dryer. The exceptional properties of these nonwoven fabrics consisted in the very good mechanical test values and excellent shrinkage characteristics (Table 2). In this case a comparison could not be made to nonwoven fabrics composed of conventional dual-component fibers having a CoPET sheath, since on account of the high shrinkage values it has not been possible heretofore to use such fibers on this nonwoven fabric apparatus; i.e., the fibers exhibited reductions in width of at least 20%. The wet nonwoven fabrics according to the invention exhibited reductions in width of approximately 3%.
[0000]
TABLE 2
Test values for nonwoven fabrics C and D
Nonwoven fabric C
Nonwoven fabric D
Weight per unit area
198
g/m 2
182
g/m 2
Thickness
1.10
mm
0.99
mm
Air permeability
714
L/m 2 s
796
L/m 2 s
Maximum longitudinal
536 N/5 cm
446 N/5 cm
tensile force
Maximum transverse
358 N/5 cm
329 N/5 cm
tensile force
Longitudinal bending
2.5
Nmm
1.9
Nmm
stiffness
Transverse bending
2.1
Nmm
1.6
Nmm
stiffness
Longitudinal shrinkage
0.0%
0.3%
at 150° C., 1 h
Transverse shrinkage
0.0%
0.0%
at 150° C., 1 h
Curl at 150° C., 1 h
0.7%
1.5%
[0036] The low-shrinkage dual-component fibers according to the invention offer advantages, in particular for use in the wet-laying process employing separate dryers for water removal and for thermal fusion, since in contrast to undrawn binding fibers these fibers may be activated multiple times, i.e., are not completely reacted upon the first drying process.
[0000] Nonwoven fabrics A, C, D according to the invention are particularly suited for use as motor oil filter media in motor vehicles.
Example 3
[0037] For use as membrane support fleeces, calendared PET nonwoven fabrics (comparative example; nonwoven fabric E) composed of a mixture of drawn and undrawn monofil PET fibers represent prior art. As a result of the calendaring process, there is a risk of surface sealing in particular for heavy nonwoven fabrics having weights per unit area >150 g/m 2 , since for good bonding of the nonwoven fabric high rolling temperatures or slow production speeds are required in order to conduct the necessary heat to the interior of the nonwoven fabric. Sealed surfaces entail the risk of film formation, which in turn results in poor membrane adhesion and lower flow rates (comparative nonwoven fabric E). FIGS. 4 and 5 demonstrate the difference in surfaces for a conventional nonwoven fabric (comparative example; nonwoven fabric E; FIG. 4 ) and for a nonwoven fabric according to the invention (nonwoven fabric F; FIG. 5 ).
[0038] The complete absence of surface sealing for nonwoven fabric F ( FIG. 5 ) is also shown in a comparison of test values for the two nonwoven fabrics. The air permeability of nonwoven fabric F increased by an order of magnitude, whereas the other test values were comparable (Table 3).
[0000]
TABLE 3
Test values for nonwoven fabrics E and F
Nonwoven fabric C
Nonwoven fabric D
Weight per unit area
190
g/m 2
190
g/m 2
Thickness
0.26
mm
0.25
mm
Air permeability (200 Pa)
5
L/m 2 s
41
L/m 2 s
Maximum longitudinal
520 N/5 cm
514 N/5 cm
tensile force
Maximum transverse
470 N/5 cm
560 N/5 cm
tensile force
[0039] Use of conventional dual-component fibers containing copolymers in the sheath has not become established in this application area due to the high shrinkage values and the associated weight fluctuations, in addition to the frequent denial of food safety authorization for sheath polymers. The nonwoven fabrics according to the invention, composed of the corresponding dual-component fibers, overcome both drawbacks, since they are low-shrinkage and pose no difficulties in food safety authorization because they are composed of homopolymers.
Example 4
[0040] To further demonstrate the differences in the nonwoven fabrics according to the invention compared to conventional nonwoven fabrics containing dual-component fibers having sheaths based on copolymers, FIGS. 6 and 7 show a comparison of differential scanning calorimetry (DSC) curves for fibers containing crystalline sheath polymer (fiber A; in this case PBT) to DSC curves for conventional dual-component fibers (fiber B; in this case CoPET). The analysis of the heats of fusion of the lower-melting component showed that the sheath for fiber B has a much lower heat of fusion, in J/g, than fiber A.
[0041] The heat of fusion is a direct measure of the crystalline fractions in the polymer. The core-to-sheath ratios in both fibers were 1:1, resulting in the following heats of fusion for the fiber sheaths:
[0000]
Fiber A
63 J/g
Fiber B
29 J/g
[0042] Here as well, the core of both fibers, which in each case is composed of PET, may be used as a measurement reference. The values obtained for the heat of fusion are comparable (59 J/g versus 54 J/g).
[0043] Independent of the measured values, in a comparison of the DSC curves the low peak height and the wider peak base are characteristic of fiber sheaths based on copolymers (in this case CoPET). The melting point as well as the crystallinity, i.e., the tendency of the polymers to crystallize, are reduced by incorporation of comonomers such as isophthalic acid into polyethylene terephthalate.
[0044] The nonwoven fabrics according to the invention are therefore based on fibers of the fiber A type. | The invention relates to a thermally bound non-woven material containing a low-shrinkage dual-component core-sheath fiber consisting of a crystalline polyester core and a crystalline polyester sheath which has a melting point at least 10° C. lower than the core, the heat-shrinkage characteristic of said fiber being less than 10% at 170° C. | 3 |
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a door housing and more particularly relates to a door hinge mechanism.
2. Description of the Related Art
A front panel of an appliance is conventionally screwed or bolted onto the appliance housing or case. The front panel improves the aesthetics, protects contained parts from harmful environment such as dust, prevents human or animal direct contact to the parts, and allows daily inspection through windows on the front panel without causing particular danger. The front panel is conventionally screwed or bolted, which is not expensive.
The appliance usually requires a regular maintenance, which may be conducted without removing the front panel but with utilizing small windows and access holes to adjust the equipment. However, on some occasion such as a major maintenance service and repair, the front panel may be needed to be removed from the appliance for the serviceman to access the inside of the appliance case. The front panel that is conventionally fixed on the appliance case may require a special tool and it may take long to unscrew (and screw) all screws on the front panel.
In order to obtain an easy access to the inside of the appliance, a front panel hingedly connected to the appliance case with a latch mechanism may be employed. However, a regular hinge does not keep the front panel open unless a special stopping mechanism is installed. Additional parts or equipment tends to complicate the hinged front panel system and to make it much more expensive.
SUMMARY OF THE INVENTION
The present invention seeks to provide a simple and inexpensive hinge system or mechanism that may apply to the front panel or door so as to obtain an easy access to the inside without making the mechanism much more complicated or expensive.
According to the present invention, the hinge mechanism for a front panel or door hingedly connected to an enclosure (or cabinet case) comprises an axis (or shaft) and an axis supporting member having an opening that supports the axis at a first position for door swinging, at a second position for holding the door in a certain state, and in a transition position for the axis moving with or without any turning.
According to another aspect of the present invention, the hinge mechanism mentioned above further comprises a latch mechanism for keeping the door steadily open.
According to yet another aspect of the present invention, the axis is fixed to the enclosure (or case) so that the door locking and latching movement can be made by pulling the door.
According to another aspect of the present invention, the hinge plate comprise a flat plate and a curved elongated opening so that the hinge mechanism can be simple.
According to another aspect of the present invention, the curved elongated opening of the axis support member has a partial bearing portion parallel with the door face and a curved-away-bearing portion from the door face, so that the hinged mechanism can utilize the door weight to latch or lock the door and create more space from the front opening trim so as to allow the hinge plate to turn around the axis.
According to another aspect of the present invention, the hinge plate comprises a projecting portion to engage with a latch edge portion secured to the case for keeping the door open.
According to another aspect of the present invention, the door lock mechanism is synchronized with the hinge mechanism so that the closed door may be prevented from vibrating and making noise with the case frame.
According to another aspect of the present invention, the hinge mechanism, the latch mechanism, and the lock mechanism may be installed separately to the cabinet case to which the door hingedly connected.
According to another aspect of the present invention, any kind of door-hingedly-connected-to-case system can apply any one of the hinged mechanisms mentioned above.
According to another aspect of the present invention, the hinge plate having an opening comprising a flat plate, a curved elongated opening, and a projecting portion so that the hinge mechanism may incorporate the latch mechanism.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a perspective view from a lower position of a cabinet case with a door hingedly connected to the case, according to a preferred embodiment of the present invention. The door is held at an open position.
FIG. 2 is a perspective view from a lower position of the cabinet case shown in FIG. A, with the door hingedly connected to the case. The door swings up and down to open and close the case, respectively.
FIGS. 3 ( a )-( d ) shows a door opening operation, for the embodiment of FIG. 1 . FIG. 3 ( a ) is a perspective view of the cabinet case with the door hingedly connected to the case when the cabinet case is closed. The door is in a closed position. FIG. 3 ( b ) is a perspective view of the cabinet case with the door hingedly connected to the case when the cabinet case is about to open. The door is in a swinging position. FIG. 3 ( c ) is a perspective view of the cabinet case with the door hingedly connected to the case when the cabinet case is opening. The door is in the swinging position. FIG. 3 ( d ) is a perspective view of the cabinet case with the door hingedly connected to the case when the cabinet case is completely open and kept open. The door is in a latched position.
FIGS. 4 ( a )-( e ) are perspective views of a left and top portion of the front opening for the embodiment of FIG. 1 with the door and cabinet case partially broken away to show operation of a hinge mechanism. FIG. 4 ( a ) is a perspective view of the hinge mechanism when the door is in the closed position. FIG. 4 ( b ) is a perspective view of the hinge mechanism when the door is pulled up to start to open the cabinet. The door (or axis) is in the swinging position. FIG. 4 ( c ) is a perspective view of the hinge mechanism when the door is swinging to open the cabinet. The door (or axis) is in the swinging position. FIG. 4 ( d ) is a perspective view of the hinge mechanism when the door is completely open. The door (or axis) is in the swinging position. FIG. 4 ( e ) is a perspective view of the hinge mechanism when the door is pushed down onto an edge portion of a side plate of the case. The door is in the latched position.
FIGS. 5 ( a ) and ( b ) show a hinge bracket for the embodiment of FIG. 1 . FIG. 5 ( a ) is a side view of the hinge bracket. FIG. 5 ( b ) is a plan view of the hinge bracket.
FIGS. 6 ( a )-( e ) are views of a lock mechanism for the embodiment of FIG. 1 with some parts broken away to show operation of a door lock mechanism. FIG. 6 ( a ) is a cross sectional view of a projecting pin with a pin head secured to the side plate along with a cross sectional view of a back panel of the door when the door lock mechanism does not operate. FIG. 6 ( b ) is a cross sectional view of the projecting pin secured to the side plate along with a cross sectional view of the back panel of the door when the door lock mechanism starts to operate. The projecting pin penetrates through a large opening of the engaging opening. FIG. 6 ( c ) is a cross sectional view of the projecting pin secured to the side plate along with a cross sectional view of the back panel of the door when the door lock mechanism locks the door. The projecting pin, having penetrated through the large opening, now slides up to a small opening.
FIG. 7 is a perspective view of a hinge mechanism of another aspect according to the present invention. A door hingedly connected to a case is completely open. A door stopping bar sits on a lever of a side plate of the case. The door is in the latched position.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings, FIG. 1 shows a cabinet case 10 with a front panel or door 12 open and at a latched position. The cabinet case 10 has an enclosure or a case 14 with a front opening 16 . At a left side of the front opening 16 a side plate 18 is secured to a case left edge 20 . Another side plate 18 is secured to a case right edge 22 of the front opening 16 . At the top of the left and right side plates 12 , a hinge system (or mechanism) 24 is installed to hinge the door 12 to the case 14 . Around mid height of the left and right side plates 18 , projecting pins 26 are installed, respectively. The hingedly connected door 12 has two key holes 28 at left and right sides, respectively. Each key hole 28 has a large opening 30 and a small opening 32 , which are connected a narrow path 34 . The left projecting pin 26 engages with the left key hole 28 and the right projecting pin 26 engages with the right key hole 28 when the door is locked.
Referring to FIG. 2, the door 12 is now swinging up to open the cabinet case 10 or swinging down to close the cabinet case 10 as shown by Arrow AA. The door opening and closing operations will be explained with reference to FIG. 3 .
FIG. 3 ( a ) shows the cabinet case 10 when the door 12 is closed. The case 14 has a top panel 36 and two side panels 38 . The top panel has two hinge openings 40 at left and right sides near the front opening 16 , respectively. When the door 12 is about to open, the door 12 is pushed (or pulled) up vertically as shown by Arrow BB such that a door lock may be released and the door 12 starts to depart from the front opening trim as shown FIG. 3 ( b ).
The door 12 is now separated from the trimming frame of the front opening 16 as shown FIG. 3 ( b ). When the door 12 is pushed (or pulled) up (FIG. 3 ( a )), the door 12 is moved forward because of the hinge mechanism, which will be described in details later. In this position the lock mechanism is released such that the projecting pins 26 may be moved out or almost moved out from the key hole 28 . Therefore, the bottom portion of the door 12 may be pulled forward as shown by Arrow CC. Since the top portion of the door 12 is connected to the case 14 via the hinge mechanism 24 , the door 12 starts to swing up when the bottom portion of the door 12 is pulled forward as shown in FIG. 3 ( c ).
The cabinet case 10 now starts to show its front opening as shown in FIG. 3 ( c ). The door 12 may be continued to open if the bottom portion of the door 12 is pulled up as shown by Arrow DD. However, the door may swing back to close the front opening 16 if the pulling force is removed during this process. The door 12 has some weight and tends to fall with gravity but the top portion of the door 12 is connected to the case 14 such that the top portion does not fall. Therefore, the door 12 swings down like a seesaw with one hand full of heavier weight.
The door 12 can be pulled up to become almost horizontal as shown in FIG. 3 ( d ). However, with this embodied cabinet case, the top and back edge of the door 12 may contact the top panel 36 of the case 14 to prevent the door from further opening. If the contact between them is prevented, the door 12 may swing even higher.
After the door 12 swings up to be almost horizontal, the door 12 may be pulled forward as shown by Arrow EE such that the hinge mechanism is latched. Because of the latch mechanism the door 12 does not swing down to close the cabinet case 10 . The latch mechanism will be described in details later.
FIGS. 4 ( a )-( e ) illustrate the hinge mechanism 24 and operation thereof. Although FIG. 4 ( a ) shows the left-and-top corner of the front opening 16 with broken door 12 and case 14 , the same or symmetrically identical mechanism applies at right-and-top corner of the front opening 16 . The case 14 has the top panel 36 with the hinge opening 40 next to the front opening 16 , which is surrounded by first, second, and third edges 42 , 44 , 46 and has one open side open to the front opening 16 . Therefore, the hinge opening 40 is formed in a cup- or C-shape on the top panel as shown in FIGS. 4 ( a )-( e ). The top panel 36 defines the upper end of the front opening 16 by first and second top front edges 48 , 50 . The first and second top front edges 48 , 50 are separated by the hinge opening 40 .
The left side panel 38 is connected to the top panel 36 at the top edge and to the side plate 18 at the case left edge 20 . The side plate 18 is also connected to the top panel 36 at the second top front edge 50 . The left side plate 18 has an inner edge 52 along a right side of the plate 18 and an opening defined by L-shaped edges at the right-and-top corner of the side plate 18 , where an axis holding plate 54 is fixed at the vertical edge of the L-shaped edges. The axis holding plate 54 may be formed by bending an upper part of the side plate 18 (i.e., it was originally a part of the side plate.) at the vertical edge of the L-shaped edges with a right angle from the side plate 18 after the upper part of the side plate 18 is cut along a first latch edge 56 , which is the bottom edge of the L-shaped edges.
The axis holding plate 54 has a axis fixing portion 58 , on which an axis 60 is securely fixed. The axis 60 , therefore, extends rightward from the axis fixing portion 58 on the axis holding plate 54 and has a stopping end 62 at the tip end of the axis 60 . The axis 60 holds a hinge plate 64 between the axis holding plate 54 and the stopping end 62 such that the axis 60 can pass through an opening of the hinge plate 64 but neither the axis holding plate 54 nor the stopping end 62 can pass through it.
The hinge plate 64 is fixed to the door 12 or the back plate 66 at the top edge (a hinge plate fixing portion 68 ) of the plate 64 . The hinge plate 64 is surrounded by the top edge ( 68 ), a hinge front edge 70 , a first hinge chamfered edge 72 , a projecting portion 74 , a second latch edge 76 , a bottom edge 78 , a second hinge chamfered edge 80 , and a hinge back edge 82 if viewed counter-clockwise. The hinge plate 64 also has an opening for receiving or bearing the axis 60 , which comprises a first position 84 and a second position 86 , and transition position 88 . In the first position the door 12 can swing and at the second position the door 12 may not swing, which will be explained later. The hinge front edge 70 is horizontal in FIG. 4 ( a ) (and perpendicular to the top edge) extending straight until the first hinge chamfered edge 70 , which is designed to allow the hinge plate 64 to turn around the axis 60 when the axis 60 is in the first position. The projecting portion 74 is designed to latch the hinge mechanism by letting the second latch edge 76 engage with the first latch edge 56 of the side plate 18 and by letting the bottom edge 78 rest on the first latch edge 56 when the door is opened. The detailed operation will be explained later. The bottom edge 78 is connected to the second hinge chamfered edge 80 , which in turn is connected to the hinge back edge 82 that is parallel with the hinge front edge 70 .
FIG. 4 ( a ) shows the hinge mechanism 24 when the door 12 is closed. The figure corresponds to FIG. 3 ( a ). The axis 60 is positioned in the second position 86 such that the door may not swing since the door 12 is locked with the lock mechanism as described later. The hinge plate 64 is positioned between the axis holding plate 54 and the stopping end 62 with the axis 60 passing through the opening of the hinge plate 64 . Thus, the hinge plate 64 is parallel or almost parallel with the axis holding plate 54 , which is vertical or almost vertical. The top edge (the hinge plate fixing portion 68 ) is vertical and in front of the front opening 16 such that the door 12 may close the front opening 16 . Therefore, the hinge front edge 70 , which may or may not touch the first latch edge 56 , is horizontal and at the bottom of the hinge plate 64 . The axis is in the second position because the weight of the door 12 pull down the hinge plate 64 to let the axis 60 find the highest position (the second position 86 ) in the opening.
FIG. 4 ( b ) shows the hinge mechanism 24 when the door is pulled up or pushed up vertically. The figure corresponds to FIG. 3 ( b ). The arrangement of the components are basically the same as shown in FIG. 4 ( a ) except the hinge plate 64 being lifted and moved forward as the axis 60 slides along front and back guide edges 90 , 92 of the opening. (Or the guide edges 90 , 92 slide around the axis 60 because the hinge plate 64 is pulled up while the axis stays still with the case 14 .) The front and back guide edges 90 , 92 are, therefore, bearing portions. The hinge plate 64 first vertically lifted up until the axis 60 touches the front guide edge 90 . Since the front guide edge 90 is curved to form a slope, which makes some angles more than 0 but less than 90 degrees against the horizontal line, the front guide edge 90 slides on the axis 60 to move the hinge plate 64 forward while the hinge plate 64 (or the door 12 ) is being lifted up. Therefore, the area sided by the front and back guide edges 90 , 92 may be called a transition position 88 . The axis 60 is, thus, in the first position 84 . Some space between the door 12 and the case 14 is created so that the door has freedom to swing around the axis 60 .
FIG. 4 ( c ) shows the hinge mechanism 24 when the door is being swung up (or down). The figure corresponds to FIG. 3 ( c ). The axis 60 is still in the first position 84 so as to allow the door to swing. The hinge plate fixing portion 68 now makes some angle (more than 0 and less than 90 degree) against the horizontal line. Since the hinge plate 64 is appropriately chamfered at the first hinge chamfered edge 72 and lifted up, the hinge plate 64 is not blocked by the first latch edge 56 . Conversely, the hinge plate 64 is well designed with the peripheral shape and size, and the opening position, pattern and size to avoid any blockage and to operate the latch mechanism properly as described later.
FIG. 4 ( d ) shows the hinge mechanism 24 when the door 12 is opened to become horizontal like the door 12 in FIG. 3 ( d ). In FIG. 4 ( d ), however, the axis 60 is still in the first position such that the projecting portion 74 is far from the first latch edge 56 of the side plate 18 . The door 12 is still being pulled at this time because the door 12 may swing back or down if the pulling force is removed. This is because the door has some weight and the axis 60 is somehow constrained in the opening such that the bottom portion of the door 12 may fall first to make the door 12 swing down around the axis 60 . In order to hold the door open, the hinge mechanism may be latched by pulling the door 12 forward. Because the front guide edge 90 is angled to be a slope, the hinge plate 64 (or the door 12 ) may lowered gradually while the door 12 is pulled forward. The back guide edge 92 helps the hinge plate come down gradually.
FIG. 4 ( e ) shows the hinge mechanism 24 when the door 12 is latched in the open position. The figure corresponds to the FIG. 3 ( d ). The hinge plate fixing portion 68 is horizontal like the door 12 and the hinge front and back edges 70 , 82 are vertical. The bottom edge 78 sits on the first latch edge 56 to hold the door 12 open. The second latch edge 76 of the projecting portion 74 may contact the front face of the side plate 18 near the first latch edge 56 so that the door 12 may be prevented from swinging down by turning around the axis 60 . Since the door 12 has some weight and is pivotably secured around the axis 60 as mentioned before, the door 12 tends to turn counterclockwise around the axis 60 in FIG. 4 ( e ). However, the bottom edge 78 sits on the first latch edge 56 , which is located between the pivotable axis 60 and the center of gravity of the door 12 . Thus, the down force moment by the door weight is cancelled by the resisting upward force moment. Since the length from the center of gravity of the door 12 to the pivotable axis 60 is longer than that from resisting upward force working point to the pivotable axis 60 , the first latch edge 56 may have to endure the door weight and more if only one first latch edge is employed for the cabinet case 10 .
FIG. 5 shows an example of the hinge plate 100 . The hinge plate 100 includes a flat plate surrounded by a hinge plate fixing portion 102 , a hinge front edge 104 , a first hinge chamfered edge 106 , an projecting portion 108 , a second latch edge 110 , a bottom edge 112 , a second hinge chamfered edge 114 , and hinge back edge 116 . The hinge plate 100 also includes an opening comprising a first position 120 , a second position 122 , a front guide edge 124 , and a back guide edge 126 . In the example, the hinge fixing portion is composed of a rib plate 128 and two bolt holes 130 . The hinge plate of the example may be fixed on the back panel of the door 12 with screws or bolts.
With reference to FIGS. 6 ( a )-( e ), the lock mechanism is described. FIG. 6 ( a )-( c ) show cross sectional views of the projecting pin 26 installed on the front face of the side plate 18 and the back plate 66 of the door 12 with broken parts. FIGS. 6 ( d ) and ( e ) are front views by Arrows FF and GG, respectively. In this particular embodiment, the door 12 comprises a back panel, a front panel and side members connecting the back and front panels. The projecting pin comprises a pin head 140 and pin stem 142 , which is fixed on the side plate 18 . The pin head may be round like semisphere so that the curved top may direct the projecting pin by contacting the hole brim to the center of a hole, which engages with the projecting pin 26 . The back panel 66 has the key hole 28 , which comprises the large opening 30 and the small opening 32 , which are connected via a narrow path 34 . The projecting pin 26 and the key hole 28 are arranged to engage with each other when the door 12 closes.
FIGS. 6 ( a ) and ( d ) show the lock mechanism when the door 12 is about to swing down to close the cabinet 10 . The hinge mechanism is adjusted to such relative height and position as shown in FIGS. 6 ( a ) and ( d ). In the figure, the pin head 140 is centered of the large opening 30 in FIG. 6 ( d ) so that the pin head 140 easily passes through the large hole 30 . However, a small deviation may be self-adjusted at the curved head of the pin head 140 and a peripheral edge of the large opening 30 .
FIG. 6 ( b ) shows the lock mechanism when the door 12 is closed but the door is still lifted. The pin head 140 has passed through the large opening 30 and the back plate 66 is located between the pin head 140 and the side plate 18 . In this particular embodiment, the displacement from the front opening 16 to the back plate 66 by the hinge mechanism is small. The figure, therefore, corresponds to FIG. 4 ( b ) although the FIG. 4 ( b ) shows the mechanism when the door is about to open.
FIGS. 6 ( c ) and ( e ) show the lock mechanism when the door 12 is closed. After the pin head 140 passes through the large opening 30 , the door 12 is lowered or dropped by gravity. The pin stem 142 slides the narrow path 34 of the back panel key hole 28 . (The narrow path 34 actually moves down relative to the projecting pin 26 when the door 12 is dropped.) Thus, the pin head 140 can be seen as shown in FIG. 6 ( e ) if viewed by arrow GG.
FIG. 7 shows another embodiment explaining another aspect of the present invention. Most components are common with the previous embodiment and FIG. 4 ( e ) may be referred to for comparison. The figure shows another embodiment of the hinge mechanism, which may apply to the previous embodiment shown in FIGS. 3 ( a )-( d ). A case 150 comprises a top panel 152 , a side panel 154 and side plate 156 . The top plate 152 comprises first and second top front edges 158 , 160 and a rectangular hinge opening 162 surrounded by first, second, and third edges 164 , 166 , 168 in a similar manner in FIGS. 4 ( a )-( e ). The top panel 152 is connected to a side panel 154 at the left edge. The side panel 154 is connected to a side plate 156 at a left side edge 170 . The side plate 156 is also connected to the top panel 152 at the second top front edge 160 . The side plate 156 is connected to a fixed hinge plate 172 , which may be formed by bending a part of the side plate 156 along a vertical right edge 174 . The fixed hinge plate 172 is surrounded by fixed hinge plate bottom edge 176 and a fixed hinge plate back edge 178 .
The fixed hinge plate 172 has an L-opening 180 which comprises a fixed hinge first position 182 , a fixed hinge second position 184 , a fixed hinge transition position, a fixed hinge front guide edge 186 , and a fixed hinge back guide edge 188 . The fixed hinge first position 182 is located at the most front and highest position and the fixed hinge second position 184 is located at the most rear and lowest position of the L-opening 180 . In the figure, a axis 190 passes through the L-opening 180 which extends from the lower portion of a axis support member 192 . The axis support member is secured to the door 194 at a axis support member fixing portion 196 .
At lower portion of the side plate 156 than the fixed hinge plate 198 , a latch member 200 extends horizontally from the side plate 156 . The latch member may be formed by cutting the side plate 156 vertically to some extent and bending the cut part toward the front. In order to make the latch member steady, upper and lower parts may be bent at the same time to form double layered fixed hinge plate 172 . Around a bar resting area 202 , a topping bar, which is fixed at the top edge (stopping bar fixing portion 206 ) and extending down vertically from the stopping bar fixing portion 206 to the resting area 202 .
The figure shows the hinge mechanism when the door 194 is open and kept open. The axis 190 is in the second position 184 and the stopping bar 204 is sitting on the bar resting area 202 to resist the downward force caused by the door weight and axis 190 in the similar manner as described with reference to FIG. 4 ( e ).
In order to close the door 194 , the bottom portion of the door 194 may be lifted up to release the latch mechanism on the latch member 200 and the door may be pulled forward to move the axis 190 forward and upward, such that the stopping bar 204 disengages from the bar resting area 202 and the door may turn counterclockwise without the stopping bar touching the latch member 200 . When the door 194 is swung down to close the cabinet case, the upper part of the door 194 may be pushed to move the axis 208 from the first position 182 to the second position 184 so that the axis settles in the second position 184 . During the last process the lock mechanism allows the pin head 140 of the projecting pin 26 to pass through the large opening 30 and slide through the narrow path 34 into the lock position.
In the foregoing description, although only the left hinge mechanism of the two hinge mechanism is explained, the other mechanism may be identical or symmetrically identical so that the same explanation may apply to the other mechanism. Since the present invention utilizes the door weight, the present invention may apply best to the equipment having a middle range of door weight. However, the invention may also be applied to equipment with a heavy door. It may be even better for such an application if the heavy weight can be cancelled by a counter spring force or the like.
Although the latch mechanism is incorporated in the hinge plate in the first embodiment, the latch mechanism may installed separately from the hinge mechanism.
In the foregoing embodiment, a pair of hinge mechanisms are employed for the cabinet case. However, it should be understood that only one hinge mechanism or more than two hinge mechanisms may be applied to the hinged-door cabinet.
In the foregoing embodiment, although only box-shaped cabinet case is employed, the present invention may apply to other types of cases such as a round shape.
Although foregoing embodiments show a door to swing only upward, the present invention may apply to the cabinet which has a door to swing in any direction.
It should be understood that the components may be made of metal such as steel, and other materials such as organic material and inorganic materials.
It should also be understood that the foregoing relates only to preferred embodiments of the present invention, and thus changes and modifications thereto may be made without departing from the spirit and scope of the invention as defined in the following claims. | A simple and inexpensive hinge system or mechanism that may apply to the front panel or door so as to obtain an easy access to the inside without making the mechanism much more complicated or expensive. The hinge mechanism for a front panel or door is hingedly connected to an enclosure (or cabinet case) and comprises an axis (or shaft) and an axis supporting member having an opening that supports the axis at a first position for door swinging, at a second position for holding the door in a certain state, and at an intermediate position for the axis moving with or without any turning. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to devices which collect solar radiation for purposes of heating a fluid, such as water.
2. Description of the Prior Art
The prior art contains numerous suggestions of flat panel solar collectors which are useful for heating water or other fluids. One type of such solar collectors employ a circuitous conduit of a good heat conducting material, such as copper, which is disposed on a flat, heat-absorbing panel. This arrangement is disposed in areas of high solar radiation, in order to heat water passing through the conduit. Alternatively, other fluids useful for transferring the heat absorbed from solar radiation into a building for other purposes may be utilized. Examples of such collectors are described by Yellott at page 31 of the December, 1973 ASHRAE JOURNAL.
A variety of other flat panel arrangements have been employed for special purposes. In U.S. Pat. No. 3,232,795, Gillette et al disclose a solar cell converter useful for space vehicles and in similar applications. Perlmutter et al, in U.S. Pat. No. 3,229,682, disclose a device for directionally controlling electromagnetic radiation. As disclosed by Perlmutter et al, this device includes a plurality of radiation-reflecting surfaces which increase the intensity of the radiation directed to a thermal energy transferring element.
Other prior art patents of interest include: U.S. Pat. Nos. 980,505 to Emmet; Pat. No. 3,089,670 to Johnson; 2,969,788 to Newton; Pat. No. 3,613,659 to Phillips; and 3,285,333 to Johnson.
SUMMARY OF THE INVENTION
The present invention contemplates apparatus for collecting heat of radiation comprising a hollow member having a panel with a substantially flat exterior surface, the panel being capable of absorbing radiation incident to the surface and transferring the heat therefrom to a fluid passing through the member. A reflector body extends away from the flat surface, the reflector body adapted to reflect radiation incident thereto toward the flat surface of the panel.
In a preferred embodiment, the reflector body has a hollow interior communicating with the interior of the hollow member, such that fluid circulating through the hollow member likewise circulates through the interior of the reflector body. Further in accordance with this preferred embodiment, each reflector body is tapered in a direction away from the flat surface of the panel, the extremity of each tapered reflector body distal to the flat surface being defined by a level surface which is likewise absorptive of radiation in the same manner as the flat surface of the panel.
THE DRAWING
FIG. 1 is top plan view, partially cut away, of a solar collector in accordance with the present invention.
FIG. 2 is a cross-sectional side view of the embodiment of FIG. 1, taken along the lines 2-2'.
DETAILED DESCRIPTION
A preferred embodiment of the solar collector in accordance with the present invention will now be described with reference to FIGS. 1 and 2.
The collector, referred to generally as 10, comprises a member 12 having a hollow interior therein. The hollow member 12 includes a panel 13 having an exterior flat surface 14 which is preferably coated with a heat-absorbing material, such as a flat, black paint, so as to render that surface relatively heat absorbing with respect to the reflective surfaces 22 of the reflector body 20, as is described in greater detail below.
The hollow member 12 further includes an input and output 16 and 18, respectively, both of which communicate with the hollow interior of the member 12 such that a fluid flowing through the input is capable of circulating through the member 12 and thence through the output 18 (note arrows in FIG. 2).
In accordance with the present invention, a plurality of hollow reflector bodies 20 are provided, each reflector body having a hollow interior communicating with the hollow interior of the member 12 and tapering inward in a direction away from the flat surface 14. As shown in FIG. 1, each reflector body 20 may comprise a trianguloid; however, it will be understood by those skilled in the art that a variety of other geometric shapes may be employed without departing from the spirit and scope of the present invention. The extremity of each reflector body 20 comprises a plane surface 26 which is preferably substantially parallel with the flat surface 14, and includes a heat-absorbing material, such as a layer of flat, black paint, so as to heat water circulating therein. As shown in FIG. 2, each reflector body 20 includes a hollow interior which communicates with the hollow interior of the member 12. The panel 13 and reflector bodies 20 may be formed from an integral sheet by conventional stamping or molding processes.
The collector 10 further includes a base 28 which carries the hollow member 12, and through which extends the input and output 18 and 20, respectively. The base 28 includes supporting sides 30, the base 28 and sides 30 being formed of a material which is relatively heat resistant with respect to the member 12, in order that little or no heat is lost through this material.
The collector 10 further includes a cover 32 which is transparent to solar radiation, in order that the heat of radiation falls onto the reflector surfaces 22 of the reflector bodies 20 and the flat surface 14. The cover 32 is supported by the sides 30, as is shown in FIG. 2.
Noting both FIGS. 1 and 2, the collector 10 is provided with brackets 40, each of which extend through the hollow interior of the member 12 along a column of the reflector bodies 20. Each bracket 40 includes a plurality of apertures 42, each aperture being positioned at the front of the corresponding reflector body 20 so as to direct fluid upward into the hollow interior of the reflector body.
The manner in which the collector 10 functions will now be described. The collector 10 is positioned on a roof, or against the wall of a building so as to be exposed to solar radiation during the course of the day. It will likewise be understood that the collector 10 may be permanently inplaced in conjunction with the building.
As with prior art flat-plate solar collectors of the type described above, the black-coated flat surface 14 absorbs incident solar radiation, the heat of which passes through the panel 13 to heat water, or any other fluid, passing through the hollow interior of the member 12. Now noting a first one of the reflector bodies 20a in the right hand portion of FIG. 1, during those periods when the angle of incidence of the sun's rays are relatively shallow, one of the reflecting surfaces 22a reflects the low-angle solar radiation onto the flat surface 14 in order to achieve the desired heat absorption (reflected radiation is defined by dotted lines).
Now noting a second one of the reflector bodies 20b in the central portion of FIG. 1, during those periods when solar radiation is substantially perpendicular to the flat surface 14, a substantial portion of all of the reflective surfaces of the reflector body 20b reflect the solar radiation onto the flat surface 14. Now noting a third one of the reflector bodies 20c at the left hand portion of FIG. 1, as the rotation of the earth changes the relative position of the sun during any given day, another reflective surface 22b receives the solar radiation at low angles of incidence on the opposite side of the collector 10, and reflect this radiation onto the flat surface 14 in order to heat the water passing through the member 12. In this way, the reflector bodies 20 serve to increase the efficiency of a flat collector, by increasing the amount of solar energy during periods of low angles of incidence of solar radiation. The relatively high heat resistive base 28 prevents heat transfer from the water, during periods when the water is circulating through the member 12. The cover 32 assists in providing a "greenhouse effect", by trapping heated air between the member 12 and the cover, to further increase the efficiency of heat absorption at the flat surface 14 and through the panel 13. As the water leaves the output 18, it may be pumped into a water storage tank. Alternatively, other fluids may be heated as described above for utilizing that heat for performing other work functions.
An important aspect of the collector of the present invention is the increased efficiency for a flat panel collector, which allows smaller absorption areas to be employed. Further, as described above the reflector bodies may take numerous shapes, and provide a decorative appearance to the collector.
Additionally, the use of the flow-directing bracket 40 provides increased efficiency with respect to the transfer of heat to the fluid flowing therethrough. | Apparatus for collecting heat of radiation includes a hollow member having a panel with a substantially flat exterior surface, the panel absorbing radiation incident to the surface and transferring the heat therefrom to a fluid passing through the member. A reflector body extends from the surface, and is adapted to reflect radiation incident thereto toward the radiation-absorbing surface. | 5 |
BACKGROUND
The logical structure of a typical relational database is determined by its dictionary objects. These objects can be of a number of object types, e.g., tablespaces, users, tables, views, sequences, stored procedures, etc.
The Oracle Metadata API, introduced in Oracle 9i, provides a central facility for extracting metadata for one or more objects of a specific object type. The 9i implementation uses an OPEN-FETCH-CLOSE programming model: the user issues an OPEN for a particular object type and then repeatedly FETCHes objects of that type; upon completion, the user CLOSEs the object type context. A user can specify one or more filters that restrict the set of objects to be fetched. The Oracle 9i implementation provides a powerful and flexible mechanism for fetching objects within a particular object type.
This API is described in U.S. application Ser. No. 09/672,914, filed on Sep. 28, 2000, “Aggregating and manipulating dictionary metadata in a database system,” the entire teachings of which are incorporated by reference herein in their entirety.
SUMMARY
Often, a user may wish to extract the metadata for a logical set of objects that belong to different object types while comprising a logical unit. Examples are (1) a table and all of its dependent objects (constraints, indexes, grants, etc.); (2) all objects in a schema (tables, views, types, procedures, etc.); (3) all objects in the database (tablespaces, users, rollback segments, etc., as well as schemas and their contents).
Furthermore, the user may wish to take this extracted metadata and use it to recreate the logical set of objects on another database. To recreate the set of objects, however, they must be created in a specific order, e.g., a table before its indexes. Unfortunately, the creation order is frequently not obvious.
In prior solutions, users had to write custom code encapsulating knowledge of the objects making up the logical set, as well as the creation order for the objects. The Oracle Export utility is one such custom program. Such custom programs are usually well-designed for their specific purpose but can be difficult to adapt to new uses.
The present system can enhance the Oracle Metadata API described in U.S. Ser. No. 09/672,914 with “heterogeneous object types,” i.e., collections of objects that, although of different object types, nevertheless comprise a logical unit. The programming model can be the same OPEN-FETCH-CLOSE model used in Oracle 9i. The differences are that (1) the user specifies, in the OPEN statement, the name of a heterogeneous object type, (2) the objects fetched belong to different homogeneous object types, and (3) the objects are returned in a valid creation order.
A particular embodiment of the present system is a method for extracting metadata for plural related objects of different types from a database. The method can include defining a heterogeneous object type as a collection of database objects of different types. Upon a request to fetch a particular heterogeneous object, member objects of the heterogeneous object can be fetched from the particular heterogeneous object. Member objects can be returned in a specific order, such as a valid order for recreating the particular heterogeneous object, based on the definition of the heterogeneous object's type.
Exemplary heterogeneous object types are table export, database export, schema export and tablespace export types. Member objects can be homogeneous object types, or can be other heterogeneous object types.
The set of member objects to be fetched can be restricted according to at least one specified filter, which itself may be translated into a second filter according to a type of a member object being fetched.
In a particular embodiment, a first table can specify whether an object type is a heterogeneous or a homogeneous object type. A second table can then define the specific order in which member types for a given heterogeneous object type are to be returned. Upon a fetch command, member objects can be fetched according to the specific order defined in the second table. A third table can specify filters that can be applied to a particular heterogeneous object type, and a fourth table can specify filter translations for individual member object types. Such translated filters can inherit values from the filter specified in the request for the particular heterogeneous object type. Alternatively, a filter can have a fixed value of some data type, such as text, boolean, numeric, date, etc.
More particularly, the extracted metadata can be formatted using a markup language, such as XML. This markup language-formatted data can be translated into statements formatted to recreate the particular heterogeneous object.
In the present system, object metadata can be extracted from a relational database using just a single request for metadata for a logical unit within the database, where the logical unit comprises plural objects of different types. The requested metadata can then be extracted, and returned in an order in which the logical unit can be recreated on this or another database. While the single request may contain multiple fetches, it is a single request in that only one object type (i.e., the particular heterogeneous object type) is opened and the user does not need to be aware of the internal dependencies to extract all of the member objects.
A logical unit may comprise, for example, a table and its dependent objects, such as, but not limited to, constraints, indexes and/or grants. Other logical units may comprise, but are not limited to, schemas and databases.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the database system having heterogeneous object types will be apparent from the following more particular description of particular embodiments, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views.
FIG. 1 is a schema diagram illustrating the objects created in an example of the present system and their relationships.
FIG. 2 is a schematic diagram illustrating a metaview$ table which, in addition to supporting homogeneous object types, supports heterogeneous object types of the present system.
FIG. 3 is a schematic diagram illustrating a metafilter$ table which, in addition to supporting homogeneous object types, supports heterogeneous object types of the present system.
FIG. 4 is a schematic diagram illustrating a metascript$ table, which is used to support heterogeneous object types of the present system.
FIG. 5 is a schematic diagram illustrating a metascriptfilter$ table, which is used to support heterogeneous object types of the present system.
FIG. 6 is a block diagram of representative organization of an embodiment of the present system.
DETAILED DESCRIPTION
The present system adds heterogeneous types to the Metadata API previously described by U.S. application Ser. No. 09/672,914.
Particular heterogeneous object types are added by inserting rows into dictionary, or system, tables. One table (metaview$) contains the names of all object types, with a flag indicating whether the type is homogeneous or heterogeneous. Another table (metascript$) defines the member types belonging to the heterogeneous type and their order. The code implementing the FETCH function determines whether the object type is homogeneous, in which case it does the normal processing, or whether the object type is heterogeneous, in which case it calls itself recursively for each of the member types.
Heterogeneous object types can be recursively nested, i.e., one heterogeneous type can be a member of another heterogeneous type. As with homogeneous object types, users can specify filters on a heterogeneous object type that restrict the set of objects to be fetched. These filters are translated into filters on the member types; the translation is specified in another dictionary table (metascriptfilter$).
EXAMPLE
The following example demonstrates how the metadata API (dbms_metadata) fetches a heterogeneous object—that is, an ordered set of objects which, although they are of different object types, nevertheless comprise a logical unit. In this example, the heterogeneous object is of type TABLE_EXPORT, consisting of a table and its indexes.
First, assume the following script is executed to create, in schema “SCOTT,” a table named “EMPLOYEE” having two columns, “empno” and “empname.” Two indexes are created on the table, namely “EMP_IND 1 ” and “EMP_IND 2 .” Connection to the schema is presumed.
create table EMPLOYEE (
empno number, empname varchar 2 (30));
create index EMP_IND 1 on EMPLOYEE(empno); create index EMP_IND 2 on EMPLOYEE(empname);
FIG. 1 is a schema diagram illustrating the resulting objects and their relationships. A heterogeneous object 20 of type TABLE_EXPORT comprises the table “EMPLOYEE” 12 , having the two columns empno 18 and empname 19 , and the two indexes 14 , 16 on each of the columns.
We now fetch, using a single request comprising a single OPEN, one or more FETCHES, and a single CLOSE command, the heterogeneous TABLE_EXPORT object 20 that comprises the table 12 and its two indexes 14 , 16 . The members 12 , 14 , 16 of the heterogeneous object 20 are returned in a valid creation order. That is, the table 12 is returned first, since it must be created before the indexes 14 , 16 . Below is an exemplary script using the present invention to extract a heterogeneous object. Put_clob( ) represents some simple function which can print out the contents of a clob (a character large object).
declare
h NUMBER; th NUMBER; c clob;
begin
h:=dbms_metadata.open(‘TABLE_EXPORT’); dbms_metadata.set_filter(h,‘NAME’,‘EMPLOYEE’); dbms_metadata.set_filter(h, ‘SCHEMA’,‘SCOTT’) th:=dbms_metadata.add_transform(h,‘DDL’); LOOP
dbms_lob.createtemporary(c,true); dbms_metadata.fetch_clob(h,c); EXIT WHEN c IS NULL; put_clob(c); dbms_lob.freetemporary(c);
END LOOP; dbms_metadata.close(h);
END;
Each of the dbms_metadata calls is described in U.S. application Ser. No. 09/672,914. As disclosed in that application, calls apply only to homogeneous objects. The present system expands the dbms_metadata interface to include heterogeneous object types such as DATABASE_EXPORT, SCHEMA_EXPORT, TABLE_EXPORT and TABLESPACE_EXPORT.
The OPEN call, dbms_metadata.open( ), provides the heterogeneous class, in this case TABLE_EXPORT, for which metadata is being requested. A handle h is returned to be used in all subsequent operations of the set of objects for which metadata is being requested.
The first FILTER call, dbms_metadata.set_filter( ), restricts the search to the table named “EMPLOYEE,” while the second FILTER call restricts the search to the schema named “SCOTT.”
The call to dbms_metadata.add_transform( ) causes the output of the FETCH command (see below), which is normally formatted in XML, to be transformed to DDL. The result is then directly usable for recreating the heterogeneous object 20 on another database.
Within the loop, bracketed by the LOOP and END LOOP lines, a temporary character large object (clob) is created. The FETCH call, dbms_metadata.fetch_clob( ), returns an member object from the designated heterogeneous object as a clob. If all such objects have already been returned, a NULL is returned and the loop is exited.
Otherwise, for purposes of this example, the object is displayed (put_clob( )). Next, the temporary clob is freed up. The loop repeats, each time returning a different member object, until all members have been fetched.
Finally, the CLOSE call, dbms_metadata.close( ) is made to end the request.
Execution of the above script results in the following output, where SCOTT is the name of the schema to which the table and the indexes belong.
. . . CREATE TABLE “SCOTT”.“EMPLOYEE” (“EMPNO” NUMBER,
“EMPNAME” VARCHAR2(30)
) PCTFREE 10 PCTUSED 40 INITRANS 1 MAXTRANS 255 LOGGING STORAGE(INITIAL 10240 NEXT 10240 MINEXTENTS 1 MAXEXTENTS 121 PCTINCREASE 50 FREELISTS 1 FREELIST GROUPS 1 BUFFER_POOL DEFAULT) TABLESPACE “SYSTEM” . . . . . . CREATE INDEX “SCOTT”.“EMP_IND 1 ” ON “SCOTT”.“EMPLOYEE” (“EMPNO”) PCTFREE 10 INITRANS 2 MAXTRANS 255 STORAGE(INITIAL 10240 NEXT 10240 MINEXTENTS 1 MAXEXTENTS 121 PCTINCREASE 50 FREELISTS 1 FREELIST GROUPS 1 BUFFER_POOL DEFAULT) TABLESPACE “SYSTEM” . . . . . . CREATE INDEX “SCOTT”.“EMP_IND 2 ” ON “SCOTT”.“EMPLOYEE” (“EMPNAME”) PCTFREE 10 INITRANS 2 MAXTRANS 255 STORAGE(IMTIAL 10240 NEXT 10240 MINEXTENTS 1 MAXEXTENTS 121 PCTINCREASE 50 FREELISTS 1 FREELIST GROUPS 1 BUFFER_POOL DEFAULT) TABLESPACE “SYSTEM” . . .
The result comprises three CREATE statements, one for the table, and one for each of the indexes.
FIGS. 2–5 are schematic diagrams of tables used to support heterogeneous object types. The tables of FIGS. 2 and 3 have been defined in the prior art, but are used further to support heterogeneous objects types. The tables of FIGS. 4 and 5 are new.
FIG. 2 illustrates four entries 31 – 34 in the metaview$ table 30 , which is described in U.S. application Ser. No. 09/672,914. This table contains the names of all object types. In an embodiment of the present invention, a new value, e.g., 2, in the properties field 43 is defined to indicate that the row identifies a heterogeneous object type. Here, the presence of the value 2 in the properties field 43 of each of rows 31 – 34 indicates that the types identified in the type field 41 , i.e., DATABASE_EXPORT. SCHEMA_EXPORT, TABLESSPACE_EXPORT and TABLE_EXPORT respectively, are heterogeneous object types.
The other fields 42 , 44 – 49 , described in U.S. application Ser. No. 09/672,914, are not of any particular interest with respect to the present system, and are not discussed further.
FIG. 3 illustrates a metafilter$ table 50 used to implement an embodiment of the present system. This table is also described in U.S. application Ser. No. 09/672,914. In order to limit fetches to a particular logical unit, a filter is specified. The metafilter$ table 50 defines the set of filters that are valid for each object type. The filter field 53 provides the name of a filter, while the type field 54 holds the name of a type for which the named filter is valid. For example, here rows 51 and 52 indicate respectively that “NAME” and “SCHEMA” are valid filters that can be applied to heterogeneous type TABLE_EXPORT.
FIG. 4 illustrates the metascript$ table 60 , a new table used to implement an embodiment of the present system. The metascript$ table 60 describes the member types of a given heterogeneous object type, as well as the order in which the different member types are to be fetched.
For each heterogeneous type, there is one row for each member type. The ptype field 64 holds the name of the heterogeneous type to which a particular row corresponds. The seq# field 65 is a sequence number. The 1type field 66 holds the leaf or member object name. Leaf or member objects are opened and fetched in the sequence indicated by the seq# field 65 .
The model field 67 identifies model properties. This field 67 is not particularly relevant to the present system in particular and is not discussed further.
Several rows 61 – 63 are illustrated for exemplary purposes. The corresponding sequence numbers in the seq# field 65 of each row indicate that, for a heterogeneous object of type TABLE_EXPORT, objects of type TABLE will be fetched first (row 61 , seq#=10), followed by OBJECT_GRANT objects (row 62 , seq#=20) and finally, in this example, by all INDEX objects (row 63 , seq#=30). Of course, in a live database, the rows can be in a random sequence, which is why a sequence number field 65 is needed.
FIG. 5 illustrates the metascriptfilter$ table 70 , which is also a new table created to implement an embodiment of the present system. The metascriptfilter$ table 70 translates the filter provided in the FILTER statement, and matched in field 53 from the metafilter$ table 50 , to a filter name for each member object type.
Each row in the metascriptfilter$ table 70 translates the filter name provided by the user to a type-specific filter. For example, a NAME filter can be specified for heterogeneous object type TABLE_EXPORT through a call such as the line in the above program:
dbms_metadata.set_filter(h, ‘NAME’, ‘EMPLOYEE’)
where the heterogeneous object type's NAME filter is set to EMPLOYEE, such that only objects where NAME=EMPLOYEE are selected.
The exemplary metacriptfilter$ table 70 of FIG. 5 translates the NAME and SCHEMA filters for the TABLE_EXPORT object to NAME and SCHEMA filters for TABLE object, corresponding to rows 71 and 72 respectively, where seq#=10. Similarly, rows 73 and 74 translate the NAME and SCHEMA filters to BASE_OBJECT_NAME and BASE_OBJECT_SCHEMA for OBJECT_GRANT objects (seq#=20), and row 75 and 76 (seq#=30) translate the NAME and SCHEMA filters to BASE_OBJECT_NAME and BASE_OBJECT_SCHEMA for INDEX objects.
In the example provided, all of the member objects have filters whose values correspond to the NAME and SCHEMA filters on the TABLE_EXPORT object. However, a fixed text or boolean (e.g., TRUE or FALSE) value could be specified for a filter.
For predetermined or fixed value filters, the filter values are stored in the vcval field 84 for text values or in the bval 85 field for boolean values. If, on the other hand, the value is inherited from a filter passed to the script, then the name of the filter is stored in the pfilter field 83 .
The metascriptfilter$ table 70 can easily be extended to support fixed value filters of additional data types, such as numbers, dates, etc., by adding additional fileds.
The seq# field 81 of a row contains the sequence number and corresponds to the seq# field 65 of the metascript$ table ( FIG. 4 ). The filter field 82 contains the filter name if the value is not fixed. The pfilter field 83 contains the parent filter name. Finally, the model field 86 is not particularly relevant to the present system and is not discussed further.
In one embodiment of the present system, recursive OPEN calls are made specifying object types in order according to the metascript$ table. After each OPEN call, the metascriptfilter$ table is checked, and a SET_FILTER is executed with the appropriate filter name and value.
Thus, in the illustrative example, first TABLE objects where NAME=EMPLOYEE are fetched, followed by OBJECT_GRANTS objects where BASE_OBJECT_NAME=EMPLOYEE, then INDEX objects where BASE_OBJECT_NAME=EMPLOYEE, and so on.
The API allows a user to specify a filter for a specific member type. For example, when fetching objects from a DATABASE_EXPORT heterogeneous type, the user might want to filter out the SYSTEM tablespace (every database automatically has a SYSTEM tablespace, so it does not need to be recreated on a target database). To do this, the user may specify a NAME_EXPR filter that applies only to TABLESPACE objects, meaning “include any tablespace whose name is not ‘SYSTEM’”, e.g.,
h:=dbms_metadata.open(‘DATABASE_EXPORT’); dbms_metadata.set_filter(h,‘NAME_EXPR’,‘!=“SYSTEM’”,‘TABLESPACE’);
FIG. 6 is a block diagram of representative organization of an embodiment of the present system, although it would be understood by one skilled in the art that other organizations are possible which would still fall within the scope of the present invention.
Here, the metadata application program interface (API) 100 accepts heterogeneous object type requests 102 from a user or application. Such requests include, but are not limited to, OPEN and CLOSE commands as well as one or more SET_FILTER and FETCH commands. The commands are passed to a metadata extractor 104 which organizes fetches of the requested heterogeneous object type's member object types in the order dictated according to the metaview$ table 30 and the metascript$ table 60 .
A filter translator 106 translates heterogeneous object type filters named in the request 102 into a member object filter for each object type according to the metafilter$ table 50 and metascriptfilter$ table 70 as described previously.
The metadata extractor 104 then extracts, i.e., fetches, the member objects from one or more logical units 20 , i.e., according to the heterogeneous object type and the filters provided by the user/application in the request 102 .
In one embodiment of the present system, the metadata is extracted as an XML document. A formatter, or format translator, 108 formats the XML document into other formats such as DDL, according to the request 102 .
Finally, the API 100 returns this formatted data 110 to the user/application.
The present system gives the user a high-level interface for extracting the objects in a heterogeneous collection. The user does not need to know which objects belong to the collection or their creation order.
The filtering capabilities allow the user great flexibility in customizing the set of objects retrieved.
Because the definition of a heterogeneous type consists of rows in dictionary tables, it is easy to define and maintain new heterogeneous object types. In a custom program such as Oracle's Export utility, for example, adding a new heterogeneous object type requires extensive programming.
The present system represents an advance on the current Export utility, which fetches metadata for heterogeneous collections, but then writes the metadata opaquely to a file in a proprietary format. In contrast, the present system can make the metadata transparently available to any database user.
There is increasing demand for specialized heterogeneous collections, e.g., transportable tablespaces and application-specific subsets of objects. The present system can make new heterogeneous collections easy to define and maintain.
Those of ordinary skill in the art should recognize that methods involved in a DATABASE SYSTEM HAVING HETEROGENEOUS OBJECT TYPES may be embodied in a computer program product that includes a computer usable medium. For example, such a computer usable medium can include a readable memory device, such as a solid state memory device, a hard drive device, a CD-ROM, a DVD-ROM, or a computer diskette, having stored computer-readable program code segments. The computer readable medium can also include a communications or transmission medium, such as a bus or a communications link, either optical, wired, or wireless, carrying program code segments as digital or analog data signals.
While this system has been particularly shown and described with references to particular embodiments, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the scope of the invention encompassed by the appended claims. For example, the methods of the invention can be applied to various environments, and are not limited to the described environment. | A method for extracting metadata for plural related objects of different types from a database includes defining a heterogeneous object type as a collection of database objects of different types. Upon a request to fetch a particular heterogeneous object, member objects of the heterogeneous object are fetched from the particular heterogeneous object in a specific order based on the definition of the heterogeneous object's type, such as a valid order for re-creating the particular heterogeneous object. The set of member objects to be fetched can be restricted according to at least one specified filter, which itself may be translated into a second filter according to a type of a member object being fetched. Such translated filters can inherit values from the filter specified in the request for the particular heterogeneous object type, or can have a fixed value of some data type. The extracted metadata can be formatted to recreate the particular heterogeneous object. | 8 |
RELATED APPLICATION
[0001] The present application is based on and claims priority to the Applicants' U.S. Provisional Patent Application 61/660,076, entitled “Method For Detecting The Extent Of Clear, Intact Track Near A Railway Vehicle,” filed on Jun. 15, 2012.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention. The present invention relates generally to railway signaling and more particularly, to rail break or vehicle occupancy detection on railroad track. More specifically, the present invention is in the technical field of railroad signaling and train control, including positive train control (PTC), centralized traffic control (CTC), automatic block signaling (ABS), communications-based train control (CBTC) and cab signaling.
[0003] Background of the Invention. Conventional railway wayside signaling systems employ the rails of the track for transmission of signals used to detect track occupancy, broken rail and/or open turnouts. Railroad track is physically divided into a plurality of electrically-distinct blocks, each block having a track circuit typically terminated by insulated joints and equipped with bi-directional track code transceivers. It should be understood that the term “code transceiver” should be broadly construed to include any type of track circuit signal transceiver or cab signal transmitter. The code transceivers typically send and receive low-frequency, pulse-modulated carrier signals through the track circuit, thereby communicating signal status to each other. The presence of a train in the block causes the rails to be shunted, interrupting this communication, while the presence of a broken rail in the track causes an open circuit, also interrupting this communication. Additionally, turnouts in the track may be wired such that when not aligned for the normal route, communications will be interrupted. This is commonly known as an open turnout.
[0004] A fundamental limitation of fixed-block track circuit systems is their inherent inability to detect a rail break that is located behind a moving train within the same block as the train. Since many rail breaks occur under a train, it would be highly desirable to have the ability to detect broken rail behind a train within the block it is occupying. This would allow immediate notification of a following train or other entity, such as a train dispatching system or back office server.
[0005] Another limitation of fixed-block track circuit systems is the inability to detect where within a block an occupancy exists. Therefore, the entire block must be assumed to be occupied from the perspective of the signaling system. This inability to distinguish a track occupancy from a rail break, and the inability to locate where the occupancy or break is within the block artificially limits maximum traffic density on the track and therefore fundamentally restricts how efficiently a given track can be utilized. It would be highly desirable to have a true “moving-block” or “virtual block” train control system, including the ability to detect rail breaks, open turnouts or occupied track behind a train's current position within the same block that the train occupies, enabling the full potential benefit of CBTC implementation.
[0006] The present invention at least partially overcomes these limitations by using equipment on the leading or trailing end (if so equipped) of a railway vehicle to detect conventional track code or cab signal code in the track, and thereby determine if the track ahead of or behind the vehicle, but still in the same block, is occupied or has a broken rail. Information regarding reception of these signals is then transmitted over a wireless RF link to following trains, possibly via one or more wayside systems or a central office system and correlated with train location information, giving a positive, fail-safe closed-loop indication of rail integrity and the extent of track vacancy. This information may be used in the generation of movement authorities or restrictions for trains as an integral part of a CBTC or PTC system, allowing a fail-safe implementation of a moving-block or virtual block train control system.
[0007] In some embodiments of the present invention, the wayside signal equipment is customized to provide additional pulsed codes assigned to a series of blocks to give a vital indication of which track a vehicle is occupying, thereby facilitating determination of vehicle location in a CBTC or PTC system.
[0008] In some embodiments of the present invention, the current present in the track circuit of each block is monitored at each wayside track code transceiver. By appropriately correlating, using an RF link, the current measurements with the pulsed carrier signals and the carrier signals received by the vehicle, it is possible to distinguish a track occupancy from a rail break ahead of or behind a vehicle. This information may form an integral part of a CBTC or PTC system.
SUMMARY OF THE INVENTION
[0009] This invention provides a method for detecting a rail break or track occupancy ahead of or behind a train in an occupied block of track. The present invention employs commonly-used wayside signaling AC track code equipment and/or cab signaling overlay equipment, in conjunction with an RF communications link, possibly a train location determination system, and may be used as an integral component of a communications-based train control (CBTC) or positive train control (PTC) system to facilitate moving-block or virtual block operation.
[0010] The present invention detects, in real time, rail breaks occurring ahead of (or behind, if a system is mounted on the rear of the train) a moving train within an occupied block, and relays this information, along with train location information, to wayside systems or to a CBTC or PTC system. This is a function not performed by current fixed-block wayside signal systems, in that currently-used fixed-block wayside signal systems do not provide an indication that track immediately behind a train within the same block is unoccupied and free of rail breaks so that a following train could occupy it, unrestricted up to the leading train.
[0011] Conventional fixed-block wayside signal systems use the track as a transmission line, transmitting and receiving pulsed codes indicating block or signal status. If equipped with a cab signal overlay system, codes are picked up by railway vehicles and used to convey signal status to the operator. The present invention receives track codes or cab signal codes on the vehicle using conventional pickup coils inductively coupled to the rails, and uses them as a positive indication of rail integrity. When codes are present on a track, they are detected, may be interpreted, and reception of the codes is communicated back, via an RF wireless link, to wayside equipment, office equipment, or equipment on a following train, which may be part of a CBTC or PTC system. Thus, an indication of rail integrity may be conveyed, directly or indirectly, to following trains, effectively extending signaling indications or movement authorities, or to relax a restriction, where appropriate. Indication of the presence of code behind a train, along with that train's location (e.g., from GPS) can be used by a CTC or PTC system to allow a following train to advance unrestricted to the leading train's end position.
[0012] Some embodiments of the present invention are fully compatible with existing traditional AC track circuit-based block signaling systems, particularly when implemented as an integral part of a CBTC or PTC system where train and traffic control functions are handled by radio communications rather than track circuits and wayside signals. Thus, in some embodiments, the present invention will allow existing traditional track-circuit based signaling infrastructure to be optimized for rail break detection rather than signaling. This could allow, for example, fewer and longer track circuits and/or improved rail break detection.
[0013] In other embodiments of the present invention, codes are placed on a separate carrier, or a continuous carrier of frequency not used by wayside signaling systems, cab signal systems or overlay systems. The present invention may be implemented as an overlay system capable of functioning simultaneously with track code and cab signal systems. In one such embodiment, the coded electrical signals may include unique identifying characteristics assigned to each track segment to enable the onboard receiving and processing unit to distinguish the track segments. For example, unique codes or carrier frequencies may be assigned to particular track segments in multiple track territory, giving a nearly continuous, positive indication of which track a vehicle is occupying and which direction it is travelling in, solving a persistent problem in CBTC or PTC systems which rely on GPS.
[0014] The present invention overcomes several fundamental limitations of conventional fixed-block track circuit broken rail detection, including the inherent minimum limit on train separation and track utilization efficiency. In railway terminology, this invention allows shorter headways.
[0015] These and other advantages, features, and objectives of the present invention will be more readily understood in view of the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention can be more readily understood in conjunction with the accompanying drawings, in which:
[0017] FIG. 1 is a pictorial diagram showing a section of railroad track divided into blocks and equipped with an AC track code signaling system with RF links. Pulses sent and received by the track code transceivers are shown, as is wayside cabling between transceivers.
[0018] FIG. 2 is a pictorial diagram showing a section of railroad track divided into blocks with a railway vehicle occupying the central block. The vehicle is equipped with magnetic field pickup coils inductively coupled to the track in front of the leading wheels and behind the trailing wheels. These pickup coils are similar or identical to those conventionally used for cab signaling. The vehicle is also equipped with an RF wireless communications system capable of communicating with wayside equipment, office equipment, or directly to a following train, possibly as part of a communications-based train control system (CBTC) or positive train control (PTC) system.
[0019] FIG. 3 is a pictorial diagram similar to that of FIG. 2 , with the exception that the rail has broken after passage of the vehicle, creating a non-conducting gap in the rail behind the vehicle.
[0020] FIG. 4 is a pictorial diagram similar to that of FIG. 2 , with the exception that a second vehicle has entered the block after passage of the first vehicle. The leading axle of the second occupying vehicle is shown.
[0021] FIG. 5 is a pictorial diagram similar to that of FIG. 2 , with the exception that a current monitoring device has been added to the track circuit at each of the track code transceivers.
[0022] FIG. 6 is a table showing the logical states and meanings associated with various conditions of the wayside track current detector and onboard pickup system.
[0023] FIG. 7 is a block diagram of an embodiment of the present invention illustrating the fundamental components and signal flow paths of the invention.
[0024] FIG. 8 is a diagram showing three consecutive blocks of railroad track on which the second train follows the first train with a clear block between them. Information about the integrity of the clear block, the portion of the block behind the leading train, and the portion of the block ahead of the following train, is communicated to the following train. Speed profiles, with and without the present invention, are shown below.
[0025] FIG. 9 is a pictorial diagram similar to that of FIG. 2 , illustrating a preferred embodiment of the present invention, in which the onboard system reports information about the track immediately behind it to a central communications-based train control (CBTC) system via RF link and network.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Before describing in detail the system and method for detecting broken rail or occupied track from a moving locomotive, it should be observed that the present invention resides primarily in what is effectively a novel combination of conventional electronic circuits, electronic components, and signal processing/estimation algorithms, and not in the particular detailed configurations thereof. Accordingly, the structure, control, and arrangement of these conventional circuits, components, and algorithms have been illustrated in the drawings by readily understandable block diagrams which show only those specific details that are pertinent to the present invention, so as not to obscure the disclosure with structural details which will be readily apparent to those skilled in the art having the benefit of the description herein. Thus, the block diagram illustrations of the figures do not necessarily represent the mechanical or structural arrangement of the exemplary system, but are primarily intended to illustrate the major structural components of the system in a convenient functional grouping, whereby the present invention may be more readily understood.
[0027] With reference now to FIG. 1 , there is shown a pictorial diagram illustrating a section of railroad track 1 . The track 1 is divided into a series of electrically-isolated blocks or track segments, one of which is shown in its entirety in the figure, and is familiar to those versed in the art. For signaling purposes, each block is typically electrically-isolated from neighboring blocks by insulated joints 3 installed in the track, shown here as gaps. The track may or may not be equipped with impedance bonds 4 , which allow conduction of common-mode traction current across the insulated joints 3 while providing isolation for out-of-phase signaling currents. The track is equipped with conventional track circuits and may have wayside signals 2 , operated by a series of code transceivers and associated equipment 6 installed at the ends of each block. In this figure, the code transceivers are shown coupled to the track via a transformer, but other connections are possible. The code transceivers and associated equipment 6 may have a landline link 8 or radio link 7 connecting it to the other transceivers or to a central office system. For the purposes of this disclosure, the term “central office” should be broadly construed to include any type of central communications or traffic control system, as well as back office servers, wayside servers, communications or traffic control systems.
[0028] With continued reference to FIG. 1 , the code transceivers 6 communicate with each other using coded electrical signals via the rails of the track 1 as a transmission line. For example, these coded electrical signals can have one or more continuous low-frequency carrier waves (typically 100 or 250 Hz, but others are in use) modulated by track code pulses 9 , 10 from the neighboring transceivers. The specific protocol and meaning of the track code pulses 9 , 10 depend on the particular code system in use. Typically, there are three or more different codes, each used to indicate wayside signal status or permissible train speed. In addition to track code pulses 9 , 10 , the transceivers may or may not transmit cab signal overlay information, depending on the particular territory and equipment in use thereon. If a CBTC or PTC system is in use, one or more of the block stations may be equipped with a wayside wireless interface 7 capable of digital communications with locomotives or other railroad vehicles and equipment over one or more RF channels.
[0029] With reference now to FIG. 2 , there is shown a locomotive or other railway vehicle occupying a block of track. The railway vehicle is equipped with an onboard receiving and processing unit to receive the coded electrical signals from code transceivers 6 via the track 1 . In addition, when a block of track or series of blocks is occupied, the track code pulses 9 , 10 are unable to reach the neighboring transceivers because of the shunting action of the axles 11 of the vehicle. The onboard train control unit on the railway vehicle may be equipped with a cab signal receiver and pickup coils 12 . These pickup coils can be laminated-core, multi-turn coils placed above and perpendicular to each rail and connected in series, but wound or connected in opposite directions. The coils 12 are inductively (magnetically) coupled to the rails, so as to respond additively when out-of-phase sinusoidal magnetic fields are present in each rail and respond destructively when a common-mode magnetic field intercepts both of the coil cores. Such pickup coils are well known by those versed in the art. Similar receiver coils may be used to receive track code information 9 , 10 when present. In the present invention, signals picked up by the receiver coils 12 are filtered and interpreted by an onboard computer 15 within the onboard receiving and processing unit on the locomotive. The onboard computer 15 is configured to communicate with (or may be an integral part of) PTC equipment 14 or a wireless communications system 13 capable of communicating over one or more external stations (e.g., over RF links to wireless interface units 7 on the wayside, to base stations, or to a central office system). In one embodiment, when code or cab signal information is received by the coils 12 and interpreted by the onboard computer 15 , the onboard computer 15 periodically or continually communicates receipt of the code or cab signal code information to the wayside or to a central office system via the RF wireless communication system link 13 , or communicates receipt of valid track code or cab signal information, detected at the rear of the train, to the onboard CBTC or PTC equipment 14 of a following vehicle. The onboard computer 15 may, additionally, communicate the status of the wayside signaling system or the type of code protocol received at the vehicle to the CBTC or PTC system or central office system as an additional check to ensure that the vehicle is traveling in the correct territory. The wayside or central office system receives information about railway vehicle location and correlates it with track code information received at the vehicle to determine the extent of clear track behind the railway vehicle and available to a following vehicle.
[0030] For the purposes of this disclosure, the term “external station” should be broadly construed to include, but not be limited to any type of wayside system, base station or central office system, as well as a mobile communications system on another railway vehicle capable of communications with the onboard receiving and processing unit described above. Communications between the onboard receiving and processing unit on the railway vehicle and an external station can be accomplished via an RF communication link, or by means of electrical signals carried via the track and code transceiver to an external station. The present invention can also be implemented using a TCP/IP communications protocol between the onboard receiving and processing unit on a railway vehicle and an external station.
[0031] With reference now to FIG. 3 , a similar arrangement is shown, with the exception that the rail 1 has broken after passage of the railway vehicle, creating a non-conducting gap 16 in the rail. In this situation, no coded electrical signals will be received by the pickup coils 12 , as the flow of current in the track circuit has been interrupted by the gap 16 . The gap 16 causes the track circuit to be open, preventing current from flowing under the pickup coils 12 and causing loss of signal at the onboard computer 15 . The onboard computer 15 reports loss of signal to the external station (e.g., the CBTC or PTC system interface 14 or directly to a wayside system 7 or a central office system via an RF communications link 13 ).
[0032] With reference now to FIG. 4 , a similar arrangement is shown, with the exception that a second railway vehicle has entered the block behind the occupying vehicle. The leading axle 17 of the intruding vehicle is shown. The axle 17 causes the rails to be shunted, preventing current from flowing under the pickup coils 12 and causing loss of the coded electrical signals at the onboard computer 15 . The control computer 15 reports the loss of signal to the external station (e.g., the CBTC or PTC system interface 14 or directly to the wayside system or a central office system computer via an RF communications link 13 ). The PTC system 14 can use this information to restrict a possible reverse move by the leading vehicle.
[0033] With reference now to FIG. 5 , there is shown a similar arrangement to those illustrated in the previous figures, with the exception that a current sensor 18 , in the form of a resistive shunt or a current transformer (toroid) has been installed on one of the track leads. With the current sensor in place, the resulting current flowing in the track circuit can be monitored. In normal situations, such as with an unoccupied block as is illustrated in FIG. 1 , current flow is measured and presence of current flow is relayed, via either wireless RF link 7 or landline link 8 (e.g., cable or optical fiber) to the next block transceiver or to an element of a PTC or CBTC system. When a rail break occurs and the block is unoccupied, no current will flow. When the block is occupied and there is neither a rail break nor an unintended occupancy in that end of the block, as illustrated in FIG. 2 , the wayside system will detect current flow and the onboard receiving unit will detect current flow as well, and will communicate this information to the external station (e.g., wayside or a central office server) via the communications link. If a rail break occurs behind a moving vehicle, as illustrated in FIG. 3 , current will be detected neither by the wayside system nor by the onboard system. However, if an unintended occupancy occurs behind the moving train, as illustrated in FIG. 4 , current will be detected by the wayside system but not by the onboard receiving and processing unit. Thus, by monitoring current in the block at each track code transceiver, and relaying such information to a CBTC or PTC system, while simultaneously monitoring the presence of track code by the onboard receiving and processing unit, a CBTC, PTC, or wayside system can distinguish between an unintended track occupancy and a rail break.
[0034] Referring now to FIG. 6 , there is shown a logic table illustrating the meaning of various combinations of states of a wayside track current sensor and the onboard receiving and processing unit located at the rear of the railway vehicle. In the table, the numeral 1 indicates that the signal is present or being detected in the block occupied by the vehicle, as shown in FIG. 5 , while a 0 indicates absence of the signal or that it is not being detected. Allowing for track circuit leakage current, when current is flowing in the track circuit and current is simultaneously flowing behind a vehicle occupying a block so as to be detected by the present invention, the system is functioning normally with neither a rail break nor a track occupancy behind the vehicle. If current is flowing in the track circuit but little or none detected by the pickup coils, an occupancy has occurred behind the train. If current is not flowing in the track circuit but the coded electrical signal is detected by the pickup coils of the onboard receiving and processing unit, a fault state is indicated, or spurious interference is being picked up by the coils, possibly indicating tampering or sabotage. If no current is detected in the track circuit and coded electrical signals are not detected by the onboard receiving and processing unit, a rail break exists behind the train. The same logic applies to the track circuit ahead of, and within the same block as the railway vehicle.
[0035] Referring now to the invention in greater detail, with reference now to FIG. 7 , there is shown a block diagram of the onboard receiving and processing unit providing a basic embodiment of the present invention. The series-connected, reversed pickup coils 12 are connected to an optional analog filter/amplifier unit 72 . The filter/amplifier 72 includes a high impedance buffer so as not to load the pickup coils or interfere with the cab signal system 73 , if present. In some embodiments, the filter/amplifier 72 includes a 50 or 60 Hz notch filter to eliminate interference caused by coupling of power line magnetic fields and may also include a 25 Hz notch filter to eliminate stray magnetic interference from traction currents. The onboard computer 15 receives the filtered and amplified signal via an analog-to-digital converter, and carries out digital signal processing operations to demodulate the received signal and interpret the pulse codes. An existing cab signal unit 73 may or may not be present. In some embodiments, the onboard control computer 15 connects to an indicator panel or device 75 to warn the operator of an impending rail break or track occupancy, and such a device can also be used to initiate a brake application. The onboard computer 15 communicates with, and may operate as an integral part of a positive train control (PTC) system 14 or may have a separate means of communicating status to wayside with an RF communications interface 13 . When loss of track code or cab signal code, possibly after waiting a suitable time, is determined by the onboard control computer 15 , the loss is communicated to wayside systems, to another vehicle, or to a central office system via the RF communications link 13 , possibly via the PTC system 14 . Location information provided by a GPS or other location determination system 78 is included in the message sent over the RF link by the wireless communications system 13 , allowing a wayside or central office server to closely determine the location of rail breaks that occur behind a moving train.
[0036] With reference to FIG. 8 , three consecutive blocks of track are shown. A following railway vehicle 81 occupies the left-most block 86 ; the center block 87 is clear, while the right-most block 88 is occupied by the trailing end of a leading vehicle 82 . Insulated joints 3 separate the blocks 86 , 87 and 88 . Wayside signals 83 , 84 may be present at the beginning of each block. Bidirectional code transceivers 6 transmit and receive through the rails of each block, and are equipped with wayside wireless RF interface units 7 . In a normal situation, without the benefit of the present invention, the following vehicle 81 would receive an approach indication from the first wayside signal 83 and a stop or restricting indication at the second wayside signal 84 , as the leading vehicle 82 is occupying the right-most block 88 . The speed curves, possibly computed by a braking algorithm in a PTC system, of the following vehicle 81 would resemble the enforcement curve 61 and warning curve 62 shown in the lower part of the figure.
[0037] With continued reference to FIG. 8 , the integrity of the track between the following railway vehicle 81 and a portion of the left-most block 86 is verified by magnetic pickup of track code or cab signal overlay code at the following vehicle 81 . The status and integrity of the entire central block 87 is conveyed to a central office system and/or to the following vehicle 81 by RF wireless communications links (e.g., wireless interface units 7 ). Alternatively, the status and integrity of the central block 87 can also be inferred at vehicle 81 by the signal 83 aspect being conveyed through the track. The track integrity of the portion of the right-most block 88 behind the leading vehicle 82 is determined by magnetic pickup by that vehicle of track code sent from signal location 84 , and such indication of integrity is relayed via wireless communications link back to the following vehicle 81 , and/or processed by a central office or wayside system before reaching the following vehicle 81 . The resultant benefit is that the following vehicle 81 may now travel to a stopping point just short of the end of the leading vehicle 82 rather than being stopped or slowed at the beginning of the third (right-most) block 88 . The speed curves, possibly computed by a braking algorithm by a PTC system, of the following vehicle 81 would now more closely resemble the enforcement curve 63 and warning curve 64 shown in the lower part of the figure.
[0038] With reference to FIG. 9 , there is illustrated a particularly preferred embodiment of the present invention, in that it does not necessarily require any modifications to existing wayside track circuit hardware, it does not necessarily require PTC or CBTC wayside interface units, nor does it require wireless communication links at each block boundary 3 . Further, it can achieve significantly shorter headways than would a conventional fixed-block train control system. This embodiment is of a moving block or virtual block PTC system. Each train has on board a location determination system (possibly comprising GPS, tachometer, inertial sensors and/or track database feeding into an onboard computer-hosted algorithm, such as a Kalman filter) and a data radio, that frequently reports the current vehicle location to a central office server, wayside server 98 , or directly to a following train through a base station radio 96 and network 97 . Along with each location report, the onboard computer also reports whether or not it is currently receiving track code from the cab signal receiver at the rear of the vehicle. Based on knowing train length and integrity thereof, the onboard computer 15 or the off-board server 98 computes the rear of the railway vehicle or train location as an offset from the reported front of the vehicle location. Movement authorities or virtual signal status indications are frequently sent (updated) to trains from the off-board server 98 . As a train moves forward and provides a new location report, the server 98 provides an updated movement authority to a following train, permitting it to advance to the most recently reported location of the rear of the leading vehicle or train. The following vehicle also reports its location and rear track code detection status to the server so that a train following it can, in turn, receive an updated movement authority, and so on. Without the present invention, a following train could not proceed without restriction beyond the track circuit block boundary nearest to, but behind the leading train. At steady state speeds for leading and following vehicles, the present invention can result in a reduction in headway of approximately one track circuit block length.
[0039] In some embodiments, the wayside track code transceivers transmit a series of pulses or a continuous carrier into the track, such carrier being at a frequency unused by any existing wayside signaling or cab signal equipment, and the onboard system is equipped with frequency-selective filters to pass only that frequency, thereby giving a continuous indication of the absence of rail breaks or shunting track occupancies.
[0040] In some embodiments, the onboard computer queries, through a variety of possible means, existing cab signal equipment, to determine if a valid cab signal code had been received. If such is the case, the control computer then communicates this status, via an RF communications link, PTC, CBTC, or other means, to wayside equipment or a central office system, as reception of cab signal information is a valid means of verifying track integrity.
[0041] In some embodiments, analog means are used to detect the code signals in the coil.
[0042] In other embodiments, a Hall Effect or other similar magnetic-field or current-sensing receiving device may be used instead of the pickup coils.
[0043] In yet another embodiment, a flat coil of relatively large area, oriented directly over the track, or wound and oriented in such a way that its magnetic flux would cut through the circuit formed by the rails and leading axle, may be used to perform the receive function.
[0044] In some embodiments, the onboard computer or another processor, automatically applies capacitances across the pickup coils or otherwise tunes a resonant circuit formed partially by the coils, adjusting the resonant frequency to improve the signal-to-noise ratio.
[0045] In some embodiments, the onboard computer has the ability to trigger a train stop or indicate to the locomotive operator that the train is approaching the end of unoccupied and intact track.
[0046] In yet another embodiment, the control computer has the ability to communicate with, directly, or indirectly via a wayside system, CBTC, or PTC system, other railway vehicles in nearby blocks, warning them of upcoming occupied track, broken rail, or open turnouts detected behind the present vehicle.
[0047] In other embodiments, the wayside transceiver units are configured to send and receive unique codes on each track in multiple track territory. The onboard computer interprets the code and confirms the code to the PTC system, giving a positive, vital, and nearly continuous indication of which track the vehicle is currently occupying, and in which direction the train is travelling.
[0048] In some embodiments, a continuous carrier of unique frequency (not on a known harmonic frequency of commonly used carriers) is superimposed on existing track codes by the wayside transceivers from wayside units to train. Narrow-band filters are applied to the signal from the pickup coils, and such frequency is continuously monitored by the onboard computer. Absence of such frequency is sufficient indication of either a rail break, track occupancy, or both.
[0049] In some embodiments, a route database containing an index of track codes used on various track segments in various geographical areas is used by the control computer, in conjunction with GPS information or other train control position, location, wheel tachometer or other systems, to provide a record of expected track codes for various geographic locations, records of known dead spots, dark territory, places where excessive interference may be encountered (i.e., galvanic protection for pipelines, etc.). Alternatively, such information may be provided by, or downloaded from a CBTC or PTC system server.
[0050] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with variations and modifications within the spirit and scope of these claims. The invention should not be limited by the embodiments described above, but by all embodiments and methods within the scope and spirit of the invention.
[0051] Further, while we have shown and described an embodiment in accordance with the present invention, it is to be understood that the same is not limited thereto but is susceptible to numerous changes and modifications as known to a person skilled in the art, and we therefore do not wish to be limited to the details shown and described herein but intend to cover all such changes and modifications as are obvious to one of ordinary skill in the art.
[0052] The above disclosure sets forth a number of embodiments of the present invention described in detail with respect to the accompanying drawings. Those skilled in this art will appreciate that various changes, modifications, other structural arrangements, and other embodiments could be practiced under the teachings of the present invention without departing from the scope of this invention as set forth in the following claims. | A method is provided for detecting broken rail, track continuity, and track occupancy ahead of or behind a railroad vehicle traveling in fixed-block territory equipped with an AC track code wayside signal system or cab signal overlay system, and a communications link. This method, when used as an integral part of a communications-based train control (CBTC) or positive train control (PTC) system, allows immediate, automatic detection of broken rail, track occupancies, or open turnouts ahead of or behind a train in an occupied block. It also facilitates true moving-block or virtual block CBTC or PTC, thereby enabling higher efficiency and track utilization. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to integrated circuits and more particularly to circuits employing complementary metal oxide semiconductors. More specifically, the present invention pertains to circuits exhibiting hysteresis such that the output switches between high and low voltage levels in response to input voltage causing the switching to occur in a first direction at an input voltage which differs from the voltage causing switching in the opposite direction by an incremental hysteresis voltage.
2. Description of the Prior Art
Hysteresis circuits of various types are well known in the prior art. An example of such prior art is U.S. Pat. No. 3,904,888 which shows a circuit exhibiting hysteresis using transistors of complementary conductivity types. A disadvantage of such prior art is that the differential amplifier input switching point cannot be precisely controlled and is highly variable.
SUMMARY OF THE INVENTION
The present invention relates to a comparator with internal hysteresis realized by CMOS techniques employing insulated gate field effect transistors. The circuit is comprised of a differential amplifier for receiving the input signal, an output inverter circuit for switching the output between high and low voltage levels in response to the signal received at the input of the differential amplifier and an internal current feedback network for introducing a prescribed offset unbalance in the differential amplifier to obtain hysteresis.
The current flowing through the input differential amplifier is established by a constant current source acting through a current mirror. The voltage applied to the input of the differential amplifier determines what fraction of the total current flows through each of the two branches of the amplifier. In addition to determining the level of the current flow through the differential amplifier, the constant current source establishes a first hysteresis feedback current. A second hysteresis feedback current is controlled by the current flowing through one of the two legs of the differential amplifier. A switching circuit is provided for connecting into the circuit the first or the second feedback current, depending upon the state of the output inverter circuit.
It is therefore an object of the present invention to provide a comparator circuit with internal hysteresis using CMOS techniques. A further object of the present invention is to provide a comparator circuit with internal hysteresis with a precisely settable voltage switching level. A still further object of the present invention is to provide a comparator circuit with internal hysteresis with low current consumption and which obtains hysteresis without affecting the loading at the input. These and further objects will become apparent to those skilled in the art upon examination of the following specification, claims, and drawing.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE in the drawing is a schematic circuit diagram illustrating the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawing illustrates a comparator with internal hysteresis in accordance with the present invention. It includes an input differential pair 15 comprised of N-channel insulated gate field effect transistors 10 and 20. The comparator further includes a first current mirror circuit 36 comprised of N-channel field effect transistors 30, 31, 32, and 33 and a second current mirror circuit 26 comprised of insulated gate P-channel field effect transistors 21, 22 and 23. Also included are a switching circuit comprised of a P-channel field effect transistor 24 and an N-channel field effect transistor 34, and an output inverter circuit comprised of P-channel field effect transistor 40 and N-channel field effect transistor 50.
The source electrodes of transistors 10 and 20 are connected to each other and also to the drain electrode of transistor 30 in current mirror circuit 36. The drain electrode of transistor 10 is connected to the drain electrode of transistor 11, while the drain electrode of transistor 20 is connected to the drain electrode of transistor 21.
In current mirror circuit 36, the source electrodes of transistors 30, 31, 32, and 33 are connected to a terminal 35 for connection to the power source. The gate electrodes of transistors 30 through 33 are connected to each other and also to the drain electrode of transistor 31, which in turn is connected to a source of control current 38. The theory and operation of current mirrors can be found in "Linear Integrated Circuits and MOS Application Devices", RCA Solid State 1974 Databook Series, page 77. The operation of a current mirror is such that the magnitude of the current established in transistor 31 will also determine the current flowing through transistors 30, 32, and 33. In other words, the currents through transistors 30, 32, and 33 are reflections of the current conducted by transistor 31, the relationships of these currents to the current conducted by transistor 31 being dependent on the physical constants associated with the individual transistors.
A second current mirror 26 is constructed of P-channel field effect transistors 21, 22 and 23. The source electrodes of transistors 21, 22, and 23 are connected to positive potential terminal 25, while the gate electrodes are connected to each other and also to the drain electrode of transistor 21. The drain electrode of transistor 22 is connected to the drain electrode of transistor 32 in current mirror 36 and to a common junction terminal 42, which in turn is connected directly to gate electrodes of P-channel field effect transistor 40 and N-channel field effect transistor 50 which form the output inverter.
Transistors 40 and 50 of the output inverter have their drain electrodes connected to each other and to an output terminal 60. The drain electrodes of transistors 40 and 50 are further connected to gate electrodes of a P-channel insulated gate field effect transistor 24 and an N-channel insulated gate field effect transistor 34. Transistors 24 and 34 form a switching circuit, whose function it is to close and open current paths for the hysteresis feedback current, as will be described later. Transistor 24 has its source connected to the drain of transistor 23 in current mirror 26 and the transistor 34 has its source connected to the drain of transistor 33 in current mirror 36. The drain electrodes of transistors 24 and 34 are connected to common junction terminal 42. Transistor 11 is used to equalize the bias condition on the differential transistor pair 15. The source electrode of transistor 11 is connected to terminal 25 and the gate electrode is connected to its drain electrode.
The sum of the currents flowing through transitors 10 and 20 of differential pair 15 is determined by transistor 30, the current flow through which, in turn, is a reflection of the current through transistor 31. As mentioned above, transistors 30, 31, 32, and 33 are connected to form current mirror 36, the currents through each of these transistors being proportionately dependent on the value of the control current applied to the drain of transistor 31. When the voltage signals applied to input terminals 12 and 14 of differential pair 15 are equal, the current flowing through transistors 10 and 20 are approximately equal, each current being equal to approximately one-half of the current flowing through transistor 30. However, as the voltage at one of the terminals increases or decreases, the current in one of the differential amplifier transistors will increase, while the current in the other transistor will decrease. The sum of the two currents will remain constant, as determined by transistor 30.
Variations in the current through transistor 20 in turn produces corresponding variations in the current through transistor 21, since transistors 20 and 21 are connected in a series path. Current mirror 26, consisting of transistors 21, 22, and 23, is connected in such a way that the currents in transistors 22 and 23 are determined by the current through transistor 21. It is quite clear then that the currents in transistors 21, 22, and 23 are a function of the control current 38 and of the differential voltage applied to input terminals 12 and 14.
Differential pair 15 and transistors 21, 22, 30, 31, and 32 of current mirrors 26 and 36 comprise a transconductance amplifier. The gain of the transconductance amplifier is represented by the incremental change in current flow through transistor 22 in current mirror 26 as a function of an incremental change in the voltage at input terminals 12 and 14. The magnitude of the transconductance amplifier output current through transistor 22, together with hysteresis currents through transistors 23 or 33, establishes the potential at common junction terminal 42 and at the gate electrodes of transistors 40 and 50 in the output inverter, thereby controlling the switching of transistors 40 and 50. The hysteresis feedback current through transistor 23 can flow only when transistor 24 is conducting, and the hysteresis feedback current through transistor 33 can flow only when transistor 34 is conducting. As mentioned before, transistors 24 and 34 form a switching circuit, controlled by the voltage at output 60. When the voltage at common junction terminal 42 is sufficiently low, transistor 40 in the output inverter is conducting and transistor 50 is non-conducting. In this condition, the voltage at output 60 is high, close to the potential of terminal 25. When the voltage at junction terminal 42 is high, transistor 50 is conducting and transistor 40 is non-conducting, rendering the voltage at output 60 to be low, close to the potential of terminal 35. The voltage at output 60 is applied to control electrodes of switching transistors 24 and 34. When the voltage at output 60 is high, transistor 34 conducts and transistor 24 is turned off. In the reverse condition, when the voltage at input 60 is low, transistor 24 conducts and transistor 34 is turned off.
As the voltage at input terminal 14 increases, transistor 20 in differential amplifier 15 becomes more conductive, causing a greater current to flow through transistors 20 and 21 and a proportionately smaller current to flow through transistors 10 and 11. Through the action of current mirror 26, the increased current through transistor 21 results in proportionately increased currents in transistors 22 and 23, resulting further in the lowering of the potential at junction terminal 42. As the voltage at input terminal 14 continues to increase, the voltage at junction terminal 42 will eventually drop to a level sufficiently low to cause transistor 40 in the output inverter to start conducting and transistor 50 to be turned off. As transistors 40 starts conducting, the voltage at output terminal 60 increases, in turn turning on switching transistor 34 and allowing the hysteresis feedback current to flow through transistor 33. The flow of hysteresis feedback current through transistor 33 further lowers the potential at junction terminal 42, assuring that transistor 40 will be fully turned on and transistor 50 will be fully turned off.
As the voltage at input terminal 14 decreases, decreasing current through transistor 22 will result in a corresponding voltage at junction terminal 42 until the voltage increases to a level sufficient to cause transistor 50 in the output inverter to conduct and transistor 40 to turn off. Because of the additional current flow through transistor 33, the negative-going voltage at input terminal 14 which will result in the switching of output transistors 40 and 50 in the output inverter will have to be lower than the voltage causing switching in the positive-going direction. As the voltage at junction terminal 42 increases to a sufficient level, transistor 50 turns on causing the voltage at output 60 to go low. The low voltage at output terminal 60 turns on switching transistor 24 and turns off switching transistor 34. The hysteresis feedback current through transistor 33 is thereby removed from the circuit and a second hysteresis feedback current flowing through transistor 23 is allowed to flow between positive terminal 25 and junction terminal 42. The flow of current through transistor 23 further increases the potential at junction terminal 42, assuring that transistor 50 is fully turned on and transistor 40 is fully turned off.
Again, as the voltage signal across the input terminals 12 and 14 increases in the positive direction, the switching at output terminal 60 will be displaced by an incremental voltage required to overcome the additional current flow through transistor 23. It can be seen, therefore, that the amount of displacement in the voltage signal appearing at the input required to switch output transistors 40 and 50 is a function of the magnitude of hysteresis feedback currents through transistors 23 and 33. The magnitude of these currents is, as has been shown previously, controllable through variations in control current applied to terminal 38 of current mirror 36.
The foregoing specification describes an improved voltage comparator with internal positive current feedback achieving a predetermined hysteresis which is controllable by an input current.
Various modifications of the inventive concept will be obvious to those skilled in the art without departing from the spirit of the invention. It is intended that the scope of the invention be limited only by the following claims. | A CMOS voltage comparator with internal positive current feedback to achieve a predetermined hysteresis. The voltage level at which the switching occurs is precisely settable. Hysteresis is introduced such that when the set voltage level is exceeded, the output switches quickly and will remain in that state until the input voltage drops by a predetermined hysteresis voltage. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 60/870,926, filed Dec. 20, 2006, entitled “ARCHITECTURES FOR SEARCH AND ADVERTISING.” In addition, this application is related to U.S. application Ser. No. 11/767,810, filed on Jun. 25, 2007, entitled “PROVIDING ALTERNATIVE CONTENT IN A WINDOWED ENVIRONMENT”, which also claims the benefit of the above-mentioned U.S. Provisional Application. The entireties of these applications are incorporated herein by reference.
BACKGROUND
Advertisers have long been preoccupied with the search for new and better ways of reaching, understanding, and/or targeting a potential audience for their advertisement content. In addition, advertisers are also continually searching for new platforms or venues to host advertisement content, preferably in a manner that maintains a high degree of audience attention. The widespread growth of the Internet serves as one illustration of advertisers' preoccupation with finding new markets. As Internet usage boomed, so too did Internet advertising.
However, although literally millions of people world-wide spend a substantial amount of time directly interacting with computers on a daily basis, conventionally, computer-based user-interfaces such as desktops or other features maintained by an operating system remains relatively untapped by advertising concerns.
SUMMARY
The following presents a simplified summary of the claimed subject matter in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview of the claimed subject matter. It is intended to neither identify key or critical elements of the claimed subject matter nor delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts of the claimed subject matter in a simplified form as a prelude to the more detailed description that is presented later.
The subject matter disclosed and claimed herein, in one aspect thereof, comprises an architecture that can facilitate extensible themes and/or advertising integration in connection with an operating system user-interface such as a desktop. To these and other related ends, the architecture can be interfaced to or implemented as an extension of a computer-based operating system or components thereof such as a desktop environment manager, a window manager, and so forth.
In accordance therewith, the architecture can acquire advertisement content from an advertiser. The advertisement content can be, e.g. a product advertisement, a link to the advertisement, an extensible and/or configurable skin, typically related to an advertiser's brand or trademark, an update, as well as other applicable types of advertisement content. The advertisement content can be stored for later retrieval and can further be examined for suitability for display based upon a wide range of potential criteria. For example, suitable content can be selected based upon preferences or settings designated by the user, by the implementation, and/or by default.
The advertisement content can also be selected based upon a bidding model wherein advertisers can compete for ad-slots, based upon contractual obligations or rights associated with either advertisers or end-users of the operating system. In addition, the advertisement content can be selected based upon transaction histories and/or demographic information, wherein such information need not be transmitted or revealed to third parties or otherwise be accessible to remote systems or entities. Accordingly, aspects of the claimed subject matter can serve to mitigate privacy concerns with respect to marketing and/or ad-targeting.
According to another aspect of the claimed subject matter, the advertisement content can be extended to other user-interfaces that are launched, accessed, and/or instantiated by the desktop or the associated operating system. Examples of such can include but are not limited to disparate applications, web portals and so forth.
The following description and the annexed drawings set forth in detail certain illustrative aspects of the claimed subject matter. These aspects are indicative, however, of but a few of the various ways in which the principles of the claimed subject matter may be employed and the claimed subject matter is intended to include all such aspects and their equivalents. Other advantages and distinguishing features of the claimed subject matter will become apparent from the following detailed description of the claimed subject matter when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a computer-implemented system that can facilitate extensible themes and/or advertising integration in connection with an operating system user-interface.
FIG. 2 provides a block diagram of a computer-implemented system that illustrates further detail in connection with the acquisition component 102 and provides various examples of advertisement content.
FIG. 3 is a block diagram a computer-implemented system that depicts various features of the selection component in greater detail.
FIG. 4 illustrates a block diagram a computer-implemented system that can monitor a user-interface to determine potential suitability for advertisement content.
FIG. 5 depicts a block diagram of a computer-implemented system that can provide for various inferences and/or determinations.
FIG. 6 is an exemplary flow chart of procedures that define a computer implemented method for facilitating extensible themes for and/or advertising integration with an operating system user-interface.
FIG. 7 depicts an exemplary flow chart of procedures that define a computer implemented method for selecting advertisement content based upon a variety of potential criteria.
FIG. 8 illustrates an exemplary flow chart of procedures for a computer implemented method for determining a suitability or appropriateness for display of particular types of advertisement content.
FIG. 9 depicts an exemplary flow chart of procedures defining a computer implemented method for applying an extensible skin from an advertiser.
FIG. 10 illustrates a block diagram of a computer operable to execute the disclosed architecture.
FIG. 11 illustrates a schematic block diagram of an exemplary computing environment.
DETAILED DESCRIPTION
The claimed subject matter is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident, however, that the claimed subject matter may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the claimed subject matter.
As used in this application, the terms “component,” “module,” “system”, “desktop”, “skin”, or the like are generally intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a controller and the controller can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers.
Furthermore, the claimed subject matter may be implemented as a method, apparatus, or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof to control a computer to implement the disclosed subject matter. The term “article of manufacture” as used herein is intended to encompass a computer program accessible from any computer-readable device, carrier, or media. For example, computer readable media can include but are not limited to magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips . . . ), optical disks (e.g., compact disk (CD), digital versatile disk (DVD) . . . smart cards, and flash memory devices (e.g. card, stick, key drive . . . ). Additionally it should be appreciated that a carrier wave can be employed to carry computer-readable electronic data such as those used in transmitting and receiving electronic mail or in accessing a network such as the Internet or a local area network (LAN). Of course, those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope or spirit of the claimed subject matter.
Moreover, the word “exemplary” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion. As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form.
As used herein, the terms to “infer” or “inference” refer generally to the process of reasoning about or inferring states of the system, environment, and/or user from a set of observations as captured via events and/or data. Inference can be employed to identify a specific context or action, or can generate a probability distribution over states, for example. The inference can be probabilistic—that is, the computation of a probability distribution over states of interest based on a consideration of data and events. Inference can also refer to techniques employed for composing higher-level events from a set of events and/or data. Such inference results in the construction of new events or actions from a set of observed events and/or stored event data, whether or not the events are correlated in close temporal proximity, and whether the events and data come from one or several event and data sources.
Referring now to the drawing, with reference initially to FIG. 1 , a computer implemented system 100 that can facilitate extensible themes and/or advertising integration in connection with an operating system user-interface is depicted. Generally, the system 100 can include an acquisition component 102 that can obtain advertisement content 104 from an advertiser 106 . According to an aspect of the claimed subject matter, the advertisement content 104 can be specifically designed and/or tailored expressly for display by an operating system 108 . The acquisition component 102 can also store the advertisement content 104 to a data store 110 , which can be interfaced to the system 100 as depicted, or, additionally or alternatively, the data store 110 can be a component of the system 100 .
Likewise, the system 100 can be interfaced to the operating system 108 , while according to additional aspects, the system 100 or portions thereof can be components of the operating system 100 . For example, the system 100 (or portions thereof) can be a component or components of an operating system desktop environment manager or another similar mechanism provided by the operating system 108 that can manage user-interfaces for the operating system 108 .
In addition, the system 100 can also include a selection component 112 that can select the advertisement content 104 for display, and a configuration component 114 that can supply the advertisement content 104 to the operating system 108 . The advertisement content 104 is described in more detail in conjunction with FIG. 2 , while the selection component 112 is further described in connection with FIG. 3 . It is to be appreciated that whether interfaced to or a component of the operating system 108 , the configuration component 114 can, potentially depending upon a type of the advertisement content 104 , supply the advertisement content 104 to an appropriate component of the operating system 108 such that the advertisement content 104 can be rendered for display in a desktop environment. It is also to be appreciated that is some situations the advertisement content 104 can be forwarded to and/or displayed by a user-interface associated with a disparate or third party application, however, the acquisition, selection, and/or configuration of the advertisement content 104 is generally not handled or managed by the third party application.
Turning now to FIG. 2 , a computer-implemented system 200 that illustrates further detail in connection with the acquisition component 102 and further illustrates various examples of advertisement content 104 can be found. Typically, the system 200 can include the acquisition component 102 that, as substantially described supra, can obtain advertisement content 104 , which can be tailored for the operating system 108 to display, and that can also store the advertisement content 104 to the data store 110 . The system 200 can also include the selection component 112 that can, e.g., access the data store 110 in order to choose the advertisement content 104 that is to be displayed.
The system 200 further depicts a number of example types of advertisement content 104 , which are indicated by reference numerals 202 - 208 . According to an aspect of the claimed subject matter, the advertisement content 104 can be an advertisement 202 for a product such as a good or service. The advertisement 202 can include a product description, a coupon or other incentive, as well as suitable text, images, audio, video, executable content and so forth. The advertisement 202 can be displayed in a static form, and activated (e.g., become dynamic) based upon an event such as a mouse or cursor hover or the like.
In addition, the advertisement content 104 can be a link 204 or reference to the advertisement 202 . For example, the link 204 can include anchor text that addresses the advertisement 202 or content associated therewith. The advertisement 202 can therefore be called based upon an event such as a mouse click or other input device selection mechanism. It is to be appreciated that in order to activate the advertisement 202 , the operating system can launch a disparate and/or third party application such as a web or content browser, a content/media player, or a similar application.
According to another aspect of the claimed subject matter, the advertisement content 104 can be an extensible skin 206 for a desktop or another user-interface associated with the operating system 108 . In particular, various features of a desktop (or other user-interfaces of the operating system 108 ) can be displayed with customized audio/visual interface aspects as well as in some cases customized content, settings, or defaults. The skin 206 can be tailored to a theme, brand, trademark, etc. associated with the advertiser 106 . Hence, that advertiser 106 can be, say, a well-known producer of cola beverages and the associated skin 206 can include customized graphical appearances for the desktop that exhibit visual aspects of the producer's brands as well as audio trademarks or themes, and so on.
The skin 206 can apply to, and thus facilitate customization of, virtually any feature of the desktop such as windows, taskbars, sidebars, avatars, icons, background, screensaver, alerts, bugs, tickers, and so on, and can even be extended to disparate applications and service portals as further described with reference to FIG. 4 . In accordance therewith, the skin 206 can represent an excellent way to further brand recognition for the advertiser 106 . Moreover, it is to be appreciated that the skin 206 can be both trendy as well as useful. Thus, a user of the operating system 108 might be attracted to the skin 206 not only because it is aesthetically appealing, but also because of customized interface options provided by the skin 206 that make some tasks more efficient or more intuitive for the user of the skin 206 .
In another aspect, the advertisement content 104 can be an update 208 . In particular, the advertisement content 104 can be updated to provide new advertisement content 104 periodically, or updated as new advertisement content 104 becomes available from the advertiser 106 . It is to be appreciated that reference numerals 202 - 208 are merely examples of advertisement content 104 intended to provide context but not necessarily intended to limit the scope of the claimed subject matter to only the described types of advertisement content 104 . Accordingly, other types of advertisement content 104 can exist and can be applicable to the appended claims.
With reference now to FIG. 3 , a computer-implemented system 300 that depicts various features of the selection component in greater detail is depicted. In general, the system 300 can include the selection component 112 that can select the advertisement content 104 as substantially described herein. In accordance with one aspect of the claimed subject matter, the selection component 112 can select the advertisement content 104 based upon a set of preferences or settings 302 associated with the operating system 108 and/or the desktop. For example, the settings 302 can be default settings, as well as settings designated by the operating system 108 or a user of the operating system 108 .
In particular, in this case, the advertisement content 104 that can be displayed on the desktop can be expressly specified, such as when choosing a particular skin 206 . Additionally or alternatively, certain types of advertisement content 104 that can be selected for display can be more generally specified, such as advertisements 202 that relate to a particular type of product or service, or advertisement content 104 of only a particular type (e.g., reference numerals 202 - 208 ) can be displayed. In another aspect, the settings 302 can specify advertisement content 104 that meets various other criteria such as a minimum discount level (e.g., 33% or greater off list price), or that has been rating or ranked in a particular fashion (e.g., video-based commercials that users have rating as humorous).
Furthermore, the settings 302 can relate to particular features or regions of the desktop as well as to certain times. For instance, it can be specified that only the upper right-hand portion of the desktop should be populated with advertisement content 104 (e.g., a particular region) or that only a side bar and window title bars are appropriate for advertisement content 104 (e.g., a particular feature of the desktop). As another example, it can be specified that advertisement content 104 should only be displayed at certain times, which can be defined temporally such as only on weekends or after 6:00 pm, or defined by events, such as only during installations, downloads, or while a screen saver is active. It is to be appreciated that all of the above can be accomplished by way of the settings 302 , which can be employed by the selection component 112 in order to select appropriate and/or suitable advertisement content 104 .
According to another aspect, the selection component 112 can utilize a bid 304 from the advertiser 106 in order to select the advertisement content 104 for display on the desktop. In particular, one or more advertisers 106 can economically compete for advertising space and/or user attention. The selection component 112 can select the advertisement content 104 with respect to a highest bidder or based upon a variety of other criteria such as advertiser 106 ranking, product quality, as well as information particular to the user, such as transaction histories or profiles, which is further detailed infra.
Furthermore, a contractual obligation 306 can provide another example of criteria the selection component 112 can employ to select advertisement content 104 . For example, a contract 306 can be formed with an advertiser 106 providing that, e.g., a certain number of impressions or a certain amount of time of display for the advertising content 104 will be provided to users of the desktop. Likewise, the contract 306 can exist with a user of the desktop. For instance, incentives can be provided to the user such as a free or discounted operating system 108 (as well as virtually any other type of consideration or incentive) in exchange for activating, say, a skinning feature (e.g., skin 206 ), or allowing other types of advertisement content 104 to be displayed, possibly under certain agreed upon conditions. Thus, in accordance with the agreement/contract 306 , the selection component 112 can select the actual advertisement content 104 for display, or select a set of advertisement content 104 , and allow the user to choose from the set, or select one instance of the advertisement content 104 from a user-selected set.
In yet another aspect, the selection component 112 can select the advertisement content 104 based upon an update 308 . For instance, certain advertisement content 104 can be newly received or modified in whole or in part. Upon the occurrence of an update 308 , the selection component can re-evaluate the content for display. It is to be appreciated that the selection component 112 need not select advertisement content 104 associated with an update 308 , but rather can select the advertisement content 104 as a result of an occurrence of the update 308 .
In accordance with other aspects of the claimed subject matter, the selection component 112 can choose the advertisement content 104 based upon demographic information 310 such as a profile associated with a user of the desktop as well as based upon an interaction/transaction history 312 . In particular, a user profile can be aggregated based upon a history 312 of transactions by a user such as past purchases, clicks, navigation, etc. as well as demographic data 310 such age, gender, income, expenses, and potentially including personal information relating to hobbies, interests, likes, dislikes, and so on. In essence, the selection component 112 can serve as an ad-targeting mechanism for the advertisement content 104 , however, unlike many conventional ad-targeting mechanism, the selection component 112 can reside on a local machine of the user. Thus, information that a user may consider personal, private, or otherwise does not wish to propagate can still be utilized by the selection component 112 , while at the same time potentially mitigating privacy concerns of the user. It should be understood that the criteria 302 - 312 are not intended to be mutually exclusive. Thus, the selection component 112 can utilize one or more of the criteria 302 - 312 simultaneously or in sequence in order to select the advertisement content 104 for display.
Referring now to FIG. 4 , a computer-implemented system 400 that can monitor a user-interface to determine potential suitability for advertisement content is illustrated. Typically, the system 400 can include an examination component 402 that can be an independent component as depicted, while, in other scenarios, the examination component 402 can be a subcomponent of the selection component 112 . The examination component 402 can determine or infer a suitable location 406 for display of the advertisement content 104 . For example, the examination component 402 can monitor a desktop 404 associated with the operating system 108 in order to identify unused, non-occluded, or nonessential display space. Unused space can be portions of the desktop 404 that display content or colors of a background (e.g., desktop 404 background, a window background . . . ). Non-occluded space can be space on the desktop 404 that is not currently concealed by other objects. Nonessential space can be space on the desktop 404 that exhibits a homogenous pattern or color scheme or provides information that is determined to be non-utilitarian and/or merely aesthetic or redundant.
It is to be appreciated that whether or not a location 406 included unused or non-essential display space can differ based upon a type of advertisement content 104 . For example, advertisement content 104 that can be displayed as a watermark can have different applications than advertisement content 104 associated with a streaming video. It is to be further appreciated that location 406 may need to meet certain size or dimension prerequisites based upon the advertisement content 104 or based upon a type of advertisement content 104 that is selected for display. Additionally or alternatively, the selection component 112 can select advertisement content 104 that meets the size or dimensions of the location identified by the examination component 402 .
According to another aspect of the claimed subject matter, the examination component 402 can also determine an appropriate time 408 for display of the advertisement content 104 . Hence, the examination component 402 can monitor either or both of the operating system 108 (or activity thereof) or the desktop 404 in order to identify a waiting period or a lapse in task-oriented activity of a user. Such wait times or lapses can be utilized for determining an appropriate time 408 in which to display the advertisement content 104 .
In another aspect of the claimed subject matter, it is to be understood that the operating system 108 can apply and/or output for display the advertisement content 104 . Typically, the advertisement content 104 is applied to the desktop 404 , however, it is to be appreciated that the operating system can, in some cases, apply the advertisement content 104 to other user-interfaces, such as a user-interface of an application 410 launched by the operating system 108 or a user-interface for a portal 412 accessed by the operating system 108 . As one example, consider a skin 206 applied to the desktop 404 as described herein. In addition, the skin 206 can be extended to a user-interface of the application 410 or to a user-interface of a portal 412 , such as a web portal.
Turning briefly to FIG. 5 , a computer-implemented system 500 that can provide for various inferences and/or determinations is depicted. The system 500 can include the selection component 112 that can select suitable advertisement content 104 for display and the examination component 402 that can determine suitable locations 406 and appropriate times 408 for display of the advertisement content 104 as substantially described above in connection with, inter alia, FIGS. 3 and 4 , respectively. In addition, the system 500 can also include an intelligence component 502 that can potentially aid one or both of the selection component 112 or the examination component 402 based upon, e.g. various machine learning techniques. In accordance therewith, the intelligence component 502 can be operatively coupled to or be subcomponents of one or both the selection component 112 or the examination component 402 .
Thus, while a number of examples have already been illustrated, it is to be appreciated that the selection component 112 and the examination component 402 can also access or employ the features of the intelligence component 502 . In particular, the intelligence component 502 can access the data sets associated with criteria 302 - 312 , as well as the data store 106 and any or portions of the data available to the examination component 402 in order to intelligently aid in one, all or portions of the selection of advertisement content 104 , the determination of a suitable location 406 , the determination of an appropriate time 408 , as well as other determinations or inferences.
In particular, the intelligence component 502 can examine the entirety or a subset of the data available and can provide for reasoning about or infer states of the system, environment, and/or user from a set of observations as captured via events and/or data. Inference can be employed to identify a specific context or action, or can generate a probability distribution over states, for example. The inference can be probabilistic—that is, the computation of a probability distribution over states of interest based on a consideration of data and events. Inference can also refer to techniques employed for composing higher-level events from a set of events and/or data.
Such inference can result in the construction of new events or actions from a set of observed events and/or stored event data, whether or not the events are correlated in close temporal proximity, and whether the events and data come from one or several event and data sources. Various classification (explicitly and/or implicitly trained) schemes and/or systems (e.g. support vector machines, neural networks, expert systems, Bayesian belief networks, fuzzy logic, data fusion engines . . . ) can be employed in connection with performing automatic and/or inferred action in connection with the claimed subject matter.
A classifier can be a function that maps an input attribute vector, x=(x1, x2, x3, x4, xn), to a confidence that the input belongs to a class, that is, f(x)=confidence(class). Such classification can employ a probabilistic and/or statistical-based analysis (e.g., factoring into the analysis utilities and costs) to prognose or infer an action that a user desires to be automatically performed. A support vector machine (SVM) is an example of a classifier that can be employed. The SVM operates by finding a hypersurface in the space of possible inputs, where the hypersurface attempts to split the triggering criteria from the non-triggering events. Intuitively, this makes the classification correct for testing data that is near, but not identical to training data. Other directed and undirected model classification approaches include, e.g., naïve Bayes, Bayesian networks, decision trees, neural networks, fuzzy logic models, and probabilistic classification models providing different patterns of independence can be employed. Classification as used herein also is inclusive of statistical regression that is utilized to develop models of priority.
FIGS. 6 , 7 , 8 , and 9 illustrate various methodologies in accordance with the claimed subject matter. While, for purposes of simplicity of explanation, the methodologies are shown and described as a series of acts, it is to be understood and appreciated that the claimed subject matter is not limited by the order of acts, as some acts may occur in different orders and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the claimed subject matter. Additionally, it should be further appreciated that the methodologies disclosed hereinafter and throughout this specification are capable of being stored on an article of manufacture to facilitate transporting and transferring such methodologies to computers. The term article of manufacture, as used herein, is intended to encompass a computer program accessible from any computer-readable device, carrier, or media.
Turning now to FIG. 6 , an exemplary computer implemented method 600 for facilitating extensible themes for and/or advertising integration with an operating system user-interface is provided. In general, at reference numeral 602 , advertisement content that is tailored for display by an operating system on a desktop can be acquired from an advertiser. That is, advertisement content can be acquired from the advertiser, wherein the content is tailored for a desktop associated with an operating system. Hence, the content can be tailored for display by the operating system.
At reference numeral 604 , the advertisement content can be stored to a data store, and at reference numeral 606 the data store can be accessed for selecting the advertisement content for display. Additional aspects associated with the act of selecting can be found in connection with FIG. 7 infra. At reference numeral 608 , the operating system can be configured to display the advertisement content by way of the desktop. For example, suitable components of the operating system such as a window manager or a desktop environment manager can be configured to display the advertisement content, e.g. by way of standardized system calls.
With reference now to FIG. 7 , an exemplary computer implemented method 700 for selecting advertisement content based upon a variety of potential criteria is depicted. Initially, at reference numeral 702 , the advertisement content can be selected based upon preferences associated with the operating system or desktop. It is to be appreciated that the preferences can relate to user-designated preferences as well as default or system-designated preferences. For example, the preferences can pertain to expressly selecting certain advertisement content or types of advertisement content or, additionally or alternatively to filtering certain particular or types of advertisement content. Thus, e.g., a particular skin can be selected as a preference or a particular type of advertisement can be filtered by the preferences. Moreover, certain regions of a desktop or certain objects or features associated therewith can be designated as preferred a recipient of advertisement content, or conversely designated to be free from advertisement content. Likewise, preferences can be associated with particular times or event-based occurrences, such that advertisement content can be displayed or precluded based upon those preferences.
At reference numeral 704 , the advertisement content can be selected based upon a bid from the advertiser. In accordance therewith, the content selection can be related to a bidding model, wherein advertisers can place bids on ad-slots that are available on the desktop. It is to be appreciated that the bidding model can be base upon not only a price paid for an ad-slot, but based upon many additional features as well, including but not limited to features of the advertiser (e.g., a quality or ranking of the advertiser), features of the desktop or ad-slot (e.g., dimensions, available types of content, location, time, duration . . . or features of the user (e.g., demographics, transaction history, contractual obligations, and so on).
At reference numeral 706 , the advertisement content can be selected based upon a contractual agreement with at least one of the advertiser or a user of the operating system or desktop. For example, the advertiser can contract for the right to display certain advertisement content, which can be a basis for the selection of advertisement content. Conversely the user can contract for the obligation to receive certain advertisement content, which can likewise provide a basis for the selection.
At reference numeral 708 , an update for the advertisement content can be received from the advertiser, and at reference numeral 710 , the advertisement content can be selected based upon the update or the act of receiving the update.
Turning briefly to FIG. 8 , an exemplary computer implemented method 800 for determining a suitability or appropriateness for display of particular types of advertisement content is illustrated. Most generally, at reference numeral 802 , It is to be appreciated that the advertisement can include substantially any type of audio, visual, or executable content and the reference to the advertisement can invoke disparate applications or portals in order to facilitate the display of the advertisement.
At reference numeral 804 , the desktop can be monitored to identify a suitable position for display of the advertisement or the reference. For example, the suitable position can be identified based upon a size or dimensions of an object, space, region of the desktop as well as based upon the content that currently exists at a particular position. At reference numeral 806 , the desktop, operating system, or activity associated therewith can be examined for determining an appropriate time for displaying the advertisement or reference. For instance, the appropriate time can be determined based upon calendar time as well as based upon event-based occurrence such as user activity, downloads or installations, or other events that tend to indicate the user is not task-oriented and would thus likely be more receptive and/or focused on the advertisement or reference.
With reference now to FIG. 9 , an exemplary computer implemented method 900 for applying an extensible skin from an advertiser is depicted. In general, at reference numeral 902 , the advertisement content can be acquired as an extensible skin for a the desktop, wherein the skin can be crated based upon a theme, brand, or trademark associated with the advertiser. More particularly, advertisement content such as that acquired at act 602 of FIG. 6 can be in the form of a skin, e.g., tailored and/or designed by the advertiser. It should be understood that the skin can be applied to a desktop and/or to various features thereof by way of, e.g. a desktop environment manager, a window manager, or the like.
At reference numeral 904 , the skin can be applied to a user-interface associate with a disparate application launched by the operating system. Appreciably, applying the skin to the disparate application can be substantially similar to accomplished in a manner similar to constructing user-interface objects or features, with the distinction being that rather than constructing the features with conventional inbuilt operating system components, these features can be constructed with components designed, supplied, updated, and/or directed to the advertiser to, e.g., facilitate advertising, brand recognition, consumer goodwill and so forth. Similarly, at reference numeral 906 , the skin can be applied to a user-interface associated with a portal accessed by the operating system. Hence, the skin can be extended to, say, a web portal such that the skinning features are consistent throughout the standard desktop and the portal.
Referring now to FIG. 10 , there is illustrated a block diagram of an exemplary computer system operable to execute the disclosed architecture. In order to provide additional context for various aspects of the claimed subject matter, FIG. 10 and the following discussion are intended to provide a brief, general description of a suitable computing environment 1000 in which the various aspects of the claimed subject matter can be implemented. Additionally, while the claimed subject matter described above may be suitable for application in the general context of computer-executable instructions that may run on one or more computers, those skilled in the art will recognize that the claimed subject matter also can be implemented in combination with other program modules and/or as a combination of hardware and software.
Generally, program modules include routines, programs, components, data structures, etc., that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the inventive methods can be practiced with other computer system configurations, including single-processor or multiprocessor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which can be operatively coupled to one or more associated devices.
The illustrated aspects of the claimed subject matter may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules can be located in both local and remote memory storage devices.
A computer typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by the computer and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer-readable media can comprise computer storage media and communication media. Computer storage media can include both 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. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the computer.
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 the any of the above should also be included within the scope of computer-readable media.
With reference again to FIG. 10 , the exemplary environment 1000 for implementing various aspects of the claimed subject matter includes a computer 1002 , the computer 1002 including a processing unit 1004 , a system memory 1006 and a system bus 1008 . The system bus 1008 couples to system components including, but not limited to, the system memory 1006 to the processing unit 1004 . The processing unit 1004 can be any of various commercially available processors. Dual microprocessors and other multi-processor architectures may also be employed as the processing unit 1004 .
The system bus 1008 can be any of several types of bus structure that may further interconnect to a memory bus (with or without a memory controller), a peripheral bus, and a local bus using any of a variety of commercially available bus architectures. The system memory 1006 includes read-only memory (ROM) 1010 and random access memory (RAM) 1012 . A basic input/output system (BIOS) is stored in a non-volatile memory 1010 such as ROM, EPROM, EEPROM, which BIOS contains the basic routines that help to transfer information between elements within the computer 1002 , such as during start-up. The RAM 1012 can also include a high-speed RAM such as static RAM for caching data.
The computer 1002 further includes an internal hard disk drive (HDD) 1014 (e.g., EIDE, SATA), which internal hard disk drive 1014 may also be configured for external use in a suitable chassis (not shown), a magnetic floppy disk drive (FDD) 1016 , (e.g., to read from or write to a removable diskette 1018 ) and an optical disk drive 1020 , (e.g., reading a CD-ROM disk 1022 or, to read from or write to other high capacity optical media such as the DVD). The hard disk drive 1014 , magnetic disk drive 1016 and optical disk drive 1020 can be connected to the system bus 1008 by a hard disk drive interface 1024 , a magnetic disk drive interface 1026 and an optical drive interface 1028 , respectively. The interface 1024 for external drive implementations includes at least one or both of Universal Serial Bus (USB) and IEEE1394 interface technologies. Other external drive connection technologies are within contemplation of the subject matter claimed herein.
The drives and their associated computer-readable media provide nonvolatile storage of data, data structures, computer-executable instructions, and so forth. For the computer 1002 , the drives and media accommodate the storage of any data in a suitable digital format. Although the description of computer-readable media above refers to a HDD, a removable magnetic diskette, and a removable optical media such as a CD or DVD, it should be appreciated by those skilled in the art that other types of media which are readable by a computer, such as zip drives, magnetic cassettes, flash memory cards, cartridges, and the like, may also be used in the exemplary operating environment, and further, that any such media may contain computer-executable instructions for performing the methods of the claimed subject matter.
A number of program modules can be stored in the drives and RAM 1012 , including an operating system 1030 , one or more application programs 1032 , other program modules 1034 and program data 1036 . All or portions of the operating system, applications, modules, and/or data can also be cached in the RAM 1012 . It is appreciated that the claimed subject matter can be implemented with various commercially available operating systems or combinations of operating systems.
A user can enter commands and information into the computer 1002 through one or more wired/wireless input devices, e.g. a keyboard 1038 and a pointing device, such as a mouse 1040 . Other input devices (not shown) may include a microphone, an IR remote control, a joystick, a game pad, a stylus pen, touch screen, or the like. These and other input devices are often connected to the processing unit 1004 through an input device interface 1042 that is coupled to the system bus 1008 , but can be connected by other interfaces, such as a parallel port, an IEEE1394 serial port, a game port, a USB port, an IR interface, etc.
A monitor 1044 or other type of display device is also connected to the system bus 1008 via an interface, such as a video adapter 1046 . In addition to the monitor 1044 , a computer typically includes other peripheral output devices (not shown), such as speakers, printers, etc.
The computer 1002 may operate in a networked environment using logical connections via wired and/or wireless communications to one or more remote computers, such as a remote computer(s) 1048 . The remote computer(s) 1048 can be a workstation, a server computer, a router, a personal computer, portable computer, microprocessor-based entertainment appliance, a peer device or other common network node, and typically includes many or all of the elements described relative to the computer 1002 , although, for purposes of brevity, only a memory/storage device 1050 is illustrated. The logical connections depicted include wired/wireless connectivity to a local area network (LAN) 1052 and/or larger networks, e.g. a wide area network (WAN) 1054 . Such LAN and WAN networking environments are commonplace in offices and companies, and facilitate enterprise-wide computer networks, such as intranets, all of which may connect to a global communications network, e.g. the Internet.
When used in a LAN networking environment, the computer 1002 is connected to the local network 1052 through a wired and/or wireless communication network interface or adapter 1056 . The adapter 1056 may facilitate wired or wireless communication to the LAN 1052 , which may also include a wireless access point disposed thereon for communicating with the wireless adapter 1056 .
When used in a WAN networking environment, the computer 1002 can include a modem 1058 , or is connected to a communications server on the WAN 1054 , or has other means for establishing communications over the WAN 1054 , such as by way of the Internet. The modem 1058 , which can be internal or external and a wired or wireless device, is connected to the system bus 1008 via the serial port interface 1042 . In a networked environment, program modules depicted relative to the computer 1002 , or portions thereof, can be stored in the remote memory/storage device 1050 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers can be used.
The computer 1002 is operable to communicate with any wireless devices or entities operatively disposed in wireless communication, e.g., a printer, scanner, desktop and/or portable computer, portable data assistant, communications satellite, any piece of equipment or location associated with a wirelessly detectable tag (e.g., a kiosk, news stand, restroom), and telephone. This includes at least Wi-Fi and Bluetooth™ wireless technologies. Thus, the communication can be a predefined structure as with a conventional network or simply an ad hoc communication between at least two devices.
Wi-Fi, or Wireless Fidelity, allows connection to the Internet from a couch at home, a bed in a hotel room, or a conference room at work, without wires. Wi-Fi is a wireless technology similar to that used in a cell phone that enables such devices, e.g. computers, to send and receive data indoors and out; anywhere within the range of a base station. Wi-Fi networks use radio technologies called IEEE802.11 (a, b, g, etc.) to provide secure, reliable, fast wireless connectivity. A Wi-Fi network can be used to connect computers to each other, to the Internet, and to wired networks (which use IEEE802.3 or Ethernet). Wi-Fi networks operate in the unlicensed 2.4 and 5 GHz radio bands, at an 11 Mbps (802.11a) or 54 Mbps (802.11b) data rate, for example, or with products that contain both bands (dual band), so the networks can provide real-world performance similar to the basic 10BaseT wired Ethernet networks used in many offices.
Referring now to FIG. 11 , there is illustrated a schematic block diagram of an exemplary computer compilation system operable to execute the disclosed architecture. The system 1100 includes one or more client(s) 1102 . The client(s) 1102 can be hardware and/or software (e.g., threads, processes, computing devices). The client(s) 1102 can house cookie(s) and/or associated contextual information by employing the claimed subject matter, for example.
The system 1100 also includes one or more server(s) 1104 . The server(s) 1104 can also be hardware and/or software (e.g., threads, processes, computing devices). The servers 1104 can house threads to perform transformations by employing the claimed subject matter, for example. One possible communication between a client 1102 and a server 1104 can be in the form of a data packet adapted to be transmitted between two or more computer processes. The data packet may include a cookie and/or associated contextual information, for example. The system 1100 includes a communication framework 1106 (e.g., a global communication network such as the Internet) that can be employed to facilitate communications between the client(s) 1102 and the server(s) 1104 .
Communications can be facilitated via a wired (including optical fiber) and/or wireless technology. The client(s) 1102 are operatively connected to one or more client data store(s) 1108 that can be employed to store information local to the client(s) 1102 (e.g., cookie(s) and/or associated contextual information). Similarly, the server(s) 1104 are operatively connected to one or more server data store(s) 1110 that can be employed to store information local to the servers 1104 .
What has been described above includes examples of the various embodiments. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the embodiments, but one of ordinary skill in the art may recognize that many further combinations and permutations are possible. Accordingly, the detailed description is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims.
In particular and in regard to the various functions performed by the above described components, devices, circuits, systems and the like, the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g. a functional equivalent), even though not structurally equivalent to the disclosed structure, which performs the function in the herein illustrated exemplary aspects of the embodiments. In this regard, it will also be recognized that the embodiments includes a system as well as a computer-readable medium having computer-executable instructions for performing the acts and/or events of the various methods.
In addition, while a particular feature may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes,” and “including” and variants thereof are used in either the detailed description or the claims, these terms are intended to be inclusive in a manner similar to the term “comprising.” | The claimed subject matter relates to an architecture or extension to an operating system (or component thereof) that can facilitate extensible themes for or advertising integration with a desktop that is managed by the operating system. In particular, the architecture can acquire advertisement content such as ads or advertiser skins, select suitable content for display, and configure the operating system to display the selected content. The architecture also provides mechanisms for identifying suitable locations as well as appropriate time for displaying the content. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application relates to U.S. patent application Ser. No. 09/775,246, filed Feb. 1, 2001, which is a continuation of issued U.S. Pat. No. 6,220,358. The present application further relates to Disclosure Document Nos. 487891 ; 488489 ; and 496525 ; respectively filed on Jan. 25, 2001, Feb. 6, 2001, and Jul. 2, 2001, with the U.S. Patent and Trademark Office under the Disclosure Document program. All of these references are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to a system for pumping fluid from a well. More specifically, this invention relates to a system in which a dual-displacement, subsurface pump is driven by reciprocating motion of a sucker rod or tubing string, thereby producing fluid with both halves of the stroke cycle.
[0004] 2. Description of Related Art
[0005] To extract fluids such as water or hydrocarbons from the earth, people traditionally drill a hole through overlying formations to the fluid-containing reservoir. If the fluid pressure in the reservoir is sufficient, the fluids will fill the hole and flow to the surface of their own accord. More commonly, however, fluids will enter the hole and remain pooled near the bottom. These fluids must be pumped to the surface.
[0006] Of particular interest to this disclosure are wells with high water/oil ratios and high fluid volumes. These may occur, for example, in secondary recovery oil wells where water is injected to “sweep” the last traces of hydrocarbons from a reservoir.
[0007] A popular pumping system for these wells includes an electric submersible pump. In this system, the pump is typically attached to the lower end of production tubing and submerged in the fluid. An electrical cable is typically attached to production tubing to supply power for the pump. However, for deeper wells, the installation of pumping system becomes cumbersome, requiring manual strapping of the cable to the production tubing, and careful insertion to avoid accidental severing of the cable downhole. Once in place, the power dissipation in the cable may become a significant portion of operational costs.
[0008] For most wells of this type, the traditional pumping system includes a single-displacement reciprocating pump. The pump is typically attached to the lower end of production tubing and submerged in the fluid. A sucker rod string extends through the production tubing between the pump and a surface pump unit on the surface. The surface pump unit reciprocates the sucker rod string to drive the single-displacement pump. Although reliable, this pumping system generally requires a large surface pumping unit, and it productively utilizes only one half of the pumping cycle.
[0009] An alternative pumping system that is sometimes employed for these wells is a progressive-cavity pumping system. In this system, a progressive-cavity pump is attached to the lower end of a sucker rod string and inserted through production tubing to be submerged in the fluid. The sucker rod string connects the pump to a surface pump unit. The surface pump unit rotates the sucker rod string to drive the progressive cavity pump. Although these pumps can be run at high speed, such operation commonly causes failure in the sucker rod string. This failure is normally attributed to improper installation and/or inertial torque stresses. These systems are also subject to depth limitations.
[0010] Accordingly, a need exists for a pumping system that can operate reliably and more economically than existing pumping systems.
SUMMARY OF THE INVENTION
[0011] The problems outlined above are addressed by a dual-displacement pumping system. In one embodiment, the system includes a dual-displacement pump, a tubing string, and a surface pumping unit connected to the dual displacement pump by a reciprocating member. The reciprocating member is preferably a continuous tubing string, but a threaded tubing string or a sucker rod string with a hollow portion at its terminal end may alternatively be used. The dual displacement pump includes a pump barrel mounted to the end of the first tubing string, and a plunger mounted to the end of the reciprocating member. A valve configuration is provided so that downward motion of the plunger in the pump barrel forces fluid from the lower end of the pump barrel to enter the reciprocating member and from there, to travel to the surface. Downward motion of the plunger also fills the upper end of the pump barrel with fluid from the well bore. The valve configuration also causes upward motion of the plunger to force fluid from the upper end of the pump barrel to enter the tubing string (and travel thence to the surface), and causes the lower end of the pump barrel to fill with fluid from the well bore. In this fashion, both movements of the pumping cycle are fully exploited to nearly double the volume of fluid pumped with a conventional surface configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
[0013] [0013]FIG. 1 is an overall view of a preferred pumping system embodiment using a reciprocated continuous tubing string;
[0014] [0014]FIG. 2 is an overall view of a preferred pumping system embodiment using a reciprocated sucker rod string;
[0015] [0015]FIG. 3 is a cross-sectional side view of a preferred embodiment a subsurface pump; and
[0016] [0016]FIG. 4 is a cross-sectional side view of an alternative embodiment of a subsurface pump.
[0017] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] Turning now to the figures, FIG. 1 shows a first pumping system embodiment. A well has been drilled through the earth to intersect a fluid reservoir 102 . The well is generally lined with casing 104 that extends from the well head 106 to below the fluid reservoir 102 . The casing 104 is perforated 108 where it intersects the reservoir to allow fluid to flow into the interior of casing 104 . A blow-out preventer 110 is attached to the well head 106 for controlling fluid and gas flows from the well.
[0019] A pump body 112 is affixed to the lower end of a production tubing string 114 and lowered through the blow-out preventer 110 to be submerged in the fluid pooling at the bottom of the well. The production tubing is secured to the well head 106 . Also, the pump body 112 is preferably set downhole using standard well servicing techniques. A pump plunger 116 is affixed to the bottom of a continuous tubing string 118 and lowered through the interior of the production tubing string until it is properly seated in pump body 112 . A packing unit (not specifically shown) in blow out preventer 110 seals the gap between the continuous tubing 118 and the blow out preventer 110 , but allows for vertical movement of the tubing 118 . A surface pump unit 120 reciprocates (cyclically raises and lowers) the continuous tubing string 118 , thereby reciprocating the plunger 116 in the pump body 112 . As discussed in greater detail below, the reciprocation of the plunger 116 forces fluid upward through the continuous tubing string 118 and/or the production tubing string 114 to the surface.
[0020] The surface pump unit 120 shown in FIG. 1 employs a “walking beam” pump configuration to reciprocate continuous tubing string 118 . It is recognized that other alternative pump configurations may be suitable for imparting reciprocative motion to a subsurface pump plunger (e.g., hydraulic pumping units), and these alternative configurations may be employed without departing from the underlying principles of the present invention.
[0021] Surface outflow from the continuous tubing string 118 is preferably conveyed to a fixed outflow passage 126 via a flexible high-pressure hose 124 . A U-shaped tube 122 is preferably connected between the continuous tubing string 118 and the flexible hose 124 to minimize wear and fatigue in flexible hose 124 . Surface outflow from the production tubing 114 exits through outflow passage 130 . Outflow passages 126 and 130 may convey the fluid outflows to an aboveground storage tank 132 . In a preferred embodiment, the pumping system produces fluid outflows through outflow passage 126 during downward motion of plunger 116 , and produces fluid outflows through outflow passage 130 during upward motion of plunger 116 . However, as explained in greater detail below, the fluid outflows may be entirely produced through the continuous tubing outflow 126 or entirely through the production tubing outflow 130 . In either of these cases, both the upward and downward motions of the plunger 116 contribute to the overall fluid outflow.
[0022] Also shown in FIG. 1 is a ball valve 134 that controls surface flow to and from the casing interior. This may be used to open the casing interior to the ambient air during the initial “priming” of the well (i.e., the initial fluid fill of the tubing) to prevent an excessive pressure differential from being built up across the subsurface pump, as this could prevent the “prime” from being established.
[0023] [0023]FIG. 2 shows an alternate pumping system embodiment that replaces the continuous tubing string 118 with a solid sucker rod string 218 that reciprocates in the same manner. A similar subsurface pump configuration is used. The pump plunger 116 is coupled to the sucker rod string 218 by a short tubing section 215 . Downward motion of the plunger 116 forces fluid from a chamber defined by the pump body 112 into the short tubing section 215 . The short tubing section 215 is preferably perforated above the pump body 112 to allow fluid from the tubing section 215 to flow to the surface through the production tubing 114 .
[0024] [0024]FIG. 3 shows a preferred subsurface pump configuration for use with either of the pumping systems shown in FIGS. 1 and 2. For clarity, however, the ensuing discussion will focus solely on the embodiment that employs a continuous tubing string, but it is recognized that the continuous tubing string may be replaced by a sucker rod string with a hollow terminal portion.
[0025] A coupler 302 connects the pump body 112 to the production tubing 114 . The pump body 112 includes an outer shell 304 , a pump barrel 306 , and an end cap 310 . A seal 312 prevents fluid leakage between the pump barrel 306 and end cap 310 . Outer shell 304 is preferably a threaded cylinder concentric with the pump barrel 306 .
[0026] The complete pump configuration includes a pump plunger 318 coupled to the lower end of continuous tubing 118 (or to the lower end of short tubing section 215 ). A check valve 322 is movably mounted on the continuous tubing 118 above the plunger 318 . Between the check valve 322 and the continuous tubing string 118 is a sealing layer that allows axial motion but prevents fluids from passing between the valve and continuous tubing string. When the plunger 318 is lowered into the pump barrel 306 , the check valve 322 preferably rests on a valve seat 323 formed by coupler 302 . The contact surfaces of the check valve 322 and coupler 302 may be conical or spherical sections.
[0027] Loosely mounted on the continuous tubing 118 above the check valve 322 is a centralizer 324 . The centralizer 324 preferably has three or more fins that fit within a landing nipple 325 attached to the bottom of production tubing 114 . (In an alternative embodiment, the fins may simply provide a tight frictional fit against the inside of production tubing 114 .) A coupling 326 (or fins, latches or other projections) is located on the continuous tubing 118 above the centralizer 324 . As the continuous tubing is through the production tubing 114 , the coupling 326 forces the centralizer 324 along before it.
[0028] During the installation of the subsurface pump, the pump body 112 is lowered into the well on the end of the production tubing 114 . After the pump body 112 has been placed at the desired depth, the plunger 318 , check valve 322 , centralizer 326 , and coupling 326 , are lowered on the end of continuous tubing 118 through the interior of the production tubing 114 until the plunger 118 enters the pump barrel 306 . Once the plunger 318 enters the pump barrel 306 , the check valve 322 rests on the valve seat 323 . The continuous tubing 118 is lowered until the centralizer 324 is forced into place just above the check valve 322 . This position of the continuous tubing 118 represents the lowest allowable stroke position. Thereafter, as the continuous tubing 118 is reciprocated, the fit between the centralizer 324 fins and the landing nipple 325 holds the centralizer 324 in place.
[0029] Once the plunger 318 is in place in the pump barrel 306 , two chambers are defined. The first chamber is defined in the pump barrel 306 below the plunger 318 . An inlet check valve 314 is provided in end cap 310 to fill the first chamber with fluid from the well bore as the plunger 318 is raised. An outlet check valve 320 is provided in plunger 318 to transfer the fluid from the first chamber to the interior of the continuous tubing string 118 as the plunger 318 is lowered. The fluid transferred to the continuous tubing string forces a similar quantity of fluid from the top of the continuous tubing string 118 at the surface.
[0030] The second chamber is defined in the annulus between the pump barrel 306 and the continuous tubing 118 . Check valve 322 operates as an outlet check valve to transfer fluid from the second chamber to the interior of the production tubing string 114 as the plunger 318 is raised. The transferred fluid forces a similar quantity of fluid from the top of the production tubing string 114 at the surface. Note that centralizer 324 operates to “hold down” the check valve 322 as the plunger 318 is raised. This keeps the check valve 322 near the seat 323 so that the check valve 322 closes quickly at the beginning of the down stroke.
[0031] A set of one or more inlet check valves 316 is provided in the end cap 316 to fill the second chamber with fluid from the well bore as the plunger 318 is lowered. The second chamber is filled via an annular passage between the pump shell 304 and the pump barrel 306 that connects the set of inlet check valves 316 to perforations 308 at the upper end of pump body 306 . The set of inlet check valves 316 are preferably evenly spaced about the circumference of the end cap 310 .
[0032] In the embodiment of FIG. 3, the check valve 322 shown is of the traveling-valve type, with a hold down provided by the centralizer 324 . One of ordinary skill in the art will recognize that alternative configurations are possible, including without limitation, a set of flapper valves, or a set of ball-and-seat valves. Each of these valve types opens in response to differential pressure in one direction, and closes in response to differential pressure in the opposite direction. In the same vein, the check valves 314 , 316 , and 320 , are shown as ball-and-seat valves. One of ordinary skill in the art will recognize that one or more of these valves can be replaced with alternate check valve configurations such as, e.g., flapper valves.
[0033] Accordingly, the subsurface pump configuration described above is a dual-displacement pump. That is, fluid is forced to the surface on both the upward and downward movements of the pump stroke. Depending on the chosen dimensions of the described dual-displacement pump, this configuration advantageously pumps about 1.8 times the fluid volume per stroke as a single-displacement pumping system configuration, without a commensurate increase in effort. As an added advantage, existing wells can be modified by simply replacing the existing single-displacement pump with the described double displacement pump.
[0034] Various contemplated dimensions for the dual-displacement pump are now provided, but these dimensions may of course be altered without departing from the underlying principles of the invention. The casing 104 may be of any standard size, although it is preferred that the minimum inner diameter be no less than five inches. The production tubing string 114 is preferably 2⅞ or 3½ inch tubing. The continuous tubing string 118 is preferably between about one- and two-inch tubing. The pump 306 barrel preferably has an interior diameter of more than 1.5 inches, and a length of more than about seventy-four inches. The pump shell 304 preferably has an exterior diameter of more than about three inches.
[0035] Of course, the dual-displacement pump configuration shown in FIG. 3 is only one of many variant configurations which may be used without departing from the scope of the attached claims. Other valve locations and configurations may be used. For example, the pump shell 304 may be eliminated and inlet check valves 316 located in coupler 302 . Additionally or alternatively, the outlet check valve 322 may be replaced with a locking pump lid, and outlet check valves placed in plunger 318 to transfer fluid from the second chamber to the interior of the continuous tubing string 118 when the plunger 318 is raised.
[0036] Numerous advantages may be obtained by using the disclosed pumping system. For example, existing well head and short stroke pumping units may be used, thereby eliminating any retrofitting requirements for a different artificial lift system such as electric submersible pumps, progressive cavity pumps, or even large capacity, long stroke pumping units.
[0037] Another advantage which may be obtained from the disclosed pumping system is the ability to pump fluid from a multilayered reservoir without losing the opportunity to avoid gas lock by unloading or venting undesired gas through the annular space. Fluids from the multiple layers are allowed to flow down the annulus between the casing and the tubing string and to submerge the pump. Gasses flow up the annulus and may be removed from the wellhead at the surface.
[0038] Advantageously, the disclosed pumping system is compatible with existing surface installations and equipment including well heads, production manifolds, prime movers and flow lines. The inclusion of the hydraulic hose assembly is considered to be a minor adaptation to any existing surface installation.
[0039] The availability of coiled tubing in different diameters, wall thickness and grades of steel, allows the disclosed pumping system to be adapted for various pump depths, various well fluids, and various pumping volumes.
[0040] Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. For example, threaded tubing may be used in place of coiled tubing. The tubing may be made of steel or composite materials (composite tubing). In fact, for highly corrosive environments, composite tubing may be preferred.
[0041] Additionally, this pumping system may be powered by means other than a beam pumping unit. For example, a hydraulic pumping unit may replace the beam pumping unit. It is intended that the following claims be interpreted to embrace all such variations and modifications. | A dual displacement pumping system is disclosed. In one embodiment, the system includes a subsurface pump, a tubing string, and a surface pumping unit connected to the subsurface pump by a reciprocating member. The subsurface pump includes a pump barrel mounted to the end of the tubing string, and a plunger mounted to the end of the reciprocating member. Valves cause downward motion of the plunger in the pump barrel to force fluid from the lower end of the pump barrel into the reciprocating member, and fill the upper end of the pump barrel with well bore fluid. They also cause upward motion of the plunger to force fluid from the upper pump barrel into the tubing string, and fill the lower pump barrel with well bore fluid. Thus, both pumping movements are exploited, nearly doubling the volume of fluid pumped with a conventional surface configuration. | 4 |
This patent application claims the benefit of non-provisional U.S. patent application Ser. No. 09/776,915, filed Feb. 6, 2001, now abandoned, which is incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to open end yarn processing and its fabric properties.
2. Description of Prior Art
The invention relates to a method and apparatus which are suitable for processing on open end (OE) spinning systems, and is more particularly concerned with rotor spinning system and downstream processing on such systems.
The open end spinning system has achieved a major breakthrough because the twist insertion in this spinning system is no longer performed by the rotation of yarn packages and thus this system eliminates the friction problem that limits ring-spinning. As a result, OE spinning techniques have had a phenomenal growth in productivity, due to amenability to automation, and elimination of roving and winding processes. Therefore, this technique has established itself as a worthy alternative to the ring spinning system. alternative to ring spinning system.
However, OE spun yarns have not penetrated the yarn market to the extent expected because along with the positive aspects there is a growing realization that the system has sectorial applicability-viz, the techo-economic considerations have restricted rotor spinning to coarse and medium counts. These demerits made this new system less attractive than ring spinning technique, which can handle a diversity of fibers and produce a broad range of yarn counts. What is more, the OE spun machine produces a weaker yarn, usually with a 10-30% lower tenacity, as compared to ring spinning. This strength loss is related to the accentuated obliquity effect and higher proportion of noncontributing fibers existing in an OE spun yarn.
However, the biggest drawback of OE yarns is the harsh feel of the fabrics made out of such yarns. Particularly, the harsh feel limits the end use of its end fabrics. For example, knitted fabrics produced from OE spun yarns are unsuitable for using as underwear material. The harsh feel can be attributed to the structure of the yarn, and especially to that of the surface fibers. In particular, it is believed that the tight surface fibers, including wrapper fibers and undulation of the yarn surface, are assumed to be the main cause of harsh feel. Besides, the higher twist adopted in OE yarn and thus higher obliquity of fibers is another significant influential factor. Moreover, fabric produced from OE yarn suffers from a duller appearance, which is also undesirable for end use.
It is therefore an object of the present invention to provide a method and an apparatus for improving OE yarn/fabric structural properties, modifying yarn physical properties, and altering the appearance and handling properties of fabrics made out of rotor spun yarn.
SUMMARY OF THE INVENTION
It is an object of this invention to overcome or at least reduce this problem.
According to the invention there is provided a method for improving structural and physical properties of open end yarn and articles made of open end yarn, including tensile drawing the yarn between rollers driven at different velocities and directing a jet of air at the yarn between the rollers to temporarily untwist the yarn as it is drawn.
An apparatus for improving structural and physical properties of open end yarn and articles made of open end yarn, comprises at least two rollers which are separated by a drawing zone, in which the rollers are controlled to rotate at different velocities to apply tension to the open end yarn as the open end yarn passes through the drawing zone and an air jet directed at the drawing zone to temporarily untwist the yarn as it is drawn.
BRIEF DESCRIPTION OF THE DRAWINGS
The method according to the invention will now be described by way of example with reference to the accompany drawings in which:
FIG. 1 is a stress-strain diagram including yarns before and after tensile drawing;
FIG. 2 is another schematic illustration of apparatus for carrying out the method;
FIG. 3, is another a schematic illustration of the apparatus shown in FIG. 2;
FIG. 4 is a working representation of tensile drawing apparatus attached to a spinning system;
FIG. 5 is a working representation of tensile drawing apparatus attached to a rewinding system.
FIG. 6 shows yarn packing density before and after tensile drawing; and
FIG. 7 shows drape images of fabric samples.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1 shows stress strain diagram of yarn before and after drawing. In FIGS. 2 to 5 , various illustrations of apparatus are shown, each involving a two-roller drawing system with an air jet nozzle located between the two rollers. In this two-roller drawing system, the back roller always runs at a speed lower than the front roller, and thus the rotor spun yarn is under tensile load when passing through these two rollers. The drawing ratio is equal to the ratio of front roller velocity to back roller velocity. However, it should be noted that in practice this drawing ratio does not represent the real extension of the generated rotor spun yarn and is only a nominal one. For example, in the case of a 16s pure cotton rotor spun yarn under a drawing ratio of 1.2, the actual elongation is at a value of 2%-3%. In some instances the effective elongation may be zero (or even negative). On the other hand, however, the extension can be as high as, say, 15% for 20 yarn under the same drawing ratio. Therefore, the actual extension should be related to yarn count and other parameters as well as drawing ratio. Embodiments of the invention preferably operate to provide certain advantages, generally stated, over original yarn under velocity ratios R ranging from 1.01<R<1.4. The adoption of the air jet nozzle can subject the OE yarn to the action of a temporary false twisting between the rollers to improve the tensile drawing effect.
In the present apparatus, OE yarn, after withdrawing from a bobbin or a spinning system as shown in FIG. 4 is fed by back roller 3 via a drawing zone 7 to a front roller 4 . The air jet nozzle 8 directs a jet of air at the yarn in the drawing zone. The yarn then passes via a thread guide 5 to a traversing guide (not shown) and is wound on a bobbin 6 . After completing this tour, the yarn has undergone tensile drawing due to the velocity difference between the front roller 4 and the back roller 3 . The air jet from nozzle 8 temporarily removes twist in the yarn to assist tensile drawing yet retain the basic twist in the drawn yarn as the twist will return once the yarn exits the air jet stream.
Among various open end spinning techniques, rotor spinning system is most widely practiced. Therefore, in the described embodiments rotor spun yarn is used and results of this type of yarn are illustrated. Up to 18 yarn types with a combination of 4 yarn counts, 4 twist factors, as well as four drawing ratios are involved, although only certain facets are illustrated to show the unexpected and positive results:
1. Yarn Properties
Yarn Diameter & Evenness
In the present invention, improvement in yarn structural properties can be attained using tensile drawing processing. Yarn diameter shows a pronounced decrease after tensile drawing processing despite of the subtle variation in yarn count. The set out in Table 1, which presents a good support to this conclusion, is the resulting properties of 16s pure cotton rotor spun yarns with a twist factor 3.6, 4.2 respectively under the drawing ratio of 1.2. Besides, a better evenness, i.e. lower yarn diameter variation, another benefit from tensile drawing, is also shown in Table 1.
TABLE 1
Yarn Diameter
Twist Factor = 3.6
Properties of the
Turns/meter
Twist Factor = 4.2
resulting yarns
Original
Drafted
Original
Drafted
Mean value mm.
4.28
2.935
4.155
3.225
S +/−
0.621
0.412
0.625
0.436
CV %
14.514
14.038
15.050
13.530
Min. Value
3.3
2.3
3.2
2.6
Max. Value
5.5
3.5
5.6
4.5
Med.
4.3
3.0
4.1
3.1
Yarn Twist
Tensile drawing would no doubt lead to a decrease in yarn twist. In the case of a staple spun yarn, twist is closely related to the magnitude of fiber-to-fiber gripping force, to the degree of yarn hairiness, to the extent of fiber obliquity effect, and to the number of fiber in yarn cross section (i.e. packing density). Therefore, the change in yarn twist deserves special attention. It's believed that this cut down in yarn twist would contribute to better luster of the downstream articles due to the more uniform light reflection caused by decreased fiber obliquity effect. And this is the reason of better whiteness for the generated fabric.
TABLE 2
Yarn Twist
Properties of the
Twist Factor = 3.6
Twist Factor = 4.2
resulting yarns
Original
Drafted
Original
Drafted
Mean value
551.6
539.8
616.6
616.4
S +/−
14.894
5.706
18.575
8.890
CV %
2.700
1.057
3.013
1.442
Min. Value
531
534
598
601
Max. Value
572
550
641
627
Med.
550
539
607
616
Packing Density
A remarkable increase in cross section packing density can be found after tensile drawing using Microtomy technique, as presented in FIG. 6 . This packing-density-increase phenomenon under tensile load has been noticed by G. A. Carnaby, who named this phenomenon as fiber lateral movement. It is said in his related publication that a staple-fiber yarn usually consists of fibers that are initially packed together in a rather loose arrangement and that an applied tensile strain causes considerable lateral movement of individual fibers, so that the deformed yarn has a much more closely packed structure. Apparently, such lateral movements will considerably influence the strain levels in individual fibers and thus change the strain distribution of deformed yarn. As a result, the mechanical properties of treated yarn are also distinctly changed. Moreover, this change will be brought into the end product when the treated yarn is produced into fabric. The wear performance as well as mechanical properties of the end product will thus be changed accordingly.
Young's Modulus
This structural change leads directly to a great change in yarn physical properties. The first sight of stress-strain diagram (see FIG. 1) gives a prompt information that Young's modulus, a measure of yarn resistance to tensile drawing, which is indicated by image slope, presents a distinct increase. This is caused by plastic deformation occurring during the tensile drawing processing. In fact, in addition to Young's modulus, i.e. the yarn's ability to resist other deformation, such as bending and torsion, is enhanced as well. This can be verified by the change in fabric structural properties.
Tenacity
Despite increase in tenacity being quite subtle and not so consistent, some of the processing conditions on a certain kind of yarns, usually those with lower twist factors, do contribute to somewhat stronger yarn. This can be explained by a combination of decreased obliquity effect, increased packing density, and a cut-down in a proportion of noncontributing fibers due to tensile drawing.
Hairiness
More hairiness is inherently unavoidable due to decreased twist created by tensile drawing. This may not be a demerit, because rotor spun yarns are lacking in hairiness due to the existence of wrapped fibers around the yarn surface. This increase in yarn hairiness may help to improve tactile feel of the end fabric.
2. Fabric Properties
Using the tensile drawn yarn for a downstream fabric leads to better appearance and physical properties in the following aspects:—
Fullness & Softness
Fukurami, a measure of fabric softness and fullness, a bulky, rich, and well-formed feeling and mainly governed by fabric bulk and compressional behavior, has acquired the most positive progress according to whichever standard, knitted fabrics for outerwear or underwear in summer or in winter. The set out in the following series of tables presenting three selected primary hands and the total hand value gives a good support of this conclusion.
Tactile Comfort
The fabrics produced from drawn rotor spun yarns, as compared with those from undrawn rotor spun yarns, shows significant improvement on hand values. The normal harsh feel of undrawn rotor spun yarn fabric is prominently changed according to the results. THV, a measure of tactile comfort, shows different extents of increase in most cases. This is a major benefit provided by embodiments of the invention.
TABLE 3
Knitted Fabrics for Outerwear
Sample
KM-402-KT
KM-301-WINTER (KT)
No.
KOSHI
NUME.
FUKU.
THV
1
0.51
5.51
3.83
1.64
2
0.97
6.59
7.84
2.60
TABLE 4
Knitted Fabrics for Underwear in Winter
Sample
KM-403-KTU (WINTER)
KM-304-WINTER
No.
KOSHI
FUKU.
NUME.
THV
1
6.65
1.92
4.78
2.83
2
6.65
8.56
4.42
3.34
TABLE 5
Knitted Fabrics for Underwear in Summer
Sample
KM-403-KTU (SUMMER)
KM-304-SUMMTER
No.
KOSHI
FUKU.
SHARI
THV
1
6.65
1.92
6.52
2.73
2
6.65
8.56
4.66
2.48
Sample numbered 1 and 2 refers to fabrics produced from 18 s undrawn/drawn pure cotton rotor spun yarns, sharing a common twist factor of 3.6 tpi, respectively. Both fabrics have undergone relaxing by scouring.
Shrinkage
Shrinkage of fabrics produced from drawn rotor yarns shows little difference from that of fabrics from undrawn yarns. This is quite encouraging because what the inventors, and also believed the potential users, worry most is whether tensile drawing will result in a deteriorated shrinkage.
Thickness
The fabric thickness in most cases is markedly improved by the tensile drawing, despite a superficial contradiction being that there is a notable decrease in yarn diameter. This revealed a significant increase of yarn bending/torsional rigidity. Higher bending/torsional rigidity results in a more prominent three-dimensional structure of loops and less compression at interlacing points in a made up fabric so as to enhance the fabric thickness.
TABLE 6
Fabric Thickness & Weight
Twist factor =
Twist factor =
Properties of
3.6, 16 s
3.6, 18 s
the resulting fabrics
original
DR = 1.2
original
DR = 1.3
THICKNESS [mm]
1.0322
1.8254
1.2874
1.3704
WEIGHT [m/cm 2 ]
31.7500
31.2800
18.100
18.6200
DR: drawing ratio
Air Permeability
TABLE 7
Air Permeability of 12 s Fabric Samples
Fabric
sample
1
2
3
4
5
Air
112.7
90.7
97.4
93.5
101.6
Permeability
[cc/s]
Air
22.2
17.9
19.2
18.4
20
Permeability
[ml/cm 2 · s]
Table 7 lists the results of air permeability for all five fabric samples in the described method from 12s yarn, original yarn as well as treated under four drawing ratios. It can be seen that fabrics produced from drawn yarns have a slightly higher air permeability than that from original yarns. This result seems at odds with the fact that drawn yarns possess higher hairiness. The deviation from what might be predicted is believed to be due to crimp levels, a consequence of higher yarn bending/torsional/tensile modulus after drawing. The drawn yarn opens up less than does an untreated yarn, as revealed by yarn cross section examination. Therefore, is the fabric made from drawn yarn tends to be more air-permeable.
Compression
LC, representing the linearity of compression, and RC, the compressional resilience, both depend upon the compressional behavior of yarn and the fabric thickness. WC, compressional energy per unit area, depends upon LC and the extent of compression of the fabric. In this respect, both fabrics produced from drawn yarns shows greater compressional properties in most cases. The increase in a 18s fabric compressional properties is much less than that in a 16s fabric. This difference is believed to be related to the different extent of drawing and thus the generated different amount of yarn diameter decrease, different degree of yarn rigidity increase and different increase pitch in fabric thickness. In the case of a 18s rotor spun yarn, a 1.3 drawing ratio leads to a slimmer yarn, and less rigidity increase than with a 16s yarn under a 1.2 drawing ratio, and thus the increase in thickness is not so prominent as revealed by Table 6. Therefore, the enhancement in compressional properties is quite subtle.
TABLE 8
Compressional properties
twist factor =
twist factor =
Properties of
3.6, 16 s
3.6, 18 s
the resulting fabrics
original
DR = 1.2
original
DR = 1.3
LC [−]
0.2100
0.3072
0.4241
0.3724
WC [g · cm/cm 2 ]
0.2366
0.4360
0.3817
0.3877
RC [%]
22.6140
34.6717
44.3835
44.6352
Draping Property
Fabric draping characteristic is a property closely related to the bending rigidity of the constituent yarns and of the fabric itself as well as fabric thickness. It is found that this property reduces significantly after tensile drawing processing (see FIG. 7 ). This property change is brought about by the increased yarn bending rigidity and confirms the improvement in yarn bending rigidity. Furthermore, the increase in thickness helps a reduction in this property.
The draping property decrease phenomenon is particularly useful since a soft hand is always a concomitant of higher draping property. The described tensile drawing processing enables these two extremely incompatibles to coexist in one fabric. This could lead to new appraisal in fashion design, especially in the case of knitted fabrics. Hitherto, poor drape properties limits application, mainly to underwear and skirting. In any event, this changed property helps for fabric dimension retention.
Appearance
It is well known that rotor spun yarn fabrics generally have a duller and mottled appearance by comparison with ring spun yarn fabrics, even when bright fiber types are used. This is associated with a combination of a peculiar rotor spun yarn surface nature and resulting turbid light refraction. These disadvantages are improved, at least to some extent, by tensile drawing, and believed to be attributable to the improved fiber alignment and fiber structural evenness provided by the described method.
The surprising results and improvements of the yarn that enhance articles (“downstream articles”) made up of the yarn after being subjected to drawing can be demonstrated for a wide range of drawing conditions, even where the effective elongation caused by drawing is near zero or even slightly negative. Further, the improvements can be manifested where the OE yearn is mixed or blended with other yarns. Thus, in the claims for example the term OE yarns is to be taken to mean OE yarns and OE blends. | Open end yarn is passed through a drawing zone located between a front roller and a back roller controlled to rotate at different velocities. An air jet nozzle is located between the two rollers and directs a jet of air at the yarn. The drawing improves various characteristics of the yarn, making the processed yarn more suitable for making textile articles. | 3 |
BACKGROUND OF THE INVENTION
[0001] Most spectroscopy systems fall into one of two categories. They can be tunable source systems that generate a wavelength tunable optical signal that is scanned over a wavelength scan band. A detector is then used to detect the tunable optical signal after interaction with the sample. The time response of the detector corresponds to the spectral response of the sample. Such systems are typically referred to as pre-dispersive. Alternatively, a tunable detector system can be used. In this case, a broadband optical signal is used to illuminate the sample. Then, signal from the sample is passed through an optical bandpass filter, which is tuned over the scan band such that a detector time response is used to resolve the sample's spectrum. Such systems are typically referred to as post-dispersive.
[0002] Between tunable source and tunable detector systems, tunable source systems have some advantages. They can have a better response for the same optical power transmitted to the sample. That is, tunable detector systems must illuminate the sample with a broadband signal that covers the entire scan band. Sometimes, this can result in excessive sample heating and power consumption at the source, making the system inefficient. In contrast, at any given instant, tunable source systems only generate and illuminate the sample with a very narrow band within the scan band.
[0003] Further, tunable source systems have advantages associated with detection efficiency. Relatively large detectors can be used to capture a larger fraction of the light that may have been scattered by or transmitted through the sample, since there is no need to capture light and then collimate the light for transmission through a tunable filter or to a grating, for example.
[0004] A number of general configurations are used for tunable source spectroscopy systems. The lasers have advantages in that very intense tunable optical signals can be generated. A different configuration uses the combination of a broadband source and a tunable passband filter, which generates the narrowband signal that illuminates the sample.
[0005] Historically, most tunable lasers were based on solid state or liquid dye gain media. While often powerful, these systems also have high power consumptions. Tunable semiconductor laser systems have the advantage of relying on small, efficient, and robust semiconductor sources. One configuration uses semiconductor optical amplifiers (SOAs) and microelectromechanical system (MEMS) Fabry-Perot tunable filters, as described in U.S. Pat. No. 6,339,603, by Flanders, et al., which is incorporated herein by this reference in its entirety. In other examples, intra cavity gratings are used to tune the laser emission.
[0006] In commercial examples of the broadband source/tunable filter source configuration, the tunable filter is an acousto-optic tunable filter (AOTF) and the broadband signal is generated by a diode array or tungsten-halogen bulb, for example. More recently, some of the present inventors have proposed a tunable source that combines edge-emitting, superluminescent light emitting diodes (SLEDs) and MEMS Fabry-Perot tunable filters to generate the tunable optical signal. See U.S. patent application Ser. No. 10/688,690, filed on Oct. 17, 2003, by Atia, et al., which is incorporated herein by this reference in its entirety. The MEMS device is highly stable, can handle high optical powers, and can further be much smaller and more energy-efficient than typically large and expensive AOTFs. Moreover, the SLEDS can generate very intense broadband optical signals over large bandwidths, having a much greater spectral brightness than tungsten-halogen sources, for example.
SUMMARY OF THE INVENTION
[0007] Moving from standard diode arrays and tungsten-halogen bulbs to edge-emitting devices such as superluminescent light emitting diodes (SLED), other edge emitting diodes including lasers, and semiconductor optical amplifiers (SOA) has the advantage that higher optical powers can be achieved.
[0008] One characteristic of these edge-emitting semiconductor devices such as SLEDs, diode lasers, and SOAs is that they tend to be highly polarization anisotropic, however. This is due to the nature of the semiconductor gain medium. Current is usually injected from a top electrode through a quantum well structure to the bottom electrode. Thus, the gain medium is not circularly symmetric around the optical axis and thus light from these devices is usually highly polarized. Most often, it emits light in only a single polarization.
[0009] Even vertical surface emitting laser (VCEL) devices, where the gain region is more symmetric, tend to be highly polarized. This is because invariably one of the polarization modes encounters more loss so that other so that the device runs in the other mode. In fact, it is common to fabricate the devices so that there is a strong preference for one of the modes to remove uncertainly as to in which mode the device operates.
[0010] For some applications, polarization isotropic semiconductor optical amplifiers have been produced. These are most common in telecom applications where polarization dependent loss (PDL) is metric for characterizing the quality of this class of devices. However, in order to obtain this polarization isotropy, typically trade-offs must be made in terms of the output power, device gain, and/or the bandwidth of operation.
[0011] These trade-offs, necessitating lower optical power and narrower band, are contrary to the typical requirements for a spectroscopy system, however. Scan band and power should be maximized in order to improve the performance of the system. Thus, for most spectroscopy applications, polarization anisotropic semiconductor gain elements are often used.
[0012] Thus, the broadband signal or the tunable signal that is transmitted to the sample is highly polarized unless a polarization diversity scheme is used requiring multiple sources with orthogonal polarizations or a polarization scrambler is employed. Both these solutions, however, are expensive because they necessitate multiple sources that operate in tandem with polarization control between the sources or a separate polarization scrambler, which usually also has a high insertion loss.
[0013] A problem arises, however, for applications requiring a high signal-to-noise operation, when the source is highly polarized. Often, the optical link between the tunable signal or broadband signal source and the sample and between the sample and the detector has substantial PDL. Moreover, this PDL may be dynamic over time especially in response to mechanical vibration or other changes to the fiber links or other optical elements in the path between the source and sample and from the sample to the detector. This PDL, in view of the highly polarized nature of the light from these semiconductor sources, can introduce spectral distortion in the measured signal and can detrimentally impact the signal-to-noise ratio and thus spectral performance of these systems.
[0014] As a result, the present invention is directed to a semiconductor source spectroscopy system. It is applicable to systems that use broadband sources, tunable sources, and tunable detector systems. It relies on using polarization control between the source and the sample and/or the sample and the detector.
[0015] In general, according to one aspect, the invention features a semiconductor spectroscopy system. It comprises a semiconductor source and polarization controlling fiber in the link between the semiconductor source and the detector.
[0016] The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention are shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention. Of the drawings:
[0018] FIG. 1 is a schematic view of a tunable source semiconductor spectroscopy system with a fiber link having polarization control.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] FIG. 1 illustrates a semiconductor source spectroscopy system 100 , which has been constructed according to the principles of the present invention.
[0020] Specifically, the system 100 comprises a semiconductor source 200 . In one example, this semiconductor source is a source as described in U.S. patent application Ser. No. 10/688,690, filed Oct. 17, 2003, which is incorporated herein by reference in its entirety. In other examples, it comprises a semiconductor source as described in U.S. patent application Ser. No. 10/953,043, filed on Sep. 29, 2004, entitled “Semiconductor Laser with Tilted Fabry-Perot Tunable Filter” by Dale C. Flanders, et al., which is also incorporated herein by this reference in its entirety. In other examples, semiconductor source is a laser system in which the laser tuning element is a movable grating, such as a Littrow configuration.
[0021] In other examples, the semiconductor source 200 , rather than generating a tunable optical signal, generates a broadband signal. In this case, the semiconductor source comprises an edge emitting light emitting diode device. In one example, the semiconductor source comprises a superluminescent light emitting diode. In other examples, the source 200 comprises a standard edge emitting semiconductor laser or vertical surface emitting laser diode. In these examples, the system is often current or thermally tuned.
[0022] As a result, the signal 105 , being either a broadband signal or a tunable signal, is generated by the semiconductor source 200 and is highly polarized. Typically, it is has only substantially a single polarization.
[0023] For example, light from the semiconductor source 200 can have a polarization extinction ratio (PER), that is ratio of powers in the two polarizations, of 10-25 dB. The present invention is applicable to these higly polarized source. More generally, the present invention is also applicable to less polarized sources since even a small PDL for a low PER source can introduce noise and impact the signal to noise ratio (SNR) of the spectroscopy system.
[0024] This signal 105 travels through, for example, a coupler 110 and a length of fiber 112 , in one example.
[0025] It further travels through another coupler 114 that connects the fiber pigtail 112 from the source 200 to another length of fiber or fiber pigtail 116 that connects or carries the optical signal 105 to the sample 50 , in some examples.
[0026] The sample optical fiber length 116 extends in the illustrated example from the connector 114 to the pigtail's end 118 . Here, the semiconductor source signal, being again either a broadband signal or a tunable signal is often columnated by, for example, a source-side lens element 120 for transmission to the sample 50 .
[0027] Further, sample-side lens 122 may be used to capture the signal from the sample 50 and couple it into another sample-side optical fiber 126 , through endface 124 .
[0028] Other couplers may be used, such as coupler 128 , to connect the sample-side fiber length 126 to a detector optical fiber length 130 . The signal is then directed to the detector 132 .
[0029] In the case where the semiconductor source 200 is a tunable source, the detector 132 is usually a standard detector. In other examples, the detector 132 may be a tunable detector, especially where the semiconductor source 120 produces a broadband signal. Specifically, in one example it is a tunable detector spectroscopy system as disclosed in U.S. patent application Ser. No. 10/688,690 filed Oct. 17, 2003. In still further examples, it can be a grating-based detector system that has a grating to disperse the broadband signal to an array detector.
[0030] It should be noted that the specific nature of the source 200 and the detector 132 is not critical. Instead, the invention is relevant to semiconductor sources, and specifically semiconductor sources that generate highly polarized broadband or tunable signals. The relevance of the detector is that it may be polarization anisotropic, having a certain degree of PDL.
[0031] The invention addresses PDL in these various components between the semiconductor source 200 and the detector 132 . Specifically, the source side connector 114 and the sample side detector 132 may have different polarization characteristics and specifically polarization dependent loss. Moreover, the PDL for these detectors may vary with the spectrum. The source side lens 120 and the detector side lens 122 can further have PDL. Moreover, the fiber end faces 118 and 124 may further have PDL problems.
[0032] According to the invention, the fiber used between the semiconductor source 200 and the detector 132 is polarization controlling fiber. As a result, in one embodiment, the first source side fiber pigtail 112 and the second source side fiber pigtail 1 16 are constructed from polarization controlling fiber. Moreover, the sample side pigtail 126 and the detector side pigtail 130 are preferably comprised of polarization controlling fiber. However, in other examples, only one or a few of these pigtails is polarization controlling fiber.
[0033] The notion is that by using even some polarization controlling fiber between the semiconductor source 200 and the detector 132 , polarization dependent loss (PDL) in the optical link and the components is managed since the polarization and thus PLD is stable with time and does not vary during scanning.
[0034] Generally, however, because of the nature of the sample, it is most important that the source side pigtails 112 and 1 16 are polarization controlling fiber and at least one of these is polarization controlling fiber.
[0035] Various types of polarization controlling fiber can be used. The most common type of polarization controlling fiber is polarization maintaining (PM) fiber, such as PANDA fiber. Here, the orthogonal polarization modes of the fiber have different propagation constants, which decouples the two polarizations on propagation and thus stabilizes and maintains the polarization distribution. In other examples, single polarization fiber or polarization stripping fiber is used. In these examples, the fiber only propagates a single polarization mode either because of the construction of the fiber, or the insertion of the components that remove light that is polarized along one of the axis.
[0036] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | A semiconductor source spectroscopy system controls optical power variation of the tunable signal due to polarization dependent loss in the system and thus improves the noise performance of the system. It relies on using polarization control between the source and the sample and/or the sample and the detector. | 6 |
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