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CROSS-REFERENCE TO RELATED CASE
This application is a divisional of my commonly assigned, copending U.S. application Ser. No. 07/087,790, filed Aug. 21, 1987, entitled "METHOD AND APPARATUS FOR CLEANING A TEXTILE MACHINE COMPRISING A PLURALITY OF OPERATING POSITIONS".
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved apparatus for cleaning a textile machine, such as by way of example and not limitation a spinning machine, containing a plurality of operating positions, in that exemplary case a plurality of spinning positions.
As to the inventive cleaning apparatus for the cleaning of a plurality of typically similar operating positions of a textile machine, such cleaning apparatus comprises a movable or mobile cleaning device which is movable on rails or the like between the different operating positions and such movable or mobile cleaning device is provided with at least one suction trunk or nozzle.
A heretofore known cleaning apparatus of this general type is shown and described in German Pat. No. 1,510,728. In that case, elements of the individual spinning positions are freed of fiber particles deposited thereon by means of pressure jets of a cleaning device travelling on rails along the spinning machine. These fiber particles then pass in free flight onto the floor upon which the spinning machine is mounted or supported and from that location they are sucked away by a suction trunk also forming part of the cleaning device.
Other cleaning devices, operating in accordance with substantially the same technique or method, are known, for example, from U.S. Pat. Nos. 3,754,992 and 3,908,346. An important disadvantage of this prior art blow-suction technique or method resides in the fact that the fiber particles can be caught or entrained only indirectly by the suction nozzle, that is to say, by means of a transfer function This undesirably results in the possibility that the fiber particles blown away by the pressure jets, while on their way or during their flight to the floor or machine supporting structure, can remain entrapped or caught at machine parts or elements located above floor level yet outside the operating range or effective region of the pressure jets. Consequently, at least to some degree there is only effected a displacement of the impurities or contaminants which should be removed from the area of the textile machine.
Furthermore, the known cleaning devices constitute rather limited or non-versatile designs or constructions which are devoid of operational flexibility and adaptability to varying contours of the objects to be cleaned, in this case the parts or elements of the associated textile machine which is to be cleaned.
SUMMARY OF THE INVENTION
Therefore with the foregoing in mind it is a primary object of the present invention to provide an apparatus for cleaning a plurality of operating positions of a textile machine in a manner not afflicted with the aforementioned shortcomings and drawbacks.
A further significant object of the present invention aims at the removal of undesired contaminants or impurities, such as dirt or fiber particles, on the one hand, effectively and, on the other hand, directly from individual elements of the individual operating positions of a textile machine, such as for instance the spinning positions of a spinning machine.
Yet a further noteworthy object of the present invention aims at the provision of an improved apparatus for reliably cleaning a plurality of operating positions of a textile machine in a highly versatile and controlled manner and which apparatus is readily adaptable to the encountered conditions prevailing at the textile machine.
Still a further significant object of the present invention is directed to the provision of a cleaning apparatus for the reliable and relatively easy and positive cleaning of predeterminate individual elements at the operating positions of the textile machine with a suction cleaning apparatus employing a programmable suction trunk or nozzle, the movements of which can be positively controlled in close adaptation to the intended cleaning operation to be performed at the individual elements of the operating positions to effect a positive, intense and reliable suction removal of undesired impurities or the like from the operating positions.
Now in order to implement these and still further objects of the present invention which will become more readily apparent as the description proceeds, the method of cleaning a textile machine containing a plurality of similar operating positions, each of the similar operating positions containing individual elements which are to be suction cleaned, contemplates moving a travelling or mobile cleaning device comprising a programmable robot having at least one suction trunk or nozzle to preselected ones of the plurality of similar operating positions for suction cleaning each of the preselected operating positions by means of the programmable robot of the travelling cleaning device. There is controlled operation of the programmable robot of the travelling cleaning device in order to suction clean predeterminate ones of the individual elements of each of the preselected ones of the operating positions by moving the suction trunk of the programmable robot such as to selectively suction clean the predeterminate ones of the individual elements of each of the preselected ones of the similar operating positions which are to be cleaned.
It is advantageous to successively move the travelling cleaning device including the programmable robot thereof from one operating position to the next following operating position during the cleaning of the textile machine.
The invention contemplates programming the individual movements of the suction trunk or nozzle to effectuate suction cleaning of the predeterminate ones of the individual elements of each of the preselected ones of the similar operating positions which are to be cleaned. In this regard there can be used at least one program for controlling the individual movements of the suction trunk for each operating position and for each employed suction trunk. It is also possible to program individual movements of the suction trunk or nozzle such as to effectuate suction cleaning of all of the individual elements of each of the preselected ones of the similar operating positions which are to be cleaned.
Furthermore, it is possible to control operation of the programmable robot such that the programmable robot performs an operating cycle entailing automatically moving the programmable robot from a predetermined starting position to a first operating position and thereafter from operating position to operating position and after the last operating position back to said predetermined starting position. The operating cycle may comprise a first operating cycle routine and a second operating cycle routine, and the operation of the programmable robot may be controlled such that the programmable robot during the first operating cycle routine cleans only some of the individual elements to be cleaned at each operating position and during the second operating cycle routine suction cleans all individual elements to be cleaned at each operating position.
As already alluded to above, the invention is not only concerned with the aforementioned method aspects, but further pertains to an improved cleaning apparatus for the cleaning of the different operating positions of a textile machine. Such cleaning apparatus, as contemplated by the present invention, is manifested by the features that there is provided a cleaning device which is mobile or movable upon rails or rail means along the various or predeterminate ones of the operating positions of the textile machine. The cleaning device comprises a suction cleaning device containing a programmable robot equipped with a suction trunk or nozzle, and means serve for controlling operation of the programmable robot such that the suction trunk or nozzle thereof is selectively moveable to predeterminate ones of the individual elements of the operating positions to be suction cleaned.
Due to the practice of the teachings of the present invention there is realized the notable advantage that the parts or elements of the textile machine, such as those of the spinning unit influencing the spinning result are extensively maintained free of undesired contaminants or impurities, in particular free of fiber particles or fiber accumulations.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings, wherein throughout the various figures of the drawings there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 schematically illustrates a section through approximately one-half or one side of a textile machine, here a spinning machine together with a cleaning apparatus constructed and operating in accordance with the present invention; and
FIG. 2 schematically illustrates a plan view of the complete spinning machine of FIG. 1 together with the cleaning apparatus constructed and operating in accordance with the present invention and as shown in FIG. 1, both the spinning machine and the associated cleaning apparatus being depicted on a scale which is smaller in comparison with that used in the showing of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that to simplify the showing thereof only enough of the structure of the inventive cleaning apparatus for cleaning a textile machine containing a plurality of typically generally similar or identical operating positions has been illustrated therein as is needed to enable one skilled in the art to readily understand the underlying principles and concepts of this invention. Turning attention now specifically to FIG. 1 of the drawings, there is depicted therein a textile machine, here for instance a spinning machine 1 containing a suitable spinning assembly or unit 2 in which a fiber sliver 4 extracted from a spinning or sliver can 3 is spun to a yarn or thread 5 which finally is wound up on a conventional bobbin or spool in order to form a yarn or thread package 6, as is well known in this technology.
Following the spinning assembly or unit 2, the yarn or thread 5 or the like is acted upon by a withdrawal roller pair 7 and is then delivered to a suitable yarn or thread traverse element 8 and by means of a friction or drive roller 9 to the bobbin or spool at which there is formed by winding the wound thread or yarn package 6.
The spinning machine 1 can be, for instance, any one of a rotor open-end spinning machine, a friction open-end spinning machine or an air-jet spinning machine. All three of these just-mentioned textile spinning machine types use known spinning methods or techniques and machine designs so that a more detailed description thereof need not be here undertaken, particularly since such details are not needed for understanding the underlying principles and concepts of the present invention.
Parallel to the symmetry plane E of the spinning machine 1, indicated in FIGS. 1 and 2 by dash-dotted lines, there is arranged a movable or mobile cleaning device 10 for cleaning the spinning machine 1. This movable or mobile cleaning device 10 is arranged to travel on rails or rail means 11 or equivalent guide structure under the action of drive means 10b in order to achieve the movement substantially parallel to the symmetry plane E as described hereinafter.
As will be apparent from an inspection of FIG. 2, the rails 11 are disposed in substantially parallel relationship to one another and to the plane of symmetry E on both sides of this symmetry plane or plane of symmetry E but also extend around one end of the spinning machine 1, so that the cleaning device 10 can be effectively used on both sides of such spinning machine 1.
FIG. 2 also shows the opposite located spinning machine end equipped with the drive head 12 and schematically indicates, by means of the two rows of rectangles 13, the two rows of operating positions, here the spinning positions, each of which comprises the same elements as those depicted for the spinning machine 1 as illustrated in FIG. 1 and discussed previously with reference thereto. Each rectangle represents one spinning position.
The cleaning device 10 for cleaning the spinning positions 13 constitutes a known type of robot, generally indicated by reference character 10a, provided with a suction trunk or nozzle 14, for example, as is commercially available from the well-known Swedish corporation ASEA.
It is known in practice that such robots are moveable with at least three degrees of freedom of motion or movement, and in the present case under discussion the direction of movement of the robot 10a substantially parallel to the symmetry plane E forms an additional degree of freedom of movement. The three degrees of freedom of movement of the illustrated robot 10a itself are defined by the robot moveability or mobility about the pivot axes S.1, S.2 and S.3. A still further degree of freedom of movement is defined by the pivotability of the suction trunk 14 of the robot 10a about the substantially vertical pivot axis S.4. The suction trunk 14 of the controllably movable robot 10a is thus capable of undertaking controlled motion which enables it to effectively reach objects or elements which are to be suction cleaned and which, seen from the viewpoint of the robot 10a, are not located in a directly visible position.
Furthermore, it is known that such robots are programmable in all their degrees of freedom of movement. Additionally, there can be readily programmed the desired movement or travel motion of the robot 10a on the rails 11.
The suction trunk or nozzle 14 also has an extension or prolongation 50 (FIG. 2) in the suction air direction, which trunk extension or prolongation 50 terminates or finally ends in a suitable dirt extractor or in a conventional underpressure generator (not shown) operatively connected thereto. This entire assembly is conveniently referred to as a suction device, merely generally indicated in FIG. 2 by reference character 60, which is operatively associated with the programmable and thus controllable robot 10a.
Before use of the programmable robot 10a and the associated suction device 60, this programmable robot 10a is precisely located at a spinning position 13 by means of a positioning element 15 provided at each spinning position 13. The programmable robot 10a is then caused to simulatingly move through various desired movements with respect to the individual elements at the spinning position 13 of the spinning machine 1. These robot movements, which simulate the desired movements of the programmable robot 10a during the actual cleaning of each of the spinning positions 13 of the spinning machine 1, are then inputted in the form of appropriate electrical signals to the control computer 52 and programmed therein. Since the individual elements at each spinning position 13 are identical the established program now appearing at the control computer or computer 52 can be used for performing the same suction cleaning operation at each of the similar or identical spinning positions 13. There also can be conventionally programmed the further travel of the programmable robot 10a to the immediately next or next desired spinning position 13 and return travel of the programmable robot 10a to a predetermined starting position B (FIG. 2) after the cleaning operation has been carried out at all spinning positions 13, and possibly waiting at the starting position B until receiving a new start command for again performing the desired suction cleaning operation; this is generally conveniently designated an operating cycle. Furthermore, emptying of the dirt extractor into a suitable collector duct (not shown) is also carried out at this robot starting position B.
As a refinement in the operation of the system there obviously could be obtained a number of different cleaning programs for each spinning position by appropriately simulatingly moving the programmable robot 10a in the aforedescribed manner to predeterminate individual elements at the associated spinning position 13, for instance a program entailing only cleaning, for example, the spinning unit 2 and the withdrawal roller pair 7. There thus would be available at the computer 52 a number of different possible cleaning programs for cleaning the spinning positions 13 depending upon the type and intensity of the cleaning operation intended for the spinning positions 13.
After programming the desired operation of the programmable robot 10a by undertaking the aforedescribed procedures, the programmable robot 10a can be set in operation for carrying out the desired operating cycle by means of a control device 54 operatively associated with the control computer 52 and provided for the programmable robot 10a.
In keeping with the foregoing explanations and as a modification of the initially explained operation of the cleaning device 10 and the programmable robot 10a thereof, the suction cleaning program can be perfected such that the programmable robot 10a performs suction cleaning during one or a first operating cycle or operating cycle routine, for example only on those individual elements of the preselected operating positions which are most prone to fouling by contaminants or impurities, such as dust or fiber accumulations. Then during the next succeeding operating cycle or operating cycle routine, however, all elements of each spinning position 13 to be cleaned are again subjected to the suction cleaning operation.
Basically, other variations in the operation of the cleaning apparatus can also be readily carried out by simply establishing a suitable program or programs as will obviously suggest themselves to those skilled in the art, so that the invention is not to be construed in any way as limited to the described programs or program combinations.
Equally, the method or the cleaning apparatus of the present development, or both, can be used on other textile or spinning machines, for example ring spinning machines, winders, roving frames or on other quite different types of textile machines generally, where these textile machines have a row of similar or identical operating positions (called spinning positions in spinning machines).
Furthermore, the invention is not limited to the use of a programmable robot travelling on floor-mounted rails. A so-called "head-down" version, in which the rails or robot travel or support means are mounted in a ceiling structure or the like and the programmable robot is suspended head-down from its foot portion, can also be used for carrying out the method.
Furthermore, the programmable robot 10a can also be used for servicing a plurality of spinning machines.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. accordingly, | A textile machine, such as a spinning machine, is suction cleaned from spinning position to spinning position by a movable programmable robot provided with a suction device. This enables individual elements of the spinning machine prone to impurity or contaminant fouling to be maintained effectively free of such impurity depositions including fiber accumulations and the like without requiring use of the heretofore employed blowing-suction fucntion. The movable programmable robot is controlled by virtue of its being programmaged such that a suction trunk or nozzle thereof is guided in such close proximity to the individual elements to be suction cleaned that the suction cleaning operation can be effectively carried out and in a short period of time, following which the movable programmable robot is moved to the next spinning position for performance of the same or desired suction cleaning operation. | 3 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a holding unit of a vacuum machining device and a method of manufacturing an element.
[0002] In a process of manufacture semiconductor elements, wafer processing steps, e.g., forming film layers on a wafer, etching the film layers, are frequently executed. During the wafer processing steps, the wafer is held and its surface is exposed to be machined.
[0003] A summarized structure of an ion milling device for etching a work piece is shown in FIG. 3. A symbol 10 stands for a vacuum chamber; a symbol 12 stands for an ion gun; a symbol 14 stands for a grid; a symbol 16 stands for a holder for holding the work piece 20 ; and a symbol 18 stands for a pressing ring for pinching the work piece 20 with the holder 16 .
[0004] The pressing ring 18 presses an outer edge of the work piece 20 to pinch and hold the work piece 20 with the holder 16 . Inner diameter of the pressing ring 18 is designed according to outer diameter of the work piece 20 . To make an exposed surface of the work piece 20 broader, width of the pressing ring 18 , which presses the outer edge of the work piece 20 , is designed 2-3 mm. The pressing ring 18 is fixed to the holder by screws 19 .
[0005] A process of etching patterns on the work piece by ion milling will be explained with reference to FIGS. 4 A- 4 C. In FIG. 4A, a film layer 6 to be etched is formed on a substrate 5 of a work piece, and a resist layer 7 , which has been formed into a prescribed shape, is formed on the film layer 6 . The resist layer 7 exposes parts of the film layer 6 , which will be removed by etching. In this state, the film layers 6 , which has been masked with the resist layer 7 , is etched, by ion milling, so as to remove the film layer 7 of the exposed parts (see FIG. 4B). In FIG. 4C, the resist layer 7 has been removed after the ion milling. The film layer 6 , whose shape corresponds to the shape of the resist layer 7 , is left on the surface of the substrate 5 .
[0006] In the above describe ion milling treatment, ions are radiated toward not only the work pieces 20 but also the pressing ring 18 , which is headed for the ion gun 12 (see FIG. 3). Upon colliding ions, the work piece 20 and the pressing ring 18 are heated.
[0007] If the work piece 20 is excessively heated, the resist 7 changes in quality, so that the film pattern cannot be correctly formed. Thus, in the conventional ion milling device, cooling water is introduced into the holder 16 so as to cool the work piece 20 .
[0008] Since the pressing ring 18 is fixed to the holder 16 by the screws 19 , the pressing ring 18 is slightly cooled by the water in the holder 16 . But contact area between the screws 19 and the pressing ring 18 is quite small, so the water in the holder 16 cannot effectively cool the pressing ring 18 .
[0009] With this structure, the pressing ring 18 of the conventional device is excessively heated, so that parts of the work piece 20 , which are directly pressed by the pressing ring 18 , will be also excessively heated. By excessively heating the work piece 20 , the resist 7 is partially fused together with the work piece 20 .
[0010] If the resist 7 is fused together with the work piece 20 , the edge part of the work piece 20 , on which the resist 7 is partially left, cannot be used for manufacturing elements, so that efficiency of manufacturing the elements is reduced. A plurality of the work pieces 20 are simultaneously processed in the ion milling device, so it is inefficient for manufacturing the elements to make the disusable parts in each work piece 20 .
[0011] In a device for forming the film layers on the work piece, the work piece 20 is pinched by the holder 16 and the pressing ring 18 so as to set and be processed as well as the ion milling device. So, the device also has disadvantages of excessively heating the pressing ring 18 and badly influencing the work piece 20 .
SUMMARY OF THE INVENTION
[0012] The present invention is invented to solve the problems occurred by excessively heating the work piece in the vacuum machining device, e.g., the ion milling device, the film forming device. Objects of the present invention are to provide a holding unit of a vacuum machining device and a method of manufacturing an element, which are capable of preventing the work piece from being excessively heated and capable of stably machining the work piece.
[0013] To achieve the objects, the present invention has following constitutions.
[0014] The holding unit of the present invention comprises: a holder for holding a work piece; a pressing member for pinching the work piece with the holder; and a heat insulating member being provided to the holder, the heat insulating member contacting the work piece to restrict heat conduction thereto.
[0015] Another holding unit of the present invention comprises: a holder for holding a work piece; a pressing member for pinching the work piece with the holder; and a heat insulating member being provided to the pressing member, the heat insulating member contacting the work piece to restrict heat conduction thereto.
[0016] In the holding unit, the pressing member may be formed into a ring shape, and an inner edge of the pressing member may contact the work piece.
[0017] In the holding unit, the insulating member may be wholly circumferentially provided on a contact face of the pressing member, which is capable of contacting the work piece.
[0018] The method of the present invention comprises the steps of: pinching the work piece by a holder and a pressing member, wherein a heat insulating member contacts the work piece; and processing the work piece, which is pinched between the holder and the pressing member, in a vacuum machining device.
[0019] In the method, film layers may be formed on the work piece in the processing step.
[0020] In the method, the work piece may be etched in the processing step.
[0021] In the holding unit and the method of the present invention, the work piece is not excessively heated by heat conduction from the pressing member even if the pressing member is heated in the vacuum machining device. Therefore, changing quality of the resist layer, etc., which are formed on the surface of the work piece, can be prevented; yield of manufacturing the elements can be improved; and the work piece can be correctly machined.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Embodiments of the present invention will now be described by way of examples and with reference to the accompanying drawings, in which:
[0023] [0023]FIGS. 1A and 1B are perspective views of a holding unit of an embodiment;
[0024] [0024]FIG. 2 is a sectional view of the holding unit;
[0025] [0025]FIG. 3 is an explanation view showing a summarized structure of an ion milling device; and
[0026] FIGS. 4 A- 4 C are explanation views showing a process of etching by ion milling.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[0028] [0028]FIGS. 1A and 1B are perspective views of a holding unit of the present embodiment. In the figures, a symbol 16 stands for a holder for holding a work piece 20 , and a symbol 18 stands for a pressing ring for pressing an outer edge of the work piece 20 toward the holder 16 to pinch the work piece 20 . Basic structures of the holder 16 and the pressing ring 18 are as same as those of the conventional device shown in FIG. 3. The work piece 20 shown in FIG. 1 is a wafer. The holder 16 and the pressing ring 18 are made of metals. Inner diameter of the pressing ring 18 is 2-3 mm shorter than diameter of the wafer 20 .
[0029] The pressing ring 18 has through-holes 22 through which screws 19 are respectively pierced; the holder 16 has screw holes 24 .
[0030] In FIG. 1B, the pressing ring 18 is fixed to the holder 16 by the screws 19 so as to hold the work piece 20 on the holder 16 . The work piece 20 is held by the manner as well as the conventional device.
[0031] A characteristic point of the present embodiment is the structure of the pressing ring 18 . Namely, there is provided a heat insulating member 30 , e.g., rubber, on a contact face of the pressing ring 18 , which is capable of contacting the work piece 20 . By the heat insulating member 30 , heat conduction from the pressing ring 18 to the work piece 20 can be restricted.
[0032] [0032]FIG. 2 is a sectional view showing a state of holding the work piece 20 on the holder 16 by the pressing ring 18 . The heat insulating member 30 is stuck on a bottom face of the pressing ring 18 , so the work piece 20 is pressed onto the holder 16 by the heat insulating member 30 .
[0033] By providing the heat insulating member 30 between the pressing ring 18 and the work piece 20 , the heat generated in the pressing ring 18 cannot be directly conducted to the work piece 20 , so that changing quality of the resist, etc., which are formed on the work piece 20 , can be prevented.
[0034] The pressing ring 18 presses an outer edge of the work piece 20 to hold the work piece 20 on the holder 16 , so the heat insulating member or members should be provided to a specific part or parts of the pressing ring 18 , which are capable of contacting the work piece 20 . In the present embodiment, the bottom face of the pressing ring 18 is wholly covered with the heat insulating member 30 , but the bottom face of the pressing ring 18 may be partially covered with the heat insulating member 30 . By providing the heat insulating member 30 , the work piece 20 can be securely held. A plurality of theheat insulating members 30 may be arranged in the circumferential direction with regular separations.
[0035] The heat insulating member 30 is provided to restrict the direct heat conduction from the pressing ring 18 to the work piece 20 when the pressing ring 18 is excessively heated. Therefore, various materials, which are capable of fully insulating the heat conduction, can be employed as the heat insulating member. For example, resin materials, e.g., silicone rubber, glass wool, etc. may be employed as the heat insulating member 30 . Heat conductivity of the heat insulating member 30 is lower than that of the holder 16 and the pressing ring 18 . Thickness of the heat insulating member 30 may be designed according to the heat conductivity between the pressing ring 18 and the work piece 20 . In some cases, temperature in the vacuum machining device is very high, so the heat insulating member 30 should be made of a material, which has enough heat-resisting property and which generates no gas when the heat insulating member 30 is heated. For example, in the case of machining the wafer 20 whose diameter is about 100-150 mm and whose thickness is about 2-4 mm, thickness of the heat insulating member 30 may be about 1 mm.
[0036] In FIG. 2, a symbol 26 stands for a supporting member provided on an upper face of the holder 16 . The work piece 20 is pinched and held between the supporting member 26 and the heat insulating member 30 of the pressing member 18 . The supporting member 26 is provide so as to securely hold the work piece 20 . If the heat insulating member 30 , which is provided to the pressing ring 18 , is made of a material having slight cushioning property, e.g., rubber, the screws 19 can securely hold the work piece 20 .
[0037] Cooling water may be introduced into the holder 16 to cool the holder 16 and the work piece 20 . By cooling the holder 16 , the pressing ring 18 can be slightly cooled via thescrews 19 .
[0038] In the holding unit of the vacuum machining device of the present embodiment, the direct heat conduction from the pressing ring 18 to the work piece 20 is restricted even if the pressing ring 18 is excessively heated while machining, e.g., ion milling; the changing quality of the resist layer, etc., which are formed on the surface of the work piece 20 , can be prevented.
[0039] In the case of employing the conventional holding unit, in which the work piece 20 is directly pressed and pinched by the pressing ring 18 without the heat insulating member, in the ion milling device, rate of producing bad products is about 14%; by employing the holding unit of the present embodiment, which includes the heat insulating member 30 , in the ion milling device, the rate of producing bad products can be reduced to about 1.64%.
[0040] Materials of the film layers, which are formed on the work piece, and the resist layer, which is formed for etching the film layers, are selected on the basis of their heat-resisting properties and processing temperature of the vacuum machining device. In the case that the processing temperature is high and in the case that the specific part or parts of the pressing ring 18 , which contact the work piece 20 , are partially excessively heated, it is advantageous to employ the holding unit of the present invention. The holding unit of the present invention can be realized by attaching the heat insulating member 30 to the pressing ring 18 , so the conventional holding unit can be used.
[0041] Note that, the vacuum machining device is used for not only forming and processing the film layers but also manufacturing liquid crystal displays, etc.. The holding unit of the present invention may be employed in many cases in which a work piece is held by the pressing member and machined in the vacuum machining device.
[0042] The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and ranging of equivalency of the claims are therefore intended to be embraced therein. | The holding unit of a vacuum machining device is capable of preventing a work piece from being excessively heated and capable of stably machining the work piece. The holding unit comprises: a holder for holding a work piece; a pressing member for pinching the work piece with the holder; and a heat insulating member being provided to the holder, the heat insulating member contacting the work piece to restrict heat conduction thereto. | 2 |
FIELD OF THE INVENTION
This invention relates generally to the field of rail transportation, and more particularly to the field of rail lubrication systems, and specifically to a wayside rail lubrication apparatus and method.
BACKGROUND OF THE INVENTION
A typical train includes one or more locomotives pulling a plurality of load cars. Each vehicle in the train includes a plurality of metal wheels that roll along the metal rail as the train is propelled along the track. The rolling contact between the wheel and the rail provides an efficient mode of transportation, particularly for heavy loads. Proper interaction between the wheel and the rail is critical for safe, reliable, efficient operation of the train.
A rail includes a bottom mounting flange, a top railhead that makes contact with the vehicle wheel, and a flange interconnecting the flange and the railhead. A vehicle wheel includes a center hub mounted onto the vehicle axle, a plate extending outwardly from the hub, and an outer rim surrounding the plate for making contact with the rail. The rim includes an outside diameter tread that may be flat or tapered and a flange extending outwardly from a back side of the tread. The tread rides along a top surface of the railhead for supporting the vertical weight of the vehicle. The flange extends along and makes contact with a side of the railhead for providing lateral support to allow the wheel to follow along the path of the railhead. Flanges are provided on only one side of each wheel along an inside of the rail. As a train negotiates a curve in the track, the flanges of the outer diameter (high side) wheels provide the lateral forces for turning the train.
Rail vehicle wheels suffer wear over time due to their contact with the rail. The treads wear as a result of their contact with the top of the rail, particularly in the event of the wheel slipping with respect to the rail during acceleration or braking events. The wheel flanges will wear due to their contact with the inside surface of the railhead, particularly on curves and through switches. It is known in the art to provide lubrication between the wheel and the rail in order to reduce wheel wear and to provide more efficient movement of the wheel over the rail. Lubrication may be provided on the top of the rail to reduce rolling friction at any location. Flange lubrication systems are especially useful in curved areas of the track where the forces between the railhead and the flange are at their maximum. Both on-board and wayside lubrication systems are used. On-board systems are useful for applying lubricant at any location along a rail line. Wayside lubrication systems are typically installed only at curved locations of the track. In some situations, it is desirable to apply lubrication between the wheel and the flange in order to minimize wear of the flange, while at the same time it is undesirable to apply lubrication to the top of the rail because of the reduction in traction that may be generated against a lubricated rail. In general, it is desired to achieve adequate lubrication while minimizing the amount of lubricant used so that the location of the lubricant can be precisely controlled, the cost minimized, and the impact upon the surrounding environment abated.
Numerous patents have issued for systems that control the amount, timing and location of lubrication applied between a wheel and a rail. U.S. Pat. No. 6,182,793 describes an on-board lubricant delivery system that changes the rate of application with the speed of the train. U.S. Pat. No. 6,009,978 describes an on-board lubricant delivery system that applies lubrication only when the rail vehicle is on a curved section of track. U.S. Pat. No. 5,896,947 describes an on-board lubricant delivery system that applies flange lubrication at the front of a locomotive and also applies both flange lubrication and top-of-rail lubrication at the rear of the locomotive. This system controls the rate of lubrication in response to train speed, track curvature, trailing tonnage, temperature, direction of travel, status of braking, and high rail verses low rail. U.S. Pat. No. 6,199,661 describes a computer-controlled on-board lubrication system that applies a lubricant only in a quantity that will be consumed by the time the entire train has passed.
Wayside lubrication systems are commonly activated by the weight of a passing vehicle. The weight of the vehicle is sometimes used as the source of energy for pumping the lubricant, as described in U.S. Pat. Nos. 4,334,596 and 5,076,396. Known wayside lubricating systems often dispense an inappropriate amount of lubrication and/or dispense lubrication when it is not beneficial. U.S. Pat. No. 4,856,617 describes a wayside lubricating system that incorporates a test cycle to provide compensation for changes in lubricant viscosity as a function of temperature. However, further improvements to wayside lubrication systems are needed.
BRIEF SUMMARY OF THE INVENTION
Accordingly, a wayside lubrication apparatus is described herein as including a sensor associated with a first position on a rail for producing a lubrication signal when a locomotive pulling a plurality of load cars passes the first position; and a lubricant dispensing apparatus for applying a lubricant to the rail at a second position on the rail in response to the lubrication signal, the lubricant adapted to reduce the friction between wheels of the load cars and the rail, the first position and the second position being separated by a distance on the rail sufficient to prevent the lubricant from contacting drive wheels of the locomotive. In a further embodiment, a wayside rail lubrication apparatus is described as including: a detection apparatus for providing a lubrication signal in response to the presence of a vehicle on a rail; a lubricant dispensing apparatus for applying a lubricant to the rail in response to the lubrication signal; and a bypass device for selectively preventing the lubricant dispensing apparatus from applying the lubricant in response to the lubrication signal. The bypass device may include an operator input device located in the vehicle for controlling the bypass device from the vehicle.
A wayside rail lubrication apparatus is further described as including: a lubricant dispensing apparatus for applying lubricant to a rail; and a means for controlling an amount of lubricant applied by the lubricant dispensing apparatus over a predetermined time period. The means for controlling may be a timer for providing a time signal, and the apparatus may include a controller for controlling the operation of the lubricant dispensing apparatus in response to the timer. The apparatus may further include: a lubricant container; a pump for delivering lubricant from the lubricant container to the rail; and a device for refilling the lubricant container with lubricant at no more than a predetermined rate.
A wayside rail lubrication apparatus is described as including: a means for applying lubricant to a rail in response to the presence of a vehicle wheel at a location on the rail; and a means for delay associated with the means for applying lubricant for delaying the application of lubricant for a time period after the vehicle wheel is present at the location on the rail. The means for delay may be an empty volume downstream of a lubricant pump.
A wayside rail lubrication apparatus is described as including: a sensor for producing a lubrication signal responsive to the presence of a train on a rail, the train comprising a locomotive pulling a plurality of load cars; and a means for applying a lubricant to a section of the rail in response to the lubrication signal only after the locomotive has passed the section of rail.
A method of applying lubricant to a rail is described herein as including: applying a first quantity of lubricant to a rail at a first time in response to the presence of a first rail vehicle; sensing the presence of a second rail vehicle at a second time; and applying a second quantity of lubricant to the rail at a second time in response to the presence of a second rail vehicle, the second quantity of lubricant being responsive to the time span between the first time and the second time.
A method of applying lubricant to a rail is further described as including: sensing the presence of a train on a rail; applying a lubricant to a section of the rail in response to the presence of the train after a locomotive at a head of the train has passed the section of rail; and terminating the application of lubricant to the section of rail before an end of the train passes the section of rail so that the quantity of lubricant on the section of rail is reduced by wheels of a plurality of cars proximate the end of the train.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will become apparent from the following detailed description of the invention when read with the sole accompanying drawing which is a schematic illustration of a train passing over a section of rail serviced by a wayside lubrication system.
DETAILED DESCRIPTION OF THE INVENTION
A wayside lubrication apparatus 10 is shown in FIG. 1 as being installed along a rail 12 over which is passing a train 14 having two locomotives 16 and a plurality of load cars 18 . The locomotives 16 at the head of the train 14 are located at a first position 20 along the rail 12 , for example at the beginning of a curved section of the rail 12 .
The wayside lubrication apparatus 10 includes a lubricant dispensing apparatus 22 incorporating a pump 24 for supplying a lubricant 26 to rail 12 through applicator 28 . The lubricant 26 may be a petroleum or soybean based oil, a molybdenum or graphite grease or any of the specialty rail lubricants known in the art. The applicator may be a spray nozzle, mechanical wiper, dispenser tube outlet or other known mechanism.
The operation of lubricant dispensing apparatus 22 is controlled by a controller 30 , although less sophisticated systems also described herein may not require the control processes utilized in the system shown in the figure. Controller 30 may include a switch, relay, microprocessor, or other known form of process control device. In one embodiment, controller 30 includes machine-executable logic expressed in the form of software and/or firmware. Controller 30 functions to operate pump 24 in response to a lubrication signal 32 provided by a train head 4 sensor (S H ) 34 located proximate first position 20 of rail 12 . Sensor 32 produces lubrication signal 32 in response to the presence of train 14 at first position 20 by sensing the weight of locomotive 16 or by other known method, such as optical, infrared and/or sonic technologies.
Lubricant dispensing apparatus 22 is located at a second position 36 along rail 12 that is separated from the first position 20 by a distance along rail 12 sufficient to prevent the lubricant from contacting drive wheels 38 of locomotives 16 . In this manner, the lubricant 26 applied by wayside lubrication apparatus 10 will function to reduce the friction between the rail 12 and the wheels 40 of the load cars 18 , but will not reduce the traction capability of the locomotive drive wheels 38 . The distance D between the first 20 and second 36 position along the rail 12 may be selected to span the length of the largest locomotive consist used on the particular rail line.
In certain applications it may not be possible to separate sensor 34 and applicator 28 by a distance D sufficient to prevent lubricant 26 from contacting the locomotive drive wheels 38 . For such applications, it may be desirable to include a timed delay between the generation of lubrication signal 32 and the actual start of the application of the lubricant 26 onto rail 12 . A timer 42 may be incorporated into controller 30 or provided as a discrete device for providing a time signal 44 to controller 30 . Logic executed by controller 30 provides that pump 24 is energized only after a predetermined time interval has elapsed after receipt of lubrication signal 32 by controller 30 . In this manner, lubricant dispensing apparatus 22 will operate to provide lubricant 26 to only the wheels 40 of the load cars 18 and not to the drive wheels 38 of locomotives 16 . The time interval of this embodiments functions as the equivalent to distance D described above. Furthermore, the time interval may be changed in response to other inputs received by controller 30 . For example, it is possible to detect the speed of the train 14 and to correlate the speed to the time delay required to achieve an effective distance D. As the speed of the train increases, the required time delay decreases. Furthermore, it is possible to detect the type and/or number of locomotives 16 included in train 14 and to correlate such information to a required effective distance D. As the size of the locomotive 16 and/or the number of locomotives 16 in the consist increase, the required time delay increases.
A time delay may also be implemented by the rime necessary to fill delivery tube 27 with lubricant. Delivery tube 27 may be empty of lubricant when pump 24 is first energized, and the internal volume of tube 27 will be filled before the lubricant begins to be expelled from applicator 28 . To ensure that delivery tube 27 is empty when pump 24 is first energized, a drain capability may be provided.
In a further embodiment, each axle of train 14 may function to pump a small quantity of lubricant through applicator 28 , either by the pumping action of the axle force on the rail or by the intermittent actuation of pump 24 in response to each axle passing a point on the rail 12 . In this manner, the total quantity of lubricant applied to the rail 12 as a result of the limited number of axles of the locomotive(s) will be insufficient to effectively lubricate the rail 12 . Only after a greater quantity of axles have passed over the point on the rail 12 will there be sufficient lubricant 26 to provide an effective degree of lubrication.
Time signal 44 may also be used to prevent the lubrication of rail 12 more often than is necessary to maintain a desired level of lubrication in the event of closely spaced trains 14 . Lubricant 26 applied to the rail 12 will lose its effectiveness due to a number of factors, including the time period since its application. Most lubricants 26 will flow away from the desired area of the rail 12 over time as a function of the viscosity of the lubricant 26 . Furthermore, many lubricants are formulated to be rapidly biodegradable in order to minimize their impact on the environment. Therefore, if a second train follows a first train 14 within a relatively short time period, no further lubrication of the rail 12 may be needed. Accordingly, controller 30 may be programmed with logic establishing a minimum time period between applications of lubricant 26 in order to conserve lubricant.
It may also be desirable to terminate the application of lubricant 26 prior to the time when all of the load cars 18 have passed the applicator 28 . The wiping/cleaning action of the wheels 40 of the load cars 46 at the rear of the train 14 can function to reduce the quantity of lubricant 26 remaining on the rail 12 after the train 14 has passed in order to prevent the lubricant 26 from adversely affecting the traction performance of any following locomotives. An end of train sensor (S E ) 48 may be located at a third position 50 along rail 12 to produce a train end signal 52 responsive the end of train 14 passing third position 50 . Train end signal 52 is processed by controller 30 to terminate the application of lubricant 26 before a predetermined number of rear load cars 46 pass the location of the applicator 28 . This process may include consideration of the speed of the train 14 and/or variables affecting the cleaning efficiency of the rear load cars 46 , such as temperature for example.
Environmental conditions such as temperature, rail, snow, fog and wind may effect the performance of the lubricant 26 on the rail 12 . It may be desirable to include as part of wayside lubrication apparatus 10 an environmental sensor such as moisture sensor (S M ) 54 for detecting the presence of moisture on rail 12 . Because water is a lubricant, it may be unnecessary to provide additional lubricant 26 when the rail 12 is wet from rain, snow or fog. A moisture signal 56 responsive to such environmental conditions may be used by controller 30 to prevent the application of lubricant 26 by the lubricant dispensing apparatus 22 in response to a predetermined environmental condition.
It may also be advantageous to provide for human intervention to prevent the application of lubricant 26 in response to the lubrication signal 32 . For example, in a system not having a moisture sensor 54 , it may be desirable to provide an operator on-board the train 14 with the capability of bypassing the operation of the lubricant dispensing apparatus 22 during wet operating conditions. One such bypass device 58 includes a wireless communication system transmitter 60 responsive to an operator action on-board locomotive 16 and an associated wireless communication system receiver 62 for producing a bypass signal 64 responsive to the operator action. Controller 30 may be programmed with instructions for bypassing the operation of pump 24 in spite of the presence of lubrication signal 32 in the presence of bypass signal 64 . Wireless communication system receiver 62 may further be responsive to a wireless signal initiated by a central control facility or weather measuring facility (not shown) positioned at a remote location. The bypass device 58 may alternatively include a hard-wired communication device for receiving a bypass signal 64 from a remote location.
Pump 24 may draw lubricant 26 directly from a large reservoir 66 , or as illustrated in the figure, from a smaller lubricant container 68 . Lubricant 26 is provided to the container 68 by gravity or preferably via forced flow. In order to limit the total volume of lubricant 26 that can be applied to rail 12 over a short period of time, a refilling device 70 is provided for adding lubricant 26 to the lubricant container 68 at no more than a predetermined rate. The refilling device 70 may include a controlled flow pump (not shown), a valve 72 controlled by controller 30 , and/or an orifice 74 located in a lubricant container refilling line 76 . Any one or combination of such devices function to limit the accumulation of lubricant 26 within container 68 , thereby limiting the amount of lubricant 26 available for delivery to applicator 28 by pump 24 . After a sufficiently long time period has elapsed since the previous lubricant application, lubricant container 68 will be completely full and a full charge of lubricant 26 can be delivered to rail 12 in response to lubrication signal 32 . If the time period elapsed since the previous lubricant application is not sufficiently long, the amount of lubricant applied to rail 12 by lubricant dispensing apparatus 22 in response to the presence of a second train 14 will be correspondingly reduced from a full charge amount.
While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those of skill in the art without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims. | A wayside lubrication apparatus ( 10 ) for applying a lubricant ( 26 ) to a second position ( 36 ) of a rail ( 12 ) in response to the head of a train ( 14 ) being proximate a first position ( 20 ) of the rail. The distance (D) between the two positions prevents the lubricant from reducing the traction capability of the drive wheels ( 38 ) of the locomotives ( 16 ). The application of the lubricant is terminated before a number of rear load cars ( 46 ) passes the lubricant applicator ( 28 ) so that the residual lubricant remaining on the rail after the train has passed is reduced. Operation of the lubricant dispensing apparatus ( 22 ) may be bypassed by an operator-controlled bypass device ( 60 ) or in response to a signal ( 56 ) indicating moisture on the rail. To avoid excessive lubricant on the rail, a timer ( 42 ) is used to prevent repeated applications of lubricant within a predetermined time period, and/or a lubricant container ( 68 ) is refilled at a controlled rate to proportion the amount of lubricant applied in response to a second consecutive train. | 1 |
This application is a continuation of application Ser. No. 07/998,745 filed on Dec. 30, 1992, now abandoned.
The present invention relates to a method for producing naphthalenedicarboxylic acids and diaryldicarboxylic acids by the oxidation of dialkyl-substituted naphthalene compounds and of dialkyl-substituted diaryl compounds with a gas containing molecular oxygen under liquid-phase conditions in an organic solvent.
BACKGROUND OF THE INVENTION
Conventionally, it is known that films and various by-products made of polyethylene naphthalate, which is formed by reacting 2,6-naphthalenedicarboxylic acid and ethylene glycol, have improved mechanical strength, heat-resistance, size stability etc. relative to those produced from polyethylene terephthalate which is formed from terephthalic acid.
As for the production of 2,6-naphthalenedicarboxylic acid (hereinafter referred to as 2,6-NDA), the following methods are known. (A) Methods of producing 2,6-NDA by the oxidation of dialkyl-substituted naphthalene with molecular oxygen in an acetic acid solvent in the presence of a catalyst comprising cobalt, manganese and bromine (Japanese Publication for Examined Patent applications No. 48-27318/1973, No. 56-3337/1981, Japanese Publication for Unexamined Patent applications No. 61-140540/1986, No. 62-212345/1987, No. 64-3148/1989, No. 1-160943/1989 and No. 1-287055/1989).
Meanwhile, for the production of aromatic carboxylic acids, (B) a method disclosed in Japanese Publication for Unexamined Patent Application No. 52-77022/1977 and (C) a method disclosed in Japanese Publication for Examined Patent Application No. 60-56694/1986 are known.
In methods (A), when the reaction is started, a large amount of catalyst in proportion to the starting material is required in order to repress the formation of undesirable by-products, including tar-like substances and naphthalene ring-scissioned by-products such as trimellitic acid, and additionally to improve the yield of 2,6-NDA. Consequently, complicated industrial processes are required in these methods in order to separate and recover the catalyst after the reaction. Moreover, in order to obtain 2,6-NDA of a high purity, a number of refining operations are necessary.
In method (B), it is disclosed that in producing terephthalic acid with a catalyst comprising cobalt, manganese and bromine in an acetic acid solvent, if a small amount (ppm) of copper is added to the acetic acid solvent, the oxidative decomposition of the acetic acid solvent is repressed. In this method, however, adding copper does not stimulate the catalytic reaction, and therefore it is hard to believe that copper contributes to the catalytic reaction. In method (C) for producing terephthalic acid with a catalyst comprising copper and bromine in a water solvent, the highest yield of terephthalic acid (molar yield) is around 70 percent, and again no statement on 2,6-NDA is disclosed in this application.
As is clear from the prior art, a method of producing 2,6-NDA from dialkyl-substituted naphthalene at a high yield has not yet been fully established.
Meanwhile, diaryldicarboxylic acids are important compounds as copolymer components for the manufacture of fibers, films, plasticizers, synthetic resins etc.
Conventionally, the production of the diaryldicarboxylic acids by the oxidation of starting material with molecular oxygen in an acetic acid solvent in the presence of a catalyst comprising cobalt, manganese and bromine is known. For this kind of method, for instance, the following four methods are known: (1) A method of producing diaryldicarboxylic acids by the oxidation of 4,4'-dimethylbiphenyl (see Zh. Prikl. Khim.40 (4), 935-6 (1967)); (2) A method of producing diaryldicarboxylic acids by the oxidation of 4,4'-dimethylbiphenyl (see Japanese Publication for Unexamined Patent Applications No. 2-32041/1990 and No. 63-63638/1988); (3) A method of producing diaryldicarboxylic acids by the oxidation of 4,4'-diisopropylbiphenyl (see Japanese Publication for Unexamined Patent Application No. 63-122645/1988); and (4) A method of producing diaryldicarboxylic acids by the oxidation of 4,4'-dicyclohexylbiphenyl (see Japanese Publication for Unexamined Patent Application No. 57-16831/1982).
Also, (5) Japanese Publication for Unexamined Patent Application No. 63-310846/1988 discloses a method of producing various kinds of diaryldicarboxylic acids in the presence of the above-mentioned catalyst.
However, these methods present the following drawbacks. In method (1), 4,4'-biphenyldicarboxylic acids can be obtained at 79 mole percent yield by oxidizing 4,4'-dimethylbiphenyl with a catalyst comprising cobalt, manganese and bromine in an acetic acid solvent. However, the amount of the high-cost cobalt catalyst required is equivalent to 20 weight percent of the amount of the starting material, thereby resulting in a high production cost. Besides, 79 mole percent yield is not high enough.
In method (2), the reaction is carried out in an acetic acid solvent in the presence of a catalyst comprising cobalt, manganese and bromine, in order to obtain 4,4'-biphenyldicarboxylic acid at a high yield of at least 80 mole percent. However, since the amount of the high-cost cobalt catalyst required is equivalent to 15 weight percent of the amount of a substrate, this method also results in a high production cost.
In method (3), the reaction is carried out in an acetic acid solvent in the presence of a catalyst comprising cobalt, manganese and bromine equivalent to at least 15 weight percent of the amount of the starting material. This method achieves only a low yield of 35.8 mole percent.
In method (4), the reaction is carried out in the presence of a catalyst comprising similar catalyst components to the catalysts in methods (1), (2), (3), whose weight ratio to the starting material is at least 30 percent. However, this method also results in a low yield of 40 mole percent.
In method (5), diaryldicarboxylic acids are produced at a high yield of at least 90 mole percent by oxidizing various kinds of dialkyl-substituted diaryl compounds in the presence of a catalyst whose essential components are cobalt and bromine. However, the present inventors examined this method and found that the products had dark color. The following two reasons are listed for this cause: firstly, due to the cobalt catalyst; and secondly, the formation of large amounts of by-products which easily to color and of tar-like substances. Moreover, since the high-cost cobalt catalyst is essential in this method, industrially its production cost is not sufficiently low.
As aforesaid, in the above conventional methods, as large amounts of catalyst comprising high-cost cobalt catalyst are used, industrially sufficiently low production costs can not be achieved. Also, a method of producing diaryldicarboxylic acids having light color from the dialkyl-substituted diaryl compounds in the presence of the above-mentioned conventional catalysts with high yields of diaryldicarboxylic acids has not yet been established.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method of producing naphthalenedicarboxylic acids (NDA) efficiently by oxidizing dialkyl-substituted naphthalene under liquid phase conditions.
Another object of the present invention is to provide a method of producing 2,6-naphthalenedicarboxylic acid of a high purity at a high yield from 2,6-diisopropylnaphthalene.
A further object of the present invention is to provide a method of producing light-colored diaryldicarboxylic acids from dialkyl-substituted diaryl compounds with an improved yield of diaryldicarboxylic acids by the use of a reduced amount of a new and low-cost catalyst compared with the conventional methods.
In order to achieve the above objects, the present inventors have studied various catalysts for use as oxidation catalyst in the method of producing 2,6-NDA, and found that, as disclosed in U.S. Pat. No. 5,144,066, a catalyst comprising copper and bromine and a catalyst comprising copper, bromine and heavy metal can permit high yields of 2,6-NDA having high purity by the use of reduced amounts of catalyst compared with the case of using a standard catalyst comprising cobalt, manganese and bromine.
Since the reaction has a high calorific value with the use of such catalysts, the way of eliminating heat is a very important matter in accelerating the reaction. In order to eliminate heat, it is effective to increase the latent heat of vaporization of an organic solvent accompanied by the air by raising the reaction temperature.
Experiments were performed by increasing the latent heat of vaporization of an organic solvent. The results show that, when the above catalysts were used, the recovery of the organic solvent was considerably lowered because of the combustion of the organic solvent. It is discovered through the experiments that, by further reducing the amount of copper in the catalysts, i.e., by increasing the atom ratio of other components, it is possible to restrain the combustion of the organic solvent and to eliminate the heat of reaction when the reaction temperature is raised.
It is also discovered that water contained in the reaction mixture eliminates the heat of reaction more effectively and restrains the combustion of the organic solvent, thereby achieving improved yield of target product.
In addition, the above-mentioned catalysts are also effective as oxidation catalyst for the production of diaryldicarboxylic acids from dialkyl-substituted diaryl compounds.
Namely, the present invention consists in a method of producing naphthalenedicarboxylic acids of general formula (II) ##STR1## by oxidizing dialkyl-substituted naphthalene of general formula (I) ##STR2## (wherein R and R' represent an alkyl group selected from the group consisting of methyl, ethyl and isopropyl groups, and wherein R and R' can be the same or different from each other),
with a gas containing molecular oxygen under liquid phase conditions, and a method of producing diaryldicarboxylic acids of general formula (IV) ##STR3## (wherein A' represents either direct bonding, O, SO 2 or CO) from dialkyl-substituted diaryl compounds of general formula (III) ##STR4## (wherein A represents either direct bonding, O, S, SO 2 , CO or CH 2 , R and R' respectively represent an alkyl group of 1 to 6 carbons or an alicyclic hydrocarbon group, and wherein R and R' can be the same or different from each other),
both the methods using a catalyst whose active components are copper and bromine in an acetic acid solvent (the ratio of copper to bromine in numbers of atoms is 1:a, a being in the range of 100<a≦10000).
The present invention uses a catalyst whose active components are copper and bromine, and preferably uses catalysts of the following compositions:
1) A catalyst whose active components are copper, bromine and manganese, wherein the ratio of copper to bromine and manganese in numbers of atoms is 1:a:b, a being in the range of 100<a≦10000, b being in the range of 0.1≦b≦10000.
2) A catalyst whose active components are copper, bromine, manganese and heavy metal, wherein the ratio of copper to bromine, manganese and heavy metal in numbers of atoms is 1:a:b:c, a being in the range of 100<a≦10000, b being in the range of 0.1≦b≦10000, c being in the range of 0.1≦c≦10000.
3) A catalyst whose active components are copper, bromine and heavy metal, wherein the ratio of copper to bromine and heavy metal in numbers of atoms is 1:a:c, a being in the range of 100<a≦10000, c being in the range of 0.1≦c≦10000.
4) A catalyst whose active components are copper, bromine and amine compound, wherein the ratio copper:bromine:amine compound, that is the ratio of the number of atoms of copper to the number of atoms of bromine and the number of moles of amine compound, is 1:a:d, a being in the range of 100<a≦10000, d being in the range of 0.1≦d≦10000.
5) A catalyst whose active components are copper, bromine, amine compound and heavy metal, wherein the ratio copper:bromine:amine compound:heavy metal, that is the ratio of the number of atoms of copper to the number of atoms of bromine, the number of moles of amine compound and the number of atoms of heavy metal, is 1:a:d:e, a being in the range of 100<a≦10000, and d being in the range of 0.1≦d≦10000, e being in the range of 0.1≦e≦10000.
As for copper constituting these catalysts, for example, the following are listed: salts formed from copper and carboxylic acids such as formic acid, acetic acid and naphthenic acid; organic compounds such as acetylacetonate complex with copper, etc.; and inorganic compounds formed from copper and hydroxide, oxide, chloride, bromide, nitrate, sulfate or the like. These copper salts can be either anhydrous salts or hydrate salts.
Regarding bromine, a variety of bromine compounds, such as hydrogen bromide, ammonium bromide and metallic bromide, are listed.
For heavy metal in the catalysts of 2), 3) and 5), at least one kind of metallic element selected from the group consisting of vanadium, manganese, iron, cobalt, nickel, palladium and cerium, is used, and most preferably cobalt and manganese are used. Further, for the compounds, salts similar to the above-mentioned copper compounds is used.
Regarding amine compounds in the catalysts of 4) and 5), for example, the following are listed: heterocyclic amine compounds, such as pyridine, pyrazine, piperazine, picoline, lutidine, and quinoline; and alkyl amines having liquid state at room temperature, such as ethylenediamine, monopropylamine, dipropylamine, monobutylamine and dibutylamine. By considering the stability under oxidation conditions, pyridine, pyrazine, quinoline are listed as suitable amine compounds, and the most suitable one is pyridine.
The reaction according to the present invention is carried out in an organic solvent. Economically, and by considering the stability with respect to oxidation, a pure acetic acid solvent is used most preferably. However, the acetic acid solvent may be mixed with an aromatic solvent such as benzene, and aliphatic monocarboxylic acids for example propionic acid if necessary.
As for the amount of water in the reaction mixture, in the case when acetic acid is used as a solvent, it is preferable to contain water equal to 2 to 30 weight percent of the acetic acid. If the amount of water exceeds 30 weight percent, the catalytic activity is lowered, causing an increase of by-products and corrosion of a device.
In the present invention, the dialkyl-substituted diaryl compounds of formula (III) illustrated above is oxidized to the diaryldicarboxylic acid of formula (IV) also illustrated. R and R' in formula (III) are oxidized to a COOH group. When A in formula (III) is S or CH 2 , S and CH 2 are also oxidized to SO 2 and CO respectively. In the mean time, if A in this formula is either direct bonding, O, SO 2 , or CO, A' in formula (IV) is the same as A.
As dialkyl-substituted diaryl compounds, dialkyl-substituted diaryl having an alkyl group of 1 to 6 carbons and alicyclic hydrocarbon group as a substitution group are listed. More specifically, the following will give some examples of dialkyl-substituted diaryl compound and obtainable diaryldicarboxylic acid: 4,4'-dimethylbiphenyl and 4,4'-biphenyldicarboxylic acid; 3,3'-dimethylbiphenyl and 3,3'-biphenyldicarboxylic acid; 3,4'-dimethylbiphenyl and 3,4'-biphenyldicarboxylic acid; 4,4'-diethylbiphenyl and 4,4'-biphenyldicarboxylic acid; 3,3'-diethylbiphenyl and 3,3'-biphenyldicarboxylic acid; 3,4'-diethylbiphenyl and 3,4'-biphenyldicarboxylic acid; 4,4'-diisopropylbiphenyl and 4,4'-biphenyldicarboxylic acid; 3,3'-diisopropylbiphenyl and 3,3'-biphenyldicarboxylic acid; 3,4'-diisopropylbiphenyl and 3,4'-biphenyldicarboxylic acid; 4,4'-dicyclohexylbiphenyl and 4,4'-biphenyldicarboxylic acid; 4,4'-dimethyldiphenyl ether and 4,4'-diphenyl ether dicarboxylic acid; 4,4'-dimethylbenzophenone and 4,4'-benzophenone dicarboxylic acid; 3,3'-dimethylbenzophenone and 3,3'-benzophenone dicarboxylic acid; 4,4'-dimethyldiphenyl sulfone and 4,4'-diphenylsulfone dicarboxylic acid; 4,4'-dimethyldiphenyl sulfide and 4,4'-diphenylsulfone dicarboxylic acid; and bis(4-methylphenyl) methane and 4,4'-benzophenone dicarboxylic acid.
The production of naphthalenedicarboxylic acids and diaryldicarboxylic acids according to the present invention is carried out through either of the following two methods, (i) and (ii).
In method (i), naphthalenedicarboxylic acids or diaryldicarboxylic acids is produced through the following process: placing a predetermined amount of solvent, of starting material and of catalyst into a reaction vessel; suppling a gas containing molecular oxygen to the reaction vessel, stirring the mixture under a pressure of the gas at a predetermined temperature, and carrying out a reaction.
In method (ii), naphthalenedicarboxylic acids or diaryldicarboxylic acids is produced through the following process: placing a predetermined amount of solvent and of catalyst into a reaction vessel; suppling a gas containing molecular oxygen to the reaction vessel while adding a starting material to the reaction vessel successively or intermittently, stirring the mixture under a pressure of the gas at a predetermined temperature, and carrying out a reaction. Here, the reaction may be carried out by introducing a part of the starting material into the reaction vessel in advance, or the reaction may continuously proceed by withdrawing some parts of the produced naphthalenedicarboxylic acids or diaryldicarboxylic acids from the reaction mixture.
As for the amount of catalyst used in the present invention, it equals 0.01 weight percent to 20 weight percent of the solvent, and more preferably from 0.5 weight percent to 5 weight percent thereof. A catalyst concentration lower than this range will not achieve a good activation, and a catalyst concentration higher than this range will deteriorate its solubility and increase the formation of by-products, and therefore it is undesirable to use a catalyst beyond this range.
Regarding a gas containing molecular oxygen, although air is the most suitable source industrially, oxygen and a mixed gas formed by diluting oxygen with an intert gas may also be used.
In the case of using air, it is desirable to set the reaction temperature between 150° C. and 250° C., i.e. in this temperature range the reaction can promptly proceed and the formation of undesirable by-products such as tar-like substances and carbide is restrained.
Meanwhile, in the case of using air, suitable reaction pressures range from 3 kg/cm 2 to 50 kg/cm 2 in which the mixture is maintained in liquid phase, and the most preferable reaction pressures range from 10 kg/cm 2 to 40 kg/cm 2 .
The following examples will explain the present invention in more detail, however the present invention is not restricted to these examples.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The conversion of starting materials, the yield of naphthalenedicarboxylic acids, the yield of trimellitic acid (hereinafter referred to as TMA) which is an undesirable by-product, and the yield of diaryldicarboxylic acid in EXAMPLES and COMPARATIVE EXAMPLES were determined based on the following definitions. ##EQU1##
EXAMPLE 1
In this example, a reaction was carried out according to method (ii) described above. More specifically, 300 g of acetic acid, and 0.1 g of copper acetate [Cu(OAc) 2 ] and 6 g of KBr as catalyst were placed into a titanium made 1 l autoclave equipped with a stirrer, a condenser, a gas blowing tube, a starting material supplying line and pressure-control valve. The mixture was heated to 200° C. and then pressurized to 30 kg/cm 2 with air.
Next, while supplying a volume of air enough for oxidation to the autoclave and while controlling the internal pressure of the autoclave at 30 kg/cm 2 , 80.0 g of 2,6-diisopropylnaphthalene (hereinafter referred to as 2,6-DIPN) was added to the mixture in three hours stepwise to commence the reaction. Only air was supplied to therein for another one hour to proceed the reaction, and then the reaction was terminated.
The reaction product was analyzed with liquid chromatography. The analysis resulted in 100 percent conversion of 2,6-DIPN, 71 percent yield of 2,6-NDA and 24 percent yield of TMA as shown in Table 2.
EXAMPLES 2 TO 16
Here, reactions were carried out under the same conditions as in EXAMPLE 1, except that the components and composition of catalyst were respectively changed as shown in Table 1 and the reaction temperature and pressure were also changed as shown in Table 2. The reaction conditions and results are respectively shown in Table 1 and Table 2.
As is clear from the results of EXAMPLES 1 to 16, high yields of 2,6-NDA, at least 71 percent, were almost achieved with small amounts of catalyst not greater than 15 percent of the amount of the starting material. Thus, the yield of 2,6-NDA was improved with reduced amounts of catalyst compared with conventional cases.
The results show that at least one kind of heavy metallic element selected from the group consisting of vanadium, manganese, iron, cobalt, nickel, palladium and cerium can be used as heavy metal in catalyst, and more preferably cobalt and manganese will be used.
COMPARATIVE EXAMPLE 1
With the use of a well known catalyst described in the prior art, i.e. the catalyst comprising manganese and bromine, a reaction was carried out under the same conditions as in EXAMPLE 1. The reaction conditions and results are respectively presented in Table 5 and Table 6.
As is clear from the results, copper is an essential component for the catalyst of the present invention.
COMPARATIVE EXAMPLE 2
Except for changes in the composition ratio of the catalyst, reaction temperature and the reaction time, a reaction was carried out under the same conditions as in EXAMPLE 1. The reaction conditions and results are respectively presented in Table 5 and Table 6.
COMPARATIVE EXAMPLE 3
Except for changes in the composition ratio of the catalyst and the reaction temperature, a reaction was carried out under the same conditions as in EXAMPLE 2. The reaction conditions and results are respectively presented in Table 5 and Table 6.
EXAMPLE 17
A reaction was carried out under the same conditions as in EXAMPLE 12, except that an acetic acid solution containing a 5 weight percent of water was used as solvent instead of acetic acid. The yield of 2,6-NDA, of TMA and the recovery of acetic acid were 85 percent, 12 percent and 95 percent, respectively.
EXAMPLE 18
A reaction was carried out under the same conditions as in EXAMPLE 16, except that an acetic acid solution containing a 10 weight percent of water was used as solvent instead of acetic acid. The yield of 2,6-NDA, of TMA and the recovery of acetic acid were 88 percent, 8 percent and 97 percent, respectively.
The results of EXAMPLES 17 and 18 show that the solutions containing water restrain the formation of TMA as well as the combustion of acetic acid.
EXAMPLES 19 TO 22
With the use of dialkyl-substituted naphthalenes other than 2,6-diisopropylnaphthalene as starting material, naphthalenedicarboxylic acids were produced.
A catalyst comprising copper, bromine and manganese was used in EXAMPLES 19 and 20, and a catalyst comprising copper, bromine, manganese and other heavy metal were used in EXAMPLES 21 and 22. The starting material was varied as shown in Table 4, and 250 g of acetic acid was used as solvent. Except for these differences, reactions were carried out under the same conditions as in EXAMPLE 1. The reaction conditions and results are respectively presented in Table 3 and Table 4.
EXAMPLE 23
A catalyst comprising copper, bromine, pyridine and manganese was used instead of the catalyst in EXAMPLE 21, and o-dichlorobenzene was used as solvent. Except for these differences, a reaction was carried out under the same conditions as in EXAMPLE 21. The reaction conditions and results are respectively shown in Table 3 and Table 4.
EXAMPLE 24
300 g of acetic acid as solvent, and 0.1 g of copper acetate [Cu(OAc) 2 ·H 2 O] and 6 g of potassium bromide as catalyst were placed into a titanium made autoclave (1 l) equipped with a stirrer, a condenser, a gas blowing tube, a starting material supplying line and a pressure-control valve. The mixture was heated to 180° C. and then pressurized to 30 kg/cm 2 with air. Next, while supplying air to the autoclave at a rate of 200 l/hr and while controlling the internal pressure of the autoclave at 30 kg/cm 2 , 80.0 g of 4,4'-diisopropylbiphenyl was added to the mixture in three hours stepwise. Only air was supplied for another one hour to proceed a reaction, and then the reaction was terminated.
The reaction product was analyzed with liquid chromatography. The analysis resulted in 100 percent conversion of 4,4'-diisopropylbiphenyl and 85 percent yield of 4,4'-biphenyldicarboxylic acid as shown in Table 8.
The amount of catalyst used was equivalent to 7.6 weight percent of the starting material.
EXAMPLES 25 TO 38
Reactions were carried out under the same conditions as in EXAMPLE 24, except that the catalyst and reaction temperature were respectively varied as shown in Tables 7 and 8. The respective results are presented in Table 8.
EXAMPLES 24 to 38 achieved high yields of 4,4'-biphenyldicarboxylic acid, at least 85 percent, with the use of small amounts of catalyst which are less than 15 weight percent of the starting material. Thus, it is clear from the results that the yield of 4,4'-biphenyldicarboxylic acid is improved with reduced amounts of catalyst compared to the prior art.
When manganese, iron, nickel, palladium and cerium were used as the components of the catalyst, a slightly colored crude cake was resulted after the reaction. Meanwhile, when cobalt and vanadium were used, the resulting crude cake was light yellow.
EXAMPLE 39
4,4'-dimethylbiphenyl was used as starting material instead of 4,4'-diisopropylbiphenyl, and reaction temperature, the composition of catalyst and the amount of catalyst were respectively varied as shown in Table 9 and Table 10. Except for these differences, a reaction was carried out under the same conditions as in EXAMPLE 24. The amount of catalyst used was equivalent to 3.8 weight percent of the starting material. The results are shown in Table 10.
EXAMPLE 40
4,4'-dimethylbiphenyl was used as starting material instead of 4,4'-diisopropylbiphenyl, and 0.01 g of copper acetylacetonate [Cu(AA) 2 ], 0.57 g of ammonium bromide and 1.5 g of cobalt acetate [Co(OAc) 2 ·4H 2 O] as catalyst were used. Except for these differences, a reaction was carried out under the same conditions as in EXAMPLE 24. The amount of catalyst used was equivalent to 3.5 weight percent of the starting material. The reaction conditions and results are respectively shown in Table 9 and Table 10.
EXAMPLE 41
A reaction was carried out under the same conditions as in EXAMPLE 39, except that 4,4'-diethylbiphenyl was used as starting material instead of 4,4'-dimethylbiphenyl and that reaction temperature was 180° C. The reaction conditions and results are respectively shown in Table 9 and Table 10.
EXAMPLE 42
A reaction was carried out under the same conditions as in EXAMPLE 41, except that 4,4'-diethyldiphenyl ether was used as starting material instead of 4,4'-dimethylbiphenyl and that the composition of catalyst was changed as shown in FIG. 9. The reaction conditions and results are respectively shown in Table 9 and Table 10.
EXAMPLE 43
A reaction was carried out under the same conditions as in EXAMPLE 41, except that 4,4'-diethyldiphenyl sulfone was used as starting material instead of 4,4'-dimethylbiphenyl. The reaction conditions and results are respectively shown in Table 9 and Table 10.
EXAMPLE 44
A reaction was carried out under the same conditions as in EXAMPLE 39, except that 4,4'-dimethylbenzophenone was used as starting material instead of 4,4'-dimethylbiphenyl. The reaction conditions and results are respectively shown in Table 9 and Table 10.
EXAMPLES 39 to 44 achieved high yields, at least 84 percent, of 4,4'-biphenyldicarboxylic acid with the use of small amounts of catalyst which were respectively equivalent to 3.5 weight percent and 3.8 weight percent of the starting material when 4,4'-diethylbiphenyl, 4,4'-dimethyldiphenyl ether, 4,4'-dimethyldiphenyl sulfone and 4,4'-dimethylbenzophenone were used as starting material. Thus, the results show that the yield of 4,4'-biphenyldicarboxylic acid is improved with reduced amounts of catalyst compared with the prior art.
EXAMPLES 45 AND 46
The catalysts given in Table 9, the isomer of 4,4'-diisopropylbiphenyl as starting material and 250 g of acetic acid as solvent were used. Except for these changes, reactions were carried out under the same conditions as in EXAMPLE 24. The reaction conditions and results are respectively presented in Table 9 and Table 10.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
TABLE 1__________________________________________________________________________ Composition (atom ratio)Example HeavyNo. Components of Catalyst (g) Cu Br Mn Metal__________________________________________________________________________1 Cu(OAc).sub.2 H.sub.2 O, KBr, -- -- 1 101 -- --(0.1) (6.0)2 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Co(OAc).sub.2 4H.sub.2 O 1 101 -- 24(0.1) (6.0) (3.0)3 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 101 24 --(0.1) (6.0) (3.0)4 Cu(OAc).sub.2 H.sub.2 O, KBr, -- VO(AA).sub.3 1 101 -- 8(0.1) (6.0) (1.0)5 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Fe(AA).sub.2 1 101 -- 17(0.1) (6.0) (3.0)6 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Pd(OAc).sub.2 1 101 -- 0.8(0.1) (6.0) (0.1)7 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Ce(OAc).sub.3 H.sub.2 O 1 168 -- 37(0.05) (5.0) (3.0)8 Cu(OAc).sub.2 H.sub.2 O, NH.sub.4 Br, -- Co(OAc).sub.2 4H.sub.2 O 1 164 -- 48(0.05) (4.0) (3.0)9 Cu(AA).sub.2, NH.sub.4 Br, -- Co(OAc).sub.2 4H.sub.2 O 1 218 -- 64(0.05) (4.0) (3.0)10 Cu(AA).sub.2, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 223 127 --(0.05) (5.0) (6.0)11 Cu(AA).sub.2, KBr, -- Co(AA).sub.3 1 223 -- 43(0.05) (5.0) (3.0)12 Cu(AA).sub.2, KBr, -- Co(AA).sub.3 1 556 -- 87(0.02) (5.0) (6.0)13 Cu(AA).sub.2, KBr, Mn(AA).sub.2 -- 1 556 614 --(0.01) (5.0) (6.0)14 Cu(AA).sub.2, KBr, -- Ni(AA).sub.2 1 556 -- 154(0.02) (5.0) (3.0)15 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 1681 1061 --(0.005) (5.0) (6.5)16 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 8403 8163 --(0.001) (5.0) (10.0)__________________________________________________________________________ Ac: acetyl group, and AA: acetylacetonate group.
TABLE 2__________________________________________________________________________Reaction Conditions Recovery ofExampleTemperature Time Pressure Conversion Yield (%) AceticNo. (°C.) (hr) (kg/cm.sup.2) (%) 2,6-NDA TMA Acid (%)__________________________________________________________________________1 200 4 30 100 71 24 882 200 4 30 100 81 14 893 210 4 30 100 83 13 874 200 4 30 100 76 13 865 200 4 30 100 73 23 906 200 4 30 100 72 12 877 200 4 30 100 75 21 908 200 4 30 100 82 13 919 200 4 30 100 82 15 8810 220 4 30 100 86 12 9011 210 4 30 100 81 16 9112 210 4 20 100 83 15 9013 210 4 20 100 88 9 9314 210 4 30 100 79 18 9415 230 4 30 100 84 15 9316 220 4 30 100 85 10 95__________________________________________________________________________ 300 g of acetic acid and 80 g of 2,6diisopropylnaphthalene were respectively used as solvent and starting material in each example. 2,6NDA: 2,6naphthalenedicarboxylic acid, and TMA: trimellitic acid.
TABLE 3__________________________________________________________________________ Composition (atom ratio)Example HeavyNo. Components of Catalyst (g) Cu Br Mn Metal Y*__________________________________________________________________________19 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O 1 101 82 -- --(0.05) (3.0) (5.0)20 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O 1 101 82 -- --(0.05) (3.0) (5.0)21 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O, Ni(AA).sub.2 1 101 82 15 --(0.05) (3.6) (5.0) (1.0)22 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O, Ni(AA).sub.2 1 101 82 15 --(0.05) (3.0) (5.0) (1.0)23 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O, Py 1 252 122 -- 316(0.02) (3.0) (3) (2.5)__________________________________________________________________________ Y: amine compound, Py: pyridine, Ac: acetyl group, and *: number of moles
TABLE 4__________________________________________________________________________ Starting Reaction Conditions Recovery ofExampleSolvent Material Tempera- Time Pressure Conversion Yield AceticNo. (g) (g) ture (°C.) (hr) (kg/cm.sup.2) (%) (%) Acid (%)__________________________________________________________________________19 AcA 2,7-DIPN 200 4 30 100 2,7-NDA 87 (60) (70)20 AcA 1,4-DIPN 200 4 30 100 1,4-NDA 91 (60) (68)21 AcA 2,7-DIPN 200 4 30 100 2,7-NDA 90 (60) (72)22 AcA 1,4-DIPN 200 4 30 100 1,4-NDA 93 (60) (69)23 DCB 2,7-DIPN 200 4 30 100 2,7-NDA -- (60) (65)__________________________________________________________________________ 250 g of solvent was used in each example. AcA: acetic acid, DCB: dichlorobenzene, DIPN: diisopropylnaphthalene, and NDA: naphthalenedicarboxylic acid.
TABLE 5__________________________________________________________________________ CompositionComparative (atom ratio)Example HeavyNo. Components of Catalyst (g) Cu Br Mn Metal__________________________________________________________________________1 -- KBr, Mn(OAc).sub.2 4H.sub.2 O -- 100 100 -- (2.13) (2.20)2 Cu(OAc).sub.2 H.sub.2 O, KBr, 1 2.5 -- -- (2.0) (3.0)3 Cu(OAc).sub.2 H.sub.2 O, KBr, Co(OAc).sub.2 4H.sub.2 O 1 12.6 -- 6.0 (0.4) (3.0) (3.0)__________________________________________________________________________ Ac: acetyl group.
TABLE 6__________________________________________________________________________Comparative Reaction Conditions Recovery ofExample Temperature Time Pressure Conversion Yield (%) AceticNo. (°C.) (hr) (kg/cm.sup.2) (%) 2,6-NDA TMA Acid (%)__________________________________________________________________________1 210 6 30 100 21 32 --2 225 6 30 100 61 32 713 200 4 30 100 81 15 75__________________________________________________________________________
TABLE 7__________________________________________________________________________ Composition (atom ratio)Example HeavyNo. Components of Catalyst (g) Cu Br Mn Metal__________________________________________________________________________24 Cu(OAc).sub.2 H.sub.2 O, KBr, -- -- 1 101 -- --(0.1) (6.0)25 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Co(OAc).sub.2 4H.sub.2 O 1 101 -- 24(0.1) (6.0) (3.0)26 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 101 24 --(0.1) (6.0) (3.0)27 Cu(OAc).sub.2 H.sub.2 O, KBr, -- VO(AA).sub.3 1 101 -- 8(0.1) (6.0) (1.0)28 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Fe(AA).sub.3 1 101 -- 17(0.1) (6.0) (3.0)29 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Pd(OAc).sub.2 1 101 -- 0.8(0.1) (5.0) (0.1)30 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Ce(OAc).sub.3 H.sub.2 O 1 168 -- 37(0.05) (5.0) (3.0)31 Cu(OAc).sub.2 H.sub. 2 O, NH.sub.4 Br, -- Co(OAc).sub.2 4H.sub.2 O 1 164 -- 48(0.05) (4.0) (3.0)32 Cu(AA).sub.2, NH.sub.4 Br, -- Co(OAc).sub.2 4H.sub.2 O 1 218 -- 64(0.05) (4.0) (3.0)33 Cu(AA).sub.2, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 223 127 --(0.05) (5.0) (6.0)34 Cu(AA).sub.2, KBr, -- Co(AA).sub.3 1 223 -- 43(0.05) (5.0) (3.0)35 Cu(AA).sub.2, KBr, -- Co(AA).sub.3 1 556 -- 87(0.02) (5.0) (6.0)36 Cu(AA).sub.2, KBr, Mn(AA).sub.3 -- 1 556 614 --(0.01) (5.0) (6.0)37 Cu(AA).sub.2, KBr, -- Ni(AA).sub.2 1 556 -- 154(0.02) (5.0) (3.0)38 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 1681 1061(0.005) (5.0) (6.5)__________________________________________________________________________
TABLE 8__________________________________________________________________________Reaction Conditions Recovery ofExampleTemperature Time Pressure Conversion Yield AceticNo. (°C.) (hr) (kg/cm.sup.2) (%) (%) Acid (%)__________________________________________________________________________24 180 4 30 100 85 9425 180 4 30 100 88 9326 180 4 30 100 93 9227 170 4 30 100 86 9528 180 4 30 100 87 9629 170 4 30 100 85 9030 170 4 30 100 86 9231 180 4 30 100 89 9332 180 4 30 100 90 9433 180 4 30 100 92 9334 190 4 30 100 91 9135 200 4 30 100 89 9436 200 4 20 100 94 9537 200 4 20 100 86 9638 190 4 30 100 88 98__________________________________________________________________________ 80 g of 4,4diisopropylbiphenyl was used as starting material and 300 g of acetic acid was used as solvent in each example
TABLE 9__________________________________________________________________________ Composition (atom ratio)Example HeavyNo. Components of Catalyst (g) Cu Br Mn Metal__________________________________________________________________________39 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 126 122 --(0.01) (0.75) (1.5)40 Cu(AA).sub.2, NH.sub.4 Br, -- Co(OAc).sub.2 4H.sub.2 O 1 154 -- 120(0.01) (0.57) (1.5)41 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 126 122 --(0.01) (0.75) (1.5)42 Cu(OAc).sub.2 H.sub.2 O, KBr, -- Ce(OAc).sub.3 H.sub.2 O 1 126 -- 46(0.1) (0.75) (0.75)43 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 126 122 --(0.01) (0.75) (1.5)44 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 126 122 --(0.01) (0.75) (1.5)45 Cu(OAc) H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 126 122 --(0.01) (0.75) (1.5)46 Cu(OAc).sub.2 H.sub.2 O, KBr, Mn(OAc).sub.2 4H.sub.2 O -- 1 503 391 --(0.01) (3) (4.8)__________________________________________________________________________ Ac: acetyl group, and AA: acetylacetonate group.
TABLE 10__________________________________________________________________________ RecoveryStarting Reaction Conditions ofExampleMaterial Temperature Time Pressure Conversion Yield AceticNo. (g) (°C.) (hr) (kg/cm.sup.2) (%) (%) Acid (%)__________________________________________________________________________39 DMB (60) 190 4 30 100 88 9740 DMB (60) 180 4 30 100 90 9841 DEB (60) 180 4 30 100 93 9542 DDE (60) 180 4 30 100 94 9843 DDS (60) 180 4 30 100 85 9644 DMBP (60) 180 4 30 100 84 9845 3,4'-DIPB 180 4 30 100 3,4'-BPDA 97(60) (82)46 3,3'-DIPB 180 4 30 100 3,3'-BPDA 97(60) (80)__________________________________________________________________________ 300 g of acetic acid was used as solvent in examples 39 to 44, and 250 g of acetic acid was used in examples 45 and 46. The yield in example 39 to 44 respectively represents the yield of 4,4biphenyldicarboxylic acid. DMB: 4,4dimethylbiphenyl, DEB: 4,4diethylbiphenyl, DDE: 4,4dimethyldiphenyl ether, DDS: 4,4dimethyldiphenyl sulfone, DMBP: 4,4dimethylbenzophenone, DIPB: 4,4diisopropylbiphenyl, and BPDA: biphenyldicarboxylic acid. | A method of producing naphthalenedicarboxylic acids by the oxidation of dialkyl-substituted naphthalene with a gas containing molecular oxygen in an organic solvent and in the presence of a catalyst comprising copper and bromine, or a catalyst comprising copper, bromine and at least one kind of element/compound selected from the group of consisting of amine compounds and heavy metallic elements which are vanadium, manganese, iron, nickel, palladium and cerium. And a method of producing diaryldicarboxylic acids by the oxidation of dialkyl-substituted diaryl compounds with a gas containing molecular oxygen in an organic solvent and in the presence of the same catalyst. These methods permit high yields of naphthalenedicarboxylic acids of high purity and of diaryldicarboxylic acids of high purity with the use of small amounts of catalyst. | 2 |
FIELD OF THE INVENTION, AND BACKGROUND
The present invention relates to a printing ink composition. More particularly, the invention is directed to a printing ink emulsion for lithographic and related printing and in which the composition is used effectively in a single-application-step printing process obviating and requirement for a separate water coat application to a non-image area of a printing plate to render that area ink-repellant.
The present invention constitutes an important improvement in both ink compositions and in the manner in which such compositions are applied in lithographic printing and in related printing such as offset printing, lithography, ect.
The art in which the present finds utility is a highly sophisticated and highly developed art in which the printing surface involved is of the type that is devoid of appreciable elevation variation, relief, or depression. This type of printing may be contrasted generally with what is known as letter press printing in which raised type or image surfaces are involved.
The general construction and composition of printing plates of the type useful in practicing the present invention are well-known in the art. Accordingly, no detailed description is deemed to be required herein. A description of lithographic printing, including a summary of the various techniques involved is found in Parkinson U.S. Pat. No. 4,045,232, and the entire disclosure of that patent is hereby specifically incorporated herein by reference, to the extent it is not inconsistent herewith.
The various methods which have been employed to apply an image to be imprinted onto the surface of the plate are described in the cited reference, which also includes a description of the preparation of the plates themselves. The method by which the printing plate is prepared for use does not constitute an element of the present invention. Rather, the invention lines in the provision of a unique printing ink composition of the type which may be used without the need to apply a water coating to the surface of the printing plate to define a non-image area which is thus rendered ink-repellant.
Various techniques and compositions have been suggested for use in lithographic type printing techniques so as to obviate the need to apply a water coating to the surface of the printing plate. Among liquid preparations which have been proposed as treating media to be applied to non-image areas of printing plates are solutions containing particular salts and glycerin. Such solutions have been found objectionable for various reasons including instability in use and as being objectionably hygroscopic. Moreover, it was necessary that the application of the solutions be frequently repeated, preferably with each successive inking of the printing plate or roll.
The desirability of being able to use an ink composition containing agents for treating both the image producing area and the non-print area, simultaneously, and from a single solution, has also been recognized. For the most part, compositions purporting to function in this manner have been found to be objectionable due to the lack of satisfactory definition and because of impaired toning. Such compositions have also failed to demonstrate the type of stability and reliability required for practical commercial use. It is, therefore, a principal aim of the present invention to proved a "single composition" printing ink for a "single application" which is effective to obviate the need for a separate water coating step in a lithographic type printing operation, and in which the composition obviates the deficiencies and shortcomings of prior art preparations and techniques.
SUMMARY OF THE INVENTION
The present invention constitutes a printing ink emulsion for use in lithographic-type printing operation. The emulsion exhibits a high degree of stability against phase separation in use and is effective as a single-application formulation for treating printing plates so that the image producing portion of the plate is effectively coated at the same time that the non-print or non-image area of the plate is rendered ink repellant.
It is an important feature of the composition of the ink emulsion that it includes a relatively small concentration of phosphoric acid as a critical component thereof.
A related feature of the invention is that the emulsion contains a diluent having the properties possessed by No. 1 and No. 2 fuel oil, the fuel oil functioning as a diluent and emulsion stabilizing agent.
A feature of the ink emulsion of the invention is the inclusion, in combination, of polyols and phosphoric acid, the latter being incorporated in a relatively small concentration and believed significant as an agent for enhancing the emulsification of the polyol constituents.
An important advantage of the single-composition, single-application-system ink emulsion of the invention is that it enables an operator readily to shift the operation to selected colors and obviates the need of balancing the ratio of water and ink phases in the treatment of the printing rollers or plates.
A related advantage of the emulsion printing ink composition of the invention and the method of its use is that the likelihood of human error is minimized, constancy of operation and quality is enhanced and significant saving in paper its achieved.
An important advantage realized through the use of the single-composition emulsion ink of the invention is a savings in paper and in paper cost. The present invention provides improved color balance from start to stop of each printed run. Less paper is thrown away prior to meeting the established color or density standards. Additionally, less paper is wasted during start up, the need for balancing of the separate water and oil phases being obviated. In accordance with the invention, the requisite "balance" is present initially (from start up), and is maintained.
Yet another important practical advantage achieved through the use of the single-composition, emulsion ink of the invention is that significant savings in roller expense is realized. Repair costs of rollers are reduced as is the cost associated with sleeving of the rollers.
A related advantage achieved through the present invention is the elimination of the need for a water-form roller system.
A feature of the emulsion, single-composition ink system of the invention is that the composition acts effectively as a leveling agent when used with other ink preparations, to prevent build-up, and serves also to prevent "toning" or filling in of plate components in unwanted areas.
It is a feature of the emulsion, single-composition ink system of the invention that it may be effectively used as well on offset presses, with letter presses and offset plates, and in offset printing.
It is a feature of the present invention that an inorganic acid is used as a component of the modified ink varnish of the ink emulsion, and it is a critical feature of the invention that the inorganic acid is phosphoric acid rather than nitric acid or sulfuric and rather than a mixture of nitric acid and sulfuric acid.
An advantage of the unique ink emulstion composition of the invention is that the shelf life of the product is greatly enchanced as compared with other off-set type printing systems.
Yet another advantage is that the need for chemical "driers" is obviated.
A related feature of the emulsion ink of the invention is that the product provides improved "drying" properties and characteristics, "excess" water being avoided.
It is an important advantage of the present invention that there is provided, as a diluent which also serves as an emulsion-promoting and stabilizing factor in the printing ink emulsion of the invention, a hydrocarbon solvent, being a petroleum fraction preferably of a nature typified by No. 1 fuel oil, No. 2 fuel oil and mixtures thereof.
Yet another important feature of the single-formulation printing ink emulsion of the invention is that it includes from about 10% to 21% by weight of added water.
A related advantage of the invention is the incorporation of fuel oil into the emulsion system, the fuel oil component serving to adjust the tack, improve the emulsion stability, and to enhance the roller transferability of the printing ink emulsion.
An important feature of the unitary lithographic ink emulsion of the invention is the incorporation of the combination of polyols and water which serve to extend the surface area of the water phase, to minimize evaporation, and to increase the longevity of the printing composition in use and in storage.
An important feature of the monolithographic varnish component of the printing ink emulsion of the invention, and which contains a mixture of varnish resins in combination with phosphoric acid and ethylene glycol, is that the varnish serves to lubricate the ink rollers, to prevent build-up on the balnket and on the printing plate, and acts additionally to maintain a proper water balance in the emulsion system.
Other and further objects, features and advantages of the invention will become apparent from a reading of the following specifications.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The aims and objects of the present invention are achieved by provding, as a single composition printing ink for use in lithographic and related printing methods, a stablized emulsion containing an aqueous phase and a non-aqueous phase, and emulsion stabilizing agents. The printing ink composition of the invention is produced by first combining a mixture of ink varnish compositions with phosphoric acid and a polyol, and incorporating a color-imparting agent to provide an ink varnish resinous phase or ink vehicle. To the ink vehicle there is then added an aqueous solution containing polyols and water to form an emulsion. Fuel oil is then intimately blended into the emulstion as a diluent and stablizer to form a single-application-step composition which may be used to define both image producing areas and non-image areas on the printing plate, and eliminating any need for separate phase application steps in a lithographic type printing process.
In the paragraphs below the preparation of each of the several systems and the method by which they are combined to provide the stabilized emulsion printing ink of the ink are described. Also provided are a series of examples which will serve to illustrate the invention and which are not to be interpreted in any limiting sense, since, based upon the teachings of the present invention those skilled in the art will be able to make variations and modifications without departing from the scope of the invention contribution. All such variations are deemed to be embraced by the claims appended hereto.
Preparation of Modified Ink Varnish
A modified ink varnish, for use as a component in the emulsion printing ink of the invention, was prepared as follows, using the designated ingredients in the following preferred concentrations and concentrational ranges.
12-25 parts by weight, and preferably eighteen parts by weight of an ink varnish including oleoresin, modified hydrocarbon resins and ester resins, 12-25 parts by weight and preferably eighteen parts by weights of additional ink varnishes containing phenol modified rosin and hydrocarbon resins, 0.5-5 and preferably 2.2 parts by weight of boiled linseed oil, up to about two parts by weight of phosphoric acid and preferably 0.7 part by weight were combined in a mixing vessel to provide component "A". 50-75 parts by weight and preferably sixty-two parts by weight, of ethylene glycol were weighed into a separate vessel, as part "B".
The contents of the first vat (part "A") were subjected to high speed mixing using a high speed shearing blade or a bow tie mixer to disperse the ingredients while the temperature of the mixture was maintained in the range of 105° F. to 150° F. While maintaining the mixing, part "B" was added at a rate of about 1% to 2% per minute to extablish a modified ink varnish. The varnish was mixed for about 15-20 minutes after completion of the addition of the part "B" component to ensure a uniform dispersion.
The tabular representation of the components of the modified varnish, and their concentration ranges, is set forth in the following Table I.
TABLE I______________________________________MODIFIED VARNISH (BR100) Concentrational Concentration RangeComponent (Parts by Weight) (Parts by Weight)______________________________________OleoresinModified Hydrocarbon 18 12-25ResinEster ResinPhenol Modified Rosin 18 12-25Hydrocarbon Resins("Gloss Enhancer")Boiled Linseed Oil 2.2 0.5-5Phosphoric Acid 0.7 up up to 2Ethylene Glycol 62 50-75______________________________________
An emulsification mix for incorporation with the modified varnish (BR100) of the invention was prepared by combining glycerin, ethylene glycol and water in the ratios designated in the following Table II.
TABLE II______________________________________EMULSIFICATION MIX (BR101) Range (Parts by Weight) (Parts by Weight)______________________________________Glycerin 25 0-50*Ethylene glycol 25 0-50*Water 50 0-90*______________________________________ *The concentrations shall not be zero, simultaneously.
Forulation of Emulsion Printing Ink (Single-Ink System)
In preparing the emulsion printing ink of the invention, the designated components were combined in the manner indicated below:
15-50 parts by weight and preferably 19 parts by weight of the BR100, resin composition for modified varnish (Table 1) were combined with 15-50 parts by weight and preferably 18 by weight of a first ink varnish containing oleoresins, modified hydrocarbon resins and ester resins and 8-15 parts by weight and preferably 11 parts by weight of a second ink varnish composition containing phenol modified rosin and hydrocarbon resins, the resulting mixture being preferably at a temperature in the range of about 105° F. to about 115° F. 10-40 parts by weight and preferably about 14 parts by weight of a coloring agent, dye or pigment were added to the heated resinous mixture, with stirrring to provide a modified varnish base constituting an ink vehicle of the invention.
While agitating the ink vehicle while at a temperature of preferably 115° F., up to 40 parts by weight and preferably about 35 parts by weight of the BR101 emulsification mix was added to the modified ink varnish base with agitation to form an emulsion. While continuing to maintain the temperature and the agitation, about 0.5 to 7 parts by weight and preferably about 3 parts by weight of No. 1 or No. 2 fuel oil was slowly added to the agitated emlsion as a stablizing agent and to contribute to ensuring the desired degree of tack. The latter is preferably in the range of 1 at 1200/90°/l to 10 at 1200/90°/l, as read on a Thwing Albert inkometer. Different values will be found under different conditions of r.p.m., temperature and time.
A designation of the components in the emulsioning formulation, including the concentrational ranges of each, is set forth in Table III, and additional specific examples of the single-ink system, emulsion ink of the invention are set forth in Table IV.
TABLE III______________________________________SINGLE INK SYSTEMEMULSION INK FORMULATION Concentrational Concentration Ranges (Parts By Weight Parts by Weight______________________________________BR100, Modified Resin 19 15-50Comp.Ink Varnish #1 18 15-50Ink Varnish #2 11 8-15Coloring Agent 14* 10-40*BR101 (Emulsification 35 25-40Mix)Fuel Oil 3 0.5-7______________________________________ *The amount of coloring agent used will depend upon and vary as a functio of the strenth of the pigment and the intensity of color required in the final product.
TABLE IV______________________________________LITHOGRAPHIC, SINGLE INK SYSTEM, EMULSION INK(Concentration in Parts by Weight)Examples 1 2 3 4 5*______________________________________COMPONENTSBR100 18 17 18 20(MonolithographicVarnish)Ink Vehicle Resins 17 17 18 16 17(including esterresins, hydrocarbonresins)Body Gum 10 14 9 8 17(Phenol modified rosin,hydrocarbon resin)BR101 35 34 35 34(Emulsification mix,polyols and water)Emulsion Stabilizer 3 4 5 6(No. 1 or No. 2fuel oil)HB5421 Pigment 13Alk. Blue 0.5Color Black Yellow Red BlueYellow 12H.S. FlushRed Flush 13Blue Flush 13Boiled Linseed Oil 2Ethylene Glycol 61Phosphoric Acid 0.7______________________________________ *BR100 monolithographic varnish | A printing ink emulsion system containing an oil-base phase and water-miscible phase and exhibiting a high degree of stability against phase separation in use. The composition contains a small amount of phosphoric acid as a stabilizer, and is characterized in that the printing emulsion functions effectively as a single-application-step formulation in which the ink is retained only by the image portion of a plate, thus obviating the need for a separate operational step in which water is applied to a non-image area of a printing plate or roller to render that area ink-repellant. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to medical beds having the capability of positioning a patient in various positions.
It has long been desirable to have multipositional beds for use in the care of certain types of medical patients, especially extended care patients. In particular, these types of beds are desirable for any patient requiring a change of position with minimal trauma, as well as for any patient who is unable to change positions by himself. For example, coronary patients, burn patients, patients with spinal cord or other back injuries, orthopedic patients, patients in traction, and patients requiring treatment for shock, as well as intensive care patients in general, often need to have their positions changed at intervals, and often they either cannot or should not do so on their own.
Body position changes may be desirable merely for reasons of convenience, such as to change bed linens; however, they also may be absolutely essential to prevent serious health problems which may occur with extended bed care, such as deterioration of cardiovascular or respiratory or urinary functions, osteoporosis, muscle atrophy, decubitus ulcers, and even static pneumonia. On the other hand, a patient who is turned, or whose position is changed, without special precautions may suffer great trauma, prolonging or even aggravating his medical problems. Burn patients, for example, may have their healing times greatly prolonged and suffer much pain and discomfort due to the necessity for moving or turning them in their beds, and it is not uncommon even to destroy skin grafts during such position changes.
A wide variety of prior art beds have been designed in attempts to overcome some of the problems associated with changing the positions of medical patients. All of them suffer from one or more deficiencies which limit their utility or desirability. Some are composed of complex structures and provide only limited access to the patient from much of the area around the bed. Some are relatively cumbersome, heavy or immobile, or they are not adaptable to being conveyed or lifted by conventional means in most hospitals. Most prior art beds are not easily cleaned, and they often have numerous crevices in which contamination may occur. Those prior art devices which achieve any significant capability for multipositional operation typically have a large number of moving parts and may require a great deal of maintenance. None of the prior art devices provides complete utility for a full range of medical treatments. Many require electric motors or other drive means which are not only subject to malfunction but may produce eddy currents which interfere with sensitive electronic equipment or even induce problems in coronary patients having electric pacemakers.
The more ambitious efforts to overcome the problems of the prior art have resulted in beds of still greater complexity, expense, and susceptibility to malfunctioning, or other problems.
It is an object of the present invention to overcome or greatly alleviate the problems of the prior art medical beds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective of the multipositional bed showing a mattress support means detached from the bed;
FIG. 2 is a side elevation showing the mattress and associated frame assembly in a variety of positions;
FIG. 3 is a fragmentary perspective view from the head of the bed showing the drive mechanisms for rotating and tilting the frame;
FIG. 4 is a partially cutaway perspective view, showing the mattress frame tilted relative to its transverse axis and partially rotated relative to its longitudinal axis;
FIG. 5 is an enlarged cross-sectional view taken along line 5--5 of FIG. 2;
FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 5 and showing the tilting mechanism in various positions;
FIG. 7 is an enlarged cross-sectional view taken along line 7--7 of FIG. 2;
FIG. 8 is a fragmentary cross-sectional view taken along line 8--8 of FIG. 2; and
FIG. 9 is a side view of FIG. 8.
SUMMARY OF THE INVENTION
This invention contemplates a medical bed having a mattress or mattresses mounted in a frame that can be rotated about a longitudinal axis and tilted about a transverse axis. The invention may include removable mattresses which are adapted to permit the complete enclosure and immobilization of a patient to permit 360° rotation about the longitudinal axis.
The mattresses may be supported on a tension sheet which is suspended within a rectangular inner frame. The inner frame, in turn, is rotatably mounted at its end by means of axles positioned at its longitudinal axis to permit rotation within a surrounding outer frame. The outer frame may, in turn, be mounted along a transverse axis on axles which are rotatably attached to a supporting platform.
The bed permits tilting from a substantially vertical position to a head-down position, substantially below the horizontal. The bed also has the flexibility of permitting positioning in an infinite variety of orientations, over a wide combination of degrees of tilt and rotation.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the major external components of the multipositional bed. A platform unit 10 comprised of a base portion 12 having cross beams 14, brace members 15, and legs 16 makes up the lower portion of the bed. The legs 16 are preferably constructed having horizontal members 18 and vertical members 20 mounted on casters 22. The horizontal members 18 and vertical members 20 may be made of separate elements joined, for example, by welding, or they may be prepared by bending or forming unitary elements. In a preferred embodiment, the horizontal members have about an 8" floor clearance to correspond to standard hospital Surgilift clearance.
Rigidly attached to the base portion of the platform unit 10 are side walls 24, which include vertical strut members 26 and longitudinal members 28. These vertical strut members and longitudinal members may also be formed of a unitary construction or they may be constructed by welding or otherwise attaching separate vertical members to longitudinal members.
The outer side of the side walls are covered by decorative covers 30 having ornamentation 32. As will be seen hereinafter, the decorative covers serve to cover the tilt-drive mechanism for tilting the bed through the various positions shown in FIG. 2. (Crank 34, shown in FIGS. 1 and 2, is detachably connected to the tilt-drive mechanism located behind the decorative cover 30.)
The platform unit supports an outer frame unit 40, which includes a generally rectangular pivotal or tilting frame 42 comprised of transverse members 44 and longitudinal members 46. A pivot casting 48 is secured to the longitudinal member 46 at each side of the bed and is used to support the outer frame unit 40 and to tilt the unit relative to the platform unit 10, as will be described hereinafter.
An inner frame unit 50 (shown partially rotated in FIG. 4) is rotatably supported within the pivotal or tilting frame 42. The inner frame unit 50 includes a rotating or gimbal frame 52, which is generally rectangular in shape and includes a transverse member 54 at the foot end of the bed and a transverse member 56 at the head end unitarily connected to longitudinal members 58 at each side of the gimbal frame.
The gimbal frame 52 is rotatably mounted by means of a shaft or axle 60 at the foot end of the bed and a similar shaft or axle 62 at the head end mounted on the center line of the gimbal frame 52. The clearance between both the transverse members and the longitudinal members of the gimbal frame and the pivotal frame is sufficient to virtually insure that the hands or fingers of a patient will not be pinched between the adjacent members during rotation of the gimbal frame. The principal structural components of the platform unit, as well as the inner and outer frame units, are preferably of closed tubular steel, welded to reduce the potential for contamination of crevices, fittings, and the like.
Four lugs 64 extend upwardly and four identical lugs extend downwardly from the gimbal frame 52, an opposed pair of lugs being positioned at each corner of the frame, as shown in FIGS. 1 and 2. Each lug includes a longitudinally bored journal 66, which is used for pinning and securing the mattress units to the gimbal frame, as described hereinafter.
A casting or clamp 68 is rigidly attached, as by welding, to the axle 62 at the head end of the gimbal frame, for mounting the axle on transverse member 56. FIG. 7 shows the casting or clamp 68 secured to transverse member 56 by means of a series of machine screws 70, so that rotation of the axle 62 will produce a concurrent rotation of the gimbal frame.
FIG. 1 shows the multipositional bed with a pair of mattress units, a lower mattress unit 80 secured to the lugs 64 beneath the gimbal frame and an upper mattress unit 82 in exploded perspective above the gimbal unit. The lower and upper mattress units may be identical in structure, and each includes a generally rectangular mattress frame 84 having transverse end members 86 and longitudinal side members 88. Each of the longitudinal side members 88 includes a connecting lug 90 extending vertically near each end to next with the corresponding lugs 64 of the gimbal frame. FIGS. 8 and 9 show an enlarged portion of the gimbal frame, showing the longitudinal member 58 of the gimbal frame and a lug 64 nested with and connected to lug 90 on the longitudinal side member 88 of the mattress frame 84. The lug 64 and lug 90 are shaped to nest together such that their journalled interiors line up and are pinned together with pin 91.
FIG. 1 also shows the cross-bracing members 92 on the upper mattress unit 82. Each cross-bracing member includes vertical legs 94 and a horizontal portion 96 which may be formed in a unitary construction or may consist of separate elements welded or otherwise securely fixed together.
Each mattress unit also includes a support unit 98, which is comprised of a flexible tension sheet or support member 100, such as a vinyl plastic, and a foam cushion element 102 (see FIGS. 5 and 8). The flexible mattress support member 100 is equipped with a tubular portion 104 around its periphery. A strengthening member 106, which may consist of a thin steel strip, extends the full length of the flexible mattress support 100 and also extends transversely across both ends of the support through the tubular portion 104. Screws 108 may be used to secure the support unit 98 to the rectangular mattress frame 84, as shown in FIGS. 1, 5, and 8, by sandwiching the strengthening member 106 within tubular portion 104 and the frame members.
FIG. 2 shows the bed with the lower mattress attached. The normal horizontal position of both the gimbal frame and the tilting frame are shown in solid lines. Also shown in broken lines "A" is the head-down or "Trendelenberg" position with the head end of the bed approximately at a 28° angle below the horizontal. A step on/step off position is shown in broken lines "B", in which the gimbal frame is maintained parallel to the tilting frame, but the tilting frame is raised to a position of about 86° from the horizontal. In this position, by using a clamp-on plate (not shown) to stand on at the foot of the bed a standing patient can easily be positioned against the bed without bending and then the bed can be lowered into normal resting position.
An intermediate position is shown in broken lines "C" in which the head end of the bed is raised to approximately 45° from the horizontal. This position may be used for various medical treatments and is also particularly desirable for use when a patient is to be rotated from a supine position to a prone position.
The method of rotating a patient from a supine position (face up) to a prone position (face down) is best illustrated by reference to FIGS. 1, 2 and 4. With the patient 109 positioned on his back in the bed in normal horizontal position, as shown in FIG. 1, elongated cushions or bolsters 83, rectangular in cross-section, are positioned along each side of the patient, as shown in FIG. 4, to brace the patient against sideways slippage. Then an air mattress or pad 85, in deflated form, is placed over the patient. An upper mattress unit is then positioned on top of the patient, and the connecting lugs 90 are engaged with the lugs 64 on the upper side of the gimbal frame, as previously discussed. The air pad 85 is then inflated sufficiently to immobilize the patient. The patient (and the bolsters) are thus sandwiched firmly between the lower mattress unit and the air pad and upper mattress unit. This prevents the patient from shifting position during the tilting or rotation of the bed. The upper mattress unit and air pad preferably have an opening 107 to permit the patient's face from being covered.
With the patient thus sandwiched securely in position, the tilting frame is tilted to elevate the head to approximately a 45° position, as shown in broken lines "C" in FIG. 2, and then the inner frame unit 50, as shown in FIG. 4, is rotated 180° so that the patient is face down with the original lower mattress unit becoming the upper mattress unit and vice versa. The tilting frame unit can then be lowered back to a horizontal position, after which the air pad can be deflated (and removed if desired) and the mattress unit above the patient can be removed leaving the patient facing downwardly on the lower mattress unit. Thus, the patient can be completely rotated in position without any physical movement or distortion at all on his part.
It is particularly important that the patient be lifted to approximately a 45° tilt position before the gimbal frame is rotated. This prevents the patient from having undue side slipping stresses, when the gimbal frame is perpendicular to the tilting frame, as would occur if the tilting frame were left in a horizontal position throughout the movement. On the other hand, it is important not to raise the tilting frame excessively above 45°, since an excessive tendency to slip toward the foot of the bed may occur. These precautions are particularly important where substantially complete immobilization of the patient is desired, as, for example, in the case of burn patients recovering from skin grafts which are located in positions in contact with the mattresses.
FIG. 3 shows the mechanisms which are employed to tilt the pivotal or tilting frame and to rotate the gimbal frame. The tilt frame drive mechanism includes a pair of transverse axles 110, which are engaged in openings in downwardly extending lugs 112 of the pivot castings 48 which cradle the longitudinal members 46 of the pivotal or tilting frame. The transverse axles 110 are supported by and rotate within conventional bearing or journal means 111 (see FIG. 5) which are secured to the side walls of the platform unit of the bed.
Each pivot casting 48 also includes a second lug descending downwardly and displaced from lug 112 toward the head end of the bed. The second lug 114 (see FIG. 6) is journalled to receive pin 116, which engages the journalled prongs 118 of clevis 120. The clevis 120 is secured to a lead screw drive means. The drive means consists of a hollow tube 122, affixed at its upper end to the clevis 120, a lead screw nut 124, affixed within the lower end of the hollow tube, and a lead screw 126, which threadedly engages and extends through nut 124.
The lead screw 126 is affixed at its lower end to a pinion bevel gear 128, which is rotatably mounted on, and is supported by, a bearing means 130, which includes conventional thrust bearings (not shown) to stabilize and support pinion bevel gear 128 and radial bearings (not shown) about transverse drive shaft 132 to permit the drive shaft to rotate within bearing means 130. The drive shaft 132 is also affixed to bevel ring gear 135, which engages pinion bevel gear 128.
The transverse drive shaft 132 extends through, and is mounted within, conventional journals or bearings 134 mounted on horizontal member 18 and brace member 15, as shown in FIG. 5.
Referring specifically to FIGS. 3 and 5, it can be seen that by engaging crank 34 with pulley drive shaft 136, the primary pulley 138 can be rotated, thus driving the drive belt 140 which, in turn, rotates secondary pulley 142. Pulley 142 extends downwardly through an opening in the upper wall 19 of member 18, fitting partially within the hollow interior 21 thereof. The secondary pulley is affixed to transverse drive shaft 132 and, thus, rotates bevel ring gear 135 to drive pinion bevel gear 128, thus rotating lead screw 126 within nut 124 of the lead screw drive means.
As the lead screw 126 threadedly moves through nut 124, it extends into or retracts from hollow tube 122, depending on the direction of rotation. When the lead screw 126 extends further into hollow tube 122, the tube is drawn downwardly pulling clevis 120 downwardly, and this, in turn, causes the head end of the bed to tilt downwardly, the tilting frame rotating about axles 110. Conversely, when the lead screw 126 is rotated to retract from nut 124, the hollow tube 122 and clevis 120 are forced upwardly, thus lifting the head end of the tilting frame.
As the mechanism is illustrated in FIG. 3, a clockwise rotation of crank 34 produces an elevation of the head end of the bed, and a counterclockwise rotation causes the head end of the bed to tilt downwardly.
FIG. 6 shows part of the tilt drive mechanism with the normal horizontal bed position depicted in solid lines, and the extreme head down position depicted in broken lines "A", and the step on/step off position depicted in broken lines "B".
While some variation is permissible, it has been found that for a normal size bed 88 inches in length and 34 inches high, the distance "X" between the axes of the transverse axles 110 of the tilting frame drive mechanism and the pins 116 securing the clevis 120 to the pivot casting 48 should be within the range from about 5 to about 8 inches and, preferably, in the range from about 6 to about 7 inches. If unduly short spacing between these pivot axes is used, the bed will lack necessary stability and also will impose undue stresses on the members of the drive mechanism or require much lower gear ratios to unduly lengthen the time required to tilt the bed. Also, if unduly long distances between the pivot axes are employed, it becomes impractical, with conventional lead screws, to move the bed through the full range of positions desired. The precise location of the axes along the length of the tilting frame depends on the length of frame used, and the transverse axles 110 must, in any event, be closer to the foot of the bed than the head, to enable the frame to tilt to a step on/step off position.
The rotating drive mechanism for rotating the gimbal frame within the tilting frame is enclosed in a protective and decorative housing 150, as shown in FIGS. 1, 2 and 4.
The details of the mechanism are illustrated in FIGS. 3 and 7. Therein is shown a crank 152, which may be detachably engaged with shaft 154 to rotate worm gear 156. The movement of the worm gear imparts rotation to driven gear 158, which is affixed to the shaft or axle 62, which extends through bearing means 160 and is affixed to the transverse member 56 at the head of the gimbal frame, as by welds 162 and bracket 68.
Bearing means 160 includes a bracket or casting 164 which may be mounted on transverse member 44 of the pivotal or tilting frame by means of screws 166. The bracket or casting 164 includes bosses 168 and 170 on either side of the casting and bearings or washers 172 to permit ready rotation of shaft 62 and the gimbal frame. The worm gear can be mounted relative to the driven gear 158 in any conventional manner. For illustrative purposes, it is shown in FIG. 7 as being mounted by means of bracket 174 which is secured to casting 164 with screw 175.
A particularly desirable feature of the invention permits removal of the cranks 34 and 152, so that, due to the lead screw and worm gear types of drive mechanisms, the gimbal frame and the tilting frame are both essentially locked in position. No normally encountered forces exerted, e.g., by heavy or violently moving patients, against the frames will cause any noticeable change of position.
A particular desirable feature which may be employed with the invention includes the use of a hollow tube for axle 62 to permit a multi-lead cable (shown in dotted lines 176) to extend all the way through the tube. The multi-lead cable can be used for telemetry or electrical monitoring devices attached to the patient and, thus, can be rotated with the patient without tangling the multiple leads and without the necessity for interrupting readings while the gimbal frame is rotated.
Many other uses and variations of the invention will be apparent to those skilled in the art, and while specific embodiments of this invention have been described, these are intended for illustrative purposes only. It is intended that the scope of the invention be limited only by the attached claims. | A medical bed is described in which mattresses are mounted in frames which can be rotated about a longitudinal axis and tilted about a transverse axis. The mattresses may be removable and adapted to permit enclosing a patient completely to permit 360° rotation. | 0 |
This application is a 371 of PCT/FR98/00035 filed Jan. 9, 1998.
FIELD OF THE INVENTION
The subject of the present invention, which relates to the field of fluorinated hydrocarbons, is the isomerization of hydrofluorocarbons (HFC) and, more particularly, that of 1,1,2,2-tetrafluoroethane (F134) into 1,1,1,2-tetrafluoroethane (F134a).
BACKGROUND OF THE INVENTION
F134a is one of the hydrofluorocarbons (HFC) falling within the context of the replacement of the chlorofluorocarbons (CFC) and hydrochlorofluorocarbons (HCFC) which have already been banned or are in the process of being banned because of their harmful effect on the stratospheric ozone layer.
Several ways of obtaining F134a are known, namely:
the fluorination of 1-chloro-2,2,2-tri-fluoroethane (F133a) in gas or liquid phase;
the fluorination of trichloroethylene in liquid phase;
the hydrogenolysis of 1,1-dichloro-1,2,2,2-tetrafluoroethane (F114a) or of 1-chloro-1,2,2,2-tetrafluoroethane (F124);
the isomerization of 1,1,2,2-tetrafluoroethane (F134).
According to the literature, the latter process is carried out using catalysts. Thus, Patents EP 365,296 and JP 03 261731 describe the use of chromium-based catalysts and U.S. Pat. No. 4,902,838 claims a catalyst of the fluorinated alumina type; Patent JP 02 115135 prefers to use a catalyst of the aluminium chlorofluoride type. The use of a catalyst is not always sufficient; thus, U.S. Pat. No. 4,902,838 recommends introducing oxygen into the medium so as to maintain the catalytic activity over time and Patent Application WO 95/15300 recommends introducing a source of chloride ions.
DESCRIPTION OF THE INVENTION
It has now been found that it is possible to isomerize F134 into F134a without the aid of a catalyst, by a simple heat treatment in the presence of hydrogen. This method may also apply to the isomerization of other HFCs, for example to that of 1,1,2-trifluoroethane (F143) into 1,1,1-trifluoroethane (F143a) or to that of 1,2-difluoroethane (F152) into 1,1-difluoroethane (F152a).
The subject of the present invention is therefore a process for the isomerization of a hydrofluorocarbon having a certain thermodynamic stability (HFC 1) into a hydrofluorocarbon of greater thermodynamic stability (HFC 2), characterized in that the hydrofluorocarbon HFC 1 is subjected to a heat treatment in the presence of hydrogen at a temperature above 500° C.
The process according to the invention is advantageously carried out at a temperature of between 500 and 1000° C., preferably between 600 and 750° C.
The pressure of the reaction may be between 0.1 and 50 bar, but it is preferred to work between atmospheric pressure and 20 bar.
The H 2 /HFC 1 molar ratio may range from 1 to 100, but it is generally preferred to work with a molar ratio of between 2 and 20. The flux of reactants (HFC 1 and H 2 ) entering the reactor may be diluted with an inert gas, such as helium or nitrogen.
The residence time of the reactants in the hot part of the reactor may vary over wide ranges. It varies inversely with the temperature and is generally between 0.1 and 1000 seconds, preferably between 1 and 300 seconds.
The isomerization may be carried out in an empty reactor, i.e. a reactor which contains no packing but which may, however, be equipped with thermocouples and baffles. The reactor may be made of quartz or metal. In this case, the metal of the material forming the reactor may be chosen from metals such as nickel, iron, titanium, chromium, molybdenum, cobalt and gold, or their alloys. The metal, chosen more particularly for limiting the corrosion or the catalytic phenomena, may form a solid wall or it may be plated onto another metal, as in the case of a reactor gold-plated on its internal surface.
EXAMPLES
The following examples illustrate the invention without limiting it.
Examples 1 to 3
Trials were carried out at atmospheric pressure in a quartz tube reactor, having a length of 47 cm and an internal diameter of 2.1 cm, placed in an electric furnace having a power of 1.5 kW; the temperature of the furnace was measured using a thermocouple.
The reactants (F134 and H 2 ) were introduced simultaneously via mass flow meters allowing the flow rates, and therefore the molar ratios, to be controlled.
The gaseous products were analysed by in-line chromatography (GC) at the outlet of the reactor.
The following table summarizes the operating conditions and the results obtained.
EXAMPLE
1
2
3
Operating conditions:
temperature (° C.)
700
700
700
H 2 flow rate (mmol/h)
509
187.1
29.9
F134 flow rate (mmol/h)
50.4
96
31.7
residence time (s)
10
21
95
Results:
conversion of F134
23%
27%
47%
F134a selectivity
81%
82%
81%
Examples 4 to 6
Trials were carried out at atmospheric pressure in a quartz tube reactor, having a length of 47 cm and an internal diameter of 1.5 cm, placed in an electric furnace having a power of 1.5 kW; the temperature of the furnace was measured using a thermocouple.
The following table summarizes the operating conditions and the results obtained:
EXAMPLE
4
5
6
Operating conditions:
temperature (° C.)
700
700
700
H 2 flow rate (mmol/h)
301.3
141.5
59.8
F134 flow rate (mmol/h)
15.2
15.2
15.2
residence time (s)
4.9
9.9
20.6
Results:
conversion of F134
13%
24%
38%
F134a selectivity
84%
78%
79%
Example 7
The operation was carried out as in Examples 1 to 3, but by replacing the quartz reactor with a reactor made of Inconel 600 of the same size. By working under the following operating conditions:
temperature
700° C.
H 2 flow rate
29.9 mmol/h
F134 flow rate
31.7 mmol/h
residence time
95 seconds
a conversion of F134 of 44% and an F134a selectivity of 74% were obtained.
Comparative Examples 8 and 9
The operation was carried out in the same way as in Examples 1 to 3, but by replacing the hydrogen with helium. The following table summarizes the operating conditions and the results obtained:
EXAMPLE
8
9
Operating conditions:
temperature (° C.)
700
700
He flow rate (mmol/h)
312.1
35.3
F134 flow rate (mmol/h)
22.3
31.7
residence time (s)
18
95
Results:
conversion of F134
3%
15%
F134a selectivity
33%
60%
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims. The above references are hereby incorporated by reference. | In order to isomerize a hydrofluorocarbon having a certain thermodynamic stability (HFC 1) into a hydrofluorocarbon of greater thermodynamic stability (HFC 2), the hydrofluorocarbon HFC 1 is subjected to a heat treatment in the presence of hydrogen at a temperature above 500° C.
This process, which does not require the use of a catalyst, applies especially to the isomerization of 1,1,2,2-tetrafluoroethane into 1,1,1,2-tetrafluoroethane. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a tissue-specific gene promoter, and in particular, to a promoter useful for anther-specific expression in plant, and application thereof.
[0003] 2. Description of the Prior Art
[0004] In the improvement of crop's characteristics, or in relative studies utilizing plant gene transfer technology, conventionally, a gene to be expressed or studied is constructed downstream of a specific promoter sequence and the gene to be studied is then expressed or modulated with the activation ability of said promoter. Among conventional techniques, over-expressing the target gene is mostly driven by the CaMV 35S promoter in plant. Unfortunately, CaMV 35S promoter is not a tissue-specific promoter in that it can not over-express a target gene at a specific plant tissue. Therefore, how to make over-expression of a target gene at a specific plant tissue or in a particular period is the key point to modulate a gene's expression.
[0005] Accordingly, for researches of bioscience or developments of the biotechnical industry, how to screen out promoters with different specificity to drive the expression of a transferred target gene at a target site and bring out a maximum benefit of gene transfer is the important topic for improving the development of biotechnical industry and increasing the economical benefit of crops.
[0006] At present, molecular biologists have found a number of promoters having spatial (i.e., specific cell or tissue) or temporal (i.e., at different growth and development stages) specificities, or promoters inducible by a specific substance such as UV-B or chemical substances, that can be used to activate the expression of a transferred target gene to achieve the purpose of modulating gene expression.
[0007] In genetic breeding, “heterosis” is a very important research trend for obtaining crop with better character. Heterosis is to be understood to mean that a first hybrid progeny (F1 progeny) generated from the hybridization of two parents has a character with average performance better than either parent. In the course of hybridization, if the crop of interest is a selfing crop, the parent should be subjected first to artificial castration and then pollination to increase in order to avoid selfing, which increases production cost. For example, in the breeding study of Cruciferae vegetables, selfing lineage of self incompatibility is currently used mostly to carry out F1 seed collection. Nevertheless, several bottlenecks such as instability of hybridization rate, difficulty in the propagation of selfing parent line, low seed collection due to selfing depression, as well as the unlikeliness for superior parent to have self incompatibility exist yet. To activate particular genes that may result in male sterility or ability to silence pollination-associated gene by means of an anther-specific promoter shall be an important contribution for improving character by applying biotechnology.
[0008] Though many studies have found promoters with anther- or pollen-specific activation activity, such as potato (Lang et al., 2008), tomato (Bate and Twell, 1998), maize (Hamilton et al., 1998), rice (Gupta et al., 2007), petunia (Garrido et al., 2006), antirrhinum (Lauri et al., 2006), lily (Okata et al. 2005), cabbage (Park et al., 2002) and the like, no study on gene promoter associated with an orchid has been reported so far.
[0009] Oncidium Gower Ramsey is an important export cut flower for Taiwan. Its flower has a bright yellow color. Since customers desire visual aesthetic feeling and prefer novel flower colors, flower color becomes one of the important factors determining values in the flower crop industry and articles. In view of the foregoing, the inventors attempted to isolate genes associated with the biosynthesis of yellow pigment from Oncidium, and screened out promoters with tissue-specificity through the analysis of a promoter of aureusidin synthase gene.
[0010] Also, in view of the importance of developing promoters with distinct specificity for the biotechnology industry, the inventors had been devoted to improve and innovate, and, after intensive studying for many years, has developed successfully a anther-specific expression promoter in plant, and application thereof according to the invention.
SUMMARY OF THE INVENTION
[0011] One object of the invention is to provide a tissue-specific promoter useful for the specific expression in plant anther.
[0012] Another object of the invention is to provide an application of the anther-specific expression promoter in plant, wherein, by using the particular tissue-specificity of said promoter, there is overexpression of the target gene on the anther of plant.
[0013] Still another object of the invention is to provide a gene expression vector containing an anther-specific expression promoter that, through transferring a target gene via said vector into plant cell, overexpression of said gene can be done specifically on the anther of said plant under the control of said promoter.
[0014] As promoter useful for plant anther-specific expression to achieve the above-described objects of the invention, the source for the sequence of said promoter is the genomic DNA of Oncidium Gower Ramsey. To this end, a gene fragment of aureusidin synthase gene AmAS1 (GenBank accession number AB044884, SEQ ID No: 1) from Antirrhinum majus was used as a probe, a plaque hybridization reaction was carried out with Oncidium genomic DNA library. The resulting products were purified several times to obtain Oncidium aureusidin synthase genomic clone, which was then subjected to restriction map analysis and nucleic acid sequencing. After matching with cDNA sequence of Oncidium aureusidin synthase gene OgAS1 (SEQ ID No: 2), it could be confirmed that a local sequence of 3,014 bp (SEQ ID No: 3) at upstream of the translation start site (gene code: ATG) of Oncidium aureusidin synthase gene OgAS1, which comprised a promoter local sequence of 2,985 bp, and a 29 bp 5′-end untranslated region (5′UTR) in the first exon (exon 1) of Oncidium aureusidin synthase gene OgAS1. This 3,014 bp DNA sequence (SEQ ID No: 3) was used as Oncidium aureusidin synthase gene OgAS1 promoter.
[0015] In order to analyze whether said Oncidium aureusidin synthase gene OgAS1 promoter (SEQ ID No: 3) was tissue-specific, said promoter sequence was ligated to the 5′-end of the gene sequence of a reporter gene β-glucuronidase (GUS) to be used as the promoter for said reporter gene. The ligation product was then constructed into an Agrobacterium tumefaciens cloning vector to form a plasmid OgAS1p-GUS; then, by using Agrobacterium tumefaciens transfection, said OgAS1p-GUS plasmid was transferred into model plants Arabidopsis thialana and Nicotiana tabacum L., and the activity of said gene promoter was assayed by GUS histochemical staining. The result indicated that said Oncidium aureusidin synthase gene OgAS1 promoter (SEQ ID No: 3) could drive target gene to be expressed at the plant anther. Accordingly, the activation ability of Oncidium aureusidin synthase gene OgAS1 promoter (SEQ ID No: 3) according to the invention was extremely tissue-specific.
[0016] In addition to providing a promoter useful for plant anther tissue-specific expression, the invention also provides a gene expression cassette, said gene expression cassette consists of: (1) a promoter sequence (SEQ ID No: 3) according to the invention, and (2) a stretch of polynucleotide encoding an open reading frame (ORF), that is a target gene, wherein said polynucleotide is connected to the 3′ end of the promoter according to the invention, and said promoter can activate the transcription of said polynucleotide in a organism containing said gene expression cassette. In a preferred embodiment, said target gene is a reporter gene β-glucuronidase (GUS).
[0017] Further, the Oncidium aureusidin synthase gene OgAS1 promoter (SEQ ID No: 3) according to the invention was constructed into a commercial gene cloning vector, including, but not limited to, pBI101, pBI121, pBIN19 (ClonTech), pCAMBIA1301, pCAMBIA1305, pGREEN (GenBank Accession No: AJ007829), pGREEN II (GenBank Accession No: EF590266) (www.pGreen.ac.uk), or pGreen0029 (John Innes Centre), to form a gene expression vector. A target gene could be inserted in said gene expression vector such that said target gene was connected to the 3′ end of the promoter according to the invention to form the above-described gene expression cassette. Through gene transferring, the promoter of the invention together with the target gene linked to its 3′ end could be transferred into an objective plant, and further, the genomic constitution of the transgenic plant might be altered such that the promoter of the invention and said target gene could activate effectively the expression of said target gene in the objective transgenic plant and its progeny.
[0018] In another aspect, the invention provides a method for producing a transgenic plant or part of the organs of said transgenic plant.
[0019] In still another aspect, the invention provides a method for producing a tissue or cell containing the above-described gene expression cassette, said method comprising steps of:
[0020] step 1: providing cells or tissue of an objective plant;
[0021] step 2: transfecting a gene expression cassette containing promoter sequence (SEQ ID No: 3) of the invention into said cells or tissue of an objective plant obtained in step 2 to obtain a transfected cell or tissue of the plant; and
[0022] step 3: cultivating said transfected cell or tissue of the plant obtained in step 2 to generate a transgenic plant or part of organs of said transgenic plant containing gene expression cassette encoding promoter sequence (SEQ ID No: 3) of the invention.
[0023] In step 2 of the above method, said transfection includes, but not limited to: Agrobacterium tumefaciens -mediation, gene recombination viral infection, transposon vector transformation, gene gun transformation, electroporation, microinjection, pollen tube transformation, liposome-mediated transformation, ultrasonic-mediated transformation, silicon carbide fiber-mediated transformation, electrophoresis, laser microbeam, polyethylene glycol (PEG), calcium phosphate transformation, DEAE-dextran transformation and the like.
[0024] These features and advantages of the present invention will be fully understood and appreciated from the following detailed description of the accompanying Drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0026] FIG. 1 is the result of Northern hybridization analysis for Oncidium; FIG. 1A shows the result of using Oncidium aureusidin synthase gene OgAS1 as the probe to analyze the expression of said gene in different sites of Oncidium plant; FIG. 1B shows the result of using actin as the internal control; wherein lane 1: root; lane 2: pseudo-bulb; lane 3: leaf; lane 4: flower.
[0027] FIG. 2A is a restriction map of the genome of Oncidium aureusidin synthase gene OgAS1 according to the invention; FIG. 2B shows the construction strategy for the plasmid OgAS1p-GUS containing the inventive Oncidium aureusidin synthase gene OgAS1 promoter.
[0028] FIG. 3 is a construction strategy for Agrobacterium tumefaciens cloning vector pGKU.
[0029] FIG. 4 shows analytical results of the expression of reporter gene β-glucuronidase (GUS) at various tissue sites of the progeny from Arabidopsis thialana transformants containing OgAS1p::GUS-NOS gene expression cassette; FIG. 4A : whole plant of 45-days old; FIG. 4B : siliques of Arabidopsis thialana; FIG. 4C : floral organ of Arabidopsis thialana; FIG. 4D : floral organ of Arabidopsis thialana; all anther present blue color.
[0030] FIG. 5 shows analytical results of the expression for reporter gene β-glucuronidase (GUS) at various tissue sites in the progeny of Nicotiana tabacum L. transformant containing OgAS1p::GUS-NOS gene expression cassette: FIG. 5A : whole seedling at vegetative growth stage; FIG. 5B : floral organ of Nicotiana tabacum L., only anther presenting blue color; FIG. 5C : the pistil and stamen of Nicotiana tabacum L.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
EXAMPLE 1
Northern Hybridization Analysis of Oncidium Aureusidin Synthase Gene
[0031] In order to reveal the expression site of Oncidium aureusidin synthase gene at Oncidium, RNA was extracted from various organs of Oncidium plant, and Northern hybridization analysis was carried out by using Oncidium aureusidin synthase gene OgAS1 (SEQ ID No: 2) as the probe.
1. Extraction of Oncidium RNA
[0032] 5 g of Oncidium material was ground with liquid nitrogen in a mortar. To each gram of ground tissue was added 2-3 ml of sarcosyl-free solution D [4 M guanidiun thiocyanate, 25 mM sodium citrate (pH 7.0), 0.1 M β-mercaptoethanol], and equal volume of PCI (phenol:chloroform:isoamyl alcohol=25:24:1), and the resulting mixture was mixed homogeneously in a homogenizer. Additional sarcosyl was added to a final concentration of 0.5%. After being mixed further in homogenizer, the mixture was centrifuged at 4° C. 10,800 rpm for 20 minutes (Beckman J2-MC, JS 13.1). The supernatant was drawn and extracted with equal volume of PCI, followed with equal volume of CI (chloroform:isoamyl alcohol=49:1). The supernatant was subjected to extracting by adding 1/10 volume of 3 M NaOAc (pH 5.2) and 2.5-fold volume of −20° C. 100% ethanol, shaking homogeneously and left to precipitate at −80° C. overnight. On the next day, the mixture was centrifuged at 4° C. 10,800 rpm for 15 minutes. The pellet was washed with each of 2 mL of 70% and 100% ethanol, and then centrifuged at 4° C. 10,800 rpm for 5 minutes. The supernatant was discarded, and RNA was dissolved completely in water treated with diethyl pyrocarbonate (DEPC). To the solution, LiCl was added to a final concentration of 2.5M. Then, 1% β-mercaptoethanol was added, and the solution was allowed to precipitate at −80° C. overnight. On the next day, it was centrifuged at 4° C. 10,800 rpm for 90 minutes. The pellet was washed with 70% and 100% ethanol. RNA thus obtained was air-dried, and dissolved again for quantitative analysis.
2. Northern Hybridization Analysis of Oncidium Aureusidin Synthase Gene
[0033] 20 μg of total Oncidium RNA was glyoxylated at 50° C. for one hour, with a total reaction volume of 50 μL, comprising 10 mM sodium phosphate buffer (pH 7.0), 1 M deionized glyoxal, and 50% dimethyl sulfate. At the end of reaction, 10 μL 1× RNA loading buffer dye [containing 50% glycerol, 10 mM sodium phosphate (pH 7.0), 0.25% bromophenol blue] was added and electrophoresis was carried out on 1% agar gel. Then, the gel was treated with 50 mM sodium hydroxide for 30 minutes, and then with 200 mM sodium acetate for 30 minutes. The gel was then soaked in 1× TBE buffer [consisting of 90 mM Tris base, 2 mM EDTA (pH 8.0), and 89 mM boric acid] containing 1 μg/mL of ethidium bromide under shaking for 30 minutes. RNA loaded on the thus-treated gel was blotted on Hybond N membrane by capillary method. After 16-24 hours, its was treated with 5× SSPE at 65° C. for 5 minutes, and then dried in a vacuum oven at 80° C. for one hour. The membrane was transferred in a pre-hybridization solution (consisting of 5× SSPE, 5× BFP, 0.5% SDS, 50% formamide, 100 μg/mL salmon sperm DNA), and pre-hybridization reaction was carried out at 42° C. for more than 2 hours. Thereafter, the membrane was transferred in hybridization solution (consisting of 5× SSPE, 5× BFP, 0.5% SDS, 200 μg/mL salmon sperm DNA, 10% Dextran sulfate), where a hybridization reaction was performed at 65° C. for 16-18 hours. At the end of the reaction, it was washed twice with 2× SSPE and 0. 1% SDS at room temperature for 15 minutes. The blotted membrane was then washed again with 1× SSPE and 0.1% SDS at 65° C. for 15 minutes. It was then subjected to exposure by pressing against an X-ray film. The result was shown in FIG. 1 , and was indicated that the gene was expressed mainly at floral organ.
EXAMPLE 2
Cloning of Oncidium Aureusidin Synthase Gene Promoter
1. Source of Oncidium λEMBL3 Genomic Library (Genomic Library)
[0034] Oncidium genomic library was constructed by extracting genome DNA from leaves of Oncidium Gower Ramsey, which, by using bacteriophage λEMBL3 as vector, and replacing DNA through enzymatic cleavage, was used to construct said genomic library.
2. Preparation of Nucleic Acid Probe and Labeling
[0035] A gene fragment of aureusidin synthase gene AmAS1 (GenBank accession number AB044884, SEQ ID No: 1) from Antirrhinum majus was used as a template to prepare a nucleic acid probe by means of Prime-A-Gene kit (Promega, USA) under following conditions: total reaction volume: 50 μL; reaction mixture consisting of 1× labeling buffer, pH6.6 {50 mM Tris-HCL, pH8.3, 5 mM MgCl 2 , 2 mM DTT, 0.2 M HEPES [N-(2-hydroxyethyl)piperazine-N′-(2-ethanesulfonic acid)], 26A 260 unit/mL of random hexadeoxyribonicleotides}, 20 μM each of dATP, dGTP, dTTP, 500 ng/mL denatured DNA template, 400 μg/mL of Bovine serum albumin (BSA), 50 μCi [α- 32 P] dCTP (333 nM), and 5 unit Klenow DNA Polymerase. After reacting at 37° C. for 2 hours, 2 μL 0.5 M EDTA (pH8.0) was added to terminate the reaction, followed by adding 8 μL of tracing dye (50% glycerol, 0.25% bromophenol blue). The reaction solution was passed through a Sephadex-G50 chromatograph column, eluted with TE buffer (pH7.6), and fractions of each 160˜180 μL was collected in tubes. Each tube was counted in a liquid scintillation counter (Beckman 1801) to determine the radioactivity. Fractions with maximum radioactivity were used as the probe.
3. Selection of Oncidium Aureusidin Synthase Genomic Library
[0036] Plaque hybridization was used to select Oncidium genomic library. To this end, E. coli XL1-Blue MRA (P2) strain was used as the infection host for λEMBL3, and was cultivated in NZY medium (5 g/l of NaCl, 2 g/l of MgSO 4 -7H 2 O, 5 g/l of yeast extract). Selection was carried out under high stringency to obtain total of 150 million plaque forming units.
[0037] Next, bacteriophages were transferred on nitrocellulose membrane. The membrane was treated first with denaturing buffer (0.5 M NaOH, 1.5 M NaCl) for 2 minutes, and then treated with neutralization buffer [0.5 M Tris base, 1.5 M NaCl, 0.035% HCl (v/v)] for 5 minutes. Finally, it was soaked in 2× SSPE (1× SSPE, consisting of 0.18 M NaCl, 10 mM NaH 2 PO 4 , 1 mM EDTA pH7.4) for 30 seconds. It was placed in a vacuum oven at 80° C. for 2 hours to fix bacteriophage DNA. Thereafter, it was placed in a solution containing 2× SSPE and 0. 1% SDS, and was shaken at room temperature for 1 hour. The nitrocellulose membrane thus treated was transferred in a pre-hybridization solution consisting of 5× SSPE, 5× BFP (1× BFP containing 0.02% BSA, 0.02% Ficoll-400000, 0.02% PVP-360000), 0.1% SDS, 50% formamide and 500 μg/mL of salmon sperm DNA, and a pre-hybridization reaction was carried out at 42° C. for 2 hours. A radio-labeled probe was used to carry out hybridization reaction with the membrane in 5× SSPE, 1× BFP, 0.1% SDS, 50% formamide and 100 μg/mL of salmon sperm DNA at 42° C. for 16˜18 hours. Then, the nitrocellulose membrane was treated twice with wash buffer I (5× SSPE, 0.1% SDS) at room temperature for 15 minutes. Subsequently, the nitrocellulose membrane was further treated twice each with wash buffer II (1× SSPE, 0.5% SDS) at 37° C. for 15 minutes to wash off non-specific probe. After developing by exposure against X-ray film at −80° C. (Kodak XAR film), bacteriophage bearing target gene DNA could be detected. Said bacteriophage was isolated from medium and was stored in SM buffer containing 0.03% chloroform and was subjected to purification several times to obtain Oncidium aureusidin synthase gene OgAS1 genome clone λOgAS9.
[0000] 4. DNA Extraction from λOgAS9 Bacteriophage Clone
[0038] Bacteriophage liquor of the above-described objective clone λOgAS9 was applied over NZY solid medium by scribing bacteriophage liquor with toothpick. 3 mL Top agar containing host cell E. coli XL1-Blue MRA (P2) was added and cultivated on the NZY solid medium at 37° C. for 8 hours. On the next day, a single plaque agar gel was dug from one line with a capillary and was cultivated further by spreading over NZY solid medium at 37° C. for 7˜11 hours. Then, the culture medium was transferred to a refrigerator at 4° C., SM was added to release bacteriophages. The solution was collected in a centrifuge tube and chloroform was added thereto to 0.03%. The resulting mixture was centrifuged at 4° C. 7,000 rpm (Beckman J2-MC, JS-13.1) for 5 minutes, and then stored at 4° C. for use. Thereafter, large amount of the objective bacteriophage clone reproduced above was used to transfect host cells at a ratio of 5:1. To this, 1 mL SM buffer and 5 mL of 2.5 mM CaCl 2 was added and mixed, stored at room temperature for 15 minutes, and then at 37° C. for 45 minutes. It was then poured into 100 mL of 2× NZY liquid medium (0.4% MgSO 4 □7H 2 O, 2% NaCl, 1% bacto-yeast extract, 2% NZ amine, 0.2% casaimino acid, 5 mM MgSO 4 , 25 mM Tris-HCl pH7.5), and cultivated by shaking at 37° C. and 240 rpm for more than 8 hours. Thereafter, 4.5 mL chloroform was added thereto, and was treated by shaking at 37° C. and 240 rpm for 15 minutes, followed by centrifuged at 4° C. and 7,000 rpm for 20 minutes (Beckman J2-MC, JA 10 rotor). To its supernatant, 100 μL DNase I (1 mg/mL) and 100 μL RNaseA (10 mg/mL) were added, and the resulting mixture was treated at 37° C. and 80 rpm for 45 minutes. Next, 33 mL of 4 M NaCl was added, placed in an ice bath for 1 hour; followed by adding 33 mL of ice cold 50% polyethylene glycol, and settled at 4° C. overnight. The mixture was centrifuged at 4° C. and 5,000 rpm for 20 minutes (Beckman J2-MC, JA 10 rotor). The supernatant was discarded, and the pellet was air-dried. The solid precipitate was re-suspended in 500 μL PKB solution (10 mM NaCl, 10 mM Tris-HCl pH8.0, 10 mM EDTA, 0.1% SDS). To this suspension, proteinase K (final concentration 12.5 μg/mL) was added, and the resulting mixture was reacted at 37° C. for 20 minutes. The reaction mixture was then extracted successively with equal volume of phenol, PCI (phenol:chloroform:isoamyl alcohol=25:24:1), and CI (chloroform:isoamyl alcohol=24:1). The combined extract was centrifuged at room temperature and 14,000 rpm for 5 minutes. To the supernatant, 2-fold volume of −20° C. 100% ethanol was added, and the resulting mixture was centrifuged at 4° C. and 14,000 rpm for 10 minutes. The supernatant was decanted off, and the pellet was air-dried. The precipitated DNA was washed with 70% ethanol and 100% ethanol, respectively, dissolved in TE buffer (pH7.5), and stored at 4° C. for use.
5. Sequencing of DNA
[0039] An automatic nucleic acid sequencer ABI sequencer 377 was used to perform the sequencing of DNA, and thus determined the sequence of Oncidium aureusidin synthase genomic clone λOgAS9. It was analyzed with PC/Gene software available from IntelliGenetics Inc., and the result was shown in FIG. 2A . As shown, Oncidium aureusidin synthase genomic clone λOgAS9 had 2 exons, exon 1 and exon 2, with its translation start site (gene code: ATG) located at 30˜32 nucleotides in exon 1, while the 3,014 bp local sequence of the promoter ahead of the transcription start site of the exon 1 (i.e. the first nucleic acid sequence on the exon 1) was as shown in SEQ ID No: 3.
EXAMPLE 3
Construction of a Vector Containing Oncidium Aureusidin Synthase Gene OgAS1 Promoter
[0040] As shown in FIG. 2B , the construction strategy of Oncidium aureusidin synthase gene OgAS1 promoter comprised of constructing the 3,014 bp promoter sequence (SEQ ID No: 3) ahead of the translation start site of Oncidium aureusidin synthase gene OgAS1 into an Agrobacterium tumefaciens cloning vector pGKU to replace the original CaMV 35S promoter (35Sp) in a manner that the 3′ end of the Oncidium aureusidin synthase gene OgAS1 promoter (SEQ ID No: 3) was linked to the 5′ end of reporter gene β-glucuronidase (GUS) gene sequence, and used as the promoter of said reporter gene.
[0000] Step 1: Construction of Agrobacterium Tumefaciens Cloning Vector pGKU
[0041] The construction strategy of Agrobacterium tumefaciens cloning vector pGKU was shown in FIG. 3 . Briefly, a fragment of CaMV 35S promoter (35Sp)-reporter gene (GUS)-terminator (NOS-ter) (CaMV 35S::GUS-NOS) in a commercial vector pRT99GUS was constructed into a commercial Agrobacterium tumefaciens cloning vector pGreen0029 (John Innes Centre) to obtain Agrobacterium tumefaciens cloning vector pGKU. The construction strategy utilized polymerase chain reaction (PCR) to synthesize CaMV 35S promoter (35Sp) DNA fragment and reporter gene (GUS)-terminator (NOS-ter) DNA fragment, respectively, wherein, by means of the design of PCR primer, cleavage sites of NcoI restrictive enzyme were inserted at the 3′ end of CaMV 35S promoter (35Sp) DNA fragment and the 5′ end of reporter gene (GUS)-terminator (NOS-ter) DNA fragment, respectively. Finally, both PCR fragments were constructed into pGreen0029 to obtain Agrobacterium tumefaciens cloning vector pGKU.
[0000] Step 1.1: Obtaining CaMV 35S Promoter (35Sp) Fragment from Commercial Vector pRT99GUS
[0042] DNA of commercial vector pRT99GUS was used as the template, and the amplification of the DNA sequence of CaMV 35S promoter (35Sp) fragment was carried out through PCR, wherein sequences of primers used in said PCR were as followed:
forward primer S5 (containing HindIII restrictive enzyme cleavage site):
[0000]
5′-tgcatgcatgc aagctt g-3′
(SEQ ID No: 4)
HindIII
reverse primer S3 (containing NcoI restrictive enzyme cleavage site):
[0000] (SEQ ID No: 5) 5′-ata ccatgg cccggggatcctctagagtcgaggtcct-3′ NcoI
The total reaction volume of PCR was 50 μl (consisted of: 1 μl genome DNA, 10 μl 5× Phusion HF buffer, 1 μl 10 mM dNTP, 1 μl 20 of μM forward primer, 1 μl of 20 μM reverse primer, 35.5 μl of sterile water, 0.5 μl Phusion DNA polymerase) and PCR conditions were: 98° C. for 30 seconds, followed with total 35 cycles of 98° C. 10 seconds, 60° C. 30 seconds, and 72° C. 60 seconds, and finally 72° C. for 10 minutes as elongation. PCR product of 544 bp in length was synthesized. PCR product was digested with HindIII and NcoI restrictive enzymes, and DNA fragment (fragment S) of 470 bp in length was recovered and stored at 4° C. till used.
Step 1.2: Obtaining Reporter Gene (GUS)-Terminator (NOS-Ter) Fragment from Commercial Vector pRT99GUS
[0045] Likewise, DNA of a commercial vector pRT99GUS was used as the template, and polymerase (PCR) was carried out to amplify DNA sequence of reporter gene (GUS)-terminator (NOS-ter) fragment, sequences of primers used in the PCR were as followed:
forward primer G5 (containing NcoI restrictive enzyme cleavage site):
[0000]
5′-ata ccatgg tacgtcctgtag-3′
(SEQ ID No: 6)
NcoI
reverse primer G3 (containing HindIII restrictive enzyme cleavage site):
[0000] 5′-acggccagtgcc aagctt gcat-3′ (SEQ ID No: 7) HindIII
Total reaction volume of PCR was 50 μl (consisted of:1 μl genome DNA, 10 μl 5× Phusion HF buffer, 1 μl of 10 mM dNTP, 1 μl of 20 μM forward primer, 1 μl of 20 μM reverse primer, 35.5 μl of sterile water, 0.5 μl Phusion DNA polymerase). PCR conditions were: 98° C. for 30 seconds, followed with total 35 cycles of 98° C. 10 seconds, 60° C. 30 seconds, 72° C. 60 seconds, and finally, 72° C. for 10 minutes as elongation. PCR product of 2,108 bp in length was synthesized. The PCR product was digested with HindIII and NcoI restrictive enzymes, DNA fragment (fragment G) of 2,093 bp in length was recovered and stored at 4° C. till used.
Step 1.3: Ligation of DNA
[0048] A commercial vector pGreen0029 was digested with HindIII restrictive enzyme. DNA fragment (fragment P) of 4,632 bp in length was recovered. DNA ligation was carried out on fragment P together with fragment S (step 1.1) and fragment G (step 1.2) to obtain Agrobacterium tumefaciens cloning vector pGKU. As shown in FIG. 3 , in Agrobacterium tumefaciens cloning vector pGKU, in addition to the character of pGreen, there were a CaMV 35S promoter (35Sp)-reporter gene (GUS)-terminator (NOS-ter) DNA fragment from commercial vector pRT99GUS, and an NcoI restrictive enzyme cleavage site at the 3′ end of CaMV 35S promoter (35Sp). Accordingly, by means of the SmaI restrictive enzyme cleavage site in pGreen0029 as the multiple cloning site and NcoI restrictive enzyme cleavage site, Agrobacterium tumefaciens cloning vector pGKU could replace CaMV 35S promoter (35Sp) with other promoter sequence so as to activate reporter gene GUS.
[0000] Step 2: Obtaining Oncidium Aureusidin Synthase Gene OgAS1 promoter (OgAS1p) Sequence
[0049] Genomic DNA extracted from leaves of Oncidium Gower Ramsey plant in Example 2 was used as the template, polymerase chain reaction (PCR) was carried out to amplify the 3,014 bp sequence (SEQ ID No: 3) ahead the translation start site of Oncidium aureusidin synthase gene OgAS1, wherein, through the design of PCR primer, NcoI restrictive enzyme cleavage site was inserted at the 3′ end of the fragment for subsequent construction.
[0050] Sequences of primers used in PCR were as followed:
[0000]
forward primer P1:
5′-gcattctagtgctctgaatgc-3′
(SEQ ID No: 8)
reverse primer P2(containing externally added NcoI restrictive enzyme cleavage site):
[0000] reverse primer P2 (containing externally added NcoI restrictive enzyme cleavage site): 5′-aca ccatgg tgattgatgatc-3′ (SEQ ID No: 9) NcoI
Total reaction volume of PCR was 50 μl (consisted of:1 μl genome DNA, 10 μl 5× Phusion HF buffer, 1 μl of 10 mM dNTP, 1 μl of 20 μM forward primer, 1 μl of 20 μM reverse primer, 35.5 μl of sterile water, 0.5 μl Phusion DNA polymerase). PCR conditions were: 98° C. for 30 seconds, followed with 35 cycles of 98° C. 10 seconds, 65° C. 30 seconds, and 72° C. 60 seconds, and finally, 72° C. 10 minutes as elongation. PCR product was digested with NcoI, whole length DNA fragment was recovered and stored at 4° C. till used.
Step 3: Ligation of DNA
[0052] Agrobacterium tumefaciens cloning vector pGKU obtained in step 1 was subjected to double SmaI+NcoI restrictive enzyme digestion. pGKU vector thus digested was recovered, and was ligated with DNA fragment prepared in step 2 to obtain plasmid OgAS1p-GUS bearing Oncidium aureusidin synthase gene OgAS1 promoter sequence (SEQ ID No: 3). In said OgAS1p-GUS plasmid, DNA sequence of reporter gene β-glucuronidase (GUS) was linked to the 3′ end of Oncidium aureusidin synthase gene OgAS1 promoter (OgAS1p::GUS-NOS). Consequently, upon transformation of OgAS1p-GUS plasmid in a plant body through Agrobacterium tumefaciens transformation, analysis on the mode for activating the gene expression of reporter gene β-glucuronidase (GUS) by Oncidium aureusidin synthase gene OgAS1 promoter could be studied.
EXAMPLE 4
Transfection into Arabidopsis Thialana Columbia via Agrobacterium Tumefaciens -Mediated Process
[0053] Model plant Arabidopsis thialana Columbia was used as the material, and plasmid OgAS1p-GUS prepared in example 3 was transfected into Arabidopsis thialana Columbia by means of Agrobacterium tumefaciens inflorescence infiltration process in a manner that the genomic constitution in the transgenic plant could be altered. As a result, the Oncidium aureusidin synthase gene OgAS1 promoter could activate the expression of reporter gene GUS in the objective transgenic plant and progeny thereof. In addition, expression site of reporter gene GUS on Arabidopsis thialana Columbia transformant could be analyzed by GUS histochemical staining, and hence detected whether Oncidium aureusidin synthase gene OgAS1 promoter exhibited tissue-specificity.
1. Cultivation of Arabidopsis Thialana Columbia Plant Material
[0054] Seeds of Arabidopsis thialana were wet and cold stratified at 4° C. for 2-4 days and sowed in a medium consisting of peat:Perlite:vermiculite in a ratio of 10:1:1. Cultivation conditions were: 22-25° C., 16 hours light cycle, and 75% relative humidity. After about 4-6 weeks, the plant was pruned. As the rachis had grown to a length of about 3 inches on 4-8 days after pruning, the plant was subjected to transformation.
2. Preparation of Agrobacterium Tumefaciens Liquor and Infiltration
[0055] Agrobacterium tumefaciens LBA4404 strain was inoculated in YEB solid medium (0.5% beef extract, 0.1% yeast extract, 0.5% peptone, 0.5% mannitol, 0.05% MgSO 4 , 1.25% agar, pH 7.5) containing suitable antibiotics (50 μg/ml of kanamycin, 50 μg/ml of ampicillin), and cultivated at 28° C. for 2 days. Then, single colony was picked and inoculated in 20 ml YEB liquid medium containing suitable antibiotics (50 μg/ml of kanamycin, 50 μg/ml of ampicillin) and cultivated by shaking at 28° C. and 240 rpm for 1 day. 5 ml bacteria liquor thus obtained was added in 200 ml YEB liquid medium and cultivated at 28° C. and 240 rpm for 9 hours. The culture suspension was centrifuged at 4° C. and 4,200 rpm for 20 minutes (Beckman J2-MC, JA-10 rotor). The supernatant was discarded, and the pellet was suspended in 20 ml pre-cooled YEB medium. The resulted suspension was centrifuged again at 4° C. and 4,200 rpm for 20 minutes. The pellet was re-suspended in 20 ml pre-cooled YEB medium and was stored at 4° C. till used. Agrobacterium tumefaciens transformation was performed employing frozen-thaw method. 500 μl suspension of Agrobacterium tumefaciens to be transformed was well mixed with 1 μg OgAS1p-GUS plasmid DNA prepared in Example 3, and the mixture was treated successively on ice, in liquid nitrogen and at 37° C., each for 5 minutes. The bacteria liquor was then mixed with 1 ml YEB medium and cultivated by shaking at 28° C. and 240 rpm for 3˜4 hours. The bacterial liquor was applied over medium containing suitable antibiotics (50 μg/ml of kanamycin, 50 μg/ml of ampicillin), and cultivated at 28° C. for 2 days.
[0056] Agrobacterium tumefaciens that had been transformed to contain plasmid OgAS1p-GUS prepared in example 3 was used to inoculate single colony of the above-described Agrobacterium tumefaciens on 5 ml YEB medium (0.5% beef extract, 0.1% yeast extract, 0.5% peptone, 0.5% mannitol, 0.05% MgSO 4 , pH 7.5) containing suitable antibiotics (50 μg/ml of kanamycin, 50 μg/ml of ampicillin) and cultivated by shaking at 28° C. and 240 rpm for 2 days. Then, it was poured in 250 ml YEB medium containing suitable antibiotics (50 μg/ml of kanamycin, 50 μg/ml of ampicillin), and cultivated again by shaking at 28° C. and 240 rpm for more than 24 hours. It was then centrifuged at 4° C. and 6,000 rpm for 10 minutes. The supernatant was discarded, and the pellet was suspended in 200 ml infiltration medium (½ MS, 5% sucrose, 0.044 μM ABA, 200 μl/l or 0.01% Silwet L-77, pH 5.7). Arabidopsis thialana Columbia plants to be transformed were placed upside down in the Agrobacterium tumefaciens suspension, and soaked there for 20 seconds. Arabidopsis thialana Columbia plants were taken off and kept wet for 24 hours. Seeds could be harvested after about 3˜4 weeks.
3. Sowing and Selection of Transformant
[0057] The transformed Arabidopsis thialana Columbia seeds thus-collected was rinsed several times with sterile water, treated with 70% ethanol for 2 minutes, treated with sterile water containing 1% Clorox and 0.1% Tween-20 for 20 minutes, and then rinsed 4-5 times with sterile water for 5 minutes each time. Thereafter, these seeds thus-treated were sown in germinating medium (½ MS, 1% sucrose, 0.7% agar, 50 μg/ml of kanamycin, 50 μg/ml of ampicillin) to carry out segregation assay of anti-antibiotic progeny. Homozygous transformant progeny thus obtained could be used in assay of promoter activity.
4. GUS Histochemical Staining
[0058] Tissue to be stained of the transformant was soaked first in pre-treatment buffer [50 mM Na 3 PO 4 (pH6.8), 1% TritonX-100] at 37° C. for 2 hours, rinsed then 2˜3 times with Triton X-100-free buffer (50 mM Na 3 PO 4 , pH6.8), and added thereto buffer (1 mM X-Gluc dissolved in 50 mM Na 3 PO 4 , pH6.8) containing X-Gluc (5-Bromo-4-chloro-3-indoxyl-beta-D-glucuronic acid). The mixture was evacuated at 25 inches-Hg for 5 minutes, returned to atmospheric pressure for 5 minutes, and this procedure was repeated once. Then, it was placed at 37° C. to react for 2 days. The enzymatic reaction and tissue discoloration were terminated with 70% ethanol, and the coloration status was observed under a microscope.
[0059] FIG. 4 shows the result of GUS activity analysis. As shown in FIG. 4 , reporter gene GUS activated by Oncidium aureusidin synthase gene OgAS1 promoter could be expressed only at anther in Arabidopsis thialana Columbia transformant floral organ ( FIGS. 4C and D), while no GUS activity could be detected in root, stem, leaf and pod of Arabidopsis thialana Columbia transformant ( FIGS. 4A and B). Results from GUS activity analysis indicated that, Oncidium aureusidin synthase gene OgAS1 promoter exhibited characteristics to activate anther-specific expression, and significant activation ability.
EXAMPLE 5
Transformation of Nicotiana Tabacum L. via Agrobacterium Tumefaciens -Mediated Process
[0060] Separately, Nicotiana tabacum L. cv Wisc. 38 was used as the material, and similarly, Agrobacterium tumefaciens -mediated transformation was employed to transform plasmid OgAS1p-GUS prepared in example 3 into Nicotiana tabacum L. to alter genomic constitution in the transgenic plant such that Oncidium aureusidin synthase gene OgAS1 promoter could activate effectively the expression of reporter gene GUS at objective transgenic plant and progeny thereof. Furthermore, GUS histochemical staining was used to analyze expression site of reporter gene GUS in Nicotiana tabacum L. transformant to detect whether Oncidium aureusidin synthase gene OgAS1 promoter exhibits likewise a tissue-specificity in Nicotiana tabacum L. plant.
1. Preparation of Agrobacterium tumefaciens liquor
The same procedure described in example 4 was followed in this example.
2. Transformation of Agrobacterium tumefaciens
The same procedure described in example 4 was followed in this example.
3. Small amount preparation of thus-transfected Agrobacterium tumefaciens plasmid
The same procedure described in example 4 was followed in this example.
4. Transformation and selection of Nicotiana tabacum L.
[0068] Leaves of sterile seeding Nicotiana tabacum L. cv Wisc. 38 plants were cut into square of 1.5 cm×1.5 cm, placed on N01B1 solid medium (MS, adding 0.1 mg/L of 1-naphthyl acetic acid, 1 mg/L of BA, 3% sucrose, pH 5.7, 0.7% agar) and cultivated at 25° C., 16-hour lighting environment for 1 day. Then, the square leaves were dipped in bacterial liquor for 3-5 minutes. Next, they were placed on N01B1 solid medium, and cultivated at 25° C., 16-hour lighting environment for 3 days. Thereafter, those square leaves were soaked and washed in 20 mL N01B1 liquid medium containing 250 mg/L of cefotaxime for 1 minute. Subsequently, they were transferred on N01B1 solid medium containing 250 mg/L of cefotaxime and 100 mg/L of kanamycin, and were selected at 25° C., 16-hour lighting environment for about 3 weeks. Upon germination of adventitious buds from square leaves, those leaves were moved onto N01B1 solid medium containing 250 mg/l of cefotaxime and 200 mg/l of kanamycin. Selection was carried out at 25° C., 16-hour lighting environment. As shoots had grown to longer than 1 cm, shoots without etiolation could be cut and cottage cultivated in MS solid medium containing 250 mg/L of cefotaxime and 200 mg/L of kanamycin at 25° C. and 16-hour lighting environment till rooting. The plants were used in GUS activity assay.
5. GUS Histochemical Staining
[0069] The Nicotiana tabacum L. transformant survived in the above selection was subjected to GUS histochemical staining analysis followed the procedure described in example 4.
[0070] Results of GUS activity analysis shown in FIG. 5 indicated that reporter gene GUS activated by Oncidium aureusidin synthase gene OgAS1 promoter could be expressed only at anther of floral organ in Nicotiana tabacum L. transformant ( FIGS. 5B and C); while Nicotiana tabacum L. seedlings at vegetative growth stage could not take place GUS coloration ( FIG. 5A ). Therefore, GUS activity analytical results from both of Arabidopsis thialana Columbia and Nicotiana tabacum L. transformants indicated that, Oncidium aureusidin synthase gene OgAS1 promoter could exhibit significant anther-specific activation ability in different species.
[0071] In summary, anther-specific promoter and application thereof provided according to the invention gives following advantages over other conventional techniques:
[0072] 1. The promoter of the invention can activate the expression of gene behind its 3′ end to express in anther, and by means of this particular tissue-specificity of said promoter, over-expressing target gene at anther of a plant.
[0073] 2. The promoter of the invention can be transferred into a plant through a form of vector, and enables the over-expression of the target gene to take place in anther of the transgenic plant and progeny thereof. As the result, a vector containing the promoter of the invention can be used as a tool to modulate gene expression, which provides great value on industrial application.
[0074] While the detailed description provided above is directed to a possible embodiment of invention, it should be understood that said embodiment is not construed to limit the scope of the invention as defined in the appended claims, and those embodiments or alteration that can be made without departing from the spirit and scope of the invention are intended to fall within the scope of the appended claims.
[0075] Accordingly, the invention has indeed not only an innovation on the species gene, but also has particularly an expression uniqueness, and therefore, the application should meet sufficiently requirement of patentability on novelty and non-obviousness, and should deserve an invention patent right.
[0076] Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, to promote the progress in science and the useful arts, the invention is disclosed and is intended to be limited only by the scope of the appended claims. | The invention provides an anther-specific expression promoter in plant, wherein said promoter is a promoter of Oncidium aureusidin synthase gene OgAS1, and has a sequence as SEQ ID No: 3. The invention provides further a gene expression cassette that comprised a promoter having a DNA sequence as SEQ ID No: 3, and a polynucleotide that encode an open reading frame and is linked to the 3′ end of said promoter, wherein said promoter can activate the transcription of said polynucleotide in an organism containing said gene expression cassette. The invention provides also a gene expression vector that contains a promoter having DNA sequence as SEQ ID No: 3. The invention provides further a process for producing a transgenic plant or part of organ, tissue or cell of said transgenic plant containing the above-described gene expression cassette. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns means for inputting characters or commands into a computer or other information receiving device without a keyboard or the like using the automatic skills of handwriting.
2. Description of the Related Art
The present day computer keyboard was initially designed to operate a typewriter. The keys were operated as levers to stamp a die onto paper to print each character. Each key carried two characters one above the other, the lower case character being reproduced by normal depression of a key onto paper with an ink ribbon therebetween and the upper case character being obtained by shifting the entire paper carriage or die set so that the impact occurs with the upper character die impression rather than the lower. Punctuation and special characters were obtained by shifting the numbers or with extra keys.
The printing method is fundamentally the same as in a printing press but the purpose of a typewriter is very different from the purpose of a press. Printing, of course, allows publication of a manuscript and the reproduction of many identical copies of the original manuscript without the effort of handwriting each copy.
The typewriter came into being with the growth of modern commerce and the need for legible business letters. At that time (and indeed presently), handwriting was highly personal and showed great variation. from one person to another. This made handwritten letters, agreements, contracts and other legal documents potentially ambiguous or unclear in meaning. It is this complexity of handwriting which mitigates against current approaches to computer analysis of handwriting.
Variations in handwriting represent simple information embedded in a mass of redundant detail. In modern information and communications, the approach to redundancy in a pattern is to throw large computing power into analysis and recognition. Computer equipment for analysing handwriting is available but does require considerable computing power and hence is relatively expensive and often cannot recognise the handwriting quickly enough, in real time, causing delays to the inputting process.
The analysis employed in such methods depends upon the extraction of salient features from the pattern of handwriting presented to the device and its software. It should be noted that the salient features chosen are often complex and any one may be specific to one character or letter. This implies that the set of such features is large and complex. In addition there exists a number of different ways in which a particular character can be drawn, each of which may contain different salient features. Add to this the difficulty that even with a single way of drawing a particular character, the actual pattern drawn will vary greatly from one person to another. The result is that such approaches to the computer recognition of handwriting have so far been limited in their success and often require a learning process in which the software adjusts to the handwriting of the user or the user learns a way of writing which allows the system to work. The overhead in terms of programme size and computing power required is often expensive and impractical in the application to hand-held computers or personal digital assistants particularly at the smaller end of the scale of size, power and cost (the high volume market of pocket. databanks, diaries, organisers and the like).
Another approach to data input to a computer from finger movements is embodied in systems that require the user to draw each character in a particular way, devoid of ambiguity. This results in a sort of short-hand code which has to be learned by the user. The short-hand forms are often not familiar or readily recognisable as the characters they represent. The result is a commercially successful system but some way removed from natural writing and which needs to be learned and practised.
Another difficulty associated with the current approaches to handwritten input to a computer is the complexity and expense of the hardware required for the sensing of the finger movements. In both the approaches described above, the moment-by-moment and point-by-point form of the motion of the fingers must be sensed, digitised and transmitted to the processor carrying out the analysis and recognition. In many devices currently available this function is performed by a pen or stylus moved by the fingers across a touch sensitive screen. The finger motions are detected by this device and transmitted to the processor, which causes an image of the movement to be displayed on the same screen. Such a complex input device is expensive and can represent a significant proportion of the cost of for example a hand-held computer.
Thus, it is not easy to input hand generated information into a computer in a direct manner.
The printed word, on the other hand, is clear and unambiguous. Every character can be standard in form and scale and easy to read. The printing press sets up its text as a block of lead type which is impressed onto one or more paper pages at a time. This allows the rapid production of many copies of a page. The typewriter, however, needed to be flexible at the level of each character, not at the level of each page. Hence, one key (one print operation) per character. Therefore, the present day keyboard has 60 to 70 keys.
Keyboards which deliver the component parts of each character (one part to one key) have been proposed. Because the form of printed numbers and letters can be simplified (they can be displayed with 7 and 14 segment displays) such a keyboard would only need a relatively small number of keys compared to the standard keyboard. However, such keyboards have not been successful possibly due to the barrier of having to learn a new way of typing which overrides the advantages of such a simple keyboard. It is to be noted that during conventional touch-typing, although the fingers of both hands cover the keys, only one finger is working at a time. With character constructing keyboards as mentioned above, a number of fingers must be employed simultaneously to print a character and so co-ordination skills must be learned by the user. This means that the typing skill called for is less natural than the one-key one-character scheme used by conventional keyboards.
SUMMARY OF THE INVENTION
An object of this invention is to provide means for inputting hand generated information into a computer.
According to one aspect of the invention there is provided means for inputting a hand generated character into a computer comprising means for drawing a character, means for abstracting a sequence of signals as the character is drawn corresponding to components of the character to produce a code representative of that character and means for recognising that code, whereby the character is inputted to the computer.
The signal abstracted preferably corresponds to a quantization of motion as the character is drawn. The signal abstracted may correspond to a change in direction as the character is drawn and/or may correspond to movement beyond one or more defined thresholds in a particular direction as the character is drawn and/or a signal abstracted may correspond to a change in position of the drawing means from one defined area to another defined are on a drawing surface.
According to a second aspect of the invention there is provided means for converting movement or force generated in reproducing a character into a coded signal corresponding to one or more elements of said movement or force that are indicative of the character, whereby the character is recognisable from said coded signal.
According to a third aspect of the invention there is provided a device for converting movement of or force applied to at least a part of said device, said movement or force being imparted by reproduction of a character, into a coded signal corresponding to one or more elements of said movement or force that are indicative of the character, whereby the character is recognisable from said coded signal.
According to a fourth aspect of the invention there is provided means for inputting a hand generated character into a computer having a monitor, comprising means for drawing a character to produce a sequence of signals corresponding to that character, means for converting signals produced for one character into a code representative of that character, means for recognising that code and means for providing visual feedback corresponding to the character being inputted as the character is being drawn.
The means according to this aspect of the invention may be used with any handwriting recognition/input system whether involving quantisation recognition or any other system of handwriting analysis.
According to a fifth aspect of the invention there is provided a visual feedback to the writer on a display screen. Feedback may take the form of a sequential build-up or animation of a character form which itself is produced from the above mentioned coded signal. Feedback may be generated by the processor which is connected to the above mentioned input means or input device or any other suitable input means.
Thus the display screen can show the results of the handwriting recognition process as a feedback of information to guide the writer. It preferably operates step by step as the elements of movement are coded by the input device and includes the aspect of computer recognition in the visual feedback process unlike all prior art. It does not indicate the moment by moment movement of the fingers or the point by point form of the character as drawn, as is the case with current approaches to handwriting input to a computer. The user is guided by the interpretation of the finger movements by the system, so as to be able easily and naturally to produce just the correct finger movements that will code as the correct sequence of elements of unambiguous recognition of the writing.
Preferably the visual feedback means comprises means for producing on a monitor a graphic simulation of a character component in response to an abstracted signal. The graphic simulation is preferably modifiable in response to a subsequent signal of a sequence for a character.
The graphic simulation preferably further includes an indicator as to position of the drawing means on a drawing surface. The indicator may comprise an icon displayed at or near an end of the latest graphic simulation component. Alternatively, the indicator may comprise an icon that moves around the graphic simulation of a character in response to movement of the drawing means.
The feedback can be a smoothly produced animation of a cursive character form that responds during its formation to the incoming flow of recognised elements or signal codes.
The computer or input device appears to the user to be cooperating in the process of writing and to be producing the characters on the screen from the prompting provided by the finger movements.
Of course, the characters shown on the screen are not representative of the actual locus or form of the movement of the fingers, but are synthetic representations of the intent of the user, and merely guide the user in the inputting process. From the user's point of view the characters seem to appear as if written by the user, with the cooperation of the computer.
Such characters can build up to display a completed word, for example, in a standard, clear, joined-up cursive writing, each character of which has been produced from the sequence of simple elements produced by or abstracted from the operation of the input device.
When the user lifts the pen or signals the end of a word in an appropriate. manner, then the processor can immediately replace the cursive characters with the same word displayed in a selected font appropriate to the application or application programme.
In contradistinction to prior art handwriting analysis systems which input information describing the character as drawn and carry out an extraction of salient features (necessarily scale and speed independent), followed by comparison with a stored library of possible shapes, strokes and their inter-relationships, both spatial and temporal, to give the best fit to one character of a complete character set, and thence to the recognised code for the character, the system of the present invention is a direct encoding system where the movements generating the character as drawn, are compared with a single template in such a way that complacent movements directly produce the elements of a code that identifies the character completely by the time the character is completed. At the instant the character is completed, the recognisable code has been completely built and no further analysis or processing is required for recognition.
Preferably recognition occurs character by character in real time. The one or more elements of movement or force are preferably unit vectors.
Preferably analysis of movements or forces into elements is by means of quantizing said movements or forces into one or a sequence of unit vectors. These elements are preferably speed independent, are preferably scale independent and are preferably substantially independent of distortions or variations in the character as reproduced.
Preferably the elements form a set common to all the characters to be reproduced, which set does not contain elements specific to only one or a few characters.
The signal is preferably recognisable by a computer or any other information handling device to which the device is connected, whereby the character can be displayed on a visual display unit operated by the computer or can be processed in the same manner as a character input from a keyboard.
If an input device were activated by movements similar to those employed in writing, then this could provide a method of inputting characters and text into a computer without the need to learn a completely new skill.
What is here described is a device providing a method of analysis which is mechanical or automatic and does not require an indirect process of analysis and comparison to produce a unique code for a character, in contrast to prior art.
This automatic generation of a unique character code may be facilitated by means of a visual feedback from a display of the recognised elements of a character as synthesised from the signal from the input device.
The automatic switch-like method of extracting the coded signal from the finger movements gives rise to relatively simple and inexpensive input devices, recognition contemporaneous with the completion of a handwritten character, low computing power requirement, natural character forms and ease of learning and use, in contrast to prior art.
Thus the invention herein described allows data input to a computer or other system by means of the natural finger movements employed in writing utilising simple and low cost input devices with high speed recognition and visual feedback.
There is an advantage to detecting motion as it is happening as opposed to analysing the space pattern of completed handwriting. The motion of a pen when writing the circle of the letter “a” is different from the motion when writing the circle of the letter “p”, although the resulting shapes are very similar. The “a” circle is normally produced by an anti-clockwise motion whilst the “p” circle is normally made with a clockwise motion. This distinction is lost if the resultant handwritten character is considered after it has been written. However, if the handwriting is analysed dynamically, as it is being written, then the information gained is far more useful. It will be appreciated that references to detection of movement include detection of applied forces in generating said movements.
In a preferred embodiment the drawing means will be a hand held pen or the like, whereby the pen or a part thereof can be moved to reproduce characters.
It is envisaged that the drawing means of the invention will have a part that may be moved relative to a real or notional template when a character is being reproduced and that the drawing means will include means for detecting said movement relative to the template. The template may be incorporated in the drawing means itself or may be separate therefrom. There are various ways in which the movement of said part of the drawing means may be detected.
For example it may be possible to have a template around which said part of the drawing means can be moved, whereby contact of that part of the drawing means on a sensor in a particular part of the template will indicate a direction of movement and again one movement or a sequence of movements will generate a signal corresponding to the character being reproduced by those movements.
Put another way assuming a pen having a body, writing tip and a real template, the template may be separate from the pen, such as on a surface, may be fixed to the pen body or may be fixed to the tip. On the other hand, for a pen having a body and a writing tip, movement of either or both may be relative to a notional template associated with the body, the tip or a separate surface.
The means for detecting a movement of the drawing means or that part thereof may include contact switches, magnetic or capacitive sensors, optical encoders, light detectors, voltage changes, piezo-electric crystal activation or any other suitable means.
The system of the invention preferably includes means for signalling completion of a drawn character. Completion may be signalled by lifting the drawing means from a drawing surface. Alternatively, completion of a character may be indicated by a unique movement of the drawing means relative to that character. Another alternative may be to indicate completion of a character by movement of one of the drawing means and an icon indicative of the drawing means to a defined position, possibly on the drawing surface or an area defined on a monitor.
The mode of analysis envisaged by the invention is actually concerned with the time patterns of muscle action, in contrast to the space patterns of completed handwriting. It is relevant to note that all communication occurs through the medium of muscle action, whether speech, body language, touch, action, handwriting or typing. The first outward expression of thought is always through muscular action. This invention is aimed at allowing the communication with a computer to take place at the level of the neuromuscular skill of writing.
It will be appreciated, however, that there is considerable redundancy present in handwriting. Although handwriting may be taught in a uniform fashion, variations and embellishments are added as a person develops his handwriting skill, so that whilst letters and words can be recognised, it is extremely difficult for, for example, a computer scanning device to extract the essential characters because of personal variations and embellishments.
Accordingly, a preferred aim of the device of the invention is to enable characters to be reproduced as unit vectors. In other words, each character as it is drawn using the device of the invention preferably produces a signal for that character as one or a sequence of steps. This may be achieved by limiting or restricting registration of the movement to one or a series of quantized steps or unit vectors.
It is important to realise that signals which solely describe the position, movement or locus of a pen or moving part of the device simply provide a copy of that movement etc. in electronic, electrical etc form. They do not of themselves facilitate logical recognition of the inputted letter form or character form.
What this invention allows is an automatic reduction of the movement etc into a quantized form. This means that the movement is divided into steps which indicate the time sequence of unit vectors which characterise the movement etc. The steps themselves do not describe the point by point and moment by moment movement which results from drawing the character form. They are rather the result of an analysis of the movement etc which indicates a series of unit vectors. This series of unit vectors cannot be used to reconstruct the original finger movements, because all redundant space and time information is discarded in the process of detecting the unit vector sequence. All that remains is the sequence of the unit vectors and the character of the unit vectors.
The character of the unit vectors will be dependent on the design of the device. In the case of a physical square template the unit vectors could be characterised for example as being up, down, left or right.
The time delay between one unit vector and the next is not of importance and is discarded information. All that matters for recognition is the sequence, eg. left then down then right then up then down for the handwritten letter form “a”.
Also the process of deriving the unit vectors disregards the scale or size of the movement or letter form. The same sequence of the same unit vectors results from a large “a” as from a small “a”. In addition, provided the physical movements which activate the movement or position detectors are smaller than the smallest character to be drawn, the sequence of unit vectors will be the same for wide variations or distortions in the form of the original character, letter or resulting motion.
It should be noted that such a family of unit vectors (one simple case being: UP, DOWN, LEFT, RIGHT) can represent all the characters to he input to a computer etc through finger movements.
In other words, each and every number, letter etc can be analysed into a sequence of the same set or family of unit vectors. The uniqueness of character resides in the sequence of the unit vectors which represents a unique code for the character. The different characters do not require analysis into unique individual features as in the prior art.
The analysis of original motion into unit vectors is according to a scheme which compares the movement to an arrangement of detectors placed in a fixed relation to a real or notional template. This allows the motion to be compared with the geometry of a template in such a way that a complacent movement will result in a single signal or part of a signal which indicates the characteristic direction or movement at that stage of the drawing of the letter or character etc.
For example, once the moving part has gone beyond the upper limit of detection, the unit vector will indicate simply “up” until the moving part has once again returned within the scope of detection in the direction, when it could be followed by “down”. Similarly with horizontal movement. This approach leads naturally to a description of operation of the device in terms of a template.
The template is simply the geometry which determines the signalling of the unit vectors, and may be a physical form eg. a square aperture within which the pen tip etc. moves, or it may be notional, and is simply the space pattern of detector switching limits in two dimensions or it may be embodied in the movement analysing processor which is connected to the input device moved by the fingers.
Either scheme will result in practical devices which convert the finger and hand movement familiar to us as handwriting into a code signals which is logically recognisable as corresponding to the character drawn.
For accuracy of coding, and in order to remove the inaccuracies introduced by personal embellishments, the writer may be guided by visual feedback from an image on a display screen, and can choose natural character shapes which can be learned quickly and easily.
Thus the device allows “typing” or inputting or textual information into a computer or other automatic text handler (eg. typewriter, portable databank or diary etc.) at handwriting speeds or faster, without the need to learn the far more complicated skills of touch typing using a conventional keyboard.
The principle of operation is based on the quantization of motion, and is not to be confused with handwriting analysis which causes automatic recognition of the form of normal personal handwriting (or even the recognition of a limited or defined or stylised set of character forms) by an analysis of its complex actual shape.
The aim of the template either real or notional is to register the movement of the device as unit vectors but not necessarily to restrict the movement of the device to unit vector form, whereby a recognisable signal corresponding to that character can be produced.
In preferred forms of the invention the relation between the template and the part or parts of the device will be flexible, thereby freeing the device from performing forced angular, rectangular or linear movements. In other words, by introducing a flexible linkage between relatively movable parts of the device or between a movable part of the device and the template, the device can follow both straight and curved lines whilst those movements will be detected as straight line movements or forces producing unit vectors.
Thus, the preferred device of the invention has the ability to detect movements of at least a part thereof in producing a character as one or a sequence of unit vectors to produce a signal corresponding to the character, even when the character is not reproduced in a format constrained by the geometry of the template.
The flexible linkage may take any suitable form. For example, when the tip of a pen device is to be movable relative to the body of the device, the flexible linkage may be provided by one or more elastic members linking the tip to the body.
Various considerations may be taken into account in deciding the nature of the real or notional template.
In one preferred embodiment, the template may be in the form of an enclosure having at spaced positions around its periphery means for detecting movement of said device part from one point to another around the periphery of the enclosure. The enclosure may be of any suitable shape but will preferably be a square or a circle. Preferably four detection positions will be provided at equidistant spacings.
The movable part of the device may be a rod or the like and its movement from one detection point to another may be by any suitable sensor means, such as already suggested above.
In another preferred embodiment, the template may be in the form of a confined track around which the movable part of the device can travel, again with spaced detection points as in the first preferred embodiment.
In a yet further preferred embodiment, the template is notional rather than real and may be embodied in the processor running the requisite software and the movable part of the device may be detectable as being in accordance with a template. Thus, the device of this preferred embodiment of the invention will include means for registering the movement of said movable part as though it were following a template. Thus, the device may be arranged to produce output signals when movement of at least a part thereof exceeds a notional boundary of the notional template.
It will be appreciated that these signals indicate major changes in direction as compared to a template or set of directions or axes. It is possible to derive the signals indicating the unit vectors as changes in velocity or other time derivatives as well as direction or position. Such a derivation is suited to the application of this invention to conventional computer pointing equipment.
For example the data stream from a computer pointing device such as a mouse, trackball, pen and tablet etc indicates the relative position of the fingers moment by moment. If this data stream is analysed by a computer or dedicated processor in such a manner that excursions of the finger position are compared with a notional template, encoded in an algorithm stored within the computer or processor or its associated memory as a pattern of excursion limits in two dimensions, movements beyond these limits or complacent with the template boundaries can trigger the generation of a sequence of signals, indicative of the unit vectors, which codes uniquely for the character drawn by the fingers which are moving the mouse, trackball, pen and tablet or other pointing device.
This invention will now be further described, by way of example only, with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically a system for writing into a computer;
FIGS. 2A and 2B show a possible arrangement for a pen device of the invention;
FIGS. 3A and 3B show possible movement of the pen body of FIG. 2 and the resulting sequence of unit vectors around the template;
FIG. 4 shows alternative forms of a letter, each of which can be represented by the same sequence of constrained movements;
FIG. 5 shows another possible arrangement for a pen device of the invention;
FIG. 6 shows a unit vector sequence resulting from forming a letter;
FIG. 7 shows a variety of forms of the same letter that may all produce the unit vector sequence illustrated in FIG. 6;
FIGS. 8A to D show schematically operation of a pen device utilising frictional forces between its tip and a surface;
FIGS. 9A and 9B show the correspondence of intended character, unit vector sequence and the animated cursive character form used in the visual feedback;
FIGS. 10, 11 and 12 show yet another form of pen device according to the invention;
FIGS. 13A and 14A are sectional views through a yet further form of pen device according to the invention; and
FIGS. 13B and 14B are sections on lines AA and BB respectively of FIGS. 13A and 14A.
FIG. 15 illustrates the principle of using a virtual template in relation to a pen device according to the invention;
FIG. 16 shows a pocket databank with conventional keyboard;
FIG. 17 shows a pocket databank with a pen device of the invention;
FIG. 18 shows a flow chart illustrating the procedure of synthesising an animated image to be displayed on a screen to provide visual feedback to the writer; and
FIG. 19 shows the flow of information in such a system employing an input device of the invention and a method of visual feedback described herein;
FIG. 20 shows a letter “a” reproduced with an additional movement to indicate completion and start of the next letter;
FIG. 21 illustrates detection of double unit vectors;
FIG. 22 shows detection of double unit vectors in drawing a letter “g”;
FIG. 23 illustrates provision of an actual pen position icon as a letter is drawn;
FIG. 24 illustrates provision of a synthetic pen position icon as a letter is drawn;
FIG. 25 illustrates how letters may be drawn starting from the same point;
FIG. 26 shows use of guide lines to aid character input;
FIG. 27 illustrates visual feedback compared to actual movement of a drawing device;
FIG. 28 illustrates a display screen with special areas for signalling completion of a character; and
FIG. 29 illustrates visual feedback with modification as new unit vectors are detected.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring to FIG. 1 of the accompanying drawings, there is shown schematically an embodiment of the invention.
A pen device 10 contains a template which constrains the movements performed automatically by the fingers during handwriting and abstracts from these movements the elements that allow computer recognition. The result will be a “pen” which senses the sequence of movement elements in each character while allowing the user to feel as if he is writing in a near-normal way. The sequence of movements can be registered electronically via mechanical switches or optical, electric or magnetic sensors or other means and the sequences decoded by a microprocessor 12 and the characters transmitted to a computer as if from a keyboard and displayed on a visual display unit of computer 14 as they are recognised. Alternatively, the sequence can be transmitted directly for simple logical recognition therein.
Taking this concept a step nearer to a practical form, one of the simplest forms of template is a square and the template could be constrained to move around the pen tip with the pen tip held stationary. Such a pen would feel like being forced to write in a squared handwriting. Add to this a “soft” or flexible linkage, integral with the pen, to allow for writing the circle of, for example, an “a” or a “p”.
Such an arrangement as shown in section in FIGS. 2A and B of the accompanying drawings allows the pen to describe a circle while the template moves around the pen tip in four segmented movements. As the pen body 18 is moved in a circle by the fingers, the flexible linkage 20 will stretch to drag the template 24 around the pen tip 22 . The forces involved can be quite small—giving a slight tactile feedback to guide the user. As the template is within the pen body, and is smaller than the smallest circle drawn by the user, the template will be pulled against the pen tip sides by the slight force of the stretched flexible linkage. The relative movement of the pen tip and template is, therefore, constrained to the four possible segments of the square template.
FIG. 2B shows the pen at rest and FIG. 2A shows the pen moved in the direction of arrow F.
These segments can be thought of as “unit vectors” which can be one of the following: up down left right or u d l or r. Thus the sequence of movements for the “a” circle would be detected as:
l, d, r, u
and the sequence for the “p” circle will be”
r, d, l, u
FIGS. 3A and B show respectively how a letter might be drawn with the pen of FIG. 2 and the resultant sequence of unit vectors. This sequence of unit vectors will be the same with a wide variation of circle shapes such as shown in FIG. 4 of the accompanying drawings.
In FIG. 4, if all the circles were drawn clockwise starting with the pen tip in the top right of the template then they would all produce the same sequence of unit vectors:
d, l, u, r
and yet the user would feel that he was drawing a free form circle.
In a practical form of this pen the body would be moved by the fingers while the tip would be pressed onto a surface and held still. The template could then be integral with, and inside, the pen body (a typical template equivalent size is 0.5 mm per side) and the tip would simply be the lower end of a spine rod that extended up the central hollow of the pen, and connected to the pen body through the flexible linkage and thus be constrained to move around the sides of the square template. The user would feel that he was writing in a near normal way while the finger movements would be converted into a sequence of unit vectors.
It turns out that a square template, for example, can code uniquely for all the lower case letters of the English alphabet and for the numerals 0-9.
In order for this device to be useful in producing movement sequences recognisable by a computer as characters, it is necessary to explore the unit vector conversion of each character in the character set a-Z and 0-9. The character forms are desirably intuitive and simple. It is proposed to write in lower case and shift to upper case (for example with a simultaneous modifier key mounted on the pen body). A shift key could allow the input of capital letters and the special characters ! @ ú$ ˜& etc as with the standard keyboard. Thus, writing the character “a” while the shift key is down could give “A”.
Further modifier keys, for example “option”, could be employed to generate commands to the computer.
It will be noted that many redundant codes of unit vectors are available for the special characters, punctuation and commands.
For example a single “left” movement giving the L unit vector could delete the last character input, with the same result as pressing the “delete” key on a computer keyboard.
To determine the start and end of each character a signal could be generated by a switch inside the pen body activated by the pressure of the pen tip on the surface or by a third key. This key would be pressed while “writing” a character and released at the end of the character sequence. The action becomes swift and automatic with a little practice. The end-signal would initiate the unit vector sequence analysis, a look-up algorithm lasting a few microseconds, and the character would then appear on the computer screen.
In another embodiment of this invention, the character end can be signalled by a slight pause (for example while the visual feedback device completes the animation of the intended cursive character form on the display screen) and the end of a word is signalled by the writer lifting the pen from the “writing” surface.
An arrangement for a template is shown in FIG. 5 of the accompanying drawings. A square template 50 has sensor switches 52 ( 1 , 2 , 3 and 4 ) to detect the position of the pen tip 54 (more accurately the spine rod) within the square. These switches 52 are located at the centre of each template side and each switch operates whenever the spine rod is pressing against a particular side. It is the time sequence of these switch transitions that signals the motion of the pen relative to the spine rod and pen tip.
This leads to reduction in the redundancy of the information contained in the motion. Just as in the space domain the variation of form is removed by reducing the motion into notional unit vectors (“unit” implying the transparency of the absolute vector length—only the direction component is abstracted; this being effected by the design of the hardware switching), so in the time domain the variation in timing is removed by abstracting only the order of the switch transitions and disregarding the absolute time intervals involved; this being effected by the design of the software sequencing.
(Note that the spine rod and the template dimensions can be many times larger than the effective template size. The effective size is equal to the possible movement of the spine rod or pen tip within the template. This can be typically 0.5 mm×0.5 mm. Compare this with the movement producing a written “a” having a diameter of about 3 mm).
The sequence of transitions generated by drawing an “a” with the arrangement of FIG. 5 will be:
2−4+1−3+4−2+3−1+1−3+
(where + signifies a switch turning on and− signifies it turning off, the number preceding the sign indicating the switch number). This is because the unit vector sequence for “a” is: l, d, r, u, d starting at the top right of the template (see FIG. 6 ).
Thus the same sequence of transitions will be generated if the user draws the first curve of the “a” slowly and then speeds up or when he begins quickly and then slows down. All that matters is the relative order of the unit vectors.
Also, provided that the miniature square template inside the pen is smaller than the smallest “a” drawn, all the “a”'s shown in FIG. 7 will also encode as:
2−4+1−3+4−2+3−1+1−3+
irrespective of variations of form or scale.
Remember that the fingers move the pen body freely and the relative movement of the tip and the template is effected through a flexible linkage. This means that the character drawn can contain curves yet the template moves around the pen tip in a series of linear steps.
Turning to the question of stylising character forms to facilitate recognition of movement sequences, it is to be remembered that the upper case forms can be generated automatically by the look-up algorithm in response to the lower case unit vector sequence plus a shift key or the like. It is important to realise that the locus of the pen body is invisible. The pen movements are felt not seen. The pen does not “write”, it simply signals codes to the computer. The stylised characters which may be used are virtual characters. The mind's eye constructs its own fond image of the character it thinks it is drawing.
Instead of the rigid finger positioning over the conventional keyboard during touch typing, the pen allows a relaxed operation. As the pen does not need to move across the “page” and as the movements may be guided automatically by tactile and/or visual feedback there is absolutely no need to look down at the pen.
One further embodiment of the invention is a pen device shown schematically in FIGS. 8A to D, wherein its tip 200 is held in contact with a “writing” surface and is moved in relation to a real or virtual template 202 by means of the frictional force between the tip and the surface. This will signal the direction of movement of the pen body on it is moved by the fingers and hand. FIGS. 8A to D show respectively the pen moving downwards, upwards, to the left and to the right. As the tip moved under frictional forces, it touches contacts 211 , 212 , 213 and 214 respectively and thus signals a unit vector sequence. Such a pen is free to move over a surface in the same manner as a conventional pen.
Referring to FIGS. 9A and 9B, these tables show character stylisations which form a character set which is only one example of many possible sets. The optimum set in any particular embodiment of the invention will depend on the template design and the arrangement and logic of the switching and the relationship to the animation sequences chosen to optimise the visual feedback as well as personal preferences.
This set relies on a flexible linkage to give a realistic feel to the drawing of the letters. Obviously the simple square template will not allow excursions (tails) up or down. However the fingers carry these out automatically, the pen body following the fingers, but the spine rod stays within the template square. Happily each character still generates a unique unit vector sequence and codes unambiguously into the target computer.
Obviously the writer will have to adapt the writing of each character to produce just the unit vectors required for error free recognition. However the abundance of codes derivable from sequences of unit vectors allows for multiple ways of drawing particular letters. (See the example of the letters “b” and “q” in the set of FIGS. 9 A and 9 B).
Most importantly the visual feedback will guide the writer effortlessly if the elements of the animation building the cursive character forms are designed to confirm the completed movements at any point in time and prompt for the required subsequent movements.
Because of the flexible linkage and the mind's own image of what it is telling its fingers to do, these letter forms seem quite natural.
After a little practice, far less than is needed to become skilled at using a conventional keyboard with all these characters, the component movements are not created individually but in a fast automatic flow, as the mind goes through the act of writing each character. The speed can be typically 20 unit vectors per second.
In FIGS. 10, 11 and 12 is shown a form of pen according to the invention in which the pen has a body 60 which is movable relative to a template 62 in the pen tip 64 which is held stationary upon a surface. The pen tip 64 may include a suitably shaped rubber or the like pad which is relatively non-slip upon say a table.
The advantage of this embodiment is that the actual movement of the pen around the template and the imagined movement of the pen tip are equivalent. With the pen described earlier, these movements are opposite in sense and the mental link between the two has to be unlearned. The template may be of any desired shape with movement sensors also of any desired type as described hereinbefore or later.
Another refinement, which may be applicable to four-switch templates and more complex templates, is to generate the character start and end signals from the template switches. The start signal may be turned on whenever at least one of the template switches is on, and may be turned off whenever all four template switches are off. This defines a starting point for the pen tip at the centre of the template. If in addition, the pen tip is centre-sprung, ie. automatically returns to centre after each excursion, either by slightly lifting the pen or simply by relaxing pressure, then the process of sending a character becomes easier and automatic. The logic of the start signal may be handled electronically.
More complicated templates can be constructed, where the freedom of movement of the pen tip is greater. An analogy would be the increasing complexity of car gearshaft gates as the number of gears increases.
When a physical or real template is being used, the effective size of the square template may be reduced until the relative movement of the pen body and the spine rod or pen tip is arbitrarily small. The unit vectors may then be sensed using pressure transducers or strain gauges on each of the four template sides.
Character start/stop signals can be derived logically from the template signals.
A degree of flexible linkage is desirable to allow a very slight movement of the pen under the pressure of the writing fingers. This can be achieved by moulding the pen tip from say rubber or like material, and/or building in a slight compression movement into the pressure transducers or some other convenient position.
The movement of the pen in this arrangement is not constrained so obviously to a square template, however the signals from the transducers will conform to the same coding sequences for the same characters.
Writing control can be effected by means of an audible feedback generated from the vector recognition circuits. For example, as the fingers go through the movements of a particular stylisation, an audible signal can be generated as each vector is completed, the frequency of the sound being arranged to be unique to each vector. After a little practice this feedback could be muted or disabled. The occurrence of a mistake (unrecognised sequence) for a particular character could switch this feature back on for a predetermined number of characters following, thus reinforcing the learning process. Just as when, while dialling a familiar number on a touch-tone telephone, a mistake immediately “sounds” wrong and familiar groups of numbers sound right.
A further feedback to facilitate both learning and the normal operation of the device could be a visual indication of the vectors themselves as they build up to describe a character. Most computer displays operating in word processing mode employ a cursor shape on screen to indicate the insertion point. This could be replaced with say a square representation of a virtual template showing the vectors as emboldened sides of the square (or whichever alternative template shape is used). At character end-signal this graphic would be replaced with the coded character and would itself move on to the next text position, ready to display the next pattern of vectors.
More sophisticated techniques of visual feedback and confirmation may be employed, in which the vector sequence information is used to synthesize a graphic image on screen which reflects the growing character as intended by the operator, using a stored programme to determine the available possibilities at each stage in order to guide the formation of the inputted character.
Such a system of visual feedback is illustrated in FIG. 18 which is to be read as a flowchart. Here the way in which characters that all begin with an “UP” unit vector (chosen as an example) may be reproduced on a display screen as a progressively developing image of the intended character in synthesised, clear, standard, cursive form (represented in the square boxes) is illustrated.
In the flowchart of FIG. 18, the sequence of unit vectors is indicated by the symbols in the circles. Thus 1U indicates that the first unit vector is “UP”. Similarly, for example, 6L indicates that the sixth unit vector is “LEFT”.
At the point of recognition, when the system decodes the finger movement into a unique unit vector sequence for a specific character, then at the corresponding point in the flowchart of FIG. 18 the recognised character is indicated by a square box containing the corresponding font character.
The progressive animation develops each character as the fingers move in drawing the character while holding the input device which converts these movements into a sequence of unit vectors. It is this stream of unit vectors which determines the animation process. Thus the feedback loop is closed allowing a completely novel method of inputting handwritten information into a computer or the like.
In other words the eye sees the character form on the screen as the fingers move in such a way as to produce the unit vector sequence. The computer etc appears to cooperate with the user in the process of writing the characters.
In the example illustrated in FIG. 18 the letters “l” “h” “b” and “t” are reproduced and recognised. It can be seen from this example that all the basic forms of the characters “a” to “z” and “0” to “9” can be similarly analysed into unit vectors and animated on a display screen.
It is important to note that the definitions of the letter forms in terms of the unit vectors bears a functional relationship to the sequence of metamorphosis of the animation of the synthetic on-screen cursive character forms. As the unit vector sequence is generated automatically, the animation responds by developing the letter through the forms possible at each stage. Thus referring to FIG. 18 the letter form for a cursive l transforms into the cursive form for the letter h with the further input of unit vectors U R D. Similarly the h transforms to the form b after an L unit vector. Thus, the design of the cursive font employed in the visual feedback animation contains the structure of the basic handwriting movements as defined by the unit vector sequences (ie simple changes of average direction) as can be easily and automatically detected.
Thus the design of the visual feedback font and the process of its animation is very important. It is envisaged that different such fonts can be designed for different applications, languages, countries and scripts and users.
This gives rise to a device which allows the writing of natural character forms to be elegantly guided by visual feedback, thus placing the brain, fingers, input pen or input device, computer processor, display screen and eye, all in the same feedback loop.
FIG. 19 shows this feedback loop. The flow of information is indicated by the arrows 406 ( 1 to 5 ). The fingers 400 of the writer perform the movements of writing a character and these movements are detected by the input device 401 which automatically produces signals indicative of the unit vectors characterising the character drawn. These signals are fed to a processor 402 which synthesises an animated image in response to the sequence of these unit vectors. The animated character is displayed on a display screen 403 and viewed by the eye 404 of the writer. Thus the brain 405 of the writer receives feedback according to the development of the unit vector sequence in terms of the development of the synthesised image indicative of the writer's intention, and is able instinctively to correct the movement of the fingers to cause correct computer recognition of the character drawn.
The process of computer recognition is thus included in the total feedback loop involving the user. This is in complete contradistinction to prior art, where the feedback is merely from the reproduction of the actual finger movements on the display screen and does not include the recognition process itself.
The end of each character is signalled in this example by a slight pause in pen movement, shown in FIG. 18 as a letter P in a circle. However, the on-screen animation can produce joined-up cursive handwriting by a simple process of stored instructions responding to the unit vector sequence, and animating the connecting links between letters.
It should be noted that the process of animation can present the user with a continuously moving cursive line on the display screen, in response to the signals from the input device, which may themselves be discontinuous in time. The eye sees what the mind intends, rather than what the fingers are doing. After a very short period of use, the process can become virtually automatic and natural.
At the end of each word the pen or input device may be lifted up just as in normal writing onto paper) to activate a signal (produced automatically from a switch or other sensing means) to the system processor to initiate the transformation of the completed cursive image of the written word on the screen into the corresponding font characters of the application programme etc which is the object of the data input.
It should be noted that each character is recognised at the pause after the last unit vector has been input. In other words the user will pause momentarily after completing each character, while the processor completes the animation of the cursive character form on the display screen. This image of a cursive character form is already a product of the recognition process and has been derived from a unique code of unit vectors already input to the system, and should not be confused with the cursive forms indicative of the actual unrecognised finger movements displayed in inventions of prior art.
In this example the cursive form is displayed on screen until the whole word is completed to facilitate useful feedback to the writer.
It should be understood that the cursive letter form so synthesised and displayed bears a functional relationship to the finger movements employed in writing the character. It would not be so useful to display the “printed” font characters at this point.
The structure of the synthesised character forms is based on the unit vectors that characterise the corresponding written characters. This relationship can be seen in the example of the flowchart of FIG. 18 .
The feedback thus guides the writer in a most natural way to input the correct sequence of unit vectors, without consciously having to pay attention to that level of analysis.
Once the whole word is completed the system has all the information required to display the recognised characters in the final form of “printed” font characters to make up the complete printed word.
It is easy to conceive computer learning programmes to take a new user through the structure of the character set stylisations, using graphics and feedbacks similar to those described above.
It is possible to use a virtual template as opposed to a physical template. The character recognition in the physical template systems is facilitated by the simplification of the movement by means of the physical boundary of the template and by the resultant reduction of that movement to scale-independent and speed-independent unit vector sequences.
However, a further refinement is still possible, in which the restriction of the movement by a physical barrier is replaced by a notional limit to the registration of that movement. If movements are only recognised by sensors in directions parallel to the sides of a notional, non-physical template, and if these movements are quantized by the sensors and/or their associated electronics and algorithms up to a specific limit of excursion, and if this limit is smaller than the smallest character drawn, then the end result will be the same for the same character stylisations as with a physical template.
This would lead to the design of physically simpler, faster pens or touch screen sensing of stylus or finger movements and allow the invention to work utilising the input devices now available for computers such as the mouse, tracker ball, finger pad, touch sensitive screen, pressure sensitive screen, pen and digitising tablet and the like.
Further refinements of the invention are described below with reference to FIGS. 20 to 29 of the accompanying drawings.
Characters to be input are defined in terms of the movements required to produce the appropriate unit vector sequence. Therefore, predetermined styles of character are pre-supposed. These characters can be very close and in most cases identical to natural character forms. Characters may be defined in terms of unit vectors in such a way that each character is represented by a unit vector sequence that is not a truncation of any longer unit vector sequence for another character. That can allow continuous input (eg within a word without necessarily signalling in some way completion of a character. Thus, completion of a character may be signalled by the last unit vector of the defined sequence for that character.
An example of such a unit vector set follows:
a=rldrud then r for start
b=uddurdl then r for start
c=rldr then r for start
d=rldruudd then r for start
e=ruldr then r for start or ruld then r for start
f=uddu then rr for start
g=rldruddl then r for start
h=uddurd then r for start
i=d then r for start
j=dl then r for start
k=uddrl then r for start
l=udd then r for start
m=dudud then r for start
n=dud then r for start
o=rldru then r for start
p=dduurdl then r for start
q=rldudd then r for start
r=duudr then r for start
s=rudl then r for start
t=udrld then r for start
u=drud then r for start or dru then r
v=du then r for start
w=dudu then r for start
x=rl then r for start
y=druddl then r for start
z=rlrdl then r for start
FIG. 20 shows an animated screen image corresponding to movement of a drawing device in drawing a letter “a” according to the above unit vector set. The last RIGHT movement signals the completion of a unique unembedded code for “a” and therefore the end of the character. That can be used to cause the visual animation on the display screen of a line extending to a standard start position for the next character.
The signalling of the end of a word may be achieved by pen lift activating a switch or sensor or other eg button press, or a special unit vector sequence or special movement sequence.
Unit vectors may be derived in the following ways:
from switches detecting motion in a pen device as described above;
from exceeding a threshold of motion in a direction;
from exceeding a threshold of any combination of time derivatives of motion in a direction;
from movement from one defined area of writing surface to another;
from substantial complacency with a direction or axis or template side;
from combinations of the above.
Here substantial complacency means that the resolved vector components of the motion parallel to the direction, axis or template side are greater than those parallel to all other defined directions, axes or template sides in the system.
To facilitate drawing and recognition of some characters, it may be useful to be able to detect doubling of unit vectors. In other words in drawing some characters unit vectors may repeat one after the other. Detection of two vectors in the same direction may be detected by arranging two detectors with different thresholds of detection or two templates (real or virtual) one after the other so that the movement produces the detection of first one and then the second unit vector in the same direction. This is illustrated in FIGS. 21 and 22 of the drawings. In FIG. 21 the arrow indicates the direction of movement of the drawing device or pointer. FIG. 22 shows how this can be used, for example, for the letter “g”.
Pen and pointer devices used in conjunction with computers and associated display screens or monitors often employ the reproduction on the screen of a line of pixels that represents the track or locus of the drawing device. This is some times termed “screen ink”. Such a display can be used in conjunction with unit vector detection to guide the user in forming the correct letter shapes.
Referring to FIG. 23 of the drawings, it is possible to cause an icon on a monitor screen to move in response to the actual movement of the drawing device. The icon 500 can be used to appear adjacent to the animated font providing visual feedback as described above. This allows the user to judge more accurately the movements required to cause correct unit vector recognition, as confirmed by the display of the corresponding animated font elements 501 , 502 , 503 , 504 , for example, corresponding to the input of a drawn letter “o”.
As the pointing device is moved to produce the display of animated font elements on the monitor screen, it is advantageous to indicate the direction of pen movement and to give a simulacrum of the pen position by causing the processor controlling the monitor to display an icon at the end of each consecutive animated font element. This icon is not to be confused with the icon which responds to and represents the actual drawing device movement. FIG. 24 of the drawings illustrates the sequence of images that result from the input of the letter “o”. Icon 520 appears at the end of each animated font element 521 , 522 , 523 and 524 as the letter “o” is input.
It is advantageous to arrange the drawing of characters so that they all start from the same point. This allows the writer to memorise one set of character forms which do not need mental re-adjustment of the pen position before the input of the next character. This leads to increased speed of writing. FIG. 25 of the drawings shows examples of letters that can be drawn from a common start.
At the end of each character it is advantageous to arrange the visual feedback to move the position of the pen position icon (whether actual or synthetic) from the end position of the character to the standard start position. This immediately re-adjusts the writer's assumption of pen position to facilitate the speedy input of the following character.
The same result may be obtained by advancing the screen ink to the standard start position, or by causing the animation of a font element on the monitor to bridge the gap between the end position and the following standard start position. That is shown, for example, in FIG. 20 of the drawings, where the final right unit vector signals completion of the character “a” and the visual feedback automatically produces a line extending to the common start position.
FIG. 26 illustrates provision of guide lines on a monitor display to aid correct input by providing indications of appropriate relative scale and necessary movement in conjunction with screen ink or actual pen position icon. This ensures a more regular drawing of characters and a scale which is consistent with the scale of the unit vector detection thresholds.
The use of extending vector images to provide visual feedback is an alternative way of guiding the user in the input of characters to produce correct unit vector sequences. The unit vector detected causes the image displayed of the pointing device movement to be locked to the corresponding direction and allows the input of a line reproduced on the screen that represents the extension of the movement. When the direction of movement changes sufficiently to trigger the recognition of a new unit vector, then the displayed line is locked in the new direction. This visual feedback allows simulacrum images of the intended character shape to be displayed as straight line segments corresponding to the degree of movement in each direction. FIG. 27 illustrates the method.
It is advantageous to use special areas or special guidelines on the display screen used in conjunction with screen ink and/or pointer icon, in order to signal character end and therefore allow continuous input (eg within a word) without lifting the pen device or otherwise needing to signal character end and/or in order to signal control or modifier characters or signals. In this method when the pen position icon and/or screen ink moves into an area of the monitor display surface corresponding to a defined area of the writing surface, or when the pen enters the defined area of the writing surface, or when the pen crosses a defined line on either surface, a signal is produced by the processor which indicates the end of a character or other control event or command.
This allows the rapid input of joined-up cursive characters without the need to lift the pen or otherwise signal the end of each character. This is shown in FIG. 28 of the drawings in which movement of screen ink or pen icon into shaded areas 550 , signals the end of a character.
Visual feedback may include the modification of displayed character elements as new unit vectors are detected. FIG. 29 of the drawings illustrates this method. The seat of the “h” is modified into the circle of the “b” upon detection of the L (left) unit vector. Subsequently, the circle of the “b” is modified into the curl of the “k” on detection of the final R (right) unit vector.
A practical drawing device for use in the invention, which has been built to prove the efficacy of quantisation of motion to produce unit vectors from the finger movements of handwriting, is now described with reference to FIGS. 13A and B and 14 A and B of the accompanying drawings. It will be appreciated that many forms of pen can be produced in for use in this invention and that in addition existing computer input devices can be adapted to embody the invention herein described.
These drawings show a pen 100 having a tubular body 102 . Extending through the lower end of the body is a rod 104 which is pivotally mounted in the body at 106 , so that when the tip of the rod is held stationary on a surface, the pen body can move relative to the tip in directions normal to each other. Within the pen body are four light sources 108 each being at the mid-point of a side of a notional square template. Opposite each light source is an optical fibre 110 for detecting an on or off situation for its own light source, whereby signals can be generated for microprocessor recognition. The rod 104 has a square shutter plate 112 on its upper end, which in a rest position, ie when the rod is centrally aligned with the axis of the pen, all of the light sources are detectable by their corresponding optical fibres 110 but when the pen body is moved relative to the rod, the shutter plate is moved to obscure two of the light sources corresponding to the direction in which the pen is moved. FIGS. 13B and 14B respectively show the shutter in the neutral position and in position where the pen has been pushed to the top right. The pen tip movement is constrained by a square template 114 in the form of an aperture at the end of the pen body through which the pen tip extends. Thus, the pen includes the means for detecting direction of movement of the pen in forming characters in order to generate a signal that can be recognised by a microprocessor or computer to produce the character on a computer screen.
If the pen tip has a built-in flexibility, the fingers can perform circular and curved movements while the signals are generated with reference to the square templates.
FIG. 15 of the drawings shows schematically a pen device operating with a virtual template. The position of the pen tip 150 relative to the centre of the virtual template 152 is sensed in terms of its x, y coordinates as shown. As the pen body is moved around the pen tip by the fingers, the notional template moves with the pen body and causes a relative movement between the pen tip and the template. The track or locus of the pen tip relative to the virtual template is indicated by line 154 .
The movement is referred to template sides, ie is registered as a mapping of the pen tip position onto the template, resulting for example in the unit vector L D R, which could decode as the character “c”.
Provided the pen tip travels around the outside of the template and the template is always smaller than the smallest character drawn, then the sequence of unit vectors will always decode for the stylised character shapes irrespective of the scale or speed they are drawn.
Another embodiment of the invention (see FIG. 17) consists of a template built in to a portable databank 300 , or portable computer or other product requiring the input of information such as a video recorder, pocket calculator, telephone, central heating controller, washing machine etc etc. The template sensors are activated by the movement of a small stylus 302 held by the fingers.
The stylus may be attached or hinged to the product or may be removable or separate. This application will allow the space taken up by data input to greatly reduce as the stylus template 304 will replace the much larger keyboard or keypad 310 of a conventional pocket databank 312 (see FIG. 16) having a screen 314 . The stylus may fold down as shown to conserve space when not in use. The advantages of this embodiment of the invention are that the product can be made considerably smaller, the stylus can be used with the eyes on the screen 314 and can be used more easily than the usually cramped keyboard keys, and data can be input more quickly. The input device can be fabricated at considerably less expense than a keyboard or touch sensitive screen. Also a data link cable between the pocket databank etc could connect with a computer to allow text input from the built-in pen device to be input to the computer. | An apparatus and method for inputting a hand-generated character into a computer. A user draws a character using a drawing apparatus. As the user draws, movement of the apparatus and characteristics of such movement are detected. The apparatus generates a code for the character being drawn as a time dependent sequence of signals by comparing the characteristics of the movement as the character is drawn with a predetermined set of characteristics, with each signal corresponding to the predetermined characteristic closest to the actual characteristic detected at each successive step of movement. The apparatus provides visual feedback to the user by displaying in sequence each component of a character that is being drawn positionally independently of the movement of the drawing apparatus. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to draperies and curtains. More particularly, the present invention pertains to hooks for draperies and curtains. Even more particularly, the present invention pertains to hooks for draperies and curtains which are particularly adapted for utilization with traverse rods.
II. Prior Art
The suspension of draperies and curtains from traverse rods is, of course, well known. Essentially, a plurality of hooks are used to suspend the curtain or drape from the mounting members associated with the traverse rod. Furthermore, as is known to the skilled artisan, conventionally, the terminal or travelling end of the traverse rod is defined by a metal bar which is laterally displaced from the rod, per se. This enables the opposed travelling ends to meet substantially at the center of the rod without collision.
However, and as is also known to the skilled artisan, the conventional type of hook which is utilized to suspend the curtain from the traverse rod, while being efficacious for the normal mounting member, creates certain problems with respect to the travelling or terminal end. Because of the nature of the construction of the curtain, which is usually pleated, as well as the bar defining the terminal end, the upper portion of the curtain which is connected to the travelling end of the rod, does not maintain its erect or upright position. Rather, there is a rotational moment created which causes the upper end of the curtain to deviate or rotate away from the vertical plane. This is aesthetically unappealing and is quite commonplace.
The reason for this occuring is due to the inherent function and structure of the hook which is ordinarily a thin wire member having certain defined curvatures and bends, which cooperates with a slot or opening formed in the bar. Because of the interrelation of the structure there is this rotational moment about the point of contact between the hook and the bar which causes this deviation of the upper portion of the curtain from the vertical plane.
As will subsequently be detailed the present invention provides a drapery hook which alleviates the problems heretofore encountered in hanging draperies and curtains from traverse rods.
STATEMENT OF RELEVANT ART
To the best of applicant's knowledge the following is the most relevant art pertaining to the present invention:
U.S. Pat. No. 3,095,033, U.S. Pat. No. 2,606,733 and U.S. Pat. No. 1,600,805.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a drapery or curtain hook particularly adapted for interconnecting a curtain or drape to the terminal or travelling end of a traverse rod.
The hook hereof, generally, comprises a substantially planar member or plate, means for telescopingly receiving the terminal or travelling end of a traverse rod and means for detachably mounting the hook to a drape or curtain.
The means for detachably mounting the plate portion of the hook comprises a pair of spaced apart bodies formed of a flexible material and having a gap therebetween which is insertable about a pleat formed in the drape in a common mode.
In an alternate embodiment hereof the drapery hook hereof has the means for detachably mounting the hook to a drape or curtain being defined by the cooperation between the planar member and an upstanding wall. The void or space between the plate and the wall is dimensioned to be less than that of the thickness of the drapery or curtain material. Hence, the drapery or curtain is frictionally retained between the plate and the upstanding wall.
For a more complete understanding of the present invention reference is made to the following description and accompanying drawing. In the drawing like reference characters refer to like parts throughout the several views in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a drapery hook in accordance with the present invention;
FIG. 2 is an elevational view depicting the utilization of the present drapery hook in the mounting thereof to a traverse rod;
FIG. 3 is a rear elevational view of the drapery hook hereof;
FIG. 4 is an elevational view, depicting in phantom, the interconnection between the present hook and a curtain;
FIG. 5 is a front elevational view of an alternate embodiment of the present invention, and
FIG. 6 is a side elevational view of the embodiment of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, and with reference to the drawing, there is depicted therein a drapery hook, generally, denoted at 10, in accordance with the present invention. The drapery hook hereof generally comprises a substantially planar member or plate 12, means for telescopingly receiving the terminal or travelling end of a traverse rod, generally, denoted at 14 and means 16 for detachably mounting the plate to a drape or curtain.
As is known to those skilled in the art to which the present invention pertains a traverse rod is ordinarily used for suspending pleated curtains or drapes therefrom. Such traverse rods generally include an elongated rod or bar 20 having a track 22 formed therein. A guide rope assembly generally including a pulley is utilized to guide a terminal plate or rod 24 through the track. Conventionally, the terminal end of the traverse rod assembly comprises an elongated bar or rod 26 which has a plurality of slots 28 formed therein. The slots, conventionally, have drapery hooks or the like insertably mounted thereinto.
It is to be understood that in the practice of the present invention, the traverse rod, per se, does not form part of the instant invention. Rather, the present invention is directed to a mode of alleviating the problem hereinabove referred to which occurs ordinarily by virtue of the interconnection which is usually achieved between the rod or bar 26 and a conventional hook. The exact construction of the traverse rod is, of course, well known.
Also, it is to be understood with respect to the present invention that the curtains or drapes 18 are fabric structures usually having a plurality of pleats 30. The pleats, usually, are spaced apart and vertically extending. Usually, the upper terminis of the drape has individual pleat material sewn together. Ordinarily, in mounting a drapery hook to a drape the hook is mounted about the situs of the sewing together of the pleats such as at 32. Again, this is known to the skilled artisan.
Referring again to the drawing the hook 10 hereof, as noted, includes a plate 12. The plate 12 is a rigid surface which is interposed between the traverse rod and the drape or curtain. The plate 12, in essence, provides a bearing surface to preclude rotation of the drape away from the terminal or travelling end of the traverse rod 26.
Projecting laterally outwardly from a first surface of the plate 12 is the means 14 for telescopingly receiving the terminal end 26 of the traverse rod. The means 14 generally is defined by a conduit 34 which is dimensioned to slidingly and insertingly receive the end of the elongated rod 26. The conduit 34 is an elongated body having at least one open end 36 through which the rod 26 is inserted. The conduit 34, as noted, is dimensioned to retain the rod 26 therewithin. By nesting the rod 26 within the conduit 34 pivotal rotation of the hook about the rod is substantially totally diminished thereby precluding the curtain from rotating away from its normal vertical plane.
In a preferred embodiment of the present invention, the conduit 34 is integrally formed with the plate 12, and, as noted projects laterally outwardly therefrom. The conduit can have any desired configuration such as a rectangle, cylinder or the like.
The hook 10 is detachably interconnected to a curtain or drape via means 16. The means 16 generally comprises a clamp or the like for pinching the body of the curtain or drape 18 between the opposed surfaces 38 and 40 of the plate 12 and the means 16, respectively.
The means 16 generally comprises a body 42 having a width substantially equal to that of the plate 12 and is integrally formed therewith. The body has a slit or gap 44 formed centrally thereof which is employed to envelop the pleat area or situs 32 in the well known manner. The means 16 can have any desired configuration but, optimally, has a sinusoidal configuration to bring the body into proximity with the surface 38 in order to effectuate the "pinching". The means 16 is ordinarily integrally formed with the plate 12 and overlies a substantial portion thereof, as shown.
The means 16 is formed from a non-resilient material in order to exert the compressive forces necessary to maintain the curtain or drape in a suspended state.
Optimally, the hook 10 hereof is formed as a unitary member comprising the plate, the means for telescopingly receiving the rod 26 as well as the means 16. Furthermore, the device hereof is, preferably, integrally formed from a synthetic resinous material such as a rigid nylon, polyvinyl chloride, or the like.
It is to be appreciated that the hook hereof, by virtue of the width of the plate 12, cooperates with the conduit 34 to prevent the rotational movement of the upper portion of the curtain away from the elongated rod of the terminal or travelling end of the traverse rod. Hence, the curtain or drape remains in its normal vertical plane.
Referring now to FIGS. 5 and 6 there is depicted therein an alternate embodiment of the present invention, generally denoted at 110. In accordance herewith there is provided a substantially planar member of plate 112, means for telescopingly receiving the terminal or travelling end of a traverse rod 114 and means for detachably mounting the plate to a drape or curtain. It should be noted in this regard that this embodiment of the present invention is substantially the same as that defined hereinabove. The major difference between this embodiment and that heretofore described is with respect to the means for detachably mounting the plate to a drape or curtain. In all other respects this embodiment is substantially the same as that heretofore described.
This means generally comprises an upstanding pin 118 which is substantially parallel to the plate 112. The pin 118 has a width less than that of the plate 112 and projects thereabove, as shown. The pin 118 terminates in a point 119 for penetrating the material to suspend the hoof hereof to the curtain or drape. The pin 118 is interconnected to the plate 112 via an interconnecting leg 120. The leg 120 is optimally, integrally formed with the pin 118, as well as with the plate or planar member 112.
A space 122 is, thus, created between the plate 112 and the pin 118. In accordance herewith the space 122 is less than that of the thickness of the fabric of the curtain or drape. Hence, in utilizing this embodiment of the present invention the portion of the fabric defining the hem of the curtain is retained in the space 122 by virtue of the pinning action. Likewise, frictional forces retain the material within the space 122 by virtue of the compressive forces being exerted thereagainst by the pin 118 and the plate 112. This embodiment of the invention negates the need for insertion about the pleat.
Also, in accordance with the present invention there is provided means for grasping the hook generally denoted at 124. The means 124 generally comprises a projecting lip 126 or the like which can be manually grasped to facilitate both mounting and de-mounting of the hook from the curtain.
It is to be appreciated that a plurality of pins 118 can be provided as the means for detachably interconnecting the hook to the material. In such instance the pins would be spaced apart and project in the manner described above with respect to the single pin 118.
As with the first embodiment of the present invention this hook can be integrally formed in a single molding operation when formed of a synthetic resinous material. Likewise metals, such as steel, aluminum or the like can be used to fabricate the hook hereof.
It is to be appreciated from the preceding that there has been described herein an improved drapery hook for traverse rods which overcomes the deficiencies noted in the prior art. Having, thus, described the invention what is claimed is: | A traverse rod drapery hook is attachable to the terminal end of a curtain or drape and includes a member into which the terminal end of the traverse rod telescopes. The hook hereof includes a plate which provides a rigid surface for maintaining the drape in an upright position. | 8 |
TECHNICAL FIELD
This disclosure relates to replaceable application substance reservoirs for toothbrushes, and to electric toothbrushes in which such reservoirs are used.
BACKGROUND
WO 03/054771 A1 describes an electric toothbrush consisting of a handpiece and a replaceable attachable brush. The attachable brush contains a memory in which information identifying the attachable brush is stored. The attachable brush also contains a transponder which outputs the information stored in the memory when it receives an inquiry signal from an inquiry station. The handpiece contains a microcontroller which calculates the cumulative use time of the attachable brush identified and can write this information into the memory of the attachable brush. The handpiece is also provided with a display with which the need for replacing an attachable brush can be displayed.
DE 10 2004 062150 describes a replaceable accessory part for an electric toothbrush and a method for determining the use time of the accessory part.
There are already known electric toothbrushes into which may be inserted a toothpaste bag from which toothpaste can be dispensed during operation of the toothbrush. The bag is replaceable, so that when it is empty, it can be replaced by a filled bag. Electric toothbrushes may also be used by multiple users, in which case each user can attach his own brush head onto/into the hand part of the electric toothbrush and/or can insert his own toothpaste bag. It may happen here that the toothpaste bags are replaced before being completely empty and that toothpaste bags that have only been filled partially and have already been used are used.
EP 0930960 B1 describes a device for body care having a cassette which contains an auxiliary liquid. The cassette is provided with a key, which enables a function of the device when the cartridge is linked to the device.
SUMMARY
In one aspect, an application substance reservoir, e.g., a toothpaste bag, has a data carrier with a data memory which can be read and written to by a suitable toothbrush. A suitable toothbrush has a data receiver for reading the data stored in the data carrier and a data transmitter for writing to the data carrier. In this way, there may be a transfer of data between the application substance reservoir and the toothbrush, whereby the data read by the data receiver may be used by a control unit present in the toothbrush, e.g., for display of the filling level in the application substance reservoir and/or for adaptation of the toothbrush operation to the particular application substance used.
The data transmitter may preferably be used to store updated filling level data characterizing the remaining amount of application substance in the application substance reservoir, so that the updated filling level data is not stored in the toothbrush but instead is stored in the data memory of the application substance reservoir. This has the advantage that the filling level data are not lost when the application substance reservoir is replaced, e.g., because another user of the toothbrush wants to use his/her own toothpaste. If the application substance reservoir that has been replaced is inserted back into the toothbrush, the toothbrush may read out and/or display the filling level stored in the data memory of the application substance reservoir.
Additional data may advantageously be stored in the data memory of the application substance reservoir and may be utilized by the control unit to control other functions. For example, a user-specific data profile, which may be entered by the control unit on insertion of the application substance reservoir or each time the toothbrush is turned on, may be stored in the data carrier of the application substance reservoir, for example, so that operation of the toothbrush is individually adaptable for the respective user. For example, this may be a tooth-brushing time which the respective user would like to maintain with the special toothpaste. Other operating parameters of an electric toothbrush such as the drive speed, greeting tone, oscillation frequency, etc., may also be adjusted as a function of the saved user-specific data.
The data carrier on the application substance reservoir may advantageously also contain control data preselected by the manufacturer on the basis of which the control unit of the toothbrush activates, controls or changes toothbrush functions. In the simplest case, these data may characterize the full status or the contents of the application substance reservoir, and the control unit may trigger a display device on the toothbrush by means of these data to display the filling level and/or the amount of application substance used. However, on the basis of the corresponding data, other operation-relevant components, in particular the drive and/or a conveyance device may be used for dispensing the application substance. For example, an application substance-specific metered quantity may be stored in the data carrier, this quantity being used to trigger the conveyance device, so that the conveyance device dispenses the predetermined quantity of application substance. In a further embodiment, data for controlling the drive mode of the toothbrush may also be stored in the data carrier; in particular, the control unit may also switch the toothbrush drive to a tooth-brushing mode on the basis of the data read out of the data carrier of the application substance reservoir, when the application substance reservoir contains a toothpaste, while the drive device is switched to a polishing mode when the application substance reservoir contains a polishing agent.
In a preferred embodiment, the toothbrush may be enabled with the help of data stored in the data carrier. In the control unit, an enabling function may be provided, allowing the enabling of toothbrush operation and/or individual operating functions as a function of the data received by the data carrier. In this way it is possible to prevent, for example, the toothbrush from inadvertently being switched to operating mode without inserting the application substance reservoir. Likewise, it is possible to prevent the toothbrush from being operated when an unsuitable application substance is inserted; in the case of application substances that are too viscous, for example, this might result in damage to the conveyance device.
The data carrier on the application substance reservoir as well as the data transfer means may be designed in various ways. The data receiver and/or the data transmitter preferably operate without contact. In a simple embodiment, the data carrier may have a magnet and the data receiver may have a reed sensor by means of which the magnet can be gripped on the application substance reservoir. If the application substance reservoir has been inserted, then the reed sensor will detect a pulse which charges a counter in the control unit at a value which corresponds to the full status of the application substance reservoir in a counter. If application substance is subsequently dispensed during operation, the amount of substance is decremented on the counter accordingly and the respective filling level of the application substance reservoir may be displayed. However, such a display yields correct values only when the application substance reservoir is full when inserted.
Preferably, however, a writable data carrier is provided on the application substance reservoir. In particular, a transponder chip may be provided, which can communicate with a suitable data transceiver in the toothbrush. In some implementations, a so-called RFID chip, i.e., a radiofrequency identification chip, may be provided as the data carrier; the RFID chip communicates with the data transceiver of the toothbrush in the frequency range of approx. 13.56 MHz.
However, other embodiments of the data carrier and the data transfer means are of course also possible. For example, the data carrier may have optical coding, which can be read by an optical sensor in the toothbrush. Likewise, an electric, inductive and/or magnetic design of the data carrier and/or the data transfer means is also possible.
In a preferred embodiment, the data transceiver of the toothbrush is a radio transceiver having multiple antennas for communication with multiple data carriers. Two completely separate data transceivers may of course be provided in a toothbrush to communicate with multiple data carriers. A substantial cost saving, however, is achieved by the fact that multiple antennas are operated with only one data transceiver. The data transceiver preferably comprises a switching device which optionally activates one antenna or the other. The antennas are preferably designed so that the one antenna can communicate with the data carrier on the application substance reservoir while the other antenna can communicate with a data carrier on a replaceable attachable brush of the toothbrush. In this way, data from the application substance reservoir can be input on the one hand to control operation of the toothbrush as a function of the application substance in the manner described previously, while on the other hand data may also be input from the respective attachable toothbrush to suitably control the operation of the toothbrush as a function thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of an electric toothbrush.
FIG. 2 shows a top view of an application substance reservoir for an electric toothbrush having a transponder chip for data communication with the toothbrush.
FIG. 3 shows a top view of an application substance reservoir with a transponder code which is applied to an appendage of the application substance reservoir.
FIG. 4 shows a top view of an application substance reservoir with a transponder chip which is mounted on the connecting means of the application substance reservoir, and
FIG. 5 shows a schematic diagram of the data transceiver of a toothbrush for communicating with the data carrier on the application substance reservoir and a data carrier on an attachable brush.
DETAILED DESCRIPTION
FIG. 1 illustrates an electric toothbrush 1 having a hand part 2 that contains a drive motor which drives a driveshaft 3 protruding out of the hand part 2 at one end in an essentially known manner. In addition, the hand part 2 contains a control unit, preferably electronic, that controls the operation of the toothbrush 1 including the drive motor. An on/off switch 4 is provided on the hand part 2 . A replaceable attachable brush 6 having a brush tube 7 which carries a bristle field 8 may be attached to the driveshaft 3 in an essentially known manner. An application substance reservoir 9 , preferably a toothpaste bag as illustrated in FIGS. 2 through 4 may be inserted into the hand part 2 . A conveyance device (not shown in FIG. 1 ), which may comprise a pump driven by the drive motor, for example, to dispense the toothpaste stored in the toothpaste bag 9 by motor drive is provided in the hand part 2 . The corresponding conveyance lines (also not shown in FIG. 1 ) may lead into the attachable brush 6 to dispense the toothpaste on the bristle field 8 .
The toothpaste bag 9 comprises a connector 10 , which is adapted to the conveyance unit of the toothbrush and with the help of which the bag can be connected to the suitably designed connection interface of the conveyance device, so that the interior of the toothpaste bag 9 has a flow connection to the conveyance device. The connector 10 has a tubular connection 11 which is welded into the bag body 12 , preferably made of a film, and protrudes out of the bag body for a distance. The connection 11 may be connected to the complementary connection interface on the conveyance device end so that toothpaste can be conveyed out of the interior of the bag body 12 . Moreover the toothpaste bag 9 is itself adapted in its shape to the housing of the toothbrush, in particular to the bag receptacle space in/on the toothbrush. A data carrier 13 consisting of a transponder chip, which is connected to a data transfer device 14 is provided on the toothbrush bag 9 . The data transfer device 14 may have an antenna in the form of a magnetic coil to exchange data with the control unit in the hand part 2 .
The control unit in the hand part 2 also has a data transfer device 15 which is depicted in FIG. 5 and also has a data transceiver. The data transceiver has two separate antennas so that the control unit can communicate not only with the data carrier 13 on the toothpaste bag 9 but also with a corresponding data carrier 16 on the brush tube 7 of the attachable brush 6 . The data carrier 16 on the attachable brush 6 is preferably also a transponder chip. The data transfer device 15 contains two antenna coils 17 and 18 which may optionally be activated by means of a switching device 19 . The one antenna coil 17 is provided for communication with the data carrier 16 on the attachable brush 6 , while the other antenna coil 18 is provided for communication with the data carrier 13 on the toothpaste bag 9 . The switching device 19 comprises two transistors, which can be controlled by the control unit of the hand part 2 via inputs 22 , 23 . Depending on which transistor is triggered, one of the antenna coils 17 , 18 is deactivated by short-circuiting a respective resonant-circuit capacitor 20 , 21 by the transistor. Therefore, no resonance sharpness of the voltage in the respective resonant circuit can develop, while the current in the resonant circuit remains low and practically no power can be emitted and/or no signal received.
Various toothbrush functions can be controlled via the data stored in the data carrier 13 of the toothpaste bag 9 . First, the control unit may trigger a display device, e.g., in the form of a display 24 , as a function of the data input to display the type of toothpaste inserted, for example, and/or the filling level in the application substance reservoir 9 . However, data may also be stored in the data carrier 13 , influencing the drive mode of the drive motor and/or the operation of the conveyance device. For example, the drive may be switched between a polishing mode and a tooth-brushing mode, depending on the data input from the toothpaste bag. Depending on the data input, the conveyance device may dispense different quantities of toothpaste, which are specific for the respective toothpaste. Likewise, enabling of any toothbrush functions can also be implemented. To this end, an enable function is provided in the control unit, enabling the operation of the toothbrush only when the “correct” code has been input by the data carrier 13 and/or 16 of the toothbrush bag 9 and/or the attachable brush 6 .
In addition, the control unit of the hand part 2 may also store filling level data in the data carrier 13 of the toothbrush bag 9 . To do so, on insertion of a toothbrush bag, the control unit will first read out the filling level stored there, but this level is then reduced each time the toothbrush is operated, decreasing it by an amount that depends on consumption. The prevailing filling level or the amount of application substance consumed is transmitted to the data carrier 13 of the toothbrush bag 9 when operation of the toothbrush stops, so that when operation of the toothbrush is resumed again or after changing and replacing the toothbrush bag 9 , the prevailing filling level is stored there and thus the filling level display is displayed correctly even when the application substance reservoir inserted into the toothbrush is not completely full.
User-specific data may advantageously also be stored in the data carrier 13 to control the operation of the toothbrush in a user-specific manner as a function of the stored data. This is appropriate, for example, when the hand part 2 is used by multiple users who use different application substances. However, even when the same toothbrush bag is being used, user-specific data may still be stored in the data carrier 13 . For example, different toothpaste dispensing quantities may be defined for different users, so that each user receives the amount of toothpaste he/she desires. Even if only one user is defined, different dispensing amounts may be defined for morning and evening, for example. Other operating parameters such as the drive speed, drive mode, etc., may be stored in the data carrier 13 in a user-specific manner.
In another embodiment, multiple application substance reservoirs or one application substance reservoir having multiple receptacle chambers may be used for dispensing different application substances, in which case two conveyance devices are then advantageously provided in the toothbrush. In this case, a mixing ratio of the two application substances may also be stored in the data carrier 13 or in the data carriers 13 so that the two conveyance devices are operated in a suitable drive mode to achieve the desired mixing ratio.
According to an especially advantageous embodiment, a complete data record or a part thereof is read into the control unit on insertion of the toothpaste bag into the hand part 2 and is stored in the data carrier 13 of the toothpaste bag 9 . Control updates may also subsequently be fed into the hand part 2 , thereby supplementing or modifying the control functions in the hand part 2 without the toothbrush owner having to seek out a suitable service shop to do so. | An application substance reservoir for a toothbrush is provided. The reservoir has a data carrier and may be filled with toothpaste or another application substance. An electric toothbrush is also provided. The data carrier of the application substance reservoir may contain, for example, information regarding the prevailing filling level of the application substance reservoir and the type of application substance. The electric toothbrush has a data receiver for reading the data stored in the data carrier, a data transmitter for writing to the data carrier, and a control unit which may display the filling level in the application substance reservoir or the particular application substance used. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation, under 35 U.S.C. §120, of copending International Application No. PCT/EP2011/054314, filed Mar. 22, 2011, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German Patent Application DE 10 2010 015 154.8, filed Apr. 16, 2010; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a device for storage or supply of an operating fluid which is used, in particular, in a motor vehicle and includes an electrode configuration for determining a filling level. The invention also relates to a method for mounting the device, a method for monitoring the device and a motor vehicle.
Devices for storing and supplying operating fluids have always been necessary in motor vehicles. For example, in order to operate motor vehicles, at least one fuel, windshield washing fluid, etc. must be carried in tanks or similar containers. Not the least of all, motor vehicles are increasingly being fitted with an exhaust system to clean the exhaust emissions from an internal combustion engine, in which case an additional operating medium (in particular an oxidation agent and/or a reducing agent in liquid form) is supplied to the exhaust system and must also be stored and carried. That guarantees particularly effective exhaust gas cleaning.
One example of an exhaust gas cleaning process for which such an operating fluid is required is selective catalytic reduction (SCR). In that process, a reducing agent (e.g. ammonia) and/or a reducing agent precursor (e.g. urea) is introduced into the exhaust system. A known reducing agent precursor solution is a 32.5% urea-water solution which is also available commercially under the trademark AdBlue. The reducing agent precursor is converted into ammonia, the actual reducing agent, in the exhaust gas or externally to the exhaust gas. Nitrogen oxide compounds in the exhaust gas are effectively reduced by the ammonia which is thus produced.
It is usually necessary to economically, easily and reliably determine the filling level of the operating fluid in the respective tank of the motor vehicle. Electrodes are suitable for determining the filling level of operating fluids which are electrically conductive or which have other significant electrical properties. With such electrodes, for example, it is possible to carry out monitoring between two adjacent electrodes as to whether or not certain electrical properties such as resistance, capacitance and/or inductance change. Depending on such a measurement it can be established whether or not operating fluid is present in the vicinity of the electrodes.
Frequently, different tanks are used to store operating fluids for different motor vehicle types. That depends firstly on the size of the motor vehicle and secondly on the space available for a device for providing reducing agent. In addition, the structure of the tank is also dependent on the consumption of the motor vehicle and/or the safety regulations and/or production restrictions, etc. Within the context of motor vehicle construction, normally as many identical parts as possible are used for different vehicle types. That allows the manufacturer of the motor vehicle to make substantial cost savings. Consequently, a device for determining the filling level in a tank must also be constructed in such a way that it can be used or adapted for different tank geometries.
It can also be sensible to use differently set devices for determining the filling level in two identical tanks for different applications or different motor vehicles. Determining the filling level is particularly important in establishing when a reserve volume of operating fluid has been reached or passed. When a reserve volume has been reached or passed, a user of the motor vehicle must be reminded to fill up the tank. Depending on area of application, different residual volumes are required. For example, in a car in which the tank is to be filled up only as part of normal service intervals, a substantially larger reserve volume must be provided than in a vehicle in which the user himself or herself is responsible for filling up the operating fluid.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a device for storage or supply of an operating fluid for a motor vehicle, a method for mounting the device, a method for monitoring the device and a motor vehicle, which overcome the hereinafore-mentioned disadvantages and alleviate the highlighted technical problems of the heretofore-known devices, methods and vehicles of this general type. In particular, a highly advantageous device for storage of an operating fluid is described which includes suitable electrodes for determining a filling level which can easily be adapted to different tank geometries and reserve volumes.
With the foregoing and other objects in view there is provided, in accordance with the invention, a device for storage of an operating fluid. The device comprises a tank having an interior space, a protrusion protruding into the interior space and having a circumferential surface, and at least one electrode running radially at least partly around the circumferential surface and configured for determining a filling level.
The at least one electrode for determining the filling level is normally in electrical contact with the operating fluid present in the interior space. Consequently, at least one of the electrodes is disposed in a region, in such a way that it forms a corresponding contact (at least on a completely filled tank). Further electrodes can also be provided which are spaced from the first electrode.
The tank constitutes a (lockable) reservoir for a reducing agent into which the reducing agent can be introduced and from which it can be extracted again (at another point). It is also preferable for the tank to include several subdivisions formed by plastic tank walls. In this case, the tank usually has at least one cover, side walls and a bottom. These delimit (at least) one interior space available for the reducing agent. Protruding into this interior space is a protrusion with a circumferential surface, wherein the circumferential surface at least partly constitutes one tank wall. The protrusion is, for example, formed as a bulge, convex curvature, concave wall segment or the like. Such a protrusion can preferably also be provided as a corresponding recess on the outside of the tank. Preferably, the protrusion extends over at least a significant extent of the filling level, for example at least 5 cm (centimeters) or even 10 cm. In particular, the protrusion is formed on the bottom or on a side wall of the tank.
The electrode, which is formed radially and at least partially circumferentially, can be fixed at a predefinable position on the protrusion extending into the tank. This allows an adaptation of the position of the electrode to different tank geometries and/or filling levels to be detected of the reducing agent. For this purpose, the protrusion can have different diameters, contact surfaces, etc. to fix the electrode at predetermined points.
The device according to the invention is suitable, in particular, for storage and supply of liquid reducing agent or liquid reducing agent precursor solution. Such a reducing agent precursor solution is usually electrically conductive. A filling level can therefore be determined advantageously through an electrode configuration.
The term electrical contact in this case means, in particular, an electrically conductive contact in which an electrical current can flow from the electrode into the fluid or from the fluid into the electrode. Alternatively, an electrical contact can be present with a capacitance or inductance which changes depending on the presence of operating fluid. For a capacitative contact, for example, an electrical capacitance can be determined at the electrode.
Preferably, the electrode runs completely around the circumferential surface of the protrusion. The electrode is thus formed in the manner of an annular strip or band. It is, however, also possible for the electrode to only partially span the protrusion, and/or for several segments of the electrode to be disposed behind each other (offset) in the circumferential direction.
In accordance with another advantageous feature of the device of the invention, an insulating material is disposed between the circumferential surface and the at least one electrode. This insulating material isolates the electrode electrically from the protrusion. The protrusion can then, for example, also be made of metal so that its surface itself has an electrical conductivity. Preferably, the insulating material is formed over a height of the protrusion which is greater than the width of the at least one electrode. In this way the electrode can be displaced on the insulation or on the circumferential surface during assembly and isolated from the protrusion by the insulating material in different positions. The insulating material can be applied to the protrusion, for example in the form of a coating or a glued strip.
In accordance with a further advantageous feature of the device of the invention, the protrusion is formed in a bottom of the tank, the at least one electrode is mounted releasably on the circumferential surface at a height measured from the bottom of the tank and a reserve volume of the tank is defined by the height. The height extends in particular, starting from a theoretical plane of the tank bottom, in a direction vertical thereto up to the at least one electrode. For an unevenly shaped bottom, the theoretical plane of the bottom can, for example, correspond to a mean bottom plane.
Through the use of the at least one electrode it can therefore easily be established when a reserve filling level of the operating fluid in the tank is reached. On a horizontal orientation of the tank, this reserve volume is delimited by the tank bottom and a plane defined by the at least one electrode. Since the electrode is mounted releasably on the circumferential surface, the height of the electrode can be changed during assembly. This also changes the reserve volume. Thus, the reserve volume can be adapted to different motor vehicle types by changing the height of the electrode. At the same time, the reserve volume can be adapted to different tank geometries. Different tank geometries have different tank cross-sectional areas. A reserve volume is the product of the cross-sectional area and the height. Therefore, an adaptation of the height of the at least one electrode is required in order to achieve the same reserve volume for different tank geometries.
In accordance with an added feature of the device of the invention, the at least one electrode includes a clamping mechanism with which the electrode is clamped to the circumferential surface. It is very easily possible to fix the at least one electrode at a specific height in the tank by using a clamping mechanism, in particular by force-locking. Such a clamping mechanism can be releasable and/or can fix at least one electrode permanently after a single installation. The clamping mechanism clamps the electrode, in particular, around the circumferential surface of the protrusion. A force-locking connection is one which connects two elements together by force external to the elements, as opposed to a form-locking connection which is provided by the shapes of the elements themselves.
In accordance with an additional advantageous feature of the device of the invention, the at least one electrode is divided circumferentially into several contacting segments which are contacted separately from each other. A segmented electrode (formed from several contacting segments) is formed, for example, as a band running around the protrusion and including individual partial regions which are electrically isolated from each other, succeed each other in the circumferential direction and, for example, each span a specific arc dimension of, for example, between 180° and 30° [angular degrees] of the circumferential surface of the protrusion. Also, in particular additionally, it is possible for the several contacting segments to also be disposed offset relative to each other in the axial direction (i.e. perpendicular to the circumferential direction of the protrusion).
In a further embodiment, the individual contacting segments can also be constructed as points and preferably distributed evenly about the circumference of the electrode. For example, between 2 and 12, preferably between 3 and 8 individual point-like contacting segments can be distributed evenly about the circumference of the electrode. Point-like in this case means, in particular, that the contacting segments only have a very short length in the circumferential direction in comparison with the circumference of the protrusion, for example less than one-tenth ( 1/10) or even one twentieth ( 1/20).
Such contacting segments, which are contacted separately from each other, can be connected to an analysis circuit which carries out a more precise calculation of the actual filling level in the tank from the values measured at the electrode (or the contacting segments). For example, a main component analysis can be carried out in which the different values measured at the different contacting segments are compared with each other. It is also possible to process the measurement values determined at the individual contacting segments together in a neuronal network. It can also be provided that a mean value is formed from the measured values determined at the different contacting segments. Thus, for example, sloshing movements occurring in the reducing agent tank can be compensated effectively. A corrected signal can thus be generated which indicates the reaching of a reserve filling level more precisely than a signal measured directly at only one contacting segment or a pair of contacting segments or electrodes. The values measured at the contacting segments are advantageously evaluated in a controller, analysis circuit or analysis electronics adapted to this end.
In accordance with yet another advantageous feature of the device of the invention, the at least one electrode is contacted through at least one flexible line which extends away from the circumferential surface of the electrode.
In accordance with yet a further advantageous feature of the device of the invention, the at least one electrode is contacted through at least one line which leads electrically isolated inward into the protrusion.
The at least one electrode, as already stated, is preferably mounted on an insulating material on the circumferential surface of the protrusion. Due to this insulating material, electrical contacting of the electrodes is only possible with difficulty so that it is proposed herein to guide the contacting lines away toward the outside and lead them out of the interior space of the tank at a point outside the insulating material. This point can, for example, be disposed on the top of the protrusion. The at least one line is thus guided inward into the protrusion. It is also possible that the at least one line is guided out of the interior space of the tank inward into the protrusion at the circumferential surface. Advantageously, the lines themselves are isolated directly from the region of the electrode (electrically and chemically resistant). Since the lines are flexible, the electrodes can also be displaced on the circumferential surface where required.
With a suitable embodiment it can even be achieved that the line is guided out of the interior space of the tank in the region of the insulating material. This can be achieved by a suitable contact rail which creates a connection, electrically isolated from the interior space of the tank, between the electrode and the protrusion. For example, the electrode can extend in regions at a distance from the circumferential surface and the line can be guided through the circumferential surface in this region. The at least one line can then also extend toward the inside to the circumferential surface of the protrusion. It can thus be achieved that the at least one line does not extend as a line loop through the interior space of the tank. Such a line loop can, for example, be damaged by mobile frozen operating fluid present in the tank.
In accordance with yet an added advantageous feature of the device of the invention, a delivery unit is disposed in the protrusion to deliver the operating fluid out of the tank. In the protrusion then, outside the interior space, a cavity is formed which is particularly suitable for the configuration of a delivery unit for the operating fluid. A delivery unit can be provided in this case without additional space being required outside the device. In addition, the protrusion can be closed from the outside by a cover so that the delivery unit is protected from external influences. The delivery unit includes at least one delivery pump and where applicable at least one of the following components: delivery line for operating fluid extracted, valve, filter, sensor, etc. It is particularly preferred that all components for delivery of operating fluid are disposed externally in the protrusion of the tank so that from there only one delivery line and one metering unit or supply unit (e.g. injector) for the operating fluid are provided.
With the objects of the invention in view, there is also provided a method for mounting a device according to the invention. The method comprises:
a) providing a tank with an interior space, a bottom and an opening in the bottom; b) providing a container having a circumferential surface; c) mounting at least one electrode running radially around the circumferential surface of the container; and d) inserting the container in the opening to form a protrusion into the interior space of the tank with the container.
In this method, the actual tank and the protrusion protruding into the tank are two separate components before assembly. Preferably, the container is made of a different material than the tank. The container can, for example, be metallic while the tank is preferably made of plastic. As long as the container is outside the tank, the radially circumferential electrode can very easily be mounted on the circumferential surface of the container. After insertion of the container in an opening of the tank, the container forms the protrusion into the interior space of the tank.
The container preferably forms an assembly with a reducing agent delivery unit disposed in the container. The installation in step c) can be permanent and not able to be released again without destruction of at least the electrodes.
In principle, it is preferred for the steps given above to be performed in the order given. It is, however, also possible to undertake a different sequence of steps. For example, steps c) and d) can be exchanged when assembly of the at least one electrode is to take place only in the tank.
With the objects of the invention in view, there is furthermore provided a method for monitoring a reserve filling level of an operating fluid in a device according to the invention having at least two electrodes disposed radially above one other. The method comprises:
x) applying an electrical voltage between the two electrodes; y) testing an electrical resistance between the two electrodes; and z) evaluating the electrical resistance.
With this method according to the invention, it is possible to measure whether or not operating fluid is present at the height of the electrodes by measuring the electrical resistance between the electrodes. Such a method is useful if the operating fluid is electrically conductive, as is the case, for example, for aqueous urea solution. The device according to the invention can very easily be adapted to the method according to the invention for monitoring a reserve filling level in that e.g. the height of the electrodes measured from the bottom of the tank is adapted accordingly. The distance of the electrodes from each other can also be adapted. This allows adaptation of the device according to the invention to different operating fluids and different conductivities of the operating fluids.
The benefits outlined for the device according to the invention and the particular embodiments can be transferred in a similar manner to the two methods according to the invention. The same applies to the particular benefits and embodiments outlined for the two methods according to the invention which can be transferred both to the other method according to the invention and to the device according to the invention.
With the objects of the invention in view, there is concomitantly provided a motor vehicle, comprising an internal combustion engine, an exhaust system configured to clean exhaust gases from the internal combustion engine and including at least one injector configured to supply an operating fluid, a device according to the invention connected to the injector, and a control unit configured or programmed to control the device and the injector. The control unit can also be configured or programmed for performing the monitoring method according to the invention.
Other features which are considered as characteristic for the invention are set forth in the appended claims, noting that the features listed individually in the claims can be combined with each other in any arbitrary, technically useful manner and be supplemented by explanatory information from the description, in which further embodiment variants of the invention are disclosed.
Although the invention is illustrated and described herein as embodied in a device for storage of an operating fluid for a motor vehicle, a method for mounting the device, a method for monitoring the device and a motor vehicle, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a diagrammatic, vertical-sectional view of a first embodiment variant of a device according to the invention;
FIG. 2 is a vertical-sectional view of a second embodiment variant of the device according to the invention;
FIG. 3 is a vertical-sectional view of a third embodiment variant of the device according to the invention; and
FIG. 4 is a vertical-sectional view of a motor vehicle including a device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawings in detail and first, particularly, to FIGS. 1, 2 and 3 thereof, there are seen embodiment variants of the device according to the invention which have a multiplicity of correlating features and are therefore initially only explained jointly below. The same components are identified with the same reference numerals in the figures.
The device 1 according to the invention has a tank 3 with an interior space 4 which is filled partially with operating fluid 2 (in particular an aqueous urea solution). A protrusion 5 with a circumferential surface 6 protrudes into the interior space 4 . An insulating material 8 , on which two electrodes 7 are mounted at a predefined height 9 , is provided on the circumferential surface 6 .
FIGS. 1 and 2 both show the height 9 which is decisive for determining a reserve filling level 23 . The height 9 is namely the filling level which the operating fluid 2 must reach in the interior space 4 so that an electrical connection exists between the two electrodes 7 . The height 9 is measured in each case in relation to a bottom 12 of the tank 3 . The electrodes 7 are formed by conductor tracks 11 running around, disposed in tiers or stacked on the circumferential surface 6 . The electrodes 7 are each contacted by lines 15 which extend initially radially away from the circumferential surface 6 starting from the electrodes 7 , and then lead to a top 26 of the protrusion or projection 5 .
A reserve volume 13 in the tank 3 , which is monitored by the electrodes 7 , is substantially defined by the height 9 in combination with a cross-sectional area 25 and extends from a height of the reserve filling level 23 to the bottom 12 of the tank 3 .
In order to adapt the electrodes 7 to different tanks 3 for different reserve filling levels 23 and/or different electrical properties of the operating fluid, firstly the height 9 of the electrodes 7 and secondly a distance 27 of the electrodes from each other, can be varied.
A special feature of the embodiment variant of the device 1 shown in FIG. 1 is a clamping mechanism 10 with which the electrodes 7 can be clamped to the circumferential surface 6 of the protrusion 5 .
A special feature of the embodiment variant of the device shown in FIG. 2 is segmented electrodes 7 which include individual contacting segments 14 . A surface of the operating fluid 2 executing a sloshing movement is also shown as an example. Due to this fluid movement, some of the contacting segments 14 are reached by the operating fluid 2 while other contacting segments 14 are not reached. The measurement values of all of the contacting segments 14 can be processed together and jointly in order to obtain reliable information about an actual filling level 29 .
FIG. 2 also shows that the protrusion 5 is formed by a (separate) container 22 which is inserted in an opening 21 in the bottom 12 of the tank 3 . In the region of the opening 21 of the bottom 12 of the tank 3 , the bottom 12 has a deeper region which forms a sump 28 running around the protrusion 5 in the bottom of the tank 3 . The container 22 and the bottom 12 are fluid-tightly connected to each other in the region of the opening 21 . The container 22 , the electrodes 7 and the opening 21 are preferably constructed in such a way that the container 22 with the electrodes 7 can be inserted in the opening 21 .
A particular feature of the embodiment variant of the device 1 according to the invention shown in FIG. 3 is that there is only one segmented electrode 7 on which several contacting segments 14 are disposed next to each other. The contacting segments 14 are each disposed as pairs 30 . One such pair 30 of contacting segments 14 is contacted by separate lines 15 . If an electrical contact is established between the two contacting segments 14 of a pair 30 , then operating fluid 2 is present at this pair 30 . Due to the structure according to FIG. 3 , the benefits of the device 1 according to the invention can be achieved with only one electrode 7 being required for this purpose. If, as shown in FIG. 3 , several pairs 30 are present and distributed over the circumference of the protrusion 5 , an effective compensation for sloshing movements in the tank 3 can even be achieved with an analysis circuit. FIG. 3 also shows that the contacting segments 14 are linear and extend over part of the height of the protrusion 5 . Thus, a certain tolerance in filling level determination in relation to sloshing movements can be achieved because the contacting segments 14 stand in electrical contact with the reducing agent 2 over a larger range of filling levels.
FIG. 4 shows a motor vehicle 17 including an internal combustion engine 18 and an exhaust system 19 to clean or purify exhaust gases from the internal combustion engine 18 . The exhaust system 19 has an injector 20 through which a reducing agent which is stored in a device 1 can be supplied to the exhaust system 19 . It is also clear that the device 1 has a tank 3 into which a protrusion 5 protrudes. A delivery unit 16 , which is disposed in the protrusion 5 according to FIG. 4 , can deliver the operating fluid out of the tank 3 or the device 1 to the injector 20 . A control unit 24 is configured or programmed to control the injector 20 and the delivery unit 16 or the device 1 .
The device according to the invention allows a particularly economical and simple adaptation of an electrode configuration for determining the filling level in the tank for an operating fluid of a motor vehicle to various tank geometries and for various reserve filling levels in the tank. | A device for storing or supplying an operating fluid includes a tank with an interior space and a protrusion which protrudes into the interior space and has a circumferential surface. At least one electrode for determining a filling level is disposed radially, running around the circumferential surface. Methods for mounting such a device and for monitoring a reserve filling level as well as a motor vehicle are also provided. | 6 |
This application is a continuation of prior application Ser. No. 596,217 filed Oct. 12, 1990, now abandoned, which was a continuation of Ser. No. 468,836 filed Jan. 19, 1990, abandoned, which was a continuation of Ser. No. 382,262 filed Jul. 20, 1989, abandoned.
FIELD OF THE INVENTION
This invention relates generally to home automation systems, and more particularly, to a home automation system using "smart" switches having a "teach/learn" function so that they can be dynamically taught to control or to be controlled by any other similar switch in the house.
DESCRIPTION OF THE PRIOR ART
Within the current development of a variety of home automation systems and products there has been a growing interest in communication networks to facilitate the interconnection of lights, appliances, sensors, control devices, etc., for purposes of remote sensing and control.
One such system, known as "Homenet", has been partially developed by the General Electric Company of Schenectady, N.Y., and has been proposed as the basis for an industry standard known as "CEBus" (Consumer Electronic Bus) by the EIA (Electronic Industries Association).
Another such communication system currently in widespread use is known as the "X-10" system manufactured by X-10 USA, Ltd., of Montvale, N.J., which utilizes a signalling means whereby simple control signals (i.e., on, off, dim, brighten, etc.) are transmitted over pre-existing power wires in the home for remotely controlling power to lights, appliances and the like.
Although extremely useful and quite popular, the X-10 system suffers from certain limitations that inhibit its application to more extensive home automation or control functions. Namely: 1) its slow data rate of approximately 120 bits per second; 2) its dependence for timing and synchronization on the AC powerline 60 Hz. zero crossing; 3) its essentially one-way communication protocol; 4) its sensitivity to electrical noise, causing both lost messages and false interpretation and spurious activation; and 5) its dependence on the user manually setting specific digital codes on electro-mechanical switches to establish the proper addressing of messages. The CEBus system and its protocol seek to establish a newer, more advanced standard system to remedy these and other limitations and to enable a broader range of remote sensing, control and communication for future application in all manner of electrical and electronic devices.
The Consumer Electronic Bus (CEBus) protocol is a low cost, low speed (1000 bits per second) local area network that uses a power line carrier to send control information over typical house electrical power wiring. Such communication is useful for turning appliances and lights on and off remotely, as well as sending more sophisticated command message packets for other consumer electronics applications. CEBus is a Carrier Sense Multiple Access with Contention Resolution and Collision Detection (CSMA-CRCD) protocol, and transmits symbols using a pulse-width encoding, non-return to zero scheme. CEBus protocol is derived from the "Homenet" protocol developed at General Electric in 1983, and is currently being incorporated into a standard by the Electronic Industries Association (EIA). CEBus protocol transmits data packets with check-sum error detection, and retransmits unacknowledged packets. CEBus is therefore more versatile than X10, and there is a much better chance of messages getting through without error, e.g., without being falsely triggered by line noise.
X10 modules are uniquely addressed via a house code and a unit code. All X10 modules in the same house share the same numeric house code, which must be different from a neighbor's house code so that signals developed in a first house do not control the lights and appliances in a neighboring house. Each X10 module in a house must have a unique numeric unit code, so that the user can uniquely select which X10 module he desires to address. The house and unit address codes are mechanically selected with small rotary switches or thumbwheel switches on the X10 module. When an additional new X10 module is purchased, its house code and unit code switches must be set to meet these addressing requirements. There is no parallel to this inconvenient requirement in any other common household object.
Other prior art devices are shown in U.S. Pat. Nos. 4,649,323, 4,733,138 and 4,792,731. U.S. Pat. No. 4,649,323 describes a microcomputer controlled light switch for initiating various control modes for a light source, such as dimming of a light. U.S. Pat. No. 4,733,138 describes a programmable lighting circuit controller for controlling a plurality of household lighting circuits, and includes a "learn" function. U.S. Pat. No. 4,792,731 also describes a control system for multi-room lighting, in which an assignment panel is associated with the multi-room controller to link several individual light controls in a group under the control of a selected individual control within the group. All linked controls mimic the last activated control.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an apparatus and method for advanced protocol and "language" that will enable the CEBus to provide not only full two-way communication, but that will also allow automatic network addressing configuration (a "plug'n play" simplified user interface) avoiding the use of mechanical switches previously required.
It is a further object to provide to the CEBus network certain novel semantic mechanisms to enable a certain degree of "distributed intelligence" throughout the network including not only address allocation but also the establishment of control relationships between independent appliances as well as other useful resource allocation functions.
Another object is to utilize such distributed intelligence to enable the CEBus to change the architecture of the traditional remote control network from one based on a central controller (i.e., hub and spoke system or master and slave system) to a system composed of a plurality of intelligent decision-making "peer" nodes and not requiring any central controller.
Yet another object of the present invention is to avoid the limitations imposed by the use of mechanical switches for setting address codes.
These objects are achieved by a control means coupled between function initiating means and media signal transmission means. The control means includes a receiving modem coupled to decoding means and decision processing means which respectively receive intelligence from said signal transmission means, decodes such intelligence and controls the function initiating means in a preselected changeable manner. User interface means are also provided for independently initiating function and for preselecting communication and control mode functionality of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing as well as other objects and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:
FIG. 1 is a block diagram of one example of the basic system of the invention;
FIG. 2 is a block diagram of a preferred embodiment of one of the modules used in the system of the invention;
FIG. 3 is a front view of a lightswitch having an interface panel according to the invention;
FIG. 4 is a front view of a wall outlet having an interface panel according to the invention;
FIGS. 5-7 are flow charts depicting the address and resource allocation processes;
FIG. 8 is a schematic circuit diagram of the modem used in the control means of the invention;
FIG. 9 is a schematic circuit diagram of the microprocessor pin connectors in the control means of the invention;
FIG. 10 is a schematic circuit diagram of the input/output connections used in the control means of the invention; and
FIG. 11 is a schematic circuit diagram of the power supply.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The communication and control system of the present invention can be briefly described as a system of simple communicating devices utilizing microprocessors and other integrated circuits and certain communication language protocol processor (in software algorithms) to exchange messages and information to facilitate remote sensing and control functions in a manner not requiring a single central control point.
If a user has installed the invention in place of conventional light switches, he can reassign them to control each other instead of just controlling themselves. This mechanism for remapping the control relationships between his light switches and wall outlets can, for example, make the lightswitch in his bedroom control all the downstairs lights. The user can accomplish this feat without any rewiring of his house.
A conventional "dumb" lightswitch can control a specific conventional ceiling light fixture, or it can control a specific conventional wall outlet. Such is the way a house is conventionally permanently wired. With the present invention, any lightswitch in the house incorporating the features of the invention can be made to control any other lightswitch or outlet in the house, or any group of lightswitches or outlets incorporating the features of the invention. A particular outlet or lightswitch or group of outlets or lightswitches of the invention may be controllable from more than one location and without any rewiring.
If a conventional "dumb" lightswitch already controls a conventional wall outlet, a user can control that same outlet by replacing its controlling "dumb" lightswitch with a lightswitch incorporating the invention because a lightswitch according to the invention can act functionally identical to a "dumb" conventional lightswitch. Since the lightswitch of the invention can also be controlled remotely from another lightswitch incorporating the features of the invention, the "dumb" outlet wired to it is also remotely controlled. This means in this case that there would be no need to purchase an outlet incorporating the invention to replace the "dumb" outlet. However, if a user wants to control another "dumb" outlet that is not wired to any wall lightswitch, he need simply replace this outlet with an outlet incorporating the invention therein, and then he can control it from any lightswitch in the house incorporating the invention, again without rewiring.
Finally, outlets and lightswitches according to the invention may also be turned on and off from centralized home automation system hubs. This is useful for automated energy management, home security, and home control through remote dial-in telephone access. Also, the technology of the present invention can serve for remote sensors for such hubs, to detect the opening of doors or windows, windows breaking, or temperature changes.
Referring to FIG. 1, the basic system of the invention is comprised of a media signal transmission means 1 for carrying messages between network nodes 2 and 3. The transmission means may comprise a powerline media (hard wire) as shown, or it may comprise radio waves, infra red, fiber optics or other known energy sources. Within each of said network nodes is provided a modem or modulator/demodulator signal processing means (physical layer) 4 for connecting media signals to/from electrical signals in a predetermined manner; a decoder means 5 for converting said electrical signals to/from specific message symbols and messages; a decision processor means 6 for processing said messages to translate or interpret meaning; and user-interface means 7 for presenting said meaning to/from some user or user process.
In a preferred embodiment of the present invention, the control and communication system of the present invention can be briefly described as a "smart lightswitch" network node, which can control or be controlled by any other similar device connected to the same media (powerline) and can be employed for the purpose of remotely controlling electrical lights, fixtures, appliances or any sensor/actuator pair in the home, office building, automobile, airplane, ship or the like.
The basic system of the preferred embodiment of the present invention is comprised of a pre-existing AC or DC powerline wiring signal transmission means for carrying signals anywhere on the premises; an ASK (amplitude shift keyed) 120 KHz carrier signal providing means for converting bursts of carrier signal into/from symbols; a microprocessor software decoder means for converting symbols into valid messages; a microprocessor software decision means for attributing such messages with meaningful information; and a toggle or momentary contact switch user interface means to allow convenient user interaction.
Referring to FIG. 2, which shows a block diagram of the preferred embodiment, a variety of devices can be employed for each of the elements in the control means, but typical ones are further described hereinafter. However, any device capable of performing the function described may be employed.
The signal processing means shown in FIG. 2 can be a Signetics NE5050 powerline modem integrated circuit 8. Such a device receives ASK signals imposed on a typical 110 VAC powerline 9 and converts them into a logic signal 10 signifying the instantaneous superior or inferior state of the communication channel (i.e., either carrier on or carrier off). The same device also transmits ASK signals by converting a logic high or logic low state 11 into a superior or inferior state signal imposed on the powerline.
The decoder means 5 and decision processor 6 shown in FIG. 2 can be a Texas Instruments TMS370C810 single ship microcontroller 12 which, through certain software algorithms, encodes or decodes the logic high or low state to/from a set of four symbols (i.e., one, zero, end of field, end of message). The decision processor 6, through certain software processes, interprets or encodes meaning to/from the mentioned symbols and composes meaningful messages or message packets and manipulates the user interface. The message packets composed by the decision processor can include both specific command message packets (e.g, to turn on or off a lamp) as well as network management message packets (e.g., to allocate a network address or resource, to declare a network address or resource, etc.). The above functions are accomplished by conventional programming techniques.
The user interface means 7 depicted in FIG. 2 can be one or more toggle switches or pushbuttons such as are typically employed in wall or appliance switches, one or more relays to control a lamp or other appliance, and could also include one or more LED or other visual indicators to reflect the current state of the switch or device under its control (see FIG. 10, for example).
Referring to the schematic diagram, the user interface of the present invention is controlled by parallel input/output ports (a) such as are commonly employed in microcontrollers, although other input/output methods could be used (e.g., Serial Peripheral interface). In the system of the present invention, the closure of the on/off switch (b) or the teach/learn switch (c) is sensed by the microcontroller as a logic signal and interpreted by the software algorithms in the microcontroller to cause certain predetermined actions. Such actions could include activation of an output logic signal (d) to activate a relay (e) to turn on a lamp (f) or initiation of a message packet to turn on some other remote lamp or to cause other network functions as will be described later.
The system of the invention is an intelligent CEBus based replacement for conventional light switches and wall power outlets. It allows remote control of lighting and home appliances. It has some similarities to an existing remote control technology currently in wide use, the X10 system discussed previously herein. However, the invention provides a mechanism for "remapping" the control relationships between light switches and wall outlets, without rewiring the house, and enables the switches and outlets to communicate with one another when properly enabled.
Modules incorporating the invention can be provided in at least three forms: a wall mounted lightswitch; a wall mounted power outlet; and a detachable plug-in power module similar to an X10 plug-in appliance or lamp module. The main difference between the lightswitch of the invention and the outlet and plug-in modules of the invention is that the invention lightswitch has an on/off switch on it, and the others do not. The lightswitch of the invention can both send and receive on/off commands, while the wall outlet and plug-in modules of the invention can only receive on/off commands. Both, however, can transmit identifying data.
Establishing Addresses With the Teach/Learn Switch of the Invention
Referring to FIGS. 3 and 4, a major novel and useful feature of the invention is its simple intuitive user interface. The lightswitch 13 of the invention has a standard on/off toggle switch or momentary contact pushbutton 14, like any conventional "dumb" lightswitch; but it also has a special recessed "learn/teach" toggle switch 15. The system of the invention has no conventional house code or unit code switches. It thinks up house and unit code addresses with minimal help from human users. When a user installs the first lightswitch module of the invention and first applies power to it, it behaves exactly like the "dumb" lightswitch it replaces. It does not hear any incoming CEBus messages, and it does not transmit any.
Referring to FIGS. 5-7, the teach/learn switch is employed in the following process. The first thing the user need do to get on the air with CEBus is to establish a house code and a unit code.
Step 1: The module of the invention is put in teach/learn mode by turning on the teach/learn toggle switch. It does not learn about any other invention modules at this time because there are not any others to teach it.
Step 2: The teach/learn mode is then switched off. When the modules comes out of teach/learn mode 16, the microprocessor is functional via its program to determine that that module has no house code or unit code. Consequently, the microprocessor makes up its own code 17. First, it transmits the house code 17, referred to as hailing 18, seeking a response and waits a predetermined interval for a response. If it hears a response, a neighboring building is already using the house code 17 and it cannot adopt this house code, since each house must use a different house code 17. It then hails for a house code 19 and listens for a response. It keeps this up with different house codes until no one answers. Then it can adopt that house code 20 as its own, since no one else is using it.
Now that it has its own house code, it must assign a unit code to itself. Of course this unit code is unique in the user's house, since this module knows it is the very first module to use this house code.
If a second module is now installed in the house, it is not necessary to find another unique house code, since all the units in that house share the same house code. It is therefore not necessary to hail a new house code. The second and subsequent modules will be taught to use the same house code that the first module selected. This process is called pollination. Right after applying power to the new "student" module, the user must not toggle its teach/learn switch on and off as he did with the first one. Instead, he must do the following:
Step 1: The second "student" module is put in teach/learn mode.
Step 2: The learn/teach switch on the first module is toggled on and then off. Upon leaving the teach/learn mode, the first module will send out an identification message in the usual way to teach any other module that is in the teach/learn mode. The student module will hear it, and since it does not yet have a house code of its own, it will adopt the house code in the identification message it receives. It will not hail for a new house code, because it has already been taught one.
Step 3: The second module is then toggled out of the teach/learn mode. This second module has now been pollinated with the same house code as the first module. It now has to come up with its own unique unit code that no other module in that house is using. To do this, it hails for an unused unit code, in a manner exactly analogous to the way the first module hailed for an unused house code.
Note that the preceding teaching ritual with the second module did not teach it to control the first module. The first time the user put it in the teach/learn mode, it learns its house code, and nothing else. Subsequently, he can perform the usual teaching ritual for establishing remote control relationships. The first pollination cycle teaches a new module its house code, and nothing else. The second and subsequent pollination cycles will teach it who to control.
If a module receives ID message packets from more than one house code while in its initial configuration teach/learn state, it does not inherit a house code from them. In that case, the module ignores all ID packets and does a cold reset. This prevents a neighbor from accidentally contaminating the user's initialization of a new module.
Installing additional modules is just like installing the second module. Any module that has been taught its house code can teach that house code to any mew modules. This ensures that every module in that house has a unique unit code, and that they all share the same house code, which is different from all neighboring house codes. The user need never know what these codes are. They are kept in non-volatile memory, immune from loss through power failures.
It is possible to restore a module to its initial, pure "dumb" state. This is useful if it is accidentally allowed to generate its own unique house code instead of being taught the house code from another module; or if the user just wants it to go back to acting like a "dumb" lightswitch. To accomplish this, it is only necessary to cycle the power (or induce reset somehow) while the teach/learn switch is set to the teach/learn position. This procedure will force a cold reset that will destroy any non-volatile state information.
If any of the units are placed in circuit (connected to a powerline) while the teach/learn switch is set to the teach/learn position, that unit will not enter teach/learn mode until the teach/learn switch is toggled once off and then on. This is to prevent the units from inadvertently starting out in teach/learn mode, which is a vulnerable state to be in.
Establishing Control Relationships With the Teach/Learn Switch
To program a lightswitch to control another lightswitch or power outlet, a user uses the teach/learn switches on both modules. Suppose one wants the bedroom lightswitch to control a power outlet next to the bed; then he has to "teach" this lightswitch how to do it.
Step 1: The "student" lightswitch is put into "teach/learn mode" by turning on its teach/learn switch.
Step 2: The teach/learn switch is toggled on, then off on the "teacher" power outlet. This "teaches" the student lightswitch the identify of the power outlet.
Step 3: The student lightswitch is taken out of teach/learn mode by turning off its teach/learn switch.
The lightswitch can now control the power outlet which has been selected. The preceding example is called "one-to-one mapping". It is also possible to do "n-to-one mapping".
If a user wished to control the same outlet mentioned in the preceding example from a different lightswitch, without disturbing the fact that it is already controlled from a different lightswitch, he need only repeat the above steps with the new student lightswitch and the same outlet. Then both switches control the same outlet. A user can teach many other switches to control this same outlet.
It is also possible to do "one-to-n mapping", as follows. To teach a lightswitch how to control more than one outlet or lightswitch:
Step 1: The "student" lightswitch is put into "teach/learn mode" by turning on its teach/learn switch.
Step 2: The teach/learn switch is toggled on, then off on the "teacher" power outlet or lightswitch. This step is repeated for each outlet or lightswitch desired to be controlled. The student lightswitch will learn them all.
Step 3: The student lightswitch is taken out of teach/learn mode by turning off its teach/learn switch.
The student lightswitch then controls all of the power outlets and lightswitches that were selected.
"One-to-n" mapping described above creates groups. All of the outlets and lightswitches controlled by a single lightswitch are members of a group. Each device can simultaneously be a member of more than one group. There can be many groups, each group can include a different subset of the population, and groups may overlap.
For each module to be a member of one or more groups, and with reference to the preferred embodiment of the invention, there can be as many groups as determined by the capacity of the microprocessor employed. Each group has a numeric group code associated with it, as for example, an integer between 1 and 32. A single CEBus message may be addressed to an entire group code, which would be simultaneously received by all units that are a member of that group. Each group can have as many members as desired. At the beginning, all the groups are unused and have no members.
Referring again to FIGS. 5-7, when a user teaches a lightswitch to control several other modules, a sophisticated electronic conference takes place to form a new group. While in the teach/learn mode, the student lightswitch learns (21) the addresses of each of the modules that will be controlled. When the student module is taken out of teach/learn mode, it processes its accumulated list of CEBus addresses (22). It must assign each of the modules listed to this new group.
Before any modules can be assigned to a new group, an unused group code must be found to identify this new group. To do this, the student module hails (23) for an unused group code. This is analogous to hailing for an unused unit code or an unused house code. When it finds a group code for which no one responds to the hail, this group code is available for use to address the new group.
The student lightswitch then sends a message to each unit in its accumulated list, instructing that unit to join the new group 24. A unit joins a group by simply remembering the group code and reacting to messages to that group in the future. This does not interfere with that unit's membership in any previous groups. When all the units in the list have joined the new group, a new group exists. The group members are all the units that were taught to the student lightswitch while it was in learn mode. Subsequently, the student lightswitch can turn all those modules on or off simultaneously by sending out a message to that group code.
When one lightswitch "learns" to control another lightswitch which employs a mechanical on/off toggle as referred to in FIG. 2, (the on/off switch 7), the on/off state of its local relay might not coincide with its switch position if it has been controlled remotely. The present invention allows local control of the relay to be regained by the user by toggling the switch again. Another embodiment of the present invention could also employ a pushbutton momentary contact switch which would avoid the case in which a remotely controlled switches toggle switch could ever reflect the incorrect position. Other embodiments of the present invention could employ other switch means including, but not limited to, sensor devices, voice activation, computers or the like.
It is to be understood that the forms of the invention herewith shown and described are to be taken as preferred examples of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims.
Appendices A and B attached hereto describe the software utilized in the system of the invention. | A control communication network system adapted for distributed control and communication between various home electrical appliances in a manner that eliminates the need for a central controller and eliminates or greatly simplifies the manual assignment of addresses, control relationships or other network resources. The system utilizes a novel and useful process of "hailing" for addresses or resources by newly introduced network devices combined with a process by which declaratory statements are used to convey identification or resource availability information to potential controlling devices. The present invention comprises an intelligent lightswitch which can be dynamically "taught" to control or to be controlled by any other similar lightswitch in a given house without special wiring or user intervention other than the toggling of a simple "teach/learn" switch associated with each lightswitch. | 7 |
BRIEF SUMMARY OF INVENTION
The present invention relates to an electrical voltage indicating device for use in the low-voltage range.
An object of the invention is to provide a cheap and small-size device enabling even a not very skilled user to monitor easily a voltage at the terminals of a variable voltage alternating current or of a direct current source, both of the order of a few volts or of a few tenths of volts.
The present invention also has among its objects an electrical voltage indicating device based on the utilization of electrochemiluminescence phenomena. It is known when a given voltage is applied under certain prescribed conditions to two inert electroes immersed in a non-aqueous electrolyte containing certain dissolved substances an emission of a light radiation of specific colour results which lasts the entire time that the voltage is applied. The wavelength of the radiation and the minimum value of the voltage to be applied to the electrodes to obtain the emission are specific to the particular substances contained in the electrolyte. An electrical voltage indicating device according to the invention is characterized in that it comprises at least one electrochemiluminescence cell comprising two electrodes immersed in an electrolyte containing at least one substance in which the value of the luminescence excitation threshold corresponds to the value of a voltage to be detected.
The device according to the invention also comprises, to great advantage, a potentiometric circuit connected with the said electrochemiluminescent cell for use particularly where the voltage of the source whose voltage is to be monitored is greater than the threshold excitation voltage of the luminescent substance in the cell.
According to a first embodiment, the said cell contains a single electrochemiluminescent substance. When the device is connected to the terminals of a voltage source, the appearance of a luminescent radiation makes it possible to detect the moment when the increasing voltage passes through the excitation threshold value of the said substance; conversely, extinguishment of the luminescence makes it possible to detect the moment when the decreasing voltage passes reversely through that threshold value. Moreover, the intensity of the luminescent radiation which increases with the applied voltage makes it possible, to a certain extent, to appreciate the value of that voltage in relation to that of the excitation threshold.
According to an improved embodiment, the said cell contains at least two different electrochemiluminescent substances whose emission wavelengths and excitation thresholds are different. A calibration of the colour of the resulting radiation gives, in this case, an indication about the valve of the tested voltage in relation to the various excitation voltages of the substance contained in the cell.
By way of an example, it is assumed hereinafter that the tested voltage is constantly increasing.
When the said voltage reaches the excitation threshold of the substance which has the lowest threshold, the cell emits a luminescent radiation whose wavelength is inherent to that substance.
When the said voltage reaches the excitation threshold of the substance whose excitation threshold occurs after the first one in increasing values, the cell emits a radiation which is a combination of the two luminescent radiations of the excited substances, and whose colour results from the mixture of the two different colours of the two radiations. As the said voltage increases, that resultant colour, however, varies according to the relative intensities of the two luminescent radiations. When the said voltage reaches the excitation threshold of a further substance of still higher threshold, the mixture of the colours is again modified and so on.
In such case, a direct comparison between the colour of the cell and a range of calibrated colours makes it possible to calculate the value of the said measured voltage and to follow the variations thereof.
According to another embodiment, a device according to the invention comprises several electrochemiluminescent cells connected up in parallel, respectively, containing substances having different excitation thresholds and possibly different emission wavelengths. The successive lighting up and extinguishment of the various cells makes it possible also to determine the voltage which is simultaneously applied to them, in a range of known values. The accuracy of the detection will increase with the number of cells used.
The invention will be better understood by reference to the following description together with the accompanying drawing given by way of illustration but having no limiting character and in which:
FIG. 1 is a diagrammatic front view, very much enlarged, of an example of an electrochemiluminescent cell according to the invention,
FIG. 2 is a diagrammatic perspective partial view, very much enlarged, of a further embodiment of the invention, and
FIG. 3 is a wiring diagram of another embodiment of this invention, and
FIG. 4 is a wiring diagram of still another embodiment of the invention.
DETAILED DESCRIPTION
The two cells illustrated in FIGS. 1 and 2 are intended, for example, for detecting a direct current voltage which is liable to vary between 4.5 and 2.7 volts approximately; this may be the range of discharge voltages of a primary battery B.
The cell in FIG. 1 comprises a sealed ampule 6 of transparent or translucent material filled with electrolyte 7 containing one or several electrochemiluminescent substances. An insulative support 1 which cannot be attacked by the electrolyte 7 and on which are fixed two electrodes 2 and 3, separated from each other by about 0.3 mm is arranged so that said electrodes are immersed in that electrolyte in any known way. The distance between the electrodes cannot exceed 0.5 mm, if the voltage to be detected is a direct current voltage. The electrodes 2 and 3 are, to great advantage, constituted by two conductive strips deposited on the support 1 by methods similar to those used for making printed circuits. The electrodes 2 and 3 are respectively soldered to two connection wires 4 and 5 passing through the walls of ampule 6 and are made of a material which cannot be attacked by the electrolyte 7.
The materials of the electrodes 2 and 3 also must be such that they cannot be attacked by the electrolyte; moreover, the material of the positive electrode 3 must withstand oxidization and the material of the negative electrode 2 must withstand reduction.
The cell illustrated partly in FIG. 2 contains an insulative support 10 made of plastic material folded over so as to form two faces 12 and 13 arranged facing each other and on which are respectively fixed the electrodes 14 and 15. Two separate supports adequately connected together could also be used, for each of said electrodes. The distance between the electrodes is defined by bosses 11 formed respectively on the faces 12 and 13. An overall sealed enclosure 16 of material similar to that of ampule 6 and containing these elements and the electrolyte with added electrochemiluminescent substance or substances is provided.
Such an arrangement makes it possible to increase the active volume, examination of the emitted radiation being made along the open edge of the support 10 within said enclosure 16.
Examples of materials used in the two cells which have just been described are as follows:
The respective electrodes 2, 3, 14 and 15 and connections 4, 5, 4', 5' are made of silver or stainless steel. The substance carrying electrolyte is constituted by a solution of tetrabutylammonium perchlorate and 1.2 dimethoxyethane.
The electrochemiluminescent substance included in the electrolyte of either cell may be selected from the group consisting of 9.10 diphenylanthracene whose emission threshold for a blue-violet radiation is 3.2 volts, or naphtacene whose emission threshold for a green radiation is 2.7 volts, or even, rubrene whose emission threshold for an orange radiation is 2.5 volts.
According to a first embodiment, a cell containing one of the said three electrochemiluminescent substances listed above may be used for testing the discharge of the above-mentioned 4.5 volt battery; and accordingly, it will be possible, depending on the substance used to determine whether the voltage of the battery is or is not respectively below 3.2 volts, 2.7 volts or 2.5 volts.
According to a second embodiment illustrated in FIG. 3, three cells 21, 22, 23 respectively containing a different one of the three different electrochemiluminescent substances listed above are connected in parallel and to the battery 24 to be tested. In such case, the device according to the invention will make it possible to indicate the successive passes of the battery voltage through three well-defined values.
According to a third embodiment, a single cell containing all three of said electrochemiluminescent substances listed above within its electrolyte is provided and connected across the battery terminals or other voltages to be detected. During the discharge of the battery, the radiation emitted by the mixture in such cell turns from blue-green to orange, the latter colour becoming clearer and clearer. The colour of the mixture is, to great advantage, compared with a range of colours calibrated for voltage.
It must be understood that the invention is not limited to the embodiments and applications described and illustrated.
Thus, for the monitoring of alternating current voltages, the cells described above may also be suitable; however, their design may be simplified, for the radiation is emitted in the vicinity of the electrodes without it being necessary for these latter to be as close together as in the case of detection of a direct current voltage.
It must be understood that if the voltages to be monitored are higher than the threshold voltages of the electrochemiluminescent substances, the device according to the invention comprises, in additon, a potentiometric circuitry illustrated in FIG. 4. A potentiometer 25 is connected across the voltage to be measured which in this case is that of a battery 26. A test cell is connected between one end 28 and the intermediate point 29 of potentiometer 25 to receive a fraction of the battery voltage. Thus, the said circuitry applies an adequate fraction of the voltage to be measured to the terminals of the said cell or cells. The assembly of the potentiometric circuitry and test cells connected thereto or test cells themselves may be permanently connected to the terminals of the battery or voltage to be tested, for their power consumption is very low.
An application which is a particular advantage may be found for a voltage testing device according to the invention in appliances using batteries (such as wireless sets, for example, wherein an indicator light derived from the test device connected to the battery energizing the appliance may be combined with a colour calibrating scale to indicate the state of charge of the battery energizing the appliance.
In the electrolyte above mentioned, the concentration of tetrabutylammonium perchlorate in dimethoxyethane is about 0.3 M.
Other suitable electrolytes, such as a solution of tetrabutylammonium perchlorate in tetrahydrofuran, may, for example, be used in the same range of concentrations.
The concentrations of electrochemiluminescent substances added to such electrolytes are in the range of from 10 - 4 M to 10 - 2 M, the preferred concentrations being:
9.10 diphenylanthracene 2.10.sup..sup.-3 M to 6.10.sup..sup.-3 M naphtacene 5.10.sup..sup.-3 M rubrene 2.10.sup..sup.-3 M to 5.10.sup..sup.-3 M
Other suitable electrochemiluminescent substances such as 1, 3, 6, 8 tetraphenylpyrene may be used.
While specific embodiments of the invention have been described, variations within the scope of the appended claims are possible and are contemplated. There is no intention, therefore, of limitatin to the exact disclosure herein presented. | Electrical voltage indicating device for use in the low-voltage range, characterized in that it comprises at least one electrochemiluminescence cell containing at least two electrodes immersed in an electrolyte containing at least one electrochemical substance whose luminescent excitation threshold value corresponds to the value of a voltage to be monitored. The use of several such substances each having a different luminescent excitation threshold in the same cell or of several cells, each with a substance of different excitation threshold value connected in parallel makes it possible to monitor several different voltage values with the device. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional of application Ser. No. 11/380,831, filed Apr. 28, 2006, incorporated hereinto by reference.
FIELD OF THE INVENTION
[0002] The disclosed invention relates to intraluminal therapeutic devices and delivery systems therefor, and more particularly, to expandable stents and delivery systems which may be used in the treatment of body vessel defects. This invention also relates to the deployment and repositioning of expandable stents within body vessels, especially those within the brain.
DESCRIPTION OF RELATED ART
[0003] On a worldwide basis, nearly one million balloon angioplasties are performed annually to treat vascular diseases such as blood vessels that are clogged or narrowed by a lesion or stenosis. The objective of this procedure is to increase the inner diameter of the partially occluded blood vessel lumen. In an effort to prevent restenosis without requiring surgery, short flexible cylinders or scaffolds, referred to as stents, are often placed into the body vessel at the site of the stenosis or defect. Stents are typically made of metal or polymers and are widely used for reinforcing diseased body vessels. Stents are also useful in treating aneurysms by providing an internal lumen to cover an aneurysm and thus reduce the flow of blood and the pressure within the aneurysm.
[0004] Some stents are expanded to their proper size using a balloon catheter. Such stents are referred to as “balloon expandable” stents. Other stents, referred to as “self-expanding” stents, are designed to elastically resist compression in a self-expanding manner. Balloon expandable stents and self-expanding stents are compressed into a small diameter cylindrical form and deployed within a body vessel using a catheter-based delivery system.
[0005] Stents have been developed with radiopaque markers to aid in the visualization of the stent upon deployment. Radiopaque markers facilitate the positioning of the stent within a body vessel by allowing a physician to determine the exact location, size, and orientation of the stent under x-ray or fluoroscopy. These markers are typically formed of a radiopaque material such as tantalum, zirconium, titanium, or platinum. Published U.S. Patent Application No. 2002/0082683 to Stinson et al., which is hereby incorporated herein by reference, discloses one such radiopaque marker comprised of a pigtail, knot, or ring, of tantalum wire wrapped around a crossing point of struts within a stent.
SUMMARY OF THE INVENTION
[0006] In accordance with one aspect of the present invention, an expandable stent and a stent delivery system are provided. The delivery system includes an elongated core member with a distal portion and a threaded core member portion disposed about the distal portion. The delivery system also includes a deployment catheter. The stent is a tubular member having a thin wall and a strut member extending away from the thin wall. The strut member defines a threaded strut member portion. At least a portion of the threaded strut member is threadably engageable with at least a portion of the threaded core member portion, and the two are interlocked when received in a lumen of the deployment catheter.
[0007] In accordance with another aspect of the present invention, a method of deploying an expandable stent within a body vessel is provided. The method involves providing an expandable stent and delivery system. The stent is mounted about a distal portion of an elongated core member of the delivery system. The stent has a strut member defining a threaded strut member portion and at least a portion of the threaded strut member portion is in threaded engagement with at least a portion of a threaded core member portion disposed at the distal portion of the elongated core member. The delivery system also includes a deployment catheter disposed about the stent to interlock the threaded strut member portion and the threaded core member portion. The expandable stent and at least a portion of the delivery system are inserted into a body vessel, and then the stent is positioned adjacent to a defect of the body vessel. When the stent is properly positioned, the deployment catheter is moved proximally with respect to the core member, which allows the stent to begin expanding within the body vessel. Finally, the deployment catheter is moved further proximally with respect to the core member, which allows the stent to fully deploy.
[0008] In accordance with yet another aspect of the present invention, a method of resheathing an expandable stent within a body vessel is provided. The method involves providing an expandable stent and delivery system. The stent is mounted about a distal portion of an elongated core member of the delivery system. The stent has a strut member defining a threaded strut member portion and at least a portion of the threaded strut member portion is in threaded engagement with at least a portion of a threaded core member portion disposed at the distal portion of the elongated core member. The delivery system also includes a deployment catheter disposed about the stent to interlock the threaded strut member portion and the threaded core member portion. The expandable stent and at least a portion of the delivery system are inserted into a body vessel, and then the stent is positioned adjacent to a defect of the body vessel. When the stent is properly positioned, the deployment catheter is moved proximally with respect to the core member, which allows the stent to begin expanding within the body vessel. If it is determined that the stent should be moved to a different position within the body vessel, then the deployment catheter is moved distally with respect to the core member, which forces the stent back into the catheter. When the stent is back in the catheter, the delivery system can be relocated.
[0009] Other aspects, objects and advantages of the present invention, including the various features used in various combinations, will be understood from the following description according to preferred embodiments of the present invention, taken in conjunction with the drawings in which certain specific features are shown.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a partial sectional view of an expandable stent and a delivery system in accordance with an embodiment of the present invention;
[0011] FIG. 1A is an enlarged detail view of the expandable stent of FIG. 1 positioned within the delivery system;
[0012] FIG. 2 is an enlarged detail view of an alternative expandable stent positioned within an alternative delivery system;
[0013] FIG. 3A is an enlarged perspective view of a strut member having an integral threaded strut member portion, according to an aspect of the present invention;
[0014] FIG. 3B is an enlarged perspective view of a strut member having an outer layer according to another aspect of the present invention;
[0015] FIG. 4 is a cross sectional view of the stent and delivery system of FIG. 1 , taken through the line 4 - 4 of FIG. 1 ;
[0016] FIG. 5 is a partial sectional view of the expandable stent and delivery system of FIG. 1 in a body vessel;
[0017] FIG. 6 is a partial sectional view of the delivery system with the deployment catheter moved proximally, allowing the distal section of the expandable stent to expand within the body vessel, while the proximal section of the expandable stent remains interlocked within the deployment catheter; and
[0018] FIG. 7 is a partial sectional view of the delivery system with the deployment catheter moved proximally and the expandable stent fully expanded within the body vessel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriate manner.
[0020] FIG. 1 illustrates an expandable stent 10 and delivery system 12 . The delivery system 12 includes a deployment catheter or microcatheter 14 which takes the form of an elongated tube having a lumen 16 . A proximal section 18 of the deployment catheter 14 is sufficiently flexible to traverse a body vessel, typically a blood vessel, but is sufficiently rigid so that it can be pushed distally through the body vessel. A distal section 20 of the deployment catheter 14 is preferably formed of a material that is more flexible than the proximal section 18 , for enhanced maneuverability through a tortuous stretch of a body vessel. For example, the proximal section 18 may be substantially comprised of stainless steel, while the distal section 20 may be substantially comprised of a nitinol material in a superelastic state at body temperature.
[0021] A winged hub 22 may be coupled to the proximal section 18 of the deployment catheter 14 . Preferably formed from a polymer material, the winged hub 22 is used to insert the deployment catheter 14 into a body vessel, such as a blood vessel within the brain of a patient.
[0022] The delivery system 12 also includes an elongated core member 24 which is formed of wire, preferably nitinol, but may also be formed from other metal alloys or a polymer material. The core member 24 is axially movable within the lumen 16 of the deployment catheter 14 and may be tapered so that a proximal portion 26 of the core member 24 has a greater diameter than an outer diameter D of a distal portion 28 .
[0023] The distal portion 28 of the core member 24 includes at least one threaded core member portion 30 , as illustrated in FIGS. 1 and 1A . The threaded core member portion 30 preferably defines a helical thread, similar to a screw thread, and may have a root diameter R greater than the outer diameter D of the core member distal portion 28 , as illustrated in FIG. 2 . In the embodiment of FIG. 1 , the core member distal portion 28 includes a second threaded core member portion 32 spaced distally from the first threaded core member portion 30 .
[0024] As for the expandable stent 10 , it is removably mounted on the core member 24 for movement therewith through the deployment catheter 14 . The expandable stent 10 may take on many different patterns or configurations, such as those disclosed in U.S. Pat. Nos. 6,673,106 and 6,818,013, both to Mitelberg et al. and both of which are hereby incorporated herein by reference. The stent 10 may be coated with an agent, such as heparin or rapamycin, to prevent stenosis or restenosis of the vessel. Examples of such coatings are disclosed in U.S. Pat. No. 5,288,711 to Mitchell et al.; U.S. Pat. No. 5,516,781 to Morris et al.; U.S. Pat. No. 5,563,146 to Morris et al.; and U.S. Pat. No. 5,646,160 to Morris et al., all of which are hereby incorporated herein by reference.
[0025] The illustrated stent 10 of FIG. 1 is laser cut from a tubular piece of nitinol to form a skeletal tubular member 34 . The skeletal tubular member 34 has a thin wall, a small diameter, and when cut forms a plurality of cells which are created by a plurality of interconnected strut members. The nitinol is preferably treated so as to exhibit superelastic properties at body temperature.
[0026] The stent 10 includes at least one strut member 36 , best illustrated in FIG. 1A , extending away from the tubular member 34 . Preferably, the stent 10 includes a plurality of strut members 36 and 38 extending away from a proximal section 40 and a distal section 42 , respectively, of the tubular member 34 , as illustrated in FIG. 1 . In one preferred embodiment, the stent 10 includes eight strut members, with four extending from each of the proximal and distal sections 40 and 42 of the stent tubular member 34 . Each strut member 36 and 38 defines a threaded strut member portion 44 , as described generally in U.S. Pat. No. 6,955,685 to Escamilla et al., which is hereby incorporated herein by reference.
[0027] A strut member 36 , 38 with an integral threaded strut member portion 44 is illustrated in FIG. 3A . As shown, the threaded strut member portion 44 is not a continuous helical thread, but has at least one row of teeth 46 . However, the threaded strut member portion 44 preferably defines a helical thread to interact with the core member 24 , as will be further described herein. Also, the threaded strut member portions 44 are preferably configured to generally occupy the space between the threaded core member portion 30 , 32 and the delivery catheter 14 , as best illustrated in FIG. 4 .
[0028] Depending on the material used to form the stent 10 , there are a number of different ways to form the threaded strut member portion 44 . For example, the threaded strut member portion 44 may be formed by cutting threads into the strut member 36 , 38 when the stent 10 is laser cut from a nitinol tubular member. Alternatively, a heat-molding technique may be used to form the threaded strut member portion 44 on the strut member 36 , 38 . Those of ordinary skill in the art will appreciated that the present invention may be practiced regardless of the method of forming the threaded strut member portion 44 .
[0029] Additionally, as illustrated in FIGS. 2 and 3B , an outer layer 48 may be deposited or wound about at least a portion of the threaded strut member portion 44 in order to increase its diameter or to provide other performance characteristics. For example, in a preferred embodiment, the threaded strut member portion 44 is wound with a radiopaque material defining a marker coil. The marker coil may be formed of a metallic or polymeric material that exhibits the characteristic of being radiopaque, such as tantalum or tantalum alloy. The marker coil may also be comprised of gold, gold alloy, platinum, platinum alloy, titanium, zirconium, bromine, iodine, barium, bismuth, or any combination thereof.
[0030] The outer layer is preferably applied onto the threaded strut member portion 44 so as to maintain the integrity of the underlying thread. Alternatively, the outer layer itself may define a thread, such as a row of teeth or a helical coil, in which case the strut member 36 , 38 need not be formed with a threaded strut member portion 44 . This may be preferred, rather than forming the strut member itself with a thread. Accordingly, when used herein, the term “threaded strut member portion” refers to a configuration wherein a thread is provided by a threaded portion integrally formed in the strut member 36 , 38 , by an integral threaded portion covered by an outer layer that preserves the underlying thread, or by an unthreaded strut member covered by an outer layer that is itself arranged to provide a thread.
[0031] In the case where an outer layer is applied to the strut member 36 , 38 , the outer layer is preferably secured to the strut member 36 , 38 using an adhesive material, such as a UV adhesive which is thermally cured. In addition to increasing the diameter of the strut member 36 , 38 , an outer layer provided as a marker coil serves as a radiopaque marker for improved visualization during the deployment of the stent within a body vessel.
[0032] As illustrated in FIGS. 1 and 5 , the stent 10 is delivered to a body vessel V by the delivery catheter 14 . The stent 10 and associated core member 24 are axially movable together within the delivery catheter 14 . The stent 10 is removably locked onto the core member 24 by the interaction between the threaded strut member portion 44 and the threaded core member portion 30 , 32 . Preferably, the threaded strut member portion 44 and the threaded core member portion 30 , 32 are provided as mating helical threads, such that at least a portion of the two may be interlocked by rotation, similar to a nut and bolt. In order to reinforce the interlocking relationship between the threaded strut member portion 44 and the threaded core member portion 30 , 32 , an adhesive 50 may be applied therebetween, as illustrated in FIG. 1A . Furthermore, the strut member 36 , 38 may be configured to simultaneously contact the delivery catheter 14 and the threaded core member portion 30 , 32 in order to prevent the strut member 36 , 38 from radially expanding and detaching from the threaded core member portion 30 , 32 . As described above, the proper fit between the threaded core member portion 30 , 32 , the strut member 36 , 38 , and the delivery catheter 14 may be achieved by adjusting the size of the strut member 36 , 38 or by increasing the diameter of the threaded core member portion 30 , 32 , as illustrated in FIG. 2 .
[0033] If only one threaded core member portion is provided, then it is preferably located proximally of the stent tubular member 34 to interlock with one or more threaded strut member portions 44 extending from the proximal section 40 of the stent 10 . This is useful for retracting and repositioning the stent 10 , as will be described herein. It may be preferred, however, to provide threaded core member portions 30 , 32 at each end of the stent tubular member 34 to discourage the stent distal section 42 from clinging to the delivery catheter 14 and “bunching up” during deployment of the stent 10 .
[0034] By the above-described configuration, the stent 10 is locked onto the core member 24 for axial movement through the delivery catheter 14 . In another embodiment, illustrated in FIG. 2 , the interaction between the threaded strut member portion 44 and the threaded core member portion 30 is supplemented by provision of at least one cylindrical member associated with the distal portion 28 a of the core member 24 a and adjacent to the threaded core member portion 30 . The general configuration and function of such cylinders may be seen in U.S. Pat. No. 6,833,003 to Jones et al., which is hereby incorporated herein by reference.
[0035] In the illustrated embodiment of FIG. 2 , the distal portion 28 a of the core member 24 a includes at least a first cylinder 52 and a second cylinder 54 , which are separated by the proximal threaded core member portion 30 . The cylindrical members 52 and 54 preferably have a greater diameter than the threaded core member portion 30 , such that they define a gap in which the threaded core member portion 30 resides. It will be appreciated that the cylinders 52 and 54 further prevent the stent 10 from moving axially along the core member 24 a while the threaded strut member portion 44 is interlocked with the threaded core member portion 30 and maintained within the gap.
[0036] In addition to constraining the axial movement of the strut member 36 , the distal cylinder 54 is used to mount the expandable stent 10 . As the stent 10 is positioned and mounted on the second cylindrical member 54 , the strut members 36 extending away from the proximal section 40 of the tubular member 34 align with and are disposed within the gap, to interlock with the threaded core member portion 30 . Similarly, if provided, the strut members 38 extending from the distal section 42 of the tubular member 34 align with and are disposed within a second gap, not illustrated, formed by a space between the second cylindrical member 54 and a third cylindrical member, not illustrated. In this configuration, the stent 10 is locked in place and may be pushed or pulled through the deployment catheter 14 without damaging or deforming the stent 10 .
[0037] FIG. 5 illustrates the expandable stent 10 and delivery system 12 of FIG. 1 positioned within a body vessel V. Initially, the stent 10 is interlocked to the core member 24 by mating at least a portion of the threaded strut member portion 44 to at least a portion of the threaded core member portion 30 , 32 . The core member 24 is then slid into the deployment catheter 14 to thereby hold the stent 10 in its constrained configuration. Alternatively, the core member 24 may be positioned within the delivery catheter 14 , and then the stent 10 is compressed, fed into the catheter 14 , and interlocked onto the core member 24 . This may be preferred if the threaded core member portion 30 , 32 and the threaded strut member portion 44 are provided as mating helical threads. When the stent 10 is positioned within the delivery catheter 14 , the delivery system 12 is inserted into the body vessel V and advanced distally until the stent 10 is aligned with a vessel defect S. Although the delivery system 12 is illustrated in use with a stenosed body vessel, it will be appreciated that it may be used with any other vessel defect treatable with a stent, such as an aneurysm.
[0038] FIG. 6 shows the deployment catheter 14 moved proximally, releasing the distal strut members 38 and allowing the distal section 42 of the expandable stent 10 to begin expanding. During expansion, the distal section 42 of the stent 10 comes in contact with the wall of the body vessel V. If adhesive is provided between the threaded strut member portion 44 and the threaded core member portion 32 , then it is preferably sufficiently weak so as to be overcome by the breakaway force of the expanding stent 10 .
[0039] As illustrated in FIG. 7 , the deployment catheter 14 is again moved proximally, releasing the proximal strut members 36 and allowing the stent 10 to fully expand. Once the stent 10 is fully deployed within the body vessel V, the core member 24 remains extended through the stent 10 and thus acts as a guide wire, providing a physician with easier access to locations within the body vessel distal of the stent 10 .
[0040] If, during the deployment process, it is determined that the stent 10 should be relocated or realigned, the deployment catheter 14 may be used to resheath the stent 10 . With the stent 10 positioned on the core member 24 as described above with reference to FIG. 6 , the proximal threaded strut member portion 44 will remain interlocked on the proximal threaded core member portion 30 . In this configuration, the stent 10 may be resheathed. To resheath the stent 10 , the deployment catheter 14 is moved distally, thereby forcing the stent 10 back into the catheter 14 and onto the core member 24 , compressing the distal section 42 of the stent 10 , and forcing the distal strut members 38 into engagement with the distal threaded core member portion 32 . The stent 10 and delivery system 12 may then be withdrawn or repositioned to a different location within the body vessel V.
[0041] When the expandable stent 10 has been properly positioned and fully expanded within the blood vessel V, as illustrated in FIG. 7 , the delivery catheter 14 and the core member 24 are removed from the body.
[0042] It will be understood that the embodiments of the present invention which have been described are illustrative of some of the applications of the principles of the present invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention, including those combinations of features that are individually disclosed or claimed herein. | An expandable stent and delivery system are provided for treating body vessel defects, such as partially occluded blood vessels and aneurysms. The delivery system includes a core member having a threaded core member portion configured to interlock with a threaded strut member portion of the expandable stent. The expandable stent is mounted thusly onto the core member for movement within a delivery catheter and deployment to a body vessel defect. The deployment catheter is used to compress the interlocked threaded strut member portion into engagement with the threaded core member portion. | 0 |
BACKGROUND OF THE INVENTION
Wild buckwheat (Polygonum convolvulus L.) is an annual taprooted weed. It occurs in agricultural areas in all of the Canadian provinces but is reported to be more abundant in the west than in the east. It is native to Europe and was first collected in Canada in Manitoba in 1873.
Wild buckwheat overwinters as achenes. It has a climbing growth habit which allows it to compete well in stands of cereals and other tall crops. This growth habit allows for rapid spread and coverage of bare ground or open spaces. The number of achenes produced by a single plant varies with soil type and seeding date, but under noncompetitive conditions a single plant can produce up to 30,000 achenes. Seed dispersal is normally accomplished by disturbance by farm machinery and long distance dispersal may take place through contaminated crop seed.
Due to its growth habit and abundant seed production, wild buckwheat is a competitive weed that causes significant losses in grain crops. Herbicides registered for use on wild buckwheat include dicamba, bromoxynil, combinations of these chemicals with 2,4-D or MCPA and other herbicides alone, as formulated mixtures, or in various combinations.
However, the efficiency of these chemicals is sometimes limited. Furthermore, the excessive use of chemicals is of concern for the environment and human health. It would therefore be highly desirable to have an herbicidal composition which has better and more selective properties against wild buckwheat, and which reduces the input of chemicals into the environment.
SUMMARY OF THE INVENTION:
The present invention relates to a novel bioherbicide which is effective in controlling the growth of Polygonum convolvulus (wild buckwheat) when used in accordance with the process described herein.
More specifically, the present invention relates to the use of composition of the fungus Phoma sp. in association with an agricultural carrier to control buckwheat infestation in agricultural crops.
Also in accordance with the present invention, there is provided a synergistic composition comprising the fungus Phoma sp., a chemical herbicide and an agricultural carrier to control buckwheat infestation.
DETAILED DESCRIPTION OF THE INVENTION
The fungal pathogen of the present invention causes a destructive leaf blight on wild buckwheat plants growing in field plots. Diseased leaves were collected and following a commonly used method, pieces of leaf tissue were cut from the margins of lesions and immersed in 10% (v/v) Javex (0.6% NaClO) for 3 min. Surface-disinfested tissue was drained on paper towels and small (1 mm dia.) pieces of tissue were aseptically cut and placed on acidified potato dextrose agar (APDA) in petri dishes. After 2 days, hyphae growing from leaf tissue were transferred to fresh APDA.
Additional isolations were made from leaves collected and air-dried for 4 months. Three single-spore isolates (A1, B2, A3) from dried leaves were identical to those obtained from fresh tissue and were selected for further study. Stock cultures were maintained on agar slants under oil at 3° C. in a refrigerator. One such isolate was identified as Phoma sp.
Numerous plant pathogens being evaluated for use as bioherbicides appear to be only partly effective when applied alone. In combination with chemical herbicides, however, they may be more effective. If used in combination with a chemical herbicide, such bioherbicides may allow a reduction in chemical use and help alleviate safety and environmental concerns.
Phoma sp. is such a plant pathogen. It causes a severe foliage blight on wild buckwheat. It produces numerous necrotic lesions on inoculated leaves and some lesions expand rapidly and kill leaves. It causes mortality of plants, however, only when applied at high inoculum densities to plants at the cotyledon stage or when environmental conditions are highly favorable with warm temperatures and long moist periods. In combination with the chemical herbicides dicamba or MCPA it causes more mortality of wild buckwheat.
A subculture of Phoma sp. has been deposited in the permanent collection of the American Type Culture Collection, Rockville, Md., U.S.A., on Feb. 5, 1990 under the Budapest treaty. The culture was assigned the accession number ATCC 20982 by the repository. The deposit is available to the public upon the grant of a patent disclosing it. However, it should be understood that the availability of a deposit does not constitute a license to practice the subject invention in derogation of patent rights granted by governmental action.
In accordance with a further aspect of the present invention, it has been found that the fungal pathogen Phoma sp., when combined with a chemical herbicide, leads to a synergistic composition which possesses remarkable properties against wild buckwheat. The preferred chemical herbicides of the present invention are dicamba and MCPA. These chemical herbicides were known to possess some herbicidal properties against buckwheat. However, when they are combined with the fungus Phoma sp. of the present invention, the synergistic effect resulting from this combination gives a much more effective composition to fight wild buckwheat. Herbicides which have general broadleaf activity and which have may also act synergistically with the fungus Phoma of the present invention further include clopyralid, DPX M6316, chlorsulfuron, fluroxypyr, pyridate, or formulated mixtures such as dicamba/2,4-D/mecoprop, dicamba/MCPA/mecoprop, diacmba/MCPA, diclorprop/2,4-D, bromoxynil/MCPA, or tank mix of two or more of the herbicides listed above, including dicamba and MCPA.
The actual recommended rate of application for MCPA alone against wild buckwheat, is about 1.2 kg/hectare. Furthermore, when the chemical herbicide is dicamba, the recommended rate is 0.3 to 0.6 kg/hectare. However, when used in combination with the fungus Phoma sp. of the present invention, the rate of application is reduced to 0.4 to 0.8 kg/hectare and 0.1 to 0.3 kg/hectare for MCPA and dicamba respectively.
The concentration of the fungus Phoma sp. in the composition of the present invention, is from about 10 3 tp 10 7 spores/ml of carrier. Also, the application rate of the composition is from about 10 5 to 10 9 spores/m 2 .
The present invention will be further illustrated by the following Examples, which are representative, and do not restrict the scope of the invention in any way.
EXAMPLE I
This example illustrates the production of wild buckwheat plants, production of fungal inoculum for application to the plants, and disease development on the plants.
Wild buckwheat seeds were obtained from Valley Seed Service, Fresno, Calif. Seeds were immersed in 95% sulfuric acid (H 2 SO 4 ) for 15 min, rinsed under running tap water, and placed on moistened filter papers in glass petri dishes. Dishes with seeds were incubated at 3° C. for 48 hr followed by incubation at 30° C. for 48 hr. Germinated seeds were then planted in 10 cm pots in potting medium (Pro-Mix BX, Premier Brands, Inc., Stamford, Conn.) and grown in growth chambers (14 hr photoperiod, 400 uEm -2 s -1 , 24°/18° C. day/night temperature). Seeds were planted four per pot and seedlings were thinned to three per pot prior to treatment.
One liquid culture medium (V-8 medium) and eight solid agar media were evaluated for sporulation by isolates A1, B2, and A3 and for possible use as growth media for inoculum production for experiments: 1) Difco potato dextrose agar (PDA) prepared according to package instructions, 2) half-strength PDA (1/2PDA, 19.5 g Difco PDA, 10 g Bacto agar, 1000 ml H 2 O), 3) 1/2PDA with half-strength torula yeast agar (7.5 g torula yeast, 0.5 g KH 2 PO 4 , 0.25 g MgSO 4 .7H 2 O, 19.5 g Difco PDA, 10 g Bacto agar, 1000 ml H 2 O), 4) 1/2PDA with plant extract (19.5 g Difco PDA, 10 g agar, Polygonum convolvulus extract [prepared by boiling 200 g chopped wild buckwheat leaves and stems in 1000 ml deionized H 2 O, straining through cheesecloth, and autoclaving for 20 min on consecutive days] added to the medium at 5, 10, or 20% [v/v], H 2 O to make 1000 ml), 5) V-8 juice agar (200 ml V-8 juice, 20 g Bacto agar, 800 ml H 2 O, adjusted to pH 6 with NaOH), 6) cornmeal agar (CMA), (7) CMA with 10% plant extract (prepared as above), and 8) CZ-8. The media were streaked with spore suspensions obtained from cultures grown on 1/2PDA with 10% plant extract or agar plugs with mycelium from cultures grown on PDA were inverted and placed in the center of each dish. Cultures were sealed with parafilm and incubated at 24° C. in the dark or at room temperature under near ultraviolet light (NUV). After 1-3 wk, cultures were visually compared for production of pycnidia and exuded droplets of conidial matrix with spores.
Inoculum was also produced on detached leaves of wild buckwheat. Leaves cut from plants grown in growth chambers were placed on moist filter papers in petri dishes (2.5 ml deionized H 2 O and 2-3 leaves/plate) and autoclaved for 20 min on consecutive days. Agar plugs (6 mm dia.) with mycelium cut from the margin of colonies growing on PDA were inverted and transferred to the center of each dish containing leaves. Leaf cultures were incubated and evaluated as described above.
Spores were collected from agar plates and leaf cultures by flooding them with deionized water and scraping the surface of the colonies with a sterile wire loop or spatula. Resulting suspensions were filtered through 8 layers of cheesecloth and washed by centrifugation at 7000 RPM for 10 min. The supernatant was discarded and the spore pellet was resuspended in deionized water. The inoculum density was adjusted to the desired level with deionized water and spores were applied to plants at a rate of 500 l of water/ha in a spray chamber using a Teejet full cone nozzle (TG 0.7).
Conidia of each of the three isolates grown on 1/2PDA with 10% plant extract were used to inoculate wild buckwheat seedlings grown in growth chambers. The plants were at the 3-leaf stage (approximately 21 days after planting germinated seeds) when inoculated with Phoma sp. at an inoculum density of approximately 5×10 7 spores/m 2 (approximately 10 6 spores/ml applied at 500 l/ha). Control plants were sprayed with deionized water. Immediately after treatment all plants were placed in a dark dew chamber with an air temperature of 24° C. After 24 hr the plants were returned to the growth chamber. Disease development was observed after 14 days and isolations were made from lesions.
Isolates A1, B2, and A3 were identified as Phoma sp. based on the production of ostiolate pycnidia and hyaline, single-celled conidia.
Phoma sp. failed to sporulate in liquid culture. On solid agar media, all three isolates produced pycnidia most abundantly on 1/2 PDA with 10% plant extract, 1/2 PDA with half-strength torula yeast agar, and PDA. There was relatively little pycnidium production on any of the other media. Pycnidium production was increased when plates were incubated under NUV. More pycnidia were produced when spore suspensions were streaked on plates than when agar plugs with mycelium were used. Inoculum production on solid agar media, however, was generally insufficient for use in inoculation experiments.
Although variable, pycnidium production on autoclaved wild buckwheat leaves was more abundant than on solid agar media. Sufficient inoculum was produced by 20-30 leaf cultures for most laboratory and greenhouse inoculation experiments.
Two weeks after treatment, all inoculated plants had developed symptoms similar to those observed in the field. Two types of leaf lesions were observed. Small lesions (approximately 1-2 mm dia.) with tan or white necrotic centers surrounded by a red border were produced most commonly. Larger lesions (approximately 1-2 cm dia.) were also produced. The large lesions were tan or light brown and appeared to originate from small lesions. The large lesions expanded rapidly and resulted in the death and abscission of infected leaves. Pycnidia were often produced on the dead leaves. Isolations from both types of lesions yielded organisms identical to the original isolates.
EXAMPLE II
This example illustrates the effect of temperature on conidium germination and growth of mycelium, important biological characteristics of the fungus.
Conidia of isolate A1 were collected from leaf plates as described above. Some conidia were used after one centrifugation and others were washed two additional times by centrifugation and resuspension in deionized water (pH=4.0). Inoculum density was adjusted to 2×10 5 spores/ml. Two 30 μl droplets of each spore suspension were placed on clean glass slides supported on bent glass rods in petri dishes with filter papers moistened with a 10% (v/v) glycerine solution. The petri dishes were sealed with parafilm and incubated for 18 hr at 18, 24, and 30° C. Spore germination was determined by observing the droplets with the aid of a compound microscope (100×) and counting 100 spores in 5 random fields per drop for a total of 1000 spores per treatment. Spores were recorded as germinated if a germ tube had been produced which was as long as the diameter of the spore. The experiment was repeated once.
There was no significant effect of washing on spore germination and the highest level of germination occurred at 30° C. (Table 1). Germination was significantly less at cooler temperatures.
TABLE 1______________________________________Spore germination (%) of Phoma sp.isolate A1 following one or threewashings by centrifugation andincubation for 18 hr at different temperatures. Washed byTemperature centrifugation: Row(°C.) 1× 3× mean.sup.a______________________________________18 31.sup.a 30.sup.a 31.sup.b24 64 69 6630 75 77 76______________________________________ .sup.a Data in these two columns are pooled treatment means for two replications of the experiment. .sup.b Data in this column are pooled means for temperature averaged over one and three washings and for two replications of the experiment. Factorial analysis of variance indicated no significant effect of washing or interaction and LSD = 3 for mean percent germination at the three temperatures (α = 0.05).
Agar plugs (6 mm diameter) with mycelium cut from the margins of actively growing PDA cultures of the three Phoma isolates were inverted and placed separately on the centers of PDA plates. Plates were incubated at 15, 18, 21, 24, 27, and 30° C. for 7 days. Colony diameters were recorded daily by measuring two diameters at right angles to each other. There were four plates per isolate per temperature and the experiment was repeated once.
After three days of growth, the maximum colony diameter for all three isolates was obtained at 24° C. and there was no significant difference between 24° and 27° C. (Table 2). At all incubation temperatures except 30° C., all three isolates had grown to cover the surface of the PDA plates after 6-7 days of incubation. At 30° C., however, the growth curves had leveled off and the fungus did not cover the surface of the agar by the completion of the experiment.
TABLE 2______________________________________Effect of temperature on mycelial growth of three Phomasp. isolates on PDA in petri dishes.sup.a,b.Incubation Isolatetemperature (°C.) A1 B2 A3______________________________________15 42cd 39cd 39c18 47c 42c 44c21 64b 59b 57b24 73a 71a 68a27 71a 71a 69a30 37d 36d 38c______________________________________ .sup.a Data are mean colony diameters (mm) for two pooled experiments wit four replicate petri dishes for each experiment. Data were collected afte three days of incubation. .sup.b Values in a column followed by the same letter are not significantly different according to the WallerDuncan Kratio t test (α = 0.05).
EXAMPLE III
This example illustrates the effects of dew period temperature and duration on disease development and biomass of wild buckwheat plants inoculated with Phoma sp. isolate A1.
Wild buckwheat seedlings at the 2-leaf stage (15 days after planting germinated seeds) were inoculated with Phoma sp. isolate A1 at an inoculum density of 1×10 9 conidia/m 2 . Inoculated plants were placed in dew chambers calibrated to provide air temperatures of 15°, 21°, or 27° C. Moisture conditions in the dew chambers were monitored using a leaf wetness digital recorder (model DP223 with leaf leaf wetness seensor LWS 223, Omnidata Int., Inc., Logan, Utah). After 6, 12, 18, 24, and 30 hr some pots were removed and transferred to the growth chamber. There were uninoculated controls included at all temperature/duration combinations. Additional controls were placed immediately in the growth chamber without receiving a dew period. Disease severity was rated on leaf two after 2 wk using the Barratt-Horsfall scale and by counting numbers of lesions. Disease ratings were converted to midpoint percentages prior to analysis. After 4 wk, mortality was recorded and plants were harvested by cutting the stems at the height of the cotyledonary node. Plants were placed in paper bags, dried at 60° C. for 7 days, and weighed. There were three pots per treatment with three plants per pot and the experiment was repeated once using a lower inoculum density (9.4 ×10 7 conidia/m 2 ). The experiment was also repeated using dew period air temperatures of 18°, 24°, and 30° C.
Discussion and conclusions for this and subsequent sections are based on regression analyses of the data. Data are presented, however, in tabular format and significant differences are presented as indicated by the Waller-Duncan K-ratio t test. The percentage of infected leaves increased with increasing dew period duration and with increasing dew period temperature (Table 3). No infection occurred on inoculated plants which did not receive a dew period. Disease severity as measured by Barratt-Horsfall ratings and by numbers of lesions per leaf also increased with increasing dew duration and with increasing temperature (Table 3). The maximum disease severity occurred following a 30 hr moist period at 27° C. The biomass of inoculated plants expressed as a proportion of the biomass of uninoculated plants which received the same dew period duration and temperature treatments also decreased with increasing dew period duration and temperature (Table 3). Little mortality occurred following any of the treatment combinations. Three of nine plants (33%) were killed following the 30 hr dew period at 27° C. and one of nine plants (11%) was killed following the 12 hr dew period at 27° C.
TABLE 3______________________________________Effect of dew period temperature and duration ondisease development and biomass of plants inoculatedwith Phoma sp. isolate A1.sup.a.Dew PeriodTem-pera-Dur- Tissue Biomassture ation Infected covered with Lesions/ (proportion(°C.)(hr) leaves (%).sup.b lesions (%).sup.c leaf.sup.d of control).sup.e______________________________________15 6 0 e 0 c 0.0 c 0.876 bcd15 12 0 e 0 c 0.0 c 0.882 bcd15 18 11 de 0 c 0.4 bc 0.914 bcd15 24 67 abc 2 c 1.4 bc 1.171 a15 30 56 abcd 1 c 1.2 bc 0.747 de21 6 0 e 0 c 0.0 c 1.077 ab21 12 22 cde 1 c 0.7 bc 0.869 bcd21 18 22 cde 1 c 0.4 bc 0.708 de21 24 22 cde 1 c 0.3 bc 0.879 bcd21 30 78 ab 27 b 3.4 ab 0.816 cd27 6 0 e 0 c 0.0 c 0.979 abc27 12 22 cde 1 c 0.6 bc 0.815 cd27 18 44 bcd 1 c 1.2 bc 0.703 de27 24 89 ab 69 a 5.5 a 0.592 e27 30 100 a 76 a 5.5 a 0.375 f______________________________________ .sup.a Values in a column followed by the same letter are not significantly different according to the WallerDuncan K ratio t test (α = 0.05). .sup.b Data are mean percent infected leaves for leaf two (for each pot o three plants: [total number of infected leaves/total number of leaves] × 100). .sup.c Data are mean percent of leaf area of leaf two covered with necrotic tissue as rated with the BarrattHorsfall scale. .sup.d Data are mean numbers of necrotic lesions on leaf two. .sup.e Data are means of biomass expressed as proportions of the biomass of uninoculated plants which received the same dew period treatment.
Similar results were obtained when the experiment was repeated with a lower inoculum density except that disease levels and damage were generally lower and no plants were killed. When the experiment was repeated with warmer dew period temperatures (18°, 24°, and 30° C.), 1 of 9 plants was killed in the 18 hr 30° C. treatment, the 24 hr 30° C. treatment, and the 30 hr 24° C. treatment.
EXAMPLE IV
This example illustrates the effect of plant age and Phoma sp. isolate A1 inoculum density on disease severity and biomass of inoculated wild buckwheat plants.
Wild buckwheat seedlings at the 3 to 4-leaf stage (21 days after planting germinated seeds) were inoculated with different inoculum densities (0, 10 5 , 5×10 5 , 10 6 , 5×10 6 , 10 7 , 5×10 7 , or 2.7×10 8 spores/m 2 ) and then placed in a dew chamber with an air temperature of 24° C. for 24 hr. Plants were then returned to the growth chamber and incubated for 5 wk. Disease severity was rated on leaf three after 2 wk using the Barratt-Horsfall scale. Disease ratings were converted to midpoint percentages prior to analysis. After 5 wk, mortality was recorded and plants were harvested by cutting the stems at the height of the cotyledons. Plants were placed in paper bags, dried at 60° C. for 7 days, and weighed. There were five pots per treatment with three plants per pot.
For plants at the 3-leaf stage, disease severity increased with increasing inoculum density (Table 4). Percentage of leaves infected increased to 100% at the highest inoculum density tested (Table 4) and percentage of leaf area covered with lesions also increased with increasing inoculum density although the maximum disease severity was only 15% (Table 4). There was a decrease in plant biomass with increasing inoculum density (Table 4) but no mortality occurred at any inoculum density.
TABLE 4______________________________________Effect of inoculum density of Phoma sp. isolate A1 ondisease development and biomass of inoculated plants.sup.a. TissueInoculum covered Biomassdensity Infected with lesions Lesions/ (proportion(log spores/m.sup.2) leaves (%).sup.b (%).sup.c leaf.sup.d of control).sup.e______________________________________5 13 c 0 b 0.0 a 1.099 a5.7 7 c 0 b 0.0 a 0.859 ab6 27 c 1 b 0.0 a 1.020 ab6.7 60 b 2 b 0.0 a 0.960 ab7 80 ab 4 b 0.8 a 0.963 ab7.7 93 a 5 b 1.4 a 0.758 b8.4 100 a 15 a 2.0 a 0.789 b______________________________________ .sup.a Values in a column followed by the same letter are not significantly different according to the WallerDuncan K ratio t test (α = 0.05). .sup.b Data are mean percent infected leaves for leaf three (for each pot of three plants: [total number of infected leaves/total number of leaves] × 100). .sup.c Data are mean percent of leaf area of leaf three covered with necrotic tissue as rated with the BarrattHorsfall scale. .sup.d Data are mean numbers of necrotic lesions on leaf three. .sup.e Data are means of biomass expressed as proportions of the biomass of uninoculated plants.
Wild buckwheat plants at three different ages (7, 14, and 21 days after planting corresponding to cotyledon, 2-leaf, and 3 to 4-leaf stages) were inoculated with conidia of Phoma sp. isolate A1 in deionized water adjusted to different inoculum densities (0, 10 8 , 10 9 , or 8.9×10 9 spores/m 2 ). Inoculated plants were incubated in a dew chamber at 24° C. for 18 hr prior to incubating them in growth chambers or a greenhouse mist frame as above. Disease severity was rated 2 wk after inoculation and plants were rated for mortality and harvested as above after 3 wk. There were three plants per pot and four pots per treatment. The experiment was repeated once using the same inoculum densities and twice using lower inoculum densities (10 7 , 10 8 , and 10 9 conidia/m 2 , and 1.5×10 6 , 1.5×10 7 , and 1.5×10 8 conidia/m 2 ).
When plants were inoculated at different growth stages and incubated in the growth chamber or greenhouse mist frame, there were interactions between incubation location and inoculum density and/or plant age for percentage of infected leaves. Thus effects of inoculum density, plant age, and their interaction were investigated separately for each location. In the growth chamber, inoculum density had no significant effect on percentages of infected target leaves (i.e. cotyledons for 7-day old plants, leaf 2 for 14-day old plants, and leaf 3 for 21-day old plants) but percentages of infected leaves decreased for 14 and 21-old plants compared to 7 day-old plants (Table 5). In the mist frame, percentages of infected target leaves increased with increasing inoculum density and decreased with increasing plant age (Table 5).
TABLE 5______________________________________Effect of inoculum density of Phoma sp. isolate A1 andplant age on disease development on inoculated wildbuckwheat plants.sup.a.Plant Inoculumage density Infected leaves (%).sup.b in:(days) (log condida/m.sup.2) Growth chamber Mist frame______________________________________ 7 8 96 a 96 a 7 9 100 a 96 a 7 9.9 92 ab 92 a14 8 17 d 58 ab14 9 42 cd 100 a14 9.9 50 cd 83 a21 8 25 cd 25 b21 9 58 bc 83 a21 9.9 25 cd 67 ab______________________________________ .sup.a Values in a column followed by the same letter are not significantly different according to the WallerDuncan K ratio t test (α = 0.05). .sup.b Data are mean percent infected leaves for leaf three (for each pot of three plants: [total number of infected leaves/total number of leaves] × 100).
There was no significant effect of location or interaction between location and other factors on disease severity measured using the Barratt-Horsfall scale and converted to midpoint percentages, mortality, or biomass of plants expressed as a proportion of the uninoculated controls. Thus data were pooled over both locations. Percentage of leaf area covered with lesions increased with increasing inoculum density but it also decreased with increasing plant age (Table 6). The highest level of mortality occurred on plants inoculated when they were 7 days old with the highest inoculum density, but due to the high level of variability there were no significant differences between this treatment and the other two inoculum densities on 7-day old plants (Table 7). No mortality occurred in any other treatment. Applications of Phoma sp. significantly reduced plant biomass expressed as proportions of controls (FIG. 6). There was also a significant effect of plant age on biomass proportion. It would thus appear that older plants are more resistant to infection and/or damage by Phoma sp. since disease severity was less on older plants and biomass proportions of controls were higher on older plants. Only 7-day old plants were killed, however, and if biomass proportion is expressed on a per plant basis only for plants still alive at the conclusion of the experiment, there was a significant effect only of inoculum density and no significant effect of plant age. Thus the biomass proportions of plants of all three ages were affected similarly by Phoma sp. at different inoculum densities. The differences in disease severity detected on plants of different ages might also be due to differences in application rate or variable plant morphology.
TABLE 6______________________________________Effect of inoculum density of Phoma sp. and plant ageon disease development and plant biomass.sup.a. Inoculum Tissue Biomass BiomassPlant density covered (proportion (proportionage (log with lesions of control) of control)(days) conodia/m.sup.2 (%) per pot.sup.c per plant.sup.c______________________________________7 8 27 b 0.763 ab 0.835 a7 9 62 a 0.606 bcd 0.720 ab7 9.9 57 a 0.486 d 0.677 ab14 8 1 c 0.779 ab 0.779 ab14 9 5 c 0.734 abc 0.734 ab14 9.9 3 c 0.554 cd 0.554 b21 8 1 c 0.898 a 0.898 a21 9 5 c 0.766 ab 0.766 ab21 9.9 5 c 0.745 abc 0.745 ab______________________________________ .sup.a Values in a column followed by the same letter are not significantly different according to the WallerDuncan K ratio t test (α = 0.05). .sup.b Data are mean percent of leaf area of leaf three covered with necrotic tissue as rated with the BarrattHorsfall scale. .sup.c Data are means of biomass expressed as proportions of the biomass of uninoculated plants.
TABLE 7______________________________________Mortality (%) of wild buckwheat plants 5 wk afterinoculation with different inoculum densities of Phomasp. isolate A1.sup.a.Plant age Inoculum density (log condida/m.sup.2)(days) 0 8 9 9.9______________________________________ 7 0 8 17 2914 0 0 0 021 0 0 0 0______________________________________ .sup.a Data are mean percent mortality pooled for both locations. Analysi of variance of the three treatments in which mortality occured indicated no significant effect of inoculum density (α = 0.05).
When the same experiments were conducted using lower inoculum densities, similar results were obtained except that no mortality occurred even on young plants.
EXAMPLE V
This example illustrates the effect of Phoma sp. applied in combination with chemical herbicides on biomass and mortality of wild buckwheat plants.
Plants at the 2-leaf stage (14 days after planting germinated seeds) were inoculated with four different inoculum densities of Phoma sp. isolate A1 alone and in all combinations with four different chemical herbicide rates. The herbicides MCPA (2-methyl-4-chlorophenoxyacetic acid) and dicamba (3,6-dichloro-o-anisic acid) were tested since both are recommended for wild buckwheat control. Chemical rates were selected by treating wild buckwheat seedlings with the chemical alone in preliminary experiments and selecting a rate which had some effect on biomass but caused no mortality of wild buckwheat. This rate was taken as the highest rate (X) and two lower rates (1/3 X and 2/3 X) plus 0 were used in the experiments. Rates of Phoma sp. varied depending on the availability of inoculum but were between 3×10 6 and 8×10 8 spores/m 2 . Treated plants were incubated in the dew chamber at 24° C. air temperature for 18 hr and were subsequently incubated in a greenhouse mistframe for 3 wk. The mistframe was calibrated to maintain leaf moisture during the night. Natural light was supplemented with 400 W high pressure sodium lamps (14-hr photoperiod, 0600-1800 hr, approximately 50 uEm -2 s -1 supplemental light. Plants were harvested and rated for mortality after 3 wk. There were 3 plants per pot and 4 pots per treatment. Data were analyzed with a factorial analysis of variance and the type of interaction between the two components was evaluated using the method of Drury.
There was a significant synergistic interaction between Phoma sp. and dicamba to increase wild buckwheat mortality (Tables 8,9). Phoma alone caused no mortality of wild buckwheat while dicamba alone caused 17-25% mortality at the two highest rates. In combination, however, they caused 100% mortality of wild buckwheat. Phoma alone had a small effect on plant biomass (Table 10). Results with MCPA were similar (Tables 11-13).
TABLE 8______________________________________Effect of Phoma sp. isolate A1 and dicamba on mortalityof wild buckwheat plants.sup.a.Dicamba Control Phoma rate (log conidia/m.sup.2)rate (kg/ha) (no Phoma) 7.51 7.71 8.94______________________________________0.0 0 0 0 00.1 0 0 42 420.2 25 50 83 500.3 17 42 67 100______________________________________ .sup.a Data were analyzed with polynominal regression but only treatment means are presented here ([number of dead plants/total number of plants] × 100).
TABLE 9______________________________________Type of interaction between Phoma sp. and dicamba toincrease wild buckwheat mortality.sup.a.Dicamba Phoma rate (spores/m.sup.2)rate (kg/ha) 7.51 7.71 8.94______________________________________0.1 S S V0.2 S S V0.3 S S V______________________________________ .sup.a S = synergistic interaction to increase wild buckwheat mortality, = Phoma promoted the action of the chemical but not vice versa.
TABLE 10______________________________________Effect of Phoma sp. isolate A1 and dicamba on biomassof wild buckwheat plants.sup.a.Dicambarate Control Phoma rate (log condida/m.sup.2)(kg/ha) (no Phoma) 7.51 7.71 8.94______________________________________0.0 2.6 2.7 2.2 2.00.1 0.7 1.1 0.5 0.50.2 0.4 0.4 0.2 0.10.3 0.4 0.2 0.1 0.0______________________________________ .sup.a Data were analyzed with polynominal regression but only treatment means are presented here (g/pot).
TABLE 11______________________________________Effect of Phoma sp. isolate A1 and MCPA on mortality ofwild buckwheat plants.sup.a.MCPArate Control Phoma rate (log conidia/m.sup.2)(kg/ha) (no Phoma) 7.6 8.0 8.6______________________________________0.0 0 0 0 00.1 0 42 33 670.2 0 25 25 1000.3 58 42 83 100______________________________________ .sup.a Data were analyzed with polynominal regression but only treatment means are presented here ([number of dead plants/total number of plants] × 100).
TABLE 12______________________________________Type of interaction between Phoma sp. and MCPA toincrease wild buckwheat mortality.sup.a.MCPArate Phoma rate (spores/m.sup.2)(kg/ha) 7.6 8.0 8.6______________________________________0.4 C* S S0.8 A* A A1.2 S S C*______________________________________ .sup.a S = synergistic interaction to increase wild buckwheat mortality, A* = antagonistic interaction to increase wild buckwheat mortality, C* = MCPA promoted the action of Phoma but not vice versa and the interaction resulted in a decrease in mortality. A = antagonistic interaction to decrease wild buckwheat mortality.
TABLE 13______________________________________Effect of Phoma sp. isolate A1 and MCPA on biomass ofwild buckwheat plants.sup.a.MCPA Control Phoma rate (log condida/m.sup.2)rate (kg/ha) (no Phoma) 7.6 8.0 8.6______________________________________0.0 1.5 1.7 1.2 1.30.4 1.0 0.3 0.4 0.10.8 0.6 0.5 0.3 0.01.2 0.2 0.4 0.0 0.0______________________________________ .sup.a Data were analyzed with polynominal regression but only treatment means are presented here (g/pot). | The present invention is concerned with a novel bioherbicide and its use alone or in compositions, to control the growth of Polygonum convolvulus in agricultural crops such as cereals and other cultivated crops. The present invention is also concerned with a synergistic composition of the novel bioherbicide and a chemical herbicide. Specifically, the new fungus is Phoma sp. ATCC 20982. | 0 |
FIELD
The present disclosure relates to liftgate systems for motor vehicles, and more particularly to a liftgate latch linear cable switch.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Many motor vehicles include rear cargo compartments that are accessible by a liftgate. In one example, sport utility vehicles (SUV)s generally include a liftgate that enables access to a rear cargo compartment from the exterior of the motor vehicle. Generally, a liftgate includes a graspable portion that when actuated releases the liftgate so that the liftgate may be pivoted or rotated: into an opened position, via pneumatics, thereby enabling the operator to access the rear cargo compartment.
SUMMARY
The present invention provides a latch system for a lifegate of a motor vehicle. The system includes a handle rotatable relative to the liftgate. The system also includes a switch having a first contact biased apart from a second contact by a biasing member. The first contact is movable relative to the second contact to close the switch upon rotation of the handle. The system further includes a power actuation system in communication with and responsive to the switch to move the liftgate from the closed position to the opened position when the switch is in the closed position.
Also provided is a latch system for a liftgate of a motor vehicle. The system includes a latch that couples the liftgate to the motor vehicle when the liftgate is in a closed position. The system also includes a handle rotatable relative to the liftgate and in communication with the latch to uncouple the liftgate from the motor vehicle upon rotation of the handle. The system also includes a switch including a first contact spaced apart from a second contact in a first, opened position. The first contact is movable into communication with the second contact in a second, closed position. The first contact is also coupled to the handle. The system further includes a power actuation system in communication with and responsive to the switch and coupled to the liftgate to move the liftgate from the closed position to the opened position when the switch is in the closed position. The rotation of the handle relative to the liftgate moves the first contact into communication with the second contact to close the switch.
Further is provided a latch system for a liftgate of a motor vehicle. The system includes a latch that couples the liftgate to the motor vehicle when the liftgate is in a closed position. The system also includes a handle graspable to be rotated relative to the liftgate and in communication with the latch to uncouple the liftgate from the motor vehicle upon rotation of the handle. The system further includes a switch including a first contact, a second contact and a biasing member. The first contact is biased apart from the second contact in a first, opened position, by the biasing member, and is slidable into communication with the second contact in a second, closed position. The first contact includes a cable coupled to the handle such that rotation of the handle pulls the cable to slide the first contact into communication with the second contact. The system further includes a power actuation system in communication with and responsive to the switch to move the liftgate from the closed position to the opened position when the switch is in the second, closed position. The biasing member moves the switch into the first, opened position when the handle is released.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a partial schematic view of an exemplary motor vehicle employing a liftgate incorporating a liftgate latch linear cable switch according to the principles of the present disclosure with the liftgate in a closed position;
FIG. 2 is a detail view of the exemplary motor vehicle incorporating the liftgate latch linear cable switch of FIG. 1 ;
FIG. 2A is a schematic illustration of a control system for the motor vehicle of FIG. 1 ;
FIG. 3 is a cross-sectional schematic view of the liftgate latch linear cable switch of FIG. 1 , taken along line 3 - 3 in FIG. 2 , with the liftgate in a first position; and
FIG. 4 is a cross-sectional schematic view of the liftgate latch linear cable switch of FIG. 1 , taken along line 3 - 3 in FIG. 2 , with the liftgate in a second position.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. Although the following description is related generally to a liftgate latch linear cable switch for use with a liftgate of a motor vehicle, it will be understood that the linear cable switch as described and claimed herein is applicable to any type of enclosure system in which automatic opening of the enclosure system is desired. Therefore, it will be understood that the following discussion is not intended to limit the scope of the appended claims to only liftgate applications.
With reference to FIGS. 1 and 2 , an exemplary portion of a motor vehicle 10 is shown. The motor vehicle 10 includes a rear cargo area 12 and a liftgate system 14 . The liftgate system 14 includes at least a glass member 16 , a door member 18 , a latch 20 and a control system 22 .
The glass member 16 and door member 18 cooperate to form a liftgate, as generally known, and the latch 20 serves to releasably secure at least the door member 18 to the motor vehicle 10 . As the glass member 16 and door member 18 are generally known in the art, and may comprise any suitable rear lift door, such as that disclosed in commonly assigned U.S. Pat. No. 5,563,483 and incorporated herein by reference, the liftgate, including the glass member 16 and the door member 18 , will not be discussed in great detail herein. Briefly, however, the liftgate includes a handle 26 pivotally coupled to the door member 18 . The handle 26 may be manually rotated or pivoted from a first position to a second position to enable an operator to access the rear cargo area 12 . The handle 26 may also include an arm 26 a that defines a receptacle 26 b for receipt of at least a portion of the control system 22 .
With reference to FIGS. 2 and 2A , in this regard, the control system 22 is responsive to the handle 26 to release the latch 20 and pivot the liftgate 24 from a closed position to an opened position. The latch 20 may comprise any suitable device for releasably coupling the liftgate 24 to the motor vehicle 10 , and may include a solenoid 20 a that actuates latch members 20 b to engage or disengage a latch pin 20 c coupled to the rear cargo area 12 of the motor vehicle 10 . For example, the latch 20 could comprise a suitable latch commercially available from Gecom Corporation of Greensburg, Ind., however, any suitable latch could be employed. The solenoid 20 a may be in communication with and responsive to the control system 22 via a conductor 20 d to output a signal 100 to actuate the latch members 20 b to engage or disengage the latch pin 20 c , as generally known in the art.
With continuing reference to FIGS. 2 and 2A , the control system 22 includes a power actuation system 28 , a switch 30 and a controller 32 . The power actuation system 28 is in communication with and responsive to the controller 32 over a conductor 28 a to output a signal 104 to raise, lift or move the glass member 16 and door member 18 from the closed position to the opened position, and vice versa, if desired. As the power actuation system 28 may comprise any suitable system capable of moving the glass member 16 and door member 18 between the closed position and the opened position (and vice versa), such as that disclosed in commonly assigned U.S. Ser. No. 08/292,662, incorporated herein in its entirety, the power actuation system 28 will not be discussed in great detail herein. Briefly, however, the power actuation system 28 may include the conductor 28 a in communication with the controller 32 to conduct or carry an electrical control signal, such as an alternating current, which activates or powers a motor associated with the power actuation system 28 to move the glass member 16 and door member 18 into the opened or closed position (not specifically shown).
With reference to FIGS. 2-4 , the switch 30 includes a first or bridge contact 40 and a second or trace contact 42 , with each of the bridge contact 40 and the trace contact 42 disposed at least partially within a housing 43 . With reference to FIGS. 3-4 , the bridge contact 40 includes a cable 44 , a biasing member or spring 46 , contact housing 48 and contacts 50 . The cable 44 may be at least partially disposed within the housing 43 , and may be slideably retained in the housing 43 such that the cable 44 moves relative to the housing 43 ( FIG. 4 ). The cable 44 includes a proximal end 44 a , a distal end 44 b and a grip 44 c.
The grip 44 c is formed at the proximal end 44 a , and extends from the housing 43 . Generally, the grip 44 c is sized to engage the receptacle 26 b , and may be sized to be snap fit into the receptacle 26 b to couple the switch 30 to the handle 26 . The coupling of the grip 44 c to the handle 26 enables the switch 30 to be mechanically responsive to the pivoting of the handle 26 . In this regard, the pivoting of the handle 26 pulls or slides the cable 44 relative to the housing 43 , from a first or opened switch position ( FIG. 3 ) into a second or closed switch position ( FIG. 4 ), which moves the contacts 50 into electrical communication with the trace contact 42 to close the switch 30 . The distal end 44 b of the cable 44 is coupled to the contact housing 48 , and is disposed within the housing 43 .
The spring 46 is disposed about the cable 44 , between the contact housing 48 and a surface 43 a of the housing 43 . The spring 46 biases the cable 44 , and thus, the switch 30 into the opened position, and serves to return the switch 30 to the closed position after the pivoting or movement of the handle 26 .
The contact housing 48 includes electronics associated with the contacts 50 . The contacts 50 may be exposed through apertures defined in the contact housing 48 . The contacts 50 include a positive contact and a negative or ground contact that are operable to enable a flow of current through the switch 30 when the contacts 50 are in communication with the trace contact 42 (i.e. when the switch 30 is closed).
The trace contact 42 includes a positive contact and a negative or ground contact. The positive contact and the ground contact each include a first end 52 , respectively, and a second end 54 , respectively. The first end 52 is in communication with the controller 32 to transmit an electrical signal, such as a current, when the switch 30 is in the closed position. The second end 54 is operable to be in electrical communication with the bridge contact 40 . In this regard, the second end 54 may be adjacent to and in electrical communication with the contacts 50 of the bridge contact 40 when the cable 44 is in the extended position. Thus, the second end 54 may be disposed within a path of travel of the cable 44 so that when the cable 44 is moved into the extended position, the bridge contact 40 is placed into electrical communication with the trace contact 42 . The electrical communication between the bridge contact 40 and the trace contact 42 closes the switch 30 so that a current may flow therethrough. The flow of the current may serve as an indicator or signal that indicates to the controller 32 that the switch 30 is in the closed position.
The controller 32 includes a conductor 56 that is in communication with the controller 32 and responsive to the trace contact 42 . The conductor 56 is in electrical communication with the first end 52 of the trace contact 42 and is in electrical communication with the controller 32 . The controller 32 is also in electrical communication with the latch 20 via the conductor 20 d . The controller 32 may transmit a signal over the conductor 20 d to the solenoid 20 a to activate the solenoid 20 a to engage or disengage the latch members 20 b from the latch pin 20 c . The controller 32 may also be in communication with the power actuation system 28 , via the conductor 28 a , to transmit the electrical control signal to activate the power actuation system 28 to move the liftgate 24 into the opened or closed position.
Thus, with at least the door member 18 in the closed position, the switch 30 is in the opened position. In order to gain access to the rear cargo area 12 , an operator pivots the handle 26 of the door member 18 . The pivoting of the handle 26 causes the grip 44 c to move relative to the housing 43 of the switch 30 , and thereby pulls the cable 44 . The movement of the cable 44 relative to the housing 43 moves the contact housing 48 relative to the housing 43 until the contacts 50 of the bridge contact 40 are in electrical communication with the trace contact 42 . Once the contacts 50 of the bridge contact 40 are in electrical communication with the trace contact 42 , the switch 30 is closed. With the switch 30 in the closed position, current may flow through the conductor 32 a to the controller 32 .
Upon receipt of the current from the switch 30 , the controller 32 outputs a signal to the latch 20 over the conductor 20 d to disengage the latch members 20 b from the latch pin 20 c . The controller 32 also outputs the control signal to the power actuation system 28 to move at least the door member 18 from the closed position to the opened position. Once the operator has released the handle 26 , the spring 46 biases the cable 44 away from the surface 43 a , and thus, opens the switch 30 .
While specific examples have been described in the specification and illustrated in the drawings, it will be understood by those of ordinary skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure as defined in the claims. Furthermore, the mixing and matching of features, elements and/or functions between various examples is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise, above. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular examples illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this disclosure, but that the scope of the present disclosure will include any embodiments falling within the foregoing description and the appended claims. | A latch system for a liftgate of a motor vehicle. The system includes a handle rotatable relative to the liftgate. The system also includes a switch having a first contact biased apart from a second contact by a biasing member. The first contact is movable relative to the second contact to close the switch upon rotation of the handle. The system further includes a power actuation system in communication with and responsive to the switch to move the liftgate from the closed position to the opened position when the switch is in the closed position. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a printing control method for controlling an enable signal of a line memory so as to allow reciprocative printing in a video printer.
A video printer is to print a picture recorded by the instant capture of a video signal, or a picture recorded by a recorder such as a still camera and reproduced on a monitor.
Referring to FIG. 1, video decoder 10 of a video color printer separates the R, G, and B analog signals from a video signal input from video input port 5, and the horizontal and vertical synchronous H-sync and V-sync signals. Upon receiving a memory instruction signal from memory instruction input port 15, memory controller 70 supplies a sampling pulse to analog-to-digital converter 20 corresponding to the separated H-sync and V-sync signals. Analog-to-digital converter 20 converts the R, G, and B analog signals from decoder 10 to R, G, and B digital signals corresponding to the sampling pulse from memory controller 70. Frame memory 30 stores the R, G, and B signals from analog-to-digital converter 20 in a storage location corresponding to a write address designated by memory controller 70. Upon receiving an instruction input signal from print instruction input port 25, a printing controller 80 simultaneously applies a read address to frame memory 30, designates a write address in line memory 31, and selects a memory selection switch.
Meanwhile, R, G, and B signals should be converted to yellow Y, cyan C and magenta M in order to be printed on paper. The R, G, and B signals recorded in frame memory 30 are sequentially recorded in line memory 31 by lines by memory selection switch 40, and the data recorded in line memory 31 is transmitted to controller 50 by printing controller 80. Controller 50 converts the R, G, and B signals from line memory 31 to Y, M, and C signals sequentially and at the same time, performs color correction and resistance correction to reduce the resistive deviation of each heat generating element of a printing head in order to compensate the error of density conversion in accordance with the correlation between the properties of the paper used and amount of heat generated by a head, then, applies the converted and compensated Y, M, and C data to the printing head of printing portion 60 in the sequence of Y, M, and C. The data is printed by lines by the printing head of printing portion 60, which is the completion of one frame printing.
Digital-to-analog converter 21 converts the R, G, and B digital signals of frame memory 30 to R, G, and B analog signals and supplies them to encoder 90. Encoder 90 converts the R, G, and B signals converted by digital-to-analog converter 21 to a composite video signal and supplies it to monitor 100. While the one frame picture is being printed by the printing portion, monitor 100 displays the picture which is being printed.
In addition, a printing head of printing portion 60 prints by lines from left to right because the number of vertical sampling is constant but the number of horizontal sampling is variable. Thus, line memory 31 stores one column data during reading out of one frame data from frame memory 30. At this time, printing controller 60 should generate a write enabling signal in order that line memory 31 stores the one column data among one frame data of frame memory 30.
Referring to FIG. 2, frequency divider 110 divides by two a vertical synchronous signal input via vertical synchronous signal input port 105 and supplies the two-divided vertical synchronous signal to up-counter 120. Whenever the vertical synchronous signal divided by two by frequency divider 110 is input to a clock port CLK, up-counter 120 counts a value by increasing it by "1", and supplies the counted value to the input port D of down-counter 130. Down-counter 130 inputs the counted value from up-counter 120 during the horizontal blanking period of a horizontal synchronous signal input via a horizontal synchronous signal input port 115. Whenever a clock signal is applied via clock port 125 during the horizontal scan period of a horizontal synchronous signal, down-counter 130 counts the input values by decreasing it by "1" until the input value becomes "0", and applies a write enabling signal in a predetermined logic state to line memory 31.
Therefore, when the output of up-counter 120 is "1", data (1, L1), (2, L1), (3, L1), . . . , (525, L1) of first column in FIG. 3 is applied and printed in printing portion 7. When the output of up-counter 120 is "2", data (1, L2), (2, L2), (3, L2), . . . , (525, L2) of second column is printed in printing portion 7. According to the sequence, as data (1, L600), (2, L600), (3, L600), . . . , (525, L600) of 600th column is printed, printing of one color is completed.
As printing of one color is completed, a platen drum is rotated two times faster to make paper return to the initial position. Then, printing is carried out again to sequentially print yellow, magenta, and cyan in the same direction, then printing is completed.
As described above, after the completion of printing, the ordinary printing controller rotates the platen drum two times faster to make paper return to the initial position. Then, printing begins again. If paper is wound on the drum, the one-direction printing may cause dislocation of color because of paper's curl and incorrect initial setting.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide a printing control method for preventing paper's curl and incorrect initial setting.
To accomplish the object, in a video color printer comprising a frame memory for storing one frame color signals, and repeatedly reading out the stored color signals from left to right and from top to bottom, a line memory for storing one column color signal whenever one frame color signals are read out from the frame memory, and a printing means for printing the color signals stored in the line memory, the printing control method of the present invention comprises the steps of: changing sampling direction so that the line memory inputs column samples among one frame data of the frame memory whenever printing is completed; sequentially designating one column sample position from left to right or vice versa according to the direction designated in the sampling direction changing step whenever one frame data is read out from the frame memory; and designating the position of unit samples so that the line memory sequentially inputs the column samples designated in the column sample designating step whenever one horizontal scan line data is read out.
BRIEF DESCRIPTION OF THE DRAWINGS
The above object and other advantages of the present invention will become more apparent by describing in detail a preferred embodiment of the present invention with reference to the attached drawings in which:
FIG. 1 is a block diagram of a video color printer;
FIG. 2 is a detailed circuit diagram of an enabling signal generator for use of a line memory of the printing controller shown in FIG. 1;
FIG. 3 illustrates the relation between picture scanning of a video signal and sampling location of a printing line;
FIG. 4 is a detailed circuit diagram of an enabling signal generator for a line memory in accordance with the present invention; and
FIGS. 5A through 5D are waveforms present at various stages of the circuit shown in FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 4, first input port 205 is coupled to decoder 10 shown in FIG. 1 to input a vertical synchronous signal. First input port 205 is coupled to the input port of frequency divider 210. The output port of frequency divider 210 is coupled to clock port CLK of up-down counter 220. Output port Q of up-down counter 220 is coupled to input port D of down-counter 230. Output port Q of down-counter 230 is coupled to output port 255. Output port 255 is coupled to a write enabling port (not shown) of line memory 31 shown in FIG. 1. To input a print completion signal, second input port 215 is coupled to printing portion 60 shown in FIG. 1 or a microcomputer (not shown) for controlling the whole system. Second input port 215 is coupled to clock port CLK of flip-flop 241, and one input port of OR gates 242 and 243. Noninverting output port Q of flip-flop is coupled to the other input port of OR gate 242, input port of inverter 244, and up/down control port U/D of up-down counter 220. The output port of inverter 244 is coupled to the other input port of OR gate 243. The output port of OR gate 242 is coupled to clear port CLR of up-down counter 220. The output port of OR gate 243 is coupled to load port LD of up-down counter 220. Flip-flop 241 has a feedback loop which is connected from inverting output port *Q to input port D. Third input port 225 is coupled to an initial value setting portion (not shown) or a microcomputer (not shown) in order to input a preset value which designates a sample at the horizontally right end. Third input port 225 is coupled to input port D of up-down counter 220. Fourth input port 235 is coupled to decoder 10 shown in FIG. 1 to input a horizontal synchronous signal. Fourth input port 235 is coupled to load port LD of down-counter 230. Fifth input port 245 is coupled to a clock source to input a clock signal. Fifth input port 245 is coupled to the clock port CLK of down-counter 230.
FIG. 5A is a waveform of a print completion signal supplied to second input port 215, FIG. 5B is a waveform of an output signal outputted from noninverting output port Q of flip-flop 241, FIG. 5C is a waveform of an output signal of OR gate 242, and FIG. 5D is a waveform of an output signal of OR gate 243.
Detailed descripton of the present invention follows with reference to FIGS. 1 and 3 through 5C.
Turning to FIG. 4, frequency divider 210 frequency-divides a vertical synchronous signal inputted via first input port 205, and generates a two-divided vertical synchronous signal. While outputting an up-down mode control signal in high logic state via noninverting output port Q, flip-flop 241 inverts the up-down mode control signal in high logic state of noninverting output port Q to a signal in low logic state as shown in FIG. 5B, when a print completion signal in the low logic state as shown in FIG. 5A is applied to clock port CLK via second input port 215. OR gate 242 logically sums the up-down mode control signal in low logic state from noninverting output port Q of flip-flop 241, and the print completion signal from second input port 215, and generates the logic signal as shown in FIG. 5C. Up-down counter 220 resets an output value to "0" by the logic signal in low logic state applied to clear port CLK from OR gate 242. While the up-down mode control signal in low logic state is applied from noninverting output port Q of flip-flop 241 to an up-down control port, up-down counter 220 counts a value according to the two-divided vertical synchronous signal applied from frequency-divider 210 to clock port CLK, and generates count values which increase by "1" from "0" to "600". Whenever a horizontal synchronous signal is applied to load port L/D via fourth input port 235, down-counter 230 inputs the counted values from up-down counter 220 via input port D. Down-counter 230 counts the counted values inputted by a clock signal applied to clock port CLK via fifth input port 245 by decreasing by "1", then, generates a write enabling signal in low logic state when the count value becomes "0". The write enable signal generated from down-counter 230 is supplied to line memory 31 shown in FIG. 1 via output port 255. When the count value of up-down counter 220 is "1", line memory 31 shown in FIG. 1 inputs data of samples (1, L1), (2, L1), (3, L1), . . . , (525, L1) of FIG. 3 according to the write enable signal generated from down-counter 230 shown in FIG. 4, and supplies the data to printing portion 60 via controller 50. Then, printing portion 60 prints L1 column data of line memory 31 inputted via controller 50. When the count value of up-down counter 220 shown FIG. 4 is "2", line memory 31 shown in FIG. 1 inputs data of samples (1, L2), (2, L2), (3, L2), . . . , (525, L2) of FIG. 3, and printing portion 60 prints L2 column data. According to the sequence, print portion 60 prints data until the L600 column to complete the printing of one color.
Meanwhile, in FIG. 4, while outputting the up-down mode control signal in low logic state via noninverting output port Q, flip-flop 241 inverts the up-down mode control signal in low logic state of noninverting output port Q to a signal in high logic state as shown in FIG. 5B, when a print completion signal in low logic state as shown in FIG. 5A is applied to clock port CLK via second input port 215. OR gate 243 logically sums the up-down mode control signal in high logic state from noninverting output port Q of flip-flop 241 inputted via inverter 244, and the print completion signal from second input port 215, and then generates a logic signal as shown in FIG. 5D. Up-down counter 220 sets an output value to "600", the preset value of third input port 225, according to the logic signal in a low logic state applied from OR gate 243 to load port LD. While the up-down mode control signal in a high logic state is applied from noninverting output port Q of flip-flop 241 to up-down control port U/D, up-down counter 220 counts a value by decreasing it by " 1" according to the two-divided vertical synchronous signal applied from frequency-divided 210 to clock port CLK, and generates counted values which decrease by "1" from "600" to "0". Down-counter 230 inputs the counted values from up-down counter 220 via input port D whenever a horizontal synchronous signal is applied to load port L/D via fourth input port 235.
Down-counter 230 counts the count values by decreasing it by "1" according to the clock signal applied to clock port CLK via fifth input port 245. When the counted value becomes "0", down-counter 230 generates a write enable signal in a low logic state. The write enable signal generated from down-counter 230 is supplied to line memory 31 shown in FIG. 1 via output port 255. When the count value of up-down counter 220 becomes "600", line memory 31 shown in FIG. 1 inputs data of samples (1, L600), (2, L600), (3, L600), . . . , (525, L600) in FIG. 3 according to the write enable signal from down-counter 230 shown in FIG. 4, and supplies the data to printing portion 60 via controller 50. Then, printing portion 60 prints the L600 column data from line memory 31 inputted via controller 50. When the counted value of up-down counter 220 shown in FIG. 4 becomes "599", line memory 31 shown in FIG. 1 inputs data of samples (1, L599), (2, L599), (3, L599), . . . , (525, L599) of FIG. 3, and printing portion 60 prints the L599 column data. According to the sequence, printing portion 60 prints data until L1 column to complete the printing of another color. As mentioned above, the count mode and initial value of up-down counter 220 can be changed to allow reciprocative printing.
As described above in detail, the present invention is advantageous in preventing paper's curl and dislocation of color by controlling an enable signal of a line memory in a video color printer to allow reciprocative printing.
While the invention has been particularly shown and described with reference 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 spirit and scope of the invention as defined by the appended claims. | A printing control method for a video color printer includes the steps of: changing sampling direction so that a line memory inputs column samples among one frame data of a frame memory whenever printing is completed; sequentially designating one column sample position from left to right or vice versa according to the direction designated in the sampling direction changing step whenever one frame data is read out from said frame memory; and designating the position of unit samples so that said line memory sequentially inputs the column samples designated in the column sample designating step whenever one horizontal scan line data is read out. The method is advantageous in preventing paper's curl and dislocation of color by controlling an enabling signal of the line memory in a video color printer to allow reciprocative printing. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority of Japanese Patent Applications No. 2004-310931 filed on Oct. 26, 2004 and No. 2005-275268 filed on Sep. 22, 2005, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a fluid injection valve suitable for injecting fuel into cylinders of an internal combustion engine (hereinafter referred to just as “engine”).
BACKGROUND OF THE INVENTION
In fuel injection valves for engines, it is important to atomize the fuel injection spray sufficiently from viewpoints of toxic substance reduction in emission gas, fuel consumption performance improvement and so on. U.S. Pat. Nos. 6,405,946-B1, 6,616,072-B2, US-2004-0124279-A1 and their counterpart JP-2001-46919-A disclose fluid injection nozzles for promoting an atomization of the fuel injection spray.
In the fluid injection nozzles disclosed in the above publications, a flat disc-shaped fuel chamber is formed between a valve seat and injection ports. By the fuel chamber provided between the valve seat and the injection ports, fuel, which has flown on an inner circumferential surface of the valve body, passes through an opening portion of the valve body, then forms a spread flow in the fuel chamber. Thus, at the outflow side of the injection ports, it is possible to decrease collisions among fuel spray columns that are injected out of the injection ports.
However, by forming the fuel chamber between the valve seat and the injection ports, a dead volume in the fluid injection nozzle increases. When the dead volume is large, a relatively large amount of fuel is left in the fuel chamber without being injected out of the injection ports. For example, in a case that a fuel injection valve is installed in an intake pipe of an engine, the fuel left in the fuel chamber is sucked by intake air that flows through the intake pipe at a large speed. Thus, a fuel ratio in the intake air increases, and it becomes difficult to control the fuel injection amount with high accuracy.
SUMMARY OF THE INVENTION
The present invention, in view of the above-described issue, has an object to provide a fluid injection valve that can promote an atomization of fluid injection spray and decrease a volume of its fluid chamber.
The fluid injection valve has: a valve body that is provided with an opening portion at one axial end thereof and is for starting and stopping a supply of a fluid out of the opening portion; and an injection port plate having a plurality of injection ports that penetrate therethrough, the injection port plate being fixed on the one axial end of the valve body to form a fluid chamber between itself and the valve body to accumulate the fluid therein and to which at least a part of the injection ports opens. A circumferential surface of the fluid chamber recedes toward the injection ports so as to decrease a cross-sectional area of the fluid chamber that is taken along a radial direction of the injection port plate and to reserve a predetermined length of distance between itself and the injection ports.
BRIEF DESCRIPTION OF THE DRAWINGS
Features and advantages of embodiments will be appreciated, as well as methods of operation and the function of the related parts, from a study of the following detailed description, the appended claims, and the drawings, all of which form a part of this application. In the drawings:
FIG. 1 is a cross-sectional view showing an injection port plate of a fluid injection valve according to a first embodiment of the present invention, which is taken along a line I-I in FIG. 3 ;
FIG. 2 is a cross-sectional view showing the fluid injection valve according to the first embodiment;
FIG. 3 is an enlarged cross-sectional view showing the fluid injection nozzle in the proximity of the injection port plate according to the first embodiment;
FIG. 4 is a further enlarged cross-sectional view showing a range IV in FIG. 4 ;
FIG. 5 is a graph schematically showing a SMD (Sauter mean diameter) variation against an arrangement of a fuel injection port;
FIG. 6A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a second embodiment;
FIG. 6B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the second embodiment, which is taken along a line VIB-VIB in FIG. 6A ;
FIG. 7A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a third embodiment;
FIG. 7B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the third embodiment, which is taken along a line VIIB-VIIB in FIG. 7A ;
FIG. 8A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a first modified example of the third embodiment;
FIG. 8B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the first modified example of the third embodiment, which is taken along a line VIIIB-VIIIB in FIG. 8A ;
FIG. 9A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a second modified example of the third embodiment;
FIG. 9B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the second modified example of the third embodiment, which is taken along a line IXB-IXB in FIG. 9A ;
FIG. 10A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a third modified example of the third embodiment;
FIG. 10B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the third modified example of the third embodiment, which is taken along a line XB-XB in FIG. 10A ;
FIG. 11A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a fourth modified example of the third embodiment;
FIG. 11B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the fourth modified example of the third embodiment, which is taken along a line XIB-XIB in FIG. 11A ;
FIG. 12A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a fifth modified example of the third embodiment;
FIG. 12B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the fifth modified example of the third embodiment, which is taken along a line XIIB-XIIB in FIG. 12A ;
FIG. 13A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a fourth embodiment;
FIG. 13B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the fourth embodiment, which is taken along a line XIIIB-XIIIB in FIG. 13A ;
FIG. 14A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a first modified example of the fourth embodiment;
FIG. 14B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the first modified example of the fourth embodiment, which is taken along a line XIVB-XIVB in FIG. 14A ;
FIG. 15A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a first modified example of the fourth embodiment;
FIG. 15B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the first modified example of the fourth embodiment, which is taken along a line XVB-XVB in FIG. 15A ;
FIG. 16A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a first modified example of the fourth embodiment;
FIG. 16B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the first modified example of the fourth embodiment, which is taken along a line XVIB-XVIB in FIG. 16A ;
FIG. 17A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a fifth embodiment;
FIG. 17B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the fifth embodiment, which is taken along a line XVII-XVII in FIG. 17A ;
FIG. 18A is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to a sixth embodiment;
FIG. 18B is a cross-sectional view showing an injection port plate of the fluid injection valve according to the sixth embodiment, which is taken along a line XVIII-XVIII in FIG. 18A ; and
FIG. 19 is an enlarged cross-sectional view showing a fluid injection nozzle in the proximity of the injection port plate according to another embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
First Embodiment
FIG. 2 depicts a fluid injection valve (hereinafter referred to as injector) 10 according to a first embodiment of the present invention. The injector 10 is for injecting fuel at an intake port of a gasoline engine, that is, for a port fuel injection engine. The injector 10 shown in FIG. 2 is merely an example, and may be modified to have other driving mechanism therein, to be applied to other types of engine, and so on.
The injector 10 has a casing 11 , a magnetic pipe 12 , a fixed core 13 and a driving portion 30 . The casing 11 is a resinous mold that covers the magnetic pipe 12 , the fixed core 13 , the driving portion 30 and so on. At one end portion of the magnetic pipe 12 is installed a nozzle 20 . Between the magnetic pipe 12 and the fixed core 13 is installed a nonmagnetic pipe 14 against a magnetic short circuit. The fixed core 13 and the nonmagnetic pipe 14 , and the nonmagnetic pipe 14 and the magnetic pipe 12 are respectively connected with each other by laser welding and the like. One axial end portion of the fixed core 13 is formed a fuel inflow port 15 . Fuel is supplied from a fuel pump (not shown) to the fuel inflow port 15 of the injector 10 . The fuel supplied to the fuel inflow port 15 flows via a fuel filter 16 into an inner space of the fixed core 13 . The fuel filter 16 is for removing foreign matters contained in the fuel.
The valve body 21 is installed on one end of the magnetic pipe 12 opposite from the fixed core 13 . The valve body 21 is connected with the magnetic pipe 12 by laser welding and the like. As shown in FIG. 3 , the valve body 21 is cylinder-shaped and has an opening portion 22 at its axial end opposite from the fuel inflow port 15 . The valve body 21 has a cone-shaped inner circumferential surface 23 , which is tapered so that its inner diameter gradually decreases as coming closer to the opening portion 22 at its leading end. The valve body 21 further has a valve seat 24 on the cone-shaped inner circumferential surface 23 . On the leading end of the valve body 21 , which is at the side of the opening portion 22 , is installed an injection port plate 40 to cover the leading end portion of the valve body 21 . The Injection port plate 40 has injection ports 41 that penetrate the injection port plate 40 in its thickness direction to communicate its one surface at the side of the valve body 21 with its another surface.
The needle (valve member) 25 is installed on the inner circumferential side of the magnetic pipe 12 and the valve body 21 to be slidable in its axial direction. The needle 25 is aligned approximately coaxial to the valve body 21 . One axial end of the needle 25 , which is opposite from the fuel inflow port 15 , is provided with a seal portion 26 . The seal portion 26 is for coming in contact with a valve seat 24 formed in the valve body 21 . The needle 25 and the valve body 21 form a fuel passage 27 therebetween.
As shown in FIG. 2 , the injector 10 is provided with a driving portion 30 for driving the needle 25 . The driving portion 30 includes a spool 31 , a coil 32 , a fixed core 13 , a magnetic pipe 12 , a plate housing 33 and a movable core 34 . The spool 31 is installed on an outer circumferential side of the magnetic pipe 12 , the fixed core 13 and the nonmagnetic pipe 14 . The spool 31 is cylinder-shaped and made of resin. On outer circumference of the spool 31 is wound the coil 32 . The coil 32 is connected to a terminal portion 36 of a connector 35 . The fixed core 35 is installed on the inner circumferential side of the coil 32 . The fixed core 13 is cylinder-shaped and made of magnetic material such as steel. The plate housing 33 is made of magnetic material and covers an outer circumference of the coil 32 . The plate housing 33 is magnetically connected with the fixed core 13 and the magnetic pipe 12 . The outer circumference of the spool 31 and the coil 32 is covered by the casing 11 , which is integrally formed with the connector 35 .
The movable core 34 is installed inside the fixed core 13 to be slidable in its axial direction. The movable core 34 is cylinder-shaped and made of magnetic material such as steel. One end of the movable core 34 opposite from the fixed core 13 is integrally connected to the needle 25 . Another end of the movable core 34 at the side of the fixed core 13 is in contact with a spring (elastic member) 17 . The spring 17 is in contact with the movable core 34 at one end and with an adjusting pipe 18 at another end. The adjusting pipe 18 is press-fitted in the fixed core 13 .
The spring 17 has a restitutive force to extend in the axial direction. Thus, the spring 17 pushes the movable core 34 and the needle 25 toward the valve body 21 . The load that the spring 17 applies to the movable core 34 and the needle 25 can be modified by adjusting a press-fitting amount of the adjusting pipe 18 press-fitted into the fixed core 17 . When the coil 32 is not energized, the spring 17 pushes the movable core 34 and the needle 25 toward the valve seat 24 , and the seal portion 26 is seated on the valve seat 24 . In the present embodiment, a coil spring is shown as an example of the spring 17 . Alternatively, the spring 17 may be realized by other elastic members such as a leaf spring, an air damper, a fluid damper and so on.
The injector 10 in the proximity to the injection port plate 40 is described in detail in the following.
The injection port plate 40 is disposed on the leading end of the valve body 21 . As shown in FIG. 3 , a spacer 50 is disposed between the valve body 21 and the spacer 50 . The spacer 50 is disc-shaped and interposed between the valve body 21 and the injection port plate 40 . As shown in FIGS. 1 and 3 , the spacer 50 has a fuel chamber opening 51 that open to the combustion chamber of the engine. An inner circumferential surface 50 a of the spacer 50 surrounds the fuel chamber opening 51 . Thus, an end surface 21 a of the valve body 21 at the side of the injection plate 40 , an end surface 40 a of the injection port plate 40 at the side of the valve body 21 and the inner circumferential surface 50 a of the spacer 50 define a space for a fuel chamber 52 . The fuel chamber 52 is provided between the opening portion 22 of the valve body 21 and the injection ports 41 of the injection port plate 40 . At least a part of the fuel chamber 52 overlaps with the opening portion 22 of the valve body 21 . Thus, the fuel that has passed through the opening portion 22 of the valve body 21 flows via the fuel chamber 52 into the injection ports 41 .
As described above, the inner circumferential surface 50 a of the spacer 50 forms a perimeter of the fuel chamber 52 . Thus, a shape of the fuel chamber opening 51 and the inner circumferential face 50 a of the spacer 50 determine a cross-sectional shape of the fuel chamber 51 . In the first embodiment, the injection ports 41 formed on the injection port plate 40 are aligned on two coaxially disposed fictive circle lines as shown in FIG. 1 . The injection ports 41 include four inner injection ports 411 a - 411 d , which are aligned on the inner fictive circle line, and eight outer injection ports 412 a - 412 h , which are aligned on the outer fictive circle line. The four inner injection ports 411 a - 411 d and the eight outer injection ports 412 a - 412 h are respectively disposed at a regular intervals on the fictive circle lines. One ends of the injection ports 41 open to the fuel chamber 52 . Alternatively, the injection ports 41 may be aligned at irregular intervals in a circumferential direction of the injection port plate 40 .
The inner circumferential surface 50 a of the spacer 50 , which forms the fuel chamber 52 , is at a specific distance from fuel inflow side openings of the outer injection ports 412 a - 412 h . Here, the fuel inflow side openings of the outer injection ports 412 a - 412 h are ends of them at the side of the fuel chamber 52 . As shown in FIG. 4 , distances from the fuel inflow side openings of the outer injection ports 412 a - 412 h and the inner circumferential surface 50 a of the spacer 50 are set to satisfy a relation of d 2 /d 1 ≧1, in which d 1 denotes inner diameters of the fuel inflow side openings of the outer injection ports 412 a - 42 h , and d 2 denotes distances from the outer injection ports 412 a - 412 h to the inner circumferential surface 50 a of the spacer 50 . As shown in FIG. 5 , as d 2 /d 1 decreases, distances from the fuel inflow side openings of the outer injection ports 412 a - 412 h to the inner circumferential surface 50 a of the spacer 50 become smaller. Then, the fuel that is not so highly turbulent in the fuel chamber 52 flows into the outer injection ports 412 a - 412 h . Accordingly, the atomization performance of the fuel is spoiled, and a Sauter outer diameter (SMD) variation ratio increases. The relation of d 2 /d 1 ≧1 is a measure against this issue.
The SMD is a value to indicate an average diameter of a fuel injection spray, and the SMD variation ratio, which is shown in FIG. 5 , is a value to indicate a variation ratio of the average diameter of the fuel injection spray. An increase of the SMD variation ratio means an increase of the average diameter of the fuel injection spray. In the present embodiment, the SMD variation ratio of 1% or smaller is accepted to secure an atomization performance of the fuel. Accordingly, a minimum threshold of d 2 /d 1 is set to 1, which corresponds to the SMD variation ratio of 1%. When d 2 /d 1 is 3 or larger, the SMD variation ratio is 0.5% or smaller. Accordingly, it is further desirable that d 2 /d 1 is 3 or larger to secure the atomization performance of the fuel further.
The distances between the outer injection ports 412 a - 412 h and the inner circumferential surface 50 a of the spacer 50 are set as described above. Thus, as shown in FIG. 1 , the inner circumferential surface 50 a of the spacer 50 may be disposed between the outer injection ports 412 a - 412 h in the circumferential direction as long as the relation of d 2 /d 1 ≧1 is satisfied. In the alignment of the injection ports 41 on the injection port plate 40 as shown in FIG. 1 , a part of the inner circumferential surface 40 a of the spacer 40 , which forms the fuel chamber 52 , juts radially inward at the intervals between the outer injection ports 412 a - 412 h . In this case, the fuel inflow side openings of the outer injection ports 412 a - 412 h and the inner circumferential surface 50 a of the spacer 50 satisfy the relation of d 2 /d 1 ≧1. The inner circumferential surface 50 a of the spacer 50 juts from the intervals between the outer injection ports 412 a - 412 h toward the inner injection ports 411 a - 411 d.
By the inner circumferential surface 50 a of the spacer 50 that juts radially inward, an entire volume of the fuel chamber 52 decreases, and a dead volume in the fuel chamber 52 decreases. If the inner circumferential surface 50 a of the spacer 50 does not juts radially inward, d 2 /d 1 is excessively large at the intervals between the outer injection ports 412 a - 412 h . As shown in FIG. 5 , even when d 2 /d 1 is excessively large, a turbulence degree of the fuel flowing into the outer injection ports 412 a - 412 h , and the atomization performance of the fuel injected out of the outer injection ports 412 a - 412 h are not improved so much. Thus, if the inner circumferential surface 50 a of the spacer 50 does not juts radially inward, the fuel chamber 52 is regarded as including a dead volume at the intervals between the outer injection ports 412 a - 412 h that does not serve the atomization performance. Correspondingly, in the first embodiment, the inner circumferential surface 50 a of the spacer 50 that juts radially inward decreases the dead volume not serving the atomization performance. Accordingly, a fuel amount left in the fuel chamber 52 decreases. The fuel chamber 72 is formed only at the periphery of the outer injection ports 732 a - 732 h , so that a dead volume in the injector 10 decreases, and the fuel sucked into the intake air decreases, so that it is possible to limit an air-fuel ratio variation of the intake air.
An operation of the injector 10 having the above-described construction is described in the following.
When the coil 32 is not energized, the fixed core 13 and movable core 34 generate no electromagnetic attraction force therebetween. Thus, the restitutive force of the spring 17 pushes the movable core 34 and the needle 25 away from the fixed core 13 . Accordingly, when the coil 32 is not energized, the seal portion 26 of the needle 25 is seated on the valve seat 24 and no fuel is injected out of the injection ports 41 .
When the coil 32 is energized, a magnetic field generated by the coil 32 forms a magnetic circuit in the plate housing 33 , the magnetic pipe 12 , the movable core 34 and the fixed core 13 . Thus, the fixed core 13 and the movable core 34 generate electromagnetic attraction force therebetween. When the electromagnetic attraction force generated between the fixed core 13 and the movable core 34 exceeds the restitutive force of the spring 17 , an integrated body of the movable core 34 and the needle 25 moves toward the fixed core 13 . Accordingly, the seal portion 26 of the needle 25 lifts off the valve seat 24 .
As shown in FIG. 2 , the fuel that has entered the injector 10 through the fuel inflow port 15 flows via the fuel filter 16 , an inside of the fixed core 13 , an inside of the movable core 34 , a clearance formed between the movable core 34 and the needle 25 , an inside of the magnetic pipe 12 and the fuel port 191 of the stopper 19 into a fuel passage 27 . The fuel in the fuel passage 27 further flow via a gap between the valve seat 24 and the seal portion 26 , and the fuel chamber 52 into the injection ports 41 . Thus, the fuel is injected out of the injection port 52 .
When the power supply to the coil 32 is interrupted again, the electromagnetic attraction force between the fixed core 13 and movable core 34 vanishes. Thus, the restitutive force of the spring 17 pushes the integrated body of the movable core 34 and the needle 25 away from the fixed core 13 . Accordingly, the seal portion 26 of the needle 25 is seated on the valve seat 24 again to interrupt the fuel flow between the fuel passage 27 and the fuel chamber 52 , and the fuel injection stops.
In the first embodiment, the inner circumferential surface 50 a of the spacer 50 juts radially inward, that is, toward the inner injection ports 411 a - 411 d , so that a dead volume of the fuel chamber 52 at the periphery of the outer injection ports 412 a - 412 h decreases. Thus, after the injection of a regulated amount of fuel, the fuel amount left in the fuel chamber 52 is decreased. As a result, the fuel amount sucked into the intake air decreases, and an air-fuel ratio variation of the intake air is limited. Further, by keeping the relation of d 2 /d 1 ≧1, the spiral flow inertia of the fuel flowing into the outer injection ports 412 a - 412 h is kept. Accordingly, it is possible to secure a fuel atomization performance and to decrease the dead volume in the combustion chamber 52 .
Further, in the first embodiment, the shape of the fuel chamber opening 51 can be changed by replacing the spacer 50 with another one. Thus, fuel atomization property of the fuel injected out of the injection ports 41 can be adjusted by replacing the spacer 50 .
Second Embodiment
FIGS. 6A and 6B depict a nozzle 20 of the injector 10 according to a second embodiment of the present invention. In the second embodiment, components that are substantially equivalent to those in the first embodiment are assigned reference numerals in common with each other not especially described in the following.
In the first embodiment is disclosed an example in which the spacer 50 having the fuel chamber opening 51 is disposed between the valve body 21 and the injection port plate 40 to provide the fuel chamber 52 between the valve body 21 and the injection port plate 40 .
Correspondingly, as shown in FIGS. 6A and 6B , the valve body 21 in the second embodiment is provided with a recess 28 to provide the fuel chamber 62 . The recess 28 has a shape equivalent to that of the fuel chamber opening 51 of the spacer 50 in the first embodiment. Thus, the fuel chamber 62 is formed by attaching the injection port plate 40 on the leading end of the valve body 21 . As a result, an inner circumferential surface 21 b of the valve body 21 determines an outer perimeter of the fuel chamber 62 . Accordingly, the spacer 50 is not necessary in the second embodiment, and the number of parts of the injector 10 is decreased.
Third Embodiment
FIGS. 7A and 7B depict a nozzle 20 of the injector 10 according to a third embodiment of the present invention. In the third embodiment, components that are substantially equivalent to those in the first embodiment are assigned reference numerals in common with each other not especially described in the following.
In the third embodiment, a recess 71 is formed on the injection port plate 70 in contrast to the second embodiment in which the recess 28 is formed on the valve body 21 . The recess 71 of the injection port plate 70 and the valve body 21 provides a fuel chamber 72 therebetween. As shown in FIG. 7B , the injection port plate 70 has a plurality of injection ports 73 . Specifically, the injection ports 73 include inner injection ports 731 a - 731 d and outer injection ports 732 a - 732 h , which are aligned on two coaxially disposed fictive circle lines. The recess 71 is defined by inner and outer circumferential wall surfaces 71 a , 71 b , which are coaxially disposed to the fictive circle lines on which the inner injection ports 731 a - 731 d and the outer injection ports 732 a - 732 h are aligned. Thus, the recess 71 is ring-shaped on the injection port plate 70 at the side of the valve body 21 .
In the third embodiment, the outer injection ports 732 a - 732 h are communicated with the fuel chamber 72 at their fuel inflow side openings. A distance from the outer injection ports 732 a - 732 h to the outer and inner circumferential wall surfaces 71 a , 71 b of the recess 71 of the injection port plate 70 satisfies the relation of d 2 /d 1 ≧1, in which d 1 denotes inner diameters of the fuel inflow side openings of the outer injection ports 732 a - 732 h , and d 2 denotes a distance from the fuel inflow side openings of the outer injection ports 732 a - 732 h to the outer or inner circumferential wall surfaces 71 a , 71 b . Thus, the fuel that has passed through the opening portion 22 of the valve body 21 forms a highly turbulent flow, then flows into each of the outer injection ports 732 a - 732 h.
The spiral fuel flow along a cone-shaped inner circumferential surface 23 of the valve body 21 , which has the opening portion 22 at its leading end, directly flows into the inner injection ports 731 a - 731 d . A distance from the fuel inflow side openings of the inner injection ports 731 a - 731 d to the inner circumferential wall 23 of the valve body 21 , which provides the opening portion 22 is enough to flow highly turbulent fuel into the inner injection ports 731 a - 731 d.
In the third embodiment, the outer injection ports 732 a - 732 h and the outer and inner circumferential wall surfaces 71 a , 71 b of the recess 71 of the injection port plate 70 satisfies the relation of d 2 /d 1 ≧1 as described above. Thus, highly turbulent fuel flows into each of the outer injection ports 732 a - 732 h . Accordingly, an enough fuel atomization performance is secured.
Further, in the third embodiment, fuel inflow side openings of the inner injection ports 731 a - 731 d open on the surface of the injection port plate 70 directly to the opening portion 22 of the valve body 21 . That is, the inner injection ports 731 a - 731 d are not adjacent to the fuel chamber 72 . The fuel chamber 72 is formed only at the periphery of the outer injection ports 732 a - 732 h , so that a dead volume in the injector 10 decreases, and the fuel left in the fuel chamber 72 also decreases.
Modified Examples of Third Embodiment
Modified examples of the third embodiment are described in the following. In these modified examples, components that are substantially equivalent to those in the third embodiment are assigned reference numerals in common with each other not especially described.
In a first modified example of the third embodiment shown in FIGS. 8A and 8B , the injection port plate 70 may have no injection port at a projection 700 radially inside of the fuel chamber 72 . In this case, the fuel that has passed through the opening portion 22 flows into the fuel chamber 72 formed by the recess 71 radially outside of the projection 700 .
In a second modified example of the third embodiment shown in FIGS. 9A and 9B , the injection port plate 70 is composed of a first injection port plate 710 and a second injection port plate 720 . The first injection port plate 710 has a flat ring shape. The first injection port plate 710 is integrally formed with the projection 700 , which is disposed at the center of the first injection port plate 710 . Specifically, two beams 713 connect the projection 700 at both sides thereof with the injection port plate 710 . The second injection port plate 720 also has a flat ring shape, and is fixed on the first injection port plate 720 at a side opposite from the valve body 21 . By fixing the second injection port plate 720 on the first injection port plate 710 , the projection 700 protrudes from the second injection port plate 720 to face the opening portion 22 of the valve body 21 , and the fuel chamber 72 is formed around the projection 700 . The outer injection ports 732 a - 732 h open to the fuel chamber 72 . The inner circumferential side surface of the first injection port plate 710 forms an outer circumferential wall surface 711 , that is, an outer perimeter of the fuel chamber 72 . The outer circumferential side surface of the projection 700 forms an inner circumferential wall surface 712 , or an inner perimeter of the fuel chamber 72 . On the projection 700 are formed the inner injection ports 731 a - 731 d.
In a third modified example of the third embodiment shown in FIGS. 10A and 10B , the second injection port plate 720 of the injection port plate 70 has a flat disc shape. The first injection port plate 710 has a construction approximately as that in the second modified example except for being provided with no inner injection port on the projection 700 .
In a fourth modified example of the third embodiment shown in FIGS. 11A and 11B , the first injection port plate 710 is not provided with the beams 713 in the second modified example. Similarly, in a fifth modified example of the third embodiment shown in FIGS. 12A and 12B , the first injection port plate 710 is not provided with the beams 713 in the third modified example. In the second and third modified examples shown in FIGS. 9A , 9 B, 10 A and 10 B, the projection 700 is integrally formed with the first injection port plate 710 , so that it is possible to handle with the first and second injection port plates 710 , 720 separately until they are fixed on the valve body 21 . Correspondingly, in the fourth and fifth embodiments shown in FIGS. 11A , 11 B, 12 A and 12 B, the projection 700 is separated from the first injection port plate 710 , so that the first injection port plate 710 and the projection 700 are fixed on the second injection port plate 720 , then they are fixed on the valve body 21 .
Fourth Embodiment
FIGS. 13A and 13B depict a nozzle 20 of the injector 10 according to a third embodiment of the present invention. In the fourth embodiment, components that are substantially equivalent to those in the third embodiment are assigned reference numerals in common with each other not especially described in the following.
In the fourth embodiment, recesses 71 ( 71 a - 71 d ) are formed on the injection port plate 70 to provide fuel chambers 72 ( 72 a - 72 d ) in an analogous way to the third embodiment. As shown in FIG. 13B , the injection port plate 70 has inner injection ports 731 a - 731 d and outer injection ports 732 a - 732 h , which are aligned on two coaxially disposed fictive circle lines. The fuel inflow side openings of the inner injection ports 731 a - 731 d open on the surface of the injection port plate 70 directly to the opening portion 22 of the valve body 21 as in the third embodiment.
In the fourth embodiment, the injection port plate 70 has four recesses 71 ( 71 a - 71 d ). The fuel inflow side openings of the outer injection ports 732 a - 732 h open to the recesses 71 of the injection port plate 70 to be communicated with the fuel chambers 72 . Every two of the eight outer injection ports 732 a - 732 h constitute one injection port group. Specifically, the outer injection ports 732 a , 732 h constitute an injection port group 74 A, the outer injection ports 732 b , 732 c constitute an injection port group 74 B, the outer injection ports 732 d , 732 e constitute an injection port group 74 C, and the outer injection ports 732 f , 732 g constitutes an injection port group 74 D. Thus, the eight outer injection ports 732 a - 732 h constitute four injection port groups 74 A- 74 D.
The injection port plate 70 has four recesses 71 a - 71 d that respectively correspond to the four injection port groups 74 A- 74 D. That is, the outer injection ports 732 a , 732 h open to the recess 71 a , the outer injection ports 732 b , 732 c open to the recess 71 b , the outer injection ports 732 d , 732 e open to the recess 71 c , and the outer injection ports 732 f , 732 g open to the recess 71 d . Accordingly, four fuel chambers 72 a - 72 d are formed between the injection port plate 70 and the valve body 21 . As a result, the fuel chambers 72 a - 72 d are provided respectively to the injection port groups 74 A- 74 D that are composed of a plurality of the outer injection ports ( 732 a , 732 h ), ( 732 b , 732 c ), ( 732 d , 732 e ), ( 732 f , 732 g ).
Inner circumferential wall surfaces 75 a - 75 d of the injection port plate 70 define the peripheries of the fuel chambers 72 a - 72 d . The correspondence between the outer injection ports 732 a - 732 h and the inner circumferential wall surfaces 75 a - 75 d are as described above. Distances from the outer injection ports 732 a - 732 h to the inner circumferential wall surfaces 75 a - 75 d of the recesses 71 a - 71 d of the injection port plate 70 satisfies the relation of d 2 /d 1 ≧1, in which d 1 denotes inner diameters of the fuel inflow side openings of the outer injection ports 732 a - 732 h communicated with the fuel chambers 72 a - 72 d , and d 2 denotes distances from the fuel inflow side openings of the outer injection ports 732 a - 732 h to the inner circumferential wall surfaces 75 a - 75 d.
In the fourth embodiment, each of the injection port groups 74 A- 74 D is provided with the fuel chamber 72 a - 72 d , and no fuel chamber is formed at the intervals between the injection port groups 74 A- 74 D. Thus, a dead volume formed at the intervals between every adjacent two of the injection port groups 74 A- 74 D. Accordingly, it is possible to decrease a fuel amount left in the fuel chambers 72 a - 72 d.
Modified Examples of Fourth Embodiment
Modified examples of the fourth embodiment are described in the following. In these modified examples, components that are substantially equivalent to those in the fourth embodiment are assigned reference numerals in common with each other not especially described.
In a first modified example of the fourth embodiment shown in FIGS. 14A and 14B , the injection port plate 70 may have no injection port at a projection 700 surrounded by the fuel chambers 72 ( 72 a - 72 d ). In this case, the fuel that has passed through the opening portion 22 flows into the fuel chambers 72 ( 72 a - 72 d ) formed by the recesses 71 ( 71 A- 71 D).
In a second modified example of the fourth embodiment shown in FIGS. 15 A and 15 B, the injection port plate 70 is composed of a first injection port plate 710 and a second injection port plate 720 . The first injection port plate 710 has four opening portions 710 a - 710 d respectively in accordance with the fuel chambers 72 a - 72 d . By fixing the second injection port plate 720 on a surface of the first injection port plate 710 opposite from the valve body 21 , the recesses 71 ( 71 A- 71 D) are formed between the valve body 21 , the first injection port plate 70 and the second injection port plate 720 . In the second modified embodiment shown in FIGS, the projection 700 is provided with no injection port (the inner injection port). Correspondingly, in the third modified example of the fourth embodiment shown in FIGS. 16A and 16B , the second injection port plate 720 has a flat ring shape, so that the projection 700 of the first injection port plate 710 are formed the injection ports, that is, the inner injection ports 731 a - 731 d.
Fifth Embodiment
FIGS. 17A and 17B depict a nozzle 20 of the injector 10 according to a fifth embodiment of the present invention. In the fifth embodiment, components that are substantially equivalent to those in the first embodiment are assigned reference numerals in common with each other not especially described in the following.
In the fifth embodiment, recesses 81 ( 81 a - 81 d ) are formed on the injection port plate 80 to provide fuel chambers 82 ( 82 a - 82 d ) in an analogous way to the third embodiment. The injection port plate 70 has a plurality of injection ports 83 . Specifically, the injection ports 893 include inner injection ports 831 a - 831 d and outer injection ports 832 a - 832 h , which are aligned on two coaxially disposed fictive circle lines as shown in FIG. 17B .
In the fifth embodiment, the injection port plate 80 has four recesses 81 ( 81 a - 81 d ). Three injection ports including one of the four inner injection ports 831 a - 831 d and two of the eight outer injection ports 832 a - 832 h constitute one injection port group. Specifically, the inner injection port 831 a and the outer injection ports 832 a , 832 h constitute an injection port group 84 A, the inner injection port 831 b and the outer injection ports 832 b , 832 c constitute an injection port group 84 B, the inner injection port 831 c and the outer injection ports 832 d , 832 e constitute an injection port group 84 C, and the inner injection port 831 d and the outer injection ports 832 f , 832 g constitute an injection port group 84 D. Thus, the four inner injection ports 831 a - 831 d and the eight outer injection ports 832 a - 832 h constitute four injection port groups 84 A- 84 D.
The injection port plate 80 has four recesses 81 a - 81 d that respectively correspond to the four injection port groups 84 A- 84 D. That is, the inner injection port 831 a and the outer injection ports 832 a , 832 h open to the recess 81 a , the inner injection port 831 b and the outer injection ports 832 b , 832 c open to the recess 81 b , the inner injection port 831 c and the outer injection ports 832 d , 832 e open to the recess 81 c , and the inner injection port 831 d and the outer injection ports 832 f , 832 g open to the recess 81 d . Accordingly, four fuel chambers 82 a - 82 d are formed between the injection port plate 80 and the valve body 21 . As a result, the fuel chambers 82 a - 82 d are provided respectively to the injection port groups 84 A- 84 D that are composed of a plurality of the inner and outer injection ports ( 831 a , 832 a , 832 h ), ( 831 b , 832 b , 832 c ), ( 831 c , 832 d , 832 e ), ( 831 d , 832 f , 832 g ).
The correspondence between the inner and outer injection ports 831 a - 831 d , 832 a - 832 h and the inner circumferential wall surfaces 85 a - 85 d , which define the peripheries of the fuel chambers 82 a - 82 d , are as described above. Distances from the inner and outer injection ports 831 a - 831 d , 832 a - 832 h to the inner circumferential wall surfaces 85 a - 85 d of the recesses 81 a - 81 d of the injection port plate 80 satisfies the relation of d 2 /d 1 ≧1, in which d 1 denotes inner diameters of the fuel inflow side openings of the inner and outer injection ports 831 a - 831 d , 832 a - 832 h communicated with the fuel chambers 82 a - 82 d , and d 2 denotes distances from the fuel inflow side openings of the inner and outer injection ports 831 a - 831 d , 832 a - 832 h to the inner circumferential wall surfaces 85 a - 85 d.
In the fifth embodiment, each of the injection port groups 84 A- 84 D is provided with the fuel chamber 82 a - 82 d , and no fuel chamber is formed at the intervals between the injection port groups 84 A- 84 D, which include not only the outer injection ports 832 a - 832 h but also the inner injection ports 831 a - 831 d . Thus, a dead volume formed at the intervals between every adjacent two of the injection port groups 84 A- 84 D. Accordingly, it is possible to decrease a fuel amount left in the fuel chambers 82 a - 82 d.
Sixth Embodiment
FIGS. 18A and 18B depict a nozzle 20 of the injector 10 according to a sixth embodiment of the present invention. In the sixth embodiment, components that are substantially equivalent to those in the first embodiment are assigned reference numerals in common with each other not especially described in the following.
In the sixth embodiment, recesses 91 ( 91 a - 91 d ) are formed on the injection port plate 90 to provide fuel chambers 92 ( 92 a - 92 d ) in an analogous way to the third embodiment. As shown in FIG. 18B , the injection port plate 90 has injection ports 93 a - 93 d , which are aligned on a fictive circle line.
In the sixth embodiment, the injection port plate 90 has four recesses 91 a - 91 d that respectively correspond to the four injection ports 93 a - 93 d . That is, the injection port 93 a opens to the recess 91 a , the injection port 93 b opens to the recess 91 b , the injection port 93 c opens to the recess 91 c , and the injection port 93 d opens to the recess 91 d . Accordingly, four fuel chambers 92 a - 92 d are formed between the injection port plate 90 and the valve body 21 . As a result, the fuel chambers 92 a - 92 d are provided respectively to the injection ports 93 a - 93 d . The correspondence between the injection ports 93 a - 93 d and the inner circumferential wall surfaces 95 a - 95 d , which define the peripheries of the fuel chambers 92 a - 92 d , are as described above. Distances from the injection ports 93 a - 93 d to the inner circumferential wall surfaces 95 a - 95 d of the recesses 91 a - 91 d of the injection port plate 90 satisfies the relation of d 2 /d 1 ≧1, in which d 1 denotes inner diameters of the fuel inflow side openings of the injection ports 93 a - 93 d communicated with the fuel chambers 92 a - 92 d , and d 2 denotes distances from the fuel inflow side openings of the injection ports 93 a - 93 d to the inner circumferential wall surfaces 95 a - 95 d.
In the sixth embodiment, each of the injection ports 93 a - 93 d is provided with the fuel chamber 92 a - 92 d , and no fuel chamber is formed at the intervals between the injection ports 93 a - 93 d . Thus, a dead volume formed at the intervals between every adjacent two injection ports 93 a - 93 d . Thus, a dead volume formed at the intervals between every adjacent two injection ports 93 a - 93 d . Accordingly, it is possible to decrease a fuel amount left in the fuel chambers 92 a - 92 d.
Other Embodiments
In the above-described embodiments are described constructions in which any one of flat plate-shaped spacer 50 and an injection port plate 40 , 70 , 80 , 90 is attached on the leading end of the valve body 21 . Alternatively, as shown in FIG. 19 , the injector may have a construction in which the leading end of the valve body 21 is capped with an approximately cup-shaped injection port plate 100 that has a cylindrical portion 101 and bottom portion 102 on which injection ports 41 are formed.
This 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 fluid injection valve has: a valve body that is provided with an opening portion at one axial end thereof and is for starting and stopping a supply of a fluid out of the opening portion; and an injection port plate having a plurality of injection ports that penetrate therethrough, the injection port plate being fixed on the one axial end of the valve body to form a fluid chamber between itself and the valve body to accumulate the fluid therein and to which at least a part of the injection ports opens. A circumferential surface of the fluid chamber recedes toward the injection ports so as to decrease a cross-sectional area of the fluid chamber that is taken along a radial direction of the injection port plate and to reserve a predetermined length of distance between itself and the injection ports. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a semiconductor device fabrication process and more particularly to an evaluation method of a resist coating in a semiconductor lithography process.
Currently, optical lithography technology using a reduction projection exposure apparatus is employed in the fabrication process of semiconductor devices or the like.
Optical lithography mainly comprises the steps of resist application, exposure, development and baking. The resist application step is particularly important. A well-controlled formation of fine patterns by optical lithography requires a uniformly applied Spin Coat of a resist on a substrate surface.
FIG. 6(a) is a perspective view of a prior art method for applying a resist and FIG. 6(b) is a sectional view of a resist applied on a semiconductor substrate.
In a manner shown in FIG. 6(a), resist 101 is dropped from a nozzle 102 onto a semiconductor substrate (a wafer) 100, and the semiconductor substrate 100 is revolved by means of a spinner. Thereby, a uniformly applied spin coat can be obtained on the semiconductor substrate for a simple case. However, if a semiconductor substrate has thereon a ridge 103 (such as wiring, as shown in the example of FIG. 6(b)), resist locally accumulates at a particular region neighboring ridge 103 depending on the spinner revolution speed and the resist viscosity or the like. This local accumulation results in a non-uniform coat over the ridge. In FIG. 6(a) and (b), an arrow A indicates a flow direction of resist and another arrow S indicates a revolution direction.
In preparation for the subsequent pattern exposure step, the semiconductor substrate 100 is aligned with a photomask (omitted from the drawing) which is to be placed on the substrate. The alignment mark on the substrate 100 is optically detected and, in response, an electric signal is generated. The above alignment is conducted in accordance with the electric signal, so that the photomask and substrate 100 are accurately positioned relative to each other. Then, the resist is exposed and developed selectively to form a pattern of resist 101.
If the aforementioned non-uniform coat takes place and is subject to these pattern exposure steps, the non-uniform coat lowers the alignment accuracy between the photomask and substrate 100. This insufficient alignment accuracy results in an insufficient dimensional accuracy of a formed resist pattern. FIG. 7(a) and (b) show an undesirable example, in which resist 101 is non-uniformly applied over a ridge (i.e. an alignment mark 103A), and a detection signal wave form 104 is asymmetrically deformed. Therefore, the non-uniform coat of FIG. 7(a) causes an erroneous detection of the alignment mark and, accordingly, an undesirable deviation 105 in positioning a photomask over the substrate.
On the basis of this background, there is a need for the resist coating method to be optimized in order to prevent a non-uniform resist coating over a ridge from occurring. However, there are no satisfactory methods hitherto to evaluate quantitatively an applied resist coating. With respect to the prior art methods to evaluate the uniformity of resist applied on a semiconductor substrate, one method employs thickness measurement making use of an optical interference, and another method employs a mechanical means to bring a small needle in contact with a semiconductor substrate and to scan it. The former method has a drawback that the location of the measurement point is limited within a scope of an object lens of a microscope, which does not allow a measurement of a resist thickness difference between the ridge top and the depression to be measured. Thus, the accurate evaluation of the resist coat non-uniformity is interrupted. The latter method has a drawback that a finite diameter of a needle end used for the ridge measurement makes it impracticable to measure resist film thicknesses at the ridge top and the depression of the fine pattern. Moreover, the contact type arrangement is likely to damage the resist.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an accurate method for quantitatively evaluating non-uniformity between a ridge top and a depression of a resist coating.
In accordance with the present invention, there is provided a method for evaluating a resist coating comprising the steps of:
forming a first layer resist pattern including an alignment mark by applying a first resist on a semiconductor substrate and by exposing and developing said first resist, said first layer resist pattern having a ridge portion;
irradiating said first layer resist pattern with a deep ultraviolet ray;
applying, onto said irradiated first layer resist pattern, a second resist having substantially the same refractive index as said first resist to form a second resist coating;
detecting said alignment mark formed in said first layer resist pattern, and relatively positioning a pattern for said second resist and first layer resist pattern; and
determining non-uniformity characteristics of said second resist coating by measuring an overlay accuracy between said first layer resist pattern and said pattern for said second resist.
The present invention ensures a quantitative evaluation in a non-contact manner for non-uniformity of resist coating, and enables a resist coating method to be optimized.
First, a resist coating formed under a certain condition is evaluated in accordance with the present invention and a corresponding evaluation result is obtained. In view of the obtained result, some changes are made in the resist viscosity, the revolutions per unit time of the semiconductor substrate at the time of resist application and the resist dropping method, so that the non-uniformity of the resist coating is rectified. After such changes are made the next resist coating is conducted and the non-uniformity of the coating is evaluated in accordance with the present invention. These operations are repeated and thus the optimization of the resist coating method is precisely achieved.
Consequently, the resist uniformity is improved and no resist pattern dimensional error occurs after the exposure step due to the non-uniform thickness of the resist coating surface at a location of an underlying ridge. At the same time, the resist coating method, optimized through a series of evaluations and rectifications in accordance with the present invention, excludes an occurrence of misalignment between the overlaid pattern and the underlying pattern resulting from the non-uniformity of the resist coating.
Thus a use of a method of the present invention ensures an improvement in the line width accuracy (the pattern accuracy) and the overlay accuracy and an improvement in the integration of a semiconductor integrated circuit.
In a preferred embodiment of the aforementioned method of the present invention, the steps after the second resist applying step may comprise:
determining non-uniformity characteristics of the second resist coating by irradiating the alignment mark in the first layer resist pattern with a coherent ray and by detecting a reflected ray from the alignment mark, or alternatively may comprise:
forming a second layer resist pattern by detecting the alignment mark formed in the first layer resist pattern, by relatively positioning a pattern for the second resist and the first layer resist pattern and by exposing and developing the second resist; and
determining non-uniformity characteristics of the second resist coating by measuring a misalignment between the first layer resist pattern and the second layer resist pattern.
In another exemplary embodiment, prior to and subsequent to the steps of applying the second resist, position detections may be performed with respect to the alignment mark in the first layer resist pattern; and
the steps of determining non-uniformity characteristics of the second resist coating may be carried out by measuring changes in at least one of wafer scaling, orthogonality and wafer rotation of the semiconductor substrate.
The steps of forming the second layer resist pattern may include relative positioning of the first layer resist pattern and the pattern for the second resist making use of two rays' interference.
The method may comprise, in replacement of the deep ultraviolet ray irradiating step, a step of baking the first layer resist patten by means of a hot plate.
The difference in the refractive index between the first resist and the second resist is preferably at most 0.1.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described by way of example only, in conjunction with the attached drawings in which:
FIGS. 1(a)-1(f) are explanatory views showing the steps of a method of the present invention for evaluating the non-uniformity of a resist coating;
FIG. 2 is a flow chart showing a procedure to optimize a resist coating method;
FIGS. 3(a) and 3(b) are explanatory views of the principle underlying a method of the present invention for evaluating the non-uniformity of a resist coating;
FIGS. 4a and 4b illustrate a schematic view of an optical system for alignment employable in an exposure apparatus which is capable of practicing an evaluation of a non-uniform resist coating in accordance with the present invention;
FIGS. 5(a) and 5(b) are graphs showing results of resist coating non-uniformity evaluations conducted in accordance with the present invention; and
FIGS. 6(a), 6(b), 7(a) and 7(b) are explanatory views of a prior art method of resist coating accompanied with the problem of non-uniformity.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1(a)-1(f) show steps of an embodiment of a method according to the present invention for evaluating a non-uniformity of the resist coating.
As shown in FIG. 1(a), the first photoresist of novolak is applied by spin coat on a semiconductor substrate with a coating thickness being from 0.5 μm to 1.5 μm. The first resist is then prebaked for about 90 seconds by means of a hot plate. The first photoresist is next selectively exposed using a reduction projection wafer stepper with a photomask having the first pattern. The reference 2A is a masked region, the numeral 3 is an exposed resist region, and the numeral 4 is an unexposed resist region.
After this exposure, the resist is developed and the first layer resist pattern 5 is formed as shown in FIG. 1(b). At this step, an arrangement shall be made so that a part of the resist forms an alignment grating 6.
The entire surface of the first layer resist pattern 5 is irradiated with a deep ultraviolet ray (DUV) 7 as shown in FIG. 1(c), so that the surface of the first layer resist pattern 5 is cured and no mixing occurs later between the first layer resist and a resist subsequently coated thereon.
Thereafter, a resist having substantially the same refractive index or a difference not greater than 0.1 as the first layer resist is applied on the first layer resist pattern 5. That is, the second photoresist 8 of the same material as the first is applied and prebaked as shown in FIG. 1(d). The numeral 80 is a portion of the resist 8 which is to be subjected to a measurement for non-uniformity of the resist coating. At this moment, the first layer resist pattern has been irradiated with DUV and the surface thereof has been cured, and therefore the second resist 8 does not mix with the underlying first layer resist pattern.
Then, the wafer alignment method using two rays' interference is used and the relative position adjustment is completed between the two rays' interference fringe 9 and the wafer alignment grating 6 formed in the first layer.
The above mentioned interference fringe 9 is accurately aligned with the alignment grating 24 of the photomask 10 as illustrated in FIG. 4(a). Accordingly the position of the interference fringe 9 correctly represents the position of photomask 10. Thus, the alignment between the interference fringe 9 and grating 6 formed at a part of the first layer resist pattern 5 has the same effect as the alignment between photomask 10 and the substrate 1.
With the photomask 10 having the second pattern and having been aligned in this manner, the second resist 8 on the first layer resist pattern is then exposed and developed as shown in FIG. 1(e)) so that the second layer resist pattern 12 is formed. During this step the first layer resist pattern 5 and the grating 6 are not dissolved by the exposure and the development, because the resist pattern 5 and the grating 6 have been irradiated with DUV.
Thereafter, the misalignment is measured between the first layer resist pattern 5 and the second layer resist pattern 12. For this purpose, the deviation between the center of the depression of the first layer resist pattern 5 and the center of the second layer resist pattern 12 are measured in terms of (X 1 -X 2 )/2. This measurement enables a non-uniformity of a resist coating over a ridge to be quantitatively determined.
FIG. 2 shows a procedure to optimize a method to provide a uniform resist coating, which comprises the steps of preparing a sample material, applying the resist, aligning and exposing the resist, measuring the misalignment, and optimizing the resist applying condition. In a manner shown in FIGS. 1(a)-1(f), the uniformity of the resist coating is evaluated, and if the result shows the resist coating to be non-uniform then the resist coating condition (including the number of revolutions for coating, the dispense volume and the viscosity) is changed so that the resist coating method is optimized.
FIGS. 3(a) and 3(b) show the principle of measurement of the resist coating non-uniformity using the two rays' interference in accordance with FIG. 2. FIGS. 3(a) and 3(b) include two cases, namely a case (FIG. 3(a)) in which the reflection from the substrate is predominant over the reflection from the top surface and another case (FIG. 3(b)) in which, on the contrary, the reflection from the top surface is predominant over the reflection from the substrate. In both drawings, a ray illustrated by a solid line represents a state with a resist and a ray illustrated by a dash-dot line represents a state without a resist.
In the former case (FIG. 3(a)), two coherent rays U W (f 1 ) and U W (f 2 ) having slightly different wavelengths are irradiated onto the wafer alignment grating 6 in the first layer pattern of the resist coating. These two rays intersect above the semiconductor substrate and generate interference fringe 9.
As previously mentioned with reference to FIGS. 1a-1f (a), the interference fringe 9 is aligned with the alignment grating 24 on the photomask 10 and is the standard of the relative positioning between the photomask 10 and the wafer alignment grating 6 on the semiconductor substrate.
The wafer alignment grating 6 has been irradiated with DUV and has almost the same refractive index as the upper layer resist coating, and does not mix with the latter. Each incident beam passes through the resist and reflects from the semiconductor substrate 1 as illustrated in FIG. 3(a), which corresponds to a case in which the reflection from the substrate is predominant over the reflection from the top surface. The respective incident beams Uw(f 1 ) and Uw(f 2 ) are reflected at the substrate 1. Beams reflected in perpendicular to the substrate interfere with each other and provide a beat signal. The phase of the beat signal contains position information of the wafer alignment grating 6, and the alignment is carried out by making the interference fringe 9 and the grating 6 coated with the resist positioned relative to each other.
As a result, the photomask 10 and the semiconductor substrate 1 are aligned with each other. At this step, if there is a non-uniform portion 14 in the resist 80, an optical path difference occurs between the beams Uw(f 1 ) and Uw(f 2 ) while the beams pass through different regions of the resist, resulting in a deviation (misalignment) 16. In other words, the non-uniformity 14 of the resist coating can be determined by measuring the deviations 16 before and after the resist coating step.
In the case of FIG. 3(b), in which the reflection from the top surface is predominant over the reflection from the substrate, a position change of the diffraction center from before the resist coating step to after the resist coating step causes a corresponding phase deviation. The resultant phase difference between the beams U 1 and U 2 causes a phase deviation in the beat signal of the detection beam, resulting in a deviation (misalignment) 16 relative to the interference fringe.
If there is a deviation (misalignment), i.e. non-uniformity of the resist coating, the condition of the resist coating (including the number of revolutions for coating, the dispense volume and the viscosity) is changed so that a deviation (misalignment), i.e. non-uniformity of the resist coating, does not occur and the resist coating is optimized.
FIG. 4(a) and FIG. 4(b) shows an optical system for alignment in an exposure apparatus which is capable of practicing an evaluation of a non-uniform resist coating in accordance with the present invention. The numeral 10 is a photomask, the numeral 21 is an acoustic oscillator, the numeral 22 is a reduction projection lens, the numeral 23 is a wafer stage, and the 24 is an alignment grating on the photomask. The numeral 6 is an alignment grating on a resist-coated wafer. I n and I W are heterodyne signals.
Two coherent rays Uw(f 1 ), Uw(f 2 ) respectively having slightly different frequencies f 1 , f 2 are irradiated onto a substrate 1 at an incident angle θ, and interference fringe 9' and 9 (providing an alignment standard) are respectively formed above the photomask 10 and the substrate 1. The interference fringe 9' has a pitch P', and the interference fringe 9 has a pitch P. If the magnification of projection is represented by m, the pitch P' of the interference fringe 9' is equal to mP. The pitch P of the interference fringe 9 is described by the following formula:
P=λ/(2 sin θ)
The photomask 10 has the alignment grating 24 at a pitch which is a multiple (a multiple-by-integer) of the pitch P' of the interference fringe 9' above the photomask 10. While on the semiconductor substrate 1, there is formed the first pattern including an alignment grating 6 a pitch of which is a multiple-by integer of the pitch P of the interference fringe 9.
If the incident rays are represented by U W (f 1 ) and U W (f 2 ), rays diffracted due to the alignment grating 6 on the semiconductor substrate 1 are described by the following formulas:
U.sub.W (f.sub.1)=A.sub.W (f.sub.1)·exp{i(2πf.sub.1 t-δ)}
U.sub.W (f.sub.2)=B.sub.W (f.sub.2)·exp{i(2πf.sub.2 t+δ)}
Wherein δ is a phase difference of a diffracted ray caused by a movement X W of a semiconductor alignment grating, which is described by the following formula:
δ.sub.W =2π·X.sub.M ·sinθ/λ
From these equations, interference ray intensity of a diffracted ray of a ±1st order ray is expressed by the following formula:
I.sub.W =|U.sub.W (f.sub.1)+U.sub.W (f.sub.2)|.sup.2
A.sub.W (f.sub.1).sup.2 +B.sub.W (f.sub.2).sup.2 +2A.sub.W (f.sub.1)·B.sub.W (f.sub.2)·cos{2π(f.sub.1 -f.sub.2)t-2δ}
A.sub.W (f.sub.1).sup.2 +B.sub.W (f.sub.2).sup.2 +2A.sub.W (f.sub.1)·B.sub.W (f.sub.2)·cos{2π(f.sub.1 -f.sub.2)t-2X.sub.W /P}
In a similar manner, rays diffracted due to an alignment grating on a photomask are described by the following formulas:
U.sub.n (f.sub.1)=A.sub.W (f.sub.1)·exp{i(2πf.sub.1 t-δ)}
U.sub.n (f.sub.2)=B.sub.W (f.sub.2)·exp{i(2πf.sub.2 t+δ)}
Wherein δ is a phase difference of a diffracted ray caused by a movement X M of a photomask relative to 2 rays' interference fringe 9', which is described by the following formula:
δ.sub.M =2π·X.sub.M ·sinθ/λ
From these equations, interference ray intensity of the ±1st order ray diffracted due to the photomask is described by the following formula.
-I.sub.n =A.sub.M (f.sub.1).sup.2 +B.sub.M (f.sub.2).sup.2 +2A.sub.M (f.sub.1)·B.sub.M (f.sub.1)·cos{2π(f.sub.1 -f.sub.2)t-2X.sub.M /P'}
It is readily understandable from these equations that the phase terms of the beat signals detected by photodetectors 20, 25 include relative displacements X W , X M between the two rays' interference fringes 9, 9' and the alignment gratings 6, 24 formed on the semiconductor substrate 1 and on the photomask 10.
A phase difference y between the beat signal I W from the substrate 1 and the beat signal I n from the photomask 10 is measured, and then the semiconductor substrate 1 is moved so that the phase difference y approaches to zero. Thus the alignment of the photomask 10 and the semiconductor substrate 1 is achieved through a medium of two rays' interference fringes 9, 9'. After this alignment, the resist 80 is exposed through the photomask 10 and developed so that the second pattern 12 is formed on the semiconductor substrate 1. Then misalignment between the first pattern 5 and the second pattern 12 is measured.
FIG. 5(a) and FIG. 5(b) show a result of the resist coating evaluation in accordance with the present invention. The length and the direction of each arrow illustrated in FIG. 5(a) and FIG. 5(b) respectively represent the magnitude and direction of the misalignment.
In FIG. 5(a) a scaling error is observed in which the misalignment becomes large in the peripheral area of the semiconductor substrate 1. This indicates that the non-uniformity 14 of the resist appears prevailingly. As a result, the misalignment 16 becomes large in the peripheral area of the wafer because of the centrifugal force generated by the revolution of the wafer. In contrast, FIG. 5(b) shows that almost no misalignment occurs because the resist coating is optimized, and the resist is uniformly coated also in the peripheral area of the substrate.
In the present invention, the non-uniformity of the resist coating is evaluated by measuring the misalignment. The non-uniformity of the second resist coating can be evaluated by detecting the position of the alignment mark before and after applying the second resist and by measuring wafer scaling, orthogonality and wafer rotation change.
Although the described embodiment employs the specific overlay method utilizing two rays' interference, another different overlay method may be employed to achieve a similar result.
Although the described embodiment employs the specific curing method utilizing DUV irradiation, another different curing method, for instance, utilizing baking by a hot plate, etc. may be employed to achieve a similar result.
As described hereinbefore, the present invention enables the non-uniformity of the resist formed over a ridge portion to be evaluated easily and quantitatively. An improvement and an optimization of the resist coating using the present invention enables one to achieve high accuracy of an overlay and high controllability of a pattern dimension. | A method for evaluating a resist coating comprising the steps of: forming a first layer resist pattern including an alignment mark by applying a first resist on a semiconductor substrate and by exposing and developing said first resist, said first layer resist pattern having a ridge portion; irradiating said first layer resist pattern with a deep ultraviolet ray; applying, onto said irradiated first layer resist pattern, a second resist having substantially the same refractive index as said first resist to form a second resist coating; detecting said alignment mark formed in said first layer resist pattern, and relatively positioning a pattern for said second resist and said first layer resist pattern; and determining nonuniformity characteristics of said second resist coating by measuring an overlay accuracy between said first layer resist pattern and said pattern for said second resist. The present invention ensures a quantitative evaluation in a non-contact manner for non-uniformity of a resist coating, and enables a resist coating method to be optimized. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application Ser. No. 10/693,541, filed on Oct. 24, 2003, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND
This invention relates generally to metal structural members for use in building construction, and more particularly to metal roof trusses for construction of roof framing for supporting roofs.
A roof truss generally comprises two or more top chord members and a bottom chord member. The ends of the top chords are secured together, and the ends of the bottom chord are connected to the lower, free ends of the top chords for forming the exterior of the roof truss. One or more web members span between and interconnect the top and bottom chords. The web members are secured at their ends to the top chords and to the bottom chord.
In building construction, a plurality of trusses are set out across a building frame. When erected upon the building frame, the bottom chord spans the wall frames of the building and is fixed to the top plate of the wall frames. The sub-roof material is then fastened to the top chords, and ceiling material may be fastened to the bottom chord. The combined load of the roof trusses, and the roofing and ceiling material attached to the trusses, is transferred through the outer edges of the trusses to the top plate of the wall frames.
In the past, roof trusses have been constructed of wooden chords and web members. More recently, various types of building systems incorporate metal trusses.
Metal trusses include chord members and web members rolled from metal sheets and formed into substantially rectangular U-shaped or C-shaped channels. The open sides of the chord members are adapted to receive the ends of the other chord members and the web members. The ends of the chords and web members are then fastened together for securing the truss elements in position. The materials cost for metal trusses is competitive with other building materials. Using metal as the material of construction also has a number of other advantages, including relatively stable price, strength, flexibility, durability, light weight, reliability, minimum waste in use, and noncombustability.
A significant problem with the use of metal trusses is the high installed cost. One factor influencing the installed cost of metal trusses is the thermal performance of metal, which is well below that of lumber framing when using standard framing techniques. This is due to the thermal conductivity of metal and the potential for thermal bridging. For example, steel conducts heat more than 300 times faster than wood. The rapid heat flow through steel reduces the insulating value of cavity insulation between 53 and 72%. With respect to metal roof trusses, heat passing through the ceiling material, if present, migrates into the bottom chord. Usually the bottom chord is covered with insulation spread on the attic floor, but heat can still be transferred into the truss at the points where the web members are fastened to the bottom chord. Heat is then conducted by the web members into the attic area and to the top chord at the underside of the roof. The result is a wicking effect whereby heat is transferred out of the building. Special considerations are necessary to reduce the tendency of metal roof trusses to transfer heat in this manner.
As a solution, some builders using metal wall frame construction, but top the building frame with wood roof trusses in order to minimize thermal bridging. However, this defeats the purpose of opting for metal frame construction. Other common solutions to improve energy efficiency include increasing the amount of cavity insulation and applying insulation to the exterior of the metal frame elements to provide a “thermal break” to the heat conducting path. Other means for reducing heat loss include punchouts in the chord members, wide truss spacing, and using thicker gauge steel. All of these approaches add to the cost, installation time and the difficulty of using metal roof trusses.
For the foregoing reasons, there is a need to provide a metal roof truss for use in a metal frame building system that is more energy efficient. Ideally, the new metal roof truss should be inexpensive, light weight, and adapted to mass production.
SUMMARY
According to the present invention, a metal truss is provided comprising a pair of elongated top chord members each having a first end and a second end. The top chord members are connected to each other at the first ends. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members. A second elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members such that the second bottom chord member is spaced below the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member.
Also according to the present invention, a metal frame building system is provided including a building frame comprising a plurality of wall frames having top ends. The building system includes a metal truss comprising a pair of elongated top chord members each having a first end and a second end. The top chord members are connected to each other at the first ends. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members. A second elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members such that the second bottom chord member is spaced below the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member. The plurality of trusses are adapted to be erected upon the building system frame such that the second bottom chord member spans the wall frames and is connected to the top ends of the respective wall frames.
Further according to the present invention, a building comprises a frame including a plurality of wall frames, each of the wall frames having a top end. A metal truss comprises a pair of elongated top chord members each having a first end and a second end and connected to each other at the first end. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members. A second elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member connected to the first bottom chord member. A plurality of the metal trusses are erected upon the frame such that the second bottom chord member spans at least two of the wall frames and is connected to the top ends of the respective wall frames. Roof material is fastened to the top chord members.
Still further according to the present invention, a metal truss is provided comprising a plurality of elongated top chord members connected to each other end to end so that the connected top chord members have two free ends. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the free ends of the connected top chord members. A second elongated bottom chord member is connected at its ends to the top chord members adjacent the free ends of the connected top chord members such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member connected to the first bottom chord member.
According to another embodiment of the present invention, a metal truss is provided comprising a pair of elongated top chord members connected together at their first ends, a first elongated bottom chord member, and means for connecting the first bottom chord member to the top chord members adjacent the second ends of the top chord members. Means are also provided for connecting a second elongated bottom chord member to the first bottom chord member such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member.
Also according to the other embodiment of the present invention, a metal frame building system is provided including a plurality of wall frames having top ends. The building system includes a metal truss comprising a pair of elongated top chord members connected together at their first ends, a first elongated bottom chord member, and means for connecting the first bottom chord member to the top chord members adjacent the second ends of the top chord members. Means are also provided for connecting a second elongated bottom chord member to the first bottom chord member such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member. A plurality of trusses are adapted to be erected upon the building system frame such that the first bottom chord member spans at least two of the wall frames and is connected to the top ends of the respective wall frames, and the ends of the second bottom chord member extend between the inner surfaces of the wall frames.
Further according to the other embodiment of the present invention, a building comprises a frame including a plurality of wall frames, each of the wall frames having a top end. A metal truss comprises a pair of elongated top chord members connected together at their first ends, a first elongated bottom chord member, and means for connecting the first bottom chord member to the top chord members adjacent the second ends of the top chord members. Means are also provided for connecting a second elongated bottom chord member to the first bottom chord member such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member. A plurality of trusses are adapted to be erected upon the frame such that the first bottom chord member spans at least two of the wall frames and is connected to the top ends of the respective wall frames, and the ends of the second bottom chord member extend between the inner surfaces of the wall frames. Roof material fastened to the top chord members.
Still further according to another embodiment of the present invention, a metal truss is provided comprising a plurality of elongated top chord members, the top chord members connected to each other end to end so that the connected top chord members have two free ends. Means are provided for connecting a first elongated bottom chord member to the top chord members adjacent the second ends of the top chord members. Means are also provided for connecting a second elongated bottom chord member to the first bottom chord member such that the second bottom chord member is spaced from the first bottom chord member. At least one web member positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference should now be had to the embodiment shown in the accompanying drawings and described below. In the drawings:
FIG. 1 is a schematic view of a roof truss assembly according to the present invention;
FIG. 2 is an elevational end view of a truss member for use in the truss assembly according to the present invention;
FIG. 3 is a schematic view of the roof truss assembly shown in FIG. 1 positioned on wall frames the bottom portion of which have been cut-away;
FIG. 4 is a schematic view of another embodiment of a roof truss assembly according to the present invention;
FIG. 5 is a cross-section of a truss member taken along line 5 - 5 of FIG. 4 ;
FIG. 6 is a schematic view of one half of the truss assembly shown in FIG. 4 positioned on a wall frame the bottom portion of which has been cut-away.
DESCRIPTION
Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the Figures. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise.
Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, FIG. 1 shows an embodiment of a roof truss assembly according to the present invention, generally designated at 10 . The roof truss assembly 10 comprises several structural truss members, including a pair of top, or upper, chord members 12 , a pair of spaced bottom, or lower, chord members 14 , 16 , and web members 18 . Adjacent upper ends of the top chord members 12 are secured together to form an apex joint. In this embodiment, the ends of both bottom chord members 14 , 16 are secured adjacent to the lower ends of the top chord members 12 . The top chord members 12 and the lower bottom chord member 14 form a triangle, with the lower bottom chord member 14 as the base and the top chord members 12 forming the sides of the triangle.
It is well known in the art that there are a number of roof truss profiles in addition to the triangular truss assembly 10 depicted in FIG. 1 . We do not intend to limit the application of the present invention to a triangular truss profile. Rather, the present invention is applicable to all such truss profiles.
The web members 18 extend between the top chord members 12 and the upper bottom chord member 16 . The opposite ends of the web members 18 are secured to the top chord members 12 and upper bottom chord member 16 for rigidifying the roof truss assembly 10 . Eight web members 18 are shown in FIG. 1 . It is understood that we do not intend to limit the application of the present invention to a roof truss assembly 10 having a predetermined position and number of web members 18 . The number and the position of web members 18 will vary as necessary depending upon the size of a building and the lengths of the chord members 12 , 14 , 16 in order to provide the required structural strength with an acceptable safety factor.
Each of the truss members is formed from a strip or sheet of metal. The preferred material of construction is steel. However, the present invention is not limited to steel, and other metals such as aluminum, copper, magnesium, or other suitable metal may be appropriate. The scope of the invention is not intended to be limited by the materials listed here, but may be carried out using any material which allows the construction and use of the metal roof truss assembly 10 described herein.
As shown in FIG. 2 , a truss member 20 which comprises the roof truss assembly 10 of the present invention is substantially C-shaped or U-shaped, having a web 24 spanning opposed side walls 26 defining a channel 22 section. When assembled ( FIG. 1 ), the open channels of the bottom chord members 14 , 16 face upwardly and the open channels of the top chord members 12 face downwardly. Joints are formed where the chord members 12 , 14 , 16 and web members 18 intersect one another. The joints can be secured using fasteners (not shown), such as metal screws, bolts and nuts, rivets, or any combination thereof. For this purpose, aligned holes may be punched or drilled through the truss members during production. A short connecting plate (not shown) may also be fitted to the chord members 12 , 14 , 16 and web members 18 on each side of a joint and fastened together with the chord members 12 , 14 , 16 and web members 18 to form a reinforced joint. Alternatively, the truss members may be joined by welding, soldering, and the like.
The truss members can all be produced on-site from coils of sheet metal using a portable roll forming machine, as is known in the art. Features for joining the truss members may be provided by the forming machine, including holes for fasteners. Notches are cut into the side walls 26 a sufficient distance to accommodate intersecting truss members, depending upon the angle at which the truss members meet each other, allowing a portion of one end of a truss member to be fitted within another truss member. All of the truss members can be formed with a common section to simplify production. Additionally, service holes may be provided in the structural member to accommodate electrical wiring or other utilities.
In accordance with the present invention, the lower bottom chord member 14 is separated from the upper bottom chord 16 . As a result of this arrangement, there is no direct thermal path from the lower bottom chord member 14 to the web members 18 of the truss assembly 10 . Moreover, the air space 27 between the bottom chord members 14 , 16 serves as an insulator. The air space 27 between the bottom chord members 14 , 16 can be insulated to further enhance thermal performance.
In building construction, a plurality of truss assemblies 10 are set out across a building frame. As seen in FIG. 3 , the lower bottom chord 14 spans the wall frames 30 of the building and is fixed to the top plate (not shown) of the wall frames 30 . Ceiling material (not shown) may be attached directly to the lower bottom cord 14 . Tensile elements 28 , schematically shown in FIG. 3 , may be provided between the bottom chord members 14 , 16 where necessary to support the weight of the ceiling material. The tensile elements 28 are spaced from the points on the truss assembly 10 where the web members 18 are fastened to the upper bottom chord 16 to minimize the potential for thermal bridging. Preferably, the tensile elements 28 are formed from a material having a low thermal conductivity.
Another embodiment of the roof truss assembly according to the present invention is shown in FIG. 4 and generally designated at 40 . In this embodiment, the roof truss assembly 40 comprises a pair of top chord members 42 , a bottom chord member 44 and web members 46 . The web members 46 extend between and interconnect the top chord members 42 and the bottom chord member 44 . A vertically-positioned heel truss 48 is fastened between each end of the bottom chord member 44 and the free ends of the top chord members 42 . As noted above, the present invention is not limited to a triangular truss profile, but rather is applicable to all known roof truss profiles. Moreover, the number and position of the web members 46 will vary as necessary depending upon the truss profile, the size of a building, and the lengths of the chord members 42 , 44 , in order to provide the required structural strength with an acceptable safety factor. Thus, the triangular truss profile and the number and position of the web members 46 depicted in FIG. 4 are merely exemplary.
Spacers 50 are positioned along the length of, and fastened to, the bottom chord member 44 . The spacers 50 are located away from the points on the truss assembly 40 where the web members 46 are fastened to the bottom chord member 44 . A ceiling support 52 is secured to the spacers 50 . As seen in FIG. 5 , the ceiling support 52 may be slightly wider than the web 24 of the bottom chord member 44 . Ceiling material 54 may be attached to the ceiling support 52 . The spacers 50 and ceiling support 52 can be formed from any material as long as the combination, along with the means for fastening the ceiling support 52 through the spacer 50 to the bottom chord member 44 , is sufficiently strong to support the ceiling support 52 and ceiling material 54 . For example, wood, fiberboard, cardboard, plastic, and the like, are all suitable materials for the spacers 50 and ceiling support 52 . Preferably, the spacers 50 have a low thermal conductivity. In keeping with the invention, the spacers 50 function to provide an insulating air space 58 between the bottom chord member 44 and the ceiling support 52 ( FIG. 3 ), which minimizes the potential for thermal bridging.
Referring to FIG. 6 , one side of a truss assembly 40 according to the second embodiment of the present invention is shown in position on a wall frame 30 . The bottom chord 44 spans the wall frames 30 (only one of which is shown in FIG. 6 ) of the building and is fixed to the top plate of the wall frames 30 . The ends of the ceiling support 54 extend between the inner surfaces of the wall frames 30 . Ceiling material 54 is attached directly to the ceiling support 52 . Optionally, insulating material 56 may be disposed in the air space 58 . For example, as seen in FIG. 6 , a length of insulating material 56 is placed between the ceiling support 52 and the bottom chord 44 where the web members 46 attach to the bottom chord member 44 .
The thermal performance of the roof truss assembly of the present invention is significantly improved over conventional metal trusses. Separation of the lower bottom chord member or ceiling support from the bottom chord member connected to the web members provides an insulating air space between the ceiling and the bottom chord member and eliminates any direct thermal path from the ceiling to the bottom chord member and the web members of the truss assembly. Although the air space 27 can be insulated to further enhance thermal performance, the improvement in thermal performance can be achieved without the additional insulating material, or the use of insulating material as a thermal break. Moreover, a truss configuration according to the present invention allows the use of light gauge metal, preferably having a thickness of less than about 1.2 mm. For example, standard light gauge metal could be used, such as 12, 14, or 16 gauge.
Although the present invention has been shown and described in considerable detail with respect to a particular exemplary embodiments thereof, it should be understood by those skilled in the art that we do not intend to limit the invention to the embodiment since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the invention, particularly in light of the foregoing teachings. For example, the truss profile and the number and position of the truss members may be any of a number of arrangements known in the art. Accordingly, we intend to cover all such modifications, omissions, additions and equivalents as may be included within the spirit and scope of the invention as defined by the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a crew may be equivalent structures. | A metal truss comprises elongated top chord members connected to each other at their ends. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the free ends of the top chord members. A second elongated bottom chord member is connected at its ends to the top chord members, or directly to the first bottom chord member via spacers, such that the second bottom chord member is spaced below the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member. | 4 |
FIELD OF THE INVENTION
[0001] The present invention is related to a pharmaceutical composition for boron neutron capture therapy (herein after abbreviated as BNCT), and in particular to a pharmaceutical composition for BNCT containing triphenylboroxin as a boron source.
BACKGROUND OF THE INVENTION
[0002] In U.S. Pat. No. 6,117,852, the inventor of the present invention discloses a boron-containing lipiodol pharmaceutical composition comprising lipiodol, submicron boron powder, lecithin and C 12 -C 22 fatty acid, wherein said submicron boron powder is suspended in said lipiodol in the presence of said lecithin and said C 12 -C 22 fatty acid such as linoleic acid. This B-lipiodol pharmaceutical composition is at least useful in boron neutron capture therapy (BNCT) of hepatoma, wherein the lipiodol has a property of a high retention in hepatoma, the lecithin has a boron carrying capacity, and the C 12 -C 22 fatty acid has a function of rendering lecithin soluble in lipiodol. In this B-lipiodol pharmaceutical composition the submicron boron powder must have an appropriate distribution of particle sizes in order to be uniformly dispersed therein. Details of U.S. Pat. No. 6,117,852 are incorporated herein by reference.
[0003] Using BSH (borocaptate sodium) and BPA (boronophenylalanine) in clinical trails for treatment of malignant melanoma and brain tumor has been reported [Mishima, Y., et al. Lancet, 12, 388-389 (1989); Hatanaka, H. and Nakagawa, Y. Int. J. Radiat. Oncol. Biol. Phys., 28, 1061-1066 (1994); Barth, R. F., et al. Int. J. Radiation Oncology Biol. Phys. Vol. 47, No. 1, 209-218 (2000)]. Further, Minoru Suzuki et al. have studied the effects of boron neutron capture therapy on liver tumors and normal hepatocytes in mice [Minoru Suzuki, et al., Jpn. J. Cancer Res. 91. 1058-1064, October 2000].
[0004] Carolyn Pratt Brock, Robin P. Minton and Kurt Niedenzu published an article in 1987 related to the structure and thermal motion of triphenylboroxin [Acta Cryst. (1987). C43, 1775-1779].
SUMMARY OF THE INVENTION
[0005] A primary objective of the present invention is to provide a boron-containing drug, which has a selectively high retention in cancer cells to be used as a boron source in the boron neutron capture therapy (BNCT).
[0006] Another objective of the present invention is to provide a pharmaceutical composition for boron neutron capture therapy (BNCT), which has the following advantages: a compound as a boron source in the pharmaceutical composition is able to be uniformly and stably dispersed in the pharmaceutical composition; the pharmaceutical composition is stable in serum; and the pharmaceutical composition can be selectively accumulated in cancer cells with a high concentration, as well as the boron-source compound.
[0007] In order to accomplish the objectives of the present invention, a pharmaceutical composition for BNCT prepared according to the present invention comprises a therapeutically effective amount of triphenylboroxin having the following formula (I) as a boron source and a pharmaceutically acceptable carrier, such as lipiodol:
[0008] wherein ph is phenyl.
[0009] The pharmaceutical composition of the present invention is useful for BNCT on a cancer, for examples hepatoma, breast cancer and malignant melanoma.
[0010] Preferably, the pharmaceutical composition of the present invention further comprises a promoter for enhancing uptake of said carrier by the cancer cell.
[0011] Preferably, the pharmaceutical composition of the present invention further comprises a dissolving agent for enhancing said promoter's solubility in said carrier.
[0012] Preferably, said promoter is lecithin and said dissolving agent is C10-C20 fatty acid.
[0013] Preferably, the pharmaceutical composition of the present invention comprises 0.1% to 3% boron, based on the weight of the pharmaceutical composition.
[0014] Preferably, the pharmaceutical composition of the present invention comprises 15-25 mg lecithin and 0.05-0.09 ml C10-C20 fatty acid per ml of the lipiodol. More preferably, said C10-C20 fatty acid is linoleic acid.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The inventor of the present application synthesizes a hydrophobic compound, triphenylboroxin (C 6 H 5 BO 3 ), having the following structure (I), and is the first person using it as a boron-containing drug in BNCT:
[0016] wherein ph is phenyl.
[0017] Lipiodol has been used as X-ray contrast medium and lymphography contrast medium. The present inventor and her co-workers in their previously study clearly demonstrated that hepatoma cells in culture are capable of rapidly active uptake of a large quantity of lipiodol by endocytosis with prolonged retention of the lipiodol intracellularly as long as the life span of the cells [Chou F I, Fang K C, Chung C, Lui W Y, Chi C W, Liu R S, and Chan W K. Lipiodol uptake and retention by human hepatoma cells. Nucl Med Biol (1995) 22(3): 379-386]. In this invention, the present inventor employs lipiodol as a boron-containing drug carrier in view of its capability of achieving selective and high retention in hepatoma cells. It is found that triphenylboroxin as the boron-containing drug has a property of uniform dispersion in lipiodol and is stable in lipiodol. This inventor further utilizes lecithin to enhance uptake of lipiodol by hepatoma cells, and linoleic acid to increase the solubility of lecithin in lipiodol. As a result, the pharmaceutical composition prepared in the present invention is suitable for use in BNCT on hepatoma. It is apparent that the pharmaceutical composition prepared in the present invention has a great potential for use in BNCT on other cancers such as breast cancer or malignant melanoma.
[0018] Preparation Example: Synthesis of triphenylboroxin (I)
[0019] To a round-bottom flask 3 g of phenylboronic acid and 1 ml of ethanolamine catalyst were added, and the mixture was heated with an oil bath at 130° C. for 24 hours while stirring by a magnetic stirrer. A red-brown solution was thus obtained. A portion of the red-brown solution was taken for thin-layer chromatography analysis (TLC), wherein a mixed solvent of hexane and ethyl acetate (hexane:ethyl acetate=5:2, V/V) was used as a mobile phase to develop the solution drop. After the silica gel TLC film being colored by I 2 vapor, a dark point was found at Rf of 0.5.
[0020] In order to remove the remaining ethanolamine, the red-brown solution was introduced into a column packed with aluminum oxide, and eluted with ethyl acetate (eluent). The eluate collected in the beginning section, after the solvent therein being evaporated, was subjected to another elution in a column packed with silica gel by using a mixed solvent of hexane and ethyl acetate (hexane:ethyl acetate 8:1, V/V) as an eluent. The cluate was collected in consecutive separate portions, each of which was dropped on a silica gel TLC film and developed by a mixed solvent of hexane and ethyl acetate (hexane:ethyl acetate=5:2, V/V) for carrying out TLC analysis. The silica gel TLC films were colored by I 2 vapor, and the one with a Rf of 0.5 was the target. The collected eluate portion having Rf of 0.5 was evaporated in vacuo to remove solvents contained therein, and a liquid product having hydrophobic triphenylboroxin as a major portion was obtained.
[0021] Identification of the Structure and Molecular Weight of Triphenylboroxin:
[0022] The liquid product purified by the aforesaid liquid chromatography was dropped on a thick silica gel TLC film (2 mm), and developed with a mixed solvent of hexane and ethyl acetate (hexane:ethyl acetate=5:2, V/V). The product at Rf of 0.5 was scrapped. The resulting powder was placed in a tube and dissolved by ethyl acetate. The solution was subjected to gas chromatography-mass spectrum (GC-MS) analysis, where a major product having a molecular weight of 312 was observed. α track of triphenylboroxin after neutron irradiation:
[0023] 5 μl of the triphenylboroxin liquid product prepared above was dropped on an α track detectable film (Koda, LR-115 film). After being allowed to dry overnight, the film was placed in Tsing Hua Open-pool Reactor (THOR), where it was irradiated by a thermal neutron beam for a predetermined period of time. The irradiated film was removed from the THOR, and developed by etching in 10% NaOH aqueous solution at 60° C. with sonication for 50 minutes. The etched film was washed with distilled water to remove residual NaOH, dried, and observed with phase-contrast microscope. α tracks were found in the area of the drop of the triphenylboroxin liquid product on the developed film.
EXAMPLE
[0024] Preparation of Triphenylboroxin Entrapped Lipiodol (Herein After Abbreviated as TEL):
[0025] To lipiodol, linoleic acid and lecithin in a round-bottom, anhydrous ethanol was added, and then heated at 70° C. for 20 minutes while stirring. Until the solution became completely clear, the triphenylboroxin liquid product prepared in Preparation Example was added, and the stirring and heating was maintained for another 10 minutes. The resulting mixture was placed in a rotary evaporator at 50° C. to remove the ethanol therefrom thoroughly, so that a triphenylboroxin entrapped lipiodol (TEL) was obtained in the form of an oily light yellow-brown clear liquid. An appropriate ratio of the components for preparing TEL was: triphenylboroxin liquid product:lipiodol:lecithinlinoleic acid:anhydrous ethanol=0.03ml:1 ml:20 mg:0.06 ml:about 30 ml.
[0026] α Track of TEL After Neutron Irradiation:
[0027] The procedures of α track of triphenylboroxin after neutron irradiation in Preparation Example were repeated except that the triphenylboroxin liquid product was replaced by TEL. The observation results of the developed film show that there are α tracks uniformly distributed in the area of the drop of TEL on the developed film, and no α track found outside the drop.
[0028] Boron Concentration of TEL:
[0029] To a Teflon® high pressure digestion vessel 0.5 ml of TEL, 3 ml of nitric acid solution (14 N, 65%) and 0.5 ml of hydrogen peroxide solution (30-35%) were added. The vessel was sealed with a cap and placed in a microwave digestion oven (MLS 1200 Miesfone, Italia) for the following digestions: 300 W for 15 minutes and 600 W for 10 minutes. After cooling for 60 minutes to reduce pressure in the vessel, the cap was turned off and the mixture in the vessel became a clear solution indicating a complete digestion. The digested solution was pour out, diluted with distill water, and assayed by inductively coupled plasma-atomic spectroscopy (ICP-AES, OPTIMA 2000 DV, Perkin Elmer Instruments). The boron content of TEL is 12000 ppm. The boron content of TEL varies with the formulation of preparing TEL. An appropriate range of the boron concentration based on the weight of TEL is from 1×10 3 ppm to 3×10 4 ppm.
[0030] The stability of TEL:
[0031] For testing the stability of TEL in human serum, 0.1 ml of B-lipiodol having 12000 ppm boron was mixed with 5 mL human serum, and then incubated at 37° C. under 75 rpm to form a suspension of TEL vesicles in the serum. For quantitatively testing the release of boron from the oily preparation into the aqueous serum, 2 ml of serum was regularly sampled from each test tube which was maintained at 37° C. and rotated with 75 rpm. The boron contents of the samples were measured by ICP-AES, and the results show that the boron content of the TEL vesicles gradually reduced to 88% in the first four hours and stabilized thereafter, and 85% of the boron content was still retained in the TEL vesicles after 96 hours, indicating that triphenylboroxin was stably retain in lipiodol.
[0032] Interaction and Retention of TEL by HepG2 Cells
[0033] 0.15 mL of TEL was added to 100 mL of the complete Dulbecco's Modified Eagle Medium (CDMEM), and then homogenized by sonication of 75 W power under sterile condition so that a TEL-CDMEM liquid was formed. 7 mL of the TEL-CDMEM was added to HepG2 cells which were cultured in CDMEM to 70% confluence, and the absolute boron content in the culture after the addition was 16 μg. When HepG2 cells were incubated with TEL-CDMEM, TEL globules were detected on the cell membrane by inverted light microscopic examination. After 1 h, the TEL on the cell membrane was found to be emulsified to form smaller globules. After 8 h of incubation with TEL-CMEM, most of the HepG2 cells had intracellular TEL globules in the cytoplasm, as confirmed by inverted light microscope. The intracellular B-lipiodol globules appeared to be larger in size and quantity as time increased. By 48 h, large numbers of TEL globules accumulated in the cytoplasm, causing the cell size to enlarge and the plasma membrane to bulge.
[0034] 7 mL of the TEL-CDMEM was added to HepG2 cells which were cultured in CDMEM to 70% confluence, and the absolute boron content in the culture after the addition was 16 μg. After exposing of the HepG2 cells to TEL-CDMEM for predetermined periods of time, cells were washed twice with 5 ml of phosphate buffer (pH 7.4) to remove any loosely attached TEL. Cell were collected by centrifugation, and digested. The boron contents of the collected and digested cells were assayed by ICP-AES. The results reveal that the boron content of the collected and digested cells increase as the culture time of TEL-CDMEM increases, the boron contents at the culture time of 12 and 24 hours are 58 and 118 ppm respectively, and by 48 hours it reaches 214 ppm, which is sufficient high for BNCT. | A pharmaceutical composition for boron neutron capture therapy (BNCT), and in particular for BNCT on hepatoma is disclosed. The pharmaceutical composition contains a therapeutically effective amount of triphenylboroxin (phenylboronic anhydride) as a boron source and a pharmaceutically acceptable carrier, such as lipiodol. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a laundry processing device, and more particularly, to a laundry processing device including a regulating unit for opening and closing an opening part.
[0003] 2. Description of the Related Art
[0004] In general, a laundry processing device refers to an apparatus for washing or drying laundry. The laundry processing device uses liquid detergent or powdered detergent when doing laundry. When using the liquid detergent, the user attaches a separate container to a detergent box and stores the liquid detergent therein. The stored liquid detergent is dissolved in washing water introduced from the outside, and supplied to a drum and a tub. However, the user has to use the container every time the user wishes to use the liquid detergent. Also, the user needs to detach the container from the detergent box to keep the container in other places after using the liquid detergent.
SUMMARY OF THE INVENTION
Technical Problem
[0005] The present invention aims to provide a laundry processing device wherein detergent is supplied by means of the pressure of the washing water.
Technical Solution
[0006] The present invention provides a laundry processing device including: a detergent box having a detergent storage unit which accommodates a detergent and which has an opening part; a washing water supply device for supplying the detergent storage unit with washing water from the outside; and a regulating unit for closing the opening part of the detergent storage unit in which the detergent is accommodated, and opening the opening part by means of the washing water supplied by the washing-water supply device.
[0007] The present invention has the advantage of supplying either liquid detergent or powdered detergent by including a regulating unit for opening and closing an opening part. Accordingly, the user can use the liquid detergent without attaching a separate container to a detergent box.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view showing one embodiment of a laundry processing device according to the present invention;
[0009] FIG. 2 is a perspective view showing one embodiment of a detergent box shown in FIG. 1 ;
[0010] FIG. 3 is a cross-sectional view taken along line of FIG. 2 ;
[0011] FIG. 4 is a perspective view showing one embodiment of a regulating unit shown in FIG. 3 ;
[0012] FIG. 5 is a cross-sectional view showing when the regulating unit shown in FIG. 4 closes an opening part;
[0013] FIG. 6 is a cross-sectional view showing when the regulating unit shown in FIG. 4 opens the opening part;
[0014] FIG. 7 is a conceptual view showing the load of the regulating unit shown in FIG. 4 ; and
[0015] FIG. 8 is a cross-sectional view showing another embodiment of the regulating unit shown in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 is a perspective view showing one embodiment of a laundry processing device 100 according to the present invention.
[0017] Referring to FIG. 1 , the laundry processing device 100 includes a cabinet 110 , a tub (not shown) arranged in the cabinet 110 to store washing water introduced from an external source, a drum 122 arranged in the tub to perform laundry washing, a drive device (not shown) to transmit driving force so as to perform laundry washing, a washing-water supply device (not shown) to supply the washing water outside the cabinet 110 to the tub, a washing water draining device (not shown) to drain out the washing water stored in the tub, and a detergent box assembly (not shown) to spray the washing water introduced from the outside and mix the washing water with detergent and an additive and store the mixture.
[0018] The cabinet 110 includes a cabinet body 111 , a cover 112 arranged on the front side of the cabinet body 111 and attached thereto, a control panel 115 arranged on one side of the cover 112 and connected to the cabinet body 111 , and a top plate 119 disposed on an upper side of the control panel 115 and coupled to an upper side of the cabinet body 111 . The cabinet cover 112 includes a laundry inlet hole (not indicated) for inserting the laundry into a drum 122 , and a door 113 rotatably coupled to the cabinet cover 112 so that it opens and closes the laundry input/outlet opening. The control panel 115 includes a display 118 for providing information of the laundry processing device 100 to a user on the outside, an input unit 117 for receiving an external command signal from the user so as to control the laundry processing device 100 , and a detergent box insert hole (not indicated) formed at one side of the control panel 115 to fit the detergent box 160 therein. The detergent box assembly (not shown) includes a washing water spraying device (not shown) for spraying washing water introduced from the outside to the detergent box 160 and a detergent box 160 for storing the sprayed washing water.
[0019] The operation of the laundry processing device 100 will be discussed. The user applies power to the laundry processing device 100 . After applying power, the user inserts either liquid detergent or solid detergent into the detergent box 160 . Once either the liquid detergent or the solid detergent is inserted, washing water is introduced from the outside and mixed with either the liquid detergent or the solid detergent. The mixed washing water flows to the drum 122 and the tub, and is mixed with laundry by the rotation of the drum 122 . When laundry washing using the rotation of the drum 122 is completed, the washing water is discharged out by the washing water draining device. Once the washing water is discharged, washing water containing neither the liquid detergent nor the solid detergent is supplied from the outside to rinse the laundry, and the laundry is dewatered.
[0020] FIG. 2 is a perspective view showing one embodiment of a detergent box 160 shown in FIG. 1 . FIG. 3 is a cross-sectional view taken along line of FIG. 2 .
[0021] Referring to FIGS. 2 and 3 , the detergent box 160 includes a detergent storage unit 161 for storing detergent and an additive storage unit 162 formed at one side of the detergent storage unit 161 , and for storing an additive. The detergent box 160 includes an opening part (not indicated) at one side of the detergent storage unit 161 . A regulating unit 170 is included which is attached to one side of the opening part and opens and closes the opening part. The regulating unit 170 includes a body portion 171 for opening and closing the opening part, an attachment portion 172 formed at one side of the body portion 171 , and for attaching the detergent box 160 and the body portion 171 , and a load portion 173 biased from the body portion 171 , and for applying force to cause the body portion to close the opening part.
[0022] The operation of the laundry processing device 100 will be discussed. The user applies power to the laundry processing device 100 and inserts the liquid detergent or the powdered detergent into the detergent box 160 . If the user inserts the liquid detergent, the liquid detergent is stored in the detergent storage unit 161 . Once the liquid detergent is stored in the detergent storage unit 161 , the liquid detergent remains in the detergent storage unit 161 by means of regulating unit 170 . Even if the liquid detergent stored in the detergent storage unit 161 applies a pressure to the regulating unit 170 , the load portion 173 applies force so that the body portion 171 closes the opening part of the detergent storage unit 161 . As a result, the liquid detergent remains stored in the detergent storage unit 161 .
[0023] After the liquid detergent is stored in the detergent storage unit 161 , the washing water supply device supplies the washing water from the outside. Once the washing water is supplied, the washing water enters the detergent box 160 and flows to the detergent storage unit 161 . If the water level of the washing water in the detergent storage unit 161 is higher than a predetermined water level, a pressure is applied to the regulating unit 170 . If the pressure becomes stronger than the force applied from the load portion 173 , the regulating unit 170 is opened. Once the regulating unit 170 is opened, the washing water flows to the drum 122 and the tub.
[0024] When the user inserts the powdered detergent into the detergent storage unit 161 , the regulating unit 170 prevents the powdered detergent from flowing out. The regulating unit 170 is prevented from being opened due to the powdered detergent. After the user inserts the powdered detergent, when washing water is supplied from the outside, the regulating unit 170 is opened in the same or similar manner as described above. Accordingly, the powdered detergent is mixed with the washing water and flows to the drum 122 and the tub.
[0025] FIG. 4 is a perspective view showing one embodiment of a regulating unit 170 shown in FIG. 3 . FIG. 5 is a cross-sectional view showing when the regulating unit 170 shown in FIG. 4 closes an opening part. FIG. 6 is a cross-sectional view showing when the regulating unit 170 shown in FIG. 4 opens the opening part. FIG. 7 is a conceptual view showing the load of the regulating unit shown in FIG. 4 .
[0026] Referring to FIGS. 4 to 7 , the regulating unit 170 includes a body portion 171 for opening and closing the opening part, an attachment portion 172 formed at one side of the body portion 171 , and for attaching the detergent box 160 and the body portion 171 , and a load portion 173 biased from the body portion 171 , and for applying force to cause the body portion to close the opening part. The load portion 173 includes a load portion body 174 extending from the body portion 171 and a load producing portion 175 arranged on the load portion body 174 and producing a load in the load direction.
[0027] The operation of the regulating unit 170 will be discussed. The user inserts the liquid detergent or the powdered detergent into the detergent storage unit 161 . Once the liquid detergent or the powdered detergent is stored in the detergent storage unit 161 , the liquid detergent or the powdered detergent applies force to the regulating unit 170 . The loads ω 1 and ω 2 produced in the regulating unit 170 prevent the regulating unit 170 from being opened by the force. The load ω 1 of the body portion 171 and the load ω 2 of the load portion 173 are applied to one side of the engaging portion 172 . The load ω 1 of the body portion 171 and the load ω 2 of the load portion 173 are applied to the same side of the engaging portion 172 to produce a moment. That is, a moment is produced clockwise by the load ω 1 of the load portion 173 . Also, a moment is produced clockwise by the load ω 2 of the body portion 171 . On the other hand, a moment is produced counterclockwise in the regulating unit 170 by the force applied from the powdered detergent. At this point, the sum of the moment produced by the load ω 1 of the load portion 173 and the moment produced by the load ω 2 of the body portion 171 is greater than the moment produced by the force applied from the powdered detergent or the liquid detergent. Accordingly, the regulating unit 170 is prevented from being opened due to the liquid detergent or the powdered detergent.
[0028] When washing water is supplied from the outside, the washing water is mixed with the liquid detergent or the powdered detergent and applies force to the regulating unit 170 . The regulating unit 170 applies force to the regulating unit 170 by the pressure of the washing water. At this point, the sum of the moment produced by the load ω 1 of the load portion 173 and the moment produced by the load ω 2 of the body portion 171 is less than the moment produced by the force produced by the pressure of the washing water, the regulating unit 170 is opened. When the regulating unit 170 is opened, the washing water flows to the drum 122 and the tub. Accordingly, the user can use the liquid detergent or the powdered detergent without attaching a separate container to the detergent box 160 . When the flow of the washing water to the drum 122 and the tub is completed, the regulating unit 170 closes the opening part by the loads ω 1 and ω 2 .
[0029] The detergent box 160 includes a restraining wall for restraining the degree of rotation. The restraining wall 180 prevents the regulating unit 170 from being rotated at more than a predetermined angle. That is, when washing water is supplied from the outside and stored in the detergent storage unit 161 , the regulating unit 170 is opened by the water pressure. At this point, the regulating unit 170 rotates counterclockwise. When the regulating unit 170 rotates at more than the predetermined angle, a moment is produced counterclockwise by the loads ω 1 and ω 2 produced in the regulating unit 170 . Due to this moment, the regulating unit 170 is not able to close the opening part even after the washing water flows to the drum 122 and the tub. However, in the case that the restraining wall 180 is formed, the regulating unit 170 restrains the angle of rotation so as not to exceed the predetermined angle. That is, the restraining wall 180 restrains the load portion 173 during the rotation of the regulating unit 170 so that the load ω 1 of the load portion 173 and the load ω 2 of the body portion 171 are produced at one side of the engaging portion 172 . Accordingly, the regulating unit 170 is not able to rotate at more than the predetermined angle because of the restraining wall 180 . Also, once the flow of the washing water is completed, the regulating unit 170 closes the opening part by the loads ω 1 and ω 2 .
[0030] The laundry processing device 100 is not limited to the foregoing description. The load ω 1 of the load portion 173 and the load ω 2 of the body portion 171 may be different. That is, the laundry processing device 100 may be configured such that the load ω 2 of the body portion 171 is larger than the load ω 1 of the load portion 173 . In the case that the load ω 2 of the body portion 171 is larger than the load ω 1 of the load portion 173 , a moment is produced by the loads ω 1 and ω 2 after the washing water flows to the drum 122 and the tub. That is, if the washing water is below a predetermined water level in the detergent storage unit 161 , the regulating unit 170 rotates by the moment produced by the load ω 2 of the body portion 171 and the moment produced by the load ω 1 of the load portion 173 . At this point, the moment produced by the load ω 2 of the body portion 171 is larger than the moment produced by the load ω 1 of the load portion 173 , the regulating unit 170 rotates clockwise. Accordingly, once the low of the washing water is completed, the regulating unit 170 closes the opening part.
[0031] FIG. 8 is a cross-sectional view showing another embodiment of the regulating unit 170 shown in FIG. 3 . The same reference numerals same as those used in the first embodiment indicate the same members. In the following, a description will be given focusing on the differences between the previous embodiment and this embodiment.
[0032] Referring to FIG. 8 , the regulating unit 270 includes a body portion 271 attached to one side of the detergent box 160 and an elastic portion 272 for producing an elastic force in the body portion 271 so as to resist the load of the liquid detergent or powdered detergent. The elastic portion 272 may include a spring for producing an elastic force in the body portion 271 .
[0033] The operation of the regulating unit 270 will be discussed. The elastic portion 272 produces the elastic force so as to resist the load of the liquid detergent or powdered detergent. That is, when the user inserts the liquid detergent or the powdered detergent into the detergent storage unit 261 , the body portion 271 closes the opening part by the elastic force. At this point, when washing water is supplied from the outside and poured into the detergent storage unit 261 , the pressure of the washing water and the elastic force become equal when the water level of the washing water reaches a predetermined water level. When the water level of the washing water exceeds the predetermined water level, the water pressure becomes greater than the elastic force. As the pressure of the washing water is increased, the body portion 271 opens the opening part. Once the opening part is opened, the washing water flows to the drum 122 and the tub. When the supply of the washing water is stopped, water level of the washing water becomes lower than the predetermined water level. Once the water level of the washing water becomes lower than the predetermined water level, the pressure of the washing water becomes smaller than the elastic force and allows the body portion 271 to close the opening part. Accordingly, the user can use the liquid detergent or the powdered detergent without attaching a separate container to the detergent box 260 . Moreover, the user benefits from an increased user convenience since there is no need to attach the container. | The present invention aims to provide a laundry processing device wherein detergent is supplied by means of the washing water. The present invention provides a laundry processing device comprising: a detergent box having a detergent storage unit which accommodates a detergent and which has an opening part; a washing-water supply device for supplying the detergent storage unit with washing water from the outside; and a regulating unit for closing the opening part of the detergent storage unit in which the detergent is accommodated, and opening the opening part by means of the washing water supplied by the washing-water supply device. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to telecommunication. In particular, the invention relates to a new and sophisticated method for utilizing a mobile station for the transmission of authorization information in a telecommunication network.
BACKGROUND OF THE INVENTION
[0002] The use of mobile stations as a means of sending and receiving information in the form of text and graphics is constantly increasing. Textual information can be transmitted using e.g. the short message service (SMS). Certain mobile station models are also capable of receiving various logos, icons or messages containing images.
[0003] The use of the Wireless Application Protocol (WAP) is gaining ground in solutions requiring a link between portable terminals, such as mobile stations, and Internet applications, e.g. electronic mail, WWW (World Wide Web), news groups. Using the Wireless Application Protocol, it is possible to transmit visual information as well. The Wireless Application Protocol provides an architecture which adapts mobile telephones, browsers used in mobile telephones and the WWW into a functional entity. The HTML (Hyper Text Mark-up Language) used in the WWW is converted into WML (Wireless Mark-up Language), which is a version developed for a wireless environment, when information is to be transmitted to mobile stations. At present, the description language of the WAP standard is the WML language, but the language may also be understood to be any other description language consistent with the future WAP standard. The Wireless Application Protocol consists of the following five layers: Wireless Application Environment (WAE), Wireless Session Layer (WSL), Wireless Transaction Layer (WTP), Wireless Transport Layer Security (WTLS) and Wireless Datagram Layer (WDP). ‘Wireless application environment’ refers e.g. to a WTA (Wireless Telephone. Application). or to some other appropriated environment. As the lowest layer there is additionally a system-dependent layer which determines the method of conveying information within the system in question. The specifications relating to the Wireless Application Protocol are available at the WWW address www.wapforum.org.
[0004] To expand the sphere of application of present-day mobile stations so as to allow even the transmission of information requiring verification, such as various types of admission tickets or cash vouchers or equivalent, many kinds of solutions have been proposed. According to one method, the solution is to transmit the information into a mobile station by utilizing the short message function. Instead of visual verification, the verification can also be accomplished by utilizing e.g. the infrared link of the mobile station or a separate ticket printer, by means of which the user himself prints out the actual ticket to be used, observing instructions received via the Internet or in connection with an order placed via the mobile station.
[0005] A problem with a verification procedure implemented using the short message function is that the user is required to perform certain actions to present the information to be verified in connection with the verification procedure. A further problem is that, if only visual verification of the information is desired, it is not possible to add to a normal text message any property or check element of a visual nature. Such visual components include e.g. various images or patterns.
[0006] A problem with the-use of an infrared link or a ticket printer is that, in order to be able to use a ticket already ordered and possibly paid for, the user has to perform complicated and time-consuming additional operations with his mobile station.
[0007] In addition, in both of the two alternative solutions described above, the user has to transfer the ticket information by some means from the mobile station to an external device in order to obtain from the device an actual ticket showing e.g. a seat number or other essential information. A separate device as described above is necessary because otherwise the text message or business card containing the ticket can be easily forged and/or copied for several people.
OBJECT OF THE INVENTION
[0008] The object of the present invention is to disclose a new type of method that will eliminate the above-mentioned drawbacks or at least significantly alleviate them. A specific object of the invention is to disclose a method that will make it possible to use a mobile station for the transmission of authorization information requiring verification in a telecommunication network.
BRIEF DESCRIPTION OF THE INVENTION
[0009] In the present invention, authorization information requiring verification is transmitted in a telecommunication network using a mobile station. Said telecommunication network comprises said mobile station. ‘Authorization information requiring verification’ refers to information which can be used to verify a person's/persons' right of admission or right to use a service, or to specify the above-mentioned rights. Examples of such rights are various tickets of admission, seat tickets, cash vouchers and equivalent. The telecommunication network comprises a digital mobile communication network, such as e.g. a GSM network (Global System for Mobile Communication, GSM), UMTS network (Universal Mobile Telecommunication System, UMTS) or equivalent. The mobile communication network preferably comprises, service extensions enabling the transmission of textual and/or graphic information, such as e.g. the implementation of a Short Message Service (SMS), GPRS service (General Packet Radio Service) and/or WAP protocol (Wireless Application Protocol). The authorization information requiring verification is transmitted to the mobile station. Next, the authorization information transmitted is presented on the display of the mobile station. Further, the authorization information presented is read from the display of the mobile station. Finally, the authenticity of the authorization information thus read is verified.
[0010] According to the invention, the authorization information is transmitted in a form comprising information to be presented graphically. Examples of this type of information are various graphic patterns and/or arrays of patterns. These allow easy visual verification of the information. In addition to a pattern/array of patterns, additional information e.g. in the form of text or and/or a sequence of digits is transmitted if necessary. Further, according to the invention, the authorization information is presented on the display of the mobile station using a user-independent function of the mobile station in question for the presentation of graphic information, such as e.g. an operator logo function. Thanks to the user of a user independent function, the user is not required to perform any actions in connection with the verification of the information to be verified.
[0011] In an embodiment of the invention, an authorization server is provided in conjunction with the telecommunication network, said server being used for the maintenance and transmission of authorization information. In other words, this server maintains the information to be verified, the associated patterns as well as information regarding their rightful owners.
[0012] In an embodiment of the invention, the authorization information presented is read manually from the display of the mobile station.
[0013] In an embodiment of the invention, the authorization information presented is read from the display of the mobile station mechanically, using e.g. a display reader.
[0014] In an embodiment of the invention, the authenticity of the authorization information is verified by transmitting predetermined identification data to a predetermined confirming party. The verification is implemented e.g. as a predetermined service number which is called and to which the identification data is returned, whereupon a confirmation/rejection of authenticity is sent from said service number.
[0015] In an embodiment of the invention, the identification data used consists of the subscriber number of the mobile station in question.
[0016] In an embodiment of the invention, a predetermined identifier is transmitted as part of the authorization information, and the identifier in question is used as identification data.
[0017] In an embodiment of the invention, the above-mentioned authorization server is used as a confirming party.
[0018] In an embodiment of the invention, the operator logo function of the mobile station is used as a presentation function. ‘Operator logo function’ refers to a function implemented in the mobile station and used to present an optional, changeable graphic pattern, such as e.g. the logo of a mobile communication operator, on the display of the mobile station.
[0019] In an embodiment of the invention, the WAP Push function of the mobile station the is used a presentation function. ‘WAP Push function’ refers to a user-independent function whereby information is transmitted to a WAP terminal, preferably a mobile station, without the user having first specifically requested the transmission of the information. The Push function involves three different parties: a WAP client program (in the mobile station), a Push Proxy Gateway and a Push Initiator. The protocol used between the WAP client program and the Push Proxy Gateway is the Push Over-the-Air protocol (Push OTA), and the protocol used between the Push Proxy Gateway and the Push Initiator is the Push Access protocol (PAP). The Push function is more amply described e.g. in 1.2 WAP specification SPEC-PushArchOverwiew-19991108.
[0020] As compared with prior art, the present invention has the advantage that the user does not have to perform any time-consuming operations. Prior to the verification of the information, the user has been automatically sent the information requiring verification, in a form that allows it to be directly seen upon visual inspection of the terminal. The information can be checked by the human eye or mechanically if further surety is needed. Further, the present invention makes it difficult to forge and/or make illicit copies of the information to be verified, such as e.g. a ticket of admission. By using ticket-specific unique visual auxiliary information and fast mechanical verification of it, forgery of the ticket can be prevented altogether yet without substantially retarding the process of verification of the information. Moreover, thanks to the present invention, terminal devices already existing at present need not be provided with any accessories and no modifications need to be made in the software used in them to permit verification of the information.
LIST OF ILLUSTRATIONS
[0021] In the following, the invention will be described by the aid of a few examples of its embodiments with reference to the attached drawing, wherein
[0022] [0022]FIG. 1 presents a diagram representing a method according to the invention,
[0023] [0023]FIG. 2 presents a diagram representing a method according to the invention, and
[0024] [0024]FIG. 3 presents a diagram representing a method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] [0025]FIG. 1 presents a flow diagram representing a method according to the invention by way of example, in which method the verification of authorization information is performed mechanically. The actual ordering and purchase of the information to be verified have already taken place, and the ticket server functioning as an authorization server knows who is the legal owner of the information to be verified, so the server is able to send the authorization information to the right mobile station.
[0026] In the method, the server maintaining owner information regarding the information to be verified first sends the information to be verified to its rightful owner, step 1 . The authorization information is transmitted in the form of an operator logo via a SMSC network component of the mobile communication network. Instead of a SMSC network component (Short Message Service Center, SMSC), it is possible to use e.g. a network component based on the GPRS technology. The information is presented on the display of the mobile station by using the operator logo function and read from the display by means of a detector functioning as a verifier, step 2 .
[0027] If the operator logo pattern is used e.g. as an electric cinema ticket, then all the information necessary for the use of the ticket can be transmitted by the method of the invention to the user's terminal in a form which can be quickly verified visually but is still very difficult to forge/copy. In the case of a cinema ticket, the authorization information transmitted comprises information relating to the movie, such as e.g. use by date, time, seat/seats reserved and a part of the title of the movie. Moreover, the authorization information comprises information relating to visual inspection, such as e.g. an array of predetermined patterns of a stochastic form. The array of patterns is used e.g. so that the array of patterns to be used in connection with each showing in the cinema is different. In this way the authenticity of the ticket being used is verified visually. In addition, if the information is only sent to the client a moment before the application of the ticket, the users will also not see the logo containing the Information until just before the application of the ticket, so it will be very difficult to fabricate any homemade tickets.
[0028] The detector comprises e.g. a display reader. For example, for verification of the information to be verified which the user has ordered, the user places the mobile station in a reader, which takes a picture of the display of the mobile station and performs an OCR-type (Optical Character Recognition, OCR) examination of the information presented on the display. The information to be verified comprises e.g. a bar code, or completely stochastic patterns which cannot be distinguished from each other by the human eye. Each ticket bears a unique pattern unambiguously identifying the ticket. The verifying device contains stored information containing all the patterns belonging to the set of tickets in question, so this feature makes it possible to completely eliminate any attempts at forging a ticket, yet without requiring the client to perform any time-consuming operations on his mobile station; it is sufficient for the client to keep his mobile station for a very short time in the reader. Further, in the communication between the mobile station and the verifying device, it is possible to take advantage of solutions based on Bluetooth technology. ‘Bluetooth’ is a wireless transmission technology designed for short distances, which is described in greater detail e.g. at WWW address www.bluetooth.com.
[0029] In step 3 , the verifying device checks whether a ticket corresponding to the image presented as an operator logo exists or not. This check may be performed e.g. as an inquiry sent to the server having issued the ticket, or the information required for the verification may be stored in conjunction with the verifying device. The result of the verification is transmitted to the mobile station, step 4 a, and/or to the verifying device, step 4 b. In step 5 , the ticket is either rejected or accepted.
[0030] [0030]FIG. 2 presents by way of example a method according to the invention in the form of a flow diagram, in which method the authorization information is verified visually by a person. The actual ordering and purchase of the information have already taken place, and the ticket server functioning as an authorization server knows who is the rightful owner of the information to be verified, so the server is able to send the authorization information to the right mobile station. In the method, the server maintaining information regarding the owner of the information to be verified first sends the information to be verified to its rightful owner, step 21 . The authorization information is transmitted as an operator logo via the SMSC network component of the mobile communication network. Instead of the SMSC network component (Short Message Service Center, SMSC), it is possible to use e.g. a network component based on GPRS technology. The information is presented on the display of the mobile station by using the operator logo function, and it is read from the display by a person acting as an inspector, step 22 . In step 23 , the ticket or equivalent information transmitted in each case as authorization information is accepted or rejected. The method illustrated in FIG. 2 is particularly well suited for the transmission of e.g. patterns giving a right to a discount, such as e.g. a cash voucher for a packet of coffee, which needs to be verified quickly at a cash desk and which, because of the low value, is unlikely to be forged.
[0031] [0031]FIG. 3 presents by way of example a method according to the invention in the form of a flow diagram, in which method the authorization information is verified visually by a personal, and in which method, in the event of ambiguity, the person performing the verification, in addition to visual verification, also contacts a ticket server functioning as an authorization server to check the authenticity of the information to be verified. The actual ordering and purchase of the information have already taken place, and the ticket server functioning as an authorization server knows who is the rightful owner of the information to be verified, so the server is able to send the authorization information to the right mobile station. In the method, the server maintaining information regarding the owner of the information to be verified first sends the information to be verified to its rightful owner, step 31 . The authorization information is transmitted as an operator logo via the SMSC network component of the mobile communication network. Instead of the SMSC network component (Short Message Service Center, SMSC), it is possible to use e.g. a network component based on GPRS technology. The information is presented on the display of the mobile station by using the operator logo function, and it is read from the display by the person acting as an inspector, step 32 .
[0032] Next, to obtain further surety, the person acting as a verifier sends a confirmation request e.g. by calling/sending a short message to a predetermined service number, from where he is connected e.g. to a server of the owner of the information to be verified, step 33 . The verification is based either on the telephone number of the client's mobile station or on an identifier included in the information to be verified, said identifier consisting of e.g. a stochastically changing sequence of digits which in connection with the ordering of the ticket has been linked to the ordering party. Thus, the verifier can inquire to whom a ticket provided with a given sequence of digits has been sold. After this, a confirmation message consisting of image or equivalent information is transmitted to the mobile station of the client being scrutinized, said message allowing the ticket inspector to definitely ascertain the rightful owner of the ticket, step 34 . In practice, the confirmation message is e.g. the original pattern sent against an operator logo. In addition/alternatively, the confirmation data can be sent e.g. to the inspector's mobile station, step 35 . In this case, the confirmation comprises e.g. the information to be verified as an operator logo and owner information in the form of text. To guarantee the reliability of the verification, it can only be performed from predetermined numbers. In step 36 , the ticket or equivalent transmitted in each case as authorization information is accepted or rejected.
[0033] The invention is not limited to the examples of its embodiments described above; instead, many variations are possible within the inventive idea defined in the claims. | The present invention relates to a method for utilizing a mobile station for the transmission of authorization information requiring verification in a telecommunication network comprising the mobile station. In the method, the information to be verified is transmitted to the mobile station, the authorization information transmitted is presented on the display of the mobile station, the authorization information presented is read from the display of the mobile station, and the authenticity of the authorization information thus read is verified. According to the invention, the authorization information is sent in a form comprising information to be presented in a graphic form, and the authorization information is presented on the display of the mobile station using a user-independent function of the mobile station in question for the presentation of graphic information. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to needle-suture combinations and particularly to a combination of a surgical needle with a suture in which the force necessary to separate the needle from the suture is within an acceptable range for convenient removal of the needle from the suture by a sharp tug.
In many surgical procedures, surgeons use a technique which employs a non-needled suture and an eyed needle. The needle is threaded by the nurse and the surgeon takes one or more passes through the tissue using a needleholder. He slips the needle off the suture, returns the needle to the nurse, and is ready for another threaded needle from the nurse. An assistant follows behind and ties the suture.
Some surgeons find that this technique is simpler than using a needled item and cutting the suture with a scissors after each pass. However, the time required for threading results in a significant waste of expensive operating room time.
The security of attachment of eyeless needles to absorbable surgical sutures or to non-absorbable surgical sutures is prescribed in the U.S. Pharmacopoeia, Vol. XVIII at Page 944 (also see U.S. Pharmacopoeia, Vol. XVII, Page 919). It has been the practice of suture manufacturers in the United States and abroad to securely attach the suture to the needle by swaging or with an adhesive so that the minimum pull-out standard recited in the U.S. Pharmacopoeia is met or exceeded.
To avoid the problems discussed above it has been found useful to use needle-suture combinations in which the needle and the suture are readily separable from each other by a sharp tug. Several methods have been devised for preparing needle-suture combinations in which the pull-out values, or the force required for separating the needle from the suture by a straight pull, is within a controlled range.
One approach to this problem is described in copending and co-assigned application Ser. No. 409,974, filed Oct. 26, 1973. This approach involves inserting into a drilled hole in the blunt end of the needle one end of the suture which has been sized with a resin and is smaller in diameter than the remainder of the suture and then swaging the needle at its blunt end to provide a controlled degree of compression to the end of the suture within the hole. This approach is restricted to needle-suture combinations wherein the suture is of large size, i.e., size 4/0 and larger (diameter greater than 7.0 mils), and produces average pull-out values of 3 to 26 ounces, indicating that it takes a straight pull of the magnitude within that range to separate the needle from the suture.
Another approach to the problem is described in copending and co-assigned application Ser. No. 446,174, filed by Robert Barclay Duncan on Feg. 27, 1974. In this approach sufficient tension is applied to the suture in a swaged needle-suture combination to move the suture relative to the needle recess and the tension is released when the force drops to the range desired for the pull-out value, the range varying for different sizes of suture. This approach is applicable to a broader range of suture sizes than the approach of application Ser. No. 409,974, and is applicable to sizes as small as 8/0.
The present invention provides another approach to the problem and provides for easy separation of needles from needle-suture combinations without requiring any change in the manner of manufacture of the needle-suture combinations. It also permits the conversion of existing stocks of needle-suture combinations to products from which the needles can be separated by application of moderate force.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a needle-suture combination comprising a needle having a sharp end and a blunt end and having a recess at said blunt end, a suture having one tip positioned within said recess, means retaining said tip of said suture within said recess to attach said suture to said needle, and a radiation-weakened segment in said suture adjacent the location of its attachment to said needle. It is essential that the suture be made of a material which is subject to weakening after exposure to radiation, as will be explained.
Radiation-weakening is preferably achieved after the needle-suture combination has been assembled by the insertion of the suture tip into the recess in the blunt end of the needle and by its attachment therein by swaging of the blunt end of the needle or by an adhesive. In some cases, it may be more convenient to subject a segment of a suture to radiation weakening before attachment of the suture to a needle.
Radiation-weakening is achieved by exposure of a segment of the suture at or near its point of attachment to the needle to a sufficient dose of beta or gamma radiation to reduce the tensile strength in the irradiated segment to a desired value. The necessary dose, or exposure, to achieve the desired weakening is dependent on the nature of the suture material and its diameter and upon the degree of weakening desired. In the case of sutures of small diameter which have pull-out values within the desired range, radiation-weakening is, of course, unnecessary.
For suture materials readily susceptible to radiation-weakening in sutures of small diameters and requiring only slight weakening to be within the desired range of pull-out values, useful radiation-weakening may be achieved with radiation doses as low as about 5 megarads. For suture materials which are more difficult to weaken by irradiation in sutures of larger diameter it may be necessary to provide a dose of 200 megarads, or more, before the rupture strength of the suture is reduced to a practical value for easy separation of the needle from the suture.
The radiation used for localized suture weakening in accordance with this invention may comprise either a high energy electron beam, of the type produced by a linear electron accelerator, or a high energy beam of electromagnetic radiation of extremely short wave length, of the type generated by cobalt-60 or by a high energy X-ray generator. These forms of radiation are conventionally referred to as "beta" and "gamma" radiation, respectively. An electron accelerator capable of delivering a large dose of energy in a short time is preferred.
Radiation generators suitable for use in this invention include those frequently used by manufacturers of needle-suture combinations for sterilization purposes. For localized suture weakening, however, the arrangement is altered so that the suture passes transversely across the path of the beam instead of longitudinally, thereby isolating the radiation effect to a small segment of the suture length; and the arrangement is also altered to permit a plurality of passes of the suture segment to be weakened under the radiation beam and to thereby subject the segment to the cumulative dosage of such a plurality of passes. The sutures are preferably aligned parallel to each other in a grooved holder encased within a lead casing or other suitable shielding, except for an exposed open slot which permits the radiation to pass through the casing and act upon a short segment of each suture at or near its junction to its needle.
Fiber-forming materials suitable for sutures which have been found to be susceptible to radiation-weakening and useful in the practice of this invention include cellulose and cellulose esters including cotton, linen, viscose rayon and cellulose acetate; polyolefins including polypropylene and polyethylene; vinyl polymers, including polyvinyl alcohol, polyvinyl acetate and polyvinylidene chloride; acrylic polymers, such as polyacrylonitrile; and homopolymers and copolymers of lactide and glycolide. It has also been found that certain other suture materials are highly resistant to radiation-weakening; and sutures made of these materials are unsuitable for weakening by the method of this invention. Such radiation-resistant suture materials include nylon, silk and polyethylene terephthalate.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more readily apparent upon consideration of the following detailed description when taken in connection with the accompanying drawings wherein:
FIG. 1 is an enlarged fragmentary elevation, partly in cross section of the needle-suture combination of this invention at the juncture of the needle and the suture;
FIG. 2 is a view similar to that of FIG. 1 but showing rupture of the suture adjacent its juncture to the needle after application of sufficient tension thereto; and
FIG. 3 is an enlarged fragmentary elevation of a holder for the exposure of a plurality of needle-suture combinations to radiation at the desired sites with a portion broken away to show the holder interior.
DETAILED DESCRIPTION
As may be seen in FIGS. 1 and 2, needle 11 and suture 12 are attached to each other by the insertion of end 13 of the suture into hole 14 in blunt end 16 of the needle. The blunt end of the needle is subjected to cold pressure to produce swaged portion 17 of the needle, resulting in the distortion of hole 14 and the compression of suture tip 13 within the hole to affix the suture end within the hole.
A short segment A of the suture is then subjected to beta- or gamma-radiation to alter and weaken its structure, as represented schematically in FIGS. 1 and 2 by zig-zag cross-hatching. When the needle is tugged after the suture has been pulled through the desired tissues in the surgical procedure, the suture ruptures in radiation-weakened segment A, as shown in FIG. 2.
FIG. 3 shows a holder suitable for exposing a plurality of needle-suture combinations to radiation at the desired sites. Holder 21 comprises a circular pipe 22 which is either made of lead, or which includes a shielding of lead or other suitable material. Slot 23 is provided near one end 24 of the pipe to permit the passage of radiation therethrough. Within pipe 22 there are a plurality of needle-suture assemblies, aligned parallel to each other (by means not shown) with needles 11 at end 24 and with a segment of each suture 12 exposed to radiation through slot 23. Cooling means (not shown) are provided to prevent excessive temperatures in the shielding.
The treatment of needle-suture combinations to provide the desired radiation weakening involves the insertion of a plurality of appropriately aligned needle-suture combinations into pipe 22. Pipe 22 is thereafter moved into position under a concentrated beam of radiation so that the radiation passes through slot 23 at one end thereof and acts upon the suture portions immediately under the slot. Pipe 22 is then rotated about its axis, keeping the concentrated radiation beam passing through the slot so that each suture will receive a radiation dose in the desired location adjacent its juncture to its needle. The procedure may be repeated until the cumulative radiation dose is sufficient to provide the desired degree of weakening.
EXAMPLE 1
Needle-suture combinations, each made of a needle holding a size 0 polypropylene monofilament suture were subjected to varying cumulative doses of gamma radiation at the site on each suture of its junction to its needle. The gamma radiation was produced by cobalt-60 in apparatus usually used to sterilize the needle-suture combinations, except that most of the length of each suture was protected from radiation by encasement in lead. At each test level of cumulative radiation dosage, 10 needle-suture combinations were tested to determine the force necessary to produce a suture break and both the range and average values were determined.
EXAMPLE 2
The procedure of Example 1 was repeated, except that the needle-suture combinations comprised needles holding sizes 2-0 white twisted cotton sutures.
The average force required for suture break and the range at different levels of exposure in Examples 1 and 2 were as follows:
Example 1 Example 2Radiation Dose Average (lbs) Range (lbs) Average (lbs) Range (lbs)__________________________________________________________________________None 8.7 7.8-9.6 5.4 5.2-5.62.5 megarads 7.1 6.4-8.3 4.6 3.4-5.07.5 megarads 5.8 4.2-6.9 4.0 3.2-4.712.5 megarads 5.1 4.2-6.1 3.5 2.3-4.017.5 megarads 4.5 3.8-5.4 2.8 1.9-3.022.5 megarads 4.3 3.5-5.4 2.5 2.0-3.027.5 megarads 3.3 2.5-4.232.5 megarads 3.5 1.7-4.6__________________________________________________________________________
EXAMPLES 3 TO 11
A plurality of sutures in two sizes each of three different suture materials were subjected to repeated doses of gamma radiation from a cobalt-60 source in 5 megarad increments at localized areas thereof while the remainder of the length of each suture was shielded from the radiation. At each test level of cumulative radiation dosage, 10 sutures were subjected to tension to determine the force necessary to produce a suture break. The average values (in pounds) were as follows:
Example 3 4 5 6 7 8 9 10 11 polypropylene twisted poly(lactide-co-Suture Type monofilament cotton glycolide) braidSuture Size 4-0 3-0 2-0 4-0 3-0 2-0 3-0 1 5-0__________________________________________________________________________Megarads 0 3.4 4.5 7.6 2.63 4.3 5.7 7.7 24.2 3.51 5 1.93 4.7 2.23 6.8 7.8 22.910 1.60 3.62 1.90 3.93 7.24 21.115 1.33 3.30 1.68 3.4 6.6 19.620 1.30 2.80 1.45 2.93 6.2 18.225 1.20 2.43 1.4 2.54 5.9 17.130 0.78 2.26 1.01 2.46 5.4 15.935 0.78 1.70 2.26 0.95 1.76 2.23 5.32 14.9 1.9140 0.64 2.10 0.79 2.00 4.70 14.945 0.69 1.59 1.97 0.70 1.52 1.72 4.60 13.4 1.6555 0.91 0.86 0.95__________________________________________________________________________
As may be seen from the foregoing data the degree of radiation-weakening at equivalent radiation dosage varies with both the nature of the suture material and its cross-sectional area although the percentage of radiation-weakening for a particular material at a particular dosage is approximately the same, regardless of its cross-sectional area. In general, and as an approximation, polypropylene and cotton sutures require from about 0.4 to about 0.7 megarads of gamma radiation for each 1% of loss of strength at the radiation-weakened segment. Poly(lactide-co-glycolide) sutures require about 0.6 to about 1.2 megarads of gamma radiation for each 1% of loss of strength at the radiation-weakened segment. Suitable radiation dosages for other suture materials may be determined by those skilled in the art with a small amount of experimentation by the methods described above.
The invention has been described with respect to preferred embodiments but other embodiments and modifications will be apparent to those skilled in the art. | A needle-suture combination is provided in which the suture has a radiation-weakened segment adjacent to its attachment to the needle. The radiation-weakened segment permits a surgeon to separate the needle from the suture by a sharp tug. | 0 |
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention is generally related to medical devices for administrating intravenous fluids, and is specifically directed to a carrying device for retaining an intravenous fluid container.
2. Description of Prior Art
Administrating medication to patients intravenously is a well known medical technique. Typically, intravenous feeding is provided to persons who are bedridden. Consequently, the conventional facility adapted to dispense such fluids is a fixed, stationary stand located near the patient. The stand is used to support a bag or other type of fluid container, and makes patient mobility difficult. Certain patients need to receive a substantial amount of medication intravenously. However, the patient may not be incapacitated and require confinement to a bed. Nonetheless, a substantial amount of time is required when medicine must be fed to a patient dropwise through intravenous feeding. Patients are then forced to either stay stationary, or move about with a bulky, hard to maneuver device.
Although there has been attempts to mobilize the patient, prior art devices have fallen short of providing true latitude of movement. Some intravenous fluid container carrying devices require that another person such as a nurse or visitor hand carry the medicine container. Other more portable stations have a mounting container support structure on a movable wheeled cart or affixed to the patient's wheel chair, cart, stretcher or bed.
Certain devices have been developed for the intravenous fluid container to be worn on a person. These prior art devices are bulky, uncomfortable and not very conducive to free flow of patient movement. For example, one such medical apparatus is disclosed in U.S. Pat. No. 3,547,322 issued to Dawson. Adapted to support and carry a container of fluid on a patient, this apparatus is extremely bulky, awkward and uncomfortable for the patient to use. Similarly, U.S. Pat. No. 4,438,763 issued to Zablen provides an ambulatory support means to be used in connection with an intravenous delivery system. The support means consists of a rigid support sized to fit adjacent to the users back. Here, an upwardly extending member is used to carry the intravenous liquid container. Wearing this device, it is next to impossible for the patient to sit down.
Another type of medical device is disclosed in U.S. Pat. No. 4,582,508 issued to Pavelka. This device is designed for holding indwelling catheters under garments. Appearing to offer more comfort to the user, the device is not suitable for an intravenous fluid container for it lacks the effect of gravity on the free flow of fluid necessary to operate the intravenous system. No prior art device has been developed to comfortably accommodate and support the intravenous fluid bag onto the patient.
Other personalized carrying apparatus have also been developed for different types of use. The invention of U.S. Pat. No. 2,506,685 issued to Sadloski is a flashlight holder adapted to be worn on the shoulder of the user leaving his hands free to manipulate tools. Although simple to attach to the body, the shoulder supported flashlight holder cannot be worn underneath clothing and is not adequately designed to restrain a bag of fluid when worn on a person.
A need exists, therefore, for a retention device for an intravenous fluid container which is comfortable to wear on top of, or underneath clothing, and allows the patient to be freely mobile.
SUMMARY OF THE INVENTION
The present invention is a portable retention device for a bag containing intravenous fluids. The subject invention is illustrated in a single preferred embodiment. This portable retention device is particularly suitable for supporting and carrying a bag of intravenous fluid (IV bag). The retention device comprises a shoulder harness, a top bracket and a strap. The shoulder harness has a front end and a back end opposite the front end. The top bracket is connected to the shoulder harness with a pin. The strap engages the back end of the shoulder harness and has two ends. One end of the strap removably attaches to the front end of the shoulder harness. To secure the device to the patient, the straps ends are removably attached to each other. In the preferred embodiment, an IV bag is positioned between the shoulder harness and the top bracket and affixed to the retention device at the pin.
The portable retention device of the subject invention is designed to be comfortable for the patient to wear. The present invention may be worn over or under clothing. This carrying device provides a full range of movement for the wearer. The intravenous feeding system is unaffected because of the bag's position on the body of the wearer allowing a natural, dynamic free flow of fluids from the pull of gravity.
As an option, the intravenous container may be secured and tightened between the shoulder harness and the top bracket with a clamping mechanism. Although not necessary for the retention device to function, the clamping mechanism attaches to the shoulder harness and extends over the top bracket to add pressure to the container, forcing the fluid out and replacing gravity flow. The clamping mechanism may be helpful if the patient wearer wishes to lie down and continue to wear the retention device.
Preferably, the clamping device has two extensions and two clamp straps, each clamp strap being connected to one extension. Each extension is attached to the shoulder harness and extends outwardly therefrom. The clamp straps extend over the top bracket and are designed to be connected to and removed from each other.
The present invention overcomes the awkward construction and overall burdensome nature of the prior art devices. The retention device of the subject invention enables a patient to receive medication through an intravenous delivery system and, at the same time, walk without restriction. This device fits to the patient like a clothing garment as opposed to wearing something that looks and feels like a bird cage. The retention device safely protects the container of intravenous fluid and allows the intravenous system to operate as if it were held up by the conventional stand.
It is, therefore, an object and feature of the subject invention to provide a device for the administration of intravenous fluids to persons who are not bedridden.
It is another object and feature of the invention to provide a device which can be conveniently carried by a patient and which supports an intravenous fluid feeding system.
It is, yet, another object and feature of the invention to provide a retention device which is adapted to support a container of fluid in a position suitable for administering the contents by intravenous means to a patient as the patient moves freely about.
It is still another object and feature of the present invention to provide a device for the administration of intravenous fluids that is comfortable to wear on one's person.
Other objects and features of the subject invention will be readily apparent from the accompanying drawings and description of the preferred embodiment.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the retention device for an intravenous fluid container as worn by the patient.
FIG. 2 is a side view of the retention device for an intravenous fluid container showing the optional clamping mechanism.
FIG. 3 is a cross sectional view of the shoulder harness with strap ends attached to each other, as one strap end is attached to the shoulder harness.
FIG. 4 is a cross sectional view of the clamping means with clamps extending over the top bracket and attached to each other.
FIG. 5 is a cross sectional view of the strap engaging the shoulder harness at the back end of the shoulder harness.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the retention device for an intravenous fluid container made in accordance with the subject invention is illustrated in FIGS. 1-5 and is designated generally by the reference numeral 10. The retention device for an intravenous fluid container 10 comprises a shoulder harness 12, a top bracket 14, and a strap 16.
The shoulder harness 12 has a front end 18 and a back end 20 and may be worn over either shoulder of the patient. The front end 18 of the shoulder harness 12 downwardly extends from the patient's shoulder and over the patient's chest. The back end 20 of the shoulder harness 12 downwardly extend of the same shoulder and over the patient's back. The shoulder harness 12 may be made of a single or multiple layers of plastic, metallic or non metallic material and may also have a padded layer for extra comfort.
The top bracket 14 connects to the shoulder harness 12 by a pin 22. Like the shoulder harness 12, the top bracket 14 may be made of a plastic or other polymer substance, or metallic material and may also have a padded layer. As shown in FIG. 2, the container of intravenous fluid 24, typically a bag or other similar flexible object, is placed between the shoulder harness 12 and the top bracket 14. The container 24 is attached to the pin 22. The top bracket 14 shields the container of intravenous fluids 24 and acts as cover. The pin 22 may also be made from various materials both metallic and non-metallic.
In the preferred embodiment and as shown with particularity in FIG. 2, the pin 22 is extended through an opening (not shown) in the intravenous fluid container 24 and screws into the shoulder harness 12. The pin 22, however, may be press fitted or be affixed to the shoulder harness 12 by other equivalent means well known to those skilled in the art. Furthermore, the intravenous fluid container 24 may hook onto the pin 22 after the pin 22 is affixed to the shoulder harness 12. The strap 16 engages the shoulder harness 12 at the back end 20 of the shoulder harness 12. As shown in detail in FIG. 5, in the preferred embodiment, the strap 16 slidably engages the back end 20 of the shoulder harness 12 by looping into and out of two openings 26, 28 that are positioned in the back end 20. The strap 16 has two ends 30, 32. The ends 30, 32 are designed to be wrapped around the patient and attached to each other 30, 32 at the front end 18 of the shoulder harness 12. As shown in FIG. 3, only one end 30 attaches to the shoulder harness 12.
Preferably, the strap ends 30, 32 are attached to each other and to the shoulder harness 12 with a first set of VELCRO or hook and loop type fasteners 34a, 34b, 35, 36. The VELCRO fasteners 34b, 35 are attached to both sides of the one end 30 of the strap 16 to allow for attachment to the shoulder harness 12. The VELCRO fastener 36 is attached to the other end 32 of the strap 16. The opposite end 32 of the strap 16 has only one VELCRO type fastener 36 attached to it. Other type of fastening mechanisms may be utilized to attach the strap ends 30, 32 to the front end 18 of the shoulder harness 12 and to each other.
As shown in FIG. 1 and FIG. 4, the retention device may comprise an option clamping mechanism 38 attached to the shoulder harness 12 which extends over the container 24 and top bracket 14. The clamping mechanism 38 may be as simple as a single clamp strap (not shown) that ties around the shoulder harness 12, container of intravenous fluid 24 and top bracket 14. The clamping mechanism 38 may be useful when the patient anticipates bending over a lot or when the patient wishes to lie down. However, the clamping mechanism 38 is not required for the retention device to be functional.
As shown in the figures, the preferred clamping mechanism 38 comprises two extensions 40, 42 and two clamp straps 44, 46. Each extension 40, 42 is attached to the shoulder harness 12 and extends outwardly therefrom. Each extension 40, 42 has an opening 48, 50. Each clamp strap 44, 46 connects to one extension 40, 42 through its opening 48, 50. Each clamp strap 44, 46 extends over the top bracket 14 is secured to the other clamp strap 44, 46 through the use of a second set of VELCRO fasteners 52a, 52b, 54, 56, or the equivalent. As shown in FIG. 4, only one clamp strap 44 is additionally secured to the top bracket 14 with a VELCRO fastener 56, or equivalent means.
To utilize the retention device 10 of the subject invention, the shoulder harness 12 is placed over the shoulder of the patient. The top bracket 14 and intravenous fluid container 24 are then placed over the shoulder harness 12 and connected by the pin 22. Alternatively, the top bracket 14 is first connect to the shoulder harness 12 and placed over the shoulder of the patient. The intravenous fluid container 24 is then hooked onto the pin 22. The strap 16 is fitted around the patient and secured to the front end 18 of the shoulder harness 12. If preferred, the clamping mechanism 38 is then fastened over the intravenous fluid container 24 and top bracket 14.
The foregoing detailed description has been given only by way of example and various modifications will be readily apparent to those skilled in the art. | A retention device is provided for supporting the container of intravenous fluids on a patient who is not bedridden. The retention device has a shoulder harness, a top bracket connected to the harness by a pin and a strap engaging and connected to the shoulder harness. The retention device is designed for wide latitude of patient mobility and comfort. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Application No. 60/539,382, of the same name, filed on Jan. 26, 2004.
BACKGROUND OF THE INVENTION
[0002] Over the years there has been much research and development effort focused on the potential for developing a commercially viable Homogenous Charge Compression Ignition (HCCI) internal combustion engine for motor vehicles. A primary interest in developing a commercially viable HCCI engine for motor vehicles is that such an engine would theoretically have comparable efficiency to a conventional diesel engine (i.e. greater than a conventional gasoline engine), but with near zero production of harmful NOx and PM emissions. As of today, development of a commercially viable HCCI engine has never been successful because of (i) the difficulty in effectively controlling the initiation of combustion in a multicylinder HCCI engine over the changing speed and load conditions that would be involved in normal operation of a motor vehicle, and (ii) the difficulty in controlling initiation of combustion in an HCCI engine at full load.
[0003] Unlike with conventional gasoline engines (with combustion triggered by spark ignition), or diesel engines (with combustion triggered by late cylinder fuel injection), the start of ignition in HCCI engines is very hard to predict when the various operative parameters for combustion are in flux (e.g. intake charge-air temperature, cylinder wall temperature, boost pressure, charge-air oxygen concentration, fuel quantity, etc), and (in the case of cylinder wall temperature) even vary cylinder to cylinder.
[0004] As a result, HCCI research engines are only now beginning to be able to operate in multicylinder conditions, generally at steady state conditions and partial load conditions (e.g. with a maximum of about 75% of full load), with some minimal capability for slowly transitioning HCCI operation from one steady state condition to another for a change in power demand from the engine. Such transient ability for HCCI engines is currently far too slow (on the order of ten to one hundred times too long) for a commercially acceptable response the for use in a conventional motor vehicle. For example, for commercially acceptable responsiveness in a conventional vehicle, the time allowed for an engine to adjust from low power output to a relatively high power output would be a fraction of a second, whereas (without a major breakthrough) the best current HCCI engines would take multiple seconds to successfully make such a significant upward power transition in HCCI mode.
[0005] In addition, HCCI engines currently preferably use some time (e.g. 20-30 seconds) after the engine is turned on to operate in a non-HCCI mode (e.g. in spark ignition mode), until the various operative parameters for successful HCCI combustion stabilize to desired levels, before HCCI combustion is initiated. 1 1 Alternatively, the engine may be made to start quickly in HCCI mode if the engine is already warm (e.g. coolant and oil temperature are above 50° C.), such as through non-HCCI operation or external warming.
[0006] For at least these reasons, HCCI engines are currently far from being considered a viable option as a power plant for conventional motor vehicles.
[0007] Given the above limitations of HCCI engines, use of an HCCI-engine in conjunction with a hybrid powertrain (e.g. internal combustion engine/electric or internal combustion engine/hydraulic) motor vehicle would at first seem to only exacerbate the complications and shortcomings of an HCCI engine. This is because virtually all hybrid powertrain methods of operation not only operate the engine through rapid transients, but also rely on frequent cycling off of the internal combustion engine (or individual cylinders thereof) in order to avoid fuel consumption when the vehicle may instead operate through the secondary (e.g. electric or hydraulic) power source. However, as discussed above, rapid transients and rapidly cycling of an HCCI engine off and on during motor vehicle use would not be conducive to use with present HCCI technology (e.g. because of the delays for the engine to be able to transition between engine operating states or into HCCI mode), and thus an HCCI engine would appear to be an illogical match for a potential hybrid vehicle.
OBJECT OF THE INVENTION
[0008] Despite the foregoing, the object of the present invention is to provide a method of operation enabling effective and efficient use of an HCCI engine in a hybrid powertrain vehicle. In fact, as will be discussed herein, a hybrid powertrain application operated under the method of the present invention enables commercially acceptable use of an HCCI engine despite the developing state of HCCI technology as discussed above.
SUMMARY OF THE INVENTION
[0009] In this invention, an HCCI engine is used in conjunction with a hybrid powertrain, but the engine generally is operated in a manner to avoid rapid transients and rapid cycling off and on during vehicle operation. Engine power production in operation is protected from having to provide a direct and immediate power response to driver power demand. In this manner, the HCCI engine: (i) is allowed to more consistently produce power at one or more preset steady state (or semi-steady state) operating conditions, relieved from the need to quickly adapt to changes in driver power demand, and/or (ii) is allowed to more slowly transition between power levels reflective of the vehicle power demands, with the secondary power source (e.g. electric or hydraulic motor(s)) providing the more immediate power response to driver demands while the HCCI engine more slowly catches up. In addition, driver power demand greater than what can be provided by the HCCI engine (e.g. in the event of heavy vehicle acceleration) can be met through the addition of power from the powertrain's reversible secondary power source (e.g. one or more electric motor/generator(s) or hydraulic pump/motor(s)), thereby avoiding the need for operation by the HCCI engine at heavy power output levels, if desired.
[0010] Furthermore, as the power produced by the HCCI engine may also occasionally exceed the vehicle power demand, the excess power from the engine may be converted and stored as energy for use later by the secondary power source. For example, excess engine power may be converted to electric energy by the motor/generator and stored in a battery or capacitator, or alternatively, converted to hydraulic energy (pressure) by a pump/motor and stored in an accumulator. In this manner, driver power demand may be met by the vehicle with commercially acceptable responsiveness, while simultaneously enabling the use of a highly efficient low emission HCCI engine.
[0011] As will be understood in the art, this buffering method of operation of an HCCI engine in a hybrid vehicle may also provide the additional benefit of narrowing the speed/load range over which the engine must operate, allowing engine power demand peak shaving, to stray less drastically from vehicle average power demand levels, and thereby improve overall fuel economy for the vehicle.
DESCRIPTION OF THE PRIOR ART
[0012] For motor vehicles, potential benefits of a hybrid powertrain in increasing fuel economy have been known for many years. For example, it has frequently been considered that use of a hybrid powertrain enables recapture of energy used for braking a vehicle, and that use of a secondary power source can help improve the match (for best efficiency) between engine power capacity and average vehicle power demand. As a result, hybrid powertrain vehicles have now been successfully implemented in multiple commercial product lines, producing significant improvements in fuel economy.
[0013] In addition, it has also been known, but less discussed, that a hybrid powertrain can enable more effective control of harmful engine emissions. For example, U.S. Pat. No. 5,495,912 to Gray discloses that a hybrid powertrain can facilitate engine operation at a more constant engine speed and load, which might allow for better optimization of emission control devices as well as engine operation near optimal efficiency levels. In addition, U.S. Pat. No. 5,495,912 to Gray also discloses that a secondary power source in a hybrid powertrain vehicle may act as a buffer between the power required to propel the vehicle and the power produced by the internal combustion engine in order to moderate the variation of power demand experienced by the engine.
[0014] However, to applicant's knowledge it has not been suggested or taught in the prior art that a hybrid powertrain could be used as a means to actually enable use of an HCCI engine (or other advanced engine presently incapable of commercially acceptable transient response, such as a free piston engine) in a motor vehicle. In addition, while there has been mention and speculation before of an HCCI engine as a potential future engine for motor vehicles, including hybrid powertrain vehicles (see, for example, Aceves, HCCI Combustion: Analysis and Experiments, SAE 2001-01-2077), there has been no disclosure in the prior art of any method enabling actual practical or effective use of an HCCI engine in a motor vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic view of the structures for the preferred embodiment of the hybrid powertrain operated in accordance with the present invention.
[0016] FIG. 2 is an illustration, in graph form, of a sample relationship between vehicle power demand and HCCI engine power output in accordance with a preferred method of the invention.
[0017] FIG. 3 is all illustration, in graph form, of the use of engine power demand peak shaving in accordance with a preferred method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] It should first be noted that the present invention is not directed to a particular method of controlling combustion in an HCCI engine itself. Instead, the present invention is directed to a hybrid powertrain vehicle with an HCCI engine, and a method of operation of said vehicle so as to enable any potential state of the art HCCI engine, despite its present deficiencies, to operate in a commercially acceptable manner in the vehicle.
[0019] A preferred example of an HCCI engine capable of operating in conjunction with the present invention is that disclosed by the applicant in U.S. patent application Ser. No. 10/733,696, “Method of Operation for Controlled Temperature Combustion Engines Using Gasoline-like Fuel, Particularly Multicylinder Homogenous Charge Compression Ignition (HCCI) Engines,” filed Dec. 11, 2003, or in “An HCCI Engine: Power Plant for a Hybrid Vehicle,” SAE Paper No. 2004-01-0933, which are both incorporated herein by reference in their entirety. These references both fully disclose and enable the setup and operation of an HCCI engine. The HCCI engines disclosed therein have already performed multicylinder HCCI combustion with a (still relatively slow) transient ability to adjust from a low HCCI power output to a relatively high HCCI power output within 5 seconds or less, and back down in 1 second. Such performance is sufficient for operation with a hybrid powertrain vehicle under the present invention. For the present invention, the engine is preferably sized such that the power level it produces at its maximum efficiency level roughly coincides with the average power demand expected of the vehicle, so that the engine can most frequently operate around its maximum efficiency power level.
[0020] As for vehicle configuration, the present invention is preferably operated as a series hybrid vehicle, but may also be operated as a parallel hybrid vehicle. The preferred methods of operation with a series hybrid powertrain vehicle will now be set forth, and are more fully described in the inventor's co-pending U.S. application Ser. No. 10/672,732, “Methods of Operating a Series Hybrid Vehicle,” which teachings are incorporated herein by reference in their entirety.
[0021] For the preferred method of operation of the present invention in conjunction with a series hybrid vehicle, with reference to FIG. 1 herein (which is the same as the FIG. 1 to the above-mentioned co-pending application hereto), FIG. 1 depicts a series hybrid vehicle 10 with a secondary power source 12 , coupled to HCCI engine 16 via a generator 28 . When the driver makes a demand for power output, the secondary power source 12 is used to propel the vehicle. Generator 28 may, for example, comprise a pump or electric generator. The secondary power source 12 may comprise, for example, one or more hydraulic pump/motors or electric motors (motor/generators).
[0022] Generator 28 may be used to start the engine 16 by acting as a motor using energy from energy storage device 14 . When engine 16 is operating, the generator 28 is used to convert engine 16 's power into energy compatible for input into the secondary power source (e.g., electric current or pressurized hydraulic fluid). The converted energy is either supplied directly to the secondary power source 12 as direct input energy to power the secondary power source 12 as a motor, or supplied to the vehicle's energy storage device 14 and stored for later use (storable energy), or both. Thus, the secondary power source 12 is supplied with, and thereby powered by, either (1) an amount of available stored energy in an energy storage device 14 , (2) direct input energy generated by HCCI engine 16 , or (3) both. The determination as to which selection is made may depend on the amount of available stored energy stored within energy storage device 14 . When the engine 16 is used, the efficiency and power output level at which the engine 16 operates may also depend, at least in part, on either (1) the amount of available secondary energy stored in the energy storage device 14 or (2) vehicle 10 's speed and overall power demand (e.g., as discussed in the co-pending application Ser. No. 10/672,732 on series hybrid vehicles, or as indicated in FIG. 2 hereto).
[0023] As is well-known in the art, fuel energy stored in a vehicle tank (not shown) is used to power the HCCI engine 16 . An engine control device 20 , coupled to the engine 16 , and in communication with a CPU 18 , controls engine 16 , including fuel delivery. A generator control device 80 , coupled to the generator 28 , and in communication with CPU 18 , controls the speed of engine 16 by varying load. Based on the available stored energy level and, optionally, the vehicle speed or power demand, the CPU 18 issues a command signal C s1 to the engine control device 20 and a command signal C s2 to the generator control device 80 to operate the engine 16 at the desired power, speed and load. CPU 18 and control devices 20 , 80 and 26 together operate as the means to control the powertrain's operation, and may also be combined into a single powertrain control unit.
[0024] Included among the many sensors (not all shown) which provide an input signal I s to the CPU 18 of the present invention are sensors which detect and monitor engine speed and engine torque. Other sensors detect the driver's command to brake the vehicle 10 , the driver's command to power the vehicle 10 , and monitor vehicle speed. For example, the driver's demand to power the vehicle is represented by throttle sensor 22 . Further, a secondary energy capacity sensor 24 monitors the amount of available stored energy at any given time and generates a signal E s representative of the energy detected. The CPU 18 also includes a memory for storing various lookup tables.
[0025] A secondary power source control device 26 is coupled to the secondary power source 12 and used to control operation of the secondary power source 12 . Thus, when a driver issues a command to power the vehicle 10 , the CPU 18 detects this command and issues a command signal C s3 directing the secondary power source control device 26 to operate the secondary power source 12 as a motor. When in motor mode, the secondary power source 12 transmits power through a mechanical linkage (drivetrain) 30 to the vehicle 10 's wheels 32 , and thereby propels the vehicle 10 . In other embodiments, the mechanical drivetrain 30 may also connect to engine 16 , thereby allowing a portion of the engine's power to flow directly to the wheels as well without conversion by generator 28 .
[0026] As mentioned above, when the HCCI engine 16 is operating, an amount of energy from the engine 16 may be converted into an amount of storable energy and stored within the vehicle's energy storage device 14 . In addition, as is known to those of ordinary skill in the art, storable energy can also be obtained by capturing the vehicle's kinetic energy during a braking event. Thus when a driver issues a command to brake the vehicle 10 and the amount of available energy stored within the energy storage device 14 is below full capacity, the CPU 18 directs the secondary power source control device 26 to operate the secondary power source 12 (or other motor/generator) as a generator (or pump). The vehicle's kinetic energy is then directed to the generator/pump 12 (or other generator), converted into an amount of storable energy, and stored within energy storage device 14 .
[0027] As mentioned above, the present invention may also alternatively be operated in conjunction with a parallel hybrid powertrain vehicle. For a parallel hybrid vehicle, the teachings of U.S. patent application Ser. No. 10/386,029, “Methods of Operating a Parallel Hybrid Vehicle,” are also incorporated herein by reference in their entirety.
[0028] In addition to the methods of operation set forth above and in the respective parallel hybrid and series hybrid co-pending applications hereto, FIG. 2 illustrates an alternative method for managing HCCI engine output, to account for inability of the HCCI engine to quickly respond to changing vehicle power demands. For explanation, FIG. 2 shows changing vehicle power demands over time, to mimic a sample driving cycle for the vehicle.
[0029] In the first portion of the FIG. 2 cycle (“A”), representing a heavy acceleration demand, it is shown in this embodiment that the HCCI engine will respond at a rate acceptable to the HCCI engine (e.g., a 10% power change per second) to the desired speed/load (power output) operating point. Vehicle power demand is met in this stage through use of stored energy to supplement the actual engine output.
[0030] In the second portion (“B”) of the FIG. 2 cycle, representing a steady and moderate vehicle power demand, it is shown in this embodiment that when the vehicle power demand becomes less than the current engine output (point B 1 ), engine acceleration ceases, and again the engine begins to transition toward the next desired speed/load (power output) operating point at a rate acceptable to the HCCI engine. As can be seen, this is a scenario in which overall efficiency is improved because of the HCCI engine's slowed response, as the speed/load range over which the engine operated has been narrowed and strays less drastically from desired efficiency levels, which correspond to vehicle average power demand. This may be referred to as engine power demand peak shaving. The ability to benefit from engine power demand peak shaving may be increased by operating the engine in a less transient manner (e.g., by limiting engine response to only significant, consistent changes in vehicle power demand, and/or by averaging sensed vehicle power demand values, etc, as will be understood in the art). FIG. 3 presents a larger illustration of this concept over a longer sample drive cycle.
[0031] In addition, continuing with portion B of the FIG. 2 sample cycle, it should be noted that the desired speed/load operating point for the engine, even at relatively steady operating conditions, may be above or below the vehicle power output demand, as may be desired for adjusting the level of stored energy in the energy storage device. Thus, in FIG. 2 , because of the previous use of stored energy for-acceleration, the engine preferably operates in B at a level of high efficiency at a power output level higher than the current vehicle power demand, so that excess engine output may be used to replenish stored energy levels. Once stored energy nears replenishment to desired levels (point B 2 ), engine power output preferably begins to match the desired vehicle power.
[0032] Finally, continuing with FIG. 2 , in the event of deceleration, braking, or other low vehicle power demands (i.e. “C” and “D”), the engine may be either cycled off, allowed to idle, or allowed to continue operating at a level of minimum efficiency, with the preferred methods in this regard described more fully in the applicant's co-pending applications cited above. For this application, however, preferably the HCCI engine is not rapidly cycled on and off, for drivability reasons and ease in operating HCCI engines.
[0033] Although the methods set forth herein are described for HCCI engines, it will also be understood in the art that such methods may enable commercial use of other advanced engine types as well that face similar challenges in being developed from steady state operations to commercially acceptable transient ability. For example, the free piston engine disclosed by the inventor in U.S. Pat. No. 6,582,204, “Fully-controlled, Free Piston Engine,” could also be used in commercial application by combination with a series hydraulic hybrid powertrain and method in accordance with the present invention.
[0034] From the foregoing it will be understood that, although specific embodiments of the invention have been described herein, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims. | A Homogenous Charge Compression Ignition (HCCI) engine is used in conjunction with a hybrid powertrain. Power production from the HCCI engine in operation may be decoupled from, or assisted in, responding to driver power demand. In this manner, the HCCI engine: (i) is relieved from the need to quickly adapt to changes in driver power demand, and/or (ii) is allowed to more slowly transition between power levels reflective of the vehicle power demands, with a secondary power source providing the more immediate power response to driver demands. In addition, driver power demand greater than what can be provided by the HCCI engine may preferably be met through the addition of power from the powertrain's reversible secondary power source (e.g. one or more reversible electric motor/generator(s) or reversible hydraulic pump/motor(s)), thereby avoiding the need for full load operation by the HCCI engine. In this manner, driver power demand may be met by the vehicle with commercially acceptable responsiveness, while simultaneously enabling the use of a highly efficient low emission HCCI engine. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to French Patent Application No. 1462081 filed Dec. 8, 2014, the disclosure of which is hereby incorporated in its entirety by reference.
Field of the Invention
This invention pertains to an iron comprising a body and a metal soleplate that is folded back against the body, the soleplate comprising a lower surface defining an ironing surface and having, at least locally, a folded-up edge that defines a peripheral edge of said ironing surface, and pertains more specifically to an iron in which the folded-up edge of the soleplate comes into contact with the body in order to help attach the soleplate to the body.
Description of Related Art
There exists, in patent application EP 0 682 724 filed by the applicant, an iron comprising a soleplate, or cap, which is folded back against a heating body, the soleplate comprising a lower surface defining an ironing surface and comprising a folded-up edge defining a peripheral edge of the ironing surface. In this patent, the soleplate is attached mechanically against the body by bringing the folded-up edge into contact with the body.
Such a solution offers the advantage of providing a simple, inexpensive mechanical means of attaching the soleplate onto the heating body, as this mechanical attachment alone can attach the soleplate onto the body or supplement a layer of glue used to attach the soleplate to the body.
However, such a peripheral edge gripping the heating body presents the disadvantage of being relatively thick, which makes it difficult to iron around clothing buttons. Moreover, the significant thickness of such a peripheral edge also detracts from the visual appearance of the iron.
Consequently, the purpose of this invention is to provide a steam iron comprising an ironing bottom that is attached in a simple, inexpensive manner to the body of the iron, and that has a peripheral edge that is not very thick. Another purpose of the invention is to provide an iron in which the soleplate attachment offers complete freedom in the positioning of steam release holes in the soleplate.
SUMMARY OF THE INVENTION
To this end, the object of the invention is an iron comprising a body and a metal soleplate that is folded back against the body, the soleplate comprising a lower surface defining an ironing surface and comprising, at least locally, a peripheral edge, where the soleplate is folded up in the direction of the body and comes into contact with said body to help attach the soleplate to the body, characterized in that the peripheral edge comprises a portion that is folded 180° at the place where the soleplate extends parallel to the ironing surface, and in that the portion folded 180° is extended by a latch part that comes into contact with the body.
Such a characteristic makes it possible to obtain an iron in which the peripheral edge of the ironing surface is flat and thus not very thick, which makes ironing around clothing buttons easier.
In another characteristic of the invention, the peripheral edge of the ironing surface is of a thickness that is roughly equal to, or less than, twice the thickness of the soleplate.
In another characteristic of the invention, the latch part comprises, successively, starting from the portion folded 180°, an intermediate portion that is folded upward, and then a free end that is pressed down against the body to attach the soleplate to the body.
Such an attachment of the soleplate by the latch parts located at the periphery of the soleplate offers the advantage of being simple and inexpensive to implement. Moreover, this attachment is independent of the positioning of the steam release holes on the soleplate, such that the distribution of steam release holes on the soleplate can be modified without impacting the soleplate attachment.
In another characteristic of the invention, the intermediate portion extends perpendicular to the ironing surface.
In another characteristic of the invention, the free end of the latch part is aligned with the intermediate portion when the soleplate is set in place on the body, and then mechanically pressed down against the body to attach the soleplate.
In another characteristic of the invention, the ironing surface and the peripheral edge of the soleplate are covered with a coating, such as enamel.
Such a coating makes it possible to improve the mechanical characteristics of the ironing surface, and specifically how it slides and/or resists scratching.
In another advantageous characteristic of the invention, the latch part is not covered with the coating.
Such a characteristic prevents the coating from cracking when the latch part is folded.
In another characteristic of the invention, the latch part is covered with the coating at the same time as the peripheral edge and the ironing surface of the soleplate.
Such a characteristic simplifies the coating application process, as the coating can be applied without having to mask the latch parts.
In another characteristic of the invention, the soleplate is made of aluminum.
Such an aluminum soleplate offers the advantage of being easy to manufacture and of transferring heat well.
In another characteristic of the invention, the thickness of the soleplate is between 0.8 mm and 1.5 mm.
In another characteristic of the invention, the body is a heating body that contains an electrical resistor.
The purposes, aspects and advantages of this invention will be better understood through the description provided below of one particular method of implementing the invention, as well as one variation of implementation, presented as non-limiting examples, in reference to the attached drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are exploded perspective views of an iron bottom set in one particular method of implementing the invention, the bottom set comprising a soleplate and a heating body;
FIG. 3 is a perspective view of the iron bottom set in FIG. 1 , with the heating body and the soleplate assembled;
FIG. 4 is a view from above of the iron bottom set in FIG. 3 ;
FIG. 5 is a cross-section view along Line V-V in FIG. 4 ;
FIG. 6 is a cross-section view, similar to FIG. 5 , before folding the latch part against the heating body;
FIG. 7 is a view from above of the soleplate before folding; and
FIG. 8 depicts a detailed view, in a transverse cross-section, of a bottom set according to one variation of implementing the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an iron bottom set situated traditionally below a container of water, not depicted in the drawings, this set comprising a metal soleplate ( 1 ) and a heating body ( 2 ) designed to be folded back onto the soleplate ( 1 ).
The heating body ( 2 ) advantageously consists of an aluminum casting comprising an electrical resistor ( 20 ) bent into a horseshoe shape, as well as an indentation ( 21 ) arranged to house a temperature-regulating thermostat.
The heating body ( 2 ) comprises, in its upper portion, a steam chamber ( 22 ) designed to be closed by a closure plate, not depicted in the drawings.
The water in the iron's container is brought, in a self-evident manner, by a drip mechanism, into the steam chamber ( 22 ), and the steam thus generated is distributed by a peripheral channel ( 23 ) extending around the steam chamber, on the upper surface of the heating body ( 2 ).
As shown in FIGS. 2 through 4 , the channel ( 23 ) has holes ( 24 ) through the heating body ( 2 ) and leading into a steam distribution chamber ( 25 ) extending on the lower surface of the heating body ( 2 ), the distribution chamber ( 25 ) supplying a network of steam release holes ( 10 ) in the soleplate ( 1 ).
The soleplate ( 1 ) comprises a flat lower surface that defines an ironing surface, comprising an area equipped with steam release holes ( 10 ), that extends through the network of steam release holes, and at which place the upper surface of the soleplate ( 1 ) comes into contact with the surfaces of the heating body ( 2 ) so as to ensure proper heat transfer from the heating body ( 2 ) to the soleplate ( 1 ), an airtight seal being arranged at the periphery of the heating body ( 2 ) to ensure a seal that is airtight against the steam between the soleplate ( 1 ) and the heating body ( 2 ).
As shown in FIGS. 5 and 6 , the soleplate ( 1 ) comprises a peripheral edge ( 11 ) that defines the perimeter of the ironing surface, the peripheral edge comprising a portion ( 12 ) that is folded 180°, obtained by successively folding the soleplate ( 1 ) upward, and then toward the interior of the ironing surface, and by pressing it down against the upper surface of the soleplate ( 1 ).
The soleplate ( 1 ) comprises, locally, in the extension of the portion ( 12 ) that is folded 180°, latch parts ( 13 ) comprising an intermediate portion ( 13 A) directed upward to form a 90° bend with the folded-up portion, said intermediate portion ( 13 A) being extended by a free end ( 13 B) that extends vertically upward, such that the heating body ( 2 ) can be inserted between the latch parts ( 13 ) and applied against the soleplate ( 1 ) during the iron assembly process.
Such a free end ( 13 B) is then pressed down horizontally on the edge of the heating body ( 2 ), such that the latch parts ( 13 ) exert pressure on the heating body ( 2 ), which holds the soleplate ( 1 ) in contact with the heating body ( 2 ).
As shown in FIG. 1 , these latch parts ( 13 ) are advantageously distributed along the periphery of the heating body ( 2 ), the soleplate ( 1 ) comprising, in the example illustrated in the drawings, two lateral latch parts ( 13 ) consisting of flaps extending from each side of the soleplate ( 1 ) from one pointed forward end of the soleplate ( 1 ), over roughly two-thirds the length of the soleplate ( 1 ), and a back latch part ( 13 ) consisting of a flap extending to the back end of the soleplate ( 1 ), the heating body ( 2 ) advantageously comprising, at the height of these latch parts ( 13 ), a flat peripheral edge with a casing ( 26 ), shown in FIG. 1 , that is adapted to receive the latch part ( 13 ).
The soleplate ( 1 ) may also advantageously comprise guide parts ( 14 ) consisting of divider flaps that remain oriented vertically and that cooperate with the edge of the heating body ( 2 ) to laterally guide the soleplate ( 1 ) with respect to the heating body ( 2 ).
FIG. 7 depicts, as an example, the shape of the soleplate ( 1 ) prior to folding, said soleplate ( 1 ) being obtained by cutting an aluminum sheet that is between 0.8 mm and 1.5 mm thick. This soleplate ( 1 ) then undergoes a first folding step, in which the latch parts ( 13 ) and the guide parts ( 14 ) are folded 90°, and then a second folding step in which the soleplate ( 1 ) is folded 180° along the perimeter of the ironing surface, illustrated by a dotted line in FIG. 7 , in order to obtain a soleplate as illustrated in FIG. 1 , in which the peripheral edge ( 11 ) of the ironing surface has a thickness that is roughly equal to twice the thickness of the soleplate ( 1 ).
Preferably, the soleplate ( 1 ) thus made, is partially coated in enamel prior to its assembly with the heating body ( 2 ), as the enamel-coated surface can be limited to the ironing surface and to the peripheral edge ( 11 ) of the soleplate ( 1 ), while the latch parts ( 13 ) can remain in the as-cast state, which is to say not coated in enamel, in order to prevent cracks from forming in the enamel when the latch parts ( 13 ) are folded.
However, in one variation of implementing the invention, the latch parts ( 13 ) may also be coated in enamel at the same time as the ironing surface, in order to simplify the coating application process. Indeed, the latch parts ( 13 ) offer the advantage of being hidden by the casing of the iron when the heating body ( 2 ) is assembled to the iron, such that any cracks forming in the coating of the latch parts will not be visible to the user.
The bottom set thus made offers the advantage of being simple and inexpensive to produce, the soleplate offering the advantage of being mechanically connected to the heating body by a simple process of folding the latch parts.
Moreover, the iron equipped with such a bottom set offers the advantage of possessing a soleplate with a flat peripheral edge that is not very thick, allowing for easy ironing around clothing buttons.
FIG. 8 depicts one variation of implementing the bottom set illustrated in the previous drawings, in which the soleplate ( 1 ) comprises one or more steam release holes ( 10 A) arranged immediately alongside the peripheral edge ( 11 ) of the soleplate ( 1 ), and advantageously near the front point of the soleplate ( 1 ).
In this variation of implementation, the soleplate ( 1 ) advantageously comprises a smaller thickness at the periphery of the ironing surface, in order to promote the diffusion of steam toward the external edge of the ironing surface.
Such an ironing variation offers the advantage of comprising steam release holes at the periphery of the ironing surface for greater efficacy when ironing difficult-to-reach corners of clothes, such as the curves of buttons or shirt collars.
Of course, the invention is in no way limited to the methods of implementation described and illustrated, which are provided only as examples. Modifications remain possible, particularly with respect to the constitution of the various components or by substituting equivalent techniques, while still remaining within the scope of protection of the invention.
Thus, in one variation of implementing the invention that is not depicted, the latch parts may cover the entire perimeter of the heating body or be located only in several places distributed along the periphery of the heating body.
Thus, in one variation of implementing the invention that is not depicted, the soleplate may be made of stainless steel.
Thus, in one variation of implementing the invention that is not depicted, the soleplate may be coated with an inorganic polymer-type coating applied using a sol-gel process.
Thus, in one variation of implementing the invention that is not depicted, the body onto which the soleplate is attached may not be a heating body. | Iron including a body ( 2 ) and a metal soleplate ( 1 ) that is folded back against the body ( 2 ), the soleplate including a lower surface defining an ironing surface and including, at least locally, a peripheral edge ( 11 ) where the soleplate is folded up in the direction of the body ( 2 ) and comes into contact with the latter to help attach the soleplate ( 1 ) to the body, wherein the peripheral edge ( 11 ) includes a portion ( 12 ) that is folded 180° at the place where the soleplate ( 1 ) extends parallel to the ironing surface, and in that the portion ( 12 ) that is folded 180° is extended by a latch part ( 13 ) that comes into contact with the body ( 2 ). | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of co-pending U.S. patent application Ser. No. 13/702,059 filed Dec. 4, 2012, which is a National Phase application of International Application PCT/JP2011/003111, filed Jun. 2, 2011, which claims the benefit of Japanese Patent Application No. 2010-130295, filed Jun. 7, 2010. The disclosures of the above-named applications are hereby incorporated by reference herein in their entirety.
TECHNICAL FIELD
The present invention relates to an electromechanical transducer device (representatively, capacitive electromechanical transducer device) and an analyte information acquiring apparatus.
BACKGROUND ART
An electromechanical transducer device that is used as an ultrasonic transducer device (also referred to as ultrasonic transducer) is used in, for example, a diagnostic apparatus for a tumor etc. in a human body by transmitting and receiving ultrasonic waves, which are acoustic waves.
In recent years, a capacitive electromechanical transducer device (capacitive micromachined ultrasonic transducer, CMUT) using a micromachining technique is being actively studied. This CMUT transmits and receives ultrasonic waves by using a vibrating membrane. Also, this CMUT has a wide frequency band of ultrasonic waves that can be transmitted and received (i.e., CMUT has wide-band characteristics). Ultrasonic diagnosis using this CMUT and hence having higher precision than that of a medical diagnostic modality in the past is receiving attention as a promising technique.
In general, imaging apparatuses using X-rays, ultrasonic waves, and magnetic resonance imaging (MRI) are frequently used in medical fields. Also, studies on an optical imaging apparatus that obtains in vivo information by causing light emitted from a light source such as a laser to propagate into an analyte such as a living body and detecting the propagation light are being actively promoted in medical fields. There is suggested photoacoustic tomography (PAT) as one of such optical imaging techniques.
PAT is a technique that irradiates an analyte with pulsed light generated from a light source, detects acoustic waves (representatively, ultrasonic waves) generated from living tissues absorbing energy of light propagating through and diffused in the analyte at a plurality of detection positions, analyzes signals of these acoustic waves, and visualizes information relating to optical characteristic values of the inside of the analyte. Accordingly, information relating to optical-characteristic-value distribution of the inside of the analyte, or more particularly to optical-energy-absorption-density distribution can be obtained.
In an electromechanical transducer device (also referred to as ultrasonic transducer device) including electromechanical transducer elements that are formed on a substrate, part of incident ultrasonic waves may interfere with reflection waves that are reflected by a back surface of the substrate (a surface opposite to a surface of the substrate with the electromechanical transducer elements formed) and generate noise.
This noise problem has been recognized by certain degree in the past. Even with a technique of related art, as long as electromechanical transducer elements with a high-frequency region of several megahertz or higher (for example, 2 to 3 MHz or higher) are used, frequencies, which may cause noise, are high and are likely attenuated. Hence, the noise problem may be addressed by certain degree by providing an acoustic attenuating member on the back surface of the substrate. With a frequency that resonates within a substrate like PTL 1, noise can be reduced by certain degree by matching an acoustic impedance of the acoustic attenuating member to an acoustic impedance of the substrate. However, in the case of CMUT, since the frequency band is wide, the frequency band may contain ultrasonic waves with a frequency lower than 2 MHz. The ultrasonic waves with the frequency lower than 2 MHz are hardly attenuated, and easily pass through the substrate. Hence, the measure of related art only has a limited effect.
FIG. 5 shows a configuration of related art. In the configuration of related art (PTL 1), an acoustic attenuating member 14 is provided on a back surface of a substrate 12 , and an electric signal is acquired from end portions of the substrate 12 through electric wiring 13 .
The above-described ultrasonic transducer device used for the above-described ultrasonic diagnosis includes transducer elements that are two-dimensionally arrayed (arrayed in a plane) on a front surface of the substrate. For an array with a higher density, the transducer device has a structure in which the front surface and the back surface of the substrate are electrically connected and electric wiring is drawn from the back surface of the substrate. To acquire signals of the two-dimensionally arrayed electromechanical transducer elements, an electric wiring substrate has to be provided on the back surface of the substrate and the electric wiring substrate has to be electrically connected with the substrate. With this configuration, since the distance between the substrate and the electric wiring substrate is small, the acoustic attenuation on the back surface of the substrate results in that the reflection waves from the back surface of the substrate and the electric wiring substrate affects the electromechanical transducer elements, and hence a signal-to-noise (S/N) ratio is degraded. Particularly in a frequency band with 1 MHz or lower, wavelengths are large and attenuation is small. The influence becomes noticeable. Also, to reduce noise crosstalk, there is a method in which an electric wiring substrate or an integrated circuit is arranged on the back surface of the substrate, and the electric wiring substrate or the integrated circuit is electrically connected with the back surface of the substrate. At this time, the distance between the back surface of the substrate and the electric wiring substrate or the integrated circuit is as small as several hundred micrometers. Hence, even if the acoustic attenuating member of related art is provided on the back surface of the substrate, low-frequency acoustic waves easily reach the electric wiring substrate, and reflection waves may become noise.
PTL 2 describes that projections and depressions are formed on a back surface of an electric wiring substrate to reduce reflection waves. However, to attenuate acoustic waves with wavelengths larger than a predetermined value (acoustic waves with frequencies lower than 2 MHz), large projections and depressions are required. At the same time, the thickness of the electric wiring substrate is limited in a fabrication process and a soldering and mounting process.
CITATION LIST
Patent Literature
[PTL 1]U.S. Pat. No. 6,831,394
[PTL 2]U.S. Pat. No. 7,321,181
SUMMARY OF INVENTION
The present invention provides a configuration of an electromechanical transducer device with a wider band and a higher S/N ratio than those of related art by reducing reflection-wave noise in a low-frequency band.
An electromechanical transducer device according to an aspect of the invention includes a first substrate; electromechanical transducer elements two-dimensionally arrayed on a front surface of the first substrate and configured to provide conversion between acoustic waves and electric signals; an electric wiring substrate that is a second substrate electrically connected with a back surface of the first substrate; a first acoustic matching layer provided between the first substrate and the second substrate; an acoustic attenuating member arranged on a back surface of the second substrate; and a second acoustic matching layer provided between the second substrate and the acoustic attenuating member.
An analyte information acquiring apparatus according to another aspect of the invention includes the electromechanical transducer device according to the above aspect; a light source configured to emit pulsed light; and a signal processing system configured to process a signal that is detected by the electromechanical transducer device. The analyte information acquiring apparatus irradiates an analyte with the light emitted from the light source, detects an acoustic wave generated as the result of a photoacoustic effect of the light emitted on the analyte by the electromechanical transducer device, and acquires physical information of inside of the analyte through processing by the signal processing system.
With any of the aspects of the present invention, the acoustic matching layer and the acoustic attenuating member are provided on the back surface of the substrate. Accordingly, when ultrasonic waves with frequencies of several megahertz or lower are used, noise, which is generated by reflection from the back surface of the substrate and which is applied to the electromechanical transducer elements arranged on the front surface of the substrate, can be reduced.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is a configuration diagram of an ultrasonic transducer device according to any of first to third embodiments of the present invention.
FIG. 1B is a comparison diagram with the first embodiment of the present invention.
FIG. 2 is a graph showing frequency characteristics for reciprocals of acoustic impedance densities on a front surface of a substrate according to the first embodiment of the present invention.
FIG. 3 is a configuration diagram of an ultrasonic transducer device according to a fourth embodiment of the present invention.
FIG. 4 is a configuration diagram of an ultrasonic diagnostic apparatus according to a fifth embodiment of the present invention.
FIG. 5 is a configuration diagram of related art.
DESCRIPTION OF EMBODIMENTS
First Embodiment
An ultrasonic transducer device according to a first embodiment is described.
FIG. 1A shows an ultrasonic transducer device 10 according to this embodiment. An electromechanical transducer element 2 is formed on a substrate 1 (first substrate). The electromechanical transducer element 2 provides conversion between an ultrasonic wave (acoustic wave) and an electric signal. An electric wiring substrate 3 (second substrate) is electrically connected with a back surface of the substrate 1 . The electric wiring substrate 3 is typically formed by arranging metal wiring lines on resin. A plurality of the electromechanical transducer elements 2 are two-dimensionally arrayed on a front surface of the substrate 1 . The electromechanical transducer element 2 may be a piezoelectric element, or a capacitive electromechanical transducer element in which a membrane, a cavity, and first and second electrodes form a counter electrode like PTL 2.
A material of the substrate 1 may be desirably silicon (Si) in view of a mechanical property, an electrical property, formability, cost efficiency, etc. However, the material does not have to be silicon, and may be, for example, glass, quartz, GaAs, or sapphire. The electromechanical transducer element 2 has at least two electric terminals. At least one of the terminals is electrically separated from the plurality of residual electromechanical transducer elements 2 . The substrate 1 electrically connects the terminal, which is electrically separated from the electromechanical transducer elements 2 and a terminal on the back surface of the substrate 1 . The substrate 1 has, for example, a plurality of electrically connecting portions like through wiring lines. The substrate itself may be electrically separated by an insulator or a trench and the substrate may allow electrical conduction only in a substrate thickness direction.
A conductor 4 that electrically connects the electric wiring substrate 3 and the substrate 1 may be a resistor with a low resistance of, for example, metal such as solder or gold.
In this embodiment, a first acoustic matching layer 5 is arranged between the substrate 1 (first substrate) and the electric wiring substrate 3 (second substrate) and also an acoustic attenuating member 7 is arranged on a backside of the electric wiring substrate 3 . The first acoustic matching layer 5 has a function of allowing the electric wiring substrate 3 to transmit an ultrasonic wave 11 that enters from the substrate 1 and restricting reflection of the ultrasonic wave 11 . The acoustic attenuating member 7 has a function of absorbing and attenuating the transmitted ultrasonic wave 11 . A second acoustic matching layer 6 is provided as a structure that restricts reflection of the ultrasonic wave 11 between the acoustic attenuating member 7 and the electric wiring substrate 3 .
With the configuration of the embodiment, noise applied to the electromechanical transducer elements 2 can be reduced in a wider frequency band by reducing the reflection at the interface and by the effect of the acoustic attenuating member.
The first acoustic matching layer 5 , the second acoustic matching layer 6 , and the acoustic attenuating member 7 are described below in detail.
The first acoustic matching layer 5 fills a space surrounding the conductor 4 . In general, an acoustic impedance of the conductor 4 does not correspond to an acoustic impedance of the first acoustic matching layer 5 . Hence, an acoustic characteristic varies depending on whether provided directly below the electromechanical transducer element 2 is the first acoustic matching layer 5 or the conductor 4 . The area occupied by the conductor 4 is desirably decreased to equalize acoustic characteristics of the electromechanical transducer elements 2 .
However, if the acoustic impedance of the conductor 4 is larger than an acoustic impedance of the substrate 1 , the ultrasonic wave transmitted to the electric wiring substrate 3 is reduced, and also transmission of the ultrasonic wave reflected by the electric wiring substrate 3 to the substrate 1 is reduced. If the substrate 1 is made of silicon and the conductor 4 is made of typical lead-free solder, the above relationship is applied. The influence of the reflection wave to the electromechanical transducer element 2 on the conductor 4 is small.
A plurality of the conductors 4 is provided on the back surface of the substrate 1 by at least a number corresponding to the number of electromechanical transducer elements 2 to electrically separate the two-dimensionally arrayed electromechanical transducer elements 2 . Hence, part of a space between the substrate 1 and the electric wiring substrate 3 not occupied by the conductors 4 is filled with the first acoustic matching layer 5 .
The acoustic impedance of the first acoustic matching layer 5 is designed to be a value between the acoustic impedance of the substrate 1 and an acoustic impedance of the electric wiring substrate 3 .
A material of the first acoustic matching layer 5 is desirably epoxy resin, which is used as an underfill (sealant). However, when the acoustic impedance is adjusted, a material with high-density fine particles mixed may be used. The fine particles may be a metal or a compound. For example, tungsten, alumina, copper, or a compound of any of these metals; or platinum, iron, or a compound of any of these metals may be used.
The second acoustic matching layer 6 is provided on a back side of the electric wiring substrate 3 , and the acoustic attenuating member 7 is provided below the second acoustic matching layer 6 . The second acoustic matching layer 6 has a role of reducing acoustic reflection at the back surface of the electric wiring substrate 3 , and allowing the acoustic attenuating member 7 to transmit the ultrasonic wave.
A material of the second acoustic matching layer 6 may be epoxy resin or the like, which is the material of the electric wiring substrate 3 . However, it is to be noted that, since the acoustic impedance of the electric wiring substrate 3 varies depending on density of the metal wiring lines, adjustment for an acoustic impedance of the second acoustic matching layer 6 is occasionally required. If required, high-density fine particles are mixed to adjust the acoustic impedance. The fine particles may be a metal or a compound. For example, tungsten, alumina, copper, or a compound of any of these metals; or platinum, iron, or a compound of any of these metals may be used.
The acoustic attenuating member 7 has an effect of absorbing and attenuating an ultrasonic wave. Hence, the acoustic attenuating member 7 is a viscoelastic body, and a material of the acoustic attenuating member 7 may be, for example, epoxy resin or urethane resin.
To increase the degree of freedom for design on a back side of the acoustic attenuating member 7 , almost all acoustic waves should be attenuated by the acoustic attenuating member 7 . To attain this, the acoustic attenuating member 7 has to have a thickness of about several millimeters or larger, and a larger thickness is more desirable. Also, a material having a higher viscosity is more desirable.
FIG. 2 shows frequency characteristics of reciprocals of acoustic impedance densities in an acoustic-wave incident direction on the front surface of the substrate 1 . An acoustic impedance density corresponds to an input impedance when viewed from the front surface of the substrate 1 . For example, if the substrate 1 is silicon with a thickness of 300 micrometers and the electric wiring substrate 3 is glass epoxy with a thickness of 1.6 millimeters, the graph shows reciprocals of acoustic impedance densities (1) when liquid with an acoustic impedance of about 1.5 MegaRayls, for example, water is present between the substrate 1 and the electric wiring substrate 3 and on the back side of the electric wiring substrate 3 ( FIG. 1B ), (2) when a member with the same acoustic impedance as that of the electric wiring substrate 3 is provided by an infinite thickness at the back side of the electric wiring substrate 3 , and (3) when a first acoustic matching layer with an acoustic impedance of 5 MegaRayls is provided between the substrate 1 and the electric wiring substrate 3 . Part of the electric wiring substrate 3 is connected with the substrate 1 through the conductor 4 , and the distance between the substrate 1 and the electric wiring substrate 3 is limited. In the graph in FIG. 2 , the distance is 0.2 millimeters.
When the reciprocal of the acoustic impedance is large, it represents that the reflection wave is large. A large peak with a frequency of 10 MHz or higher indicates resonant reflection by the substrate 1 . FIG. 1B shows a configuration of (1) in FIG. 2 . The ultrasonic wave 11 transmitted through the electromechanical transducer element 2 resonates as the result of reflection at an interface between the back surface of the substrate 1 and liquid 20 , an interface between the liquid 20 and the electric wiring substrate 3 , and the lower surface of the electric wiring substrate 3 , and propagates to the front surface of the substrate 1 on which the electromechanical transducer element 2 is present. Accordingly, the acoustic impedance density of frequencies around 1 MHz is decreased and becomes a factor that causes large reflection noise. It is found from FIG. 2 that a reflection wave around 1 MHz is decreased by matching of acoustic impedances at the back surface of the electric wiring substrate 3 . However, a frequency band with large reflection waves is present around 1 MHz ((2) in FIG. 2 ). Regarding (3) provided with the first acoustic matching layer 5 , it is found that the peak around 1 MHz is lowered, and the reflection wave in the low-frequency region is reduced by the first acoustic matching layer 5 and the acoustic attenuating member 7 . This represents that the ultrasonic wave 11 transmitted through the respective layers is absorbed and attenuated by the acoustic attenuating member 7 as shown in the propagation state of the ultrasonic wave 11 in FIG. 1A .
Second Embodiment
An ultrasonic transducer device according to a second embodiment is described. A configuration of this embodiment is the same as that shown in FIG. 1A . For a center frequency of an ultrasonic wave emitted from the electromechanical transducer element 2 , when the first acoustic matching layer 5 has a thickness that is ¼ of a wavelength of an ultrasonic wave that is transmitted through the inside of the first acoustic matching layer 5 and when the acoustic impedance of the first acoustic matching layer 5 is a geometric average of the acoustic impedance of the first substrate 1 and the acoustic impedance of the electric wiring substrate 3 , a transmission factor of the ultrasonic wave becomes maximum.
If there is an ultrasonic wave with a frequency that should not be reflected the most (or that should be attenuated), the thickness of the first acoustic matching layer 5 may be ¼ of a wavelength of that ultrasonic wave. In particular, if a frequency band of ultrasonic waves to be received is a wide band, frequencies that result in large reflection are frequencies subject to resonant reflection by the substrate 1 . (4) in the graph in FIG. 2 represents this case. Regarding (4), it is found that a peak with 15 MHz, which is a resonant frequency, is further lowered.
It is assumed that Zs is an acoustic impedance of the substrate 1 , Zm is an acoustic impedance of the first acoustic matching layer 5 , and Ze is an acoustic impedance of the electric wiring substrate 3 . When L is a thickness of the first acoustic matching layer 5 , and k is the number of waves of the ultrasonic wave, a reflection factor R of the ultrasonic wave at a three-layer structure including the substrate 1 , the first acoustic matching layer 5 , and the electric wiring substrate 3 is expressed as follows.
R
=
Zin
-
Zs
Zin
+
Zs
[
Math
.
1
]
Zin
=
Zm
·
Ze
+
j
Zm
tan
kL
Zm
+
j
Ze
tan
kL
[
Math
.
2
]
When kL is p/2, i.e., when L is ¼ of a wavelength, R becomes minimum. Also, in the following situation, R becomes 0 and all waves are transmitted.
Zm =√{square root over ( Zs·Ze )}(= Z 0) [Math. 3]
When the reflection factor is 10% or lower, and a tolerance of the acoustic impedance of the first acoustic matching layer is within about 5% of Z0, a tolerance of the thickness L is within about 6% of the thickness that is ¼ of the wavelength. Since the relationship between the reflection factor R and the noise to the electromechanical transducer element 2 affects the structure, the reflection factor R cannot be simply determined. However, in the embodiment, the reflection factor R is within a range of 10% or lower.
Third Embodiment
An ultrasonic transducer device according to a third embodiment is described. A configuration of this embodiment is similar to that shown in FIG. 1A . The acoustic impedance of the first acoustic matching layer 5 has a gradient in the thickness direction. Impedance matching is provided at the interface between the substrate 1 and the electric wiring substrate 3 . Accordingly, the reflection wave can be reduced regardless of the thickness of the first acoustic matching layer 5 .
In the embodiment, the provision of the acoustic impedance matching represents a situation in which a reflection factor at an interface is 10% or lower. If acoustic impedances of two substances that form an interface are the same, the reflection factor becomes zero. The situation in which the reflection factor is 10% or lower is a situation in which the difference between the acoustic impedances of the two substances at the interface is about 18% or lower.
The material of the first acoustic matching layer 5 according to this embodiment is fabricated by mixing high-density particles into resin.
By changing particle density distribution in the thickness direction, the acoustic impedance has a gradient in a thickness direction.
Fourth Embodiment
An ultrasonic transducer device according to a fourth embodiment is described. FIG. 3 shows a configuration of this embodiment. In this embodiment, the second acoustic matching layer 6 and the acoustic attenuating member 7 in the first or third embodiment are integrated (structure in which the second acoustic matching layer 6 also functions as the acoustic attenuating member 7 ), and are formed as an acoustic matching and attenuating member 9 . At this time, acoustic impedance matching is desirably provided between the acoustic matching and attenuating member 9 and the electric wiring substrate 3 .
Here, the provision of the acoustic impedance matching represents a situation in which the reflection factor is 10% or lower. If acoustic impedances of two substances that form an interface are the same, the reflection factor becomes zero. The situation in which the reflection factor is 10% or lower is a situation in which the difference between the acoustic impedances of the two substances at the interface is about 18% or lower.
A material of the acoustic matching and attenuating member 9 may be a viscoelastic body such as urethane resin that contains high-density fine particles for acoustic impedance adjustment. The fine particles may be a metal or a compound. For example, tungsten, alumina, copper, or a compound of any of these metals; or platinum, iron, or a compound of any of these metals may be used.
Fifth Embodiment
An analyte information acquiring apparatus according to a fifth embodiment is described.
FIG. 4 shows a configuration of this embodiment.
When light 41 emitted from a light source 40 is emitted on an optical absorber 46 in an analyte 42 , an ultrasonic wave 43 called a photoacoustic wave is generated. Although the frequency of the ultrasonic wave 43 varies depending on a substance of the optical absorber 46 and the size of a solid body, when a certain variation band is assumed, frequencies are within a range from about 300 kHz to 10 MHz. The ultrasonic wave 43 passes through liquid 47 that provides good propagation for the ultrasonic wave 43 , and the ultrasonic transducer device 10 detects the ultrasonic wave 43 . A signal with amplified current and voltage is transmitted to a signal processing system 45 through a signal line 44 . The signal processing system 45 processes the detected signal and extracts analyte information.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
REFERENCE SIGNS LIST
1 substrate
2 electromechanical transducer element
3 electric wiring substrate
4 conductor
5 first acoustic matching layer
6 second acoustic matching layer
7 acoustic attenuating member
9 acoustic matching and attenuating member
10 ultrasonic transducer device
11 ultrasonic wave | To suggest an electromechanical transducer device with a high S/N ratio, an electromechanical transducer device includes a first substrate; electromechanical transducer elements two-dimensionally arrayed on a front surface of the first substrate and configured to provide conversion between acoustic waves and electric signals; an electric wiring substrate that is a second substrate electrically connected with a back surface of the first substrate; a first acoustic matching layer provided between the first substrate and the second substrate; an acoustic attenuating member arranged on a back surface of the second substrate; and a second acoustic matching layer provided between the second substrate and the acoustic attenuating member. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of and claims priority in U.S. patent application Ser. No. 10/724,459, filed Nov. 28, 2003, now U.S. Pat. No. 7,326,217.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to implant systems and methods for orthopedic and dental applications. More specifically, the present invention relates to implant insertion and extraction with couplings for attachment to manual and power force transducers with control over force variables.
[0004] 2. Description of the Related Art
[0005] Many orthopedic procedures involve implants for replacing damaged and dysfunctional joints. For example, total joint replacement (TJR) and hemi arthroplasty (replacing one-half of the joint) procedures have been developed. Hips, knees, elbows, shoulders and wrists are commonly reconstructed with implants, such as prosthetic joints that are designed for optimal wear, comfort, biocompatibility and performance. Such replacement joint implants have benefited many patients by restoring their mobility and other functions.
[0006] Reconstructive dental procedures include installing implants such as prosthetic teeth, bridges, mandibles, temporomandibular (TMJ) joints and other dental prostheses. Significant improvements in dental function can be achieved for many patients using such procedures.
[0007] An important objective in designing orthopedic and dental implants and in performing implant procedures relates to effectively and permanently bonding the prosthetic components to patients' existing, viable bone and dental structure. For example, TJR orthopedic surgery typically involves removing damaged and degenerated existing joints and adjacent bone structure for replacement with prostheses. The remaining bone structure is preferably sound, dense and capable of withstanding dynamic loads in order to maximize patient function and mobility. A general objective of orthopedic and orthodontic surgery is to retain as much original, healthy bone structure as possible.
[0008] Orthopedic and orthodontic revision procedures are necessitated by prosthetic failures from various causes. For example, further deterioration and trauma can lead to prosthetic joint failures. Another problem relates to loosening and disengagement of the components. For example, orthopedic cement, which is commonly used to bond prosthetic components to bone, can loosen and disengage. Looseness and “play” in implants, such as prosthetic joints, can cause significant problems. These include patient discomfort and immobility. Moreover, such looseness can increase under dynamic loading, and can ultimately lead to complications associated with implant failure.
[0009] When revision procedures are indicated by such conditions, extracting existing implants and the cement mantels bonding same can present significant difficulties. Extracting prostheses that have been permanently bonded in place with high-strength adhesives can require substantial force, with resulting trauma and collateral damage. For example, perforated and cracked existing bone structures can result from forces associated with extracting failed prostheses.
[0010] Moreover, implants can become stuck during installation. For example, if the cavity formed for the implant shaft is too small, a test fit can result in immobility with resistance to both insertion and extraction. Extracting a stuck implant can require breaking the surrounding bone structure, with resulting complications.
[0011] The prior art has attempted to address some of the problems associated with orthopedic implant extractions. For example, the Engelbrecht et al. U.S. Pat. No. 4,248,232 discloses the use of a vibrating tool to soften the cement between nested components bonded together. The Hood et al. U.S. Pat. No. 5,045,054 discloses an ultrasound power generator adapted for coupling to endoprostheses and vibrating same to soften their adhesive bonds. Hood et al. disclose an ultrasonic tool for attachment to and removal of surgical components in U.S. Pat. No. 5,318,570. Vandewalle et al. U.S. Pat. No. 6,190,392 disclose an auger tool connected to an ultrasonic transducer/handpiece for extracting an osteal cement mantel.
[0012] Heretofore there has not been available an orthopedic and dental implant system and method with the advantages and features of the present invention.
SUMMARY OF THE INVENTION
[0013] In the practice of the present invention, systems and methods are provided for installing and extracting orthopedic and dental implants. In one aspect of the invention, a manual or power force transducer is coupled to an implant for imparting installation or extraction forces, ranging from low-amplitude vibrations to impact blows through a range of frequencies. The forces can act in either direction. i.e. insertion or extraction, or both in an alternating operational mode. The amplitudes of the forces can be varied, including amplitude differentials on insertion/extraction strokes. The forces can be linear reciprocating, rotorary reciprocating, oscillatory (side-to-side) or orbital.
[0014] In another aspect of the invention, a power source connects to a working tip adapted for melting an engagement portion of a cement mantel. Discontinuing the application of power to the working tip causes the cement to resolidify on and capture same. A second power application vibrates the entire homogenous portion of the cement loose for extraction.
[0015] In another aspect of the invention, the controller scans predetermined frequency, amplitude and other variable ranges and selects optimum values for such operating parameters based on feedback received from sensors connected to vibrating tools or patients. The sensors can detect current loading as a function of variable patient and system conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
[0017] FIG. 1 is a schematic, block diagram of an implant system embodying the present invention.
[0018] FIG. 1A is a perspective view of a hip femoral implant.
[0019] FIGS. 2-9 are fragmentary views of the coupling in the process of attachment to the implant.
[0020] FIGS. 10-12 are fragmentary views of a coupling embodying another aspect of the invention, showing the process of attachment to the implant stem.
[0021] FIG. 13 is a top plan view of the coupling and the implant, taken generally along line 13 - 13 in FIG. 12 .
[0022] FIG. 14 is a top plan view of the coupling and the implant, with the coupling compressed onto the implant stem.
[0023] FIG. 15 is a block diagram of an automated system embodying another aspect of the present invention.
[0024] FIG. 16 is a flowchart showing an aspect of the method of the present invention.
[0025] FIGS. 17-18 are cross-sectional views of a femur, showing an aspect of the method of the present invention for removing an orthopedic cement mantel from the intramedullary canal.
[0026] FIGS. 19-22 are vertical, cross-sectional views of a femur, showing the removal of a femoral implant and the cement mantel associated therewith according to an aspect of the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
1. Introduction and Environment
[0027] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0028] Referring to FIG. 1 , the reference numeral 2 generally designates an orthopedic and dental implant system embodying an aspect of the present invention. The system 2 generally includes an external subsystem 3 including a force transducer 4 , which can comprise a manual device, such as a slaphammer, or an electrical, pneumatic or hydraulic power device. The transducer 4 is adapted for variable operation, including such variable operating parameters as frequency, amplitude, direction (i.e. in or out with respect to the patient) and insertion and/or extraction. The transducer 4 can apply linear reciprocating, rotary reciprocating, oscillatory (side-to-side) or orbital force. A coupling 6 is connected to the force transducer 4 . The coupling 6 and its ancillary components can be disposable for one-time usage in conjunction with a TMJ or other procedure, or they can be adapted for sterilization and reuse.
[0029] A patient subsystem 5 includes an orthopedic or dental implant 8 , which is adapted for placement in a patient 12 with an interspace 10 therebetween, which can receive suitable orthopedic cement for bonding the implant 8 in place.
[0030] FIG. 1A shows a femoral implant 15 , which can be used in a hip joint replacement procedure. The implant 15 includes an intramedullary canal shaft 17 integrally formed with a head 19 including a transverse passage 20 . The shaft 17 can be finished with a scratch fit texture or engraving to facilitate bonding to bone. A stem 22 projects upwardly at an oblique angle from the head 19 and mounts a spherical cap 24 on a Morse taper 25 . The cap 24 is pivotably received in an acetabular cup (not shown) to form a ball-and-socket type hip joint. Various configurations and designs of femoral and other implants can be used with the system of the present invention.
2. Transducer-to-Implant Couplings
[0031] FIG. 2 shows a distal end 26 of the coupling 6 with a clevis configuration including a pair of receivers 28 with hexagonal recesses 30 , which are adapted for alignment with the passage 20 ( FIG. 3 ). FIG. 4 shows a guide wire 32 forming a loop 34 extending through the implant passage 20 and the coupling receivers 28 . The loop 34 can be captured with a suture 36 , which can be inserted into the patient from an entry location spaced from the entry location for the guide wire 32 . FIGS. 5 and 5A show a flexible guide extension member 38 , which tapers from a maximum diameter at a female-threaded base 40 to a minimum diameter at a pointed tip 42 with an eyelet 44 . The guide member 38 is adapted for pulling a fastener, such as a bolt 46 , through the aligned implant passage 20 and the clevis end receivers 28 . The bolt 46 is threadably received in the guide member base 40 and the guide member eyelet 44 receives the guide wire 32 , which is adapted for pulling the guide member 38 ( FIG. 5 ). The flexibility of the guide member 38 enables it to approach the passage 20 and the receivers 28 from oblique angles.
[0032] FIG. 6 shows the bolt 46 in place with the guide member 38 extending therefrom. The bolt 46 includes a bolt loop 48 extending from its threaded end and adapted to capture the guide wire 32 or a suture to provide an alternative or auxiliary technique for installing the bolt 46 . A nut 50 is threadably received on the end of the bolt 46 and can be drawn into the hexagonal recesses 30 ( FIGS. 7 and 8 ), or surface-mounted on the clevis 26 ( FIG. 9 ) with a washer 52 .
[0033] The coupling distal, clevis end 26 transmits force from the force transducer 4 to the implant 8 , as shown by the double-ended force arrow 54 ( FIG. 8 ), which represents the application of linear, reciprocating “in” strokes 14 , “out” strokes 16 , or both ( FIG. 1 ). As noted above, such forces can also be rotary reciprocating, oscillatory (side-to-side) or orbital. In operation such forces can be applied as necessary by the physician installing or extracting the implant 8 . Moreover, test fitting same is facilitated with reduced risk of the implant becoming irretrievably stuck in an overly-tight intramedullary canal.
[0034] FIGS. 10-14 show an alternative configuration coupling distal end 60 comprising another aspect of the invention. The coupling end 60 has a clevis configuration with a shaft 62 extending at an oblique angle therefrom and connected to the force transducer 4 . The coupling end 60 receives the implant stem 22 below a frusto-conical cap thereof and is clamped thereon ( FIGS. 13-14 ) by a fastener, which can comprise a bolt received in coupling end receivers 66 and including hexagonal recesses for the bolt head 70 and a nut 72 ( FIGS. 11 and 12 ), as required. A washer 74 can also be provided on either or both sides of the coupling end 60 . As shown in FIG. 14 , the coupling end 60 is deformable in order to securely clamp the implant stem 22 .
3. Orthopedic Cement Extraction System and Method
[0035] A system 102 and a corresponding method comprising an alternative aspect of the present invention are shown in FIGS. 15-22 and are adapted for installing and removing orthopedic and dental implants 103 and orthopedic cement 104 . Implants are commonly bonded in place with orthopedic cement, which may require removal in connection with revision procedures. For example, femoral implants are inserted into intramedullary canals and secured therein by cement.
[0036] Orthopedic cement 104 is placed in an interspace 130 around the implant 103 within the intramedullary canal of a bone 105 in a patient 107 . Although an exemplary application of the invention is described in connection with a hip TJR, applications for same are virtually unlimited and include other replacement joints, such as knees, shoulders, etc.
[0037] The system 102 generally includes a controller 116 including a programmable microprocessor 118 . The controller 116 can include various components, such as input and output devices, memory storage, etc. A foot pedal switch assembly 120 is connected to the controller 116 for providing input thereto and includes frequency and amplitude control switches 122 , 124 , which are adapted for hands-free operation by an operator pressing same with his or her feet, for example in a sterile operating environment.
[0038] A transducer 126 is controlled by the controller 116 and is operably connected to a tool 127 for imparting mechanical energy to the implant 103 and/or the cement 104 . For example, the transducer 126 can provide rotorary reciprocating linear reciprocating, oscillatory (side-to-side), orbital and other types of motion. The tool 127 can comprise a coupling, as described above, or various reciprocating and oscillatory saws, which are suitable for use with the system 102 . Other types of tools include drills, vibrators and reciprocating chisels. The tool 127 is preferably designed for engaging the implant 103 or cutting, forming or shaping the cement 104 , and can be used for dynamically coupling the transducer 126 to the implant 103 and/or the cement 104 . A power source 128 provides power to the transducer 126 and can be controlled by the controller 116 . The power source 128 can comprise electrical power, compressed air, compressed nitrogen, hydraulic fluid, etc.
[0039] The microprocessor 118 receives input signals from sensors 109 , 111 , 113 , 115 , 117 and 119 connected to the system components as shown in FIG. 1 . For example, sensors 109 , 111 provide feedback from the transducer 126 and the tool 127 respectively. The sensors 113 , 115 , 117 and 119 provide feedback from the implant 103 , the cement 104 , the bone 105 and the patient 107 respectively. It will be appreciated that fewer or more sensors can be utilized with the present invention, and can monitor and provide feedback with respect to the operation of various system components and the operating parameters associated with same. For example, the power load on the transducer 126 can be sensed for reaction by the controller 116 , if necessary. Similarly, patient conditions such as temperature, blood pressure, stress indicators, etc. can be monitored and the microprocessor 118 can be preprogrammed to react to particular patient conditions and control the appropriate operating parameters of the system 102 whereby the primary functions thereof can be automated.
[0040] One or more of the sensors can comprise an energy-sensing device, such as an infrared thermal sensor. The controller 116 can be configured for thermally mapping the joint area whereby the temperature changes in the prosthetic joint 106 , the patient 107 and the cement mantel 104 can be monitored in real-time. Such a thermal map can be displayed on a monitor 125 connected to the controller 116 , which processes the thermal characteristics detected by the infrared thermal sensor as input for automatic control functions by the controller 116 and/or visual observation by means of the monitor 125 .
4. Orthopedic Cement and Implant Extraction Method
[0041] FIG. 16 is a flowchart of a method embodying the present invention. From start 132 a patient 107 is prepared at 134 and the controller 116 is initialized at 136 . Initializing the controller can include preprogramming certain operating parameters and conditions. For example, various common prostheses can be accommodated by preprogramming the controller to operate the transducer 126 at presumed optimum conditions, subject to varying the output signals to correspond to the actual conditions encountered. The existing joint 6 is accessed at 138 and the existing mass or mantel of cement 4 is exposed at 140 . Polymethylmethacrylate (PMMA) cement is commonly used for implant attachment, particularly in medullary canals. Such cement is susceptible to softening when vibrated in the ultrasonic range, and tends to reform and reharden when the energy application is discontinued. The transducer 126 is activated at 141 and operates at a first frequency f 1 and a first amplitude A 1 .
[0042] Accordingly, an engagement portion of the cement mantel 104 is melted at 142 and the tool 127 is embedded therein at 144 . The melted engagement portion resolidifies at 146 , thereby bonding the tool 127 to the cement mantel 104 . The transducer 126 operates at a second frequency t 2 and a second amplitude A 2 at 148 . For example, low-frequency vibration can be utilized to extract the cement. Feedback is received at 150 . Such feedback can be derived from the various sensors 109 , 111 , 113 , 115 , 117 , 119 and can correspond to such conditions as temperature and transducer current flow (corresponding to load conditions). For example, greater cement resistance to vibration can cause a greater load on the transducer 126 , which in turn causes the current flow to increase. Such changing conditions can be sensed and predicted and can cause the controller 116 to respond accordingly. For example, upon encountering lessening resistance due to the cement mantel 104 softening, the controller 116 can reduce the amplitude of the energy applied to the transducer 126 . Moreover, the resonant frequency of the components can be monitored. Frequency and amplitude changes can thus be detected and reacted to, for example by reducing or discontinuing the application of power.
[0043] It will be appreciated that the microprocessor 118 can be programmed to provide appropriate reactions to accommodate various operational parameters. For example, it is generally desirable to avoid excessive heat, which can damage both bone and soft tissue thereby prolonging patient recovery. The microprocessor 118 can thus be programmed to reduce or cut off transducer power upon detecting certain conditions at any of several locations in the prosthetic joint or the patient. Moreover, manual inputs from the foot pedal switches 122 , 124 or other operator-controlled inputs can be coordinated with automatic control features. For example, the operator can manually adjust such operating parameters as amplitude and frequency within predetermined operating ranges, beyond which automatic controls take over to avoid potential harm or discomfort to the patient.
[0044] If a frequency adjustment is indicated at decision box 152 , the controller provides another frequency (f n+1 ) at 154 , and returns to the feedback step 150 . When no further frequency adjustment is needed (negative branch from decision box 152 ), the method proceeds to lock in frequency at 156 . Another feedback step occurs at 158 and leads to an amplitude adjustment decision box at 160 from which a positive decision leads to the next amplitude (A n+1 ) being generated at 162 . The negative branch from the decision box 160 leads to a lock in amplitude step at 164 . Extraction occurs at 166 , the joint is revised at 168 and the method terminates at 170 .
[0045] FIGS. 17-18 show applications of the cement removal system 102 and the method described above in connection with removing a cement mantel 170 from the intramedullary canal 172 in a femur 174 . The mantel 170 is segmented with cuts 176 . The blade 178 forms an engagement portion 180 whereat the liquefied cement 170 is permitted to solidify on the blade 178 . The respective segments 182 can thus be extracted with the controlled application of force, such as low-frequency vibration, as shown in FIG. 18 .
[0046] FIG. 19 shows a femur 210 and a femoral implant 208 , which are separated by an interspace 230 filled with orthopedic cement 204 . FIG. 20 shows the implant 208 removed, leaving the cement 204 within the intramedullary canal 206 . As shown in FIG. 21 , the tool 227 has penetrated an engagement portion 232 of the cement 204 , which resolidifies to capture same. FIG. 22 shows a chunk 234 of cement 204 being removed from the intramedullary canal 206 . By properly adjusting the frequency and amplitude of the transducer 126 , substantial portions of the cement 204 can be removed. Upon completion of the extraction procedure, the walls of the intramedullary canal 206 are preferably free of cement 204 , as shown in FIG. 22 . The treating physician can then proceed with the revision procedure, including installation of replacement prosthetic components.
[0047] Although the system 102 and its methods of use have been described in connection with computer-controlled automation, the methods of the present invention can be practiced manually.
[0048] It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects. | A system for removing osteal cement and prosthetic joint components in connection with a prosthetic joint revision includes a controller connected to and controlling operation of a transducer, such as a surgical saw or drill. A tool mounted on the transducer is adapted for engaging the prosthetic joint cement mantel and melting an engagement portion of same. The cement in the engagement portion is resolidified with the tool tip embedded therein. The tool thus bonds to the cement mantel, and is used for vibrating softening and breaking up same when operation of the transducer resumes. An osteal cement and prosthetic device removal method includes the steps of melting an engagement portion of the osteal cement mantel, bonding a transducer-mounted tool to the cement mantel by resolidifying the cement engagement portion and reactivating the transducer for vibrating, softening and breaking up the cement mantel whereby it can be removed from the patient. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/952,354, filed on Jul. 27, 2007. The entire disclosure of the above application is incorporated herein by reference.
GOVERNMENT RIGHTS
This disclosure was made with government support under National Science Foundation, grant number 0234806, and National Institutes of Health, grant number 5R01HG003491-03. The Government has certain rights in the invention.
FIELD
The present disclosure relates to methods and systems for determining the significance and relevance of a particular biological pathway in a disease.
BACKGROUND
This section provides background information related to the present disclosure which is not necessarily prior art.
Together with the ability of generating a large amount of data per experiment, high throughput technologies also brought the challenge of translating such data into a better understanding of the underlying biological phenomena. Independent of the platform and the analysis methods used, the result of a high-throughput experiment is, in many cases, a list of differentially expressed genes. The common challenge faced by all researchers is to translate such lists of differentially expressed genes into a better understanding of the underlying biological phenomena and in particular, to put this in the context of the whole organism as a complex system. A computerized analysis approach using the Gene Ontology (GO) was proposed to deal with this issue. This approach takes a list of differentially expressed genes and uses a statistical analysis to identify the GO categories (e.g. biological processes, etc.) that are over- or under-represented in the condition under study. Given a set of differentially expressed genes, this approach compares the number of differentially expressed genes found in each category of interest with the number of genes expected to be found in the given category just by chance. If the observed number is substantially different from the one expected just by chance, the category is reported as significant. A statistical model (e.g. hypergeometric) can be used to calculate the probability of observing the actual number of genes just by chance, i.e., a p-value. Currently, there are over 20 tools using this over-representation approach (ORA). In spite of its wide adoption, this approach has a number of limitations related to the type, quality, and structure of the annotations available. An alternative approach considers the distribution of the pathway genes in the entire list of genes and performs a functional class scoring (FCS) which also allows adjustments for gene correlations. Arguably the state-of-the-art in the FCS category, the Gene Set Enrichment Analysis (GSEA), ranks all genes based on the correlation between their expression and the given phenotypes, and calculates a score that reflects the degree to which a given pathway P is represented at the extremes of the entire ranked list. The score is calculated by walking down the list of genes ordered by expression change. The score is increased for every gene that belongs to P and decreased for every gene that does not. Statistical significance is established with respect to a null distribution constructed by permutations.
Both ORA and FCS techniques currently used are limited by the fact that each functional category is analyzed independently without a unifying analysis at a pathway or system level. This approach is not well suited for a systems biology approach that aims to account for system level dependencies and interactions, as well as identify perturbations and modifications at the pathway or organism level. Several pathway databases such as KEGG, BioCarta, and Reactome, currently describe metabolic pathway and gene signaling networks offering the potential for a more complex and useful analysis. A recent technique, ScorePage, has been developed in an attempt to take advantage of this type of data for the analysis of metabolic pathways. Unfortunately, no such technique currently exists for the analysis of gene signaling networks. All pathway analysis tools currently available use one of the ORA approaches above and fail to take advantage of the much richer data contained in these resources. GenMAPP/MAPPfinder and GeneSifter use a standardized Z-score. PathwayProcessor, PathMAPA, Cytoscape and PathwayMiner use Fisher's exact test. MetaCore uses a hypergeometric model, while ArrayXPath offers both fisher's exact test and a false discovery rate (FDR). Finally, VitaPad and Pathway Studio focus on visualization alone and do not offer any analysis.
The approaches currently available for the analysis of gene signaling networks share a number of important limitations. Firstly, these approaches consider only the set of genes on any given pathway and ignore their position in those pathways. This may be unsatisfactory from a biological point of view. If a pathway is triggered by a single gene product or activated through a single receptor and if that particular protein is not produced, the pathway will be greatly impacted, probably completely shut off. If the insulin receptor (INSR) is not present, the entire pathway is shut off. Conversely, if several genes are involved in a pathway but they only appear somewhere downstream, changes in their expression levels may not affect the given pathway as much.
Secondly, some genes have multiple functions and are involved in several pathways but with different roles. For instance, the above INSR is also involved in the adherens junction pathway as one of the many receptor protein tyrosine kinases. However, if the expression of INSR changes, this pathway is not likely to be heavily perturbed because INSR is just one of many receptors on this pathway. Once again, all these aspects are not considered by any of the existing approaches.
Probably the most important challenge today is that the knowledge embedded in these pathways about how various genes interact with each other is not currently exploited. The very purpose of these pathway diagrams is to capture some of our knowledge about how genes interact and regulate each other. However, the existing analysis approaches consider only the sets of genes involved on these pathways, without taking into consideration their topology. In fact, our understanding of various pathways is expected to improve as more data is gathered. Pathways will be modified by adding, removing or re-directing links on the pathway diagrams. Most existing techniques are completely unable to even sense such changes. Thus, these techniques will provide identical results as long as the pathway diagram involves the same genes, even if the interactions between them are completely re-defined over time.
Finally, up to now the expression changes measured in these high throughput experiments have been used only to identify differentially expressed genes (ORA approaches) or to rank the genes (FCS methods), but not to estimate the impact of such changes on specific pathways. Thus, ORA techniques will see no difference between a situation in which a subset of genes is differentially expressed just above the detection threshold (e.g., 2 fold) and the situation in which the same genes are changing by many orders of magnitude (e.g., 100 fold). Similarly, FCS techniques can provide the same rankings for entire ranges of expression values, if the correlations between the genes and the phenotypes remain similar. Even though analyzing this type of information in a pathway and system context would be extremely meaningful from a biological perspective, currently there is no technique or tool able to do this.
We propose a radically different approach for pathway analysis that attempts to capture all aspects above. An impact factor (IF) is calculated for each pathway incorporating parameters such as the normalized fold change of the differentially expressed genes, the statistical significance of the set of pathway genes, and the topology of the signaling pathway. We show on a number of real data sets that the intrinsic limitations of the classical analysis produce both false positives and false negatives while the impact analysis provides biologically meaningful results.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
Methods, systems, computational processes and recordable media are provided for analyzing the significance of a pathway or network in a disease state. The methods comprise (a) providing data on the expression levels of a plurality of biomolecules differentially expressed in a disease state as compared with the same biomolecules expressed in a non-diseased state within the pathway: (b) determining the probability of the presence of the plurality of biomolecules in said diseased state; (c) determining the effect of each biomolecule from the plurality of biomolecules on the expression of different downstream biomolecules within the pathway thereby providing a perturbation factor for each biomolecule in the pathway; (d) combining the statistical significance of the differentially expressed biomolecule within the pathway present in the disease state with a sum of perturbation factors for all of the biomolecules in the pathway to generate an impact factor for the pathway relevant to the disease state; (e) calculating the statistical significance of the impact factor based upon a determined probability of having a statistical significant presence of differentially expressed biomolecules in step (b) and the sum of perturbation factors within the pathway in step (c); and (f) outputting the statistical significance of the impact factor for the pathway relevant to the disease for a user.
The systems, computational processes and recordable media including the methods for analyzing the significance of a pathway or network in a disease state can be used to tailor specific disease treatments that impact on pathway(s) that has been found to be of significant relevance in a particular disease. Moreover, specific drugs can be designed or synthesized that are effective for one or more biomolecules found in a pathway having a statistical significance in a particular disease state.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 (shown in the drawings as FIG. 1A and FIG. 1B ) depicts the pathway Complement and Coagulation Cascades as affected by treatment with palmitate in a hepatic cell line. There are 7 differentially expressed genes out of 69 total genes. All classical ORA models would give any other pathway with the same proportion of genes a similar p-value, disregarding the fact that 6 out of these 7 genes are involved in the same region of the pathway, closely interacting with each other. Both ORA and GSEA would yield exactly the same significance value to this pathway even if the diagram were to be completely re-designed by future discoveries. In contrast, the impact factor can distinguish between this pathway and any other pathway with the same proportion of differentially expressed gene, as well as take into account any future chanaes to the topology of the pathway.
FIGS. 2A-2C depict a comparison between the results of the classical probabilistic approaches (FIG. 2 A—over-representation approach (ORA) hypergeometric, FIG. 2 B—Gene Set Enrichment Analysis (GSEA) and the results of the pathway impact analysis ( FIG. 2C ) for a set of genes differentially expressed in lung adenocarcinoma. In FIGS. 2A-2C , the pathways shaded in green are considered most likely to be linked to this condition in this experiment. The pathways shaded in orange are unlikely to be related. The ranking of the pathways produced by the classical approaches is very misleading. According to the hypergeometric model shown in FIG. 2A , the most significant pathways in this condition are: prion disease, focal adhesion, and Parkinson's disease. Two out of these 3 are likely to be incorrect. In FIG. 2B , GSEA yields cell cycle as the most enriched pathway in cancer but 3 out of the 4 subsequent pathways are clearly incorrect. In contrast, all 3 top pathways identified by the impact analysis are relevant to the given condition. The impact analysis is also superior from a statistical perspective. According to both hypergeometric and GSEA, no pathway is significant at the usual 1% or 5% levels on corrected p-values. In contrast, according to the impact analysis the cell cycle is significant at 1%, and focal adhesion and Wnt signaling are significant at 5% and 10%, respectively.
FIG. 3 depicts a focal adhesion pathway as impacted in lung adenocarcinoma vs. normal. In this condition, both ITG and RTK receptors are perturbed, as well as the VEGF ligand (the 3 genes shown in red). Because these 3 genes appear at the very beginning and affect both entry points controlling this pathway, their perturbations are widely propagated throughout the pathway and this pathway appears as highly impacted. All classical approaches completely ignore the positions of the genes on the given pathways and fail to identify this pathway as significant.
FIGS. 4A-4C depict a comparison between the results of the classical (ORA) probabilistic approach ( FIG. 4A ), GSEA ( FIG. 4B ) and the results of the pathway impact analysis ( FIG. 4C ) in tabular form for a set of genes associated with poor prognosis in breast cancer. The pathways shaded in green are well supported by the existing literature. The pathways shaded in orange are unlikely to be related. After correcting for multiple comparisons, GSEA shown in FIG. 4B fails to identify any pathway as significantly impacted in this condition at any of the usual significance levels (1%, 5% or 10%). The hypergeometric model shown in FIG. 4A pinpoints cell cycle as the only significant pathway. Relevant pathways such as focal adhesion, TGF-beta signaling, and MAPK do not appear as significant from a hypergeometric point of view. While agreeing on the cell cycle, the impact analysis shown in FIG. 4C also identifies the 3 other relevant pathways as significant at the 5% level.
FIGS. 5A-5B depict a comparison between the results of the classical probabilistic approach ( FIG. 5A ) and the results of the impact analysis ( FIG. 5B ) for a set of genes found to be differentially expressed in a hepatic cell line treated with palmitate in tabular form. Green shaded pathways are well supported by literature evidence while orange shaded pathways are unlikely to be relevant. The classical statistical analysis shown in FIG. 5A , yields 3 pathways significant at the 5% level: complement and coagulation cascades, focal adhesion and MAPK. The impact analysis shown in FIG. 5B agrees on these 3 pathways but also identifies several additional pathways. Among these, tight junction is well supported by the literature.
FIG. 6 depicts a actin cytoskeleton pathway in a hepatic cell line treated with palmitate. Differentially expressed genes on the actin cytoskeleton pathway are connected with arrows. For genes with no measured changes upstream, such as FN1 and CD14 (shown in blue), the gene perturbation will be equal to the measured expression change. The perturbation of genes such as ITG (shown in blue) will be higher in absolute value, reflecting both its own measured change as well as the fact that the FN1 gene immediately upstream is also differentially expressed.
FIG. 7 illustrates a computation of the permutation factor, PF for a gene and the subsequent propagation of the perturbation according to Eq. 3. The genes are part of regulation of actin cytoskeleton pathway shown in FIG. 4 . Some of the interactions between the genes have been removed in order to simplify the figure. The labels next to each gene indicate the PF and the colored genes BAIAP2 (red), DIAPH1, LOC286404 and WASF2 (yellow) and RAC2, RAC1, RACP4 and RAC3 (green) are shown to illustrate different perturbation effects propagated upstream or downstream of the genes as indicated by the colored arrows.
FIG. 8 depicts tabulated results of the computation and propagation of the perturbations in a small area of an actin cytoskeleton pathway (shown in its entirety in FIG. 4 ) using the software package “Pathway-Express” as part of “Onto-Tools” available online at http://vortex.cs.wayne.edu/Projects.html. As already mentioned, in all data shown here the regulatory efficiency is β=1 for all genes. In this case, the gene DIAPH3 is the input gene with an observed fold change ΔE=1.4841. Since there are no genes upstream of DIAPH3, its second term in Eq. 3 is zero. Using Eq. 3, the PF of gene DIAPH3 is simply its measured expression change:
FIG. 9A depicts a KEGG diagram illustrating the regulation of actin cytoskeleton as impacted in breast cancer: the KEGG pathway diagram. Note that the unique symbol GF (blue) in the KEGG diagram shown in FIG. 9A , actually stands for 25 FGF genes in the internal graph illustratively shown in FIG. 9B , only one of which is differentially expressed (1). The colors show the propagation of the gene perturbations throughout the pathway. The differentially expressed genes are FGF18 (1) and DIAPH3 (2). Arrows from FIG. 9A to FIG. 9B and vice versa are used to illustrate select gene interactions between those displayed in the KEGG pathway diagram and the internal graph represented by FIG. 9B .
FIG. 9B depicts the internal graph representation of the genes in FIG. 9A . The colored genes and colored arrows to and/or from these colored genes show the propagation of the gene perturbations throughout the pathway merely for ease of illustration depicting different classes of perturbations being propagated. The differentially expressed genes are FGF18 (blue in FIG. 9B and represented by arrow 1 ) and DIAPH3 (red in FIG. 9B and represented by arrow 2 ). Changes in the color of the arrows and genes from blue/green to yellow/red and vice versa correspond to inhibitory interactions. For instance, since ROCK inhibits MBS, the negative perturbation of ROCK propagates as a positive perturbation of MBS (3).
DETAILED DESCRIPTION
In various embodiments of the present disclosure, an impact factor (IF) is calculated for each pathway incorporating parameters such as the normalized fold change of the differentially expressed genes, the statistical significance of the set of pathway genes, and the topology of the signaling pathway. The present methods tested on a number of real data sets provide that when compared to prior art methodologies, the intrinsic limitations of the classical analysis produce both false positives and false negatives while the impact analysis of the present disclosure provides biologically meaningful results. The present disclosure provides for systems, methods, computation methods and computer readable media containing steps for developing an analysis model of biological networks including gene signaling networks and metabolic networks. In some embodiments, the present methods for analyzing a gene signaling pathway includes both a statistically significant number of differentially expressed biomolecules, (for example, genes) and biologically meaningful changes on given pathways. In this model, the impact factor (IF) of a pathway P i is calculated as the sum of two terms:
I
F
(
P
i
)
=
log
(
1
p
i
)
+
∑
g
∈
P
i
P
F
(
g
)
Δ
E
_
·
N
de
(
P
i
)
(
1
)
The first term is a probabilistic term that captures the significance of the given pathway P i from the perspective of the set of genes contained in it. This term captures the information provided by the currently used classical statistical approaches and can be calculated using either an ORA (e.g., z-test, contingency tables, a FCS approach (e.g., GSEA) or other more recent approaches. The p i value corresponds to the probability of obtaining a value of the statistic used at least as extreme as the one observed, when the null hypothesis is true. The results shown in the present example were calculated using the hypergeometric model in which p i is the probability of obtaining at least the observed number of differentially expressed gene, N de , just by chance.
The second term in Eq. 1 is a functional term that depends on the identity of the specific genes that are differentially expressed as well as on the interactions described by the pathway (i.e., its topology). In essence, this term sums up the absolute values of the perturbation factors (PF) for all genes g on the given pathway P i . The perturbation factor of a gene g is calculated as follows:
P
F
(
g
)
=
Δ
E
(
g
)
+
∑
u
∈
US
g
β
ug
·
P
F
(
u
)
N
ds
(
u
)
(
2
)
In this equation, the first term captures the quantitative information measured in the gene expression experiment. The factor ΔE (g) represents the signed normalized measured expression change of the gene g determined using one of the available methods. The second term is a sum of all perturbation factors of the genes u directly upstream of the target gene g, normalized by the number of downstream genes of each such gene N ds (u), and weighted by a factor β ug , which reflects the type of interaction: β ug =1 for induction, β ug =−1 for repression. US g is the set of all such genes upstream of g. The second term here is similar to the PageRank index used by Google (Page et al., 1998) only that we weight the downstream instead of the upstream connections (a web page is important if other pages point to it whereas a gene is important if it influences other genes).
Under the null hypothesis which assumes that the list of differentially expressed genes only contains random genes, the likelihood that a pathway has a large impact factor is proportional to the number of such “differentially expressed” genes that fall on the pathway, which in turns is proportional to the size of the pathway. Thus, we need to normalize with respect to the size of the pathway by dividing the total perturbation by the number of differentially expressed genes on the given pathway, N de (P i ). Furthermore, various technologies can yield systematically different estimates of the fold changes. For instance, the fold changes reported by microarrays tend to be compressed with respect to those reported by RT-PCR. In order to make the impact factors as independent as possible from the technology, and also comparable between problems, we also divide the second term in Eq. 1 by the mean absolute fold change |ΔE| , calculated across all differentially expressed genes. Assuming that there are at least some differentially expressed genes anywhere in the data set, both |ΔE| and N de (P i ) are different from zero so the second term is properly defined.
It can be shown that the impact factors correspond to the negative log of the global probability of having both a statistically significant number of differentially expressed genes and a large perturbation in the given pathway. Impact factor values, if, will follow a Γ(2,1) distribution from which p-values can be calculated as: p=(if+1)·e −if (see details in Supplementary Materials).
The impact analysis proposed here extends and enhances the existing statistical approaches by incorporating the novel aspects discussed above. For instance, the second term of the gene perturbation (Eq. 2) increases the PF scores of those genes that are connected through a direct signaling link to other differentially expressed genes (e.g., the perturbation factor of F5 and F11 in FIG. 1 are both increased because of the differentially expressed SERPINC1 and SERPINA1). This will yield a higher overall score for those pathways in which the differentially expressed genes are localized in a connected subgraph, as in this example. Interestingly, when the limitations of the existing approaches are forcefully imposed (e.g., ignoring the magnitude of the measured expression changes or ignoring the regulatory interactions between genes), the impact analysis reduces to the classical statistics and yields the same results. For instance, if there are no perturbations directly upstream of a given gene, the second term in Eq. 2 is 0, and the PF reduces to the measured expression change ΔE, which is the classical way of assessing the impact of a condition upon a given gene. A more detailed discussion of various particular cases is included in the Supplementary Materials.
EXAMPLE 1
We have used this pathway analysis approach to analyze several data sets. A first such set includes genes associated with better survival in lung adenocarcinoma (Beer et al., 2002). These genes have the potential to represent an important tool for the therapeutical decision and, if the correct regulatory mechanisms are identified, they could also be potential drug targets. The expression values of the 97 genes associated with better survival identified by Beer et al. were compared between the cancer and healthy groups. These data were then analyzed using a classical ORA approach (hypergeometric model), a classical FCS approach (GSEA), and our impact analysis. FIGS. 2A-2C show the comparison between the results obtained with the 3 approaches.
From a statistical perspective, the power of both classical techniques appears to be very limited. The corrected p-values do not yield any pathways at the usual 0.01 or 0.05 significance levels, independently of the type of correction. If the significance levels were to be ignored and the techniques used only to rank the pathways, the results would continue to be unsatisfactory. According to the classical ORA analysis, the most significantly affected pathways in this data set are prion disease, focal adhesion and Parkinson's disease. In reality, both prion and Parkinson's diseases are pathways specifically associated to diseases of the central nervous system and are unlikely to be related to lung adenocarcinomas. In this particular case, prion disease ranks at the top only due to the differential expression of LAMB1. Since this pathway is rather small (14 genes), every time any one gene is differentially expressed, the hypergeometric analysis will rank it highly. A similar phenomenon happens with Parkinson's disease, indicating that this is a problem associated with the method rather than with a specific pathway. At the same time, pathways highly relevant to cancer such as cell cycle and Wnt signaling are ranked in the lower half of the pathway list. The most significant pathways reported as enriched in cancer by GSEA are: cell cycle, Huntington disease, DRPLA, Alzheimer's and Parkinson's (see FIG. 2B ). Among these, only cell cycle is relevant, while Huntington's, Alzheimer's and Parkinson's are clearly incorrect. However, although ranked first, cell cycle is not significant in GSEA, even at the most lenient 10% significance and with the least conservative correction.
In contrast, the impact analysis reports cell cycle as the most perturbed pathway in this condition and also as highly significant from a statistical perspective (p=1.6·10−6 ). Since early papers on the molecular mechanisms perturbed in lung cancer, until the most recent papers on this topic, there is a consensus that the cell cycle is highly deranged in lung cancers. Moreover, cell cycle genes have started to be considered both as potential prognostic factors and therapeutic targets. The second most significant pathway as reported by the impact analysis is focal adhesion. An inspection of this pathway (shown in FIG. 3 ) shows that in these data, both ITG and RTK receptors are perturbed, as well as the VEGF ligand. Because these 3 genes appear at the very beginning and affect both entry points controlling this pathway, their perturbations are widely propagated throughout the pathway. Furthermore, the CRK oncogene was also found to be up-regulated. Increased levels of CRK proteins have been observed in several human cancers and over-expression of CRK in epithelial cell cultures promotes enhanced cell dispersal and invasion. For this pathway, the impact analysis yields a raw p-value of 0.005, which remains significant even after the FDR correction (p=0.048), at the 5% level. In contrast, the ORA analysis using the hypergeometric model yields a raw p-value of 0.155 (FDR corrected to 0.627) while the GSEA analysis yields a raw p-value of 0.16 (FDR corrected to 0.384). For both techniques, not even the raw p-values are significant at the usual levels of 5% or 10%. This is not a mere accident but an illustration of the intrinsic limitations of the classical approaches. These approaches completely ignore the position of the genes on the given pathways and therefore, they are not able to identify this pathway as being highly impacted in this condition. Note that any ORA approach will yield the same results for this pathway for any set of 4 differentially expressed genes from the set of genes on this pathway. Similarly, GSEA will yield the same results for any other set of 4 genes with similar expression values (yielding similar correlations with the phenotype). Both techniques are unable to distinguish between a situation in which these genes are upstream, potentially commandeering the entire pathway as in this example, or randomly distributed throughout the pathway.
The third pathway as ranked by the impact analysis is Wnt signaling (FDR corrected p=0.055, significant at 10%). The importance of this pathway is well supported by independent research. At least three mechanisms for the activation of Wnt signaling pathway in lung cancers have been recently identified: i) over-expression of Wnt effectors such as Dvl, ii) activation of a non-canonical pathway involving JNK, and iii) repression of Wnt antagonists such as WIF-1. The present understanding with regards to Wnt signaling also suggests that the blockade of Wnt pathway may lead to new treatment strategies in lung cancer.
In the same data set, Huntington's disease, Parkinson's disease, prion disease and Alzheimer's disease have low impact factors (corrected p-values of above 0.20), correctly indicating that they are unlikely to be relevant in lung adenocarcinomas.
A second data set includes genes identified as being associated with poor prognosis in breast cancer FIGS. 4A-4C show the comparison between the classical hypergeometric approach, GSEA, and the pathway impact analysis. On this data, GSEA finds no significantly impacted pathways at any of the usual 5% or 10% levels. In fact, the only FDR-corrected value below 0.25, in the entire data set is 0.11, corresponding to the ubiquitin mediated proteolysis. Furthermore, GSEA's ranking does not appear to be useful for this data, with none of the cancer-related pathways being ranked towards the top. The most significant signaling pathway according to the hypergeometric analysis, cell cycle is also the most significant in the impact analysis. However, the agreement between the two approaches stops here. In terms of statistical power, according to the classical hypergeometric model, there are no other significant pathways at either 5% or 10% significance on the corrected p-values. If we were to ignore the usual significance thresholds and only consider the ranking, the third highest pathway according to the hypergeometric model is Parkinson's disease. In fact, based on current knowledge, Parkinson's disease is unlikely to be related to rapid metastasis in breast cancer. At the same time, the impact analysis finds several other pathways as significant. For instance, focal adhesion is significant with an FDR-corrected p-value of 0.03. In fact, a link between focal adhesion and breast cancer has been previously established. In particular, FAK, a central gene on the focal adhesion pathway, has been found to contribute to cellular adhesion and survival pathways in breast cancer cells which are not required for survival in non-malignant breast epithelial cell. Recently, it has also been shown that Doxorubicin, an anti-cancer drug, caused the formation of well defined focal adhesions and stress fibers in mammary adenocarcinoma MTLn3 cells early after treatment. Consequently, the FAK/PI-3 kinase/PKB signaling route within the focal adhesion pathway has been recently proposed as the mechanism through which Doxorubicin triggers the onset of apoptosis.
TGF-beta signaling (p=0.032) and MAPK (p=0.064) are also significant. Both fit well with previous research results. TGF-beta1, the main ligand for the TGF-beta signaling pathway, is known as a marker of invasiveness and metastatic capacity of breast cancer cells. In fact, it has been suggested as the missing link in the interplay between estrogen receptors and HER-2 (human epidermal growth factor receptor 2). Furthermore, plasma levels of TGF-beta1 have been used to identify low-risk postmenopausal metastatic breast cancer patients. Finally, MAPK has been shown to be connected not only to cancer in general, but to this particular type of cancer. For instance the proliferative response to progestin and estrogen was shown to be inhibited in mammary cells microinjected with inhibitors of MAP kinase pathway. Also, it is worth noting the gap between the p-values for regulation of actin cytoskeleton (p=0.111), which may be relevant in cancer, and the next pathway, Parkinson's disease (p=0.239), which is irrelevant in this condition.
A third data set involves a set of differentially expressed genes obtained by studying the response of a hepatic cell line when treated with palmitate. FIGS. 5A and 5B show the comparison between the classical statistical analysis (ORA) and the pathway impact analysis. The classical statistical analysis yields 3 pathways significant at the 5% level: complement and coagulation cascades, focal adhesion and MAPK. The impact analysis agrees on all these, but also identifies several additional pathways. The top 4 pathways identified by the impact analysis are well supported by the existing literature. There are several studies that support the existence of a relationship between different coagulation factors, present in the complement and coagulation cascades pathway, and palmitate. It has also been demonstrated that a high palmitate intake affects factor VII coagulant (FVIIc) activity. Interestingly, FIG. 1 shows not only that this pathway has a higher than expected proportion of differentially expressed genes, but also that 6 out of 7 such genes are involved in the same region of the pathway, suggesting a coherently propagated perturbation. The focal adhesion and tight junction pathways involve cytoskeletal genes. Others have considered the presence of the cytoskeletal genes among the differentially expressed genes as very interesting and hypothesized that the down-regulation of these cytoskeletal genes indicates that palmitate decreases cell growth. Finally, the link between MAPK and palmitate has been established indicating that p38 MAP kinase is a key player in the palmitate-induced apoptosis.
A statistical approach using various models is commonly used in order to identify the most relevant pathways in a given experiment. This approach is based on the set of genes involved in each pathway. We identified a number of additional factors that may be important in the description and analysis of a given biological pathway. Based on these, we developed a novel impact analysis method that uses a systems biology approach in order to identify pathways that are significantly impacted in any condition monitored through a high throughput gene expression technique. The impact analysis incorporates the classical probabilistic component but also includes important biological factors that are not captured by the existing techniques: the magnitude of the expression changes of each gene, the position of the differentially expressed genes on the given pathways, the topology of the pathway which describes how these genes interact, and the type of signaling interactions between them. The results obtained on several independent data sets show that the proposed approach is very promising. This analysis method has been implemented as a web-based tool, Pathway-Express, freely available as part of the Onto-Tools software package. (Wayne State University, Detroit, Mich., USA).
The approach proposed here evaluates the strength of the null hypothesis H 0 (that the pathway is not significant), by combining two types of evidence. In a first analysis, a classical over-representation analysis (ORA) approach provides a p-value defined as the probability that the number of differentially expressed genes, X, is larger than or equal to the observed number of differentially expressed genes, N de , just by chance (when the null hypothesis H 0 is true):
p i =P ( X≧N de |H 0 ) (3)
Next, in a separate perturbation analysis, the impact of topology, gene interactions, and gene fold changes come into play and are captured thought the pathway perturbation factor:
P
F
=
∑
g
∈
P
i
P
F
(
g
)
Δ
E
_
·
N
de
(
P
i
)
(
4
)
where N de (Pi) is the number of differentially expressed genes on the given pathway P i , PF (g) is the perturbation of the gene g:
PF ( g ) = Δ E ( g ) + ∑ u ∈ US g β ug · PF ( u ) N ds ( u ) ( 5 )
and ΔE is the mean fold change over the entire set of N differentially expressed genes:
Δ
E
_
=
∑
k
=
1
N
Δ
E
N
(
6
)
Let PF denote the perturbation factor as a random variable and pf be the observed value for a particular pathway. The score pf is always positive, and the higher its value, the less likely the null hypothesis (that the pathway is not significant). Moreover this likelihood decays very fast as pf gets away from zero. These features point to the exponential distribution as an appropriate model for the random variable PF. Under the null hypothesis, differentially expressed genes would fall on the pathway randomly, and would not interact with each other in any concerted way. In other words, in the second term in Eq. 5 (which captures the influence of the genes upstream) roughly half of those influences will be positives, and half negative, canceling each other out. In such circumstances, the perturbation of each gene would be limited to its own measured fold change (due to random unrelated causes):
PF
(
g
)
=
Δ
E
(
g
)
+
∑
u
∈
US
g
β
ug
·
PF
(
u
)
N
ds
(
u
)
=
Δ
E
(
g
)
+
0
=
Δ
E
(
g
)
(
7
)
Consequently, under the same null hypothesis, the expected value for the perturbation of a pathway (from Eq. 4) will be:
E
(
PF
)
=
E
(
∑
g
∈
P
i
PF
(
g
)
Δ
E
_
·
N
de
(
P
i
)
)
=
E
(
1
Δ
E
_
∑
k
=
1
N
de
(
P
i
)
Δ
E
(
g
)
N
de
(
P
i
)
)
=
E
(
Δ
E
P
i
_
Δ
E
_
)
=
1
(
8
)
The last fraction above is the ratio between the mean fold change on the given pathway, Pi, and the mean fold change in the entire data set. Under the null hypothesis, the genes are distributed randomly across pathways and the two means should be equal. Since this expected value is 1, the distribution of the random variable PF can be modeled by the exponential of mean 1, exp(1).
If we use the PF score as a test statistics and assume its null distribution is exponential with mean 1, then the p-value p pf resulting from the perturbation analysis will have the form:
p pf =P ( PF≧pf|H 0 )= e −pf (9)
This is the probability of observing a perturbation factor, PF, greater or equal to the one observed, pf, when the null hypothesis is true.
Let us now consider that for a given pathway we observe a perturbation factor equal to pf and a number of differentially expressed genes equal to N de. A ‘global’ probability p global . of having just by chance both a higher than expected number of differentially expressed genes AND a significant biological perturbation (large PF in the second term), can be defined as the joint probability:
p global =P ( X≧N de ,PF≧pf|H 0 ) (10)
Since the pathway perturbation factor in Eq. (4) is calculated by dividing the total pathway perturbation by the number of differentially expressed genes on the given pathway, the PF will be independent of the number of differentially expressed genes X, and the joint probability above becomes a product of two single probabilities:
p global =P ( X≧N de |H 0 )· P ( PF≧pf|H 0 ) (11)
This p global provides a global significance measure that requires both a statistically significant number of differentially expressed genes on the pathway, N de , and at the same time, large perturbations on the same pathway as described by pf. Using equations (3) and (9), the formula (11) becomes:
p global =p i ·e −pf (12)
We take a natural log of both sides and obtain:
−log( p global )=−log( p i )+ pf (13)
which can be re-written as:
−log( p global )=−log( p i )+ pf (14)
in which we can substitute the definition of pf from (4) above to yield:
−log( p global )=−log( p i )+ PF (15)
The right hand side of this expression is exactly our definition of the impact factor:
IF
=
-
log
(
p
i
)
+
∑
g
∈
P
i
PF
(
g
)
Δ
E
_
·
N
de
(
P
i
)
(
16
)
This shows that the proposed impact factor, IF, is in fact the negative log of the global probability of having both a statistically significant number of differentially expressed genes and a large perturbation in the given pathway.
Ignoring the discrete character of the hypergeometric distribution, under the null hypothesis p i =P (X≧N RP H 0 ) has a uniform distribution. By taking negative log, the distribution changes into exponential with parameter 1, similar to the distribution we assumed for PF, the second term in IF formula.
−log( p i )˜exp(1); PF ˜exp(1);exp(1)=Γ(1,1) (17)
Then, as the sum of two independent exponential random terms, the IF will follow a Gamma distribution Γ(2, 1). The pdf of this distribution is:
f ( x )= xe −x ,x≧ 0 (18)
Finally, the p-value corresponding to the observed value if of the statistic IF can be easily computed by integrating the density (16):
p
=
P
(
IF
≥
if
❘
H
0
)
=
∫
if
∞
f
(
x
)
ⅆ
x
=
∫
if
∞
x
ⅇ
-
x
ⅆ
x
=
(
if
+
1
)
*
ⅇ
-
ⅈ
f
(
19
)
The impact analysis proposed includes and extends the classical approach both with respect to individual genes and with respect to pathways. We discuss briefly a few interesting particular cases. These cases illustrate how, when the limitations of the classical approach are forcefully imposed (e.g., ignoring the magnitude of the measured expression changes or ignoring the regulatory interactions between genes), the impact analysis reduces to the classical approach and yields the same results.
In our analysis, the gene perturbation factor for a gene g is defined as:
PF
(
g
)
=
Δ
E
(
g
)
+
∑
u
∈
US
g
β
ug
·
PF
(
u
)
N
ds
(
u
)
(
5
)
If there are no measured differences in the expression values of any of the genes upstream of g, PF (u)=0 for all genes in US g , and the second term becomes zero. In this case the perturbation factor reduces to:
PF ( g )=ΔE (20)
This is exactly the classical approach, in which the amount of perturbation of an individual gene in a given condition is measured through its expression change ΔE. Examples could include the genes FN1 and CD14 in FIG. 6 .
The pathway analysis framework can also be used in the framework in which the ORA approach is usually used. If the expression changes measured for the pathway genes are to be ignored (as they are in the ORA approach), the pathway impact analysis can still be used to assess the impact of a condition upon specific pathways. This is achieved by setting all measured expression changes ΔE(g)=0 for all genes on the given pathway g εP i . This will make all gene perturbation factors zero:
PF
(
g
)
=
Δ
E
(
g
)
+
∑
u
∈
US
g
β
ug
·
PF
(
u
)
N
ds
(
u
)
=
0
(
21
)
Assuming that there are at least some differentially expressed genes somewhere in this data set a , (i.e. ΔE=0) the pathway impact factor in Eq. 16 becomes:
IF
(
P
i
)
=
log
(
1
p
i
)
+
∑
g
∈
P
i
PF
(
g
)
Δ
E
_
·
N
de
(
P
i
)
=
log
(
1
p
i
)
+
0
=
-
log
(
p
i
)
(
22
)
Since the expression now involves a single random variable, the IF values will follow a Γ(1, 1)=exp(1), rather than a Γ(2, 1) distribution, and our p value can be calculated as:
p
=
P
(
IF
≥
-
log
(
p
i
)
❘
H
0
)
=
∫
-
log
(
p
i
)
∞
ⅇ
-
x
ⅆ
x
=
-
ⅇ
-
x
❘
-
log
(
p
i
)
∞
=
ⅇ
log
(
p
i
)
=
p
i
(
23
)
This expression shows that in this particular case, the impact analysis reduces to exactly the classical approach which measures the impact of a pathway by looking exclusively at the probability of the given number of differentially expressed genes occurring just by chance, i.e., the p-value yielded by an analysis in which only the set of genes is considered.
It is entirely possible that certain genes are in fact changing their expression level but the change is below the sensitivity threshold of the technology, or below the threshold used to select differentially expressed genes. It is also possible that the regulation between genes happens at levels other than that of the mRNA (e.g., phosphorylation, complex formation, etc.). Hence, signals should be allowed to be propagated around the pathway even through those genes for which no expression change has been detected at the mRNA level. The perturbation factor model accounts for these situations. If the measured expression change is zero, the perturbation of the gene becomes:
PF
(
g
)
=
∑
u
∈
US
g
β
ug
·
PF
(
u
)
N
ds
(
u
)
(
24
)
In this case, the perturbation of a given gene is due to the perturbations of the genes upstream, propagated through the pathway topology.
In certain situations, one might not wish that the analysis propagate the gene perturbations through specific graph edges or types of graph edges (e.g., for edges corresponding to indirect effects or state changes). This can be easily achieved by setting β=0 for the desired edges or edge types.
If no perturbation propagations are to be allowed at all, the expression of the gene perturbation in Eq. 5 reduces to:
PF ( g )=ΔE (25)
and the impact factor for the pathway becomes:
IF
(
P
i
)
=
log
(
1
p
i
)
+
∑
g
∈
P
i
PF
(
g
)
Δ
E
_
·
N
de
(
P
i
)
=
log
(
1
p
i
)
+
1
Δ
E
_
∑
k
=
1
N
de
(
P
i
)
Δ
E
(
g
)
N
de
(
P
i
)
=
log
(
1
p
i
)
+
Δ
E
P
i
_
Δ
E
_
(
26
)
In this case, the impact analysis would assess the pathways based not only on the number of differentially expressed genes that fall on each pathway but also based on the ratio between the average expression change on the pathway and the average expression change in the entire set of differentially expressed genes.
FIG. 7 illustrates the computation and propagation of the perturbations in a small area of an actin cytoskeleton pathway (shown in its entirety in FIGS. 9A and 9B ). As already mentioned, in all data shown here the regulatory efficiency is β=1 for all genes. In this case, the gene DIAPH3 is the input gene with an observed fold change ΔE=1.4841. Since there are no genes upstream of DIAPH3, its second term in Eq. 5 is zero. Using Eq. 5, the PF of gene DIAPH3 is simply its measured expression change:
PF ( DIAPH 3)=1.4841+0=1.4841 (26)
The next step involves the computation of the perturbation for BAIAP2. This gene receives signals from DIAPH3 but also from RAC1, RAC1P4, RAC2 and RAC3. Using Eq. 5, the PF for the gene BAIAP2 can be calculated as:
PF ( BAIAP 2 ) = Δ E ( BAIAP 2 ) + PF ( DIAPH 3 ) N ds ( DIAPH 3 ) + PF ( RAC 1 ) N ds ( RAC 1 ) + PF ( RAC 1 P 4 ) N ds ( RAC 1 P 4 ) + PF ( RAC 2 ) N ds ( RAC 2 ) + PF ( RAC 3 ) N ds ( RAC 3 )
The previously calculated perturbations for RAC1, RAC1P4, RAC2 and RAC3 are:
PF ( RAC 1)= PF ( RAC 1 P 4)= PF ( RAC 2)= PF ( RAC 3)=−0.251 (27)
Each of these genes signals only to BAIAP2 so for each of them the number of downstream genes, N ds will be equal to 1. Hence, the PF for the gene BAIAP2 can be calculated as:
PF ( BAIAP 2 ) = 1.4841 + - 0.251 1 + - 0.251 1 + - 0.251 1 + - 0.251 1 = 0.4801 ( 28 )
Similarly, using Eq. 5, the PF for the gene DIAPH1 is
PF
(
DIAPH
1
)
=
Δ
E
(
DIAPH
1
)
+
PF
(
BAIAP
2
)
N
ds
(
BAIAP
2
)
=
0
+
0.4801
3
=
0.16
(
29
)
The perturbation of the other two genes, LOC286404 and WASF2 is analogous and yields the same numerical value.
If the pathway includes loops, Eq. 5 becomes recursive, and the computation of the gene PFs will involve an iterative process. The best way of treating such loops would probably involve modeling the pathways as dynamical systems and using differential (or difference) equations to study them from the point of view of stability and convergence. However, at the moment, the expression data generated by the currently available techniques do not appear to be sufficiently accurate to allow this type of analysis. The very same biological samples analyzed on various platforms yield numbers that often correlate only around 0.7. Treating the pathways as dynamical systems with such data runs quickly into stability problems. In order to address this in a feasible way, we perform the computation of the perturbation factors by going around each loop once. This approach appears to be a good compromise for the nature of the data: loops are not completely ignored and, at the same time, stability problems created by noisy data are avoided. The drawback is that the impact factor can only be interpreted in a probabilistic framework, and cannot be put into any type of quantitative correspondence with any biochemical product anywhere on the pathway.
The typical output window using the methods of the present disclosure is shown in FIG. 8 . The tool uses pathway data from KEGG and implements both the classical statistical approach (ORA), as well as the impact analysis described above, allowing a side by side comparison. The tool also allows rapid queries for genes or pathways, visualization of entire pathways (see FIG. 6 ), etc.
Currently, all signaling pathways for human, mouse and rat are downloaded from KEGG and stored in a relational database. In order to calculate the impact factor for a given pathway, the pathway database is queried to retrieve all genes and gene interactions in the pathway, and a graph data structure for this pathway is created. The genes are represented as nodes, and the gene interactions as edges of the graph (see FIGS. 9A and 9B ). The user-provided normalized fold changes are mapped on the pathway graph and used to calculate the gene perturbation factors as described in Eq. 5. Once the perturbation factors of all genes in a given pathway are calculated, Eq. 16 is used to calculate the impact factor of each pathway. The impact factor of each pathway is then used as a score to assess the impact of a given gene expression data set on all pathways (the higher the impact factor, the more significant the pathway).
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. | Significance of biological pathway in disease state is predicted by (a) providing expression level data for a plurality of biomolecules differentially expressed in a disease state, compared with same biomolecules expressed in a non-diseased state: (b) determining presence probability of the biomolecules in disease state; (c) determining effect of each biomolecule from the plurality of biomolecules on the expression of different downstream biomolecules within pathway to provide perturbation factor for each biomolecule in the pathway; (d) combining statistical significance of differentially expressed biomolecules present in the disease state, with a sum of perturbation factors for all of the biomolecules, generating an impact factor; (e) calculating statistical significance of impact factor based upon determined probability of having statistical significant presence of differentially expressed biomolecules in step (b) and the sum of perturbation factors in step (c); and (f) outputting statistical significance of impact factor for the pathway relevant to the disease. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to a spray nozzle for use in precision farming. More particularly, but not by way of limitation, the present invention relates to an attitude controller which accounts for vehicle velocity in the delivery of an agricultural product.
[0003] 2. Background
[0004] Precision farming is a term used to describe the management of intrafield variations in soil and crop conditions. Site specific farming, prescription farming, and variable rate application technology are sometimes used synonymously with precision farming to describe the tailoring of soil and crop management to the conditions at discrete, usually contiguous, locations throughout a field. The size of each location depends on a variety of factors, such as the type of operation performed, the type of equipment used, the resolution of the equipment, as well as a host of other factors. Generally speaking, the smaller the location size, the greater the benefits of precision farming, at least down to approximately one square meter.
[0005] Typical precision farming techniques include: varying the planting density of individual plants based on the ability of the soil to support growth of the plants; and the selective application of farming products such as herbicides, insecticides, and, of particular interest, fertilizer.
[0006] In contrast, the most common farming practice is to apply a product to an entire field at a constant rate of application. The rate of application is selected to maximize crop yield over the entire field. Unfortunately, it would be the exception rather than the rule that all areas of a field have consistent soil conditions and consistent crop conditions. Accordingly, this practice typically results in over application of product over a portion of the field, which wastes money and may actually reduce crop yield, while also resulting in under application of product over other portions of the field, which may also reduce crop yield.
[0007] Perhaps even a greater problem with the conventional method is the potential to damage the environment through the over application of chemicals. Excess chemicals, indiscriminately applied to a field, ultimately find their way into the atmosphere, ponds, streams, rivers, and even the aquifer. These chemicals pose a serious threat to water sources, often killing marine life, causing severe increases in algae growth, leading to eutrophication, and contaminating potable water supplies.
[0008] Thus it can be seen that there are at least three advantages to implementing precision farming practices. First, precision farming has the potential to increase crop yields which will result in greater profits for the farmer. Second, precision farming may lower the application rates of seeds, herbicides, pesticides, and fertilizer, reducing a farmer's expense in producing a crop. Finally, precision farming will protect the environment by reducing the amount of excess chemicals applied to a field, which may ultimately end up in the atmosphere, a pond, stream, river, or other water source.
[0009] Agricultural applicators that apply fertilizers, pesticides, and other materials are typically attached to a moving tractor and must account for vehicle velocity, material velocity, and elevation above the target, if the machine is to apply the material at the intended rate only to a specific target. Existing applicators are adjusted manually, by trial and error, or use an estimate of the flight time of the applied material and the vehicle velocity to calculate the time at which the applicator is triggered in order to deposit material on the target. The former method does not permit dynamic adjustment for changes in vehicle velocity, material ejection velocity, or elevation of the nozzle above the target. The latter method is difficult to calculate, may not be fast enough to account for changes in elevation of the nozzle above the target and changes in the material ejection velocity, and does not account for differences in the in-flight velocities of different sized particles. In addition, the measurement of elevation changes is difficult and expensive.
[0010] The present invention is important because it enables the agronomist to minimize applicator boom height, material exit velocity, and applicator vehicle velocity as factors affecting the location that the material impacts the target surface. The art is developing mobile optical sensing technologies that enable one to identify specific plant targets, determine the amount of material to be applied, and apply material only to the plant target. Applicator boom height, material exit velocity, and vehicle velocity normally vary during farming operations. Current technologies attempt to hold these variables constant, which greatly reduces the flexibility of operation and needlessly complicates the system. A device that automatically counteracts controllable factors causing off target deposition of materials will greatly improve the efficiency of an optical sensor based variable rate applicator.
SUMMARY OF THE INVENTION
[0011] The invention disclosed herein adjusts the angle of the device emitting the material (hereinafter referred to as the “nozzle”) so that the horizontal exit velocity of the material is equal in magnitude and opposite in direction to the applicator vehicle velocity. By negating the horizontal velocity of the vehicle, the horizontal velocity of the material emitted from the nozzle is zero, absent other external disturbances. Consequently, if the material is ejected over the target from any height above the target, it falls onto the target. While the inventive device can apply liquid, granular or gaseous materials, by way of example and not limitation, the preferred embodiment is described herein with regard to the delivery of liquid materials. However, as will be apparent to those skilled in the art, devices to apply granular or gaseous materials would be similar in design.
[0012] The nozzle attitude controller consists of a horizontal manifold or pipe, oriented perpendicular to the direction of travel by the applicator-vehicle. This manifold is suspended from a frame or boom. Liquid material is conveyed through the manifold to a series of nozzles oriented perpendicular to the axis of the manifold and in the same plane. The manifold is supported by bearings and is linked to a linear actuator as shown in FIG. 1 . The linear actuator rotates the manifold around its axis. Liquid materials are ejected through the nozzle orifice. Ejection velocity can be calculated by:
V j =C v (2Δ p/ρ ) 1/2 (1)
[0013] Where:
[0014] V J =Liquid jet velocity
[0015] C v =nozzle velocity coefficient
[0016] Δp=difference in pressure across the orifice
[0017] ρ=liquid density
[0018] The velocity coefficient is a known or measurable property of the nozzle; the liquid density is a known or measurable fluid property. Pressure transducers can be installed to measure the spray system differential pressure. The ejection angle, where the horizontal component of liquid velocity is equal to the vehicle velocity, can be calculated by the following equation:
Θ=cos −1 V v /(2Δ p /ρ) (2)
[0019] Where:
[0020] Θ=nozzle angle of inclination
[0021] V v =applicator vehicle velocity
[0022] Nozzle angle may be measured to provide position feedback for a control system.
[0023] Further objects, features, and advantages of the present invention will be apparent to those skilled in the art upon examining the accompanying drawings and upon reading the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1A is a side elevation of a vehicle, to which the device of the present invention is attached.
[0025] [0025]FIG. 1B is a top view of the vehicle, to which the device of the present invention is attached.
[0026] [0026]FIG. 2 is a semi diagrammatic side elevation of a portion at the rear of the truck of FIG. 1, showing some of the details of the controls of the spray nozzles; and
[0027] [0027]FIG. 3 is a view similar to FIG. 2, but showing a modified form of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Before explaining the present invention in detail, it is important to understand that the invention is not limited in its application to the details of the construction illustrated and the steps described herein. The invention is capable of other embodiments and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.
[0029] Before referring to the drawings, it is believed that a few comments concerning nozzle and actuator geometry would be helpful to an understanding of this invention.
[0030] Normal pattern uniformity of agricultural spray nozzles at standard spacing is sensitive to changes in height above the target. This problem can be minimized by using jet nozzles, mounted to produce parallel fluid jets, when the material can be applied in parallel bands. Spacing of parallel fluid jets will remain constant independent of height above the travel distance (the combination of height above the target and nozzle inclination angle). When materials must be continuously and uniformly distributed over the target surface, the problem of flight distance is more difficult. The effect of flight distance can be minimized by mounting nozzles with very small fan angles close together, a high-density nozzle manifold. Nozzles customarily used have fan or distribution angles of 65 to 110 degrees, and nozzles are spaced so that distribution patterns overlap only about 30%, typically 20 to 30 inches. We propose to mount nozzles with fan angles as small as 15 degrees at 3 to 4 inch spacing. This will produce a pattern with 30 to 200% overlap, with only minor changes in distribution uniformity with large changes in spray material travel distance.
[0031] The nozzle attitude controller may operate as follows:
[0032] 1. At start up, the spray nozzle velocity coefficient and spray solution density will be transmitted to a single-board microprocessor controller via a controller area network (CAN)
[0033] 2. The microprocessor will receive applicator vehicle velocity and spray system operating pressure from remote sensors via the network at regular intervals.
[0034] 3. The controller calculates the spray solution discharge velocity, with equation 1 (below) and the nozzle angle, with equation 2 (below), required to negate the applicator vehicle velocity.
[0035] 4. The controller then powers the linear actuator, which rotates the manifold and nozzle bank, while polling a sensor, which measures manifold angular displacement. The manifold is rotated until the nozzles are oriented at the calculated angle.
[0036] 5. The microprocessor continues to monitor spray system pressure and applicator velocity. Should pressure change (which can occur if spray solution flow-rate is changed to compensate for changes in vehicle velocity) and/or applicator velocity is changed, the microprocessor recalculates nozzle angle and adjusts that angle to compensate for changes in the system
[0037] The nozzle attitude controller consists of a horizontal manifold or pipe, oriented perpendicular to the direction of travel by the applicator-vehicle. This manifold is suspended from a frame or boom. Liquid material is conveyed through the manifold to a series of nozzles oriented perpendicular to the axis of the manifold and in the same plane. The manifold is supported by bearings and is linked to a linear actuator as shown in FIG. 2. The linear actuator rotates the manifold around its axis. Liquid materials are ejected through the nozzle orifice at an ejection velocity calculated by:
V j =C v (2Δ p /ρ) (1)
[0038] Where:
[0039] V j =Liquid jet velocity
[0040] C v =nozzle velocity coefficient
[0041] Δp=difference in pressure across the orifice
[0042] ρ=liquid density
[0043] The velocity coefficient is a known or measurable property of the nozzle; the liquid density is a known or measurable fluid property. Pressure transducers can be installed to measure the spray system differential pressure. The ejection angle, where the horizontal component of liquid velocity is equal to the vehicle velocity, can be calculated by the following equation:
Θ=cos −1 V v /(2Δ p /ρ) 1/2 (2)
[0044] Where:
[0045] Θ=nozzle angle of inclination
[0046] V v =applicator vehicle velocity
[0047] Nozzle angle will be measured to provide position feedback for a control system.
[0048] Referring now to the drawings, where reference numerals indicate the same parts throughout the several views, FIG. 1A shows a vehicle 20 of the type used to spray fertilizer or pesticides. The vehicle has a boom 22 , which extends laterally from the rear of the vehicle 20 . A plurality of spray nozzles 26 are arranged in spaced relation behind the boom 22 and attached thereto in a manner later to be described.
[0049] Turning now also to FIG. 2, each nozzle 26 connects with a manifold 28 through a nozzle housing 30 . The manifold 28 is rotatable as shown by the arrow in FIG. 2 in a manner to be described. The manifold and the nozzle housing 30 are both hollow, so as to provide liquid or powdered material under pressure through the nozzle 26 to create the spray pattern indicated. A plurality of nozzle supports 32 (only one of which is shown in FIG. 2) project outwardly and rearwardly from the boom 22 and connect at spaced intervals with the manifold 28 . The connections between the ends of the horizontal supporting members 32 and the manifold 28 are such that the manifold is rotatably received at the ends of these supports 32 .
[0050] In order to provide pivotal movement of the manifold 28 an arm 34 is connected to the manifold 28 and projects outwardly and upwardly therefrom.
[0051] The arm 34 can be singular or plural. The outer end of the arm 34 connects pivotally with a shaft 36 through a bolt 38 , which permits pivotal movement between the arm 36 and the arm 34 . The shaft 36 is preferably connected to, or is part of, a linear actuator 40 which includes a ball-screw-type mechanism (not shown) whereby the shaft 36 can move to the right or to the left so as to pivot the arm 34 counterclockwise or clockwise, as the case may be. A stepper motor 41 (shown only diagrammatically) connects with the linear actuator 40 , which also constitutes the housing for the ball screw actuator. The internal details of the ball screw are not shown, but one needs only to know that the ball screw mechanism turns around the shaft 36 so as to cause inward or outward movement of the shaft 36 relative to linear actuator 40 . The stepper motor 41 turns the ball mechanism (not shown) to move the shaft 36 longitudinally. A radar sensor 42 connects with the stepper motor 41 and also connects with the truck. The radar sensor is adapted to sense the speed of the truck and to deliver pulses to the stepper motor 41 commensurate with the speed of the truck. The pulses provided by the radar sensor 42 through the stepper motor 41 will determine the angle Θ
[0052] As will be apparent to those skilled in the art, linear actuators are available in a variety of types and any type of such actuator is suitable to steer the inventive nozzle. By way of example and not limitations other suitable types of linear actuators include: hydraulic cylinders, pneumatic cylinders, rack and pinion mechanisms, and the like.
[0053] In a typical application as shown in FIG. 1B, multiple sensors, of which sensor 24 is representative, will be located along the manifold or boom in essential alignment with the inventive nozzles, of which nozzle 26 is representative. Each sensor 24 , whose function will be set forth in a separate disclosure, and which form no part of the present invention, is adapted to sense the needs of the plants (not shown) in its immediate view below the boom 22 and vary the quantity of material exiting from the corresponding nozzle 26 , which is associated with that particular sensor.
[0054] As shown in FIG. 3, in an alternate embodiment, the nozzle 26 connects with the manifold 28 in essentially the same manner as previously described, and the manifold 28 will be supported by a plurality of horizontal supporting members 32 extending outwardly from the boom 22 . In the environment shown in FIG. 3, the elements 36 through 42 are not included. Instead, an upper horizontal support 44 extends rearwardly from the boom 22 . A protractor 46 is attached to one end of the manifold 20 so as to be rotatable therewith. If the fluid density and orifice velocity coefficients are fixed, the outer arcuate portion 48 of the protractor 46 may be provided with graduations representing miles per hour. If fluid density and orifice velocity coefficients are not constant, the outer arcuate portion 48 would preferably be graduated in degrees, Θ. A coordinating pointer 50 , attached to the horizontal support 44 is adapted to cooperate through the outer arcuate surface 48 to indicate what particular speed is represented by the given relationships between the pointer and the graduations. As shown in FIG. 3, the pointer 50 could very easily represent a condition relating to ten miles per hour of the vehicle 20 . The protractor 46 may be locked in place relative to pointer 50 to maintain the desired nozzle attitude for proper delivery of the material. Preferably, to lock protractor 46 in place, an arcuate slot 52 is provided through which a bolt 54 passes so as to be threadedly received within the horizontal support 44 . If it is desired, for example, to operate the vehicle at 10 mph, the pointer 50 and the protractor 46 would be positioned as shown in FIG. 3 and the bolt 54 thereafter tightened. The vehicle is then configured to maintain the indicated speed during the spraying operation. The manifold pressure may be modulated somewhat according to the equations given above to account for minor fluctuations in vehicle velocity.
[0055] As will be apparent to those skilled in the art, while two means have been shown for rotating manifold 28 , many other variations are possible. By way of example and not limitation, the manifold could be supported directly from the output shaft of a motor while the boom is secured to the housing of the motor to cause rotation of the manifold, or a turnbuckle could be installed in the position of linear actuator 40 and provided with a graduated linear scale for positioning the nozzles for a given set of spraying conditions.
[0056] Returning now to FIGS. 1 and 2, the vehicle 20 will be traversing toward the right at a velocity of V v . The liquid coming out of the nozzle 26 will be sprayed at a velocity of V j and under pressure Δp. The horizontal component of the spray nozzle velocity is V j horizontal, as shown on the drawing. If the velocity of V j horizontal equals V v then the liquid coming out of the nozzle will be deposited over the ground (not shown) at zero horizontal velocity. This, of course, is the situation hoped for with the invention described herein.
[0057] Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those skilled in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the appended claims. | A nozzle attitude controller for use in connection with a farming apparatus for precision farming, the apparatus comprising an applicator vehicle, a boom supported by and extending across the rear of the vehicle, a manifold rotatably supported by the boom, a plurality of nozzles disposed from the manifold and oriented in a direction opposite to the direction of movement of the vehicle, but disposed at an angle with respect to the horizontal, the attitude controller including a linear actuator operated by a stepper motor and a radar sensor which connects to the stepper motor and which measures the speed of the vehicle such that pulses from the radar sensor to the stepper motor moves the linear actuator to change the angle of the nozzle so that the horizontal component of its velocity is equal and opposite to the speed of the vehicle. | 8 |
FIELD AND BACKGROUND
The present invention refers, in general, to a positioning device for the positioning of loops and to a sewing machine comprising said device. More particularly, the present invention relates to a positioning device and to a sewing machine comprising said device, to appropriately arrange and position a loop on a garment during processing, for instance trousers.
As is known, several typologies of garments need loops, which are small fabric or leather strips through which bands, belts, strings or similar elements pass.
As represented in FIG. 1 , a loop 10 is usually fixed on an article of clothing 12 by means of seams 14 of the ends 18 , 20 of the strip 16 that forms the loop. In particular, in order to make the fixing more stable, the ends 18 , 20 are turned towards the article of clothing 12 so that the seam 14 is stitched on the portions 22 , 24 of the strip 16 , these portions being superimposed on the ends 18 , 20 bent. In this way, it is possible to double the portion of strip sewn on the article of clothing and the seam is made more solid.
In order to stitch said seam, the sewing machines of the prior art comprise suitable devices which allow to bend the ends 18 , 20 of the strip 16 inwards and to position the strip on the fabric area on which the loop has to be formed.
In particular, once the positioning devices according to the prior art have grabbed the strip 16 acting as a loop, the positioning devices rotate both ends 18 , 20 180 degrees so that both ends are arranged under the remaining part of the strip 16 .
The positioning devices according to the prior art do not ensure a perfect positioning of the strip ends 18 , 20 to bend so that an unwished effect is obtained as represented in FIG. 2 from which it appears how the ends 18 , 20 are not perfectly hidden under the remaining part of the strip 16 .
SUMMARY OF THE INVENTION
An aim of the invention is to remove the above-mentioned drawbacks and others, through the realization of a positioning device for the positioning of loops allowing a precise positioning and a perfect alignment of the strip forming the loop on the article of clothing.
In particular, an aim of the invention is to provide a positioning device allowing a precise positioning of each portion of the strip, and precisely a perfect overlap of the ends 18 , 20 with the portions 22 , 24 of the strip 16 , as represented in FIG. 3 .
Another aim of the invention is to carry out a loop positioning device that must be not only precise but also rapid and reliable at the same time.
Another aim of the invention is to carry out a positioning device that must be simple as regards the construction.
The above-mentioned aims and others are achieved according to the invention through a positioning device adapted to dispose a strip of fabric or other similar material on an article of clothing on which said strip has to be sewn so as to form a loop, said strip being divided in a central portion and two opposite ends. The positioning device comprises rotation means to rotate at least one of the two ends of the strip in order to bring this end in abutment with the central portion of the strip.
The positioning device according to the invention is characterized by the fact of comprising guide means to guide the at least one of said two ends of the strip in the rotation of the same end so that this end is superimposed completely to the central portion of the strip without showing any hems out of the area covered by the central portion.
Advantageously, the guide means of the positioning device according to the invention may comprise at least two plates positioned substantially perpendicular to the strip and adapted to be put in contact with the respective opposite side edges of the strip. The two plates allow that the end of the strip is received, in its rotation, between the two plates so as to be guided by said two plates up to go in contact with the central portion of the strip on completely overlapping the same central portion.
Besides, the guide means may comprise lifting means to lift the two or more plates so as to allow the positioning of the strip on the article of clothing on which the strip has to be sewn, after the strip has been appropriately bent at its ends.
Advantageously, the guide means may comprise first adjusting means to adjust the distance between said two plates acting on the same end of the strip so as to adapt the guide means to the width of the strip.
The guide means may comprise at least one support on which the two or more plates are connected by means of a pin and elastic means so that the two plates may rotate in relation to the support on maintaining the contact with the opposite side edges of the strip and are forced to return to their initial rest position by the elastic means.
Besides, the rotation means may comprise at least one fork which rotates on itself so as to cause the rotation of one or both of the two ends; since the fork goes in contact, in its rotation, with at least one of the two plates and the two plates are pivoted on the support, the two plates follow the movement of the fork and rotate.
The positioning device according to the invention may comprise two first plates and two second plates; the first two plates are adapted to guide a first end of the strip in its rotational motion so as to be completely superimposed to the central portion of the strip; the two second plates are adapted to guide a second end of the strip in its rotational motion so as to be completely superimposed to the central portion of the strip.
Advantageously, in the positioning device according to the invention, second adjusting means may be comprised to adjust the distance between the two first plates and the two second plates so as to adapt the guide means to the length of the strip.
In addition, chamfers are obtained in the plates and act as invitation in the receiving phase of an end between two plates.
In the positioning device according to the invention, hook means may be comprised to lift a part of the central portion of the strip in order to create a sufficient space for the passage of a belt or strap or other equivalent element between the article of clothing and the strip, once said strip has been sewn. It is to be intended that the aims and advantages of the invention are also achieved by a sewing machine comprising a positioning device for the positioning of loops.
DESCRIPTION OF THE DRAWINGS
Further features and details of the invention can be better understood from the following description which is provided as a non-limiting example as well as from the accompanying drawings wherein:
FIGS. 1 , 2 are side and top views, respectively of a loop, sewn on an article of clothing according to the prior art;
FIG. 3 is a top view of a loop positioned and sewn on an article of clothing in the optimal position;
FIG. 4 is a side view of a positioning device according to the invention, in the initial phase of the process of positioning of a loop;
FIG. 5 is an enlarged view of a portion of device as shown in a cutout “A” in FIG. 4 ;
FIG. 6 is a side view of the device in FIG. 4 during a first working phase;
FIG. 7 is a bottom view of the positioning device according to the invention when it is arranged in the configuration represented in FIG. 6 ;
FIGS. 8 , 9 , 11 , 13 are side views of the device in FIG. 4 during the following working phases;
FIG. 10 is an enlarged view of the portion of device as shown in a cutout “B” in FIG. 9 ;
FIG. 12 is an enlarged view of the portion of device shown in a cutout “C” in FIG. 11 ;
FIG. 14 is a top view of the positioning device according to the invention. With reference to the accompanying figures, in particular FIG. 4 and following figures, number 100 denotes a positioning device that can be mounted on a frame of a sewing machine. The positioning device 100 is used to suitably bend and position a strip 16 in a wished area of an article of clothing on which the strip has to be sewn in order to obtain a loop 10 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The positioning device comprises:
a slide and support device 26 for the strip 16 , this device being adapted to bring and support the strip 16 in a processing position in which the strip is prearranged to be sewn; a first fork 28 and a second fork 30 , each of them being able to cause the rotation of the first end 18 and the second end 20 of the strip 16 , respectively; a hook device 32 for the lifting of a portion of the strip 16 so as to form a sufficient space between the loop and the article of clothing for the passage of a belt or other similar element; a straightening device 34 allowing a correct positioning of the first end 18 and second end 20 when these ends are rotated.
The slide and support device 26 comprises movement and traction means (not represented in the figures) and more specifically pliers to displace the strip 16 from a loading position to a machining position in which the strip 16 is subjected to the necessary operations in order to be appropriately conformed, as described below, before being sewn on the article of clothing.
The slide and support device 26 comprises supporting elements 36 that support the strip 16 in the machining position.
The first fork 28 comprises a first tooth 38 and a second tooth 40 which are put side by side and are connected to a first shaft 42 , visible in FIG. 8 , which may rotate around its own axis. The first tooth 38 is coaxial to the first shaft 42 so that when the first shaft 42 rotates, also the first tooth 38 rotates around itself while the second tooth 40 rotates around the first tooth 38 .
Similarly, the second fork 30 comprises a first tooth 44 and a second tooth 46 which are put side by side and are connected to a second shaft 48 , visible in FIG. 8 , which may rotate around its own axis. The first tooth 44 of the second fork 30 is coaxial to the second shaft 48 so that when the second shaft 48 rotates, also the first tooth 44 rotates around itself while the second tooth 46 rotates around the first tooth 44 .
The hook device 32 comprises a support 49 on which an actuator, not visible in the figures, is fixed. An L-shaped element 50 is adjustably united to said actuator and comprises a lower portion 52 which is arranged under the strip 16 and acts as a hook for the lifting of a portion of the strip 16 .
The fixing of the L-shaped element 50 to the actuator is obtained by means of a screw 54 that allows to vary the position of the L-shaped element 50 depending on the space to be obtained between the loop 10 and the article of clothing 12 .
Besides, a first pin 56 and a second pin 58 are fixed to the support 49 and are arranged at a side of the L-shaped element and above the strip 16 when the strip 16 is in the machining position.
The first pin 56 and the second pin 58 are fixed in relation to the support 48 while the L-shaped element 50 is movable.
The straightening device 34 comprises a support 60 fixed to the frame of the sewing machine. A block 62 is connected to the support 60 by means of an actuator 64 which may move the block 62 vertically according to a direction E. A return spring 63 , visible in FIG. 6 , is united through an end to the support 60 and through the other end to the block 62 so that the block 62 is forced to rise when the actuator 64 is not actuated.
A rod 66 is fixed to the block 62 rigidly and has an oblong hole 68 . A first support 70 and a second support 72 are fixed adjustably to the rod 66 by means of adjusting screws 74 , 76 which pass through the oblong hole 68 and may adjust the position of the first support 70 and second support 72 horizontally.
Two first plates 78 are pivoted to the first support 70 and similarly, two second plates 80 are pivoted to the second support 72 ; the two first plates 78 as well as the two second plates 80 are separated from each other by a distance equal to the width of the strip 16 . Only in FIG. 8 it is possible to see the two first plates 78 and the two second plates 80 .
In addition, each of the first plates 78 and each of the second plates 80 are connected with first springs 82 and second springs 84 to the first support 70 and to the second support 72 , respectively. The first springs 82 and the second springs 84 allow to bring the first plates 78 and the second plates 80 again in the vertical position in case the plates are forced to tilt.
The operations performed by the positioning device 100 to suitably bend and position the strip 16 on the wished area of the article of clothing 12 on which said strip has to sewn to obtain a loop 10 are described below.
As it appears from FIGS. 4 , 5 , the strip 16 is unrolled from a roll and is brought and supported in the machining position by the slide and support device 26 . In particular, the strip 16 is pulled by the movement and traction means, specifically by the pliers, and supported by the supporting elements 36 . As represented in FIGS. 6 , 7 , once the strip 16 is disposed in the machining position, the first plates 78 and the second plates 80 are lowered so that the strip 16 is received between plates 78 , 80 .
In particular, the actuator 64 is actuated so as to lower the block 62 and consequently the bar 66 , the first support 70 and the second support 72 and therefore, also the first plates 78 and the second plates 80 . The first fork 28 and the second fork 30 are advanced so that on a side, the strip 16 is disposed between the first tooth 38 and the second tooth 40 of the first fork 28 and on the opposite side, the strip 16 is disposed between the first tooth 44 and the second tooth 46 of the second fork 30 while centrally, the strip 16 is kept in position on the upper part by the first pin 56 and second pin 58 and on the lower part by the lower portion 52 of the L-shaped element of the hook device 32 , in addition to the support elements 36 .
The first tooth 38 and the second tooth 40 of the first fork 28 separate ideally the left end 18 (according to the accompanying drawings) from the central portion of the strip 16 and similarly, the first tooth 44 and the second tooth 46 of the second fork 30 separate ideally the right end 20 (according to the accompanying drawings) from the central portion of the strip 16 .
The strip 16 , arranged in its machining position as indicated above, is cut at the opposite end to the pliers according to the wished length.
Then, as it appears from FIG. 8 , the hook device 32 is actuated to lift a portion of the strip 16 in order to obtain a sufficient space between the loop 10 and the article of clothing 12 for the passage of a belt or strap.
In particular, the actuator included in the support 49 is actuated to move up the L-shaped element 50 and its lower portion 52 that lifts the central portion of the strip 16 .
Then, as represented in FIGS. 9 , 10 , the first fork 28 is rotated 180 degrees anticlockwise (considering the point of observation of FIG. 10 ) so that the first tooth 38 rotates around itself and the second tooth 40 rotates around the first tooth 38 . In this way, the left end 18 is brought below the remaining portion of the strip 16 .
The first plates 78 guide the movement of the left end 18 on avoiding that the left end 18 protrudes laterally in respect to the remaining portion of the strip 16 and indeed, causing the left end 18 to be exactly positioned under the strip 16 and more precisely, under the overlying lateral left portion, ideally identified in FIGS. 1 , 13 and denoted here by reference number 22 .
Likewise, the second fork 30 is rotated 180 degrees clockwise (considering the point of observation of FIG. 10 ) so that the first tooth 44 rotates on itself and the second tooth 46 rotates around the first tooth 44 . In this way, the right end 20 is brought below the remaining portion of the strip 16 .
Like the first plates 78 , the second plates 80 guide the movement of the right end 20 on avoiding that the right end 20 protrudes laterally in respect to the remaining portion of the strip 16 and indeed, causing the right end 20 to be exactly positioned under the strip 16 and more precisely, under the overlying lateral right portion, ideally identified in FIGS. 1 , 13 and denoted here by reference number 24 .
As represented in FIGS. 11 , 12 , in order to facilitate the sewing of the strip 16 on the article of clothing 12 , the left end 18 and the right end 20 are brought in contact with the strip 16 .
In particular, the first fork 28 is rotated 40 degrees so that the second tooth 40 forces the left end 18 to contact and press the overlying lateral left side 22 . The second tooth 40 of the first fork 28 contacts and pushes the first plates 78 which are forced to tilt, even if pulled in the opposite direction by the springs 82 , but which keep the left end 18 in the correct position.
Likewise, also the second fork 30 is rotated an additional 40 degrees so that the second tooth 46 forces the right end 20 to contact and press the overlying lateral right side 24 . The second tooth 46 of the second fork 30 contacts and pushes the second plates 80 which are also forced to tilt, even if pulled in the opposite direction by the springs 84 , but which keep the right end 20 in the correct position.
Then, as represented in FIG. 13 , the actuator 64 of the straightening device 34 is deactivated and the return spring 63 provokes the lifting of the block 62 , the bar 66 , the first support 70 and the second support 72 . Consequently, also the first plates 78 and the second plates 80 are lifted and positioned vertically through the action of the respective springs 82 , 84 .
Thus, the strip 16 is so shaped that the strip 16 may be sewn at the lapels made by the positioning device 100 , namely at the overlying lateral left portion 22 and the overlying lateral right portion 24 and consequently, at the left end 18 and the right end 20 .
Finally, the positioning device 100 translates the so-shaped strip 16 by means of the first fork 28 and second fork 30 above the article of clothing 12 in the position in which the strip 16 has to be sewn to form a loop 10 .
The positioning device 100 according to the invention allows to arrange a strip in the suitable configuration for the realization of a loop; in particular, the positioning device 100 allows to bend the strip ends and place them exactly under the portions of the strip on avoiding unwished projections that would cause undesirable aesthetic effects.
The positioning device 100 according to the invention has a considerable flexibility of use and may be used regardless of the size of the loop to obtain; indeed, the presence of oblong holes and adjusting screws allows to horizontally vary the position of the first plates 78 and second plates 80 as well as the position of the first fork 78 and second fork 30 in order to adjust the processing when the length of the strip varies.
Besides, also the distance between the two first plates 78 as well as between the second plates 80 may be varied so that it is possible to use the positioning device 100 also when the length of the strip 16 to be shaped varies. Indeed, as it appears from FIG. 14 , the first support 70 and the second support 72 are provided with two first adjusting screws 86 and two second adjusting screws 88 , respectively. Each of the screws fixes the first plates 78 and the second plates 80 releasably. For instance, by unscrewing one of the two first adjusting screws 86 it is possible to laterally displace one of the two first plates 78 and to vary its position according to the width of the strip 16 .
The first plates 78 as well as the second plates 80 are shaped in such a way as to facilitate the insertion of the strip 16 between the plates when the plates are lowered. The shape is represented by a chamfer suitably made to facilitate a correct insertion of the strip 16 between the plates.
A technician of the sector may provide amendments or variants that are to consider as included in the scope of protection of the present invention. | Positioning device adapted to dispose a strip of fabric or other similar material on an article of clothing do as to form a loop, the strips divided into a central portion and two opposite ends, the positioning device rotates at least one of the two ends of the strip in order to bring that end or ends into abutment with the central portion of the strip; and wherein guide means guide the end or ends of the strip during rotation. | 3 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a machine for washing cloth; allowing the construction and fiber of cloth, dirts and impurities therein to swell in steam, and to soak in water repeatedly to remove such dirts and impurities.
A washing machine similar to this type is generally used for removing oily and fat components, dirts, impurities and the like stuck on and contained in cloth, and a typical construction thereof is disclosed in Japanese Utility Model Publication (examined) No. 58-29189 titled "Cloth washing machine" for example. To be specific according to the prior art, a steaming chamber is formed to supply hot air into a closed chamber, and several water tanks are arranged side by side at bottom of the steaming chamber. Furthermore, a group of lower guide rollers is arranged side by side below in the chamber and some water tanks. A group of upper guide rollers are arranged above in the steaming chamber corresponding to the arrangement of the lower guide rollers. In the above construction, cloth supplied (fed) into the steaming chamber from a side and conveyed to another, being guided by and taken up on the upper and lower guide rollers. Accordingly, cloth is washed repeatedly by swelling in steam and soaking in water respectively, being guided and conveyed by the guide rollers.
On the other hand, there is an adapted method of giving vibrating motion to cloth in water tank using ultra-sonic generator trying to improve the washing effect. For example, as disclosed in the Japanese Laid-Open Patent Publication (unexamined) No. 59-15558 titled "Ultra-sonic processing method and apparatus thereof", proposed is a method to transfer vibrating motion indirectly to cloth in water through a sliding guide plate.
As mentioned above, various methods have been proposed including ultra-sonic washing method to improve washing effect. However, there still remains a problem that no sufficient washing effect is obtained. Namely, cloth which is free in motion and not stretched would never be vibrated effectively even if vibrating motion is given all over the range in its width, because the vibrating motion generated by a ultra-sonic vibrator is transferred to cloth indirectly and fail to get a sufficient vibrating effect.
SUMMARY OF THE INVENTION
The present invention was made to solve the above problem in aiming to provide a cloth washing machine with both of a stretching mechanism and a vibrating mechanism; a stretching mechanism for stretching cloth between the guide rollers in rotational drive, and conveying cloth in their driving direction, and a vibrating mechanism for vibrating cloth so stretched directly.
By such construction, vibrating motion is given directly to cloth which is kept stretched, and therefore, washing effect of the vibrating motion generated by the vibrating mechanism is improved.
Other objects and futures of the present invention are clearly shown in the following description and supplement drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a sectional view of the cloth washing machine embodying the present invention: and
FIGS. 2 and 3 are showing perspective view of an example of the vibrating mechanism applied to the cloth washing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention is now described below with reference to the drawings.
In FIG. 1 a longitudinal sectional view shows essential parts of the cloth washing machine as an embodiment of the invention; a closed chamber forming a steaming chamber 1 is provided on the base 2. The reference numeral 6 denotes an inlet of steam (saturated steam) and the numeral 7 an outlet thereof. Water tanks 3, 4 and 5 are arranged side by side at the lower portion of the steaming chamber 1 i.e., on the base 2. A group of guide rollers R1 to R6, L1 to L12 are also arranged side by side in the steaming chamber 1. The reference W denotes cloth supplied from the right side to the steaming chamber 1 and sent out to the left. The numeral 8 denotes a squeezing roller, and 9 a shower. When steam is supplied through inlet 6, temperature in the steaming chamber 1 rises and remains to be 100° C. approximately. Each of water tanks 3, 4, and 5 is filled with water, and water is also heated by steam.
The cloth W supplied first into the first water tank 3 is taken up on guide roller L1 in it and then guided through between the guide rollers L1 to L2 upward to the guide roller L3. Cloth W is then taken up on the guide roller R1, and conveyed further downward. Cloth W is thereafter conveyed through the guide roller from L4 through R2-L5-R3-L6-R4-L8-R5-L9-R6 to the guide roller L10 in the third water tank 5, and then guided further through the guide rollers L11 and L12 to the squeezing roller 8. Water so squeezed from cloth W is drained.
Although the construction mentioned above is not changed from the known art in comparison, the guide rollers R1, R2 and $5 on the upper part in the construction are so forced to drive rotationally in the cloth conveying direction by the torque motors 10, 11 and 12 that a tension force or stretching force is given to cloth W between the guide rollers L3 and R1, guide rollers L4 and R2, and guide rollers L8 and L5 respectively. The stretching force between the rollers L4 and R2 is extended to cloth W between the guide rollers L6 and R4.
Furthermore, according to the present invention, provided are two units of vibrating mechanism B1 and B2. B1 unit is to give vibrating motion to cloth between the guide rollers L3 and R1, and B2 between the guide rollers L6 and R4.
An ultra-sonic micro-vibration generator or oscillator with a rotary plate is, for example, applied to the units of vibrating mechanism B1 and B2. Each of the units B1 and B2 is to be featured in the function to come in contact with cloth in all area in its horizontal direction, and to transfer the vibrating motion directly thereto. Construction of each unit is shown in FIGS. 2 and 3.
FIG. 2 shows the perspective view of vibrating mechanism including ultra-sonic vibration generators 13 and 14. Each of them contacts cloth W linearly in the horizontal direction to transfer micro-vibrating motion. FIG. 3 shows the perspective view of vibrating mechanism of an oscillator in rotary plate type with oscillating rotary plates 15 and 16 which are arranged horizontally being spaced with a certain vertical interval.
Both of the plates turn at about 30° angle with rotational drives 17 and 18. Accordingly, the plates function to fold and bend cloth as shown in FIG. 3 to keep a direct and forced contact with cloth so that their micro-vibrating motion can be transferred directly to cloth.
As the vibrating motion is transferred directly to cloth W in stretching form, cloth W is vibrated without fail. In addition, water tanks 3, 4, and 5 are so smaller than those known in the prior art that the more frequent replacement of water can be performed.
According to the washing machine of the above construction, cloth W guided by the guide roller L1 upward is loaded with heavy water, more or less almost three times as heavy as cloth itself in consequence of being first supplied into the first water tank 3. However, the vibrating motion given by the unit B1 removes such water effectively down to half of the cloth weight. Cloth W is, thus processed through the first half portion of steaming chamber 1. During so processed, the temperature of cloth W rises nearly to 100° C. to make the construction and fiber of cloth, dirts and impurities contained therein swell. Swelling effect helps dirt and impurities remain deeply in the construction of cloth to come up to the surface to make them ready to run off.
Also, 100° C. steam in which cloth W is processed up and down heats up even the stained fat and oily impurities hotter than their melting points to be soluble in water and removable easily, The dirt and impurities are thus quickly washed out from cloth, when soaked into water in the second water tank 4. Temperature of water in the second water tank 4 also rises so much to improve washing effect in consequence of being contacted both with steam and heated cloth W.
Cloth W coming out from the second water tank 4 is further given vibrating motion by the unit of vibrating mechanism B2 so that dirts and impurities still remained after processed at the first half section are now washed off. In the third water tank 5, dirts and impurities being more swelled and soluble sufficiently are finally washed off. Namely, fresh water from the shower 9 brings out dirts and impurities from cloth completely. The squeezing roller 8 squeezes water out of cloth considerably.
Foregoing are the futures of the cloth washing machine being provided according to the present invention, but the scope of the invention is not limited to the above description and drawings.
That is, cloth, when conveyed, snakingly moves up and down in the vertical direction in the foregoing embodiment, it can also move snakingly in horizontal direction too, being guided by a group of the guide rollers arranged perpendicularly in rows from a lower part to upper. Three torque motors are arranged to keep cloth stretched in the foregoing embodiment, but one, or more or less than three motors can work, as far as the motor or motors can keep cloth stretched sufficiently. Further, method to keep cloth stretched is not limited to the torque motors. Any other methods can function. Likewise, the number of corresponding unit of vibrating mechanism is not to be limited to two, and the vibrating mechanism itself is not to be limited to those illustrated in FIGS. 2 and 3, but there is another mechanism; a slender bar to which high frequency vibration is given by a vibrator can vibrate cloth directly. Moreover, the number of water tank is neither limited to three, nor always necessary to be smaller in capacity, although the less volume of water for water tank is to improve the washing effect keeping cloth in consecutive contact with fresh water. All of the above modifications or versions are to be included in the scope of the present invention.
The cloth washing machine of the invention is to be so constructed as mentioned above in detail, and the experiment using the machine shows that the cloth washing effect was considerably improved. That is, in a cloth sinking test finding how many seconds or minutes it takes for a piece of cotton cloth cut in 2 ;l cm by 2 cm to sink, when put afloat on the surface of water, it was found: a test piece processed by the machine built according to the invention took 2.5 seconds, while another sample piece not so washed continued to float over 30 minutes. It has also been found that a test piece washed by a usual soaping machine takes 9.9 seconds to sink. The test piece processed by the machine according to the invention sinks 3-4 times faster than it.
These tests show that cloth processed by the machine was improved in the osmotic performance. Such improvement was resulted mainly from two factors of having given to cloth the vibrating motion directly and kept it stretched, and subsequently from another factor of having made the direct vibrating motion work well to squeeze cloth effectively. | A cloth washing machine has a group of water tanks arranged in a steaming chamber, and a group of guide rollers arranged either in and out of water tanks, in order to wash cloth supplied into the steaming chamber in swelling in steam and soaking in water repeatedly, and the machine further has a cloth stretching mechanism that keeps cloth stretched on rotationally driving guide rollers and conveys cloth in direction, and a vibrating mechanism that gives direct vibrating motion to cloth so stretched, in order to improve washing effect. | 3 |
ORIGIN OF THE INVENTION
The invention described herein was made in the performance of work under a NASA contract and is subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958, Public Law 85-568 (72 Stat. 435, 42 U.S.C. Sec. 2457).
BACKGROUND OF THE INVENTION
This invention relates to an automated system for quantitative biopsy analysis of muscle tissue.
Research studies into muscular dysfunction and, in particular, the clinical diagnosis of neuromuscular diseases frequently require a biopsy analysis for the classification and characterization of muscle tissue. By analyzing such characteristics as the size, texture or density of the muscle fibers, neurologists can use the information to more accurately diagnose both the type and severity of each disease. One tool to aid in that effort has been found using the science of histochemistry, wherein the chemical constitution and microscopic anatomy of living cells and tissue are studied on stained microscope slides. While enzyme histochemical methods have been implemented only in the past decade, the techniques have proved to play an essential and significant role in both research and clinical medicine during that relatively short time.
By producing specimens in a manner such that the various types of muscle fibers are distinguishable by color, a quantitative analysis of the muscle tissue may be accomplished. In a normal human being, one would observe that the numbers of each type of muscle fiber are roughly equal and the fiber diameter distributed about a mean value. Although the average fiber diameter in males is usually larger than in females, the sizes of individual fiber diameters typically average approximately fifty microns. It is both the muscular fiber size and the relative proportion of each type of the roughly polygonal fiber shapes which are primarily affected and altered by various neuromuscular diseases. For example, muscular atrophy reduces the mean fiber diameter while, on the other hand, certain diseases produce a disproportionate number of one type of fibers. A record of these abnormal changes can be maintained by a fiber diameter histogram taken for each muscle fiber type. Although use of the histogram in this manner has been shown to be a valuable tool both in the diagnosis of neuromuscular disease and for the research study of the progression of degenerative muscle diseases, the prior art methods of generating the histograms have been painstakingly tedious and unfortunately fraught with human errors. The reasons for this can be found in the approach applied by the prior art, which was subjective in its methodology. In essence, the fiber diameter and the relative proportion of the fiber types to each other were judged visually by the human eye to be either normal or abnormal while, at the same time, the quantitative information available from the specimen was virtually ignored. In other instances, the fiber diameters would be measured by hand on photomicrographs and then fiber diameter histograms were plotted manually from the measurements.
SUMMARY OF THE INVENTION
In accordance with the present invention, an automated computerized system performs a quantitative scientific analysis of the sizes and relative numbers of the muscle fibers in a muscle biopsy specimen. A microscope slide containing muscle biopsy tissue is stained by commonly used techniques to produce a specimen wherein the different types of muscle fibers are distinguishable by color. The slides are first placed under a microscope which has an attached television camera. The video signal of the magnified image from the camera is then converted into digital form to be processed by a multi-microprocessor computer specially designed for clinical laboratory instrumentation. The computer employs a sequential programmed, step-oriented pipeline architecture which accommodates most of the analytical procedures for biomedical research studies. The individual muscle fibers are isolated and measured, and then classified by their staining intensity. A fiber-size histogram of the specimen is plotted for each type of muscle fiber. The architecture of the multi-microprocessor computer is based on the use of modular components iterated or cascaded to any degree of complexity required for the analytical procedures. A basic module comprises a microprocessor, a first read-write memory used for data storage, and a second read-only or read-write memory containing stored program instructions for execution by the microprocessor. When iteration is required, the first read-write memory of each subsequent iteration accepts as its input data the output data of the last iteration. The memories and microprocessors are connected in cascaded, iterative T-bus formations. The architecture of the invention thus lends itself to a simple, compact system.
The novel features of the invention are set forth with particularity in the appended claims. The invention will best be understood from the following description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram illustrating the method steps of the invention.
FIG. 2 is a block diagram illustrating the primary system functions of the invention.
FIGS. 3a, 3b and 3c illustrate a microscopic image of a muscle biopsy section, a display of fiber boundaries for the muscle biopsy section and a histogram for the muscle biopsy section.
FIG. 4 is a block diagram showing the architecture of the multi-microprocessor computer used in the invention.
FIG. 5 is a perspective view showing the memory and interconnection of microprocessor modules of the computer in accordance with the diagram of FIG. 5.
FIG. 6 is a logic circuit diagram for a single shared memory module.
FIG. 7 is a logic diagram for a typical microprocessor module.
FIG. 8 is a diagram of the clock timing activity during a memory access conflict.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Attention is now directed to FIG. 1 wherein a first step 10 entails preparing, staining, and mounting a muscle biopsy section on a microscope slide. Once the biopsy section has been surgically obtained, it is then suitably prepared with a histochemical reaction, such as ATPase, whereby type 1 (slow) muscle fibers react weakly and appear light while, at the same time, type 2 (fast) muscle fibers react strongly and appear dark. It is this contrasting color differentiation utilizing histochemical techniques and resulting from the staining which makes it feasible for the invention to classify the type 1 and type 2 fibers. As stated above, the number of each type muscle fiber are roughly equal in a normal human being. In step 12, the microscope slide, upon which has been mounted the stained section of muscle tissue, is itself placed in the specimen plane of a standard commercially-available light microscope. A closed circuit television camera capable of transmitting in a black-and-white format is attached to the ocular of the microscope. Step 14 is accomplished by imaging the magnified stained biopsy section on the attached television camera in a transmission mode. The television system preserves the color differentiation between the dark (fast) fibers and the light (slow) fibers. The television camera video signal is transformed in step 16 to digital form by conventional analog-to-digital converter means. This produces a numerical representation of the specimen image consisting of a rectangular array of discrete "pixels" (or picture elements). Each pixel possesses a digital value representing the optical density or staining intensity of the corresponding point in the television image of the muscle tissue specimen. The data is loaded into the memory of a computer, at step 18. Afterwards, in step 20, the digital image of the biopsy section is processed by the computer; in this manner, the individual muscle fibers first are isolated. The area and average optical density of each fiber is measured. The fibers are then classified by their staining intensity (optical density). A fiber-size histogram for both types of fibers is next generated on a suitable graphics display terminal in step 22. The histogram curve reveals the number of fibers as a function of the fiber area measured in square microns. It may then be used as an aid to diagnosis or research.
FIG. 2 depicts a conventional microscope 30 having a light source 32 for illumination. In the specimen plane between microscope 30 and light 32 is positioned a slide 34 upon which a biopsy section of muscle tissue (not shown) is mounted. In the preferred embodiment, the biopsy specimen has been prepared using an ATPase reaction and then has been stained in order to distinguish between "fast" and "slow" type muscle fibers. A television camera 40, which is capable of transmitting a black-and-white magnified image of the stained biopsy section, attaches by appropriate means to the ocular of microscope 30 and scans an area of microscope slide 34. The televised black-and-white image 38 (FIG. 3a) of the muscle specimen is transmitted electronically to a digitizer unit 42. Digitizer 42 converts the analog signal output of television camera 40 into a plurality of discrete pixels (or picture elements), each having a digital value corresponding to the particular density of the corresponding point in the stained biopsy section. The digital values are then processed by a special-purpose digital computer 44 capable of isolating and classifying individual muscle fibers.
In the preferred embodiment, special-purpose computer 44 is designed and particularly adapted for use in a scientific, clinical environment by reason of a sequential programming, step-oriented pipeline architecture comprising an LSI microprocessor and program 46 and two memory units 48, 50. The digital values of the pixels are loaded into the memory 48 of computer 44. Depending upon the particular analysis required, a computer program, which is stored in a third memory (not shown), commands the microprocessor 46 to access and process the data stored in input memory 48.
The processing is designed to compute measurements of the number and area, as well as the density of each of the muscle fibers. Classification of each type of fiber according to average optical density is also accomplished by the processing step. At the end of the processing step, the total number of each type of muscle fiber having each discrete area value are outputed by the computer program to display fiber area histograms for each fiber type on a suitable output terminal 51.
This procedure provides digital analysis of video information which is not limited in what can be done, as opposed to prior art analog analysis, which is restricted to what can be done in real time. Here the system feeds the microscope image into the computer which then isolates and counts the fibers and measures their size. It then generates for display graphs (histograms) showing the size distribution for each type fiber. This information will assist physicians in diagnosing and treating muscle disease, and will facilitate research aimed at understanding human muscle disease processes, as discussed, for example, by V. Dubowitz and M. H. Brooke in Muscle Biopsy, A Modern Approach, W. B. Saunders Co., Ltd. (1973).
A brief review of the procedure will now be described with reference to FIGS. 3a, 3b and 3c, and discussed with reference to iterative microprocessing techniques. It should be understood, however, that the specific iterative microprocessing techniques are exemplary, and not in any limiting since those skilled in the art will know of other techniques which may be employed, such as those described by Azriel Rosenfeld and Avinash C. Kah in Digital Picture Processing, Academic Press (1976), and Richard O. Duda and Peter E. Hart in Pattern Classification and Scene Analysis, John Wiley & Son (1973).
FIG. 3a is a microscope image of a muscle biopsy section as presented to the television camera. It is digitized and stored as discrete pixel values proportional to the optical density of corresponding points in the specimen. For simplicity, only two distinct densities are illustrated: one for type 1 (slow) fibers which appear light, and one for type 2 (fast) which appear dark (shaded), although in practice there will be some fibers which will appear between light and dark, but which may nevertheless be classifiable as one of the two types. (In some analysis, three types are classified, and in such analysis the techniques are simply expanded to accommodate the third type and ultimately generate a histogram for these types.) In the normal human, the number of each type fiber is roughly equal, with fiber diameter distributed around approximately 50 microns, although various neuromuscular diseases affect fiber size and the relative proportion of the types. In this example, both the fiber size and type is relatively normal.
Once the pixel data is loaded into memory, the boundaries of the fibers are determined. Then they are classified as to type, and as to size for each type, in order to display a histogram. FIG. 3b illustrates the fiber boundaries, and FIG. 3c illustrates a typical histogram. To determine the boundaries, the microprocessor scans the pixels systematically beginning, for example, at the upper left and proceeding row by row from top to bottom. For each pixel, beginning with the second one, a comparison is made between the values of the pixels before and after it in the horizontal direction, and beginning with the second row, between the values of the pixels above and below it. Any marked change of greater than some predetermined magnitude indicates a boundary. This technique of computing the mathematical gradient magnitude at each pixel is relatively simple and accurate for determining fiber image boundaries. An isolated muscle fiber image is then defined as a connected (adjacent) set (group) of pixels all having gradient magnitudes less than some preset threshold value. Each fiber thus isolated is assigned a unique number for reference purposes.
It would be feasible to determine all of the boundaries, and to display the boundaries as by FIG. 3b for a human operator to interactively correct since experience will enable the operator to determine where the microprocessor has likely failed to detect a boundary between fibers. It would also be feasible to program such review for automatic correction. That is accomplished by causing the program to start at a specified point inside a particular fiber and execute a region growing algorithm thereby sequentially expanding a boundary about the point until the border of the fiber is reached. This algorithm is relatively simple from an imaging process point of view because the fiber boundary about any point is convex. In either case, the next procedure would be to classify each bounded area as to type, and to classify it as to size for each type. The area measurement of a particular fiber is simply the number of pixels inside the boundary multiplied by the area, at the specimen plane, of a single pixel, while the optical density of the fiber is the average of the pixel values inside the boundary. Typing is accomplished by comparing the optical density of each fiber with a predetermined range of optical density for each type. At the same time, the number of fibers of each type and size are also counted, to complete the data required for a fiber size histogram. In that manner automatic quantitative analysis is provided to replace the usual prior art analysis which is quite subjective in its classification of fiber types and size, and is extremely tedious and subject to many errors due to operator fatigue.
From the foregoing it is seen that the major processing is that of isolating the areas. The gradient-based fiber isolation technique just described separates the fibers in the digitized image format very simply and with a high degree of accuracy. Before measuring the fibers as to density (type) and area (size) a shape analysis program may be employed to examine each fiber, and to separate those shapes corresponding to touching fibers where the isolation program has failed to properly isolate the fibers, or an operator examines the image of FIG. 3b and interactively separates touching fibers. Alternatively, both the isolation program and the human operator may be used to perfect isolation of the fibers.
In FIG. 4, the preferred architectural arrangement for the computer 44 is illustrated as comprising a plurality of microprocessors P 2 , P 4 . . . and a plurality of memory blocks M 1 , M 2 . . . Each of the memory blocks is a two-port memory block; the capacity of each block holds 4096 eight-bit bytes. Each of the microprocessors may be a conventional microprocessor such as the MC6800 manufactured by Motorola and American Microsystem Inc. Processor P 2 is connected electronically with data memory blocks M 1 , M 3 and also with a program memory block M 2 ; while processor P 4 is similarly connected to data memory blocks M 3 , M 5 and to program memory block M 4 . In operation, processor P 2 is controlled by a computer program stored in memory block M 2 . Processor P 2 reads its program from memory block M 2 , takes its input data from M 1 , and stores its output data in M 3 . Similarly, P 4 reads its instructions from a program stored in M 4 , and its input data from M 3 and writes its output data into M 5 . Each of the memory blocks is comprised of a commercially available integrated circuit memory chip, such as the 2012 memory chip manufactured by Intel Corporation.
The architecture depicted by FIG. 4 makes it possible for input data, such as the televised images of a muscle biopsy specimen, to be passed from left to right through various stages of processing. A program bus 52 has the capability of being used to load the required programs directly into the program memory blocks M 2 and M 4 before the processing begins. Due to the novel iterative arrangement of the components, it is necessary that each of the data memory blocks M 1 , M 2 , M 3 , M 4 , M 5 be designed to have two ports for access by two separate processors. Since the processors are required to share the memory blocks, memory access conflicts may arise and must be resolved. One exemplary way to do this is to have one of the two micro-processor units stop until the memory-sharing conflict is terminated using clock stretching techniques.
FIG. 5 shows one embodiment of the preferred hardware configuration for the architecture illustrated in FIG. 4. Printed electronic circuit boards 54, 55 comprise two processors P 2 , P 4 having clock stretching capabilities and five memory blocks M 1 , M 2 , M 3 , M 4 , M 5 . The circuit boards are placed adjacent to each other and plugged into a power and clock bus 56. In the preferred embodiment, the boards are ordered in the following sequence: M 2i-1 , M 2i , P 2i , . . . for i=1,2,3 . . . . Bus 56 is implemented as back-plane wiring carrying five volts, a ground GD, and dual phase clock pulses Φ 1 , Φ 2 on a conventional card rack (not shown). On top of each processor and memory card are located two connectors 58, 60 forming the two access ports required for communication between each iterative module. Each port is comprised of address, data and control lines. The communication is carried via ribbon cables 62 each having four connectors 64. For instance, a single strip of ribbon cable 63 can connect P 2 with M 1 , M 2 and M 3 ; while, at the same time, a second strip of cable 65 can connect P 4 with M 3 , M 4 and M 5 . By using this arrangement of but two standard types of processor and memory printed circuit cards 54, 55 many different configurations are possible. For example, one need not be limited in the number of such memory cards 54 which can be utilized for either data or program memory blocks. The configuration depicted in FIG. 5 can easily be modified to reflect those changes by appropriately rewiring ribbon cables 62.
Attention is now directed to FIG. 6 which illustrates the logic diagram for a typical two-port memory block module. The unbuffered solid state memory block 66 holds a capacity of 4096 bytes, each having eight bits, and is implemented with standard integrated circuit memory chips, such as the Intel 2102 referred to hereinbefore. In addition to a Read/Write (R/W) line and an active low ENABLE (E) line, memory 66 has twelve bits of ADDRESS (ADR) input, eight bits of DATA IN (D IN ) and eight bits of DATA OUT (D OUT ). The circuit itself has two ports through which two separate processors can access memory 66. A first Port 1 is the high-priority port and a second Port 2 is assigned low priority. In each case, the lower order twelve bits of the ADDRESS (A 11 -A 0 ) together with the eight-bit DATA bus 67 are routed to the memory chips in block 66 by suitable port select logic as shown. In the preferred embodiment, four groups of tri-state buffers 68 are employed, under logical control, to connect or disconnect the ADDRESS and DATA lines from each port to block 66.
The logic circuitry used to accomplish the actual port selection function is also shown in FIG. 6. When the most significant four bits (A 15 -A 12 ) of the ADDRESS applied to Port 1 select this particular memory block 66 by specifying its assigned address, then a first block select signal (BS 1 ) goes high. Likewise, when the processor which is connected to Port 2 selects memory block 66, a second block select signal (BS 2 ) goes high. The memory is enabled only when either BS 1 or BS 2 goes high; otherwise, it is dormant. At any given time, a port select signal (PS) determines which of the two ports is actually connected to block 66. By default, Port 1 is assigned access to the memory block and, correspondingly, PS goes low. However, when BS 2 goes high and, at the same time, BS 1 is low to signify that only the processor connected to Port 2 has selected the memory block, PS goes high and the memory is awarded to Port 2. Should a memory access conflict arise, it is reflected by the fact that both BS 1 and BS 2 are high. In that instance the PORT SELECT (PS) line automatically awards the memory to Port 1. In addition, an active low WAIT signal is generated by the logic circuitry and sent to the processor connected to Port 2. This signal is generated by an open collector gate 70 so that WAIT lines from several memory blocks (not shown) can be wire-OR'ed and used at the same time. In the preferred embodiment, a dummy WAIT signal 72 is applied to Port 1, but it is at no time pulled low. Depending upon which port is selected, the Read/Write (R/W) input for memory 66 can be derived from the active low WRITE input. In turn, the routing of the bidirectional DATA bus from memory 66 to either Port 1 or Port 2 is controlled by the PORT SELECT (PS) line and the data direction by the Read/Write (R/W) lines.
FIG. 7 diagrams a microprocessor (μP) 74 with two access ports Port 1 and Port 2 for memory and data bus connection. An active low WAIT input signal having the capability of stopping processor 74 by clockstretching is also shown. The Phase 1 (Φ 1 ) and Phase 2 (Φ 2 ) clock signals for microprocessor 74 are both derived from a master clock (Φ 1 M , Φ 2 M ). As long as the WAIT signal is high, the master clock signal is propagated intact to the microprocessor. However, when the WAIT signal is pulled low, the microprocessor clock lines are, in effect, frozen with Phase 1 high and Phase 2 low. An active low WRITE signal is created as the product of a Read/Write (R/W) signal, which is generated by the microprocessor, and of the Phase 2 (Φ 2 ) clock signal. In the preferred embodiment, Port 1 and Port 2 are implemented by dual connectors 58, 60 wired in parallel.
The clock timing for the shared memory port and microprocessor are shown in FIG. 8. At the top is a two-phase master clock having non-overlapping Phases 1 and 2 (Φ 1 M , Φ 2 M ) alternatively going high. For purposes of illustration, one may assume that block select signal BS 1 goes high at point 1, thereby indicating that a first processor is using the memory via its port number 1. At point 2, a second block select signal BS 2 goes high to indicate that a second processor is attempting to use the memory via its port number 2. Since both BS 1 and BS 2 are high, a memory-access conflict has occurred and the WAIT signal goes low (active). During the period from point 2 to point 3 the memory is awarded to the first processor and at the same time, the clock signal to the second processor is frozen with Phase 1 (Φ 1 ) high and Phase 2 (Φ 2 ) low. The second processor is thus effectively stopped temporarily. At point 3, the first processor accesses a memory location outside the memory block 66, thus terminating the conflict. In that manner BS 1 goes low after being active for, in this case, three cycles. At that moment, the WAIT signal is caused to go high (inactive) and access to the memory is awarded to the second processor. During the period from point 3 to point 4, the second processor completes its extended clock cycle. The net result of the timing sequence depicted in FIG. 8 is that when two microprocessors attempt to access the same memory, the WAIT line goes low, in turn freezing the second processor in Phase 1 (Φ 1 ) of its clock cycle. The second processor is thereby stopped until the first processor finishes accessing the memory. As soon as the memory access conflict terminates, the second processor is allowed to continue its operation in phase with the master clock.
When the microcomputer system is started up, all processors are in the RESET condition. They remain idle while an external computer loads the required programs into the appropriate Read/Write program memory blocks. If some or all of the program memory blocks are Read only memory, they need not be loaded. Next the operator removes the reset condition and each processor begins checking a specified status control word location in its input data memory block. The first processor, however, begins immediately reading input data from some image data source such as an image digitizer. When it completes the processing of the first image it writes a pre-arranged status code into its output data memory block which is the input data memory block of the next processor. When the second processor detects this status code it begins processing the image. This process continues with the processors communicating their status via control words in the shared memory blocks. When a particular processor finishes one image it executes an idle loop checking its status code word, waiting for the signal that another image is ready for processing.
Although particular embodiments of the invention have been described and illustrated herein, it is recognized that modifications and variations may readily occur to those skilled in the art. Consequently, it is intended that the claims be interpreted to cover such modifications and equivalents. | An automated system to aid the diagnosis of neuromuscular diseases by producing fiber size histograms utilizing histochemically stained muscle biopsy tissue. Televised images of the microscopic fibers are processed electronically by a multi-microprocessor computer, which isolates, measures, and classifies the fibers and displays the fiber size distribution. The architecture of the multi-microprocessor computer, which is iterated to any required degree of complexity, features a series of individual microprocessors P n each receiving data from a shared memory M n-1 and outputing processed data to a separate shared memory M n+1 under control of a program stored in dedicated memory M n . | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to improvements in a door latch and more particularly to an improved locking latch mechanism for positively securing roll-up doors such as used on trailer-tractor vehicles or the like so that the door is automatically latched with its closing and can only be opened by activating an unobvious release member.
Trailor-tractor roll-up doors are commonly latched in a closed position, by manually operated locking mechanism which are readily accessible from the ground. For security to prevent unauthorized opening, the release handle is manually pivoted to a latching position after the door is closed and most often secured with a padlock. In the absence of the driver, the padlock or exposed locking mechanism can be broken, the door opened and the contents tampered with or stolen. Security of the roll-up door is imparative to protect valuable contents of a truck or trailer. As an example of the lack of security offered by conventional padlocking, insurance companies have found that a padlocked roll-up door can be broken and the contents stolen within a very short time, even while a truck is waiting for a traffic light.
While the features of the invention, as will be described herein, are particularly well suited for use on trucks or tractor-trailer type vehicles, it will be appreciated by those skilled in the art that the features of this invention may be employed for securely locking various other roll-up doors as well.
SUMMARY AND OBJECTS OF THE INVENTION
A feature of the present invention is the provision of a secure door latch for roll-up doors which will automatically latch when closing the door and can only be opened thereafter by a simple cocking or release setting operation. Herein, a latch member is set in an unlatching position with the aid of a cooperating release or trigger member and the latch is maintained in this unlatching position until the roll-up door is elevated. Thereupon, the latch member is disengaged from the release member to assume a latchable position. When the door is again lowered to a closed position, the latch will automatically latch to hold down the door by engagement with a keeper, carried on the trailer doorway post. Preferably, an enclosed cylinder lock is employed to prevent unauthorized persons from opening the roll-up door once it is latched.
An object of the present invention is to provide a locking latch device arranged to secure roll-up doors on trucks or tractor-trailer vehicles which will automatically latch when closing the door.
A further object of the invention is to provide a particularly simple and secure locking latch mechanism for roll-up doors wherein the latch member is set to a self-acting position by a release member which will permit the roll-up door to be raised to an open position and provides automatic relatching when the door is lowered to its closed position.
Other objects, features and advantages of the invention will be readily apparent from the following description of a preferred embodiment thereof, taken in conjunction with the accompanying drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the following disclosure.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of the rear of a truck equipped with a roll-up door and showing the locking latch device of the present invention;
FIG. 2 is an enlarged view of the locking latch device showing the latch member in a latched and locked condition;
FIG. 3 is an enlarged vertical sectional view taken along line III--III of FIG. 2;
FIG. 4 is a transverse sectional view taken generally along the line IV--IV of FIG. 2;
FIG. 5 is a vertical sectional view showing the latch member cocked in an unlatching position to pass over the keeper when the roll-up door is moved toward its open position;
FIG. 6 is a fragmentary sectional view showing the latch in latching engagement with the keeper;
FIG. 7 is a fragmentary elevational view of an alternate locking arrangement for the device;
FIG. 8 is a view in side elevation view illustrating a modified form of the latch and keeper arrangement;
FIG. 9 is a fragmentary transverse sectional view taken through the rear of the truck roll-up door showing the locking latch device of FIG. 8; and
FIG. 10 is a vertical sectional view showing the latch member set in the unlatching position to pass over the keeper when the roll-up door is moved toward its open position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The embodiment of the invention illustrated in FIG. 1 of the drawings shows a lading carrying vehicle such as a truck 11 or the like provided with a conventional roll-up door 12. The door is equipped with the usual cable tensioned lift arrangement 13 to counter balance the weight of the door to facilitate lifting the door. The door is elevated along vertical tracks 14 on rollers 15 in a conventional roll-up door arrangement (See FIGS. 4 and 9). The tracks are secured to the inside of spaced vertical door posts 16, 17 which define the doorway of the vehicle. The door is further provided with a locking latch device 18 constructed in accordance with the principles of the present invention. A keeper 19 is mounted in the door post 16 by welding or other suitable means to cooperate with the latching device 18 to secure the roll-up door 12 in a closed condition. As best seen in FIGS. 2 and 3, the device 18 includes a housing 21 having an elongated back plate 22 bolted to a section of the roll-up door 12 as with carriage bolts 23 and "t" nuts 24. The shim 26 is provided between the back plate 22 and the door section to facilitate mounting. The back plate 22 is shown with an outward bent top portion 27 to extend over the latch device to protect the latching mechanism 28. The housing 21 also includes a formed cover plate 29 which is secured to the back plate 22 to enclose the latching mechanism 28. The cover plate is also shown provided with a cable guide 30 for the cable lift arrangement 13.
In FIG. 4, I have shown a horizontal sectional view taken through the locking latch device 18 having a latch member 31 transversely pivoted between the back plate 22 and the cover plate 29 of the housing 21 on a transverse pivot pin 32. As best seen in FIG. 5, the latch member 31 includes a latching head 33 extending horizontally from a lower end of a vertically disposed pendulous portion 34 and a counterweight portion 35 extending horizontally from an upper end of the pendulous portion and on a side opposite the latching head 33. The counterweight 35 is effective to provide a biasing force to urge the latch member 31 to the position shown in FIG. 2. Herein, the latch member is in abutment with wall 36 of the cover plate 29 whereby the latching head 33 engages the keeper 19 to prevent the roll-up door from opening. An opening in the wall 36 of the cover plate provides access to the keeper 19 by the latch head 33.
As best seen in FIGS. 2 and 5, the latch member 31 is virtually completely enclosed within the housing 21 and is only operable from outside the housing by the use of a release member 37 which must be activated to set the latch member to its unlatching position. The release member is pivoted between the back plate 22 and the cover plate 29 on a pivot pin 39 spaced above and slightly to the right of pivot pin 32 as seen in FIG. 5. A counterweight 41 is formed as an upper portion of the release member 37 and extends behind a guard plate 42 which is secured to the front of the cover plate 29. The release member 37 extends through an opening in a top wall 43 of the cover plate to provide access for manual operation. As shown in FIG. 2, the release member 37 is virtually hidden from view but may be readily operated by the thumb or fingers of the truck driver. The counterweight 41 is arranged to bias the release member to the released position shown in FIG. 2.
When it is desired to raise the roll-up door 12, the release member 37 is activated to cock or set the latch member 31 to its unlatching position shown in FIG. 5. Herein, to release the latching head 33 from the keeper 19, a lower end of the release member is moved in a clockwise direction to engage a stepped portion 44 to cam the latch to a release position. At this setting, an inclined surface 46 of the latching head 33 is effectively located so as to strike a complementary surface of the keeper when the door is raised. In contacting the keeper, the latch 31 is cammed backward to the broken line unlatched position, whereupon the counterweight 41 of the release member 37 causes disengagement with the latch member to drop down to the position shown in FIG. 2. The latching head 33 rides upward against the door post as the door is raised under the influence of its counterweight 41. The latch member is now again in a latching position and will automatically latch when the door is closed.
As shown in the drawings, the lower end of the vertically suspended pendulous portion 34 of the latch 31 has had metal removed as indicated by the reference number 47 to provide a more desirable weight distribution. Herein, the counterweight 35 is rendered most effective to hold the latching head in a latching position relative to the keeper 19. Since the latch member 31 is supported in a pendulous manner and with the latching surface laterally offset from the pivot pin 32 a small camming angle is present which could tend to pivot the latch member toward an unlatching position when a lifting force is applied to the door. To for stall this possibility, a notch 49 is formed in the latching surface of the latching head which will engage an inner edge of the keeper to positively prevent raising the roll-up door without first sitting the latch member in its unlatching position by the use of the release member 37.
A key operated locking device 51 is preferably incorporated into the housing 21 to lock the latch member 31 in a latched position as shown in FIG. 2. Herein, a finger is rotated by the locking device to a position immediately behind the latch member so that it will be rendered inoperative. Obviously, in this condition, the release member is also inoperative.
FIG. 7 shows an alternate locking arrangement in which the guard plate 42 is provided with an angled hole 52 through which a padlock 53 may be inserted to block the operational movement of the release member 37. Alternately, a cable seal may be used to lock the latching mechanism 28. Further, the use of a seal 54 may be desirable in some instances as a safeguard against tampering. As best seen in FIGS. 2 and 3, a weather guard 55 may be utilized to protect the latching mechanism 28.
In another embodiment of my invention, seen in FIGS. 8 to 10, a modified latch and keeper arrangement is provided in the locking latch device 56. Herein, the keeper comprises a rectangular tube section 57 secured to the door post 16 and extending therefrom to receive a latching head 58 of the latch member 59 similar to the latch member 31. Herein, the latching head 58 is formed as a recessed portion of the lower end of a vertical suspended pendulous portion 61 of the latch member 59, while a counterweight 62 extends from an upper end of the pendulous portion 61 to urge the latching head 58 into a counterclockwise direction as seen in FIG. 8, for engagement with the keeper 57. The latch member 59 is pivotably supported on a pivot pin 63 in the manner of the FIG. 2-5 embodiment. While the housing 64 has been somewhat modified to accommodate the keeper/latch arrangement of this embodiment, the remaining elements of the locking latch device 56 are substantially identical in form and operation with the elements of the FIGS. 25 embodiment.
In FIG. 9, there are shown a sway guard 66 mounted on the roll-up door 12 for guiding movement along the door post 17 at the opposite side of the doorway from the locking latch device 56. Herein, the locking latch device is maintained at a minimal spacing with respect to the keeper 57 despite excessive clearances which may otherwise permit an undesirable sideways shifting of the door relative to the doorway opening. This same sway guard 66 is also provided on the FIGS. 2-5 embodiments as shown in FIG. 1. | Locking latch device for use with roll-up doors on trucks and tractor-trailer vehicles which will automatically latch when closing the door and which can only be opened after a pendulous latch member is set to an unlatching position by the use of a release member. A locking device is provided to render the latching mechanism inoperable to prevent unauthorized opening of the roll-up door. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is the U.S. National Stage of International Application No. PCT/EP2004/006258, filed Jun. 9, 2004 and claims the benefit thereof. The International Application claims the benefits of German Patent application No. 103 26 426.4 DE filed Jun. 10, 2003, both of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a method for increasing the capacity of an installation used to carry out an industrial process.
BACKGROUND OF THE INVENTION
[0003] An increase of a few percentage points in the capacity of an installation for carrying out an industrial process results as a rule in a disproportionately high improvement in profits for the operator of the installation. This type of industrial process can typically be a process with production lines which run through the installation, such as lines for the manufacture of paper, textiles, plastics or metal foils. With such processes the capacity of the process is determined by the speed of the track, e.g. measured in meters per second.
[0004] When a machine part for a machine contained in the installation or a complete part of the installation is designed for such an installation, this is mostly done on the basis of similar machines or parts of the installation, taking into account a certain amount of capacity reserve. However, under the operating conditions which actually occur in the installation, the loads imposed on the machine or the parts of the installation are mostly different to those in previously known installations. It is thus not possible to say with any certainty in what way it is possible to increase the capacity of an installation without overloading one or more parts of the installation.
[0005] Previous measures for increasing the capacity in such installations, especially in complex installations such as installations for carrying out continuous processes for manufacturing of goods on a production line have also generally lacked long-term sustainability.
SUMMARY OF THE INVENTION
[0006] The object of the present invention is therefore to specify a method which allows the capacity of an installation to be increased in a sustained and economical manner.
[0007] This object is achieved in accordance with the invention by a method in accordance with the claims. Advantageous embodiments of the method are the object of the subclaim.
[0008] The invention in this case is based on the knowledge that previous measures for increasing the capacity in installations has always only been based on considering particular points in the installation and has therefore as a rule ignored long-term sustainability. The determination of the process variables relevant to the capacity of the installation envisaged by the invention and the recording of these variables under changing operating conditions guarantees that all aspects of the influencing factors restricting the capacity of the installation will be taken into consideration. Changing operating conditions here are taken to mean the operating conditions occurring during regular operation of the installation, i.e. in the case of a paper machine the operation of the machine with paper of different qualities and types for example. This avoids looking at only a few specific individual aspects of the installation such as the drive system, under a number of specific operating conditions, but not taking into account other factors and operating conditions which dictate the capacity. As a result this makes not just a short-term increase, but a sustained increase in capacity possible.
[0009] The smallest control reserve of the control loops determines the increase in capacity which can be obtained without any further measures. This guarantees that first of all the existing capacity reserves that can be secured are checked and these reserves are secured if necessary. This represents the increase in capacity that can be most easily achieved from the economic standpoint.
[0010] If the aim is to use additional measures to obtain an increase in capacity which goes beyond the existing capacity reserve, this can be done by defining a capacity increase target for the installation, determining the necessary control reserves in the control loops for the desired increase in capacity and determining the control loops with a control reserve which is too low for the desired capacity increase.
[0011] From the number of control loops with control reserves which are too low it is already evident what effort will be needed for further investigations and possibly also for the implementation of measures for increasing capacity. With a large number of control loops a decision can be taken under some circumstances to define a smaller increase in capacity, so that further investigations are only required for the correspondingly smaller number of control loops.
[0012] According to an advantageous embodiment of the invention further steps include a technical and/or technological investigation of the control loops with a control reserve which is too small and formulation of measures for producing the control reserves needed in each case by relieving the load on the relevant control loops and/or by replacing components in the relevant control loops by higher-performance components
[0013] These measures can finally be evaluated from a technical and or commercial standpoint. On the basis of this evaluation the decision process for the implementation of the improvement measures can be simplified and a solution found which is the optimum solution for the operator of the installation from the cost/benefits standpoint.
[0014] Overall the sequence of the above steps ensures that priority is given to dealing with the points for which there is the greatest potential for improvement or for which the cost effectiveness of a conversion is the greatest. At the same time this process allows available capacity reserves to be secured in the most economical way even in a highly-complex installation.
[0015] The method in accordance with the invention is especially suitable for increasing the capacity in an installation for executing a continuous process, especially a process for manufacturing goods on production lines, e.g. paper, textiles, plastic or metal foils, for which the capacity is determined by the speed of the production line.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention as well as a further advantageous embodiments of the invention in accordance with the features of the subclaims are explained in more detail below with reference to exemplary embodiments in the figures. The Figures show:
[0017] FIG. 1 a recording of process variables in an installation for manufacturing paper,
[0018] FIG. 2 a representation of an inventive process sequence depicted as a flowchart,
[0019] FIG. 3 a basic diagram for determining the process variables relevant for the capacity of an installation,
[0020] FIG. 4 a diagram of the process variables relevant for a paper machine,
[0021] FIG. 5 a machine velocity/moment diagram for determining the control reserve for a drive motor and
[0022] FIG. 6 a determination of the control reserve for the drive motor of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0023] FIG. 1 shows an installation 1 for manufacturing paper. The installation 1 comprises a wide diversity of installation parts which are needed for the different steps in the production process for paper, for example a material preparation system 1 a, a paper machine 1 b, a roller/calendar 1 c, roll cutter 1 d and cross cutter 1 e. The paper runs as a production line 8 through major parts of the installation 1 .
[0024] The installation 1 features a plurality of drive components 11 , automation components 12 and energy supply components 13 for driving, supplying power to and controlling the different components in the production process.
[0025] A device 2 is used to determine the control reserves in the installation 1 . The device 2 features a recording unit 3 , an evaluation unit 4 , an input unit 7 and an output unit 5 .
[0026] The recording unit 3 is used for recording process variables P 1 . . . P 10 of the paper production process on the installation 1 . This can for example involve measurement signals which are recorded using signal generators already present and/or to be provided in the installation 1 .
[0027] The process variables can originate from a wide diversity of sources of the processor and be present in any form, including different forms, e.g. analog, binary, numeric and/or as a changeable physical variable. The evaluation unit 4 is used for determining the control reserves in the control loops of the installation 1 . To this end a large number of characteristic capacity curves for a plurality of components, especially standard components occurring in the installation are stored in a memory of the evaluation unit 4 . The output unit 5 can be used to present the control reserves for display. Furthermore the device 2 features an input unit 7 for entering a desired capacity increase into the installation 1 .
[0028] In FIG. 2 the method in accordance with the invention is explained on the basis of a flowchart. The procedure is advantageously carried out by a service provider who has the appropriate know-how and technical facilities to do so.
[0029] In a first step 31 —as explained in detail in FIG. 3 and 4 —the process variables relevant for a capacity of the installation are determined. In a second step 32 these process variables are recorded under changing operating conditions of the installation, and in a third step 33 —as illustrated by the examples in FIG. 5 and 6 —a smallest control reserve of the control loops of the installation is determined on the basis of the recorded process variables. This control reserve can be used to increase the capacity of the installation without any appreciable investment outlay. In a step 33 a a check is therefore made as to whether an increase in capacity beyond this smallest control reserve is desired. If this is not required, the procedure can be ended in step 39 b, by securing the available capacity reserve.
[0030] If an increase in the capacity of the installation which exceeds the reserve is required, in a further procedural step 34 such a desired capacity increase of the installation can be defined. In a further step 35 the control reserves necessary for the desired increase in capacity are determined in the control loops of the installation and in a further step 36 the control loops with a control reserve which is too small for the desired capacity increase are determined.
[0031] For the control loops with a control reserve which is too small, technical and/or technological investigations of the control loops can be performed in a further step 37 to establish the control reserves needed in each case by relieving the load on the relevant control loops and/or through replacing components in the relevant control loops by more powerful components. In a further step 38 a technical and/or commercial evaluation of these measures can be undertaken, on the basis of which a final implementation of the measures is undertaken in step 39 a.
[0032] The process variables relevant for the capacity of an installation can be easily established in this way by applying in the more general sense the method of “cutting free” known per se from technical mechanics.
[0033] This is done in a first step by determining a process variable representing the capacity of the installation. In the case of an installation for paper production this might typically be the speed of the paper in the installation
[0034] Tn a next step, as basically shown in FIG. 3 , a core process 6 of the installation is defined and all interfaces 21 - 25 of the core process 6 to the ancillary processes 41 - 45 surrounding it (e.g. ancillary processes for energy, water and compressed air supply) are determined and investigated for their effect in relation to this representational process variable. This can be done by measuring the physical effects (e.g. forces, currents, fields, throughflows, pressures) at these interfaces. These physical effects of process variables can be measured by signal generators already present and/or to be provided, which if necessary must be accommodated at the interfaces.
[0035] If there is a effect relationship with the representational process variable at an interface, a process variable which is relevant to the capacity of the installation is present at this interface and a more precise technical investigation is undertaken for the components of the ancillary process to determine the control reserve. The interfaces which do not have an effect relationship are not considered any further and instead the interfaces the interfaces are drawn closer to the core process or moved to within the core process and an investigation is conducted at these new interfaces for an effect relationship with the representational process variable. In this case too interfaces with an effect relationship to the representational process variable are identified as relevant process variables for which in further steps more precise technical investigations for determining the control reserves are to be performed.
[0036] Such a systematic, step-by-step “drawing closer” of the interfaces of the ancillary process into the core process ensures that all of the process variables relevant for determining the capacity of the installation are determined, not only in the area of the core process but also in the area of the ancillary processes.
[0037] In the case of an installation for paper production the subprocess running on the paper machine can be defined as the core process for example. Interfaces to ancillary processes with effect relationships to the speed of the paper passing through the installation are then to be found in the area of material and energy flows, for example for feeding energy, steam, water, fibers, chemicals and additives as well as for removal of water, condensate and waste heat. The relevant process variables in the area of the ancillary processes are thus in this case—as shown in FIG. 4 —the supply of energy 51 (e.g. measured as power P), the supply of steam 52 (measured as volume per unit of time), the supply of water 53 (measured as volume per unit of time) the supply of fibers 54 (measured as mass per unit of time), the supply of chemicals 55 (measured as mass per unit of time) the removal of water 56 (measured as volume per unit of time), the removal of condensate 57 (measured as volume per unit of time) and the removal of waste heat 58 (measured as power P). These relevant process variables can only be recorded under changing operating conditions of the installation, e.g. for different qualities and types of paper, and—as explained below—the control reserves in the control loops of the installation for paper production determined.
[0038] An advantageous procedure for determining the control reserve for an electric motor for driving a paper machine of installation 1 in accordance with FIG. 1 will be explained with the aid of FIG. 5 and FIG. 6 . The procedure is basically also applicable to other control loops of the installation (e.g. steam, vacuum, coating).
[0039] At a defined velocity v of the paper in the paper machine a defined load (moment) M is present at the electric motor. This operating point defines a specific class K in the speed/load plane v/M shown in FIG. 4 . For each class K the time (duration) T is counted in which the motor is operated in this class and shown in a plane perpendicular to the v/M plane. The classes K with the longest times can thus be determined. These can subsequently be approximately described by a linear relationship between moment M and machine velocity v described and represented by a straight line gradient G. Basically the relationship between moment M and machine velocity v can naturally also be described through complex functions.
[0040] The diagram in FIG. 6 shows the moment M of the motor over the velocity v of the machine, with these two parameters being approximated by a linear relationship in accordance with FIG. 4 represented by the straight line gradient G. With a speed-regulated drive the maximum power of a motor or a converter (depending on which is the smaller) is a hyperbolic curve HK in the velocity/moment plane v/M. The distance RV of this hyperbolic curve HK to the straight line gradient G is a measure for the control reserve and thereby for the maximum possible increase in speed.
[0041] In the case of determination of the control reserve for example with regard to the positioning of a vacuum or steam control valve, velocity and load of an ancillary drive, of fluid streams etc. the machine velocity can also be plotted by the position of the valve, the speed of the ancillary drive or the fluid stream instead of via the load, the duration determined and the approximately linear or complex relationship with the velocity v determined.
[0042] The processes to be considered in the case of an installation with a continuous production process, e.g. an installation for paper production, are as a rule not very dynamic. The dynamic components in the process variables are not even of primary interest for the determination of the control reserves. Of greater interest instead is the average long-term behavior of the process variables. The process variables are therefore preferably filtered (appr. 2 s) and only sampled appr. every 5 s.
[0043] Preferably an online evaluation of the recorded data with subsequent data compression is undertaken for a subsequent offline evaluation of the recorded data. | The invention relates to a method for increasing the capacity of an installation used to carry out an industrial process in an economical and sustainable manner. Said method consists of the following steps: process variables relevant to the capacity of the installation are determined; said process variables are monitored during variable operating conditions of the installation; and a very small control reserve of the control loops of the installation is established on the basis of the monitored process variables. | 3 |
[0001] The present invention relates to a halving joint structure, and particularly, but not exclusively, to a halving joint structure which improves the strength and rigidity of the joint.
BACKGROUND
[0002] A conventional halving joint is created by forming a slot in opposite edges of a first member and a second member, which are to be joined. Commonly, the slots formed in the first and second member are of equal length and the slots extend half of the way through the thickness of each member. However, if the members are of differing thicknesses, only one of the slots may extend half of the way through the thickness of the member.
[0003] The two members are arranged perpendicularly and the slot of one member is introduced into the slot of the other member until a bottom surface of the slot of the first member contacts a bottom surface of the slot of the second member. This forms an overlapping interconnection between the two members. Where the slots of the first and second members are of equal length and extend half of the way through the thickness of each member, the edges of the first and second members align to form a continuous connection.
[0004] The conventional halving joint is simple to manufacture and assemble, and is therefore widely used. The conventional halving joint is usually created with wooden members, but can also be formed from cardboard, plastic or metal members (particularly sheet metal). A plurality of members each having a plurality of slots can be used to form a grid-type arrangement. This is particularly useful for forming compartments, for example, for packaging.
[0005] However, the conventional halving joint is relatively weak and the first and second members may become misaligned easily. Furthermore, the joint can be easily separated, which in certain applications is undesirable. Where the members are formed from metal, this can be prevented by welding the first and second members together. However, welding causes distortion of the members, and also increases the cost and lead-time of the component. Furthermore, it is then not possible to separate the joint if desired. Alternatively, the first and second members may be connected using rivets or bolts. Rivets provide a semi-permanent connection but they add significantly to the parts-count of the component and again increase the cost and lead-time of the component. Although bolts provide a disassemblable connection, they also increase the parts-count, cost and lead-time of the component.
[0006] The present invention seeks to provide a halving joint structure which solves some or all of the problems associated with the conventional halving joint described above.
STATEMENTS OF INVENTION
[0007] In accordance with an aspect of the invention, there is provided a halving joint structure comprising: a first member and a second member couplable to one another in a nonparallel arrangement by a halving joint, wherein each of the first and second members has a joint slot for receiving a portion of the other of the first and second members to form the halving joint; wherein the first and second members have cooperating locking slots, the locking slot of the first member intersecting the joint slot of the first member, and the locking slot of the second member being formed in the portion of the second member which is received by the joint slot of the first member; the structure further comprising: a locking member which is receivable within the locking slots of the first and second members.
[0008] The halving joint structure in accordance with the present invention increases the parts-count by just one part, the locking member. The locking member may be a simple component which can be lightweight and may be easily assembled and disassembled. Furthermore, the locking member may be formed using the same processes as used for the first and second members (e.g. laser cutting) and the halving joint structure may not require any further preparation before assembly. Consequently, the present invention does not add significantly to the cost and lead-time of the halving joint structure.
[0009] The locking slots of the first and second members may lie in the same plane when the first and second members are coupled to one another.
[0010] The locking slot of the first member may be perpendicular to the joint slot.
[0011] The locking member may be a locking plate.
[0012] The locking member may have a retaining portion which may be movable between a first configuration which allows the locking member to be received within the locking slots of the first and second members and a second configuration which prevents the locking member from being withdrawn from the locking slots of the first and second members.
[0013] The retaining portion may lie in the plane of the locking slots when in the first configuration and may be out of the plane of the locking slots when in the second configuration.
[0014] The retaining portion may be deformable between the first and second configurations.
[0015] The retaining portion may be bendable between the first and second configurations.
[0016] The retaining portion may comprise a pair of bendable retaining arms.
[0017] The locking member may comprise a head portion.
[0018] The head portion may have an extraction hole. The extraction hole may provide an attachment point for gripping the locking member to aid in removing the locking member from the locking slots.
[0019] The locking member may be adapted to maintain the nonparallel arrangement of the first and second members.
[0020] The head portion may be sized to maintain the nonparallel arrangement of the first and second members.
[0021] The retaining portion may be sized to maintain the nonparallel arrangement of the first and second members.
[0022] The retaining portion may be sized to maintain the nonparallel arrangement of the first and second members when in the second configuration.
[0023] The first member, second member, and/or locking member may be metal.
[0024] The first member, second member, and/or locking member may be formed from sheet metal.
[0025] The first and second members may have additional cooperating locking slots, the additional locking slot of the second member intersecting the joint slot of the second member, and the additional locking slot of the first member being formed in the portion of the first member which is received by the joint slot of the second member; and the structure may further comprise: an additional locking member which is receivable within the additional locking slots of the first and second members.
[0026] In accordance with another aspect of the invention, there is provided a locking member for a halving joint structure comprising a first member and a second member couplable to one another in a nonparallel arrangement by a halving joint, wherein each of the first and second members has a joint slot for receiving a portion of the other of the first and second members to form the halving joint; wherein the first and second members have cooperating locking slots, the locking slot of the first member intersecting the joint slot of the first member, and the locking slot of the second member being formed in the portion of the second member which is received by the joint slot of the first member; wherein the locking member is adapted to be received within the locking slots of the first and second members.
[0027] In accordance with another aspect of the invention, there is provided a method of assembling a halving joint structure, the method comprising: providing a first member and a second member, each having a slot for receiving a portion of the other of the first and second members; wherein the first and second members have cooperating locking slots, the locking slot of the first member intersecting the joint slot of the first member, and the locking slot of the second member being formed in the portion of the second member which is received by the joint slot of the first member; inserting the portion of the first or second member into the slot of the other of the first and second members to form a halving joint, with the first and second members in a nonparallel arrangement; and inserting a locking member into the locking slots of the first and second members.
[0028] The method may further comprise moving a retaining portion of the locking member from a first configuration which allows the locking member to be received within the locking slots of the first and second members to a second configuration which prevents the locking member from being withdrawn from the locking slots of the first and second members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
[0030] FIG. 1 is a perspective view of a halving joint structure according to an embodiment of the invention, prior to assembly;
[0031] FIG. 2 is a top view of a locking member of the halving joint structure;
[0032] FIG. 3 is a perspective view of the assembled halving joint structure;
[0033] FIG. 4 is a perspective view of the assembled halving joint structure showing the locking member in a first unlocked configuration; and
[0034] FIG. 5 is a perspective view of the assembled halving joint structure showing the locking member in a second locked configuration.
DETAILED DESCRIPTION
[0035] With reference to FIG. 1 , a halving joint structure according to embodiment of the invention is formed by a first member 2 and a second member 4 . The first and second members 2 , 4 are constructed from sheet metal.
[0036] A joint slot 6 a is formed in the first member 2 and a joint slot 6 b is formed in the second member 4 . The joint slots 6 a , 6 b extend perpendicularly from opposite edges of the first and second members 2 , 4 . The joint slots 6 a , 6 b of the first and second members 2 , 4 widen at a bottom end to form a bulbous portion 8 a , 8 b having a flat bottom surface 10 a , 10 b.
[0037] A locking slot 12 a is formed in the first member 2 . The locking slot 12 a of the first member 2 is located along the length of the joint slot 6 a and extends perpendicularly to the joint slot 6 a . The locking slot 12 a is arranged so that the joint slot 6 a is at its centre. Accordingly, the joint slot 6 a and locking slot 12 a are in the shape of a cruciform.
[0038] The second member 4 is also provided with a locking slot 12 b . Unlike the locking slot 12 a of the first member 2 , the locking slot 12 b of the second member 4 is remote from the joint slot 6 b and is located in a portion 14 b between the bottom surface 10 b of the joint slot 6 b and an opposite edge of the second member 4 .
[0039] As indicated in FIG. 1 , the first member 2 and second member 4 are introduced to one another with the first member 2 arranged perpendicularly to the second member 4 (i.e. rotated 90 degrees about an axis running along the joint slot 6 a ). The first and second members 2 , 4 are urged towards one another with the joint slots 6 a , 6 b in alignment until the bottom surface 10 a of the slot 6 a of the first member 2 contacts the bottom surface 10 b of the slot 6 b of the second member 4 . Accordingly, the portion 14 b of the second member is received within the joint slot 6 a of the first member 2 and a corresponding portion 14 a of the first member 2 is received within the joint slot 6 b of the second member 4 .
[0040] In this position, the locking slots 12 a , 12 b of the first and second members are located so that they are aligned and lie in the same plane. Consequently, the locking slots 12 a , 12 b are arranged so as to allow a locking member 16 to pass through the locking slots 12 a , 12 b.
[0041] As shown in FIG. 2 , the locking member 16 is a flat elongate plate of sheet metal which comprises a head portion 18 at one end and a retaining portion 20 at the other end.
[0042] The head portion 18 of the locking member 16 comprises an extraction hole 20 which passes through the head portion 18 . The head portion 18 further comprises a pair of shoulders 22 a , 22 b on either side of the head portion 18 , and which are separated from one another by the extraction hole 20 . The shoulders 22 a , 22 b protrude from the locking member 16 and define the head portion 18 , which is wider than the remainder of the locking member 16 .
[0043] The retaining portion 20 of the locking member 16 comprises a pair of slits 24 a , 24 b which extend from either side of the retaining portion 20 into the body of the locking member 16 . The slits 24 a , 24 b are angled towards the head portion 18 . The slits 24 a , 24 b are separated by an indentation 26 which is formed in the retaining portion 20 and extends towards the head portion 18 of the locking member 16 . The indentation 26 defines a pair of retaining arms 28 a , 28 b located on either side of the indentation 26 . The retaining arms 28 a , 28 b are separated from the remainder of the locking member 16 by the slits 24 a , 24 b . This allows the retaining arms 28 a , 28 b to be bent out of the plane of the remainder of the locking member 16 , as will be described in further detail below.
[0044] As shown in FIG. 3 , when the bottom surfaces 10 a , 10 b contact one another, the edges of the first and second members 2 , 4 are in alignment.
[0045] The coupled first and second members 2 , 4 define four quadrants 30 , 32 , 34 , 36 and the slots 12 a , 12 b define a passage through the first and second members 2 , 4 from one of the four quadrants to an opposite quadrant i.e. from quadrant 30 to quadrant 34 , for example. The width of the passage through the first and second members 2 , 4 is defined by the distance across a quadrant from an edge of the locking slot 12 a of the first member 2 to an edge of the locking slot 12 b of the second member 4 . Accordingly, where the first and second members 2 , 4 are in a perpendicular arrangement, the width of the passage is equal to the hypotenuse of a triangle having two other sides which have a length that is approximately equal to half of the length of the locking slots 12 a , 12 b.
[0046] The locking member 16 is passed from the quadrant 30 , through the locking slots 12 a , 12 b with the retaining portion 20 leading, until the shoulders 22 a , 22 b of the head portion 18 contact the first and second members 2 , 4 respectively in the quadrant 30 . The shoulders 22 a , 22 b of the head portion 18 contact the first and second members 2 , 4 and thus maintain the angle between the first and second members 2 , 4 .
[0047] The width of the locking member 16 is such that it is just narrower than the width of the passage through the first and second members 2 , 4 . Furthermore, the length of the locking member 16 is such that, with the shoulders 22 a , 22 b contacting the first and second members 2 , 4 in the quadrant 30 , the slits 24 a , 24 b and the retaining arms 28 a , 28 b protrude into the opposite quadrant 34 , as shown in FIG. 4 .
[0048] As shown in FIG. 5 , once the locking member 16 is received in the locking slots 12 a , 12 b , the retaining arms 28 a , 28 b are bent down from the first unlocked configuration where they lie in the plane of the remainder to a second locked configuration where the retaining arms 28 a , 28 b are out of the plane of the remainder of the locking member 16 and, more importantly, out of the plane of the locking slots 12 a , 12 b . This prevents the locking member 16 from being withdrawn from the locking slots 12 a , 12 b . In the second locked configuration the retaining arms 28 b , 28 a contact the first and second members 2 , 4 respectively in the opposite quadrant 34 . Similarly to the shoulders 22 a , 22 b of the head portion 18 , the retaining arms 28 a , 28 b contacting the first and second members 2 , 4 helps to maintain the angle between the first and second members 2 , 4 .
[0049] To remove locking member 16 , the retaining arms 28 a , 28 b must be first bent from the second locked configuration back to the first unlocked configuration so that the retaining arms again lie in the plane of the locking slots 12 a , 12 b . The locking member 16 may then be pulled out of the locking slots 12 a , 12 b using the extraction hole 20 . This allows the first and second members 2 , 4 to be separated from one another when desired. The retaining arms 28 a , 28 b may move from the first unlocked configuration to the second locked configuration and back to the first unlocked configuration many times.
[0050] Although the retaining arms 28 a , 28 b of the locking member 16 have been described and shown as being bent down from the plane of the remainder of the locking member 16 , they could alternatively be bent up from this plane. Furthermore, each retaining arm 28 a , 28 b could be bifurcated (akin to a split pin) to allow the retaining arms 28 a , 28 b to be bent both up and down.
[0051] Furthermore, the retaining portion 20 may prevent the locking member 16 from being withdrawn from the locking slots 12 a , 12 b using alternative means. For example, the retaining portion 20 could have a portion which is twisted (i.e. about a longitudinal axis of the locking member 16 ) out of the plane of the locking slots 12 a , 12 b or which is pivoted out of the plane of the locking slots 12 a , 12 b and locked in position. Further still, the locking member 16 may have a portion which is deformed once the locking member 16 is inserted so that it is larger than the passage defined by the locking slots 12 a , 12 b.
[0052] Although only one pair of locking slots 12 a , 12 b has been described, further locking slots may be provided on the first and second members 2 , 4 . For example, the first and second members 2 , 4 may be provided with an additional pair of locking slots. The additional locking slots may be identical to the locking slots 12 a , 12 b but in the reversed configuration, whereby the additional locking slot of the first member is located in the portion 14 a and the additional locking slot of the second member 4 is located along the length of the joint slot 6 b . An additional locking member 16 is provided which is received in the additional locking slots of the first and second members 2 , 4 . Consequently, with this arrangement the first and second members 2 , 4 are identical. Furthermore, each of the first and second members 2 , 4 may comprise a plurality of joint slots 6 a , 6 b , locking slots 12 a , 12 b and locking members 16 so as to allow the first and second members 2 , 4 to form multiple halving joints with other members. This allows a grid-type arrangement to be formed.
[0053] The first and second members 2 , 4 do not necessarily need to be arranged perpendicularly to one another. The first and second members 2 , 4 may be joined in any nonparallel arrangement. Furthermore, the locking slot 12 a of the first member need not be perpendicular to the joint slot 6 a of the first member. However, the locking slot 12 a of the first member 2 must be angled with respect to joint slot 6 a of the first member 2 . Further still, although the locking slots 12 a , 12 b of the first and second members 2 , 4 have been described as lying in the same plane when the first and second members 2 , 4 are coupled to one another, this need not be the case. For example, the locking slots 12 a , 12 b may be arcuate and receive a similarly arcuate locking member 16 . In this case, the locking slots 12 a , 12 b of the first and second members 2 , 4 lie on a curved surface when the first and second members 2 , 4 are coupled to one another. However, when the first and second members 2 , 4 are coupled to one another, the locking slots 12 a , 12 b must be configured so as to allow a suitable locking member 16 to be received within the locking slots 12 a , 12 b , thereby locking the first and second members 2 , 4 together.
[0054] Although the first and second members 2 , 4 have been described as being constructed from sheet metal, they could be formed from alternative materials. Furthermore, where the base material of the locking member 16 is unsuitable for forming the retaining arms 28 a , 28 b , metal (or other suitable material) retaining arms may be joined to the locking member 16 .
[0055] The halving joint structure of the present invention may find particular applications in the aerospace industry. For example, the halving joint structure may be used to form ducts or other sheet metal structures. The halving joint structure of the present invention may be particularly useful for circular components. | A halving joint structure including: a first member and a second member couplable to one another in a nonparallel arrangement by a halving joint, wherein each of the first and second members has a joint slot for receiving a portion of the other of the first and second members to form the halving joint; wherein the first and second members have cooperating locking slots, the locking slot of the first member intersecting the joint slot of the first member, and the locking slot of the second member being formed in the portion of the second member which is received by the joint slot of the first member; the structure further including: a locking member which is receivable within the locking slots of the first and second members. | 4 |
FIELD OF THE INVENTION
The present invention relates to the field of fastening members of the rivet type and particularly to adaptations for enhancing the mechanical resistance features thereof.
DESCRIPTION OF THE PRIOR ART
The invention particularly relates to a two-part fastening member of the rivet type such as those known under the trade name “lockbolt”.
This rivet such as that described in the document FR 2503805 comprises a pin and a ring, said pin comprising a head at one end and having on the body thereof a plurality of locking grooves or slots enabling the ring engaged on the pin to fasten thereto by means of deformation.
Such a design is suitable for fastening parts together by drilling a through hole therein, with said head bearing on one end of the hole and with said ring acting, once deformed and fastened to the pin, as a bearing surface opposite the head at the other end of the hole.
Said pin comprises a first grooved portion for engaging with the ring and a second grooved portion for engaging with the tool for holding the pin during the extrusion of the ring on the first grooved portion. To facilitate the manufacture of such members, the grooves of each portion are conventionally identical.
This second grooved pin portion is separated from the first by a deeper groove or slot suitable for enabling the rupture of the pin, once a tensile force threshold has been exceeded.
The mechanical features of the fastener obtained such as the tear strength are thus primarily dependent on the link between the first grooved pin portion and said ring.
Designers of such fasteners have conducted research to enhance said features.
In this way, for example, extending the length of the pin and the ring is suitable for increasing the mechanical features, it being understood that such an extension results in an equivalent increase in the protrusion formed by the fastener and requires tools with a greater travel.
Suitable choice of materials may help enhance the mechanical features but such a choice may prove to be costly and require specific tools.
As described in the document FR 2283347, fastening members were designed to provide a first grooved pin portion for engaging with the ring preformed with the grooves adopting a pitch tending to increase progressively on moving away from the head. Enlarging the pitch makes it possible, with the same depth, to allow more material of the ring to engage with the pin during the deformation thereof.
Nonetheless, the ring does not exhibit regular deformation along the entire length thereof enabling equal engagement thereof with each groove. Conventionally, the ends of the hollow core of said ring do not fill the corresponding grooves to the same extent as the central portion thereof. This disparity increases for the limit conditions of use of the fastening member, i.e.:
when the available length of the first grooved portion of the pin for engaging with the ring is maximal and where the thickness of the assembly is minimal (scenario hereinafter referred to as “mini grip”), or when the available length of the first grooved portion of the pin for engaging with the ring is minimal and where the thickness of the assembly is maximal (scenario hereinafter referred to as “maxi grip”).
It is thus obvious that the number of completely filled grooves differs and may not be deemed to be sufficient. Progressively enlarging the pitch of the grooves does not guarantee that the number of completely filled grooves will be sufficient and likewise does not guarantee an equal number of grooves in a “maxi grip” scenario or in a “mini grip” scenario. This difference is all the more detrimental in a progressive pitch design in that, in the two scenarios described, the same first grooved pin portion area is not involved in receiving the ring.
These variations in the number and type of grooves engaged result in variable mechanical resistance features of the fastener obtained, according to whether the fastener required is far from or close to the limit conditions of use.
DESCRIPTION OF THE INVENTION
On the basis of this situation, the applicant conducted research intended to:
firstly, enhance the mechanical features obtained using a two-part fastening member, and, secondly, render these technical features as regular as possible despite variations in position of the ring according to whether the fastener required is far from or close to the limit conditions of use.
This research led to the design and embodiment of a technological solution not only applicable to two-part fastening members but also more generally to any fastener comprising at least one pin with grooves or slots and at least one ring fastening by means of deformation onto said grooves or slots.
The fastening member according to the invention is of the type comprising a pin and a ring, said pin comprising a head at one end and having on the body thereof a first grooved portion with a plurality of locking grooves or slots enabling the ring engaged on the pin to fasten thereto by means of deformation and a second grooved portion for engaging with a tool for holding the pin during the extrusion of the ring on the first grooved portion,
a rupture slot facilitating the detachment of the second portion once a stress threshold has been exceeded during fitting.
According to the invention, this fastening member is characterized in that said grooved portion of the pin is preformed to have a sequence of non-helical grooves, the start and end whereof are formed by grooves having different profiles to the identical grooves situated in the central portion of said sequence, the different profile adopting an identical depth but a greater width to those of the profile of the grooves situated in the central portion of the sequence.
The presence of different profiles in the sequence of grooves is suitable for optimizing the mechanical features of the fastener obtained. The presence thereof at the start and end of the sequence of preformed slots associated with that of mutually identical slots situated in the intermediate portion in the grooved portion is suitable for guaranteeing this optimization whether in a “mini grip” or “maxi grip” configuration.
Furthermore, having a wider groove at the ends makes it possible to have a larger empty space to be filled by the ring. The larger this empty space, the lower the force required to crimp the ring (it is easier to deform the ring since it does not come into direct contact with a rib).
The fact that the sequence of grooves does not adopt a helical structure is in compliance with the basic design of a “lockbolt” type fastening member and prevents any risk of loosening due to unscrewing.
According to a further particularly advantageous feature of the invention, the start and end grooves of the sequence of grooves which have different profiles to those situated in the central portion are mutually identical. In addition to facilitating manufacture, such a feature tends to render the mechanical behavior of the fastener equivalent in both “maxi grip” and “mini grip” scenarios.
Further particularly advantageous features are suitable for being associated with all or some of those already mentioned, as such, for example:
a single groove adopts a different profile at the start and end of the sequence; a plurality of grooves adopt a different profile at the start and end of the sequence; said width of the different grooves is substantially equal to 1.5 times that of the identical grooves situated in the central portion of the sequence; the different profile is non-symmetrical; the pin head is countersunk, the top surface of the pin head is convex.
The applicant has devised a plurality of associations of materials, a list whereof is provided hereinafter:
the pin made of 7000 series aluminum and the ring made of 6000 series aluminum the pin made of TA6V titanium and the ring made of 2024 T42 aluminum the pin made of titanium with a mechanical resistance (Rm) greater than 1000 MPa (TA6V, Ti6-6-2, etc.) and the ring made of T40 titanium (Rm) greater than 400 MPa or Ti3Al2.5V Titanium (Rm greater than 500 MPa).
As a general rule, the material of the pin would have an Rm value greater than 1.5 times that of the ring.
It should be noted nonetheless that, according to the size and number of the grooves present at the ends, this ratio of 1.5 could be reduced since the wider said grooves are, the lower the crimping force (there is more empty space and it is thus easier to deform the ring and fill the grooves).
The fundamental concepts of the invention having just been described above in the most basic form thereof, further details and features will emerge more clearly on reading the following description with reference to the appended figures, giving merely as a non-limiting example, an embodiment of a fastening member according to the invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic drawing of an embodiment of a fastening member according to the invention.
FIG. 2 is a schematic drawing of the first grooved portion of a pin according to the prior art.
FIG. 3 is a schematic drawing of the first grooved portion of the pin according to the invention.
FIG. 4 is a schematic sectional drawing illustrating the operation for fitting a fastening member according to the invention based on a “maxi grip” at the start of fitting.
FIG. 5 reproduces the drawing in FIG. 4 during ring deformation.
FIG. 6 illustrates the rupture of the pin.
FIG. 7 is a schematic sectional drawing illustrating the operation for fitting a fastening member according to the invention based on a “mini grip” at the start of fitting.
FIG. 8 reproduces the drawing in FIG. 4 during ring deformation.
FIG. 9 illustrates the rupture of the pin.
DESCRIPTION OF PREFERRED EMBODIMENTS
As illustrated in the drawing in FIG. 1 , the fastening member according to the invention, in this case a “lockbolt” type rivet referenced R as a whole, comprises two parts:
a pin 100 and a ring 200 .
Said pin 100 comprises at one end a head 110 which is in this case countersunk and has, on the body thereof, a plurality of grooves or slots situated on different parts of said pin.
More specifically, said pin 100 comprises a first grooved portion 120 for engaging with the ring 200 and a second grooved portion 130 for engaging with the tool 0 (see FIGS. 4, 5, 7, 8, 9 ) for holding the pin 100 during the extrusion of the ring 200 on the first grooved portion 120 .
A rupture slot G facilitates the detachment of the second portion once a stress threshold has been exceeded during fitting.
The invention will emerge more clearly in the comparison between a first grooved portion according to the prior art illustrated by the drawing in FIG. 2 with the first grooved portion 120 of the rivet R according to the invention.
It is obvious that the preformed grooves in said first portion according to the prior art are non-helical and identical with an identical pitch, depth and profile.
On the other hand, said first grooved portion 120 of the pin 100 of the rivet according to the invention adopts a sequence of non-helical grooves 121 where the first groove 121 p and the last groove 121 d are identical but different to those 121 c arranged between the two.
These grooves are parallel and have a plane of symmetry or a median plane perpendicular to the longitudinal axis of the pin.
As illustrated, these start and end grooves 121 p and 121 c of the first grooved portion 120 intended to receive the ring, adopt a different pitch and a non-symmetrical profile.
This profile has a rib depth and a height equal to those of the profile of the grooves 121 c but with a different slope on either side of the bottom of the groove.
In this way, moving away from the head, the slope joining the upper edge of the groove 121 p is more progressive than that starting from the bottom of the groove to join the second upper edge. According to one preferred embodiment, the width of the grooves 121 p and 121 c is equal to 1.5 times that of the grooves 121 c.
The same applies for the groove 121 d whereas said slopes on either side of the bottoms of the grooves 121 c are equal.
In order to enhance the behavior of the countersunk head 110 during fitting to prevent the so-called umbrella deformation phenomenon, the head has, prior to fitting, a slightly convex top surface.
According to one preferred but non-limiting embodiment, the grooves are preformed by rolling.
According to a further preferred embodiment, the ring is made of 6000 series aluminum alloy and the pin is made of a 7000 series aluminum alloy.
FIGS. 4, 5 and 6 illustrate fitting of the rivet R in a “maxi grip” configuration.
As illustrated, the rivet R is positioned in a countersunk through hole T provided in the two parts P 1 and P 2 for the purposes of assembly. The pin 100 is positioned to bear the countersunk head 110 thereof on the countersink of the hole T and the ring 200 is engaged on the pin 100 . A tool O is associated with the second grooved portion 130 of the pin 100 so as to perform, by pulling on the pin 100 , the deformation of the ring 200 on the first grooved portion 120 .
It is obvious, in the drawing in FIG. 6 , that the inner surface of the ring 200 molds as closely as possible to the grooves 121 d and 121 c and, to a lesser extent, the groove 121 p.
FIGS. 7, 8 and 9 illustrate the fitting of the same rivet R in a “mini grip” configuration.
As illustrated, the rivet R is positioned in a countersunk through hole T′ provided in the two parts P 1 ′ and P 2 ′ for the purposes of assembly. The pin 100 is positioned to bear the countersunk head 110 thereof on the countersink of the hole T′ and the ring 200 is engaged on the pin 100 . The same tool O is associated with the second grooved portion 130 of the pin 100 so as to perform, by pulling on the pin 100 , the deformation of the ring 200 on the first grooved portion 120 .
It is obvious, in the drawing in FIG. 9 , that the inner surface of the ring 200 molds as closely as possible to the grooves 121 p and 121 c and, to a lesser extent, the groove 121 d.
The applicant conducted tests based on these embodiments enabling the fastener obtained to have an equivalent tear strength to that of a solid rivet both in a “mini grip” configuration and in a “maxi grip” configuration. The fastening member according to the invention, an example whereof is described above, thus achieves the aims of the invention. It is also obvious that minimizing the fitting force helps reduce the rupture slot and thus limit the tensile force applied on the pin head. This limits umbrella deformation of the head.
It is understood that the fastening member has been described above and represented with a view to disclosure rather than restriction. Obviously, various adjustments, modifications and enhancements may be made to the above example, without leaving the scope of the invention. | The invention relates to an attachment member (R) of the “lockbolt” type comprising a pin ( 100 ) and a ring ( 200 ), said pin ( 100 ) comprising a head ( 110 ) at one end and having, on its body, a first part ( 120 ) grooved with a plurality of locking grooves or channels ( 121 p, 121 c, 121 d ) enabling the ring ( 200 ) engaging with the pin ( 100 ) to attach itself thereto by deformation, and a second part ( 130 ) that is grooved in order to cooperate with a tool (O), characterized in that said grooved part ( 120 ) of the pin ( 100 ) is preformed so as to provide a series of non-helical grooves ( 121 p, 121 c, 121 d ), the beginning and the end of the series consisting of grooves ( 121 p, 121 d ) that have different profiles from the identical grooves ( 121 c ) located in the central part of said series, the different profile having an identical depth but a greater width compared to the profile of the grooves ( 121 c ) located in the central portion of the series. The invention is applicable to the production of attachments and rivets. | 5 |
This application is a division of application Ser. No. 07/467,750, filed Jan. 19, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for manufacturing a multi-element sintered material such as a superconducting ceramic material.
2. Description of the Prior Art
Heretofore, superconducting ceramic materials or the like have been manufactured by manually proportioning powdery ingredients with an electronic scale or the like, putting the proportioned ingredients into a sample pot, manually placing the sample pot on a pair of drive rollers of a drive device, rotating the sample pot by the drive device for a predetermined period of time to mix the ingredients, then molding the mixture into a sample of a certain shape, sintering the molded sample, preparing a test piece for testing the sintered sample and preserving the sample. Most of these manufacturing steps have been manually carried out.
However, the above manual process for preparing superconducting materials is disadvantageous for various reasons. If the number of samples to be prepared is increased, then a larger work force and a greater expenditure of time and money are required to produce the samples. The quality of the produced samples may vary depending on how skillful the work force involved in the preparation of the samples are, and errors may occur due to the increased number of samples.
The inventors achieved the present invention based on the belief that the aforesaid problems can be solved by automatically manufacturing multi-element sintered materials of various compositions, typically superconducting materials, each of uniform quality from powdery elements (raw material ingredients) with no or very little manual intervention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an apparatus for automatically manufacturing a multi-element sintered material such as a superconducting ceramic material.
In other words, the object of the present invention is to manufacture a multi-element sintered material by automatically effecting steps of various kinds which would otherwise tend to affect the quality of the sintered material, the steps ranging from weighing and mixing predetermined amounts of powdery ingredients to preliminarily molding the mixture into a pellet, so that a large quantity of pellets of different kinds (compositions) can be efficiently manufactured without quality variations which would otherwise result from manual intervention.
Another object of the present invention is to automate various steps ranging from preliminarily molding a mixture into pellets to fully sintering the pellet, so that completed pellets of stable quality can be manufactured.
A further object of the present invention is to provide an apparatus for automatically proportioning powdery ingredients accurately in appropriate amounts, preparing the proportioned ingredients for mixing, and mixing the prepared ingredients.
According to the present invention, there is provided a method of manufacturing a multi-element sintered material, comprising automatically weighing and supplying powdery ingredients to make up a superconducting material into a pot fed by a conveyor (weighing step), automatically supplying a plurality of balls and a predetermined amount of volatile liquid into the pot, closing the pot with a lid which bears a first code, reading the first code on the lid and storing information of the first code and the ingredients supplied into the pot in corresponding relation to each other (preparing step for mixing), thereafter moving the pot to mix the ingredients therein (mixing step), opening the lid, removing the balls with a screen, transferring only the mixed ingredients into a receiver container which bears a second code, reading the second code, and storing information relative correspondence of the second code to the first code (ball-removing step), thereafter heating the receiver container to dry the ingredients therein (drying step), and preliminarily molding an amount of the dried ingredients preferably by pressing with a mold assembly into a sample and storing information on the ingredients of the sample in corresponding relation to the second code (preliminary molding step) using the apparatus of the present invention.
According to the present invention, there is also provided an apparatus for manufacturing a multi-element sintered material, comprising a horizontally movable horizontal weighing hopper table, a plurality of weighing hoppers disposed on the weighing hopper table at predetermined positions, vertically held thereon and detachably attached thereto, a moving device for horizontally moving the weighing hopper table while stopping the weighing hoppers successively at a first predetermined position, an electronic scale disposed directly below the first predetermined position, a drive device for driving the weighing hopper to cause the ingredient contained therein to drop out after each of the weighing hoppers is stopped in the first predetermined position, a pot supply/discharge device for supplying one sample pot at a time onto the electronic scale to store the ingredients dropped from each of the weighing hoppers at the first predetermined position, so that the ingredients stored in the sample pot is weighed by the electronic scale, and for discharging the sample pot in a first direction if the weights of the ingredients measured by the electronic scale agree with the indicated weights, or in a second direction if the weights of the ingredients measured by the electronic scale disagree with the indicated weights, a conveyor for feeding the sample pot discharged in the first direction to a subsequent process, a pot stopping device for stopping the sample pot fed by the conveyor at a second predetermined position, a liquid spraying and scattering device for detecting when the sample pot is stopped at the second predetermined position, scattering a volatile liquid uniformly into the stopped sample pot, thereafter releasing the sample pot and feeding the sample pot by a conveyor to a subsequent process, and a ball supply device for supplying a predetermined number of balls each covered with a resin layer into the sample pot while the sample pot is being stopped at the second predetermined position by the pot stopping device.
According to the present invention, there is further provided an apparatus for manufacturing a multi-element sintered material, comprising a plurality of pairs of roller shafts each comprising a pair of shafts and a frictional roller fitted over each shaft, preferably at substantially equally spaced intervals therealong, a support device on which the roller shafts are rotatably supported such that the roller shafts are grouped into said pairs with the rollers on the paired shafts being spaced from each other in confronting relation in each pair, the support device including an attachment frame on which the roller shafts are horizontally spaced equally, a robot hand, a vertical feeder for vertically moving the robot hand, the robot hand being mounted on the vertical feeder, a horizontal orthogonal feeder for moving the vertical feeder over the roller shafts supported on the frame to cause the robot hand to supply a cylindrical sample pot onto the confronting rollers of a pair of roller shafts and also to cause the robot hand to feed a cylindrical sample pot from the rollers of a pair of roller shafts to a next process, a drive device for rotating each pair of roller shafts preferably by rotating one of each pair of roller shafts to rotate both roller shafts through an idle gear therebetween, and a rotating pot holding device for holding the sample pot in position when the sample pot is rotated by each pair of rollers of the roller shafts after being supplied onto the pair of rollers.
The above and other objects, features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system incorporating apparatuses according to a first embodiment of the present invention for carrying out the method of manufacturing a multi-element sintered material according to the present invention;
FIG. 2 is a schematic plan view of the system shown in FIG. 1;
FIG. 3 is a flowchart showing the steps of operation of a weighing unit;
FIG. 4 is a flowchart showing the steps of operation of a preparing unit for mixing;
FIG. 5 is a fragmentary perspective view of the weighing unit and the preparing unit for mixing;
FIG. 6 is perspective view of a mixing unit (ball mill type);
FIG. 7(a), 7(c), and 7(d) are plan, front elevational, and side elevational views of the mixing unit shown in FIG. 6;
FIG. 7(b) is an enlarged fragmentary view of the mixing unit;
FIG. 8 is a flowchart showing operation of a robot of the mixing unit;
FIG. 9 is a flowchart showing the steps of operation of a separation preparing unit;
FIG. 10 is a flowchart showing the steps of operation of a ball separating unit;
FIGS. 11(a) and 11(b) are plan and side elevational views, respectively, of the separation preparing unit and the ball separating unit;
FIG. 12 is a flowchart showing the steps of a drying unit;
FIGS. 13(a) and 13(b) are plan and side elevational views, respectively, of the drying unit;
FIG. 14 is a flowchart showing the steps of operation of a preliminary molding preparing unit;
FIG. 15(a) and 15(b) are flowcharts showing the steps of operation of a preliminary molding unit;
FIG. 16(a) is a plan view of a tray;
FIG. 16(b) is a cross-sectional view taken along line C--C of FIG. 16(a);
FIG. 17 is a flowchart showing the steps of operation of a sample preserving unit;
FIG. 18 is a flowchart showing the steps of operation of a preliminary sintering unit;
FIG. 19(a) and 19(b) are flowcharts showing the steps of operation of a crushing unit;
FIG. 20(a) and 20(b) are flowcharts showing the steps of operation of a main (full) molding unit;
FIG. 21 is a flowchart showing the steps of operation of a sample preserving unit;
FIG. 22 is a flowchart showing the steps of operation of a main (full) sintering unit;
FIG. 23 is a flowchart showing the steps of operation of a measurement preparing unit and a sample preserving unit; and
FIG. 24 is a block diagram of a system according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a system incorporating apparatuses and steps for carrying out a method of manufacturing a multi-elements sintered material, typically a superconducting material, from a plurality of powdery ingredients.
The system has a weighing unit 10 and a preparing unit 11 for mixing. The weighing unit 10 and the preparing unit 11 for mixing will first be described below with reference to FIGS. 3, 4, and 5.
The weighing unit 10 operates as follows: A sample pot 101 in the form of a cylindrical can-like container with a lid removed therefrom is prepared in a step S31 (FIG. 3), and supplied to a multi-element powdery ingredient weighing device by a pot supply conveyor 102 in a step S32. Powdery ingredients of different elements which have been prepared and stored in different containers are transferred from the containers into different weighing hoppers 109 1 , 109 2 , . . . , 109 8 , in steps S33, S34. The powdery ingredients may be those which will make up a superconducting material. Then, the weighing hoppers are set on a turntable 108 of the multi-element powdery ingredient weighing device in a step S35. Thereafter, the ingredients are weighed and supplied in a step S36 to the sample pot 101, which is then delivered into the preparing unit 11 for mixing in a step S37.
The weighing process in the step S36 will be described in detail below with reference to FIG. 5. The sample pot 101 with no lid on its upper open end has been fed by the pot supply conveyor 102, and is stopped by a stopper 103. An electronic weighing device 105, which is the multi-element powdery ingredient weighing device referred to above, is disposed in a first predetermined position below the turntable 108. If there is nothing placed on the electronic weighing device 105, then a sample pot 101 is released from the stopper 103 and fed onto the electronic weighing device 105 by a double-stage feed cylinder 104 under a command from a controller (not shown). When the controller produces an accepting signal indicating that the measured weight is acccepted, the cylinder 104 pushes the sample pot 101 onto a main conveyor 123 having two parallel conveyor belts. When the controllers produces a rejecting signal indicating that the measured weight is not accepted, another cylinder 107 pushes the sample pot 101 onto a rejecting conveyor 106 which delivers the sample pot 101 onto a rejecting conveyor 106 which delivers the sample pot 101 into a reject container (not shown).
The weighing hoppers 109 1 , 109 2 , . . . , 109 8 are positioned radially outward from the center of the turntable 108, preferably equidistant from the center of the turntable, preferably at angularly equally spaced locations thereon. Each of the weighing hoppers has a central vertical shaft disposed therein. When the central shaft, preferably in a brush like structure, or a screw feeder structure, or the like, of each weighing hopper moves, preferably rotates to a certain angle, vibrates or move with a like motion, the powdery ingredient contained in the weighing hopper is dropped downward from the weighing hopper through the turntable 108 in an amount commensurate with the angle or amount of the movement by which the central shaft has rotated or moved. The weighing hoppers have different sizes depending on the ingredients to be supplied thereto. However, the turntable 108 is designed such that a weighing hopper of any size can be placed in each location thereon. The turntable 108 is angularly moved by a turntable rotating device 110 under the control of the controller to bring and stop the weighing hoppers successively in (or above) the first predetermined position in which the electronic weighing device 105 is disposed.
A hopper actuator device 111 comprises a central pole 111 1 coaxial with the turntable 108, an arm 111 2 fixed to and extending radially outward from the central pole 111 1 , and an actuator 111 3 fixedly mounted on the radially outer end of the arm 111 2 . The hopper actuator device 111 is controlled by the controller such that each time a weighting hopper is stopped in the first predetermined position, the central pole 111 1 is lowered to bring the actuator 111 3 into engagement with the stopped weighing hopper, and the actuator 111 3 is operated to turn or move the central shaft of the weighing hopper by a prescribed angle or amount of movement. The ingredient contained in the weighing hopper then falls from the weighing hopper through the turntable 108 and leg of the hopper in an amount commensurate with the angle or amount of movement, by which the central shaft of the weighing hopper has turned or moved, into the sample pot 101 on the electronic weighing device 105. The ingredient thus supplied to the sample pot 101 is weighed by the electronic weighing device 105, and the weighed value is compared with a predetermined weight value by the controller. The above process of supplying an ingredient from the weighing hoppers and weighing the supplied ingredient is repeated until all the ingredients are supplied to the sample pot 101 and weighed by the electronic weighing device 105. If the weights of the ingredients supplied from the weighing hoppers fall within predetermined weight ranges, then the controller generates an accepting signal. If the weights do not fall within the predetermined weight ranges, then the controller generates a rejecting signal.
In the event that an ingredient is charged excessively into the sample pot 101, however, the controller produces commands enabling the weighing hoppers to supply those ingredients to be weighed after the excessively charged ingredient, in amounts that are with an excess proportional to the excess of the excessively charged ingredient. The controller also produces commands enabling the weighing hoppers to supply additional amounts of those ingredients weighed before the excessively charged ingredient, the amounts also being proportional to the excess of the excessively charged ingredient. Therefore, the controller can reduce wasteful loss of ingredients which would otherwise be caused if a rejecting signal were produced by the controller without such correction.
The preparing unit 11 for mixing will be described below.
As shown in FIG. 4, a liquid alcohol is prepared and supplied to a tank 115 in a step S41. Mixing balls are prepared and supplied to a ball hopper in a step S43. A bar code is issued by a bar code issuing machine in a step S45, and a lid is prepared and the bar code is applied to the lid in a step S46. The lid is then supplied to a lid stocker 120 4 , (FIG. 5) of an automatic lid closing machine or robot 120 in a step S47.
The sample pot 101 containing the ingredients which have been successfully weighed by the weighing unit 10 is delivered to the mixing preparing unit 11 while the bottom of the sample pot 101 is being supported by and on the two belts of the main conveyor 123. The sample pot 101 is stopped in a second predetermined position by a stopper 119, whereupon a step S42 is started. More specifically, the controller detects through a position sensor 117 when the sample pot 101 has come to the second predetermined position. The controller then instructs a metering device 114 to supply a slight squirt of an alcohol, typically ethanol, from the tank 115 into the sample pot 101. The metering device 114 also gives another supply of alcohol when instructed again by the controller. When the first squirt of alcohol is finished, the controller instructs a ball-stopper 118 to release a certain number of balls from the ball hopper 116 into the sample pot 101 in a step S44. When a sensor 117 2 detects that these balls have been dropped into the sample pot 101, the controller actuates the stopper 118 to block the supply of balls from the ball hopper 116 into the sample pot 101.
After the balls have been supplied to the sample pot 101, a second squirt of alcohol is supplied from the metering device 114 to the sample pot 101. When the supply of the second squirt of alcohol is over, the controller operates the stopper 119 to release the sample pot 101. The first squirt of alcohol dampens the powdery ingredients in the sample pot 101 to the extent that the ingredients and the added alcohol will be prevented from being raised and scattered around when the balls are dropped into the sample pot 101. It is preferable to spray the first squirt of alcohol uniformly over the powdery ingredients.
The sample pot 101 is moved from the second predetermined position by the main conveyor 123, and stopped in a third predetermined position by a lever 121 1 of a positioning/fixing device 121. The controller detects through a position sensor 117 3 , when the sample pot 101 is stopped in the third predetermined position, after which a lever 121 2 of the positioning/fixing device 121 is moved from a position off the main conveyor 123 into a position over the main conveyor 123 to clamp the sample pot 101 in cooperation with the lever 121 1 . When the controller detects the full clamping of the sample pot 101, it starts a lid closing process in a step 48 by initiating operation of the lid closing robot 120. The lid closing robot 120 has a central pole 120 1 , an arm 120 2 , fixed to the central pole 120 1 , a lid closer 120 3 mounted on the distal end of the arm 120 2 , and the lid stocker 120 4 for supplying lids with bar codes prepared in steps S46 and S47, one at a time, to the lid closer 120 3 . The lid closing robot 120 instructs the lid stocker 120 4 to supply one of the lids at a time to a position directly below the lid closer 120 3 . When a lid is supplied below the lid closer 120 3 in a step S47, the lid closing robot 120 lowers the central pole 120 1 to cause three radial fingers on the lower end of the lid closer 120 3 to grip the lid. The lid closing robot 120 then rotates the central pole 120 1 until the lid closer 120 3 is brought to a position directly above the third predetermined position, and lowers the central pole 120 1 . The lid closer 1203 rotates the lid to fasten the same to the upper end of the sample pot 101, whereafter the fingers are released from the lid in a step S48. The central pole 120 1 is elevated and rotated to return the lid closer 120 3 to its original position. After the lid has been closed, the levers 121 1 , 121 2 of the positioning/fixing device 121 are opened, i.e., swung away from each other, and the sample pot 101 with the lid secured thereto is further fed by the main conveyor 123. After the sample pot 101 has moved past the lever 121 1 , the lever 121 1 is brought back onto the main conveyor 123.
When the thus lid covered sample pot 101 has reached a fourth predetermined position, a position sensor 117 4 applies a signal to the controller which now starts a step S49. More specifically, a rotating device 122 moves a shaft upward between the two belts of the main conveyor 123 to lift the sample pot 101, and rotates the sample pot 101 off the main conveyor 123. The bar code applied to the lid on the sample pot 101 is now read by a suitable reading means such as a bar code reader 124. Thereafter, the sample pot 101 is placed on the main conveyor 123 again, and delivered to a subsequent process. The bar code corresponds to information about the ingredients and amounts thereof (compositions) stored in each specific sample pot 101, and the information read by the bar code reader 124 is sent to the controller and recorded in a suitable manner.
The sample pot 101 is preferably of a shouldered structure such that the top opening or port thereof is smaller in diameter than the barrel portion of the sample pot, the sample pot 101 being thus tapered from the barrel portion toward the opening thereof. The shouldered structure is advantageous in that the ingredients will not flow (leak) out of the sample pot 101 when they are mixed by rotating the sample pot 101 while it is lying in a horizontal position.
The inner surfaces of the ball hopper 116, the sample pots 101, and the lids, and the outer surface of the balls are preferably covered by one of certain various synthetic resin such as polyethylene, polypropylene, fluoroplastic, and polyimide, so that the ingredients, which are of various minerals, are less contaminated, even though by fine particles of the synthetic resins, than if these inner surfaces were made of metal or ceramic materials and not covered by the resin. While the turntable 108 is employed in the illustrated embodiment, a linearly movable table may be employed for successively moving the weighing hoppers.
The system shown in FIGS. 1 and 2 also includes a mixing unit 20. The mixing unit 20 will be described with reference to FIGS. 6 and 7(a) through (d).
The mixing unit 20 has a mixing device. The mixing device is constructed as follows:
The mixing device has a plurality of roller shafts 207 each comprising a shaft 206 and a plurality of substantially equally spaced rollers 204 each having a surface layer of rubber. The opposite ends of each of the roller shafts 207 are supported on a frame 211 by bearings 208. The roller shafts 207 are grouped into pairs, and the rollers 204 on the paired roller shafts 207 are spaced a substantially constant distance from each other in confronting relation. The mixing device also includes a horizontal orthogonal feeder 201 and a vertical feeder 202 with a robot hand 203 mounted thereon. The horizontal orthogonal feeder 201 moves the vertical feeder 202 in perpendicular X- and Y-axes over the roller shafts 207. The mixing device also has a plurality of holder clamps 205 disposed above the roller shafts 207. When a sample pot 101 is placed on a pair of confronting rollers 204 by the robot hand 203 so as to be rotated by these rollers 204, a holder clamp 205 is rotated and lowered to prevent the sample pot 101 from being displaced out of position, with two holder rollers 205 1 on the holder clamp 205 being positioned above the sample pot 101. While the sample pot 101 is in normal position on the rollers 204 on rotation, the holder rollers 205 1 are preferably kept out of contact with the sample pot 101. However, when the sample pot 101 jumps upward, it is contacted by the holder rollers 205 2 and prevented from being displaced out. This arrangement is advantageous in that the drive power for rotating the roller shafts 207 is subject to a reduced power loss.
One of the paired roller shafts 207 is driven by a drive device 212 through a bolt 213, whereas the other roller shaft 207 is driven by an idler gear 209 disposed between the rollers 204 or the shafts 206. When the paired roller shafts 207 are thus rotated, the sample pot 101 on the rollers 204 is rotated to mix the powdery ingredients contained in the sample pot 101. Each drive device 212 includes an electric motor and an infinitely variable transmission. The speed of rotation of the drive device 212 can be adjusted by a speed adjusting handle 214. The horizontal orthogonal feeder 201 is controlled by a controller 219 according to a program.
In this embodiment, there are four sets or pairs of roller shafts 207, and each pair of roller shafts 207 can rotate five sample pots 101 at a time. Sample pots 101 supported on the rollers shafts 207 are therefore arranged in a substantially square pattern which minimizes the distance that the robot hand 203 traverses.
The mixing unit 20 with the above mixing device operates as follows:
A sample pot 101 delivered from the mixing preparing unit 11 by the main conveyor 123 reaches a stopper 220. When the arrival of the sample pot 101 at the stopper 220 is detected by a position sensor associated with the stopper 220, the position sensor sends a signal to the controller 219 which instructs the robot hand 203 to grip the sample pot 101 and also instructs the horizontal orthogonal feeder 201 and the vertical feeder 202 to bring the gripped sample pot 101 to a position over a pair of confronting rollers 204 with nothing thereon in a step S51 (FIG. 8). The roller shafts 207 with those confronting rollers 204 are stopped against rotation, and then the sample pot 101 is placed on the rollers 204 by the robot hand 203, which is thereafter lifted back. While the sample pot 101 is being brought over the rollers 204, the robot hand 203 is rotated through 90° to turn the sample pot 101 until the axis of the pot is turned from the vertical position to the horizontal position parallel to the axes of the rollers 204. After the robot hand 203 has placed the sample pot 101 on the rollers 204 and before the robot hand 203 grips a next sample pot 101 at the stopper 202, the robot hand 203 is turned back through 90° so that it can grip the vertically positioned next sample pot 101 on the main conveyor 123. After the robot hand 203 has been elevated, the holder clamp 205 is lowered and rotated to bring the holder rollers 205 1 over the sample pot 101 so that the sample pot 101 will not jump off. Then, the drive device 212 is started to rotate the roller shafts 207 and hence the sample pot 101 to mix the ingredients therein with the aid of the balls also therein in a step S52. After the sample pot 101 has been rotated by the rollers 204 for a predetermined period of time, the holder clamp 205 is lifted and rotated to release the sample pot 101. The robot hand 203 is moved again to the position over the sample pot 101, grips the sample pot 101, and carries the sample pot 101 onto a discharge conveyor 221 in a step S53.
The holder clamp 205 is movable vertically and rotatable horizontally by a clamp shaft 205A fitted in a support cylinder 205T, a guide pin 205P attached to the clamp shaft 205A, a guide slot 205U defined in the support cylinder 205T and receiving the guide pin 205P, and a means (not shown) for vertically moving the clamp shaft 205A.
A separation preparing unit 21 and a ball separator unit 22 will be described below with reference to FIGS. 9 through 12.
The sample pot 101 is transferred from the mixing unit 20 by the discharge conveyor 221 in a step S61 (FIG. 9). When the sample pot 101 is detected by a pot sensor 301 (FIG. 11(a), a robot 302 grips the sample pot 101 and sets the sample pot 101 on an automatic lid opener 303 of the separation preparing unit 21. Then, the bar code on the lid of the sample pot 101 is read by a bar code reader 304 in a step S62. The information thus read from the bar code is stored in a controller (not shown), and its correspondence to a bar code on a receiver container of the ball separator unit 22 is recorded. In the automatic lid opener 303, the sample pot 101 is detected by a position sensor, and fixed in place by a pot fixing device under the control of the controller. Fingers of the automatic lid opener 303 are lowered, chucks the lid of the sample pot 101, rotates the lid back to remove the lid off the sample pot 101 in a step S63. In the step S63, the fingers of the automatic lid opener 303 are elevated and turned, while holding the lid, and are moved apart above a lid collecting container 307 to drop the lid into the lid collecting container 307. Thereafter, the lid is processed in a step S64.
The ball separator unit 22 has a shelf 305 supporting vertically separable assembled receiver containers 306 which have been delivered by a feed robot (not shown). Each of the receiver containers 306 comprises an upper screen 306 0 , and a lower container 306 1 with a heat-resistant bar code applied thereto. Another assembled receiver container 306 which has been delivered from the shelf 305 by the robot 302 is also placed on a vibratory table 310. When the receiver container 306 is set on the vibratory table 310, the bar code of the container 306 1 thereof is read by a bar code reader 314 in a step S65.
After the lid is removed from the sample pot 101 by the lid opener 303, the robot 302 takes the sample pot 101 from the lid opener 303 and moves the sample pot 101 into the ball separator unit 22 in a step S66. The robot 302 turns the sample pot 101 upside down above the assembled receiver container 306 on the vibratory table 310 to dispose the ingredients into the receiver container 306 in a step S67. A washing nozzle 312 of a washing device 311 is introduced into the open end of the reversed sample pot 101 held by the robot 302, and ejects a spray of an alcohol from a tank 313 to wash the interior of the sample pot 101. Thereafter, the washing nozzle 312 is retracted out of the sample pot 101, which is allowed to drop into a pot retrieval container 315 in a step S70. In a step S68, an upper lid (screen-cover) is lowered onto the receiver container 306 to close the same, and the vibratory table 310 starts vibrating the receiver container 306. A spray of an alcohol is ejected from a spray nozzle (not shown) on the upper lid over the screen of the receiver container 306 for a given period of time to wash the screen in a step S69. After the vibratory table 310 stops vibrating the receiver container 306 and the spray nozzle is inactivated, the lower container 306 2 of the receiver container 306 is fixed in position by a fixing device. The robot 302 removes the upper screen from the receiver container 306, throws the balls into a ball collecting container 316, and returns the upper screen back to the shelf 305 in a step S71. The lower container 306 1 is released from the fixing device, and fed onto a conveyor 320 by the robot 302 for a subsequent process in a step S72.
A drying unit 23 will be described with reference to FIGS. 11, 12, 13(a), and 13(b).
The lower container 306 1 is moved from the robot 302 by the conveyor 320 (FIG. 11) to a position P and positioned in a step S73 (FIG. 12). The positioned container 306 1 is then fed into an inlet/outlet port 402 in the drying unit and set in a hole in a turntable 410 by a robot 401 in a step S74. In the drying unit 23, the alcohol mixed in the ingredients in the mixing preparing unit 11 and the ball separator unit 21 is evaporated for a predetermined period of time by heating, depressurization, or the like in a step S75. More specifically, as shown in FIGS. 13(a) and 13(b), the turntable 410, which is intermittently rotatable through a certain angle under the control of a command signal, is disposed in a drying chamber 400 surrounded by a thermally insulating material. The turntable 410 has a plurality of holes defined at equal angular intervals in a circumferential pattern, for receiving containers 306 1 therein. Circular heaters 0 mounted on each air cylinder are positioned immediately below these holes. These heaters 420 can independently be turned on and off. Air nozzles 433 for ejecting hot air are disposed above the turntable 410 in vertical confronting alignment with the heaters 420, respectively. Hot air made by heating the air taken in from air intake means 435 by an air heater 430 is supplied to the air nozzles 433 through ducts 432 by an air blower 431 for the air nozzles. The air blower 431 also supplies hot air below the turntable 410 through ducts 434. When a container 306 1 is moved through the inlet/outlet port 402, doors 442 which separate the drying chamber 400 from the inlet/outlet port 402 are opened and closed by air cylinders 441. When a temperature sensor on the turntable 410 detects an abrupt temperature rise of the bottom surface of container 306 1 after the ethanol has been evaporated, it is determined that the ingredients in the container 306 1 have been dried. After the alcohol has been evporated and the ingredients have been dried, the container 306 1 is removed from the inlet/outlet port 402 by the robot 401 in a step S76, and delivered to a next process by the conveyor 320 in a step S77.
The bar code on the container 306 1 is read on the conveyor 320 in a step S78. Though the bar code may not necessarily be read on the conveyor 320, it is preferably read to prevent errors if the container 306 1 is revolved by the turntable 410 in the drying unit as shown in FIGS. 13(a) and 13(b). The condition in the drying unit 23, particularly the information indicating whether the drying unit 23 can accept a container 306 1 or not, is fed back to the mixing unit 20 to control the operation of the mixing unit 20.
A preliminary molding preparing unit 30 will be described with reference to FIG. 14.
The container 306 1 , after the ingredients therein have been dried, is fed by the conveyor 320 in a step S81. New scraper blades have been set on a sample scraper in a step S82. The delivered container 306 1 is positioned and fixed on the conveyor 320, and the ingredients in the container 306 1 are scraped by the scraper blades in a step S83, so that any powder on the inner wall of the container 306 1 is scraped off. The used scraper blades will subsequently be replaced with new scraper blades by a blade replacing machine having an automatic blade feeder.
A predetermined molding unit 31 will be described with reference to FIGS. 15(a) and 15(b). The container 306 1 with the ingredients scraped off the inner wall thereof is supplied from the preliminary molding preparing unit 30. The container 306 1 is moved to a position just above a hopper held at a predetermined position and reversed by a reversing device and the content of the container 306 is transferred in a step S85 into the hopper which has been positioned on a feed conveyor at the predetermined position in a step S87. After the container 306 1 has been reversed, it is removed to a prescribed position. An array of empty hoppers is generally manually arranged in a hopper supplying machine in a step S86. The hopper is filled with the ingredients supplied from the reversed container 306 1 , and transferred to and positioned in a preliminary molding machine in a step S88. The ingredients or sample is automatically measured and supplied by a weighing feeder in a step S89. The sample is supplied to a molding machine and molded thereby, preferably by pressing, and the molded sample is taken out of the molding machine and received by a tray of an orthogonal robot, and the molding machine from which the molded sample has been taken is cleaned by a vacuum device. This process is repeated until a predetermined number of preliminarily molded samples are formed in a step S90. Trays with bar codes applied thereto are prepared in advance on a robot table, generally through a manual operation. The trays which have received the molded samples of the same composition are automatically fed from the robot table by a feed conveyor on which the bar codes on the trays are read in a step S92. Thereafter, the trays are classified into first trays container samples to be reserved, second trays containing samples to be thrown away, and third trays containing samples to be preliminarily sintered. The second trays contain one sample or a certain small number of samples molded in (an) initial molding shot(s), so that any contamination from those samples molded in the previous molding cycle will not affect the present samples. The third trays usually keeps a certain additional number of samples which may make up for any loss of samples. A layer of alumina powder is applied in advance as an adhesion-resistant material to the inner bottom surfaces of the third or other trays to be sintered for preventing the preliminarily sintered molded samples from adhering (being welded) to the trays.
When the first, second, or third trays of the same composition are moved to a preliminary sintering process or the like, it is efficient to place about ten trays in a larger tray as shown in FIGS. 16(a) and 16(b). The trays placed in the larger tray will be referred to as smaller (small) trays. No adhesion-resistant material is applied between the larger and smaller trays. The adhesion-resistant material and the larger tray will also be employed in a main sintering unit 35 which will be described later on as well as in a preliminary sintering unit 32. After samples are delivered into small trays in a large tray in a step S93, the large tray containing small trays is transferred in a step S94 to a preliminary molding unit 31. During the step S94, the bar code on the large tray is read by a bar-code reader.
The preliminarily molded sample of ceramic superconducting material or the like is delivered from the preliminary molding unit 31 to a sample reserving unit 40 as shown in FIG. 17.
More specifically, the trays fed from the preliminary molding unit 31 are fed by a feed conveyor of the sample preserving unit 40 in a step S100. While the trays are being fed by the feed conveyor, the bar codes on the trays are read by a bar code reader, and their correspondence to the composition of the material is recorded. Thereafter, the trays are delivered to a sample removing position, at which the samples are taken out in a step S101, and inserted and reserved in a storage container having a bar code in a step S102. The information represented by the bar codes applied to the tray and the storage container will be processed in various subsequent processes for correspondence between itself and the composition of the sample supported on the tray or contained in the container. The information is automatically recorded in a central control/storage/command system typically in the form of a host computer, the bar codes are automatically compared based on the recorded information, and command signals are automatically supplied to various units and devices.
Delivery of the preliminarily molded superconducting material from the preliminary molding unit 31 to the preliminary sintering unit 32 will be described below with reference to FIG. 18.
When the trays are delivered from the preliminary molding unit 31 to the preliminary sintering unit 32 by the feed conveyor, the trays are placed on the bottom of preliminary sintering furnaces A, B, typically Muffle furnaces, by a robot in a step S110. When the trays are placed in the furnaces, the doors thereof are automatically opened and closed. After the samples have been preliminarily sintered in a step S111, the furnace doors are automatically opened, the trays are removed by the robot in a step S112 and then fed to the next process by a feed conveyor in a step S113. While the trays are being fed by the feed conveyor, their bar codes are read.
A crushing unit 33 will be described with reference to FIGS. 19(a) and 19(b). When the trays are fed from the preliminary sintering unit 32 to the crushing unit 33, the trays are aligned by an aligning robot in the crushing unit 33 in a step S121, and the smaller trays are taken out and the samples transferred from the smaller trays into a container by a transfer robot in a step S122. While the smaller trays are being transferred, it may be necessary to draw or blow air to remove alumina powder, being the adhesion-resistant material, from the molded samples. Any remaining alumina powder or adhesion-resistant material in the smaller trays is collected in a retrieval (recovering) container by rotating the smaller trays or under a vacuum in a step S123. The empty larger and smaller trays are collected by a collecting means (not shown). The samples which have been transferred into the container in the step S122 are then charged into an automatic crushing machine and crushed thereby in a step S125. The crushed sample is then transferred to a collecting container comprising a hopper in a step S126. A bar code applied to the hopper is read by a bar code reader and recorded, and then the hopper is delivered to a next process by a conveyor in a step S127.
A main molding unit 34 will be described with reference to FIG. 20.
After the hopper arrives from the crushing unit 33 at the main molding unit 34, the hopper is transferred to a main molding machine by a transfer mechanism in a step S130. The sample is automatically metered (weighed) by a (weighing) metering feeder in a step S131. Then, the weighed sample is supplied to a mold assembly and molded thereby in a step S132. The molded sample is removed by a removing robot in a step S133, transferred to a tray which has been delivered by an orthogonal robot in a step S134, and the mold assembly is cleaned by a vacuum device. The above process is repeated to produce a predetermined number of molded samples similar to the above preliminary molding. The tray is manually positioned in advance on a robot table. After the molded samples have been produced, the tray filled with the molded samples is automatically removed from the robot table by a feed conveyor in a step S135. On the feed conveyor, a bar code applied to the tray is read. Trays thus delivered are classified into first trays containing samples to be reserved, second trays containing samples to be thrown away, and third trays containing samples to be fully sintered. This classification, use of an adhesion-resistant material, and use of larger and smaller trays are the same as with the preliminary molding process described above. The third trays are then delivered to a next process in a step S136.
Delivery of the trays from the main molding unit to a sample preserving unit 41 will be described with reference to FIG. 21.
The trays delivered from the main molding unit 34 is fed by a feed conveyor in a step S140. While the trays are being fed by the feed conveyor, their bar codes are read by a bar code reader, their correspondence to the composition of the molded samples is recorded, after which the trays are fed to a sample removing position in a step S140, in which the samples are taken out in a step S141, and inserted in a storage container having a bar code in a step S142. The bar code on the storage container is read in a step S143.
The samples are fed from the main molding unit 34 to a main sintering unit 35 as shown in FIG. 22.
More specifically, the trays transferred to the feed conveyor of the main molding unit 34 is fed to the main sintering unit 35. Then, the trays are transferred to forks in front of main sintering furnaces J, K, L, M, N, typically tubular furnaces, by an automatic loader in a step S144. The doors of these main sintering furnaces are automatically opened and closed, and the trays are introduced from the forks into the furnaces by an automatically loading and unloading device, placed in core tubes in the furnaces, and the samples are fully sintered in a step S145. Thereafter, the trays are removed from the furnaces by the automatic loading and unloading device, and then transferred to a conveyor leading to a next process by the automatic loader in a step S146. While the trays are being fed by the conveyor in a step S147, the bar codes on the trays are read.
A measurement preparing unit 36 will be described below with reference to FIG. 23.
The trays transferred to the feed conveyor of the main sintering unit 35 is fed to the measurement preparing unit 36. The trays are stopped in a predetermined position in a step S150. The samples are fed for measurement and preservation by the feed conveyor. Bar codes are printed or labeled on the trays storing those samples which are to be measured, read and recorded at a certain position. The samples to be preserved are taken out at a step S151, at which time alumina powder is removed from the samples and the larger and smaller trays are recovered in the same manner as with the process in the crushing unit shown in FIG. 19.
A second embodiment of the present invention will be described with reference to FIG. 24.
In the second embodiment, the processes in the preliminary molding unit 31, the preliminary sintering unit 32, and the crushing unit 33 are repeated, and then the processes in the main molding unit 34 and the main sintering unit 35 are carried out.
According to a third embodiment, the preliminary molding unit 31, the preliminary sintering unit 32, and the crushing unit 33 may be dispensed with (or bypassed), and the preliminary molding preparing unit may be directly incorporated as a molding preparing unit into the main molding unit 34.
Although certain preferred embodiments have been shown and described, it should be understood that many changes and modifications may be made therein without departing from the scope of the appended claims.
In block diagrams or flowcharts in the drawings for the present invention, portions in broken-line arrow may be operated manually with little loss in diminishing or covering up the disadvantages of the conventional method or apparatuses. | An apparatus for manufacturing a multielement sintered material is provided, more particularly an appartus of the automated type which weighs and mixes predetermined amounts of powdery elements, molds the mixed elements and then sinters them. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional application Serial No. 60/343,483, filed Dec. 21, 2001, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to the use of oilgomers and polymers capable of rendering insoluble drugs soluble, protecting unstable drugs, and facilitating the delivery of drugs to their site of action. This invention further relates to processes for the preparation of such oilgomers and polymers, and to compositions containing them.
BACKGOUND OF THE INVENTION
[0003] Medicinal and veterinary drugs are only effective if they are able to reach their site of action in the body of the human or animal. There are a number of situations in which drug molecules cannot reach their site of action, preventing many potential drug candidates from being utilized. These situations include those where the drugs (1) are poorly soluble in the relevant physiological fluids, such as blood serum or digestive fluids, (2) are unstable due to the action of enzymes, extremes of pH, or other physiological conditions, (3) are unable to cross various barriers, such as epithelial, mucosal, or membranous barriers, (4) stimulate an undesired immune response, and/or (5) are excreted from the bloodstream via the kidneys.
[0004] Some specific drug delivery problems for which there is no general solution include (1) the lack of oral bioavailability of hydrophobic drugs, (2) the inability of injectable drugs intended for treatment of diseases or conditions of the brain or nervous system to reach their site of action due to poor solubility or an inability to cross the blood-brain barrier, (3) the inability of hydrophilic drugs in general to cross mucosal and epithelial barriers, such as the intestinal mucosa, and (4) the inability of hydrophilic drugs to access targets inside of cells because of an inability to cross cellular membranes. In addition, the delivery of hydrophilic drugs such as proteins, peptides, nucleic acids, and other macromolecules is hampered by the degradation of these molecules in intestinal fluids or blood serum as well as renal clearance and immunogenicity.
[0005] A number of approaches have resolved some of these issues in specific cases, but there is yet no general solution to the problems of drug delivery. Some examples of existing approaches for solving these problems include (1) solublization of hydrophobic drugs in micelles formed from surfactants in aqueous media (Wiedmann and Kamel, J. Pharm. Sci. 2002, 91, 1743; MacGregor, et al., Adv. Drug Deliv. Rev. 1997, 25, 33), (2) encapsulation of drugs in polymeric matrices in the nanometer to micrometer size range which may be biodegradable and may contain bioadhesive functional groups or ligands (WO 02/15877, WO 02/49676), (3) encapsulation of hydrophilic drugs in liposomes (Anderson, et al., Pharm. Res. 2001, 18, 316; WO 99/33940), which may also display bioadhesive functional groups or ligands, (4) conjugation of drugs to molecules that are substrates for active transport systems (Kramer, et al., J. Biol. Chem. 1994, 269, 10621; WO 01/09163; US 2002/0098999), and (5) chemical derivatization of protein drugs with hydrophilic polymers to protect them from degradation, immune recognition, or renal excretion (Belcheva, et al., Bioconjugate Chem. 1999, 10, 932; Zalipsky, Bioconjugate Chem. 1995, 6, 150; U.S. Pat. No. 4,002,531; U.S. Pat. No. 4,179,337). None of these approaches, however, offers a general solution for all cases of drug delivery problems.
[0006] One deficiency of the micellar, liposomal, and polymeric nanoparticulate systems is the inability to tightly control the size of the complexes (particle size). There is substantial evidence that particles of specific size in the nanometer size range (5-100 nm) are especially capable of traversing epithelial, mucosal, and membranous barriers (Florence, et al., J. Control. Rel. 2000, 65, 253; Desai, et al., Pharm. Res. 1996, 13, 1838; WO 99/65467). A technology able to generate perfectly or nearly monodisperse populations of particles with the ability to control particle size at will has the potential to enhance uptake and tightly control the pharmacokinetics of the drugs being delivered. Technologies for generating liposomes of small size are especially lacking, as are methods to load these vesicles, such that most or all of the drug is contained within the interior aqueous compartment, rather than in the extraliposomal solution.
[0007] A second deficiency of current drug delivery strategies is the inability of existing systems to incorporate all of the functions required for delivery into a single system. For example, micelles have been used to solublize hydrophobic drugs, but have no means to target the drug to the intestinal mucosa and enhance permeation of the barrier. Nanoparticulate systems can protect proteins from the low pH and proteolytic enzymes of the stomach, but have not been designed to then protect these proteins in blood serum or lymph. These systems can also contain bioadhesive groups or ligands, but there is no way to regulate the presentation of these moieties to control the timing of adhesive and binding interactions or transmembrane or intracellular transport.
[0008] A third deficiency, which applies specifically to the stabilization of proteins by hydrophilic polymers, is that existing methods require covalent attachment of the polymers, such as poly(ethyleneglycol) (PEG) or oligosaccharides, at defined locations that do not interfere with binding. Current technology requires development of expression systems capable of post-translational attachment of oligosaccharides at these sites, random chemical derivatization with PEG, which can decrease activity, or laborious chemical synthesis of proteins to allow synthetic polymers to be attached to desired residues (WO 02/19963, WO 02/20033). In order to avoid attaching hydrophilic polymers at locations that interfere with the biological activity of a protein, detailed knowledge of the 3-dimensional structure of that protein, including its interaction with its binding partners, is required.
SUMMARY OF THE INVENTION
[0009] The present invention provides a surfactant comprising a hydrophobic element having a log P value greater than 0 covalently attached to a hydrophilic element, wherein the hydrophobic element has a molecular weight of between about 10-2000 daltons, and wherein the surfactant is capable of forming a micelle that encapsulates a hydrophobic drug. The micelle has a core comprising the hydrophobic drug, wherein the core is substantially free of the hydrophobic element.
[0010] The present invention further provides a micelle for encapsulating a hydrophobic drug comprising a plurality of surfactants of the present invention, wherein the micelle has a core comprising the hydrophobic drug, and wherein the core is substantially free of the hydrophobic element.
[0011] The present invention further provides a surfactant comprising a first hydrophilic element covalently attached to a first end of a hydrophobic element and a second hydrophilic element covalently attached to a second end of the hydrophobic element, wherein the first and second hydrophilic elements are different in size and/or shape, and wherein the surfactant is capable of forming a micelle that has a core comprising a hydrophilic drug.
[0012] The present invention further provides a micelle for encapsulating a hydrophilic drug comprising a plurality of surfactants of the present invention.
[0013] The present invention further provides oligomers, polymers, and/or mixtures thereof for the protection of a protein drug comprising at least one recognition element covalently attached to a hydrophilic clement, wherein the recognition element or elements interact noncovalently with the protein drug to form a complex in which the protein drug is protected from degradation, recognition by the immune system, and/or renal excretion.
[0014] The present invention further provides a complex comprising at least one oligomer or polymer and a protein drug, wherein the oligomer or polymer comprises at least one recognition element covalently attached to a hydrophilic element, wherein the recognition element or elements interact noncovalently with the protein drug to form a complex in which the protein drug is protected from degradation, recognition by the immune system, and/or renal excretion.
DESCRIPTION OF THE DRAWINGS
[0015] It is to be understood that the disclosed drawings are merely exemplary schematic representations of the invention that may be embodied in various forms. The figures are not necessarily drawn to scale, as some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0016] [0016]FIG. 1: Schematic drawing showing the self-assembly of a smart micelle comprising a hydrophobic drug for the delivery of that drug. The smart surfactant is depicted as a hydrophilic element covalently attached to a hydrophobic element. Combining the surfactant with a hydrophobic drug in an aqueous buffer and applying mechanical agitation causes the self-assembly of a smart micelle comprising the hydrophobic drug at its core, depicted here in a cross-sectional view. The hydrophobic elements of the surfactant molecules interact with the drug particle, while the hydrophilic elements are oriented to interact with the exterior aqueous environment, as well as with the hydrophilic elements of neighboring surfactant molecules in a lateral fashion.
[0017] [0017]FIG. 2: Schematic drawing depicting the unmasking of a binding element (BE) in a smart micelle. A smart micelle encapsulating a hydrophobic drug particle is exposed to conditions (such as a change in pH or exposure to enzymatic activity), which triggers controlled decomposition to reveal a binding element (BE) capable of binding to or interacting with a barrier to delivery. Once unmasked, the binding element causes the micelle to interact with, adhere to, or bind to a receptor, mucosal layer, epithelial barrier, or membrane, resulting in enhanced uptake across that barrier.
[0018] [0018]FIG. 3: Schematic drawing depicting the uncoating of a drug particle and the enhancement of its uptake across a barrier to delivery. Depicted is a hydrophobic drug particle encapsulated in a smart micelle. In response to a trigger (such as a change in pH or exposure to enzymatic activity), the outer hydrophilic element undergoes a controlled decomposition. The associated loss of lateral interactions among the hydrophilic elements causes the coating to become unstable, which results in the exposure of the hydrophobic drug particle and release of the smart surfactant as individual molecules. As depicted here, this process also results in the simultaneous conversion of the smart surfactant into a form in which it is capable of enhancing the permeation of the drug across a barrier to delivery, such as a mucosal surface, epithelial barrier, or a membrane.
[0019] [0019]FIG. 4: Schematic drawing showing the self-assembly of a polar-core smart micelle comprising a hydrophilic drug for the delivery of that drug. The smart surfactant is depicted as a hydrophilic element covalently attached to a hydrophobic element, which is covalently linked to a polar loading element (PLE). Combining the surfactant with a hydrophilic drug in an aqueous buffer and applying mechanical agitation causes the self-assembly of a polar-core smart micelle comprising the hydrophilic drug at its core, depicted here in a cross-sectional view. All or a substantial portion of the hydrophilic drug is encapsulated in the micelle, and little or none remains in the aqueous solution outside of the micelle due to the preferential interaction of the drug with the polar loading element. The hydrophobic elements of the surfactant molecules interact with each other in a lateral fashion, stabilizing the complex, as well as effectively sealing the polar core from the external aqueous environment. The particle is also stabilized by the lateral interactions among the hydrophilic elements of adjacent surfactant molecules. These hydrophilic elements are oriented such that they also interact with the exterior aqueous environment.
[0020] [0020]FIG. 5: Schematic representation of a hydrophilic copolymer for the stabilization of a protein drug. The upper drawing depicts a recognition element capable of binding noncovalently to the protein (RE1) linked covalently to a hydrophilic element. The lower drawing shows a hydrophilic element linked covalently at each end to different recognition elements (RE1 and RE2) each capable of binding noncovalently to a different site on the protein.
[0021] [0021]FIG. 6: Schematic drawing depicting a method for the discovery of ligands (A, B, C, etc.) that bind to a protein at sites other than its active site. Shown is a protein, which binds to a ligand via its active site. The ligand is covalently attached to a resin bead, and the protein is added so as to form a complex between the protein and the ligand on the surface of the resin bead. The complex is then exposed to a phage library L1 under conditions allowing the phage-displayed ligands to bind to the protein. Unbound phage are washed away, and then bound phage are released and eluted under suitable conditions, to generate phage library L2. Next, resin-bound protein, in the absence of bound ligand, is exposed to phage library L2 under conditions allowing ligands displayed on the phage to bind to the protein. Unbound phage are washed away, and bound phage are released and eluted under suitable conditions to generate phage library L3. From inspection of similarities and differences among the sequences of ligands recovered in library L3, ligands A, B, C, etc. that bind to mutually distinct sites on the protein are chosen.
[0022] [0022]FIG. 7A: Schematic drawing depicting a method for the discovery of a ligand (ligand A) that binds to a protein at a site other than its active site. Shown is a protein, which binds to a ligand via its active site. The ligand is covalently attached to a resin bead, and the protein is added so as to form a complex between the protein and the ligand on the surface of the resin bead. The complex is then exposed-to a phage library L4 under conditions allowing the phage-displayed ligands to bind to the protein. Unbound phage are washed away, and then bound phage are released and eluted under suitable conditions, to generate phage library L5. Next, resin-bound protein, in the absence of bound ligand, is exposed to phage library L5 under conditions allowing ligands displayed on the phage to bind to the protein. Unbound phage are washed away, and bound phage are released and eluted under suitable conditions to generate phage library L6. A single sequence, designated “ligand A,” is chosen from the sequences of ligands recovered in library L6.
[0023] [0023]FIG. 7B: Schematic drawing depicting a method for the discovery of a second and third ligand (ligands B and C, respectively), that have mutually distinct binding sites, and do not bind to the active site. First, a complex is formed between the protein and its active-site ligand, which is covalently attached to a resin bead. Ligand A (derived as in FIG. 7A) is added under conditions which allow it to bind to the protein, but which do not disrupt the binding of the active-site ligand to the protein, and unbound ligand A is washed away. The complex thus formed is exposed to phage library L6 under conditions that allow phage-displayed ligands to bind to the protein. Unbound phage are washed away, and bound phage are then released and eluted under suitable conditions to generate phage library L7. A single sequence, designated “ligand B,” is chosen from library L7. To discover a third ligand, ligands A and B are added to a complex already formed between the protein and its resin-bound active-site ligand, under conditions that allow ligands A and B to bind to the protein. Unbound ligands A and B are washed away, and the complex so formed is then exposed to phage library L7, under conditions that allow phage-displayed ligands to bind to the protein. Unbound phage are washed away, and bound phage are then released and eluted under suitable conditions to generate phage library L8. A single sequence, designated “ligand C,” is chosen from library L8.
[0024] [0024]FIG. 8A: Schematic drawing depicting the discovery of a ligand (ligand X), that binds to a protein at a site other than the active site, in the case where the protein contains two active sites. First, the ligand for active site 1 (ligand 1) is attached covalently to a resin bead. Next, the protein is allowed to bind to the resin-bound ligand 1 under suitable conditions, and excess protein is washed away. Then an excess of ligand 2 (which is the same or different from ligand 1, but binds to active site 2, and has similar or lesser affinity for active site 2 than ligand 1 has for active site 1), is added to the complex, under conditions which allow ligand 2 to bind to active site 2, without disrupting the interaction of ligand 1 with active site 1. Unbound ligand 2 is then washed away, and the resulting complex is exposed to phage library L9 under conditions that allow phage-displayed ligands to bind to the protein. Unbound phage are washed away, and the bound phage are released and eluted under suitable conditions, to generate phage library L10.
[0025] [0025]FIG. 8B: Schematic drawing depicting the discovery of a ligand (ligand X), that binds to a protein at a site other than the active site, in the case when the protein contains two active sites. The protein from FIG. 8A, without active site ligands bound, is covalently attached to a resin bead, and then exposed to phage library L10 under conditions that allow phage-displayed ligands to bind to the protein. Unbound phage are washed away, and the bound phage are released and eluted under suitable conditions to generate phage library L11. A single sequence, designated “ligand X,” is chosen from library L11.
[0026] [0026]FIG. 9A: Schematic drawing depicting a method for protecting a protein with a hydrophilic copolymer comprising a hydrophilic element covalently linked to a recognition element. Two different such copolymers, one which comprises ligand A as the recognition element covalently linked to a hydrophilic element, and the other comprising ligand B as the recognition element covalently linked to a hydrophilic element, are added to the protein under conditions which permit the noncovalent interaction of the ligands A and B with their binding sites on the protein. A stoichiometric amount or a slight excess of the copolymers is added. The ligands A and B in these copolymers bind to the protein at mutually distinct sites that are also not the active site of the protein, forming a complex. The protein is thereby protected from degradation by enzymes, recognition by the immune system, or renal excretion, while remaining able to bind its active-site ligand.
[0027] [0027]FIG. 9B: Schematic drawing depicting a method for protecting a protein with a hydrophilic copolymer comprising a hydrophilic element covalently linked to two different recognition elements. One copolymer is synthesized, comprising a hydrophilic element covalently linked at one end to ligand A, and covalently linked at the other end to ligand B, where ligands A and B function as recognition elements that bind to mutually distinct sites on the protein that are also not the active site. The copolymer is added to the protein under conditions that permit the noncovalent interaction of the ligands A and B with their binding sites on the protein. A stoichiometric amount or a slight excess of the copolymer is added. A complex is formed between the copolymer and the protein in which the hydrophilic element of the copolymer forms a looping structure, thereby protecting the protein from degradation by enzymes, recognition by the immune system, or renal excretion, while remaining able to bind its active-site ligand.
ABBREVIATIONS AND DEFINITIONS
[0028] ADA: adenosine deaminase. BBB: blood brain barrier. BE: binding element. TE: transport element. CNS: central nervous system. DBU: 1,8diazabicyclo[5.4.0]undec-7-ene. DIEA: N,N-diisopropylethylamine. DMF: N,N-dimethylformamide. EPO: erythropoietin. Fmoc: N-(9-fluorenylmethoxycarbonyl). HBTU: O-benzotriazol-1-yl-N,N,N′,N′-tetramethyluronium hexafluorophosphate. HCV: hepatitis C virus. HPLC: high pressure liquid chromatography. NLS: nuclear localization sequence. PBS: phosphate-buffered saline. PEG: poly(ethyleneglycol). PLE: polar loading element. PVP: poly(vinylpyrrolidone). RNA: ribonucleic acid. TFA: trifluoroacetic acid.
[0029] The term “drug” means a biologically-active molecule.
[0030] The term “hydrophobic,” as it refers to the hydrophobic element of surfactants for forming hydrophobic-core micelles that encapsulate hydrophobic drugs, means preferably having a log P value of greater than 0. Log P values measure the partitioning of a molecule between an octanol-rich and a water-rich layer in contact with one another (see CRC Handbook of Chemistry and Physics, 79 th edition, Lide, ed., pp. 16-42-16-46, CRC Press, 1998; and references within, all of which are incorporated herein by reference). Log P values are measured at a nominal temperature of 25 C. More preferably, hydrophobic means having a log P value greater than about 0.5, even more preferably a log P value greater than about 1, even more preferably a log P value greater than about 1.5, and most preferably a log P value greater than about 2. In this regard, poly(ε-caprolactones), such as those disclosed in U.S. Pat. No. 6,322,805, are not within the scope of the hydrophobic element as it pertains to surfactants for forming hydrophobic-core micelles. Using a table of log P values such as that found in the above-mentioned reference to estimate the log P value of poly(ε-caprolactone), a value of about 1.8 is obtained, 1.82 being the log P value for butyl acetate, which can be viewed as being similar to the repeat unit of poly(ε-caprolactone) in terms of its relative aliphatic content and the presence of the ester functional group. As this is only an estimate based on the perceived similarities between butyl acetate and poly(ε-caprolactone), it is contemplated that the actual log P value of poly(ε-caprolactone) may vary somewhat from the value of 1.8. Using a similar analysis, poly(lactic acid), also claimed in U.S. Pat. No. 6,322,805 for use as a hydrophobic element, has a log P value of approximately 0.2, using the log P of methyl acetate (log P=0.18) as a gauge.
[0031] The phrase “substantially free of the hydrophobic element,” as it refers to the core of a micelle encapsulating a hydrophobic drug means preferably less than about 50% hydrophobic element, more preferably less than about 30% hydrophobic element, even more preferably less than about 10% hydrophobic element, even more preferably less than about 5% hydrophobic element, even more preferably less than about 3% hydrophobic element, and most preferably less than about 1% hydrophobic element by weight, in which such comparisons are being made to the total mass of the hydrophobic core, which comprises the hydrophobic drug, the hydrophobic element, and any other hydrophobic molecules or moieties present, such as, but not limited to enzyme inhibitors and permeation enhancers.
[0032] The phrase “large volume,” as it refers to the drug content of a micelle encapsulating a hydrophobic drug, is a relative term that depends upon the size of the micelle, as well as assumptions about the thickness of the hydrophilic layer of such micelles, and the relative lack of hydrophobic element in the core. It is assumed that a hydrophilic layer as thin as 5 nm will be sufficient to form a stable micelle, given that the shape of the surfactant is sufficiently optimal to allow the hydrophilic elements of adjacent surfactant molecules to interact strongly with each other. Based on this assumption, when calculating the drug volume as a percent of the total volume defined by the outer hydrodynamic diameter of the micelle, a 15 nm diameter micelle will contain at least about 3% drug, a 20 nm diameter micelle will contain at least about 10% drug, a 30 nm diameter micelle will contain at least about 25% drug, a 40 nm diameter micelle will contain at least about 35% drug, a 60 nm diameter micelle will contain at least about 50% drug, an 80 nm diameter micelle will contain at least about 60% drug, and a 100 nm diameter micelle will contain at least about 65% drug. It should be noted that these numbers are not directly comparable to those calculated on a weight basis for a number of reasons. First, as is noted above, the drug loading of a micelle depends upon its size. Second, such percentages may not be based on the total weight or mass of the micelle, but rather the weight or mass of the surfactant alone. Finally, the density of the hydrophobic core may vary considerably depending on how tightly the core is packed, and the density of the hydrophilic layer may also vary depending on how optimal the interactions are among the hydrophilic elements of adjacent surfactants (which will affect the access of the bulk exterior solvent to this layer). The density of the core and the hydrophilic layer may also be significantly different from each other. It is therefore not straightforward to convert percentages based upon volume to those based upon weight or mass.
[0033] The term “analog” means a molecule with a structure closely related to that of the parent compound, including homologs, geometric and stereochemical isomers, precursors, derivatives, etc.
[0034] The phrase “narrow distribution,” as it refers to chain lengths means such a distribution for which the standard deviation about the mean chain length is about ±20%.
[0035] The phrase “binding element” refers to a moiety or molecule that is capable of interacting with a receptor or a mucosal, epithelial, or membranous barrier or layer. A binding element can be a simple functional group such as for example a cationic group or a thiol, known as “bioadhesive functional groups,” which are known to interact with mucosal layers. A binding element can also be a ligand capable of binding to a protein receptor. Many examples of these are known in the art. All such binding elements known in the art are considered equally useful for the purposes of the current invention. Further, it is contemplated that new binding elements will be conceived, invented, or discovered in the future, and that these new binding elements will be equally useful for the purposes of the current invention.
[0036] The phrase “transport element” refers to a moiety or molecule that is capable of carrying an attached cargo into or through a membranous barrier or a portal in a membranous barrier. The membranous barrier can be any membranous barrier, such as a cellular membrane or intracellular membrane. Many examples of these are known in the art, and include membrane-traversing molecules such as peptides or unnatural stepwise oligomers bearing cationic (especially guanidinium) groups, and also include peptidic nuclear localization sequences that are capable of entering a cellular nucleus through nuclear membranes, especially via pores in the nuclear membranes. All such transport elements known in the art are considered equally useful for the purposes of the current invention. Further, it is contemplated that new transport elements will be conceived, invented, or discovered in the future, and that these new transport elements will be equally useful for the purposes of the current invention.
[0037] The concepts of size and shape as used in the current invention can be thought of in either geometrical or hydrodynamic terms. The term geometrical in this context refers to those sizes and shapes that are generated by a chemical moiety due to its covalent and 3-dimensional structure, wherein that structure is in an energetically-preferred conformation, but is assumed to be static. The term hydrodynamic in this context refers to those sizes and shapes that are the result of movement of a chemical moiety in solution on a given timescale, such that other molecules or chemical moieties are prevented from occupying the same space on a similar timescale. The term hydrodynamic thus includes the concept of the generation of an excluded volume due to the motions of a chemical moiety. The concept of size can also be thought of in terms of the molecular weight of a molecule or chemical moiety.
[0038] The phrase “cone-like” refers to shapes generated by surfactant molecules or portions of surfactant molecules used to generate micelles, in which, as the surfactant is traversed longitudinally from the end closest to the core of the micelle to the end furthest from the core of the micelle, the radial dimensions of the surfactant increase, defined in terms of molecular weight, or in geometrical or hydrodynamic terms.
[0039] The phrase “permeation-enhancing molecule” means any molecule capable of increasing the ability of a drug to cross a barrier to delivery. Examples of such barriers include membranous, mucosal, or epithelial barriers. Permeation-enhancing molecules may achieve these results by any mechanism, examples of such mechanisms being increasing the porosity of membrane bilayers, lowering the energy barriers for crossing a membrane, and opening of tight junctions between the cells that form the barrier. Many such permeation-enhancing molecules are known in the art, and some examples include EDTA, sodium lauryl sulfate, sodium caprate, saponins, bile salts, sugar esters such as n-lauryl-β-D-maltopyranoside and sucrose palmitate, polycationic materials, and mannitol. All such permeation-enhancing molecules known in the art are considered equally useful for the purposes of the current invention. Further, it is contemplated that new permeation-enhancing molecules will be conceived, invented, or discovered in the future, and that these new permeation-enhancing molecules will be equally useful for the purposes of the current invention.
[0040] The term “undesirable,” as it refers to enzymatic activities, means enzymatic activities such as those of P-glycoprotein, cytochrome P450 3A, nucleases, proteases, esterases, and other enzymes, that result in alteration of the chemical or 3-dimensional structure of the drug or that prevent the drug from reaching its site of action, such that the drug does not have or loses its intended biological activity.
[0041] The phrase “self-assembly” refers to a process by which molecules are capable of arranging themselves with respect to each other in a particular way to form a complex without additional outside intervention. If additional outside intervention is required in particular cases, it will generally require only an input of energy via mechanical agitation, and potentially dissolution of a molecule in a solvent so as to aid its dispersion in an aqueous medium.
[0042] The phrase “unnatural stepwise oligomers” refer to those oligomers that can be synthesized by the addition of a single monomer or submonomer at a time, such that oligomers of a single length and chemical composition may be generated. These oligomers also have a structure that does not occur in nature, hence the term unnatural. Many examples of such unnatural stepwise oligomers are known in the art, and include examples such as peptoids, oligocarbamates, and oligoureas. Many others are known in the art, and are contemplated to be equally as useful as those specifically mentioned for the purposes of the current invention. It is also contemplated that new types of unnatural stepwise oligomers will be conceived of and invented in the future, and that these new unnatural stepwise oligomers will also be equally useful for the purposes of the current invention.
[0043] The phrase “traceless linker” refers to a covalent linkage connecting two chemical moieties that can be cleaved under some set of conditions, especially physiological conditions, such that all remnants of the linker are removed from either or both chemical moieties, and that these moieties are released in their free, unmodified form. Many examples of such traceless linkers are known in the art. All such traceless linkers known in the art are considered equally useful for the purposes of the current invention. Further, it is contemplated that new traceless linkers will be conceived, invented, or discovered in the future, and that these new traceless linkers will be equally useful for the purposes of the current invention.
[0044] The term “prodrug” refers to the form of a chemical moiety in which a protective chemical group or a linker is attached covalently to that moiety, and which is cleaved under some set of physiological conditions to release the moiety in its free, unmodified form. Many examples of such prodrugs are known in the art. All such prodrugs known in the art are considered equally useful for the purposes of the current invention. Further, it is contemplated that new prodrugs will be conceived, invented, or discovered in the future, and that these new prodrugs will be equally useful for the purposes of the current invention.
[0045] The phrase “reactive chemical group” refers to those functional groups or chemical moieties capable of reacting with a functional group in a protein. Many examples of such reactive chemical groups are known in the art for the purposes of conjugating molecules to proteins (Lemieux and Bertozzi, Trends Biotechnol. 1998, 16, 506; Hermanson, Bioconjugate Techniques, Academic Press, 1996; Means and Feeney, Chemical Modification of Proteins, Holden-Day, 1971; Pierce Chemical Company catalog, 2001-2002, pp. 294-362; and references within, all of which are incorporated herein by reference), and include active esters, activated disulfides, maleimides, photoreactive groups, etc. These reactive chemical groups can react with functional groups found in proteins such as amino, hydroxyl, and thiol groups, as well as others. The phrase “reactive linker” refers to covalent linkers containing reactive chemical groups.
[0046] The present invention provides basic technologies that can be used to solve general drug delivery problems. For instance, “smart” surfactants can be used to improve the delivery of hydrophobic (non-polar) and hydrophilic (polar) drugs. The term “smart” refers to specific features that give the surfactants novel properties, which will enable them to compensate for the deficiencies of current drug delivery methods.
DETAILED DESCRIPTION OF THE INVENTION
[0047] In one embodiment, the present invention provides a smart surfactant wherein the smart feature is a high degree of control over the particle size of micelles formed from the surfactants. This control results from exact specification of the size and shape of the surfactants through the use of stepwise solid- and solution-phase synthetic methods or chemical conjugation techniques to generate surfactants comprised of a single chemical entity or a tightly controlled distribution of chain lengths.
[0048] Combinatorial and parallel synthetic methods, combined with high throughput screening can be used to identify surfactants with desirable properties. Such methods are well known to those skilled in the art. For example, in Fmoc Solid Phase Peptide Synthesis, Chan and White, ed.s, Oxford University Press, 2000; and Bodanszky and Bodanszky, The Practice of peptide Synthesis, Springer-Verlag, 1984; methods for the synthesis of peptides are described. Methods for the synthesis of oligosaccharides by stepwise synthetic approaches, as well as enzymatic methods have been developed recently (Seeberger and Haase, Chem. Rev. 2000, 100, 4349; Fukase, in Glycoscience Fraser-Reid, et al., ed.s, 2001, 2, 1621-1660; Flitsch, Curr. Opin. Chem. Biol. 2000, 4, 619; Zhang, et al., J. Am. Chem. Soc. 1999, 121, 734). Stepwise solid-phase chemical syntheses of unnatural oligomers such as peptoids, oligocarbamates, and oligoureas are also known. See Barron and Zuckermann, Curr. Opin. Chem. Biol. 1999, 3, 681; Soth and Nowick, Curr. Opin. Chem. Biol. 1997, 1, 120; Guichard, in Solid - Phase Synthesis, Kates and Albericio, ed.s, Marcel Dekker, 2000, 649-703, all of which are incorporated herein by reference. Combinatorial methods are well known in the art (Bunin, The Combinatorial Index, Academic Press, 1998), as are methods for chemical conjugation (Lemieux and Bertozzi, Trends Biotechnol. 1998, 16, 506; Hermanson, Bioconjugate Techniques, Academic Press, 1996).
[0049] In another embodiment, the present invention provides a smart surfactant wherein the smart feature is the inclusion of linkages within the hydrophilic portions of the surfactants which break down under specific conditions, such as a change in pH, the presence of enzymatic activity, or the presence of reducing conditions. In this embodiment, triggering mechanisms can be used to unmask a binding element, a transport element, and/or a linker hidden within the hydrophilic portion of the surfactants, allowing for targeting and adhesion to, or transport through or within, mucosal, epithelial, or membranous barriers to increase permeation (Hussain, Adv. Drug Deliv. Rev. 2000, 43, 95; Kast and Bernkop-Schnürch, Biomaterials 2001, 22, 2345, both of which are incorporated herein by reference). Alternatively, or in addition, the decomposition of the hydrophilic portion of the surfactant can be designed to destabilize the micellar coating, causing the drug cargo to be released or exposed and thus more available for absorption. The decomposition of the surfactant can also be designed to generate an agent that possesses permeation-enhancing properties that increase the ability of the drug cargo to cross a mucosal, epithelial, or membranous barrier.
[0050] The smart surfactants of the present invention are “self-emulsifying,” which involves a process of mixing the drug and surfactant in an aqueous buffer, and applying gentle mechanical agitation to form the micelles by a self-assembly process (Craig, et al., Drugs Pharm. Sci. 2000, 105, 323). Alternatively, an insoluble hydrophobic drug can first be dissolved in a volatile solvent system or FDA-approved oils before dispersion in the smart-surfactant-laden aqueous phase. The smart surfactants and their physiological breakdown products will also comprise chemical entities that are non-toxic, non-immunogenic, and readily excretable.
[0051] In a particular embodiment, the present invention provides smart surfactants, which encapsulate and deliver hydrophilic drugs, that also contain a “polar loading element” (PLE), which enables these surfactants to incorporate all or nearly all of the hydrophilic drug into the core of the micelle, with little or none remaining in the extramicellar aqueous solution.
[0052] Additional specific features of the smart surfactants are described in detail below.
[0053] In another embodiment, the present invention provides a method of protecting protein drugs from degradation, renal excretion, and immune recognition using oligomers, polymers, and mixtures thereof, but without requiring chemical modification of the protein, and without interfering with the biological activity of the protein. This embodiment relies upon the discovery of ligands that bind noncovalently to the protein but not to the active site of the protein. Methods are provided for the discovery of these ligands and their use in protecting a protein via conjugation to oligomers, polymers, and mixtures thereof. The lack of covalent modification of the protein simplifies the synthesis and formulation processes used to generate the protected protein. Both the protein and oligomers, polymers, and mixtures thereof can be rigorously purified prior to the formulation process, and no subsequent purification is required once the complex has been formed.
Smart Surfactants for the Encapsulation and Delivery of Hydrophobic Drugs
[0054] The basic structure of the smart surfactants for the encapsulation and delivery of hydrophobic drugs is shown schematically in FIG. 1. A hydrophobic element is covalently attached to a hydrophilic element. The covalent attachment is noncleavable or cleavable under physiological conditions. The hydrophobic element interacts with the hydrophobic drug, without significantly interpenetrating the hydrophobic drug particle at the core of the micelle, such that the hydrophobic drug nanoparticle is predominantly pure drug and substantially free of the hydrophobic element. This is a novel feature of the micelles formed with these surfactants, and differs from those formed from amphiphilic diblock or triblock copolymers in the prior art, in which the hydrophobic core is traversed and/or deeply penetrated by hydrophobic polymer chains, thereby greatly reducing the amount of drug that can be loaded into the core (Yamamoto, et al., J. Control. Rel. 2001, 77, 27; Lavasanifar, et al., Adv. Drug Deliv. Rev. 2002, 54, 169; Kwon, et al., J. Control. Rel. 1994, 29, 17; U.S. Pat. No. 6,322,805). The smart surfactant and its physiological breakdown products are non-toxic, non-immunogenic, and readily excretable.
[0055] The desired effect of a hydrophobic drug core of substantially pure drug, and therefore a high loading capacity, is achieved in the current invention by use of a small hydrophobic element, rather than a long polymer chain. In the current invention, the hydrophobic element is a small molecule, an oligomer, or a polymer. Preferably, the oligomer or polymer has a single chain length or a narrow distribution of chain lengths. Suitable oligomers or polymers include peptides having hydrophobic side chains and unnatural stepwise oligomers having hydrophobic side chains such as peptoids, oligocarbamates, oligoureas, and mixtures thereof. When the oligomer or polymer is a peptide, it is preferably a short peptide comprising less than about 20 amino acids, more preferably between about 2-20 amino acids, more preferably between about 2-15 amino acids, more preferably between about 2-10 amino acids, and most preferably between about 2-5 amino acids. Suitable small molecules include the hydrophobic drug itself or an analog thereof, cholesterol, cholesterol derivatives, bile acids, bile acid derivatives, steroidal sapogenins, triterpenoid sapogenins, steroidal sapogenin derivatives, triterpenoid sapogenin derivatives, steroid derivatives, amino acids including aromatic amino acids, and mixtures thereof.
[0056] The hydrophilic element is intended to orient itself toward the bulk aqueous solution upon formation of the micelle, and additionally may interact in a lateral fashion with the hydrophilic elements of different, but adjacent surfactant molecules (e.g. via hydrogen bonding or charge/charge interactions). This lateral interaction may be strong enough to stabilize the micellar structure. This additional stabilization allows the use of a relatively small hydrophobic element, as discussed above, with only a modest affinity for the hydrophobic drug core.
[0057] The hydrophilic element is an oligomer or polymer. Preferably the oligomer or polymer has a single chain length or a narrow distribution of chain lengths. Also preferably the oligomer or polymer has a linear, branched, or cyclic structure, and/or includes side chains of gradually increasing size to generate a cone-like shape. Suitable oligomers or polymers include oligosaccharides, polysaccharides, peptides, unnatural stepwise oligomers, and mixtures thereof. More specifically, suitable oligomers or polymers may include poly(ethyleneglycol) (PEG), poly(propyleneglycol), poly(vinylpyrrolidone) (PVP), poly(hydroxyethylmethacrylate), poly(ε-caprolactone), poly(lactic acid), poly(glycolic acid), peptoids, oligocarbamates, oligoureas, and mixtures thereof. The peptides and unnatural stepwise oligomers may bear hydrophilic side chains such as PEG oligomers, PVP oligomers, monosaccharides, oligosaccharides, and cyclodextrins or those side chains comprising polar functional groups such as —OR (wherein R is hydrogen or an alkyl or aromatic group), —CONRR′ (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NRR′ (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NR(CNR′(NR″R′″)) (wherein R, R′, R″, and R′″ are independently hydrogen or an alkyl or aromatic group), —COOR (wherein R is a hydrogen or an alkyl or aromatic group), —SO 3 R (wherein R is a hydrogen or an alkyl or aromatic group), —P(O)(OR)(OR′) (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NRR′R″(+) (wherein R, R′, and R″ are all alkyl or aromatic groups), and mixtures thereof.
[0058] The hydrophilic element may further comprise labile linkages that are capable of being cleaved under specific physiological conditions including, for example, pH, presence of enzymatic activity, oxidizing or reducing conditions, presence of nucleophiles, etc. Suitable linkers comprise functional groups such as amides, carbamates, thiocarbamates, oxygen esters, thioesters, glycolate esters, lactate esters, orthoesters, acetals, ketals, phosphodiesters, disulfides, and mixtures thereof. The linker as depicted in FIG. 1 can be any covalent linkage, and can be stable or cleavable under physiological conditions. In a particular embodiment, the linkers are capable of generating a permeation-enhancing molecule as further described below. In another particular embodiment, the linkers are capable of unmasking an element selected from the group consisting of binding elements and transport elements as further described below.
[0059] The hydrophilic element itself may further comprise binding elements and/or transport elements. Suitable binding elements include elements selected from the group consisting of ligands, bioadhesive functional groups, and mixtures thereof. Suitable transport elements include elements selected from the group consisting of nuclear localization sequences, membrane-traversing molecules, and mixtures thereof.
[0060] The hydrophobic element of the surfactant interacts preferentially with the hydrophobic drug particle. The micelle thus formed has a hydrodynamic diameter in the range of from about 1-100 nm, and preferably about 5-80 nm. The hydrophilic element is oriented to interact with the external aqueous environment, but may also interact significantly in a lateral fashion with the hydrophilic elements of adjacent surfactant molecules, such that the micellar structure is stabilized.
[0061] The smart surfactant will be used to form a micelle containing the hydrophobic drug at its core via a self-assembly process, shown schematically in FIG. 1. The micelle therefore comprises a plurality of surfactants for encapsulating a hydrophobic drug, wherein the micelle has a core comprising the hydrophobic drug, wherein the core is substantially free of the hydrophobic element. In a preferred embodiment, the micelle comprises a large volume of the hydrophobic drug. As mentioned above, the micelles can be formed by a self-assembly process, which comprises the steps of combining a smart surfactant with a hydrophobic drug in an aqueous buffer and gently agitating to form micelles in which the hydrophobic drug is sequestered at the core of the micelle. The system is thus of the self-emulsifying type. Alternatively, micelles are formed by a method comprising dissolving the hydrophobic drug in a volatile solvent or FDA-approved oil to facilitate the dissolution of the drug and adding the dissolved drug to an aqueous solution comprising the surfactant.
[0062] The functions of particular smart features of these surfactants and corresponding micelles are depicted in FIGS. 2 and 3. FIG. 2 shows the unmasking of a binding element, which includes, for example, ligands, bioadhesive functional groups, and mixtures thereof. The binding element is initially masked by its incorporation into the chemical structure of the hydrophilic element as a monomer, a linking group, or a chemically-protected functional group. In addition to the binding element, a transport element such as nuclear localization sequences, membrane-traversing molecules, and mixtures thereof, can be incorporated into the chemical structure of the hydrophilic element as a monomer, a linking group, or a chemically-protected functional group. Cleavage of a chemical linkage or group within the hydrophilic element (or the linkage between the hydrophilic and hydrophobic elements) in response to a triggering condition (such as a change in pH, the presence of enzymatic activity, or a change in the reduction potential of the environment) unmasks the binding element or transport element, allowing it to interact with a receptor or a mucosal, epithelial, or membranous barrier. Such an interaction increases the ability of the micelle, or the hydrophobic drug contained within, to permeate the barrier, by, for example, increasing the residence time on the barrier surface, inducing a receptor-mediated transcytosis or endocytosis processes, or penetrating a cellular or nuclear membrane. The binding element or transport element may alternatively not be initially masked, such that no triggering event is required to unmask it.
[0063] [0063]FIG. 3 depicts the uncoating process of a smart micelle, and subsequent permeation of a mucosal, epithelial, or membranous barrier by the drug. Depicted in cross-sectional view is a smart micelle containing a hydrophobic drug particle. In response to a triggering condition (such as a change in pH, the presence of enzymatic activity, or a change in the reduction potential of the environment), the hydrophilic element partially or completely degrades in a controlled fashion due to the cleavage of an incorporated labile linkage. The size of the hydrophilic element is decreased, as are the stabilizing interactions occurring laterally among the hydrophilic elements of adjacent surfactant molecules. As the stability of the micellar coating decreases, the surfactant molecules disassociate themselves from the hydrophobic drug particle and each other partially or completely, enabling the drug particle to permeate a mucosal, epithelial, or membranous barrier. Thus, the linkers are capable of destabilizing the micelle, whereby a plurality of the surfactants are shed from the core and the hydrophobic drug is exposed to an external environment.
[0064] The surfactant molecule of a smart micelle in which the hydrophilic element is partially or completely degraded in this process may also possess the property of enhancing the permeation of the drug into or through the barrier. In one particular embodiment, the hydrophilic element further comprises linkers that are capable of generating a permeation-enhancing molecule. In another particular embodiment, the surfactant itself is a permeation-enhancing molecule. Examples of molecules that enhance permeation are EDTA, sodium lauryl sulfate, sodium caprate, saponins, bile salts, and sugar esters such as n-lauryl-β-D-maltopyranoside and sucrose palmitate (Uchiyama, et al., J. Pharm. Pharmacol. 1999, 51, 1241; Fricker, et al., Brit. J. Pharmacol. 1996, 117, 217; Nakada, et al., J. Pharmacobio - Dyn. 1988, 11, 395; U.S. Pat. No. 5,650,398, all of which are incorporated herein by reference). Hydrophilic polymeric materials bearing multiple positively-charged functional groups are known to increase the permeability of epithelial and mucosal barriers by the paracellular route (Dodane, et al., Int. J. Pharm. 1999, 182, 21; Kotzé, et al., Pharm. Res. 1997, 14, 1197, both of which are incorporated herein by reference). Mannitol is known to increase the permeability of the blood brain barrier (Koenig, et al., J. Neurochem. 1989, 52, 1135; Koenig, et al., Brain Res. 1989, 483, 110, both of which are incorporated herein by reference). Oligomeric transporters containing positively charged functional groups, especially guanidinium groups, are known to traverse cellular membranes, carrying an attached cargo into the cellular cytoplasm, into the nucleus, or across epithelial layers (Futaki, et al., J. Biol. Chem. 2001, 276, 5836; U.S. Pat. No. 5,807,746; U.S. Pat. No. 5,804,604; Mitchell, et al., J. Peptide Res. 2000, 56, 318; Wender, et al., Proc. Natl. Acad. Sci. USA 2000, 97, 13003; Wender, et al., J. Am. Chem. Soc. 2002, 124, 13382; WO 01/62297; WO 02/069930, all of which are incorporated herein by reference).
[0065] The uncoating and permeation process shown in FIG. 3 can also occur contemporaneously with the unmasking of a binding element or a transport element (and its subsequent interaction with its target). The micelle can further comprise inhibitors of undesirable enzymatic activities, such as those of P-glycoprotein, cytochrome P450 3A, and proteases, esterases, or nucleases. Additionally, the micelles may further comprise a permeation-enhancing molecule, different from the surfactant.
Smart Surfactants for the Encapsulation and Delivery of Hydrophilic Drugs
[0066] The basic structure of the smart surfactant for the delivery of hydrophilic drugs is depicted schematically in FIG. 4. A second hydrophilic element is covalently attached to a hydrophobic element, which is covalently attached to a first hydrophilic element termed the “polar loading element” (PLE), wherein the first and second hydrophilic elements are different in size and/or shape, and wherein the surfactant is capable of forming a micelle that has a core comprising a hydrophilic drug. The covalent attachments are noncleavable or cleavable under physiological conditions. The smart surfactant and its physiological breakdown products, are non-toxic, non-immunogenic, and readily excretable.
[0067] The desired effect of the PLE is that it is capable of interacting with a hydrophilic drug such that the hydrophilic drug is sequestered in the core. In general, the PLE comprises a chemical structure or functional group that is capable of interacting favorably with the hydrophilic drug, such as a positive or negative charge, a hydrogen-bonding functionality, a ligand that binds noncovalently to the drug, a traceless linker, or a prodrug. In a preferred embodiment, the PLE further comprises a functional group or ligand that is capable of noncovalently binding to the hydrophilic drug. In another preferred embodiment, the PLE further comprises a traceless linker or a prodrug that is capable of being cleaved under physiological conditions, wherein the traceless linker or the prodrug is capable of covalently linking the PLE to the hydrophilic drug. For examples of suitable traceless linkers and prodrugs see Gharat, et al., Int. J. Pharm. 2001, 219, 1; Zalipsky, et al., Bioconjugate Chem. 1999, 10, 703; Matsumoto, et al., Bioorg. Med. Chem. Lett. 2001, 11, 605; Zhu, et al., J. Am. Chem. Soc. 2000, 122, 2645; Norbeck, et al., J. Med. Chem. 1989, 32, 625; Senter, et al., J. Org. Chem. 1990, 55, 2975; WO 01/47562, all of which are incorporated herein by reference.
[0068] The hydrophobic element in the micellar structure plays the role of stabilizing the structure by interacting noncovalently with the hydrophobic elements of adjacent surfactant molecules. These interactions also serve to effectively seal the core of the micelle, protecting the drug from conditions in the external medium. In the current embodiment, the hydrophobic element is a small molecule, an oligomer, or a polymer. Preferably, the oligomer or polymer has a single chain length or a narrow distribution of chain lengths. Suitable oligomers or polymers include peptides having hydrophobic side chains and unnatural stepwise oligomers having hydrophobic side chains such as peptoids, oligocarbamates, oligoureas, and mixtures thereof. Suitable small molecules include cholesterol, cholesterol derivatives, bile acids, bile acid derivatives, steroidal sapogenins, triterpenoid sapogenins, steroidal sapogenin derivatives, triterpenoid sapogenin derivatives, steroid derivatives, amino acids, and mixtures thereof.
[0069] The second hydrophilic element in the surfactants used to form polar-core micelles may have the same compositions, functions, and smart features as the hydrophilic element described above for the surfactants used to form smart micelles for the encapsulation and delivery of hydrophobic drugs. As such, the second hydrophilic element is an oligomer or polymer. Preferably the oligomer or polymer has a single chain length or a narrow distribution of chain lengths. Also preferably the oligomer or polymer has a linear, branched, or cyclic structure, and/or includes side chains of gradually increasing size to generate a cone-like shape. Suitable oligomers or polymers include oligosaccharides, polysaccharides, peptides, unnatural stepwise oligomers, and mixtures thereof. More specifically, suitable oligomers or polymers may include poly(ethyleneglycol) (PEG), poly(propyleneglycol), poly(vinylpyrrolidone) (PVP), poly(hydroxyethylmethacrylate), poly(ε-caprolactone), poly(lactic acid), poly(glycolic acid), peptoids, oligocarbamates, oligoureas, and mixtures thereof. The peptides and unnatural stepwise oligomers may bear hydrophilic side chains such as PEG oligomers, PVP oligomers, monosaccharides, oligosaccharides, and cyclodextrins or those side chains comprising polar functional groups such as —OR (wherein R is hydrogen or an alkyl or aromatic group), —CONRR′ (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NRR′ (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NR(CNR′(NR″R′″)) (wherein R, R′, R″, and R′″ are independently hydrogen or an alkyl or aromatic group), —COOR (wherein R is a hydrogen or an alkyl or aromatic group), —SO 3 R (wherein R is a hydrogen or an alkyl or aromatic group), —P(O)(OR)(OR′) (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NRR′R″(+) (wherein R, R′, and R″ are all alkyl or aromatic groups), and mixtures thereof.
[0070] The second hydrophilic element may further comprise binding elements and/or transport elements. Suitable binding elements include elements selected from the group consisting of ligands, bioadhesive functional groups, and mixtures thereof. Suitable transport elements include elements selected from the group consisting of nuclear localization sequences, membrane-traversing molecules, and mixtures thereof.
[0071] The second hydrophilic element may further comprise labile linkages that are capable of being cleaved under specific physiological conditions including, for example, pH, presence of enzymatic activity, oxidizing or reducing conditions, presence of nucleophiles, etc. Suitable linkers comprise functional groups such as include amides, carbamates, thiocarbamates, oxygen esters, thioesters, glycolate esters, lactate esters, orthoesters, acetals, ketals, phosphodiesters, disulfides, and mixtures thereof. In a particular embodiment, the linkers are capable of unmasking an element selected from the group consisting of binding elements and transport elements, as described above. The linker can be any covalent linkage, and can be stable or cleavable under physiological conditions. In another particular embodiment, linkers are capable of destabilizing the micelle, whereby a plurality of the surfactants are shed from the core and the hydrophilic drug is exposed to an external environment. In another particular embodiment, the linkers are capable of generating a permeation-enhancing molecule, as described above. The surfactant itself can also be a permeation-enhancing molecule.
[0072] Surfactants of this type form what are termed here as “polar-core micelles,” via a self-assembly process, as shown in FIG. 4. The polar-core micelle therefore comprises a plurality of surfactants for encapsulating a hydrophilic drug. The micelle thus formed has a hydrodynamic diameter in the range of from about 1-100 nm, and preferably about 5-80 nm. The micelles are formed by a self-assembly process, which comprises the steps of combining a smart surfactant with a hydrophilic drug in an aqueous buffer and gently agitating to form polar-core micelles (shown in cross section), with the hydrophilic drug encapsulated at its core. The system is therefore of the self-emulsifying type. In a particular embodiment, the core is surrounded by a hydrophobic layer, and the hydrophobic layer is in turn surrounded by a hydrophilic layer.
[0073] To ensure consistent formation of micelles in which the PLE is always present at the interior surface, the structure of the smart surfactant is asymmetrical by design. The second hydrophilic block is larger than the PLE, such that the resulting cone-like shape of the smart surfactant ensures self-assembly into the desired structure. In the micelle, the function of the PLE is to preferentially interact with the hydrophilic drug such that the hydrophilic drug is sequestered at the core, with little or none in the surrounding external aqueous medium.
[0074] It is anticipated, in the current embodiment, that the differing size and shape of the second hydrophilic element and the PLE will be sufficient to cause the surfactant molecules to orient themselves in a parallel, rather than antiparallel, fashion. However, if additional features are necessary to cause the surfactant chains to orient themselves relative to each other in a parallel fashion, an off-center uncharged polar group can optionally be interposed within the hydrophobic element. The presence of such a polar group within the hydrophobic element will prevent surfactant molecules from aligning antiparallel to each other, since the polar group would then interact with a hydrophobic region of the adjacent surfactant molecule, which is unfavorable energetically. If the surfactant molecules are aligned in a parallel orientation, the uncharged polar groups can interact with each other, which is favorable energetically. This situation occurs in the structure of the naturally-occurring protein GCN4 due to the presence of an asparagine residue, causing the formation of a parallel coiled coil (Gonzalez, et al., Nature Struct. Biol. 1996, 3, 1011). Positively and negatively charged groups may also be interposed within the hydrophilic-, hydrophobic-, or polar-loading elements to aid in the self-assembly process, either by favoring the desired micellar structure, or disfavoring an alternative, but undesired structure. This concept can include formation of micelles from an equimolar mixture of two different smart surfactants, each bearing charges of opposite sign.
[0075] The structure of the smart surfactants for the formation of polar-core micelle is conceptually a fusion of two surfactant molecules of a liposome, in which the hydrophobic moiety of a surfactant molecule in the outer leaflet of the membrane bilayer is covalently linked to the hydrophobic moiety of a surfactant molecule in the inner leaflet of the bilayer, to form a single molecule of the smart surfactant. The single hydrophobic element of these smart surfactants thus corresponds to the hydrophobic interior of a liposomal membrane bilayer, while the covalently-linked PLE corresponds to the hydrophilic moiety of the inner leaflet surfactant molecule of the liposome, and the second hydrophilic element linked covalently at the other end of the hydrophobic element corresponds to the hydrophilic moiety of the outer leaflet surfactant molecule of the liposome. Fusion of the hydrophobic moieties of two surfactant molecules of a liposomal bilayer in this fashion creates the possibility for much more robust control of the particle size and stability of the resulting polar-core micelles than is possible for conventional liposomes. Such micelles will also be much less likely to leak the entrapped drug than conventional liposomes.
[0076] Polar-core micelles are useful for the encapsulation and delivery of a range of hydrophilic molecules, due not only to their hydrophilic interior, but also to the protection afforded by the hydrophobic seal created by lateral interactions among the hydrophobic elements of adjacent surfactant molecules in the micelle. This seal prevents exposure of the encapsulated drug to degradative conditions or enzymatic activities in the outside environment. This feature is especially useful for labile molecules such as peptides, proteins, oligosaccharides, polysaccharides, and nucleic acids.
[0077] Specifically, with regard to the delivery of nucleic acids, polar-core micelles may be far superior to current delivery strategies that rely upon condensation of the nucleic acid with a polycationic material, which tightly sequesters the nucleic acid, preventing its facile release at the site of action (Zabner, Adv. Drug Deliv. Rev. 1997, 27, 17; U.S. Pat. No. 5,942,634; Byk, et al., J. Med. Chem. 1998, 41, 224). Polar-core micelles of the current invention, by contrast, do not rely upon such condensation, and should thus be able to release the nucleic acid more easily and efficiently at the site of action.
[0078] Polar-core micelles formed from these surfactants can also comprise inhibitors of undesirable enzymatic activities, such as those of P-glycoprotein, cytochrome P450 3A, and proteases, esterases, or nucleases. Further, the micelles may also comprise a permeation enhancing molecule, different from the surfactant.
Oligomers, Polymers, and/or Mixtures Thereof for the Protection of Protein Drugs
[0079] Shown in FIG. 5 is the basic structure of the hydrophilic copolymer for protein drug protection. The upper drawing depicts one version, in which a recognition element (RE1) capable of binding noncovalently to a protein at a site other than its active site is covalently linked to a hydrophilic element. The lower drawing depicts a second version, in which a recognition element (RE1) is linked covalently to a hydrophilic element, which is linked covalently at its other end to a second recognition element (RE2), which is capable of binding noncovalently to the same protein at a site distinct from the binding site of RE1, which is also not the active site of the protein.
[0080] In one embodiment, the present invention provides an oligomer, polymer, and/or mixtures thereof for the protection of a protein drug comprising at least one recognition element covalently attached to a hydrophilic element, wherein the recognition element or elements interact noncovalently with the protein drug to form a complex in which the protein drug is protected from degradation, recognition by the immune system, and/or renal excretion. The covalent attachment is noncleavable or cleavable under physiological conditions. The oligomer, polymer, and/or mixtures thereof and its physiological breakdown products, are non-toxic, non-immunogenic, and readily excretable. In a particular embodiment, when the protein drug has an active site, the active site is not obstructed by the oligomer or polymer, thereby maintaining biological activity of the protein drug in the complex.
[0081] In another embodiment, the oligomers, polymers, and/or mixtures thereof have a plurality of recognition elements, wherein each recognition element binds to a mutually distinct site on the protein drug, which may be produced by using branched architecture offering multiple chain ends. Alternatively, a plurality of recognition elements may be distributed throughout linear or branched hydrophilic elements at discrete locations. In a particular embodiment, when the PLE of the smart surfactants for the delivery of hydrophilic drugs depicted in FIG. 4 is equivalent to a recognition element (e.g. RE1 or RE2) as described above, that surfactant can then be utilized for the formation of polar-core micelle for the protection and delivery of protein drugs.
[0082] The recognition element or element comprise peptides and cyclic peptides (derived from phage library selection as described below), unnatural stepwise oligomers, cyclic unnatural stepwise oligomers, natural small molecules, and synthetic small molecules. Alternatively, the recognition element or element may be peptide or non-peptide ligands discovered by combinatorial chemical methods in which the potential ligand libraries are displayed on a surface or resin beads for assay screening (Burbaum and Sigal, Curr. Opin. Chem. Biol. 1997, 1, 72) or selection, and may further be displayed in an arrayed fashion to aid this process. Examples of such molecules include libraries of unnatural stepwise oligomers such as peptoids, oligocarbamates, and oligoureas, or synthetic small molecules such as heterocyclic compounds. The recognition element or elements may further comprise multivalent ligands to increase their affinity for their binding sites.
[0083] The hydrophilic element comprises an oligomer or polymer. Preferably the oligomer or polymer has a single chain length or a narrow distribution of chain lengths. Also preferably the hydrophilic element has a branched, linear, or cyclic structure. Suitable oligomers or polymers include oligosaccharides, polysaccharides, peptides, unnatural stepwise oligomers, and mixtures thereof. More specifically, suitable oligomers or polymers may include poly(ethyleneglycol) (PEG), poly(propyleneglycol), poly(vinylpyrrolidone) (PVP), poly(hydroxyethylmethacrylate), poly(E-caprolactone), poly(lactic acid), poly(glycolic acid), peptoids, oligocarbamates, oligoureas, and mixtures thereof. The peptides and unnatural stepwise oligomers may bear hydrophilic side chains such as PEG oligomers, PVP oligomers, monosaccharides, oligosaccharides, and cyclodextrins or those side chains comprising polar functional groups such as —OR (wherein R is hydrogen or an alkyl or aromatic group), —CONRR′ (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NRR′ (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NR(CNR′(NR″R′″)) (wherein R, R′, R″, and R′″ are independently hydrogen or an alkyl or aromatic group), —COOR (wherein R is a hydrogen or an alkyl or aromatic group), —SO 3 R (wherein R is a hydrogen or an alkyl or aromatic group), —P(O)(OR)(OR′) (wherein R and R′ are independently hydrogen or an alkyl or aromatic group), —NRR′R″(+) (wherein R, R′, and R″ are all alkyl or aromatic groups), and mixtures thereof.
[0084] The hydrophilic element may further comprise binding elements and/or transport elements. Suitable binding elements include elements selected from the group consisting of ligands, bioadhesive functional groups, and mixtures thereof. Suitable transport elements include elements selected from the group consisting of nuclear localization sequences, membrane-traversing molecules, and mixtures thereof. The hydrophilic element may further comprise positively or negatively charged groups covalently linked to or within its structure in masked or unmasked form.
[0085] The hydrophilic element may further comprise labile linkages that are capable of being cleaved under specific physiological conditions including, for example, pH, presence of enzymatic activity, oxidizing or reducing conditions, presence of nucleophiles, etc. Suitable linkers comprise functional groups such as amides, carbamates, thiocarbamates, oxygen esters, thioesters, glycolate esters, lactate esters, orthoesters, acetals, ketals, phosphodiesters, disulfides, and mixtures thereof. In a particular embodiment, the linkers are capable of unmasking an element selected from the group consisting of binding elements and transport elements. The linker between the recognition element or elements and the hydrophilic element can be any covalent linkage, and can be stable or cleavable under physiological conditions.
[0086] In another embodiment, the present invention provides oligomers, polymers, and/or mixtures thereof having a recognition element or elements which are covalently attached to at least one reactive chemical group or reactive linker, wherein the reactive chemical group or the reactive linker is capable of reacting with at least one functional group on the protein drug, and wherein the reactive chemical group or reactive linker is capable of forming at least one covalent linkage between the recognition element or elements and the protein drug. Examples of such reactive chemical groups are known in the art, and are used for the covalent modification of proteins. Suitable reactive chemical groups include active esters, activated disulfides, maleimide derivatives, photoreactive groups, and others. These reactive chemical groups form covalent linkages with functional groups on the protein such as amino, hydroxyl, thiol, and other groups.
[0087] As a result of the formation of a covalent linkage to the protein, the oligomer, polymer or mixtures thereof will be even more tightly bound to the protein than with a purely noncovalent interaction, thus further increasing the durability of the complex. It is also possible that the covalent linkage thus formed, or other parts of the chemical moiety that is interposed between the original recognition element and the protein, may be cleavable under physiological conditions.
[0088] In a particular embodiment, the oligomers, polymers, and/or mixtures thereof further comprise at least one linker that is capable of being cleaved under physiological conditions. Suitable linkers comprise functional groups such as amides, carbamates, thiocarbamates, oxygen esters, thioesters, glycolate esters, lactate esters, orthoesters, acetals, ketals, phosphodiesters, disulfides, and mixtures thereof.
[0089] The complex of this invention comprises at least one oligomer or polymer and a protein drug, wherein the oligomer or polymer comprises at least one recognition element covalently attached to a hydrophilic element, wherein the recognition element or elements interact noncovalently with the protein drug to form a complex in which the protein drug is protected from degradation, recognition by the immune system, and/or renal excretion. In a particular embodiment, when the protein drug has an active site, the active site is not obstructed by the oligomer or polymer, thereby maintaining biological activity of the protein drug in the complex. In another embodiment, the complex has a plurality of recognition elements, wherein each recognition element binds to a mutually distinct site on the protein drug, which may be produced by using branched architecture offering multiple chain ends. Alternatively, a plurality of recognition elements may be distributed throughout linear or branched hydrophilic elements at discrete locations.
[0090] FIGS. 6 - 9 show methods for the discovery of recognition elements suitable for the invention that can be incorporated into hydrophilic copolymers of a structure depicted in FIG. 5, which can subsequently be formulated with proteins to generate protected proteins useful as drugs. The methods described here rely upon the use of phage display techniques (Nilsson, et al., Adv. Drug Deliv. Rev. 2000, 43, 165; U.S. Pat. No. 5,622,699), but those skilled in the art of ligand generation will be able to devise other methods of finding peptide or non-peptide ligands, e.g. by combinatorial chemical methods in which the potential ligand libraries are displayed on a surface or resin beads for assay screening or selection, and may further be displayed in an arrayed fashion to aid this process, as mentioned above. Other schemes for finding peptide ligands utilizing phage-display techniques may also be devised by those skilled in the art.
[0091] Phage display techniques for the discovery of ligands offer the advantage of ready generation of diverse libraries, and ease of selection for binding using resin-based strategies. Positive and negative (i.e. subtraction) selections are possible. It is also possible with these techniques to generate families of ligands that bind with any desired affinity for their binding sites by gradually increasing the stringency of their elution. This can be achieved by increasing the concentration of a denaturant, increasing or decreasing the ionic strength, changing the pH of the buffer, changing the proportion of an organic cosolvent, etc. in a gradual or stepwise fashion, such that ligands of low affinity can be eluted first, followed by ligands of medium affinity, and finally by those of the highest affinity.
[0092] The simplest mode in which ligands for a protein can be discovered with phage display techniques is shown in FIG. 6. The success of this mode depends upon the ability to discern which ligands selected from a library actually bind to mutually distinct sites on a protein by simple inspection and comparison of their sequences. As shown in FIG. 6, a protein with a single active site is complexed with its active-site ligand, which has previously been covalently or noncovalently linked to a resin bead. Unbound protein is washed away, after which the resin-bound complex is exposed to phage library L1, under conditions that allow the phage-displayed ligands to bind to sites on the protein. Unbound phage are washed away, and the bound phage are released and eluted under suitable conditions (e.g. change in ionic strength, pH, temperature, solvent composition, denaturing agents, surfactants, etc.) to generate phage library L2. The protein without a bound active-site ligand is then covalently or noncovalently linked to a resin bead, and is exposed to library L2 under conditions which allow the phage-displayed ligands to bind to the protein. Unbound phage is washed away, and bound phage are then released and eluted under suitable conditions to generate phage library L3. The sequences of the ligands from library L3 are inspected and compared to determine which sequences bind to mutually distinct sites based upon similarities and differences in their sequences. Ligands A, B, C, etc. that bind to mutually distinct sites are chosen based on this analysis.
[0093] If it is not possible to readily discern by inspection of ligand sequences those which bind to mutually distinct sites on a protein, other methods may be employed to find such ligands sequentially. Two cases are described here in detail. The first case involves the discovery of ligands that bind to mutually distinct binding sites that are not the active site, for a protein having a single active site.
[0094] As shown in FIG. 7A, such a protein is complexed with its active-site ligand, which has previously been covalently or non-covalently linked to a resin bead. Unbound protein is washed away, after which the resin-bound complex is exposed to phage library L4, under conditions that allow the phage-displayed ligands to bind to sites on the protein. Unbound phage are washed away, and the bound phage are released and eluted under suitable conditions (e.g. change in ionic strength, pH, temperature, solvent composition, denaturing agents, surfactants, etc.) to generate phage library L5. The protein without a bound active-site ligand is then covalently or noncovalently linked to a resin bead, and is exposed to phage library L5 under conditions, which allow the phage-diplayed ligands to bind to the protein. Unbound phage is washed away, and bound phage are then released and eluted under suitable conditions to generate phage library L6. A single sequence, designated “ligand A,” is chosen from the sequences of ligands recovered in library L6.
[0095] The discovery of an additional ligand B, which does not bind to the active site or the binding site of ligand A, and ligand C, which does not bind to the active site, or the binding sites of ligands A and B, is depicted in FIG. 7B. A complex is formed between the protein and its resin-bound active site ligand as described above. Next, ligand A is added to the complex in excess under conditions that allow it to bind to its binding site, and unbound ligand A is washed away to form the complex shown in the upper left of FIG. 7B. Alternatively, ligand A could be linked to a bulky moiety to provide additional steric hindrance of its binding site. This complex is then exposed to phage library L6, under conditions that allow the phage-displayed ligands to bind to the protein. Unbound phage are washed away, and bound phage are released and eluted under suitable conditions to generate phage library L7. A single sequence, designated “ligand B,” is chosen from library L7.
[0096] Again a complex is formed between the protein and its resin-bound active site ligand as described above. Ligands A and B are added in excess under conditions that allow them to bind to their respective binding sites, and then unbound ligands A and B are washed away to form the complex depicted at the lower left of FIG. 7B. Alternatively, ligands A and B could individually be linked to bulky moieties to provide additional steric hindrance of their binding sites. This complex is exposed to phage library L7 under conditions that allow the phage-displayed ligands to bind to the protein. Unbound phage are washed away, and the bound phage are then released and eluted under suitable conditions to generate phage library L8, from which a single sequence is chosen, designated “ligand C.”
[0097] Additional ligands D, E, F, etc. that have mutually distinct binding sites can be discovered, if desired, by iterating the above procedure. Note that an alternative method to the one above can be employed in which the protein is directly attached covalently or non-covalently to the resin support, rather than the active-site ligand. In this case, the free active-site ligand would be added to the resin-bound protein to form the complex used for phage selection.
[0098] A second case for the sequential discovery of ligands with mutually distinct binding sites, which do not bind to the active site involves a protein having two active sites. One active site, designated active site 1, is bound by ligand 1, and the second active site, designated active site 2, is bound by ligand 2. Ligand 1 and ligand 2 may be the same or different, and the affinities of ligands 1 and 2 for their active sites may be the same or different. As shown in FIG. 8A, ligand 1 is bound covalently or noncovalently to a resin bead, and the protein is added in excess under conditions that allow the ligand to bind to active site 1. Unbound protein is washed away, and then ligand 2 is added in excess under conditions that allow ligand 2 to bind to active site 2, while allowing ligand 1 to remain bound to active site 1. Unbound ligand 2 is washed away to form the complex shown in the upper right of FIG. 8A. This complex is exposed to phage library L9 under conditions, which allow the phage-displayed ligands to bind to the protein. Unbound phage are washed away, and the remaining bound phage are released and eluted under suitable conditions to generate phage library L10.
[0099] As shown in FIG. 8B, the protein without bound active site ligands is covalently or noncovalently attached to a resin bead. The resin bound protein is exposed to phage library L10 under conditions that allow the phage-displayed ligands to bind to the protein. The unbound phage are washed away, and the remaining bound phage are released and eluted under suitable conditions to generate phage library L11. A single sequence, designated “ligand X,” is chosen from library L11.
[0100] By repeating this procedure in a fashion similar to that described above for the case of a protein with a single active site, additional ligands Y, Z, etc. can be discovered such that they do not bind to the active sites of the protein, and that ligands X, Y, Z, etc. have mutually distinct binding sites. An alternative method to the one above can be employed in which the protein is directly attached covalently or non-covalently to the resin support, rather than the active-site ligand. In this case, the free active-site ligand would be added to the resin-bound protein to form the complex used for phage selection.
[0101] The ligands A, B, C, etc, and X, Y, Z, etc. generated using the above procedures can be utilized as the recognition elements of the hydrophilic copolymer of this invention. Those skilled in the art of ligand generation can devise alternative means to identify A, B, C, etc. and X, Y, Z, etc., including methods not involving phage display techniques. All such identified ligands shall be equally useful for incorporation as the recognition elements of the hydrophilic copolymers of FIG. 5. As described above, each can be covalently linked to the hydrophilic element, either as individual ligands, or in a repeated fashion as multivalent ligands to increase their affinity for their respective binding sites.
[0102] [0102]FIGS. 9A and 9B show how these copolymers could be used to generate a protected protein. Shown in FIG. 9A is a protein with a single active site, for which two ligands, A and B, with mutually distinct binding sites, which also do not bind the active site, are each linked covalently to different hydrophilic elements. Both the protein and the hydrophilic copolymers can be rigorously purified before formulation. Both hydrophilic copolymers are mixed with the protein in an aqueous solution under conditions which allow the ligands to bind to their binding sites on the protein, generating a complex in which the hydrophilic copolymers are bound to the protein noncovalently.
[0103] Shown in FIG. 9B is another means to protect the protein utilizing ligands A and B. In this case, the ligands A and B are linked covalently to opposite ends of the same hydrophilic element. Again, both the protein and the hydrophilic copolymer can be rigorously purified before formulation. The hydrophilic copolymer is mixed with the protein in an aqueous solution under conditions which allow the ligands to bind to their binding sites on the protein, generating a complex in which the hydrophilic copolymer is noncovalently bound to the protein at the ends, with the hydrophilic element forming a looping structure in between.
[0104] Complexes such as those depicted in FIGS. 9A and 9B protect the protein from degradation, renal excretion, and immune recognition, and since the active site of the protein is unhindered, its biological activity is preserved. There is no need for further purification of the protein/hydrophilic copolymer complex. Inclusion of cleavable linkers, and/or masked or unmasked binding elements or transport elements within the hydrophilic element, as described earlier, may further enhance the potency of the therapeutic protein at the site of action.
[0105] Although this invention has been described with respect to certain specific embodiments, it will be appreciated by those skilled in the art that various modifications may be made without departing from the spirit and scope of the invention. The present invention is further illustrated by the following examples.
EXAMPLES
Example 1
Synthesis of a Peptide-Oligosaccharide Conjugate Using a Carbamate Linker as a Smart Surfactant for the Encapsulation of Hydrophobic Drugs
[0106] A peptide tetramer, consisting of 4 phenylalanine residues, is synthesized on Rink amide resin using standard Fmoc chemistry. After removal of the final Fmoc group, cleavage from the resin with 95:5 TFA/water liberates the peptide with a C-terminal carboxamide and a free α-amino group. An oligosaccharide is synthesized using an acceptor-bound glycosylation strategy on Merrifield resin employing a photocleavable linker. The first glycosyl donor is coupled to the hydroxyl-bearing linker at its anomeric carbon. Acetyl groups are used for temporary protection of the primary hydroxyl acceptor groups, cleavable after each coupling step with DBU; all other hydroxyl groups are protected as their benzyl ethers. After coupling of the final glycosyl donor, the final acetyl group is removed with DBU, and the resulting free primary hydroxyl group is activated with alkaline cyanogen bromide. An excess of the peptide tetramer is added and allowed to react with the activated resin-bound oligosaccharide in the presence of a hindered organic base, resulting in the formation of a carbamate linkage between the peptide and the oligosaccharide. Unreacted peptide is washed away, and the benzyl-protected peptide-oligosaccharide conjugate is cleaved from the resin by irradiation with light. The benzyl protecting groups are removed by catalytic hydrogenation, and the fully deprotected conjugate is purified to homogeneity by HPLC.
Example 2
Synthesis of a Peptide-Oligosaccharide Conjugate Using an Amide Linker as a Smart Surfactant for the Encapsulation of Hydrophobic Drugs
[0107] A peptide pentamer, consisting of 5-tryptophan residues in which the side chain indole nitrogens are protected as tert-butylcarbamates, is synthesized on Rink amide resin using standard Fmoc chemistry. After the final coupling reaction, the terminal Fmoc group is removed, leaving the protected peptide with a free amino group attached to the resin. An oligosaccharide is synthesized using an acceptor-bound glycosylation strategy on Wang resin. The first glycosyl donor is coupled to the hydroxyl-bearing linker at its anomeric carbon. Acetyl groups are used for temporary protection of the primary hydroxyl acceptor groups, cleavable after each coupling step with DBU; all other hydroxyl groups are protected as their benzyl ethers. The final glycosyl donor is a derivative of glucuronic acid in which the carboxylic acid group is protected as its tert-butyl ester, and the hydroxyl groups are protected as their benzyl ethers. After coupling of the final glycosyl donor, the resin bound intermediate is treated with 95:5 TFA/water, releasing the benzyl-protected oligosaccharide with a free carboxylic acid group at one terminus and a free anomeric hydroxyl group at the other terminus. The carboxylic acid group of the protected oligosaccharide is activated by treatment with HBTU and DIEA, and then added to the resin-bound, side-chain-protected tryptophan pentamer, and allowed to react with it to form an amide bond. Excess activated oligosaccharide is washed away, and the protected peptide-oligosaccharide conjugate is cleaved and partially deprotected by treatment with 95:5 TFA/water. The remaining benzyl groups are removed by catalytic hydrogenation, and the completely deprotected peptide-oligosaccharide conjugate is purified to homogeneity by HPLC.
Example 3
Synthesis of a Branched Peptoid as a Smart Surfactant for the Encapsulation of Hydrophobic Drugs
[0108] Using a Fmoc-based monomer strategy, a tetrameric peptoid with 2-phenethyl side chains is synthesized on Rink amide resin, using HBTU/DIEA activation. After removal of the final Fmoc, three peptoid residues are added containing a side-chain mannosyl C-glycoside with isopropylidine-protected hydroxyl groups. Next, a symmetrical linker containing one free carboxyl group and two primary amino groups protected with Fmoc groups is activated with HBTU/DIEA, and coupled to the resin-bound peptoid. After removal of the Fmoc groups, five peptoid residues containing a side-chain mannosyl C-glycoside with isopropylidine-protected hydroxyl groups are added to each amino group in succession to generate a branched structure. The final Fmoc groups are removed, and the N-terminal secondary amines are acetylated with acetic anhydride/pyridine in DMF. The resin is treated with 95:5 TFA/water, to cleave the peptoid and remove the protecting groups. The deprotected peptoid is purified to homogeneity by HPLC.
Example 4
Synthesis of a Peptoid with Side Chains of Gradually Increasing Size as a Smart Surfactant for the Encapsulation of Hydrophobic Drugs
[0109] Using a Fmoc-based monomer strategy, a pentameric peptoid with indole-containing side chains, in which the indole nitrogens are protected as their t-butylcarbamates, is synthesized on Rink amide resin, using HBTU/DIEA activation. After removal of the final Fmoc, three peptoid residues are added containing a side-chain monosaccharide with isopropylidine-protected hydroxyl groups. Next, three peptoid residues are added containing a side-chain disaccharide with isopropylidine-protected hydroxyl groups. Finally, three peptoid residues are added containing a side-chain trisaccharide with isopropylidine-protected hydroxyl groups. The final Fmoc group is removed, and the N-terminal secondary amine is acetylated with acetic anhydride/pyridine in DMF. The resin is treated with 95:5 TFA/water, to cleave the peptoid and remove the protecting groups. The deprotected peptoid is purified to homogeneity by HPLC.
Example 5
Intravenous Delivery of a Hydrophobic Small Molecule Drug
[0110] Drug “M” is a hydrophobic small molecule drug that is poorly soluble in aqueous media. A smart surfactant can be synthesized in which the hydrophobic element is comprised of a peptide with aromatic side chains, and the hydrophilic element is comprised of an oligosaccharide. The oligosaccharide is attached to the peptide by means of a short noncleavable linker. Drug M is combined with the smart surfactant in an aqueous buffer and the mixture is agitated to form a nearly monodisperse population of micelles each containing a nanoparticle of the drug. Dextrin is added to this suspension, and the mixture is then lyophilized to produce a powder with an adequate shelf life. Immediately prior to administration, the powder is resuspended in sterile phosphate buffered saline (PBS) at pH 7.5, and delivered intravenously. The solublized drug circulates throughout the bloodstream, and intact surfactant molecules are gradually shed from the micelle, exposing drug M, which then travels to its site of action via low affinity binding to serum albumin.
Example 6
Intravenous Delivery of Cyclosporin A to the CNS for the Regeneration of Damaged Neurons
[0111] Cyclosporin A is a hydrophobic drug that is poorly soluble in aqueous media. A smart surfactant, designed to encapsulate hydrophobic drugs, can be synthesized such that L-glutamate is covalently linked to the free end of the hydrophilic element as a ligand. Within the hydrophilic element is a labile thioester linkage positioned in the middle of the hydrophilic element. Cyclosporin A is combined with this smart surfactant in an aqueous buffer, and gentle agitation is applied to generate a nearly monodisperse population of micelles containing a drug nanoparticle of 15 nm average diameter. Glucose is added to the aqueous suspension of micelles, which is then lyophilized to produce a powder with an adequate shelf life. Just prior to administration, the powder is dissolved in sterile PBS at pH 7.5, and delivered intravenously to the patient. The solublized drug circulates throughout the bloodstream, and the L-glutamate ligand binds to receptors in the blood brain barrier, localizing the drug-containing micelles. Gradual hydrolysis of the thioester linkage causes the hydrophilic element to decompose, resulting in the uncoating of the cyclosporin A nanoparticle, which is deposited at the same location. Cyclosporin A then crosses the blood brain barrier by diffusion through the membranes of the epithelial cells to reach the interstitial fluid of CNS.
Example 7
Intravenous Delivery of Cyclosporin A to the CNS for the Regeneration of Damaged Neurons
[0112] This example is the same as Example 6, except that the hydrophilic element, upon decomposition, is converted into a permeation enhancing agent, which then increases the permeability of the epithelial barrier to the passage of cyclosporin A.
Example 8
Intravenous Delivery of Methotrexate to the CNS for the Treatment of Brain Cancer
[0113] Methotrexate is an anticancer drug that is hydrophilic, and thus unable to cross the blood brain barrier. Methotrexate is covalently linked, via a cleavable traceless linker to the PLE of a smart surfactant for the formation of a polar-core micelle. Contained within the hydrophilic element of the surfactant is a glycolate ester linkage positioned in the middle of the hydrophilic element. At the free end of the hydrophilic element a ligand containing a 1,4 dihydronicotinamide moiety is present, attached via a covalent linkage. The methotrexate-smart surfactant conjugate is added to an aqueous buffer at pH 3 and gentle agitation is applied to generate a nearly monodisperse population of polar-core micelles of 35 nm average diameter. Dextrin is added to this suspension, and it is lyophilized to produce a powder with an adequate shelf life. Just prior to administration, the lyophilized powder is resuspended in sterile PBS pH 7.5 and delivered to the patient intravenously. The micelle-encapsulated methotrexate circulates throughout the bloodstream, and the 1,4 dihydronicotinamide moiety binds to receptors in the blood brain barrier. Receptor-mediated transcytosis occurs, transporting the polar-core micelles containing methotrexate into the interstitial fluid of the brain. Gradual hydrolysis of the glycolate ester linkages causes the hydrophilic element of the micelles to decompose, resulting in the disassembly of the micelles. Exposure of the core to physiological conditions results in the cleavage of the linker that attaches the methotrexate to the PLE, causing free methotrexate to be released into the interstitial fluid of the brain.
Example 9
Intravenous Delivery of Methotrexate to the CNS for the Treatment of Brain Cancer
[0114] This example is the same as Example 8, except that the hydrophilic element of the surfactant contains many masked amino groups that are protected in an uncharged state with a chemical group that breaks down gradually at physiological pH to unmask the amino groups, which become protonated and positively charged. Micelles formed from this surfactant and carrying methotrexate bind to dihydropyridine receptors of the blood brain barrier. The amino groups become unmasked at pH 7.5, and the resulting network of covalently linked positive charges increases the permeability of the barrier by the paracellular route. Concomitant decomposition of the hydrophilic element due to gradual cleavage of the glycolate ester causes the methotrexate cargo to be released, which then moves through the blood brain barrier via the paracellular route into the interstitial fluid of the brain.
Example 10
Intravenous Delivery of Erythropoietin Protected by Hydrophilic Copolymers
[0115] Using the phage-display methods described in the invention for a protein with two active sites, two ligands for EPO, R and S, are discovered that have mutually distinct binding sites and do not bind to the active sites of EPO. The extracellular domain of the EPO receptor is used for both ligand 1 and ligand 2. Ligands R and S are each trimerized using a suitable covalent linker, and the trimeric ligands are then each individually attached covalently to a branched hydrophilic peptoid of a single length and structure. These conjugates are purified to near homogeneity. EPO is generated by expression in eukaryotic cells such that no oligosaccharide chains have been added post-translationally, or by chemical synthesis. The EPO so produced is also purified to near homogeneity. The hydrophilic copolymers containing R and S ligands are added to EPO in an aqueous buffer to form a stabilized complex. The solution is lyophilized to generate a powder with an adequate shelf life. Just prior to administration, sterile PBS at pH 7.5 is added to the powder, and it is redissolved. The resulting solution is administered intravenously. The stabilized EPO complex circulates in the blood stream to its target receptors, whereupon it binds those receptors. As a result, the production of red blood cells is stimulated.
Example 11
Intravenous Delivery of Cholera Toxin A Subunit to a Tumor for the Treatment of Metastasized Cancer
[0116] Using the phage-display methods of the invention, two ligands F and G are discovered that bind to mutually distinct binding sites on cholera toxin A (catalytic) subunit, but do not bind to the active site. An inhibitor of cholera toxin activity is used as the active site ligand. Ligands F and G are individually linked covalently to branched oligosaccharides of a defined single length and composition, which also contain ester linkages that are substrates for esterases present in blood serum. The hydrophilic copolymers so produced are purified to near homogeneity, and are added to a buffered aqueous solution at pH 7 containing purified cholera toxin A subunit, thereby forming a stabilized protein complex. To this solution is added a smart surfactant whose PLE contains chemical groups of charge opposite to the net surface charge of the cholera toxin A subunit at pH 7. The hydrophobic element of the smart surfactant contains an α-helical peptide with hydrophobic side chains. One-third of the way through the hydrophobic peptide sequence are interposed three asparagine residues, which have the effect of forcing the surfactant chains to align in a parallel fashion by hydrogen bonding to asparagine side chains in the hydrophobic elements of adjacent surfactant molecules. Attached covalently at the end of the hydrophilic element is a synthetic ligand that binds with high selectivity to subtype 2 somatostatin receptors overexpressed on tumor cells. The hydrophilic element also contains a disulfide linkage within its chain. The solution is agitated mechanically to form nearly monodisperse polar-core micelles containing the protected cholera toxin complex at its core. The micellar suspension is dialyzed to remove unencapsulated cholera toxin complex, dextrin is added, and the suspension is lyophilized to produce a powder with an adequate shelf life. Just prior to administration, the powder is dissolved in sterile PBS pH 7.5, and is then administered intravenously. The polar-core micelles containing stabilized cholera toxin circulate in the bloodstream, and the synthetic ligands bind to somatostatin subtype 2 receptors on the surface of metastasized cancer tumor cells. Receptor-mediated endocytosis causes the micelles to enter the tumor cells, and the hydrophilic element of the micelles decomposes as the disulfide in the chain is reduced in the cancer cell cytoplasm. Decomposition of the micelle releases the protected cholera toxin A subunit, which then kills the cancer cell. Once the cancer cell is destroyed, the protected cholera toxin is exposed to esterases present in the bloodstream, which cleave the ester linkage in the hydrophilic element of the hydrophilic copolymer that protects the toxin. As a result, the hydrodynamic radius of the protected cholera toxin is dramatically reduced such that it is rapidly excreted from the bloodstream by the kidneys.
Example 12
Intravenous Delivery of a Repressor of Gene Transcription to the Cytoplasm of a Macrophage
[0117] A repressor protein with a pI of 9 is added to a buffered aqueous solution at pH 7 containing a smart surfactant for the formation of polar-core micelles. The PLE of the smart surfactant contains carboxylate groups, which impart a net negative charge to the PLE at pH 7. The hydrophilic element also contains a glycolate ester linkage within its chain, and a pentavalent mannose ligand attached covalently to its free end. Due to favorable interactions between the opposite charges of the PLE and the protein at pH 7, polar-core micelles are formed with gentle agitation by a self-assembly process such that all of the repressor protein is contained within the core of the micelles, which are nearly monodisperse and have an average diameter of 50 nm. To the micellar suspension is added glucose, and it is lyophilized to produce a powder with an adequate shelf life. Just prior to administration, the powder is dissolved in sterile PBS at pH 7.5, and delivered intravenously. The micelles containing the repressor protein travel in the bloodstream until they encounter macrophages, to which they bind because of the presence of a cell-surface mannose receptor. Receptor-mediated endocytosis causes the micelles to be transported inside the cell, and the gradual decomposition of the glycolate ester linkage in the hydrophilic element of the surfactant causes the micelle to decompose. As a result, the repressor protein is released within the cellular cytoplasm, allowing it to access and bind to its target DNA operator in the nucleus, thus shutting down transcription of the target gene.
Example 13
Oral Delivery of a Hydrophobic Small Molecule Drug
[0118] Drug “N” is a hydrophobic small molecule drug that is poorly soluble in aqueous media. A smart surfactant is synthesized in which the hydrophobic element is comprised of drug N, and the hydrophilic element comprises an oligosaccharide. The oligosaccharide is attached to drug N by means of a short noncleavable linker. Drug N is combined with the smart surfactant in an aqueous buffer and the mixture is agitated to form a nearly monodisperse population of micelles each containing a nanoparticle of the drug. To this suspension is added dextrin, and the mixture is then lyophilized to produce a powder with an adequate shelf life. The powder is formulated into tablets, which are administered orally. Upon entering the stomach, the tablet breaks down, releasing the micelles into the gastric fluid. The micelles travel to the small intestine, where they are transported by transcytosis through the mucosal enterocytes into the bloodstream. Due to gradual shedding of intact surfactant molecules from the micelle, drug N is exposed, and travels to its site of action via low affinity binding to serum albumin.
Example 14
Oral Delivery of a Hydrophobic Small Molecule Drug
[0119] A hydrophobic small molecule drug “Q” lacks oral bioavailability due to its low solubility in aqueous media, and because it is a substrate for cytochrome P450 3A and P-glycoprotein in mucosal enterocytes. A smart surfactant for the delivery of hydrophobic molecules is synthesized containing a thioester linkage within the hydrophilic element. The hydrophobic element is the drug itself. Drug Q and a compound that inhibits both cytochrome P450 3A and P-glycoprotein are both added to an aqueous solution containing the smart surfactant. The mixture is agitated mechanically to generate a nearly monodisperse suspension of smart micelles containing drug Q and the inhibitor at the core. Glucose is added to the suspension, and it is lyophilized to produce a powder with an adequate shelf life. The powder is formulated into tablets. The drug is administered orally in tablet form and the tablet breaks down in the stomach to release the micellar emulsion. The micelles travel through the stomach and enter the small intestine, where the increase in pH to 7.2 causes hydrolysis of the thioester, unmasking a thiol group, which causes the micelle to adhere to the mucin layer of the small intestine. The breakdown of the hydrophilic element due to hydrolysis of the thioester causes drug Q and the inhibitor to be released. Drug Q and the inhibitor permeate the apical membrane of the mucosal enterocytes, and the inhibitor inhibits the activity of cytochrome P450 3A and P-glycoprotein. Drug Q is therefore able to traverse the enterocytes intact and permeate the basolateral membrane of the enterocytes, thus entering the bloodstream.
Example 15
Oral Delivery of Insulin by Transcytosis
[0120] Insulin is conjugated to the PLE of a smart surfactant for the formation of polar-core micelles with a traceless cleavable linker attached to the tyrosine aromatic hydroxyl group of insulin. The hydrophobic element of the smart surfactant is comprised of a hydrophobic peptoid oligomer. The hydrophilic element contains an ester linkage, which is a substrate for intestinal lipases, such that cleavage of this linker will unmask a pentavalent monosaccharide ligand of a lectin found on the surface of mucosal enterocytes of the small intestine. A buffered aqueous solution at pH 4.5 containing the smart surfactant with insulin linked covalently to its PLE is agitated mechanically to generate nearly monodisperse polar-core micelles with the insulin contained in the core. Glucose is added to this suspension, and the suspension is then lyophilized to generate a powder with a long shelf life. The powder is formulated into tablets. The tablets are delivered orally, and break down in the stomach, releasing the micelles containing the insulin. The micelles protect the insulin from the degradative enzymes and pH in the gastric environment. The micelles travel to the small intestine, where lipases cleave the ester linkage in the hydrophilic element. The cleavage of this linker unmasks the pentavalent monosaccharide ligand, which then binds to lectins present on the apical membrane surface of mucosal enterocytes, localizing the micelles to the cells. The micelles then cross the mucosal enterocytes by receptor-mediated transcytosis induced by the binding of the ligand to the lectin, which transports the micelles to the bloodstream. Gradual decomposition of the micelles, initiated by cleavage of the hydrophilic element, results in the release of insulin into the bloodstream.
Example 16
Oral Delivery of Insulin Via the Transcellular Route
[0121] This example is the same as Example 15, except that the hydrophobic element of the smart surfactant is comprised of a steroidal sapogenin. The hydrophilic element is comprised of an oligosaccharide, which contains a cleavable linker sensitive to pH 7.5, such that it is cleaved in the small intestine to unmask a positively-charged group. Cleavage at this location also generates a permeation enhancing agent comprising a sapogenin linked to an oligosaccharide. The micelles are formed in the presence of a protease inhibitor, such that the protease inhibitor is incorporated into the core of the polar-core micelles that are formed. The formulation and administration process is as described in Example 15. Upon reaching the small intestine, the alkaline pH of the intestinal environment causes the cleavage of the linker in the hydrophilic element, unmasking a positively-charged group, which results in the adhesion of the micelles to the mucin layer of the intestinal enterocytes. The cleavage event also causes the micelles to break down into individual molecules of a permeation enhancer linked to the insulin. The linker from the PLE to the insulin is cleaved in the alkaline environment, and the permeation enhancer allows the insulin and the protease inhibitor to enter the mucosal enterocytes via the apical membrane. The protease inhibitor prevents proteases within the enterocytes from degrading the insulin, which is then able to cross the basolateral membrane of the enterocytes due to the presence of the permeation enhancer and enter the bloodstream.
Example 17
Oral Delivery of Insulin via the Paracellular Route
[0122] This example is the same as Example 15, except that the hydrophilic element of the smart surfactant contains a linkage that is cleaved by lipases to unmask groups containing multivalent positively-charged groups at the end of each hydrophilic element. The polar-core micelles are formed such that they contain a protease inhibitor in the core as well as insulin. The micelles are formulated and delivered orally as described in Example 15. Once the micelles reach the small intestine, lipases cleave the linkage in the hydrophilic element, unmasking the multivalent positively-charged groups. The unmasking of the positively-charged groups causes the micelles to bind to the mucin layer of the intestinal enterocytes, and also creates gaps between the enterocytes at the location of their tight junctions with each other. Cleavage of the hydrophilic element also causes the micelle to decompose, releasing the protease inhibitor. Exposure of the linkage between the insulin and the PLE to alkaline intestinal pH causes the linkage to cleave and release insulin. The protease inhibitor inhibits any protease activity present, and the insulin travels via the paracellular route into the bloodstream.
Example 18
Oral Delivery of Erythropoietin
[0123] EPO protected with hydrophilic copolymers as in Example 10, is incorporated into polar-core micelles using a smart surfactant. The PLE of the smart surfactant bears groups with a charge opposite to the net charge of EPO at pH 7. The hydrophilic element of the smart surfactant contains a linkage cleavable at the alkaline pH present in the small intestine, such that a pentavalent monosaccharide ligand for a lectin present on the surface of enterocytes in the intestinal mucosa is unmasked. Cleavage of the linker will also result in the gradual decomposition of the micelle to release the protected EPO. The protected EPO is added to a buffered aqueous solution of the smart surfactant, and gentle agitation is applied to generate a nearly monodisperse population of polar-core micelles containing protected EPO at their core. Dextrin is added to the micellar suspension, which is then lyophilized to produce a powder with a long shelf life. The powder is formulated into tablets, which are administered orally. The tablets break down in the stomach, releasing the micelles containing the protected EPO. The EPO is protected from the degradative enzymes and low pH of the gastric environment by the micellar structure. The micelles travel to the small intestine, where cleavage of the linker in the hydrophilic element occurs due to the alkaline pH of the intestinal environment. The cleavage results in the unmasking of the pentavalent monosaccharide ligand, which then binds to lectins present on the surface of intestinal enterocytes. Binding of the ligand induces receptor-mediated transcytosis, which transports the micelles to the bloodstream. Gradual decomposition of the micelles due to the cleavage of the linker in the hydrophilic element releases the protected EPO into the bloodstream.
Example 19
Oral Delivery of HCV E2 Protein to the Lymphatic System for the Generation of Immune Protection
[0124] Hepatitis C virus E2 protein is encapsulated in a polar-core micelle formed with a smart surfactant. The smart surfactant contains a PLE bearing groups with a charge opposite to the net charge of E2 protein at pH 7. The hydrophilic element contains a linker cleavable by lipases in the small intestine, such that positively-charged groups are unmasked. The E2 protein and an adjuvant are added to a buffered aqueous solution at pH 7 containing the smart surfactant. With gentle agitation, polar-core micelles containing E2 protein and the adjuvant in the core are produced. The micelles are nearly monodisperse, and are about 50 nm in average diameter. Glucose is added to the suspension of micelles, and the suspension is lyophilized to produce a powder with a suitable shelf life. The powder is formulated into tablets, which are administered orally. The tablets break down in the stomach to release the micelles, which protect the E2 protein contained inside from the degradative enzymes and low pH of the gastric environment. The micelles travel to the small intestine, where lipases cleave the linkage in the hydrophilic element of the smart surfactant, causing positively-charged groups to be unmasked. The unmasked positively-charged groups cause the micelles to adhere to the mucin layer of the intestinal wall. The particles are taken up by the M-cells of Peyer's patches due to their size, and are transported to the lymphatic system by transcytosis. Gradual breakdown of the micelles, initiated by cleavage of the linkage in the hydrophilic element by lipases, results in the release of the E2 protein contained within into the lymph. The presence of the E2 protein in the lymph results in an immune response that induces protective immunity to Hepatitis C virus infection.
Example 20
Oral Delivery of a Hydrophobic Small Molecule Drug to the Bloodstream Via the Stomach
[0125] A hydrophobic small molecule drug “P” lacks oral bioavailability due to its low solubility in aqueous media. A smart surfactant for the delivery of hydrophobic molecules is synthesized containing a linkage within the hydrophilic element sensitive to a pH of less than 3. The hydrophobic element is the drug itself. Drug P is added to a buffered aqueous solution at pH 7.5 containing the smart surfactant. The mixture is agitated mechanically to generate a nearly monodisperse suspension of smart micelles containing drug P at their core. Glucose is added to the suspension, and it is then lyophilized to produce a powder with an adequate shelf life, and which can be formulated into tablets. The drug is administered orally in tablet form and the tablet breaks down in the stomach to release the micellar emulsion. The breakdown of the hydrophilic element of the surfactant due to cleavage of the labile linkage in the hydrophilic element at the low pH present in the gastric environment causes the micelle to decompose, and drug P to be released. Drug P permeates the epithelial layer of the stomach wall, and enters the bloodstream.
Example 21
Intravenous Delivery of an Artificial Chromosome to Bone Marrow Stem Cells
[0126] A smart surfactant for the formation of polar-core micelles is synthesized, in which the PLE contains chemical groups, which are positively charged at pH 7.5. Within the hydrophilic element is a peptidic nuclear localization sequence (NLS) in masked form, and at the free end of the hydrophilic element a ligand is attached that binds to receptors on bone marrow stem cells. An artificial chromosome containing a functional copy of the human adenosine deaminase (ADA) gene is added to a buffered aqueous solution of the smart surfactant at pH 7.5, and the mixture is agitated to generate a suspension of nearly monodisperse polar-core micelles of an average diameter of 50 nm containing the artificial chromosome at their core. Glucose is added to this suspension, and the mixture is lyophilized to generate a powder with an acceptable shelf life. Immediately prior to administration, the powder is resuspended in sterile PBS pH 7.5, and then administered intravenously to a patient with ADA deficiency. The micelles containing the artificial chromosome circulate in the bloodstream, and travel to the bone marrow, where the ligand binds to receptors on the surface of bone marrow stem cells. The micelles are transported inside the cells by receptor-mediated endocytosis. The micellar coating protects the artificial chromosome from damage by the low pH, oxidizing conditions, and enzymatic activities present in the endosomes. Upon reaching the cytoplasm, reduction of a disulfide linkage in the hydrophilic element of the smart surfactant unmasks the NLS, which then causes the micelle to be transported through pores in the nuclear membrane into the nucleus. Gradual decomposition of the micelle, initiated by reduction of the disulfide linkage, causes the artificial chromosome to be released into the nuclear environment, allowing expression of the ADA gene.
Example 22
Oral Delivery of an Antiviral Ribozyme to HCV Infected Liver Cells
[0127] A smart surfactant for the formation of polar-core micelles is synthesized in which the PLE contains chemical groups, which are positively charged at pH 5. At the free end of the hydrophilic element a pentavalent galactose ligand is attached, and within the hydrophilic element is contained a disulfide linkage. A ribozyme capable of site-specifically cleaving HCV RNA is added to an aqueous buffer at pH 5 containing the smart surfactant, and the mixture is agitated to generate a nearly monodisperse suspension of polar-core micelles of 30 nm average diameter containing the ribozyme at their core. Mannan is added to the suspension, and the mixture is lyophilized to produce a powder with an acceptable shelf life. The powder is formulated into tablets, which are administered orally to patients infected with HCV. In the stomach, the tablet breaks down, releasing the micelles into the gastric fluid. The micelles protect the encapsulated ribozyme from degradation due to the low pH of the stomach and alkaline pH of the small intestine, as well as digestive enzymes. The micelles travel to the small intestine, where they are absorbed due to their small size, and are transported via transcytosis to the bloodstream. The micelles circulate in the bloodstream to the liver, where the galactose ligand interacts with liver cell receptors for galactose, resulting in receptor-mediated endocytosis of the micelles. The micellar structure protects the encapsulated ribozyme from degradation due to conditions (low pH, enzymatic activity, oxidative conditions) in the endosome. Upon arriving in the cytoplasm, the disulfide in the hydrophilic element is reduced, resulting in cleavage of the hydrophilic element, and uncoating of the micelle, thereby releasing the ribozyme into the cytoplasm. The ribozyme is then able to site-specifically cleave conserved sequences of HCV RNA present in the cell, eliminating the virus. | The invention relates to the use of oilgomers and polymers capable of rendering insoluble drugs soluble, protecting unstable drugs, and facilitating the delivery of drugs to their site of action. This invention further relates to processes for the preparation of such oilgomers and polymers, and to compositions containing them. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to water controlling devices and in particular to a faucet operating device having a foot operated valve for controlling the flow of water from faucets.
2. Prior Art
An object of the present invention is to provide a device for use in controlling the flow of fluids, particularly water, the device being particularly adapted for use in controlling the flow of water to a faucet by the use of a foot pedal.
Structures are readily available for the control of water to a wash fountain by a foot operated pedal encircling the wash fountain In the control of individual wash basins the entire wash basin must be specifically designed to accommodate the controls and is built as a particular unit.
Another object of the present invention, therefore, is to provide a foot operated water controlled device that can be easily adapted to wash basins or lavatory cabinets.
Further, the wash basins of the prior art required that the foot pedal be continuously depressed in order to have a water flow from the faucet. The person operating the water flow must continually stand on the foot pedal to control the flow from the faucet This may be fine for workers and non-handicapped people but is non-functional for persons who are handicapped and cannot stand immediately adjacent to the wash basin or who cannot coordinate the depression of the foot pedal while washing themselves at the wash basin.
Therefore, another object of the present invention is to provide a fluid controlling device that can be easily actuated by a foot pedal and latched to continue the flow of the fluid until released.
SUMMARY OF THE INVENTION
This invention contemplates, among other features, the provision of a faucet operating mechanism for wash basins which is operated by the foot so that the operator can wash himself without necessitating the use of his hands in operating the device. According to the present invention, a foot pedal can be depressed to control the operation of a push button valve through a wire cable that operates a lever to actuate the push button valve. The push button valve in turn controls the flow of the fluid into the faucet and the basin The foot pedal includes a latching mechanism that keeps the foot pedal depressed to keep the valve actuated and the fluid flowing. A separate release pedal releases the latch to permit the return of the foot pedal and the closing of the valve to stop the fluid flow.
An object of the present invention, therefore, is to provide a fluid controlling mechanism that can be actuated by the depression of a foot pedal and remains actuated until released.
Yet another object of the present invention is to provide a foot operated fluid controlling device that can be easily adapted to presently installed wash basins to permit the continued flow of water from a faucet when the foot pedal is depressed and stops the flow of water when a release pedal is depressed.
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The various novel features of this invention, along with the foregoing and other objects, as well as the invention itself both as to its organization and method of operation may be more fully understood from the following description of illustrated embodiments when read in conjunction with the accompanying drawing, wherein:
FIG. 1 is a perspective view of the present invention as adapted to a wash basin with a cut away view to show the internal connections;
FIG. 2 is a side view of the valve operation shown in the cut out section of FIG. 1;
FIG. 3 is a cut away side view of the foot pedal of FIG. 1 showing the pedal in the non-operating position;
FIG. 4 is a cut away view of the foot pedal of FIG. 1 showing the foot pedal in the latched position;
FIG. 5 is a cut away view of the foot pedal of FIG. 1 showing the operation of the latch mechanism in the latched position of FIG. 4;
FIG. 6 is a cut away view of the foot pedal of FIG. 1 showing the operation of a release pedal to release the latching mechanism;
FIG. 7 shows a partial perspective view of the latching mechanism interacting with the cable actuating mechanism; and
FIG. 8 shows an exploded view of the interaction of the parts in the foot pedal of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In general, the fluid controlling mechanism of the present invention can be used with any type of wash basin such as the lavatory cabinet shown in FIG. 1. The mechanism can be used to control either a single supply of water, either hot or cold, or a dual supply mixing valve which can supply a combination of hot and water.
Referring now to FIG. 1, a wash basin shown as a lavatory cabinet 10 includes a sink 12 and at least one faucet 14. The lavatory cabinet 10 generally includes doors 16 which can be opened for access to the area internal to the lavatory cabinet 10. In FIG. 1, the lavatory cabinet 10 includes a cut away portion to show the interconnections of the mechanism of the present invention. Further water supply pipes and sewer interconnections to the sink 12 are not shown in order to simplify the Figure while continuing to show applicant's unique structure.
Leading from the faucet 14 is a water connecting pipe 18 and an inlet water pipe 20 suppling the water fluid to a push button valve 22. The push button valve 22 operates to control the water flow from the inlet water pipe 20 to the connecting water pipe 18 for discharge of the water through the faucet 14. A lever mechanism 24, shown in more detail in FIG. 2, operates the push button valve 22 via a wire cable 26 passing through a guide 28 that is clamped by a clamp 30 to a standard 32 mounted to a base 34 of the lavatory cabinet 10. The wire cable 26 and the guide 28 exit through an opening 35 in a panel 36 located at the base of the lavatory cabinet 10. The wire cable 26 and guide 28 connect to a foot pedal assembly 38. A more complete operation of the push button valve 22 of FIG. 1 as interconnected to wire cable 26 is shown in FIG. 2.
Referring now to FIG. 2, the push button valve 22 has its plunger 40 operated by a lever 42 pivotally connected to a support arm 44 through a lever pin 46 which all form a part of the lever mechanism 24, see FIG. 1. The free end of the cantilevered lever 42 is operated by the wire cable 26 through a lever spring 48. The lever spring 48 actuates the lever 42 by the operation of the wire cable 26. The lever spring 48 is held in place by a retainer 50 and a washer 52. As shown also in FIG. 1, the wire cable 26 passes into the guide 28 for connection to the foot pedal 38. The guide 28 is held in place in the lavatory cabinet 10 by virtue of the clamp 30. The connection of the wire cable 26 and the guide 28 to the foot pedal 38 is shown in the exploded view of FIG. 8.
The prior art is replete with various valve structures having a valve stem in the form of a plunger which is biased into a normally closed position. Lever mechanism 24 was especially devised for adapting a push button type plunger valve to open in response to the pull of cables 26. It will be appreciated by those skilled in the art that valves having a pull type plunger can also be actuated by cable 26. The cable may be secured to the pull type plunger by any conventional means, directly or indirectly, such as by a clevis.
Referring now to FIG. 8, the guide 28 is threadably connected to a side plate 50 at a rear section of the side plate 50 and foot pedal 38. The wire cable 26 is shown entering from the guide 28 and by hashed line 52 interconnecting to a wire cable block 54. The wire cable block 54 is rotatably connected to a crank 56 via a cable pin 58. The crank 56 in turn is rotatably connected to a base plate 60 via a crank pin 62. The side plate 50 is attached to the base plate 60 by screws 64. A foot plate 66 is pivotally connected to the side plate 50 through a pin (not shown) in the position as shown by hashed lines 68. A corrugated resilient material 70 is fastened to the exposed top section of the foot plate 66. The corrugated resilient material 70 may be made of rubber or any other slip-resistant material for preventing slippage when the foot plate 66 is stepped on and actuated by the foot of an operator. A crank actuator block 72 is connected to the interior of the foot plate 66 by screws, for instance, in a position as shown by a hashed line 74. The crank actuator block 72 includes a camming section 76 and a latch spring 78. A release pedal 80 pivotally connects to the cable actuator block 72 together with a latch 82 through a latch pin 84. The interconnection of the release pedal 80, the crank actuator block 72, and the latch 82 by the latch pin 84 is shown in more detail in FIG. 7 add will be discussed in more detail later in the operation of the foot pedal portion of the present invention. The release pedal 80 also includes a corrugated resilient material 84. The release pedal 80 has its corrugated resilient material 84 and its supporting block exit into an opening 86 in the foot plate 66. A release pedal spring 88 holds the release pedal 80 above the corrugated material 70 of the foot plate 66 for release actuation as will be discussed later. The camming section 76 of the cable actuator block 72 interfaces with a camming pin 90 of the crank 56 to actually perform the movement of the wire cable 26 within the guide 28. A latch hook 92 is formed in the base plate 60 to interface with the latch 82.
The operation of the foot pedal 38 can best be described by referring to FIGS. 3-7. FIG. 3 shows the foot pedal 38 in the non-operational position. The same reference numerals are used for the same parts in all Figures to assist in the understanding of the interconnection and operation of the present invention. A cut away view of FIG. 3 shows the interconnection of the crank actuator block 72 interfacing with the crank pin 90 of the crank 56. The crank 56 is shown cut away to show the interaction of the camming section 76 of the crank actuator block 72 with the crank pin 90 and the interaction of the wire cable block 54 also with the crank 56 via the cable pin 58. The depression of the foot plate 66 and the interaction of the parts of the foot pedal 38 is shown in FIG. 4 while the operation of the push button valve 22 via the wire cable 26 can be shown by referring to FIG. 2.
Referring to FIG. 4, when the foot plate 66 is depressed and rotates about a plate pin 96, the camming section 76 of the cable actuator block 72 presses against the crank pin 90 and causes the crank 56 to rotate about the crank pin 62. The wire cable block 54 follows the movement through the cable pin 58 and thereby withdraws a portion of the wire cable 26 through the guide 28. In FIG. 2, pulling the wire cable 26 into the foot pedal 38, pulls the lever 42 downward through the lever spring 48 and the retainer 50. Pulling the lever 42 downward rotates the lever 42 about the lever pin 46 and causes the plunger 40 of the push button valve to be depressed into the valve 22. If the push button valve 22 is a normally closed valve, depressing the plunger 40 will open the valve and cause the water flow from the inlet water pipe 20 into the connecting water pipe 18 to exit out the faucet 14, see FIG. 1. The depression of the foot plate 66 thereby causes the water to exit the faucet 14. The foot plate 66 is held into the depressed position by a latching mechanism as is shown in FIG. 5.
Referring now to FIG. 5, when the foot plate 66 is depressed and the crank pin 90 and the crank 56 is rotated, the latch 82 is actuated forward by the latch spring 78 which is also fastened to the cable actuator block 72 (see FIG. 8). The latch 82 pivots forward about the latch pin 84 and connects to the latch hook 92 formed in the base plate 60 (see FIG. 8). The latch 82 and the latch hook 92 hold the foot plate 66 in its depressed position This is best shown by referring to FIG. 7.
In FIG. 7, the arms of the release pedal 80 (shown in cross-section in FIG. 7) and the latch 82 are shown pivotally connected to the cable actuator block 82 via hashed lines 94. The latch spring 78 urges the latch 82 in the forward position when the cable actuator block 72 is pressed downward together with the foot plate 66 (not shown). The camming section 76 operates against the crank pin 90 of the crank 56 to cause the wire cable 26 to be pulled into the foot pedal as was discussed in FIG. 4. Thus the latch 82 is urged by the latch spring 78 to contact the latch hook 92 as was discussed for FIG. 5.
Continuing with the discussion of FIG. 5, the latching of the latch 82 to the latch hook 92 holds the foot plate 66 in the depressed state. The release pedal spring 88, fastened to the underside of the foot plate 66 then urges the release pedal 80 upward to protrude from the opening 86 in the foot plate 66 (see FIG. 8). In this position, the water is flowing from the faucet 14 and the operator can wash himself in the standard manner as with any lavatory system. When the operator has completed his washing procedure, the operator can depress the release pedal 80 as is shown in FIG. 6.
Referring now to FIG. 6, the depression of the release pedal 80 causes the latch 82 to rotate out of position from the latch hook 92 against the latch spring 78. This will release the foot plate 66. The lever spring 48 will cause the wire cable to be retracted in the guide 28, see FIG. 2. The retraction of the wire cable 26 will cause the crank 56 to rotate in the clockwise direction, see FIG. 4. The rotation of the crank 56 causes the foot plate to be released upward to its non-operational position as shown in FIG. 3. The mechanism thus returns to its non-operational position for actuation again by an operator when desired.
As shown in FIG. 1, a standard lavatory cabinet can be modified for foot operation control by the installation of the apparatus of the present invention. At least one push button valve 22 is installed into the inlet water pipe to control the flow of the water to the faucet 14. The lever 42 is pivotally connected to the push button valve 22 through support arm 44, see FIG. 2, to cause the actuation of the plunger 40 of the push button valve 22. The free end of the lever 42 is then connected to the wire cable 26 via the lever spring 48 and the retainer 50. The clamp 30 and the standard 32 hold the wire cable in position for the apparation of the push button valve 22 by fastening the standard 32 to the base 34 of the lavatory cabinet 10. The opening 35 is drilled in the base front 36 of the lavatory cabinet 10 for insertion of the wire cable 26 and the guide 38 into the interior of the lavatory cabinet 10. The foot pedal 38 is then positioned outside of the lavatory cabinet 10 adjacent to the base front 36. The foot plate 66 can then be depressed as shown in FIGS. 3 and 4 to actuate the push button valve 22 to cause the water to flow. The foot plate 66 will be latched in the actuating position as discussed in FIG. 5. The depression of the released pedal 80 will unlatch the foot plate 66 and the lever spring 48 will retract the wire cable 26 causing the lever 42 to be released and the plunger 40 to retract and thereby retract the plunger 40 from the push button valve to stop the water flow again.
The principles of the present invention have now been made clear in an illustrated embodiment. It will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportion, the element, materials, and components used in the practice of the invention. For instance, the push button valve 22 is shown normally closed and actuated open by the operation of the lever 42 pressing against the plunger 40 of the push button valve 22. It should be obvious that by changing the lever structure a normally open push button valve could be used and remain within the scope of the present invention. Likewise, the push button valve 22 is shown operating a single inlet water pipe. It should be obvious that the push button valve 22 could operate at the outlet of the mixing valve to control the hot and cold water combination. It is also within the scope of the instant invention that the release pedal may assume other structural equivalents such as a push button or slide for the purpose of engaging or disengaging for the latch 82. The appendant claims are, therefore, intended to cover and embrace any such modification, within the limits only of the true spirit and scope of the invention. | A remote control wash basin is disclosed having a foot pedal operation. The foot pedal operates a crank to pull a wire cable that operates a lever to open a normally closed push button valve. Depressing the foot pedal latches the valve into the open position where it remains until a release pedal is depressed. The release pedal occupies the portion of the face of the foot pedal and releases the latch to allow the foot pedal to return to its normally non-operational position. The foot pedal operated fluid controlling mechanism can be added to a wash basin cabinet with minimal changes. | 4 |
This is a continuation-in-part of application Ser. No. 750,212, filed on Dec. 13, 1976, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electric shavers and, more particularly, to electric shavers adapted to erect low-lying facial hairs for cutting above the skin line.
2. Description of the Prior Art
Implements such as razors or electric shavers for cutting or shaving hair are well known in the prior art. Conventional shaving implements include a handle adapted to be manually held and means for mounting a blade on the handle. Most prior art shaving implements for cutting human facial hair are designed to cut hair close to the skin level and preferably beneath that level without nicking or cutting the skin. Toward this end, electric shavers have included a guard member or outer foil vibrated at an ultrasonic rate to substantially enhance the ability of facial hairs to enter guard apertures and be cut by a moving shear cutter to provide high cutting efficiency and close shaves. An example of such a shaving implement is disclosed in U.S. Pat. No. 3,756,105 entitled "Ultrasonic Electric Shaver," issued to Lewis Balamuth et al, on Sept. 4, 1973. Another electric dry shaver having a perforated freely rotatable outer foil or shear plate for following facial contours and improving operating efficiency is disclosed in U.S. Pat. No. 2,526,153 entitled "Multihead Dry Shaver," issued to Herbert E. Page on Oct. 17, 1950. However, prior art shaving implements designed to provide a close shave are unsuitable for use by people who suffer from a condition of pseudofolliculitis or inflammation of one or more hair follicles and pseudofollicles caused by ingrown hairs. It has been determined that pseudofolliculitis occurs in two principal forms of abnormal beard hair growth. First, beard hairs cut below the skin line may grow to penetrate the walls of their follicles in which they are growing and continue to grow along paths within the dermis or epidermis beneath the stratum corneum. Second, beard hairs growing along paths substantially parallel to the skin surface may penetrate folds or mounds of skin lying across their paths to form pseudofollicles which may become inflamed. It has been determined that both of these kinds of abnormal beard hair growth can be prevented by means of electric shaver and foil design according to the invention. Ingrown hairs of the first type are prevented by cutting all hairs above the skin line so as to negate the possibility of their penetrating the follicle wall. Ingrown hairs of the second type are prevented by cutting them before they attain sufficient length to span a furrow separating them from an adjacent fold of skin.
Shaving instruments such as prior art blade razors and electric shavers having a perforated stationary outer shaving foil are adapted to cut erect hairs at, and preferably below the skin line. This effect is obtained because the fluid-like nature of the fleshy layers beneath the skin permit razors or electric shavers to apply sufficient force to depress the skin around a beard hair causing the beard hair to protrude from the skin level by a length substantially equal to one or more hair diameters (the diameter of an adult beard hair is about 0.005 inch). In addition to depressing the skin around the hair, the fluid-like nature of the fleshy substrate permits the beard hair and immediately adjacent skin to protrude into the holes in a prior art electric shaver foil having a thickness generally less than 0.005 inch. It will be appreciated that a relatively thin electric shaver foil enables the cutter blades to shear or cut the hair substantially at the depressed skin level. When the force applied against the skin by a prior art razor or electric shaver is removed, it has been determined that beard hairs are often cut below the skin level or skin line. It has also been determined that hairs cut below the skin line tend to cause a pseudofolliculitis problem since such hairs sometimes become ingrown by penetrating the wall of the follicle and growing under the skin.
Prior art blade razors and electric shavers fail to exert sufficient lifting action on hairs growing substantially parallel to the skin surface. Hence, they remain uncut after repeated shaving, and grow to a length sufficient to penetrate and enter adjacent skin folds.
Obviously, a shaving implement designed to cut facial hair at or slightly above the skin line would probably prevent one cause of pseudofolliculitis. For example, shaving implements such as a prior art electric clipper with a stationary cutter normally held in contact with a user's beard are adapted to cut hair above the skin line. However, such a prior art electric clipper would not cut hairs emerging from the skin at a low angle. These low-lying hairs are a cause of pseudofolliculitis when they become ingrown by penetrating the stratum corneum across furrows and crevices in rough skin after about 2 days growth.
Accordingly, an electric shaving implement is arranged to cut hair, including low-lying facial hairs, so that all hairs are cut above the skin line and to a length selected to minimize future penetration of the cut hair into the skin.
SUMMARY OF THE INVENTION
An electric shaver comprises a shaving foil having a plurality of apertures extending from a shaving foil outer surface to a shaving foil inner surface and a plurality of projections from the shaving foil front surface. Cutting means are positioned substantially adjacent to the shaving foil inner surface. Motor means are arranged to simultaneously move the shaving foil and cutting means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are frontal and side views of an electric dry shaver partially sectioned to reveal principal parts according to the invention.
FIG. 3 is a top view of a cutting foil.
FIG. 4 is an edge view of a cutting foil.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, there is shown frontal and side views, respectively, of an electric dry shaver 10 partially sectioned to reveal principal parts. A housing 12 of insulating material encases a suitable motor 14 arranged to reciprocally move a blade block 16 in a lateral direction. A perforated cutting foil 18 or plate is attached by screws 20 inserted through clearance holes 22 in the foil and threaded into a metallic cutting head frame 24 attached to the housing 12. For example, the motor 14 may be an oscillating armature type with a stator including stator windings 26 and 28 wound around laminated iron cores 30 and 32 having pole shoes 34 and 36 extending from adjacent core ends 38 and 40. A lower end 42 of an armature 44 is disposed between the pole shoes 34 and 36. The stator is arranged in a known manner to provide a magnetic circuit for moving the lower end 42 of the armature 44 in an oscillating manner in response to an electrical current signal coupled to the windings 26 and 28 from a source, not shown. An upper end 46 of the armature 44 is slidably coupled to a bottom portion 48 of the blade block 16. The armature 44 is pivotally connected to a motor housing 49 by inserting a pivot pin 50 into a hole 47 in the armature 44 between the armature ends 42 and 46 and attaching ends of the pivot pin 50 to opposite sides 51 and 52 of the motor housing 49. Thus, when the motor 14 is activated by an electrical signal, the moving armature 44 causes the blade block 16 and attached semicircular blades 54 to reciprocally move in a lateral direction at a predetermined frequency. For example, the blade block 16 may be moved at 120 cycles per second. It will be appreciated that hairs projecting through the perforations 56 in the cutting foil 18 are sheared by the moving blades 54 at an inner surface 58 of the cutting foil 18.
Prior art dry shavers have a shaving head generally comprising a stationary perforated cutting foil which engages the face and a movable blade block with blades adapted to cut or shear facial hair at a length substantially determined by the cutting foil thickness and the size of the foil perforations 56. Usually, prior art cutting foils are made very thin in order to cut hairs below the skin line. Unlike prior art dry shavers, the cutting foil 18 of the present invention is relatively thick and includes projections 62 on an outer surface 64 of the foil 18. The projections 62 are designed to move and to lift low-lying facial hairs for cutting by the blades 54 to a length terminating slightly above the skin line. As well known in the prior art, a forced vibration of an unbalanced body mounted on springs or other elastic supports is produced when a periodically varying force is applied to the unbalanced body. The forced vibrations are, in turn, transmitted to a supporting member, such as a shaver casing, supporting the vibrating unbalanced body. Thus, means for moving the cutting foil 18 and projections 62 include weights 60 and 61 attached to the blade block 16 and positioned beneath and against the cutter blades 54 to unbalance the blade block 16 so that lateral movement of the unbalanced blade block 16 causes the housing 12 and the attached cutting foil 18 and projections 62 to vibrate and reciprocally move in a lateral direction. An example of the projections 62 include a plurality of ribs formed on outer surface 64 of the cutting foil 18. Under operating conditions, the moving cutting foil 18 is pressed against a user's face so that the ribs 62 rub against the face to erect and direct low-lying facial hairs into the perforations 56 between the ribs. Hairs projecting through the perforations 56 are then cut by the moving blades 54 at the inner surface 58 of the cutting foil 18. For example, it has been determined that the ribs 62 will satisfactorily direct low-lying facial hairs into the perforations 54 if the moving cutting foil 18 has a peak-to-peak lateral displacement of about 0.080 inch at a frequency of about 120 cycles per second.
Referring to FIGS. 3 and 4, there is shown top and edge views, respectively, of the cutting foil 18 with the perforations 56 designed to admit hair and reject skin without interfering with free movement of the cutter blades 54. For example, the perforations 56 are in the form of a parallelogram having opposing corner angles being either obtuse or acute and parallel walls or sides, S 1 and S 2 , aligned substantially perpendicular to the direction of movement of the cutting blades 54 to prevent the cutting blades 54 from becoming jammed against the inner surface 58 of the foil 18. Each of the perforations 56 have a width, P, between walls, S 1 and S 2 , selected to easily admit hair while preventing skin from being cut by the blades. It has been determined that a perforation width, P, equal to 0.015 inch and an overall length, L, equal to 0.050 inch is suitable for use in the cutting foil 18.
The perforations 56 and ribs 62 are cooperatively arranged to efficiently direct hairs into the perforations 56. For example, two columns of perforations 56 are disposed between pairs of ribs 62 with walls or sides, R 1 and R 2 , aligned substantially parallel to the sides, S 1 and S 2 , of the perforations 56. The ribs 62 have a width, W, of 0.020 inch and the sides, R 1 and R 2 , of adjacent ribs are separated by a distance, D, of approximately 0.045 inch. The sides, R 1 and R 2 , of the ribs 62 are coextensive with a side of an adjacent perforation 56 to permit the ribs 62 to easily direct hairs into the perforations 56. It is desired that hairs erected by the moving ribs 62 will tend to be directed into the perforations 56 against the rib walls, R 1 and R 2 , and the coextensive wall, S 1 , of the perforations 56 without interference from the remaining foil outer surface 64. The hairs directed into the perforations 56 by the ribs 62 are sheared or cut by the moving blades 54 to a minimum length substantially determined by thickness, t, of the cutting foil 18 and the size of the foil perforations 56. It has been determined that cutting facial hair to a length between 0.001 and 0.010 inch minimizes the possibility of future penetration by the cut hair into the skin when shaving is practiced daily. The dimensions of the foil perforations 56, the thickness, t, of the foil 18 determine the minimum length that hair will be cut. The dimensions of the thickness, T, of the ribs 62 and the separation, D, between ribs 62 are selected so that the ribs 62 would not substantially interfere with cutting hair to a desired length. Accordingly, the thickness, t, of the cutting foil 18 is selected to be 0.005 inch to prevent hairs from being cut below the skin line and thickness, T, of the ribs 62 is 0.010 inch when the distance, D, is 0.045 inch.
One embodiment of the invention has been shown and described by way of example. Various other embodiments and modifications thereof will be apparent to those skilled in the art, and will fall within the scope of the invention as defined in the following claims. | An electric shaver is arranged to alleviate a cause of psuedofolliculitis by cutting low-lying facial hairs to a predetermined length. The electric shaver comprises a movable cutter and a perforated shaving foil having ribs protruding from a surface normally placed in contact with a user's beard. The shaving foil is arranged to move simultaneously with the cutter so that the ribs might lift and direct low-lying facial hairs through the perforations in the foil for shearing by the moving cutter. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for controlling the supply of air to a burner used to recombust diesel particulates trapped in a filter.
In order to prevent air pollution, particulates discharged from diesel engines are usually removed from the exhaust gas by a ceramic filter. At intervals, this diesel particulate filter is subjected to reburning for two purposes, regeneration of the filter and discharging the trapped particulates as a harmless substance. The reburning of the particulates requires a proper temperature and oxygen supply. If the burning temperature is too low, a significant amount of the particulates remains. If the burning temperature is excessively high, the filter itself is burnt.
A burner is frequently used as a heating source for the filter, and one of the atomization type, which atomizes the fuel with a small amount of primary air at a high pressure and burns the particulates with a large supply of secondary air at a low pressure, is most common. The optimum supply rate of the primary air to the burner is substantially proportional to the fuel supply rate, and in order to ensure a constant fuel flow rate, the flow rate of the primary air is usually kept constant. On the other hand, the secondary air flow is at low pressure but must be supplied in a large and controlled amount to ensure the gravimetric air flow rate necessary for burning the particulates. The secondary air is usually supplied by a positive displacement air pump, which type of pump ensures a constant volumetric air flow rate if the rotating speed is held constant. On the other hand, the required flow rate is sensitive to variations of the atmospheric pressure and ambient temperature, as well as in the pressure of the exhaust gas. It is therefore required that, with the use of a positive displacement air pump, any variation in the gravimetric flow rate be corrected without sacrificing the most significant advantage of this type of pump, namely, a high air discharge rate.
Common positive displacement air pumps have characteristics as shown in FIGS. 1 to 3. FIG. 1 shows an example of the volumetric flow rate vs. discharge pressure characteristics. From FIG. 1, it can be seen that, by reducing the cross-sectional area of an air line on the discharge side, the volumetric flow rate of air is decreased whereas its discharge pressure is increased. FIG. 2 shows an example of the gravimetric flow rate vs. discharge pressure characteristics for different altitudes at which the air pump is used; the results at a low altitude are indicated by the solid line whereas those at a high altitude are represented by the dashed line. As can be seen from this Figure, in order to obtain the same gravimetric air flow, the discharge pressure at high altitudes must be made lower than at low altitudes by increasing the cross-sectional area of the air line. Even if the altitude is the same, the gravimetric flow rate from the positive displacement air pump varies (as shown by the two dashed lines in FIG. 3) depending upon fluctuations in the pump performance and the atmospheric pressure.
An example of a conventional particulate filter system supplying secondary air with a positive displacement pump having the characteristics shown above is illustrated in FIG. 4. A diesel engine generally indicated at 1 includes a turbocharger 2 and a filter 5 in an exhaust line 3 at a point downstream of the turbocharger 2. The exhaust gas is discharged through a muffler 200 positioned downstream of the filter 5. A burner 4 is provided in the exhaust line 3 at a point upstream of the filter 5. The burner has an ignition unit using an ignition coil 6. The burner atomizes the fuel from a fuel pump 8 with primary air from a pump 7 whose flow rate is adjusted by a pressure regulating valve 201. At the same time, the burner uses secondary air from a pump 9 to produce a hot gas having a predetermined excess air ratio. Using the excess oxygen, the burner burns the particulates trapped in the filter 5. The cross-sectional area of a secondary air line 10 is adjusted by the operation of a flow control valve 11, and a vacuum chamber for actuating the switching operation of this valve is connected to a vacuum pump (negative pressure source) 12 via a vacuum regulating valve 13 and a solenoid valve 14.
With the system shown in FIG. 4, it is necessary that the flow of exhaust gas have no adverse effects on the regeneration of the particulate filter. In order to meet this requirement, as shown in FIG. 4, the exhaust line 3 is provided with a bypass 202 that is connected to the line 3 at two points, one upstream and the other downstream of the line. A valve switch 210 is positioned at the upstream junction between the exhaust line 3 and bypass 202. The valve switch 210 is driven by a link mechanism connected to a diaphragm 203 which further communicates with the vacuum pump 12. A solenoid valve 204 is provided between the diaphragm 203 and vacuum pump 12. The solenoid valve 204 is composed of a plunger 205, a coil 206 and a spring 207. When the coil 206 is energized, the plunger 205 is attracted toward the coil 206, thereby opening the valve 204. Then, the negative pressure in the vacuum pump 12 acts on the diaphragm 203 and the valve switch changes its position from a to b so as to close the exhaust line 3. As a result, the exhaust gas from the engine 1 is guided to the muffler 200 through the bypass 202. Accordingly, the exhaust gas from the engine 1 has no effect on the combustion in the burner 20. In FIG. 4, reference numerals 17 and 18 indicate a fuel regulating valve and a pressure regulating valve, respectively. Reference numeral 15 indicates a controller for controlling the ignition coil 6, air pumps 7 and 9, solenoid valve 14 and the fuel regulating valve 17. Reference numeral 16 refers to an atmospheric pressure sensor.
When the filter 5 is overloaded with particulates from the engine 1, the controller 15 detects with the senosr 19 that the pressure in the exhaust line at a point upstream of the filter 5 has exceeded a preset value, and upon detection of this fact, the controller initiates reburning of the particulates in the filter. If the engine is running at a high altitude where low atmospheric pressure is prevalent, an input signal from the atmospheric pressure sensor 16 causes the controller 15 to produce the necessary output to the solenoid valve 14 so as to increase the cross-sectional area of the secondary air line to a level which is greater than the reference level by a given amount. This produces an increase in the volumetric air flow rate that compensates for the decrease in the gravimetric flow rate due to a drop in the density of air. However, this system simply controls the change in the level of atmospheric pressure by the flow control valve 11 which relies on a diaphragm that receives a constant negative pressure. A significant problem with this diaphragm system is its inability to control the flow of secondary air with high accuracy, and this is particularly so if the characteristics of the secondary air pump vary.
SUMMARY OF THE INVENTION
The primary purpose of the present invention is to provide a burner air control apparatus for use with a diesel particulate filter system that ensures a precise control over the flow rate of secondary air.
The control apparatus of the present invention comprises an exhaust bypass line that bypasses the filter, an air supply line leading to the burner, a flow control valve that adjusts the cross-sectional area of the flow in the air supply line, a relief valve that maintains a constant difference between the pressure at points upstream and downstream of the flow control valve, and a control unit that controls the degree of opening of the flow control valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the discharge pressure versus volumetric air flow of a positive displacement air pump;
FIG. 2 is a graph showing changes in gravimetric air flow with altitude;
FIG. 3 is a graph showing variations in the gravimetric flow of air discharged from the air pump;
FIG. 4 is a schematic diagram of a conventional burner air control system;
FIGS. 5, 7, 8, 10, 11 and 12 are schematic diagrams showing various embodiments of a burner air control system of the present invention;
FIG. 6 is a graph showing the temperature of exhaust gas from the burner versus the fuel supply rate; and
FIG. 9 is a longitudinal sectional view of a typical example of a constant pressure source.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 5 shows the burner air control apparatus for use with a diesel particulate filter system according to a preferred embodiment of the present invention. This burner air control apparatus includes components which are the same as those used in the conventional system shown in FIG. 4, and components common to both Figures are identified by like reference numerals.
A burner 20 that supplies the filter 5 on the exhaust line 3 with hot air having a predetermined temperature and excess oxygen ratio receives secondary air that is supplied from the secondary air pump 9 through a secondary air line 21. The secondary pump 9 causes secondary air to flow into the secondary line 21 through an air filter 22, and supplies this air into the burner 20 through a flow control valve 28 that adjusts the cross-sectional area for the air flow in the secondary line 21. The secondary line 21 has an atmosphere temperature sensor 25 disposed between the air filter 22 and secondary pump 9, as well as a pressure sensor 26 that detects the pressure in the secondary line at a point upstream of the flow control valve 28. The output signals of the two sensors are transmitted to a combustion control unit 27 for controlling the flow of the secondary air.
A valve drive unit 23 has a diaphragm 29 connected integrally with the flow control valve 28. This diaphragm divides the unit 23 into a chamber 30 which is open to the atmosphere and a negative pressure chamber 31 provided with a compressive spring 47. The flow control valve 28 is positioned in the secondary air line 21 in such a manner that it is capable of varying the cross-sectional area for the air flow in that line. The negative pressure chamber 31 is connected to a vacuum pump 12 (negative pressure source) through a duty solenoid valve 32. The duty valve 32 switches on and off the plunger at a frequency 10 to 20 Hz for selecting between two modes, one communicating the negative pressure chamber 31 with the vacuum pump 12, and the other introducing atmospheric pressure into the chamber 31. The pulse width that determines the time period during which the plunger remains in the on position is controlled by the output signal from the combustion control unit 27. In response to this output signal, the value of the negative pressure in the chamber 31 is changed and the flow control valve 28 is shifted to a position where the bias of the compressive spring is balanced with the atmospheric pressure, thereby changing the cross-sectional area S for the air flow in the line 21. When the flow control valve 28 shifts from the fully open position to the fully closed position, a position sensor 33 feeds back the amount of this shift to the control unit 27 as an output signal corresponding to a variable electrical resistance.
The secondary line 21 is provided with a relief valve 34 that causes the secondary air to be released into the atmosphere at a point between the flow control valve 28 and the secondary pump 9. This relief valve has a diaphragm 36 which is integral with the plunger 35 and divides the valve apparatus into a chamber 37 which is open to the atmosphere and a negative pressure chamber 38. The negative pressure chamber 38 is connected to the vacuum pump 12 through a flow control throttle 39. A negative pressure regulating valve 40 is connected to a negative pressure regulating line a connected between the throttle 39 and the negative pressure chamber 38.
The negative pressure regulating valve 40 is divided into a front chamber 41 and a rear chamber 42 by a diaphragm 43; the front chamber 41 receives a static pressure at a point upstream of the flow control valve 38, whereas the back chamber 42 receives a static pressure at a point downstream of the valve 28. The chamber 42 is provided with a compressive spring 45 and a pipe 44 whose opening 48 may be closed by the diaphragm 43 working as a plunger. The other end of the pipe 44 is connected to the negative pressure regulating line a. If the differential pressure across the flow control valve 28 is such that the valve closing force exerted by the diaphragm 43 exceeds the valve opening force of the compressive spring 45, the opening 48 of pipe 44 is closed. Otherwise, the pipe 44 remains open. In this latter case, the throttle 39 is actuated and air flows from the rear chamber 42 through the negative pressure regulating line a into the negative pressure chamber 38, with the result that the pressure in the chamber 38 increases to shift the plunger 35 in the valve closing direction C. On the other hand, if the opening 48 of the pipe 44 is closed, only the negative pressure from the vacuum pump 12 is applied to the line a and the plunger 35 shifts in the valve opening direction P.
Essential parts of the combustion control unit 27 are implemented with a microcomputer. The unit receives output signals from the pressure sensor 26, atmospheric temperature sensor 25, position sensor 33 and an emission temperature sensor 46. The control unit 27 adjusts the volumetric flow rate of secondary air to the proper level depending upon the detected atmospheric temperature and the pressure in the secondary line at a point upstream of the flow control valve 28, and at the same time, the unit performs proper adjustment of the fuel flow rate according to the detected temperature of the exhaust gas from the burner.
In greater detail, the gravimetric flow rate G a of secondary air is given by:
G.sub.a =SC√2ΔP·ρ, (1)
where S is the cross-sectional area of the air flow line, ΔP is the differential pressure across flow control valve 38, and ρ is the density of air at a point upstream of the flow control valve 28. In the embodiment under consideration, P is held constant, whereas C, which is a coefficient of the flow rate, can be assumed to be substantially constant. Therefore, by correcting S to cancel a change in ρ, G a can be held constant.
Equation (1) can be rewritten as follows in terms of the temperature and pressure of air:
S=G.sub.a /C√2ΔP·ρ=K√T/P, (2)
where T is the temperature of air at a point upstream of the flow control valve 28, P is the pressure of air at a point upstream of the flow, and K is a constant of proportionality.
Equation (2) shows that, if T increases, G a can be held constant by increasing S, whereas if P increases, the same result can be obtained by decreasing S. It should be noted that since S corresponds directly to the lift of the flow control valve 28, a map or some other kind of reference table that indicates the required lifts for various values of T and P may be used for the purpose of maintaining G a at a constant level. In Equation (2), P is assumed to be the pressure of air at a point upstream of the flow control valve 28, but in fact, P may be the pressure in the secondary line 21 at any point near the control valve 28, and Equation (2) is still valid if the pressure of air at a point downstream of the flow control valve 28 is substituted for P.
The theory by which the fuel control unit 27 controls the fuel injection rate q so as to keep the temperature T of the exhaust gas from the burner constant is illustrated in FIG. 6. If T is below the reference value T 0 by a difference greater than a preset value Δt, the fuel is injected at a rate q 1 which is greater than the reference value q 0 , whereas if T exceeds T 0 by more than ΔT, the fuel is injected at a rate q 2 which is smaller than q 0 .
The operation of the burner air control apparatus shown in FIG. 5 proceeds as follows. The pressure sensor 19 detects the pressure of exhaust gas at a point upstream of the filter 5, and if the detected value exceeds a preset level, the apparatus 27 initiates the particulate burning mode. First, it issues signals to turn on the primary and secondary air pumps 7 and 9 as well as fuel pump 8 and ignition coil 6. At the same time, in response to an output signal from the sensor 46 that detects the temperature of the exhaust gas from the burner, the apparatus 27 furnishes the fuel regulating valve 17 with an input signal that adjusts the fuel injection from q 0 to q 1 if the detected temperature is lower than the reference T 0 , and makes an adjustment from q 0 to q 2 if the detected temperature is higher than T 0 . The negative pressure regulating valve 40 detects the differential pressure across the flow control valve 28 and controls the relief valve 34 so that the difference between the pressure in the secondary line 21 at a point downstream of the valve 28 and the pressure at a point upstream of that valve is held equal to the preset value limited by the compressive spring 45. Stated more specifically, if the differential pressure across the control valve 28 exceeds the preset level, the pipe 44 is closed and the entire negative pressure generated by the vacuum pump 12 is applied to the negative pressure chamber 38, whereupon the plunger 35 shifts in the valve opening direction P by a relatively long stroke and causes the air flowing in the secondary line to be released into the atmosphere. If the differential pressure across the control valve 28 is lower than the preset level, the pipe 44 becomes open and the air in the rear chamber 42 flows into the negative pressure regulating line a. As a result, the chamber 38 receives only a relatively low negative pressure, and thus the plunger 35 shifts in the valve closing direction C so as to suppress the air discharge from the secondary line 21. These pneumatic operations are the only requirement for the system of FIG. 5 to maintain a constant differential pressure across the flow control valve 28.
The negative pressure chamber 31 of the valve drive unit 23 receives negative pressure through the duty valve 32. The combustion control unit 27 determines the specific lift position of the valve 28 that is capable of obtaining the required gravimetric flow rate G a of secondary air. For this purpose, the unit may use a map in which various valve lift positions have been stored on the basis of the ambient temperature and the pressure in the secondary line at a point upstream of the control valve 28. In order to bring a signal indicative of the determined lift position into agreement with the output signal from the position sensor 33, the combustion control unit 27 performs feedback control on the duty valve 32 by adjustment of the duty factor. The map for various lift positions of the control valve 28 is preloaded into the control unit 27 after determining the proportionality constant K and other necessary factors through experimentation on the basis of Equation (2). By this procedure, the secondary air flowing through the secondary line 21 is adjusted to achieve a constant gravimetric flow rate before it is supplied to the burner 20.
As will be understood from the foregoing description, even if there occurs a change in the density of air due to variations in the operation of the secondary air pump 9 or fluctuations in the atmospheric temperature or the pressure in the secondary line 21 at a point upstream of the flow control valve 28, the differential pressure across the valve 28 is held constant by pneumatically operating the relief valve drive unit 34, and at the same time, the duty valve 32 is controlled by the unit 27 in such a manner that it corrects the cross-sectional area S of the air flow in the line 21 to a predetermined value, thereby cancelling any variations due to changes in the ambient temperature or the pressure in the line 21 at a point upstream of the control valve 28. As a result, the flow rate of the secondary air is controlled with high precision, and moreover, there is no need for the combustion control unit 27 to effect control to compensate for variations in the discharge of the secondary pump 9, which contributes to increased simplicity of the overall system.
With the burner air control system of FIG. 5, the differential pressure across the control valve 28 on the secondary line 21 is detected by the negative pressure regulating valve 40, and in response to the detected signal output, the negative pressure in the line a is properly corrected to operate the relief valve drive unit 34. This drive unit 34 may be replaced by another type of drive unit 50 which, as shown in FIG. 7, releases air from the secondary line 21 into the atmosphere and is directly operated by the difference between the pressure at a point upstream of the flow control valve 28 and the pressure at a point downstream thereof. This unit is divided into a rear chamber 53 and a front chamber 54 by a diaphragm 55. The rear chamber is provided with a compressive spring 52 that depresses a relief valve 51 in the valve closing direction C, whereas the front chamber receives a pressure developed between the flow control valve 28 and the secondary pump 9. The combustion in the two chambers exerts a pneumatic pressure on the diaphragm. If the depressive force due to the differential pressure across the relief valve 51 exceeds the force exerted by the spring 52, the relief valve 51 shifts in the valve opening direction P, and in the contrary case, the valve shifts in the closing direction C. By this valve operation, variations in the discharge of air from the secondary pump 9 can be eliminated and a consistent air flow supplied to the flow control valve 28. One particular advantage of the system shown in FIG. 7 is that it does not require the use of the negative pressure regulating valve 40 included in the embodiment of FIG. 5. However, the compressive spring 52 must have a high spring constant sufficient to overcome the depressive force of the secondary air in the front chamber 54, thereby providing a downstroke for the valve 51 in the closing direction C.
In the burner air control apparatus of FIG. 5, the valve drive unit 23 is operated with signals from the combustion control unit 27, sensor 26 for detecting the pressure in the secondary line 21 at a point upstream of the valve 28, and the ambient temperature sensor 25. Alternatively, the same results may be obtained by a flow control valve 61 (see FIG. 8) that is controlled only by the atmospheric pressure. This valve 61 is connected integrally to a diaphragm 62 in a drive unit 60 that is separated by this diaphragm into a chamber 63 which is open to the atmosphere and a constant pressure chamber 65 having a compressive spring 64 that exerts a depressive force acting in the valve opening direction P. The chamber 65 is connected to a constant pressure source 66 that produces a constant pressure with respect to the absolute pressure. A typical configuration of the constant pressure source 66 is shown in FIG. 9. The valve consists of a constant pressure chamber 301 enclosed with a hermetic housing 300, a vacuum bellows 302 disposed within the chamber 301, a negative pressure pipe 303 having a throttle 303 and communicating the vacuum pump 12 with the constant pressure chamber 301, a pressure release pipe 306 one end of which is open to the atmosphere and which has incorporated therein a spring 304 and a spherical ball 305 as shown in FIG. 9, and a communicating pipe 37 for supplying a constant pressure. When the pressure in the chamber 301 decreases, the vacuum bellows 302 inflates to press the spherical ball 305 in the pipe 78, whereupon atmospheric pressure is applied to the chamber 301 through the pipe 78. As a result, the pressure in the chamber 301 increases to contract the bellows 302, whereupon the ball 305 returns to the position where it closes the pipe 306. By repeating this procedure, the pressure in the chamber 301 is held at a generally constant level.
This pneumatic control system is operated as follows. When the atmospheric pressure decreases such as at high altitudes, the flow control valve 61 shifts in the opening direction P so as to increase the cross-sectional area S, and hence the volumetric flow rate of the air passing through the secondary line 21. If the atmospheric pressure increases, the valve 61 shifts in the closing direction C, thereby reducing S, and hence the volumetric flow rate, of the air passing through the line 21. By this operation, the secondary air is made to flow through the line 21 at a substantially constant gravimetric flow rate. The control system shown in FIG. 8 has a simplified configuration and requires fewer components.
FIG. 10 shows another embodiment of the burner air control system of the present invention wherein the relief valve drive unit 50 shown in FIG. 7 and the flow control unit 60 depicted in FIG. 8 are provided on the secondary line 21. This embodiment is characterized by the use of an even smaller number of components since the valve of each unit is controlled pneumatically.
As shown in FIGS. 11 and 12, the flow control units 23 and 60 may be replaced by a flow control unit 102 which performs direct control over the flow control valve 28 by means of a bellows 100, the interior of which is maintained as a vacuum. Referring to FIG. 11, the flow control unit 102 consists of the bellows 100 connected to the valve 28, a casing 104 which encloses the bellows and is open to the atmosphere, and spring 105 provided within the bellows. When the pressure of the atmosphere is low, the bellows 101 expands to the extent determined by the balance between the ambient atmospheric pressure and the biasing force of the spring 105, and as a result, the valve 28 descends to increase the cross-sectional area S for the air flow. If, on the other hand, the atmospheric pressure is high, the bellows 100 contracts, with the result that the valve 28 ascends to reduce S.
It may be appreciated that the embodiment of FIGS. 11 and 12 provides a very simple system for controlling the cross-sectional area S for the air flow in the secondary line 21 depending upon the level of the atmospheric pressure. The flow control unit 102 shown in FIG. 12 is the same as used in the embodiment of FIG. 11, where like components are identified by like reference numerals.
The control unit shown in FIG. 5 is such that the cross-sectional area S for the air flow in the secondary line 21 is varied depending upon both the ambient temperature and the pressure in the secondary line at a point upstream of the flow control valve 28. It should be understood that S may be varied depending upon only one of these two parameters. Alternatively, other parameters may be added, such as the engine speed and load. | An apparatus for controlling the supply of air to a burner used to recombust diesel particulates trapped in a ceramic filter. The inventive control apparatus includes an exhaust bypass line that bypasses the filter, an air supply line leading to a burner associated with the filter, a flow control valve that adjusts the cross-sectional area for the air flow in the air supply line, a relief valve that maintains a constant difference between pressures at points upstream and downstream of the flow control valve, and a control unit that controls the degree of opening of the flow control valve. With the invention, precise control over the flow rate of secondary air is ensured. | 5 |
The present application is a continuation of U.S. application Ser. No. 08/280,681, filed Jul. 26, 1994, now abandoned, which in turn is a continuation-in-part of U.S. application Ser. No. 08/101,598, filed Aug. 3, 1993, now U.S. Pat. No. 5,510,383.
BACKGROUND OF THE INVENTION
The present invention relates to the treatment of glaucoma and ocular hypertension. In particular, the present invention relates to the use of cloprostenol and fluprostenol analogues for the treatment of glaucoma and ocular hypertension.
Cloprostenol and fluprostenol, both known compounds, are synthetic analogues of PGF 2 α, a naturally-occurring F-series prostaglandin (PG). Structures for PGF 2 α (I), cloprostenol (II), and fluprostenol (III), are shown below: ##STR1##
The chemical name for cloprostenol is 16-(3-chlorophenoxy)-17,18,19,20-tetranor PGF 2 α. Monograph No. 2397 (page 375) of The Merck Index, 11th Edition (1989) is incorporated herein by reference to the extent that it describes the preparation and known pharmacological profiles of cloprostenol. Fluprostenol has the chemical name 16-(3-trifluoromethylphenoxy)-17,18,19,20-tetranor PGF 2 α. Monograph No. 4121 (pages 656-657) of The Merck Index, 11th Edition (1989) is incorporated herein by reference to the extent that it describes the preparation and known pharmacological profiles of fluprostenol. Cloprostenol and fluprostenol are 16-aryloxy PGs and, in addition to the substituted aromatic ring, differ from the natural product PGF 2 α in that an oxygen atom is embedded within the lower (omega) chain. This oxygen interruption forms an ether functionality.
Naturally-occurring prostaglandins are known to lower intraocular pressure (IOP) after topical ocular instillation, but generally cause inflammation, as well as surface irritation characterized by conjunctival hyperemia and edema. Many synthetic prostaglandins have been observed to lower intraocular pressure, but such compounds also produce the aforementioned side effects which severely restrict clinical utility.
SUMMARY OF THE INVENTION
It has now been unexpectedly found that certain novel cloprostenol and fluprostenol analogues are useful in treating glaucoma and ocular hypertension. In particular, topical application of ophthalmic compositions comprising these novel cloprostenol and fluprostenol analogues result in significant IOP reduction.
DETAILED DESCRIPTION OF THE INVENTION
The compounds useful in the present invention have the following general formula: ##STR2## wherein: R 1 =H; C 1 -C 12 straight-chain or branched alkyl; C 1 -C 12 straight-chain or branched acyl; C 3 -C 8 cycloalkyl; or a cationic salt moiety;
R 2 , R 3 =H, or C 1 -C 5 straight-chain or branched alkyl; or R 2 and R 3 taken together may represent O;
X=O, S, or CH 2 ;
---- represents any combination of a single bond, or a cis or trans double bond for the alpha (upper) chain; and a single bond or trans double bond for the omega (lower) chain;
R 9 =H, C 1 -C 10 straight-chain or branched alkyl, or C 1 -C 10 straight-chain or branched acyl;
R 11 =H, C 1 -C 10 straight-chain or branched alkyl, or C 1 -C 10 straight-chain or branched acyl;
Y=O; or H and OR 5 in either configuration wherein R 15 =H, C 1 -C 10 straight-chain or branched alkyl, or C 1 -C 10 straight-chain or branched acyl; and
Z=Cl or CF 3 ;
with the proviso that when R 2 and R 3 taken together represent O, then R 1 ≠C 1 -C 12 straight-chain or branched acyl; and when R 2 =R 3 =H, then R 1 ≠a cationic salt moiety.
As used herein, the term "cationic salt moiety" includes alkali and alkaline earth metal salts as well as ammonium salts.
Preferred compounds include the 3-oxa form of cloprostenol isopropyl ester (Table, 1, compound 5), 13,14-dihydrofluprostenol isopropyl ester (compound 6), cloprostenol-1-ol (compound 7), and 13,14-dihydrocloprostenol-1-ol pivaloate (compound 8).
The compounds of formula (IV) are useful in lowering intraocular pressure and thus are useful in the treatment of glaucoma. The preferred route of administration is topical. The dosage range for topical administration is generally between about 0.01 and about 1000 micrograms per eye (μgye), preferably between about 0.1 and about 100 μg/eye, and most preferably between about 1 and 10 μg/eye. The compounds of the present invention can be administered as solutions, suspensions, or emulsions (dispersions) in a suitable ophthalmic vehicle.
In forming compositions for topical administration, the compounds of the present invention are generally formulated as between about 0.00003 to about 3 percent by weight (wt %) solutions in water at a pH between 4.5 to 8.0. The compounds are preferably formulated as between about 0.0003 to about 0.3 wt % and, most preferably, between about 0.003 and about 0.03 wt %. While the precise regimen is left to the discretion of the clinician, it is recommended that the resulting solution be topically applied by placing one drop in each eye one or two times a day.
Other ingredients which may be desirable to use in the ophthalmic preparations of the present invention include preservatives, co-solvents and viscosity building agents.
Antimicrobial Preservatives:
Ophthalmic products are typically packaged in multidose form, which generally require the addition of preservatives to prevent microbial contamination during use. Suitable preservatives include: benzalkonium chloride, thimerosal, chlorobutanol, methyl paraben, propyl paraben, phenylethyl alcohol, edetate disodium, sorbic acid, ONAMER M®, or other agents known to those skilled in the art. Such preservatives are typically employed at a concentration between about 0.001% and about 1.0% by weight.
Co-Solvents:
Prostaglandins, and particularly ester derivatives, typically have limited solubility in water and therefore may require a surfactant or other appropriate co-solvent in the composition. Such co-solvents include: Polysorbate 20, 60 and 80; Pluronic F-68, F-84 and P-103; Tyloxapol®; Cremophor® EL; sodium dodecyl sulfate; glycerol; PEG 400; propylene glycol; cyclodextrins; or other agents known to those skilled in the art. Such co-solvents are typically employed at a concentration between about 0.01% and about 2% by weight.
Viscosity Agents:
Viscosity greater than that of simple aqueous solutions may be desirable to increase ocular absorption of the active compound, to decrease variability in dispensing the formulations, to decrease physical separation of components of a suspension or emulsion of formulation and/or otherwise to improve the ophthalmic formulation. Such viscosity building agents include, for example, polyvinyl alcohol, polyvinyl pyrrolidone, methyl cellulose, hydroxy propyl methylcellulose, hydroxyethyl cellulose, carboxymethyl cellulose, hydroxy propyl cellulose or other agents known to those skilled in the art. Such agents are typically employed at a concentration between about 0.01% and about 2% by weight.
The following Examples 1-4 describe the synthesis of compounds 5-8 (Table 1). These syntheses are representative in nature and are not intended to be limiting. Other compounds of formula (IV) may be prepared using analogous techniques known to those skilled in the art.
TABLE 1______________________________________COMPOUNDNAME COMPOUND STRUCTURE______________________________________5 3-oxacloprostenol isopropyl ester ##STR3##6 13,14-dihydro- fluprostenol isopropyl ester ##STR4##7 cloprostenol-1-ol ##STR5##8 13,14-dihydroclo- prostenol-1-ol pivaloate ##STR6##______________________________________
In the examples below, the following standard abbreviations are used: g=grams (mg=milligrams); mol=moles (mmol=millimoles); mol %=mole percent; mL=milliliters; mm Hg=millimeters of mercury; mp=melting point; bp=boiling point; h=hours; and min=minutes. In addition, "NMR" refers to nuclear magnetic resonance spectroscopy and "CI MS" refers to chemical ionization mass spectrometry.
EXAMPLE 1
Synthesis of 3-Oxacloprostenol (5) ##STR7## A: Ethyl(3-chlorophenoxy)acetate (10)
Acetone (320 ml), 75 g (450 mmol) of ethyl bromoacetate, and 40.0 g (310 mmol) of 3-chlorophenol were mixed together, then 69.8 g (505 mmol) of potassium carbonate was added. The mixture was mechanically stirred and heated to reflux for 4 h, and after cooling to room temperature, was poured into 350 mL of ethyl acetate. To this was then cautiously added 400 mL of 1M HCl, taking care to avoid excess foaming. The layers were separated and the aqueous layer was extracted with portions of ethyl acetate (3×200 mL). The combined organic layers were dried over MgSO 4 , filtered, concentrated, and the resulting solid was recrystallized from hexane to afford 58 g (87%) of 10 as a white solid, m.p.=39°-40° C. 1 H NMR δ 7.20-7.08 (m, 1H), 6.95-6.82 (m, 2H), 6.75-6.70 (m, 1H), 4.53 (s, 2H), 4.21 (q, J=7.2 Hz, 2H), 1.23 (t, J=7.2 Hz, 3H).
B: Dimethyl[3-(3-chlorophenoxy)-2-oxoprop-1-yl]phosphonate (11)
To 20.6 g (166 mmol, 238 mol %) of dimethyl methylphosphonate in 110 mL of THF at -78° C. was added dropwise 65 mL (162 mmol, 232 mol %) of a 2.5M solution of n-BuLi in hexanes. After addition was complete, the mixture was stirred for an additional 1 h, after which 15.0 g (69.9 mmol) of aryloxyester 10 in 40 mL of THF was added dropwise. The reaction was stirred for 1 h and then quenched by the addition of 100 mL of saturated NH 4 Cl. The mixture was poured into 200 mL of a 1/1 mixture of saturated NaCl/ethyl acetate, layers were separated, and the aqueous layer was further extracted with ethyl acetate (2×100 mL). Combined organic layers were dried over MgSO 4 , filtered, and concentrated, to afford 20.5 g (100%) of 11 as a viscous oil. 1 H NMR δ 7.22 (t, J=8.1 Hz, 1H), 7.05-6.90 (m, 2H), 6.85-6.78 (m, 1H), 4.72 (s, 2H), 3.84 (s, 3H), 3.78 (s, 3H), 3.27 (d, J=22.8 Hz, 2H).
C: (3aR,4R,5R,6aS)-5-(Benzoyloxy)-4-[(E)-4-(3-chlorophenoxy)-3-oxo-1-butenyl]hexahydro-2H-cyclopenta[b]furan-2-one (13)
Phosphonate 11 (20.5 g, 70.0 mmol), 2.6 g (62 mmol) of LiCl, and 200 mL of THF were mixed together at 0° C. and 6.10 g (60.4 mmol) of NEt 3 was added. Aldehyde 12 (14.0 g, 51.1 mmol) dissolved in 50 mL of CH 2 Cl 2 was then added dropwise. After 1 h, the reaction was poured into 200 mL of a 1/1 mixture of saturated NH 4 Cl/ethyl acetate, the layers were separated, and the aqueous layer was extracted with ethyl acetate (2×100 mL). Combined organic layers were dried over MgSO 4 , filtered, concentrated, and the residue was chromatographed on silica gel eluting with ethyl acetate/hexanes, 3/2, to afford 16.2 g (72%) of 13 as a white crystalline solid, m.p.=101.0°-102.0° C. 1 H NMR δ 8.0-7.9 (m, 2H), 7.62-7.52 (m, 1H), 7.50-7.38 (m, 2H), 7.18 (t, J=8.2 Hz, 1H), 7.0-6.82 (m, 3H), 6.75-6.70 (m, 1H), 6.54 (d, J=15.1 Hz, 1H), 5.32 (q, J=6.2 Hz, 1H), 5.12-5.05 (m, 1H), 4.66 (s, 2H), 3.0-2.8 (m, 3H), 2.7-2.2 (m, 3H).
D: (3aR,4R,5R,6aS)-5-(Benzoyloxy)-4-[(E)-(3R)-4-(3-chlorophenoxy)-3-1-butenyl]-hexahydro-2H-cyclopenta[b]furan-2-one (14)
To a solution of 9.70 g (22.0 mmol) of enone 13 in 60 mL of THF at -23° C. was added dropwise a solution of 11.1 g (34.6 mmol) of (-)-B-chlorodiisopinocampheylborane in 30 mL of THF. After 4 h, the reaction was quenched by the dropwise addition of 5 mL of methanol and then warmed to room temperature. After pouring into 200 mL of a 2/1 mixture of ethyl acetate/saturated NH 4 Cl, the layers were separated, and the aqueous phase was extracted with ethyl acetate (2×100 mL). Combined organic layers were dried over MgSO 4 , filtered, concentrated, and the residue was chromatographed on silica gel eluting with ethyl acetate/hexanes, 3/2, to afford 4.7 g (48%) of 14 as a white solid, m.p. 101.0°-102.5° C. 1 H NMR δ 8.05-7.95 (m, 2H), 7.62-7.40 (m, 3H), 7.18 (t, J=8.0 Hz, 1H), 7.0-6.92 (m, 1H), 6.85 (t, J=2.1 Hz, 1H), 6.77-6.70 (m, 1H), 5.85 (d of d, J=6.2, 15.5 Hz, 1H), 5.72 (d of d, J=4.5, 15.5 Hz, 1H), 5.30 (q, J=5.8 Hz, 1H), 5.12-5.04 (m, 1H), 4.58-4.48 (m, 1H), 3.92 (d of d, J=3.5, 9.3 Hz, 1H), 3.80 (d of d, J=7.3, 9.4 Hz, 1H), 2.9-2.2 (m, 8H).
E: (3aR,4R,5R,6aS)-4-[(E)-(3R)-4-(3-Chlorophenoxy)-3-(tetrahydropyran-2-yloxy)-1-butenyl]-5-(tetrahydropyran-2-yloxy)-hexahydro-2H-cyclopenta[b]furan-2-one (16)
To a mixture of 5.1 g (11.5 mmol) of 14 in 200 mL of methanol was added 1.7 g (12 mmol) of K 2 CO 3 . After 1 h, the mixture was poured into 100 mL of 0.5M HCl and extracted with ethyl acetate (3×100 mL). The combined organic layers were washed successively with water (2×100 mL) and saturated NaCl (2×100 mL). The organic layer was dried over MgSO 4 , filtered, and concentrated to afford 4.85 g of crude diol 15, which was used in the next step without further purification.
To a mixture of 4.85 g of crude 15 and 2.4 g (28 mmol) of 3,4-dihydro-2H-pyran in 75 mL of CH 2 Cl 2 at 0° C. was added 370 mg (1.9 mmol) of p-toluenesulfonic acid monohydrate. After stirring for 45 min, the reaction was poured into 40 mL of saturated NaHCO 3 , layers were separated, and the aqueous layer was extracted with CH 2 Cl 2 (2×40 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated. The residue was chromatographed on silica gel eluting with 40% ethyl acetate in hexanes, to afford 6.0 g (100%) of 16 as an oil. 1 H NMR (CDCl 3 ) δ (characteristic peaks only) 7.25-7.14 (m, 1H), 6.95-6.87 (m, 2H), 6.83-6.72 (m, 1H), 5.8-5.4 (m, 4H), 5.1-4.8 (m, 2H).
F: (13E)-(9S,11R,15R)-11,15-Bis(tetrahydropyran-2-yloxy)-16-(3-chlorophenoxy)-2,3,4,5,6,17,18,19,20-nonanor-9-triethylsilyloxy-13-prostenol Triethylsilyl Ether (18)
To a suspension of 400 mg (10.5 mmol) of lithium aluminum hydride in 20 mL of THF at 0° C. was added dropwise a solution of 4.5 g (8.8 mmol) of lactone 16 in 20 mL of THF. After 1 h at 0° C. the mixture was cautiously poured into 100 mL of a 1/1 mixture of ice-cold saturated NH 4 Cl/ethyl acetate. The layers were separated, and the aqueous layer was extracted with ethyl acetate (2×50 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated to afford 4.5 g (100%) of diol 17 which was used in the next step without further purification
Triethylsilyl chloride (3.0 g, 20 mmol) was added to a mixture of 4.5 g (8.8 mmol) of crude 17, 40 mL of DMF, 1.85 g (27.0 mmol) of imidazole, and 310 mg (2.5 mmol) of 4-(dimethylamino)pyridine. After 2 h, the reaction was poured into 100 mL of a 1/1 mixture of ethyl acetate/saturated NH 4 Cl, layers were separated, and the aqueous layer was extracted with ethyl acetate (2×25 mL). The combined organic layers were washed with water (3×25 mL), added over MgSO 4 , and concentrated. The residue was chromatographed on silica gel eluting with 20% ethyl acetate in hexane to afford 5.2 g (80%) of 18. 1 H NMR (CDCl 3 ) δ (characteristic peaks only) 7.22-7.12 (m, 1H), 6.95-6.88 (m, 2H), 6.83-6.71 (m, 1H), 5.8-5.4 (m, 4H), 5.1-4.8 (m, 2H), 1.0-0.85 (m, 18H), 0.7-0.5 (m, 12H).
G: (13E)-(9S,11R,15R)-11,15-Bis(tetrahydropyran-2-yloxy)-16-(3-chlorophenoxy)-2,3,4,5,6,17,18,19,20-nonanor-9-triethlsilyloxy-13-prostenal (19)
To a mixture of 1.6 g (12.6 mmol) of oxalyl chloride and 15 mL of CH 2 Cl 2 at -78° C. was added dropwise a solution of 1.54 g (19.7 mmol) of DMSO in 2 mL of CH 2 Cl 2 . After 10 min, 4.6 g (6.2 mmol) of bissilane 18 in 8 mL of CH 2 Cl 2 was added dropwise. After 95 min, 3.0 g (30 mmol) of NEt 3 was added. The mixture was then warmed to room temperature and poured into 70 mL of saturated NH 4 Cl. The solution was extracted with of CH 2 Cl 2 (3×70 mL) and the combined organic layers were dried over MgSO 4 , filtered, and concentrated. The residue was chromatographed on silica gel eluting with 20% ethyl acetate in hexane to afford 2.06 g (53%) of 19 as well as 1.5 g (26%) recovered 18. 1 H NMR (CDCl 3 ) δ (characteristic peaks only) 9.78 (t, J=1.4 Hz, 1H), 7.22-7.12 (m, 1H), 6.95-6.88 (m, 2H), 6.83-6.71 (m, 1H), 5.8-5.4 (m, 4H) 5.1-4.8 (m, 2H), 1.0-0.85 (m, 18H), 0.7-0.5 (m, 12H).
H: (5Z,13E)-(9S,11R,15R)-11,15-Bis(tetrahydropyran-2-yloxy)-16-(3-chlorophenoxy)-2,3,4.17,18,19,20-heptanor-9-triethylsilyloxy-5,13-prostadienoic Acid Methyl Ester (21)
To a solution of 1.35 g (4.24 mmol) of phosphonate 20 and 2.60 g (9.84 mmol) of 18-crown-6 in 20 mL of THF at -78° C. was added dropwise 6.9 mL (3.45 mmol) of a 0.5M solution of potassium hexamethyldisilazane in toluene. After stirring for 15 min, a solution of 1.65 g (2.64 mmol) of aldehyde 19 in 20 mL of THF was added dropwise. One hour later, the mixture was poured into 100 mL of saturated NH 4 Cl/ethyl acetate, 1/1, layers were separated, and the aqueous layer was extracted with ethyl acetate (3×30 mL). The combined organic layers were dried over MgSO 4 , filtered, concentrated and the residue was chromatographed on silica gel eluting with 20% ethyl acetate in hexane to afford 1.135 g (63%) of 21. 1 H NMR (CDCl 3 ) δ (characteristic peaks only) 7.22-7.11 (m, 1H), 6.97-6.86 (m, 2H), 6.85-6.75 (m, 1H), 6.4-6.2 (m, 1H), 5.8-5.32 (m, 3H), 3.66 (s, 3H).
I: (5Z,13E)-(9S,11R,15R)-11,15-Bis(tetrahydropyran-2-yloxy)-16-(3-chlorophenoxy)-2,3,4,17,18,19,20-heptanor-9-tetrathylsilyloxy-5,13-prostadien-1-ol (22)
To a solution of 850 mg (1.25 mmol) of ester 21 in 10 mL of THF at 0° C. was added 2.4 mL (3.6 mmol) of a 1.5M solution of diisobutylaluminum hydride in toluene. After 1 h, the mixture was poured into 20 mL of saturated NH 4 Cl and was extracted with ethyl acetate (3×20 mL). Combined organic layers were dried over MgSO 4 , filtered, and concentrated down to 800 mg (98%) of 22 as an oil. 1 H NMR (CDCl 3 ) δ (characteristic peaks only) 7.25-7.15 (m, 1H), 6.97-6.90 (m, 2H), 6.86-6.75 (m, 1H), 5.81-5.41 (m, 4H).
J: (5Z,13E)-(9S,11R,15R)-11,15-Bis(tetrahydropyran-2-yloxy)-16-(3-chlorophenoxy)-3-oxa-17,18,19,20-tetranor-9-triethylsilyloxy-5,13-prostadienoic Acid Isopropyl Ester (23)
To a solution of 415 mg (6.37 mmol) of alcohol 22 in 4 mL of THF at -78° C. was added dropwise 0.35 mL (0.87 mol) of a 2.5M solution of n-BuLi in hexane. After 15 min, this solution was transferred via syringe to a -78° C. solution of 195 mg (1.08 mmol) of isopropyl bromoacetate in 2 mL of THF. The mixture was kept at -78° C. for 40 min, warmed to room temperature overnight, and then poured into 20 mL of a 1/1 mixture of saturated NH 4 Cl/ethyl acetate. Layers were separated, and the aqueous layer was extracted with ethyl acetate (2×10 mL). The combined organic layers were dried over MgSO 4 , filtered, concentrated, and the residue was chromatographed on silica gel (20% ethyl acetate in hexane) to afford 242 mg (53%) of 23 as an oil. 1 H NMR (CDCl 3 ) δ (characteristic peaks only) 7.24-7.15 (m, 1H), 6.97-6.90 (m, 2H), 6.86-6.75 (m, 1H), 5.81-5.41 (m, 4H), 1.57 (d, J=5.7 Hz, 6H).
K: (5Z,13E)-(9S,11R,15R)-16-(3-Chlorophenoxy)-3-oxa-17,18,19,20-tetranor-9,11,15-trihydroxy-5,13-prostadienoic Acid Isopropyl Ester (5)
To a solution of 230 mg (0.32 mmol) of silane 23 in 5 mL of THF at room temperature was added 0.33 mL (0.33 mmol) of a 1M solution of Bu 4 NF in THF. After 20 min, the reaction was poured into 4 mL of saturated NH 4 Cl and was extracted with ethyl acetate (4×5 mL). The combined organic layers were dried over MgSO 4 , filtered, concentrated, and the residue was chromatographed on silica gel (ethyl acetate/hexane, 1/1), to afford 126 mg (65%) of desilylated compound 24.
To 120 mg of 24 in 5 mL of methanol was added 0.4 mL of 2M HCl. After 1 h, the mixture was added to 3 mL of saturated NaHCO 3 , and the resulting mixture was extracted with ethyl acetate (3×8 mL). Combined organic layers were dried over MgSO 4 , filtered, concentrated. The resulting residue was then chromatographed on silica gel eluting with ethyl acetate to afford 54 mg (56%) of 5. 13 C NMR (CDCl 3 ) δ 169.92 (C), 159.26 (C), 135,13 (CH), 134.95 (CH), 134.81 (C), 124.93 (CH), 121.22 (CH), 115.06 (CH), 113.08 (CH), 77.75 (CH), 72.02 (CH), 71.94 (CH 2 ), 70.76 (CH 2 ), 68.77 (CH), 67.78 (CH 2 ), 66.50 (CH 2 ), 55.46 (CH), 49.93 (CH), 42.47 (CH 2 ), 25.85 (CH 2 ), 21.75 (CH 3 ). CI MS, m/z calcd. for C 24 H 34 O 7 Cl 1 (MH + ), 469.1993, found 469.1993.
EXAMPLE 2
Synthesis of 13,14-Dihydrofluprostenol Isopropyl Ester ##STR8## A: (3aR,4R,5R,6aS)-5-Hydroxy-4-[(3R)-4-(3-trifluoromethylphenoxy)-3-hydroxy-1-butyl]-hexahydro-2H-cyclopenta[b]furan-2-one (26)
A mixture of 1.2 g (3.2 mmol) of diol 25 (for synthesis of diol 25, see U.S. Pat. No. 4,321,275) and 0.05 g of 10% (wt/wt) Pd/C in 20 mL of methanol was hydrogenated at 30 psi for 1.5 hours. After filtration through a short pad of Celite® concentration afforded 1.2 g (100%) of 26 as a colorless oil. 1 H NMR (CDCl 3 ) δ 7.44 (m, 2H), 7.12 (m, 2H), 4.95 (dt, 1H), 4.15-3.80 (m, 4H), 2.82 (dd, J=10.8, 1H), 2.55 (m, 2H), 2.3 (m, 1H), 2.1-1.3 (m, 6H).
B: (3aR,4R,5R,6aS)-5-(Tetrahydropyran-2-yloxy)-4-[(3R)-4-(3-trifluoromethylphenoxy)-3-(tetrahydropyran-2-yloxy)-1-butyl]-hexahydro-2H-cyclopenta[b]furan-2-one (27).
A mixture of 1.2 g (3.2 mmol) of diol 26 and 0.05 g of p-toluenesulfonic acid monohydrate in 100 mL of CH 2 Cl 2 at 0° C. was treated with 3,4-dihydro-2H-pyran (1.1 ml, 12 mmol) and the solution was stirred for 2 h at 0° C. After pouring into saturated NaHCO 3 , phases were separated and the organic layer was dried over MgSO 4 , filtered, concentrated, and purified by chromatography on silica gel (1/1, hexanes/EtOAc) to afford 1.1 g of 27 as a clear, colorless oil. 1 H NMR (CDCl 3 ) δ 8.04 (dd, J=7.0, 1.6, 1H), 7.44 (m, 2H), 7.12 (m, 1H), 4.95 (dt, 1H), 4.8 (m, 1H), 4.7 (m, 2H), 4.15-3.80 (m, 4H), 3.5 (m, 2H), 2.82 (dd, J=10.8, 1H), 2.55 (m, 2H), 2.3 (m, 1H), 2.1-1.3 (m, 6H).
C: (5Z)-(9S,11R,15R)-11,15-Bis(tetrahydropyran-2-yloxy)-9-hydroxy-17,18,19,20-tetranor-16-(3-trifluoromethylphenoxy)-5-prostenoic Acid Isopropyl Ester (31)
To a solution of 2.1 g (3.9 mmol) of 27 in 100 mL of THF at -78° C. was added 3.9 mL (5.8 mmol) of a 1.5M solution of diisobutyaluminum hydride in toluene. The solution was stirred for 2 h, then quenched by the sequential addition of 0.4 mL of isopropanol at -78° C. followed by; 0.4 mL of water at 23° C. Volatiles were removed under reduced pressure and the aqueous solution was extracted with Et 2 O/EtOAc (1/1). Organic extracts were dried over MgSO 4 , filtered, and concentrated to furnish 1.9 g of lactol 28.
To a 250 mL 3-necked round bottom flask equipped with a mechanical stirrer and a thermometer were added anhydrous DMSO (100 mL) and NaH (80% dispersion in mineral oil; 0.48 g, 16 mmol). The mixture was heated to 75° C. (internal) for 30 min, after which it was allowed to cool to room temperature for 1 h. Phosphonium bromide 29 (3.5 g, 8 mmol) was then added. After stirring for 30 minutes, 1.9 g (3.5 mmol) of lactol 28 in 50 mL of DMSO was added, and the resulting solution was heated to 50° C. for 2 h and then brought to room temperature for 16 h. The solution was poured into 100 mL of water and approximately 2 mL of 50% NaOH added. The aqueous phase was extracted with ether (3×100 mL), then made acidic (pH=5.5) by the addition of a 10% citric acid solution, and extracted with Et 2 O/hexanes, 2/1 (3×100 mL). The combined organic extracts were added over MgSO 4 , filtered, and concentrated to afford 1.9 g of 30 as a colorless oil.
To 1.9 g of carboxylic acid 30 dissolved in 10 mL acetone was added 0.95 g (6.0 mmol) of DBU and 1.0 g (6.1 mmol) of isopropyl iodide at 23° C. After 16 h, the solution was poured into 100 mL of water and extracted with 100 mL of EtOAc. The organic extract was dried over MgSO 4 , filtered, concentrated, and purified by silica gel chromatography (3/2, hexanes/EtOAc) to afford 1.9 g of isopropyl ester 31 as a colorless oil. 1 H NMR (CDCl 3 ) δ 7.44 (t, 1H), 7.12 (d, 1H), 7.12 (dd, 2H), 5.5-5.3 (m, 2H), 4.99 (heptet, 1H), 4.15-3.80 (m, 4H), 2.82 (dd, J=10.8, 1H), 2.55 (m, 2H), 2.3 (m, 1H), 2.1-1.3 (m, 24H), 1.23 (s, 3H), 1.20 (s, 3H).
D: (5Z)-(9S,11R,15R)-17,18,19,20-Tetranor-16-(3-trifluoromethylphenoxy)-9,11,15-trihydroxy-5-prostenoic Acid Isopropyl Ester (6)
Ester 31 (1.9 g, 2.8 mmol) was dissolved in 14 mL of a mixture of AcOH/THF/H 2 O (4/2/1) and the solution was heated to 50° C. for 1 h, allowed to cool to 23° C., poured into a saturated solution of NaHCO 3 , and extracted with Et 2 O (2×100 mL) and EtOAc (100 mL). The combined organic extracts were dried over MgSO 4 , filtered, concentrated, and purified by silica gel chromatography (1/1, hexanes/EtOAc) to furnish 0.5 g of triol 6 as a clear, colorless oil. 1 H NMR (CDCl 3 ) δ 7.44 (t, J=7.8, 1H), 7.12 (dd, J=7.8, 2.0, 1H), 7.12 (ddd, J=15.6, 7.2, 2.0, 2H), 5.5-5.3 (m, 2H), 4.99 (heptet, J=6.3, 1H), 4.15-3.80 (m, 4H), 3.2 (d, 1H), 2.95 (s, 1H), 2.82 (dd, J=10.8, 1H), 2.75 (d, J=5.9, 1H), 2.55 (m, 2H), 2.3 (m, 1H), 2.1-1.3 (m, 24H), 1.23 (s, 3H), 1.20 (s, 3H). 13 C NMR (CDCl 3 ) δ 173.5, 158.7, 132.1, 131.5, 130.0, 129.5, 129.2, 123.3, 120.8, 117.7, 117.6, 111.4, 111.4, 78.6, 74.4, 72.4, 69.9, 67.6, 52.6, 51.7, 42.5, 34.0, 31.5, 29.4, 26.8, 26.6, 24.9, 21.7.
EXAMPLE 3
Synthesis of Cloprostenol-1-ol (7) ##STR9## A: (52Z,13E)-(9S,11R,15R)-11,15-Bis(tetrahydropyran-2-yloxy)-16-(3-chlorophenoxy)-9-hydroxy-17,18,19,20-tetranor-5,13-prostadienoic Acid Isopropyl Ester (34)
A 1.5M solution of diisobutylaluminum hydride in toluene (10 mL, 15 mmol) was added dropwise to a solution of 5.8 g (11.4 mmol) of lactone 16 in 55 mL of THF at -78° C. After 1 h, 10 mL of methanol was added dropwise, and the mixture was stirred for 10 min at -78° C. before being warmed to room temperature. The mixture was then poured into 100 mL of a 1/1 solution of saturated aqueous potassium sodium tartrate/ethyl acetate and stirred. After separating layers, the aqueous phase was extracted with ethyl acetate (2×40 mL). Combined organic layers were dried over MgSO 4 , filtered, concentrated, and purified by silica gel chromatography (3/2, ethyl acetate/hexane), to afford 4.4 g (76%) of lactol 33, which was used immediately in the next step.
A 1M solution of potassium t-butoxide in THF (50.0 ml) was added dropwise to 12.1 g (27.3 mmol) of phosphonium salt 29 in 100 mL of THF at 0° C. After 30 min, a solution of 4.4 g (8.6 mmol) of lactol 33 in 20 mL of THF was added dropwise, and the mixture was stirred at room temperature overnight. The solution was then poured into 150 mL of a 1/1 mixture of ethyl acetate/saturated NH 4 Cl. Layers were separated and the aqueous layer was extracted with ethyl acetate (2×100 mL). Combined organic layers were dried over MgSO 4 , filtered, concentrated, and the residue was redissolved in 80 mL of acetone. To this was added 6.5 g (45 mmol) of DBU followed by 7.3 g (43 mmol) of isopropyl iodide. After stirring overnight, the reaction was poured into 100 mL of a 1/1 mixture of ethyl acetate/saturated NH 4 Cl. Layers were then separated and the aqueous phase was further extracted with ethyl acetate (2×100 mL). The combined organic layers were dried over MgSO 4 , filtered, concentrated, and purified by silica gel chromatography (40% ethyl acetate in hexane) to afford 2.92 g (53% from lactone 16) of ester 34.
B: (5Z,13E)-(9S,11R,15R)-16-(3-Chlorophenoxy)-17,18,19,20-tetranor-9,11,15-trihydroxy-5,13-prostadienol (7)
A solution of 500 mg (0.79 mmol) of 34 in 10 mL of THF was added dropwise to 61 mg (1.60 mmol) of lithium aluminum hydride in 20 mL of THF at 0° C. After 40 min, the reaction was carefully poured into 15 mL of saturated NH 4 Cl, and the mixture was then extracted with ethyl acetate (3×40 mL). Combined organic layers were added over MgSO 4 , filtered, and concentrated to afford 500 mg of crude 35.
To a solution of 500 mg of 35 in 20 mL of methanol was added 0.5 mL of 2M HCl. After 1 h, the reaction was quenched with 20 mL of saturated NaHCO 3 and the mixture was extracted with ethyl acetate (4×30 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated. Silica gel chromatography (EtOAc) provided 101 mg (31% from 34) of 7. 13 C NMR (CDCl 3 ) δ 159.27 (C), 135.44 (CH), 134.82 (C), 130.64 (CH), 130.26 (CH), 128.23 (CH), 121.25 (CH), 115.07 (CH), 113.08 (CH), 77.35 (CH), 72.35 (CH), 71.90 (CH 2 ), 70.89 (CH), 62.22 (CH 2 ), 55.40 (CH), 49.87 (CH), 42.79 (CH 2 ), 31.83 (CH 2 ), 26.77 (CH 2 ), 25.60 (CH 2 ), 25.33 (CH 2 ). CI MS m/z calcd for C 22 H 32 O 5 Cl 1 (MH + ) 411.1938, found 411.1938.
EXAMPLE 4
Synthesis of 13,14-Dihydrocloprostenol-1-ol Pivaloate (8) ##STR10## A: (3aR,4R,5R,6aS)-4-[(3R)-4-(3-Chlorophenoxy)-3-hydroxybutyl]-5-hydroxyhexahydro-2H-cyclopenta[b]furan-2-one (37):
A mixture of 2.4 g (5.4 mmol) of 14 and 250 mg of 10% (wt/wt) Pd/C in 35 mL of ethyl acetate was hydrogenated at 40 psi for 1 h. After filtration through a short pad of Celite®, the filtrate was evaporated down to 2.3 g (100%) of hydrogenated product 36.
The crude benzoate 36 was dissolved in 25 mL of methanol, and 610 mg (4.4 mmol) of K 2 CO 3 was added. After 3.5 h, the mixture was poured into 100 mL of water/ethyl acetate (1/1). Layers were separated, and the aqueous phase was further extracted with ethyl acetate (2×50 mL). The combined organic layers were dried over MgSO 4 , filtered and concenirated. Silica gel chromatography (EtoAc) provided 1.50 g (82%) of 37 as a white solid, m.p.=102.0°-103.5° C. 1 H NMR δ 7.22 (t, J=8.2 Hz, 1H), 7.0-6.94 (m, 1H), 6.91-6.88 (t, J=2.1 Hz, 1H), 6.83-6.77 (m, 1H), 4.97 (dt, J=3.0, 8.3 Hz, 1H), 4.12-3.91 (m, 3H), 3.82 (dd, J=7.4, 9.0 Hz, 1H), 2.85 (dd, J=8.0, 16.5 Hz, 1H), 2.6-1.4 (m, 11H).
B: (3aR,4R,5R,6aS)-4-[(3R)-4-(3-Chlorophenoxy)-3-(tetrahydropyran-2-yloxy)butyl]-5-(tetrahydropyran-2-yloxy)-hexahydro-2H-cyclopenta[b]furan-2-one (38)
Diol 37 (3.4 g, 10 mmol) and 2.2 g (26 mmol) of 3,4-dihydro-2H-pyran were dissolved in 80 mL of CH 2 Cl 2 , and 240 mg (1.3 mmol) of p-toluenesulfonic acid monohydrate was added at 0° C. After 1 h, the reaction was poured into 50 mL of saturated NaHCO 3 and the mixture was extracted with CH 2 Cl 2 (3×40 mL). The combined organic layers were dried over MgSO 4 , filtered, concentrated, and the residue was chromatographed on silica gel (hexane/ethyl acetate, 1/1) to afford 4.5 g (87%) of bis-THP ether 38.
C: (5Z)-(9S,11R,15R)-11,15-Bis(tetrahydropyran-2-yloxy)-16-(3-chlorophenoxy)-9-hydroxy-17,18,19,20-tetranor-5-prostenoic Acid Isopropyl Ester (41)
A 1.5M solution of diisobutylaluminum hydride in toluene (1.8 mL, 2.7 mmol) was added to the solution 1.05 g (2.06 mmol) of 38 in 10 mL of THF at -78° C. After 1 h, 4 mL of methanol was added and the mixture was warmed to 25° C., then poured into 40 mL of ethyl acetate/saturated aqueous potassium sodium tartrate (1/1). Layers were separated and the aqueous phase was further extracted with ethyl acetate (3×30 mL). The combined organic layers were then dried over MgSO 4 , filtered, concentrated, and the residue was chromatographed on silica gel (ethyl acetate) to afford 740 mg (70%) of lactol 39.
A 1.5M solution of potassium t-butoxide in THF (8.6 mL, 8.6 mmol) was added dropwise to a mixture of 15 mL of THF and 1.92 g (4.33 mmol) of phosphonium salt 29 at 0° C. After stirring for 1 h, a solution of 740 mg (1.45 mmol) of lactol 39 in 5 mL of THF was added dropwise, and the reaction was allowed to warm to 25° C. overnight. The mixture was then poured into 100 mL of ethyl acetate/saturated NH 4 Cl (1/1). Layers were separated, and the aqueous phase was further extracted with ethyl acetate (2×70 mL). Combined organic layers were dried over MgSO 4 , filtered, and concentrated to afford 1.6 g of crude acid 40.
Crude acid 40 (1.6 g) was dissolved in 11 mL of acetone and cooled to 0° C., then 850 mg (5.6 mmol) of DBU was added dropwise to the solution. The resulting mixture was stirred for 15 min at 0° C. and 30 min at 25° C., after which 850 mg (5.0 mmol) of isopropyl iodide was added. The reaction was stirred overnight and poured into 100 mL of ethyl acetate/saturated NH 4 Cl (1/1). Layers were separated, and the aqueous phase was further extracted with ethyl acetate (2×50 mL). Combined organic layers were dried over MgSO 4 , filtered and concentrated. The resulting residue was purified by silica gel chromatography (ethyl acetate/hexanes, 3/2) to afford 560 mg (61% from lactol 39) of isopropyl ester 41.
D: (5Z)-(9S,11R,15R)-16-(3-Chlorophenoxy)-17,18,19,20-tetranor-9,11,15-trihydroxy-5-prostenol Pivaloate (8)
A solution of 400 mg (0.63 mmol) of 41 in 5 mL of THF was added dropwise to a suspension of 35 mg (0.92 mmol) of lithium aluminum hydride in 5 mL of THF at 0° C. After 2 h, the reaction was poured into 50 mL of a 1/1 mixture of ethyl acetate/saturated NaHCO 3 . The layers were then separated, and the aqueous phase was extracted with ethyl acetate (2×2 mL). Combined organic layers were dried over MgSO 4 , filtered, and concentrated. The resulting residue was purified by silica gel chromatography (ethyl acetate) to afford 350 mg (95%) of diol 42.
Pivaloyl chloride (90 mg, 0.75 mmol) was added to a mixture of 350 mg (0.60 mmol) of 42, 60 mg (0.76 mmol) of pyridine, 22 mg (0.18 mmol) of 4-(dimethylamino)pyridine, and 7 mL of CH 2 Cl 2 . After 1.5 h, the mixture was poured into 30 mL of saturated NH 4 Cl/ethyl acetate (1/1). Layers were then separated and the aqueous phase was extracted with ethyl acetate (2×20 mL). The combined organic layers were dried over MgSO 4 , filtered, concentrated, and purified by silica gel chromatography (ethyl acetate/hexane, 3/2) to afford 370 mg (93%) of pivaloate 43.
Water (approximately 10 drops) and concentrated HCl (approximately 3 drops) were added to a solution of 370 mg (0.56 mmol) of 43 in 5 mL of methanol. After stirring overnight, the reaction was quenched by the addition of 20 mL of saturated NaHCO 3 , and the mixture was extracted with ethyl acetate (3×20 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated. The residue was chromatographed on silica gel (ethyl acetate/hexane, 3/2), to afford 165 mg (59%) of triol 8. 13 C NMR (CDCl 3 ) δ 178.77 (C), 159.27 (C), 134.80 (C), 130.20 (CH), 128.62 (CH), 121.19 (CH), 114.97 (CH), 112.97 (CH), 78.50 (CH), 74.46 (CH), 72.31 (CH 2 ), 69.86 (CH), 64.16 (CH 2 ), 52.53 (CH), 51.67 (CH), 42.50 (CH 2 ), 31.51 (CH 2 ), 29.40 (CH 2 ), 28.10 (CH 2 ), 27.12 (CH 3 ), 26.77 (CH 2 ), 26.65 (CH 2 ), 25.77 (CH 2 ). CI MS, m/z calcd for C 27 H 41 O 6 Cl 1 (MH + ), 497.2670, found 497.2656
EXAMPLE 5
PGF 2 α analogues are known to contract the iris sphincter of cats and this assay is a generally accepted reference for activity. For this reason, the pupil diameter of cats may be used to define the activity of PGF 2 α analogues and, as demonstrated by Stjernschantz and Resul (Drugs Future, 17:691-704 (1992)), predict the IOP-lowering potency.
Compounds of the present invention were therefore screened for pupillary constriction in the cat. Data for compounds 6, 7, and 8 are presented in Table 2, below. The response is quantitated as Area 1-5 values (area under the pupil diameter versus time curve from 1-5 hours), and the equivalent response dose (ED 5 ) is estimated from its dose response relationship.
TABLE 2______________________________________Cat Pupil Diameter ResponseCompound ED.sub.5 (μg)______________________________________PGF.sub.2α Isopropyl Ester 0.02Cloprostenol Isopropyl Ester 0.016 0.27 0.028 0.06______________________________________
Discussion:
The two standard compounds, PGF 2 α isopropyl ester and cloprostenol isopropyl ester, produced marked change in cat pupillary diameter, displaying ED 5 values of 0.02 and 0.01 μg, respectively. Compound 7 (cloprostenol-1-ol) and compound 8 (13,14-dihydrocloprostenol-1-ol pivaloate), displayed nearly equivalent potency. 13,14-Dihydrofluprostenol isopropyl ester (compound 6) was approximately one order of magnitude less potent, with an ED 5 of 0.2 μg.
EXAMPLE 6
In the study presented below, compound 6 (Table 1, above) was tested for IOP-lowering effect in cynomolgus monkey eyes.
The right eyes of the cynomolgus monkeys used in this study were previously given laser trabeculoplasty to induce ocular hypertension in the lasered eye. Animals had been trained to sit in restraint chairs and conditioned to accept experimental procedures without chemical restraint. IOP was determined with a pneumatonometer after light corneal anesthesia with dilute proparacaine. The test protocol included a five-dose treatment regimen because of the typical delayed response to prostaglandins. The designated test formulations were administered to the lasered right eyes, and the normal left eyes remained untreated, although IOP measurements were taken. Baseline IOP values were determined prior to treatment with the test formulation, and then IOP was determined from 1 to 7 hours after the first dose, 16 hours after the fourth dose, add 1 to 4 hours after the fifth dose.
The equivalent response dose (ED 20 ) is estimated from the dose response relationship to be the dose producing a 20% peak reduction in IOP.
TABLE 3______________________________________Monkey IOP ResponseCompound ED.sub.20 (μg)______________________________________PGF.sub.2α Isopropyl Ester 0.46 0.3______________________________________
Discussion:
As can be seen in Table 3, compound 6, the 13,14-dihydro analogue of fluprostenol was quite potent in the monkey IOP model, producing a 20% reduction at 0.3 μg. This was even more potent than the standard compound, PGF 2 α isopropyl ester.
EXAMPLE 7
The following Formulations 1-4 are representative pharmaceutical compositions of the invention for topical use in lowering of intraocular pressure. Each of Formulations 1 through 4 may be formulated in accordance with procedures known to those skilled in the art.
______________________________________FORMULATION 1Ingredient Amount (wt %)______________________________________Compound 5 (Table 1) 0.002Dextran 70 0.1Hydroxypropyl methylcellulose 0.3Sodium chloride 0.77Potassium chloride 0.12Disodium EDTA 0.05Benzalkonium chloride 0.01HCI and/or NaOH pH 7.2-7.5Purified water q.s. to 100%______________________________________
______________________________________FORMULATION 2Ingredient Amount (wt %)______________________________________Compound 6 (Table 1) 0.01Monobasic sodium phosphate 0.05Dibasic sodum phosphate 0.15(anhydrous)Sodium chloride 0.75Disodium EDTA 0.01Benzalkonium chloride 0.02Polysorbate 80 0.15HCl and/or NaOH pH 7.3-7.4Purified water q.s. to 100%______________________________________
______________________________________FORMULATION 3Ingredient Amount (wt %)______________________________________Compound 7 (Table 1) 0.001Dextran 70 0.1Hydroxypropyl methylcellulose 0.5Monobasic sodium phosphate 0.05Dibasic sodium phosphate 0.15(anhydrous)Sodium chloride 0.75Disodium EDTA 0.05Benzalkonium chloride 0.01NaOH and/or HCl pH 7.3-7.4Purified water q.s. to 100%______________________________________
______________________________________FORMULATION 4Ingredient Amount (wt %)______________________________________Compound 8 (Table 1) 0.003Monobasic sodium phosphate 0.05Dibasic sochum phosphate 0.15(anhydrous)Sodium chloride 0.75Disodium EDTA 0.05Benzalkonium chloride 0.01HCl and/or NaOH pH 7.3-7.4Purified water q.s. to 100%______________________________________
The invention has been described by reference to certain preferred embodiments; however, it should be understood that it may be embodied in other specific forms or variations thereof without departing from its spirit or essential characteristics. The embodiments described above are therefore considered to be illustrative in all respects and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description. | Disclosed is the use of cloprostenol and fluprostenol analogues for the treatment of glaucoma and ocular hypertension. Also disclosed are ophthalmic compositions comprising said compounds. | 0 |
FIELD OF THE INVENTION
The present invention relates to a plant and process for continuous manufacture of products formed of foam material and having recesses, such as latex foam mattresses, cushions and the like.
BACKGROUND OF THE INVENTION
Mold processes for manufacturing the above type of products with recesses or cells are known. For example, according to a known process, the manufacture of a cellular mattress is effected by employing a mold which opens into two halves and filling the mold partially with latex foam material and allowing the latex foam material to foam when the mold is closed. One or both parts of the mold are provided with a plurality of protuberances which have an overall conical shape or a substantially cylindrical shape with a conical end; these protuberances have a shape corresponding to the recesses or cells of the mattress to be formed. The mold is adequately heated by introducing a liquid at a predetermined temperature for thermal treatment of the article along an appropriate outer hollow space. In a subsequent step, the mold is opened and the mattress must be manually removed from the upper cover since the mattress becomes adhered to the protuberances of the upper cover during the molding process. In succeeding steps, the mattress is washed to remove undesired substances in the finished product and it is then subjected to a drying process.
In another heretofore known process, a plurality of molds arranged on trolleys placed one after the other are advanced through a tunnel vulcanizer which is steam heated. Unlike the first mold process, in this case a foam material which is emulsified with air and free of swelling agents is injected through particular holes provided on the cover until the whole volume of the mold is filled and fins of material overflow from proper openings of the mold to guarantee the appropriate dimension of the final product. Further steps of the process, i.e., opening of the molds and removal of the mattress, washing and lastly drying, are more or less the same as those of the first mold process.
It will be readily understood that the above-described mold processes require, to achieve certain dimensions for each product, a mold with corresponding dimensions. Therefore, if the width or height of the mattress is to be varied, it is necessary to plan and provide a new mold in order to satisfy the various market demands for different sized products.
Mold processes for manufacturing and marketing products with recesses, which are for the same use but have different dimensions, generally have a drawback in that they incur a high cost for their realization. Moreover, to implement such processes requires manual intervention by one or more operators, as, for instance, the removal of the mattress from the protuberances of the open mold with the negative consequence of damaging the products resulting from an excessive pull on a just-shaped spongy material and the great discomfort that the operator suffers from the significant heat emission resulting from the opening of the mold. Unfortunately, such mold processes furthermore result in cellular products with some flaws relative to the desired product. The cause of such product flaws is mainly connected to the vulcanizing step. In fact, to effect the vulcanizing step, it is necessary to utilize pressurized, very hot steam which is caused to circulate all around the mold along appropriate hollow spaces with consequent transfer of heat from the steam to the metallic masses of the mold, i.e., to the walls and protuberances of the mold. As the protuberances are numerous and are distributed in a regular manner in the foam mass, they transfer the vulcanization heat also to the product.
Unfortunately, the connections between protuberances and cover may give rise to an irregular cross-linking from one point to the other of the foam. This negative circumstance is due to the fact that each protuberance is associated with the cover through a metal plate that closes completely the inside of the protuberance to form a closed cavity. In some cases, the steam, due to its high pressure, is able to penetrate between the plate and the lateral wall of the protuberance to occupy at least partially a part of the cavity. Subsequently, at the end of the cycle, the steam deposits as a condensate and, as a consequence, the mold may have, in the vulcanizing step, either protuberances with empty cavities or protuberances whose cavities are partially filled with steam condensate.
It will be readily understood that the different heating conditions to which the different protuberances may be subjected can cause non-uniform cross-linking operations of the foam giving rise to a cellular product with characteristics different from one zone to the other. In these circumstances, the product, for instance a mattress, may exhibit during use the drawback of tearing in the zone which is less vulcanized as a result of numerous folding cycles of said zone.
Another process is known for manufacturing a layer of spongy material of unlimited length based on a technique of continuously rotating a steel tape between rollers forward the planar portion of the tape through a tunnel vulcanizer heated with high-pressure steam. At the entry of the planar portion of the tape, the foam material is injected and distributed in opposite senses to each other along a direction transverse to the advancing direction of the tape to form the desired thickness of the layer. After the vulcanization step, the foam layer is cut according to desired dimensions and then is passed through the usual washing and drying steps.
This continuous process could overcome some of the drawbacks cited in the above-described mold processes, i.e., either that of (1) obtaining products with different widths through suitable cutting operations transverse of the layer, (2) overcoming the numerous manual operations following the opening of the molds to remove the single products or (3) eliminating the discomfort experienced by the operators due to heat emission into the working ambient upon opening the molds.
However, it noted that this process is not suitable for manufacturing products with recesses in which, conventionally, the thicknesses of the foam can reach 20 cm and over.
In fact, the heat inside the steam tunnel can be used tor vulcanizing products with a low thickness, namely of several centimeters, but it is not sufficient for vulcanizing products with greater thicknesses. In substance, since this continuous process lacks the plurality of protuberances present in the molds of the mold processes described above and immersed in the surrounding foam mass to which the protuberances transfer vulcanization heat, the continuous process described above, which is based on the use of a steel tape, can be used only for manufacturing products without recesses with a thickness to a maximum of 5 cm, for instance, for plugs used for removing facial make-up and to be thrown away after use or to form possible upper and lower layers in a spring mattress. It is therefore readily understandable how this continuous process excludes the possibility of manufacturing products with recesses of latex foam, among other things mattresses with recesses having thicknesses between 14 and 18 cm, as for example mattresses of 14 cm thickness with cells having a depth of 11 cm.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide a process and plant for manufacturing products having recesses and formed of a foam material such as a latex polymer material which overcome all of the above-noted disadvantages in the prior art.
The present invention provides a process for manufacturing products having recesses and formed of foam material, wherein the products are in the form of a continuous layer of unlimited length divisible into single pieces of predetermined dimensions. The process includes the steps of: (1) continuously rotating a laying surface closed in a ring configuration defined at any moment by a planar portion moving forward according to a first direction and a return portion moving in an opposite sense to the first direction; (2) laying the foam material at the beginning of the planar portion of the laying surface in a transverse sense to the first direction to provide a foam layer of predetermined thickness on the laying surface; (3) vulcanizing the foam layer downstream of the beginning of the planar portion between a first and a second position by supplying heat between the first position and the second position via pressurized steam; (4) forming a plurality of recesses in the foam layer as it is being laid on the laying surface, the recesses comprising a base open at the laying surface and having a predetermined height which is smaller than the total thickness of the foam layer; and (5) introducing pressurized steam through the base of the recesses to supply heat into the cavity formed during the recess-forming step.
It should be noted that the present process has a characteristic step of molding a plurality of recesses in the thickness of the foam layer as it is being laid and a further characteristic step of introducing steam under pressure into the molding cavity during the vulcanizing step. The result obtained via these characteristic steps enables the drawbacks resulting from the vulcanizing step of the prior art process employing a mold open into two halves to be overcome. In fact, the molding cavities corresponding to the cells are of the order of some thousands in a portion of the continuous foam layer corresponding to a mattress and may have heights equal to 70% and 80% of the total thickness of the finished product. Consequently, the heat supplied by the steam inside the cavities can spread directly in a uniform and complete manner over the entire portion of the cellular foam. In practice, by introducing steam inside all of the molding cavities of the cells, the cross-linking of the cellular foam mass is complete and homogeneous and overcomes thus the drawbacks of the mold vulcanizers discussed above in which the presence of metallic protuberances which are hollow but closed at their bases, resulted in, due to possible steam infiltrations either with empty protuberances or protuberances with condensate, unacceptable products deriving from a non-uniform cross-linking from one zone to the other.
Moreover, the present process provides the advantage of enabling the formation of a continuous foam layer having recesses with possible variations of the thickness of the foam layer over the recesses. In fact, the invention makes it possible to conveniently act on the advancing speed of the laying surface on which the foam layer is laid and on the transverse injection speed of the foam to obtain a product of predetermined height. In the preferred embodiment, the desired height is conveniently regulated by means of a leveling operation through a rigid surface arranged at a predetermined distance from the laying surface of the foam layer. Moreover, the formation of a continuous layer of foam with recesses enables advantageously a plurality of transverse cuts to be made on the vulcanized layer maintaining the continuous cutting lines at a desired distance from one another so as to obtain, for instance, mattresses all having the same width or mattresses having a variable width each time depending on customer requirements.
Therefore, the present process overcomes all of the drawbacks of the prior art mold processes in which the fixed dimensions of the mold did not permit formation of recessed articles for the same use but with different dimensions.
The present invention further provides a plant for continuously manufacturing products having recesses and formed of foam material in the form of a layer of unlimited length divisible into single pieces of predetermined dimensions. The plant includes: (1) a conveyor element closed in a ring configuration around at least two circular units rotating around parallel axes, the ring configuration being defined by a planar portion and a return portion connected together by curvilinear portions; (2) a tunnel vulcanizer provided with high-pressure steam and crossed by said planar portion between two extreme positions thereof; (3) a foam laying device for laying foam material on the conveyor element; and (4) a station for the entry of the planar portion comprising a support structure which is suspended with respect to the conveyor element and a driving means associated with the support structure for moving the laying device back and forth in a transverse direction relative to the conveyor element. The conveyor element comprises a supporting surface formed by a plurality of plates. Each plate is provided with outwardly projecting protuberances which are shaped to have an outer configuration which corresponds to the shape of the recesses of the product to be manufactured. The protuberances are hollow inside and open at their base adjacent the surface of the plates. Each plate is laterally associated with means for transmitting motion in cooperation with the rotating units.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, advantages and features of the invention will be more fully understood when considered in conjunction with the following discussion and the attached drawings, of which:
FIG. 1 is a lateral view of the plant with various parts broken away in the middle;
FIG. 2 is a top partial view of FIG. 1 with parts broken away.
FIG. 3 is a cross section of the vulcanizer shown in FIG. 1;
FIG. 4 shows schematically two laying plates of the plant of FIG. 1 associated to a gearing chain;
FIG. 5 shows one of the lateral boundary walls of the laying plates;
FIG. 6 is a front view of a laying plate with the lateral boundary walls;
FIG. 7 shows a continuous layer formed by the plant of FIG. 1;
FIG. 8 shows a blade used to mold undulations on the layer of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, reference numeral 1 refers to a plant for continuously manufacturing products formed of latex foam material and having recesses or cells, for instance a synthetic latex of butadiene styrene.
Plant 1 provides for manufacturing a continuous layer of unlimited length divisible into single pieces of predetermined dimensions. For example, plant 1 is suitable for manufacturing mattresses, comprising cells open on their innermost surface.
With reference to FIG. 1, plant 1 comprises a conveyor element 2 closed as a ring around rotating circular units 3-5, a tunnel vulcanizer 6 provided with pressurized steam, a device 7 for injecting foam material, and a mechanism 8 for automatically removing the continuous layer.
More specifically, the configuration of conveyor element 2 is defined instantaneously in its upper part by a planar portion 9 and in its lower part by a return portion 10.
Portions 9 and 10 are connected at their outermost ends by a curvilinear portion 11 shaped in a circular arc and at their other ends by two circular arc-shaped curvilinear portions 12 and 13 joined together by a vertical rectilinear portion 14.
Tunnel vulcanizer 6 is crossed by planar portion 9 of the conveyor element between two extreme positions 15 and 16.
Moreover, in proximity of extreme position 15 of the vulcanizer above planar portion 9 there is provided a heating element 17.
Injection device 7, placed at the entry station of planar portion 9, comprises substantially a flexible tubular duct 18 connected at one end to a pump (not shown) sucking into a tank containing the butadiene styrene latex foam.
End 19 of tubular duct 18 is associated with a structure 20 which is suspended with respect to conveyor element 2. End 19 is moved back and forth in a direction transverse of conveyor element 2 through driving means of any type, for example, a trolley set in action by a chain control moved by a motor.
Mechanism 8 for automatically removing the continuous layer is formed by a pair of cylindrical rollers 23, 24 arranged opposite to each other and above conveyor element 2 in proximity of the final end of planar portion 9.
The essential characteristics of conveyor element 2 is described in detail below.
The supporting structure of the foam layer is formed by a plurality of plates 25 (FIGS. 1 and 2) of aluminium. Each plate connects through a soldering or screwing operation a plurality of conical protuberances 26 of aluminium projecting outwardly.
Inside, the protuberances are hollow and open at their bases (FIG. 3) to permit the introduction of steam during the vulcanizing step.
Plates 25 are associated at their ends with two lateral chains engaging laterally with the respective gear wheels 3-5 (FIG. 1).
Each chain, which may be of any known type, comprises in the schematic view made by way of example in FIG. 4, adjacent links 27-29 forming empty spaces and connected to one another by pins 30 adapted to receive thrusts or to transmit motion during the meshing step with teeth 31 (represented with a dashed line) of a gear wheel.
As shown in FIG. 4, the ends of one same side of plates 25 are integral or of a one-piece construction with the lateral chains in the zones 32 of a link (FIG. 5) so as to permit, during the continuous movement of conveyor element 2, the passage from a configuration in which plates 25 are all placed side by side along planar portion 9 and return portion 10 to a configuration in which plates 25 are separated from one another according to polygonal profiles in circular arc-shaped curvilinear portions 12 and 13 (FIG. 1).
Further, plant 1 is characterized in that it comprises boundary means for providing a lateral boundary of the foam layer to obtain mattresses of the desired length.
Preferably, the boundary means comprise on each plate 25 rigid walls 33, 34, preferably of aluminium, opposite to each other and arranged perpendicular to the surfaces of plates 25 (FIG. 6).
Also preferably, one of walls 33, 34 is movable with respect to the other to enable the apparatus to be used to make mattresses of different predetermined lengths.
According to one of the possible embodiments (FIGS. 5 and 6), in proximity of one end of each plate 25, there is provided a supporting block 36 with respect to which an L-shaped strap 37 or the like can slide longitudinally of plate 25. Strap 37 is provided with a projecting mobile part or rigid wall 34 to be inserted between two contiguous rows of protuberances 26.
Both block 36 and strap 37 are provided with connection means for providing a mutual connection therebetween. The connection means can comprise two rows of holes 38 for providing mutual blocking through suitable pins 39.
Manufacture of the continuous layer of cellular foam to obtain single mattresses is effected as follows.
The conveyor element 2, which undergoes continuous rotation, moves the various laying plates 25 (FIG. 1) cyclically at a spraying station 40 placed below the first part of the return portion 10.
In the spraying station, a plurality of nozzles inject antiadhesive substances on protuberances 26 so as to facilitate subsequent removal of the continuous layer from protuberances 26 themselves (FIG. 7).
After travelling over return portion 10, plates 25 associated with the lateral chains and separated from one another along the arcs traversed while winding around gear wheels 3-5 reach gradually the entry station of the planar portion 9 placed side by side below foam injecting device 7.
At the entry station of planar portion 9 the mechanism for setting in action the laying device moves end 19 of the tubular duct back and forth in the transverse direction between rigid walls 33, 34 (FIG. 6) of each plate 25.
The foam, already emulsified with air to reach the desired viscosity, reaches tubular duct 18 through a pump sucking into a tank where the aqueous dispersion of natural or synthetic latex is mixed with the usual surface-active fillers having the task of avoiding the formation of agglomerates of particles before injection.
The laid foam material covers plates 25, the spaces between protuberances 26 and the portion on protuberances 26 up to a level so as to constitute a layer T (FIG. 7) of a given thickness, which is levelled then at the desired height by a blade 41 maintained at a predetermined distance from moving plates 25.
Blade 41 may be mounted with its upper end oscillating around a horizontal axis.
Alternatively, blade 41 may be replaced by a blade 42 (FIG. 8) shaped in its lower part with a series of undulations 43' in order to provide a plurality of longitudinal undulations on the outer surface of the foam layer.
Between blade 41 and entrance 15 of the tunnel, the foam layer is conveniently heated via emission of infrared rays through an infrared device 43 in order to facilitate a freezing of the foam and a superficial hardening of the layer.
The freezing of the layer, as known, avoids collapsing of the foam and a corresponding chemical reaction based on the use of a freezing agent. For example, sodium flurosilicate, already introduced in the starting compound, is favored by the characteristic step of feeding heat with the emission of infrared rays.
In particular, and very advantageously, the superficial hardening carried out through the infrared rays protects the continuous foam layer from imprintings and the like that could be caused for whatever reason by action of the outer ambient on the layer.
Moreover, according to one of the characteristics of the invention, the pre-arrangement at the entrance of the vulcanizer of heating element 17 advantageously avoids a problem wherein the steam of the vulcanizer, escaping from the tunnel above and in an opposite direction to the advancing direction of the conveyor element, may be transformed into condensate drops with the risk that falling downwardly such drops might cause indentations on the continuous foam layer in an unacceptable manner.
Following the freezing step, the foam layer passes through the tunnel while remaining subjected to the action of the pressurized steam ejected from appropriate injectors 44, 45 and 46 and then travels in the direction of the arrows shown in FIG. 3.
The pressurized steam striking the bottom of plates 25 penetrates through the openings on plates 25 and passes into hollow protuberances 26 which in turn transfer heat directly to the foam mass in which they are embedded.
Upon coming out of the vulcanizer 6, the continuous layer passes through rollers 23, 24 (FIG. 7) which are moved in opposite directions to each other at a peripheral speed equal to the speed of advance of plates 25 in order to maintain traction forces of constant value suitable for automatically removing the layer from protuberances 26 while avoiding any risk of tearing.
The foam layer which has been vulcanized and removed from the conveyor element is then sent to a suitable chute and is passed through the necessary washing and drying steps, followed by the cutting step to obtain the individual mattresses.
Alternatively, the continuous layer could be cut immediately after vulcanization and then the various lengths could be sent one by one to the subsequent washing and drying steps.
The various mattresses are obtained by making cutting lines which are oriented transversely to the length of the foam layer and maintaining between the contiguous cuts a distance equal to the desired width of the individual mattresses.
The washing steps are carried out substantially according to known techniques and are briefly summarized below.
According to one embodiment, the foam layer or the single mattresses are advanced into one or more water tanks through a plurality of pairs of rotating rollers arranged in opposite sense to one another and at a mutual distance lower than the thickness of the product.
Substantially, the subsequent passage of the product between opposite rollers and subsequent pairs of rollers provides alternate steps including wringing of the foam layer and water intake into the foam layer in order to expel undesired substances from the foam layer.
In particular, during the washing operation, the surfaceactive fillers introduced in the starting compound are expelled.
The further drying operation is carried out by laying the foam layer or the single mattresses on a conveyor belt and causing them to pass through suitable ovens or the like.
It is readily apparent from the above description that the plant according to the invention achieves the objects described above.
In fact, the plurality of plates 25 provided with hollow protuberances 26 projecting outwardly and open at their base permits a capillary and uniform vulcanization of the foam due to the passage of the steam inside the cavities of each protuberance.
Therefore, due to the cited characteristic the disadvantages present in the prior art mold processes during the vulcanizing step, i.e., the possible residue of steam condensate inside the protuberances, are overcome.
Moreover, the independence of plates 25 with respect to each other is a significant feature of the plant of the present invention.
In fact, each plate 25 is individually connected laterally to a link of a chain, so that each plate 25 follows the flexibility of the chains while traversing an arc while winding around the gear wheels.
In practice, due to the cited characteristic, plates 25 are positioned side by side in the planar portion of the conveyor where the continuity of the conveying surface assures the regular laying of the foam material and plates 25 themselves are separated from one another according to a polygonal configuration when they traverse the curvilinear portions around wheels 3-5.
Therefore, the conveyor element is characterized in that it comprises laying planes which are independent of the bending effect around the pulleys and which therefore are not affected by mechanical stresses that would arise in a tape with a continuous surface of a given thickness while traversing an arc while winding around the wheels of the driving device
From this characteristic it follows that the various protuberances 26 projecting from plates 25 are also free of mechanical stresses.
Consequently, since the positions of protuberances 26 on plates 25 are unchanged, the desired recessed geometry of the final product is guaranteed.
Therefore, it can be readily understood how the plant according to the invention overcomes the drawbacks of the prior art plants which use a continuous steel tape and a tunnel vulcanizer unsuitable for forming continuous layers of products with recesses of substantial thickness.
Moreover, the preferred characteristic of the plant of the invention relating to the presence of walls 33 and 34 on each plate 25, one of which is movable with respect to the other, enables the width of the foam layer to be varied as desired so that the length of the individual product can be varied after the transverse cut of the foam layer.
Therefore, it is readily apparent how the plant of the invention can be advantageously used, without cost increases for the production of mattresses with recesses and the like for which frequent variations of size are required.
The further preferred characteristic of an undulated blade 42 enables production of, for instance, mattresses having wavy surfaces by using a simple apparatus and an equally simple [continuous superficial imprinting operation of the foam layer.
A further advantageous aspect of the invention is provided by the continuous removal of the already vulcanized foam layer through rollers 23, 24 thus overcoming either the prior art disadvantages of manual steps removing the recessed products from the molds or uncomfortable working conditions to which the operators are subjected due to significant heat emission upon opening the molds.
It should be noted that the above description and the accompanying drawings are merely illustrative of the application of the principles of the present invention and are not limiting. Numerous other arrangements which embody the principles of the invention and which fall within its spirit and scope may be readily devised by those skilled in the art. | The process includes molding a plurality of recesses on a layer of foam material which is laid on a laying surface and moved forward. These recesses include a base open on the laying surface and are subsequently cross-linked by introducing steam under pressure through the bases of the recesses into cavities of the recesses formed during the molding step. The plant includes a conveyor element in which a plurality of plates disposed side-by-side are provided with protuberances corresponding to the recesses to be formed in the foam layer. The protuberances are open at their bases to enable introduction of steam into an inner space within each of the protuberances. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
Pursuant to 35 USC §371, this application is a National Stage of International Application No. PCT/EP2009/007325, filed Oct. 12, 2009, which claims priority to German Patent Application No. 10 2008 051 488, filed Oct. 13, 2008 under applicable paragraphs of 35 USC §119, wherein the entire contents of each above-noted document is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a head piece for a setting device and a setting device equipped with this head piece, particularly for joining a setting bolt or a punch rivet.
BACKGROUND OF THE INVENTION
Various versions of head pieces for setting devices are known in the prior art. Such head pieces contain a joining channel through which the auxiliary joining part is joined using the punch of the setting device. Auxiliary joining parts are setting fasteners or punch rivets, for example.
Before the auxiliary joining part is placed in a component, it is moved through the joining channel in the head piece. Therefore, the head piece is used, for example, for braking or positioning of the auxiliary joining part so that it can be optimally placed by the punch of the setting device. For this purpose, a braking path, which is comprised of two half shells, is known from DE 297 19 744. These half shells form a part of the joining channel. The half shells at their one end are fastened so as to pivot, and at their other end are connected together via spring rings so that an auxiliary joining part moving through the joining channel is braked due to friction. The document, EP 0 746 431 B1, describes a head piece in which spring preloaded spheres project into the joining channel. The auxiliary joining part is retained at these spheres so that it can be taken along out of this retaining position by the punch for the setting process. This sphere arrangement has the disadvantage that with rapid setting movements of the auxiliary joining part, these spheres are subjected to strong acceleration forces which leads to uneconomical wear of this arrangement.
The document, EP 0 387 430 A2, discloses the arrangement of multiple sleeve-like elements whose resilient fingers narrow the joining channel. These resilient fingers catch an incoming auxiliary joining part and position it so that later it can be moved along by the punch of the setting device. The document, DE 197 04 480 A1, similarly describes the arrangement of a sphere construction in the joining channel, in order to influence the movement of the auxiliary joining part in the joining channel. The disadvantages described above, apply here too.
The document, DE 10 2008 018 428, describes a joining channel having a braking path. This braking path is comprised of multiple webs extending in the longitudinal direction of the joining channel that project into the joining channel preloaded by a spring. This braking path catches an auxiliary joining part that is fed loose to the setting device or joining channel, in order to then be carried along by the punch of the setting device during the setting or riveting process.
The object of the invention is to provide a head piece for a setting device and a setting device having this head piece that supports both the positioning of the auxiliary joining part beneath the punch of the setting device as well as an optimal feed of the auxiliary joining part for the join location.
SUMMARY OF THE INVENTION
The above object is achieved by a head piece, a setting device, and a setting method according to the claims.
The inventive head piece for a setting device comprises a joining channel, which extends in the longitudinal direction of the head piece. The head piece has the following features: an inner hollow cylinder in which the joining channel runs, a plurality of braking webs that are movable and extend radially spring preloaded into the joining channel, and a casing tube that encloses the inner hollow cylinder so that springs for the preloading of the braking paths are held between the inner hollow cylinder and the casing tube.
The present invention yields a compact design of a head piece having braking paths. This braking path is comprised of braking webs, spring preloaded into the interior of the joining channel, that are preloaded and held by a specific spring arrangement. The springs for the preloading of the braking webs are disposed and clamped between the inner hollow cylinder and the casing tube of the head piece. This results in increased stability and also an adapted spring behavior of the clamped springs because these springs cannot yield at will into a free space. Instead, with mechanical loading, the yielding of the springs is restricted by the clamping casing tube. This has a positive effect particularly during high speed joining of auxiliary joining parts because a resilient rebound of the auxiliary joining part is reduced by the braking webs.
For the advantageous design of the head piece, the springs are configured so that the braking web can be deflected damped, and can be reset delayed into its initial position. In this manner the spring initially absorbs a lateral impact of a setting fastener and its energy, and returns this energy temporally delayed in comparison to a standard steel spring. As a result, the braking web does not spring back immediately into its initial position, rather returns temporally delayed. According to a further embodiment, the springs of the head piece are configured so that the braking web can be deflected with a progressive spring characteristic, and can be reset damped into its initial position. As a result, the deflected braking web during its radially outward directed movement experiences an increasing spring resistance as a counteracting force. The reset of the braking web is damped so that the braking web does not immediately spring back in the joining channel. In this manner, the energy absorbed by the braking web from the setting fastener is returned delayed to the setting fastener. The spring behavior described here is preferably implemented for all spring configurations described here, that is, for the springs or O-rings in the same manner as for the spring loaded channel segments have a damping layer (see below).
According to a preferred design of the head piece, the inner hollow cylinder has a plurality of channels opening into the joining channel that can be connected via the casing tube to the environment or to a compressed air source.
The channels opening into the joining channel are used to create a directed air stream counter to the setting movement of the auxiliary joining part in the joining channel. This directed air stream is generated either by suction of air out of the head piece of the setting device, or by blowing compressed air in through the channels into the joining channel in the direction of the setting device. Due to the air stream, the auxiliary joining part is pressed against the front side of the punch of the setting device, so that the auxiliary joining part is prepositioned in this manner. If the punch of the setting device starts the setting process, the auxiliary joining part is taken along by the punch, without the auxiliary joining part rushing ahead of the punch movement. In this manner, the movement of the auxiliary joining part is better controlled during the setting process.
According to a further design of the present head piece, it has a connection end for connecting to a setting device. In addition, its braking webs are disposed in each case in a continuous longitudinal groove the inner hollow cylinder, and are fastened there by means of pins provided in the end regions of the braking webs. This type of fastening of the braking webs guarantees a free movement of the braking webs in the radial direction, and sufficient mechanical stability of the braking webs within the head piece during the setting movement of the punch.
According to a further preferred embodiment of the present invention, the springs used in the head piece are composed of plastic or rubber O-rings, which are clamped between the casing tube and the outer wall of the inner hollow cylinder, so that their spring behavior can be changed, compared to the unclamped state.
The targeted clamping of the O-rings, which are composed of plastic or rubber, reduces the elastic behavior of the spring preloaded braking webs. In this manner, a rebounding of the auxiliary joining part during the joining process is reduced because the radial yielding and spring back of the braking webs is slower, and occurs with a greater loss of energy compared to steel springs, for example.
In addition, it is preferred to combine several O-rings into spring packets so that the braking webs are held with three equally spaced spring packets.
A further inventive head piece for a setting device having a joining channel has the following features: a casing tube, an inner hollow cylinder, in which the joining channel runs, and which is formed by a plurality of channel segments subdivided in the longitudinal direction, and a damping layer, which is disposed between the inner hollow cylinder and the casing tube, so that the channel segments are damped in the radial direction and can be moved so as to be reset in a spring loaded manner.
In comparison to the previously discussed braking webs, the channel segments guarantee a support of the auxiliary joining part at any location, also including changing locations, within the joining channel during the setting procedure. This reduces wear, for example, of the auxiliary joining part and channel segment during the setting procedure. A further advantage consists in the areally disposed damping layer, at which the individual channel segments are supported. Due to the areal arrangement of the damping layer, not only is the radial yielding of the channel segments cushioned, but the channel segments are supported three-dimensionally due to this damping layer.
It is preferable to produce the channel segments from wear resistant materials, preferably from plastic, hardened steel or ceramics. In addition, according to one embodiment the damping layer is composed of plastic, preferably an elastomer. It is further preferred to subdivide the inner hollow cylinder into three to five channel segments which are supported hanging or standing in the head piece.
The present invention discloses in addition, a setting device for an auxiliary joining part, particularly setting fasteners or punch rivets, having a driven punch which for a setting movement is movable in a joining channel that can be fed the loose auxiliary joining part. The setting device has the following features: a head piece, in which a part of joining channel runs, and a suction arrangement having a suction channel which opens into the joining channel of the setting device adjacent to the punch face side moving the auxiliary joining part, so that by means of a negative pressure, compared to the atmospheric pressure, that can be generated in the suction device, an air stream can be generated in the direction of the punch face side moving the auxiliary joining part with which the auxiliary joining part can be positioned at the punch face side.
In the present setting device, the auxiliary joining part is fed loose into the joining channel beneath the joining punch face side. Therefore, the auxiliary joining part is located without support in the joining channel, and remains in the channel, or is moved up to the braking web. To now attain a precise positioning of the auxiliary joining part at the joining punch face side, a directed air stream is generated in the joining channel in the direction of the joining punch face side. This air stream is a result of a negative pressure generated in a suction arrangement that suctions the air out of the joining channel adjacent to the joining punch face side. As a result of this directed air stream, the auxiliary joining part is pressed with its head against the joining punch face side, and is held in this position. Thus, the auxiliary joining part is appropriately positioned for the setting procedure, and is taken along by the punch during the setting movement, without rushing ahead of the punch. This increases control during the setting procedure and increases the quality of the created join connections compared to the prior art.
In addition, the present invention comprises a setting device having the following features: a head piece, in which a part of the joining channel runs that comprises a plurality of compressed air channels opening into the joining channel, and an exhaust channel that opens in the joining channel of the setting device adjacent to the punch face side moving the auxiliary joining part, so that in the joining channel by means of an over-pressure, in comparison to the atmospheric pressure, that can be generated in the plurality of compressed air channels, an air stream can be generated in the direction of the punch face side moving the auxiliary joining part with which the auxiliary joining part can be positioned at the punch face side.
With this design of the setting device, the auxiliary joining part is not positioned within the joining channel by means of an air stream generated by negative pressure, rather by a directed air stream generated by means of overpressure in comparison to the atmospheric pressure. Because the direction of the air stream and its effect are the same, as was already described above, reference is made to the above embodiment. Here, the type of generation of the air stream occurs in a different manner than in comparison to the setting device described above. A source of compressed air is connected to the plurality of compressed air channels in the joining channel or head piece. On this basis, air having an overpressure in comparison to the atmospheric pressure can be blown into the joining channel that can exit again through a corresponding exhaust channel adjacent to the joining punch face side. Using this directed air stream, the auxiliary joining part can be positioned at the joining punch face side in the same manner as was already described above.
According to a preferred embodiment, the setting devices described above are combined with a head piece whose joining channel has a hollow cylinder shape having an inside and an outside. The inside, for tapering the joining channel over a specific length, is composed of a plurality of braking webs, spring preloaded and projecting in the radial direction into the joining channel. In a further design, the head piece comprises at least four, preferably five or six of these braking webs, that each have the same length and are disposed uniformly distanced and concentrically about the center of the hollow cylinder channel.
The present invention comprises furthermore, setting devices in combination with the different head pieces described above.
According to a further design of the setting devices described above, these comprise a joining channel in the head piece whose diameter is dimensioned so that a gap of 0.1 to 0.5 mm results between the maximum cross section of the auxiliary joining part and an inner wall of the joining channel. Based on this dimensioning, a gap width of 0.1 to 0.5 mm results between the auxiliary joining part and the inner wall of the joining channel. This small gap dimension makes it possible that an auxiliary joining part is positioned and/or braked in a head piece solely by a directed air stream generated by means of a suction device or compressed air connection. With this configuration, it is therefore not necessary to provide an additional braking path within the head piece having a small gap dimension; however, this can be optionally implemented as well. The springs in the head piece of the setting device are configured so that the braking web(s) can be deflected with a progressive spring characteristic, and can be reset damped into its initial position, as was already described above.
DETAILED DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention are explained in more detail in the accompanying drawings, in which:
FIG. 1 depicts a setting device with head piece and braking path in accordance with a first embodiment;
FIG. 2 is a sectional view of the head piece of FIG. 1 ;
FIG. 3 depicts a further embodiment of a setting device with head piece;
FIG. 4 is a sectional view of the head piece of FIG. 3 ;
FIG. 5 depicts a further setting device with a head piece;
FIG. 6 is a sectional view of the head piece of FIG. 5 ;
FIG. 7 is a perspective exterior view of a portion of the head piece from FIG. 5 ;
FIG. 8 depicts the braking webs in a perspective view of the head piece of FIG. 5 ;
FIG. 9 is an additional perspective detail view of the head piece of FIG. 5 ; and
FIG. 10 , 11 illustrate two further preferred embodiments of a head piece for a setting device.
DETAILED DESCRIPTION
The present invention describes a setting device 1 for joining auxiliary joining parts B, such as a setting fastener or a punch rivet, for example. This is represented in a section in FIG. 1 . The auxiliary joining part B is accelerated via a driven punch 10 and specifically by its joining punch face side 13 , and joined into a component (not shown). For this purpose, the auxiliary joining part B, which is subsequently referred to as setting fastener B, is fed loose into a joining channel 20 through which the punch 10 moves. A loose feeding of the setting fastener B means that it is not held by a tape or similar, rather is loose in the joining channel 20 . The joining channel 20 extends partially into the setting device 1 and partially into a head piece 3 . The setting device S is represented by means on an example in FIG. 4 . It comprises a drive 2 , the magazine 1 , a head piece 5 having a joining channel and a drive 7 for the magazine 1 . The magazine 1 is disposed between the drive 2 and the head piece 5 of the setting device S, so that joining elements are fed directly out of the magazine 1 to the head piece 5 , in order to join them there by means of the punch (not shown) of the setting device S. The magazine 1 comprises a base element 10 having a covering 30 . A connection module 15 , to which the provisioning module B can be coupled, is provided at the base element 10 . The magazine 1 is shown in greater detail in FIGS. 5 and 6 .
The head piece 3 , as will be described in different constructions, alone and/or in combination with the setting device 1 , implements a positioning of the setting fastener B at the punch face side 13 moving the setting fastener. For this purpose, the setting fastener B is positioned at this punch face side 13 by an air stream directed onto the moving or joining punch face side 13 . Thereby, the setting fastener B, with its side of the head facing away from the shaft, lies against the punch face side 13 and is thereby correctly aligned. The setting fastener is thereby in a coaxial alignment with the longitudinal axis of the punch 10 and of the joining channel 20 in the head piece 3 . This corresponds to the alignment of the setting fastener as with the use of feed tapes having the setting fastener attached therein. It is advantageous here that the positioning can be implemented even with a loose feeding of the setting fastener, while the setting device 1 can be used in a normal position as well as in an overhead operation.
In order to support a position stable movement of the setting fastener B through the joining channel 20 of the headpiece 3 , the head piece is optionally equipped with a braking path 40 ; 50 , as is described in more detail below. The braking path 40 , 50 brakes the setting fastener B during its movement through the joining channel 20 so that its contact at the punch face side 13 , and with it the alignment of the setting fastener, is supported for the joining. For this purpose, braking webs 42 (see FIGS. 1 to 9 ) or channel segments 52 (see FIG. 10 , 11 ) of the joining channel 20 in the head piece 3 are spring preloaded damped radially inward into the joining channel 20 . For improved braking compared to the prior art, each braking path 40 , 50 is preloaded radially into the joining channel 20 such that the braking webs 42 or channel segments 52 can be moved damped radially outward by an incoming setting fastener B. The reset of the braking webs 42 or the channel segments 52 into their initial position occurs temporally delayed so that the setting fastener B does not receive a radially directed impulse from this reset movement. According to one embodiment, preferred in this respect, the springs of the headpiece, or of the setting device, are configured with a specific headpiece so that a plurality of braking webs or channel segments 52 can be deflected with a progressive spring characteristic, and can be reset damped into their initial position. In addition, the setting fastener is led to the center of the feeding channel 20 by the inclined alignment of the braking webs 42 or of the channel segments 52 . In this manner, tumbling movements of the setting fastener B during high speed joining are reduced. For constructive implementation of the properties described above, a casing tube is used, that is described in more detail below. The aim of the casing tube, along with other functions, is to limit the radial deflection movement of the braking webs, which according to one alternative are spring preloaded plastic O-rings. Using the casing tube, the deflection movement is limited with low constructive costs, in an effective manner and without temporal delay. In addition, a vibration damped return of the braking webs into the joining channel is guaranteed due to the enclosure and the arrangement of the plastic O-rings between the joining channel and the casing tube, whereby the overall vibration of the braking webs is minimized.
In comparison to a disclosed ordinary steel spring, here a damped and delayed resetting spring preloading of the braking webs 40 , 50 is used. This is implemented by different constructions, as described in more detail below.
FIG. 3 shows the setting device 1 with head piece 3 and without braking paths. The inner diameter of the joining channel 20 in the head piece 3 is dimensioned in comparison to the maximum cross-section of the setting fastener B so that in comparison to the maximum cross-section of the setting fastener, only a free gap having a small gap width arises between the setting fastener B and the inner wall 22 of the joining channel 20 . This gap width extends in an interval between 0.1 to 0.5 mm. Preferably, the gap width is adjusted to 0.2 to 0.3 mm. Due to this dimensioning of the joining channel 20 in the head piece 3 , the setting fastener B is fed tightly in this joining channel 20 . In addition, suction of the air out of the joining channel 20 , as described in detail below, is supported, because due to the small gap width between the punch face side 13 and the head of the setting fastener B, a negative pressure develops more rapidly than would be the case for a gap of a larger width.
In the setting device 1 , the setting fastener B is fed loose into the joining channel 20 . This occurs, for example, using a design as is described in the patent application DE 10 2007 017 689. With this, the setting fastener is fed into the joining channel 20 above the head piece 3 . It is also preferred to feed the setting fastener B into the joining channel 20 in the head piece 3 .
The setting device 1 comprises a channel 30 that opens into the joining channel 20 adjacent to or near the punch face side 13 . The channel 30 is connected to a suction device (not shown). The suction device creates a negative pressure in comparison to the atmospheric pressure, so that using the channel 30 , which is used here as a suction channel, air is suctioned out of the joining channel 20 . This creates a directed air stream L within the joining channel 20 that is directed onto the punch face side 13 . The strength of the air stream L can be adjusted using the amount of the negative pressure so that the setting fastener B is pressed by the air stream against the rams face side 13 , and positioned there. The small gap dimension between the setting fastener and the inner wall of the joining channel 20 (see above) supports the positioning of the setting fastener B at the punch face side 13 , because the air fed through the gap between the setting fastener and the wall of the joining channel 20 is minimized. It is also preferred to provide channels at the end of the head piece 3 facing toward the setting device 1 , which open into the joining channel 20 . This is exemplified in another embodiment shown in FIG. 5 , where these channels are designated with the reference number 62 . These channels are connected to a source of compressed air so that compressed air can be blown into the joining channel 20 in the direction of the punch face side 13 . By blowing air into the joining channel 20 using an adjustable overpressure in comparison to the atmospheric pressure, the air stream L for the positioning of the setting fastener B is generated or supplemented. Therefore, the setting fastener B can also be positioned by a combined suctioning via the channel 30 , and blowing in compressed air via additional channels in the joining channel 20 .
FIGS. 1 and 2 show a preferred embodiment of a setting device 1 having a head piece 3 that has a braking path. Here, the setting fastener B was already fed loose into the joining channel 20 . Air is suctioned out of the joining channel 20 via the suction channel 30 that is connected to the suctioning device (not shown). The air stream L which is generated in the joining channel 20 due to the generated negative pressure in comparison to the atmospheric pressure, positions the setting fastener B at the punch face side 13 .
It is also preferred to equip the head piece 3 of FIGS. 1 and 2 with additional channels, as shown in FIG. 5 , for instance, and described in connection with this. These channels guarantee the inflow of compressed air into the joining channel 20 , in order to position the setting fastener at the punch face side 13 using an air stream L generated over it.
The head piece 3 comprises a hollow cylinder 22 in whose interior the joining channel 20 extends. In the longitudinal direction of the hollow cylinder 22 , multiple grooves, uniformly distanced about the circumference, are formed in which individual braking webs 42 are disposed. These braking webs 42 project radially into the joining channel 20 and thereby taper the joining channel 20 . These braking webs 42 are spring preloaded directed radially inward via the springs 44 . The springs 44 are preferably uniformly distanced from each other and distributed over the entire length of the braking webs. According to a preferred embodiment, the head piece 3 comprises at least four braking webs which each have the same length and are disposed concentrically about the center of the joining channel 20 . For improved feeding of the setting fastener B in the joining channel 20 , it is further preferred to provide five or six braking webs.
The braking webs 42 of the head piece 3 are pretensioned using the springs 44 . As springs, spiral springs, a plurality of spring rings, preferably O-rings composed of plastic or rubber, as well as wormed springs can be used, for example. According to a further preferred embodiment, the springs 44 are configured so that the braking web 42 can be deflected damped radially outward and its return into its initial position is delayed. Due to this spring behavior, which can be attained using plastic O-rings, for example, the lateral movement of the setting fastener B in the joining channel 20 is damped, and no new laterally inward direct impact is applied to it via braking webs 42 springing back. This guarantees a stable movement of the setting fastener B through the joining channel 20 . In addition, the damping behavior of the springs 44 is adjusted so that the braking webs 42 do not spring so far radially outward due to the impact of the setting fastener B that they lose the contact to the setting fastener B. In this manner, improved guidance of the setting fastener B is guaranteed in the joining channel 20 . According to a further preferred embodiment, the braking webs can be deflected with a progressive spring characteristic and can be reset, damped into their initial positions. This results in the fact that the deflected braking web during its movement experiences an increasing spring resistance as a counteracting force. The reset of the braking web is damped so that the braking web does not immediately spring back in the joining channel. In this manner, the energy absorbed by the braking web from the setting fastener is returned delayed to the setting fastener. The spring behavior described here is preferably implemented for all spring configurations described here, that is, for the springs or O-rings in the same manner as for the channel segments (see below) spring loaded with a damping layer.
A further preferred embodiment of the setting device 1 with head piece 3 is represented in FIGS. 5 to 9 . The setting device 1 comprises the channel 30 , which is used here as an exhaust channel. The head piece 3 is connected to the setting device 1 by means of a screw S, for example.
The head piece 3 is comprised of a casing tube 70 , an inner hollow cylinder 24 , and a plurality of braking webs 42 , which are preloaded radially into the joining channel 20 by means of springs 44 . A compressed air connection 60 is provided at the head piece 3 which is connected to a compressed air source (not shown). Air is supplied via the compressed air connection 60 to an air reservoir 68 , and from there via a plurality of compressed air channels 62 to the joining channel 20 . The compressed air channels 62 are preferably disposed inclined in the direction of the setting device 1 , so that the air is blown into the joining channel 20 onto the setting device 1 . A seal 66 is provided in order to seal the air reservoir 68 located between the hollow cylinder 24 and the casing tube 70 . If compressed air having an adjustable overpressure in comparison to the atmospheric pressure is blown into the joining channel 20 , and flows out via the channel 30 , the positioning air stream L arises in the direction of the punch face side 13 . This air stream L positions the setting fastener B at the punch face side 13 , as was already described above in connection with the suction device.
The braking webs 42 are disposed in longitudinally directed grooves within the hollow cylinder 24 , and project into the joining channel 20 . The webs have a lead-in chamfer at their end facing the setting device 1 . This lead-in chamfer creates a soft entry of the setting fastener B into the braking path of the head piece 3 .
The braking webs 42 are fastened preferably using pins 46 , disposed perpendicularly to the longitudinal axis of the respective braking web 42 , and are guided so they can slide radially in a groove of the hollow cylinder 24 . In addition, these pins 46 are disposed only in both end regions of the respective braking webs 42 . The braking webs 42 are preloaded by springs 44 . The springs are not disposed distributed over the length of the braking webs 42 , rather combined into spring packets. The spring packets are uniformly distanced from each other and preferably three spring packets are used for preloading the braking webs 42 . The springs 44 or the spring packets are held, preferably clamped, between the hollow cylinder 24 and the casing tube 70 . The springs 44 used here also have the spring properties described above. According to this, they implement a damped yielding of the braking webs 42 and a delayed restoring of the braking webs 42 into their initial position. This is implemented by the use of O-rings composed of rubber or plastic, for example, as springs 44 that are fastened clamped between the hollow cylinder 24 and the casing tube 70 . Due to the casing tube 70 , the braking strips/O-rings are limited in their radial deflection. In addition, it is guaranteed that the braking webs return quickly and vibration-damped into the joining channel 20 , and the overall vibration of the braking webs is minimized. Using the casing tube, the deflection movement is limited with low constructive costs, in an effective manner and without temporal delay.
Further embodiments of the head piece 3 that can also be used with the setting device 1 , are shown in FIGS. 10 and 11 ; the head pieces 3 of FIGS. 10 and 11 can be combined optimally with the suction device and/or the compressed air channels 62 with the compressed air source. Thereby, these head pieces 3 also guarantee the positioning described above, and a controlled guidance and braking of the setting fastener B.
The head piece 3 of the FIGS. 10 and 11 having a braking path 50 is comprised of a casing tube 70 which forms the outer enclosure of the head piece 3 . The joining channel 20 is formed by an inner hollow cylinder 24 , which is composed of a plurality of channel segments 26 . Due to the discontinuity of the inner hollow cylinder 24 in the channel segments 26 , these can yield radially outward, when they are loaded by the setting fastener B. The channel segments 26 are composed of a wear-resistant material, for example, plastic, hardened steel or ceramics. This guarantees low wear and reliable guidance of the setting fastener B moving through the joining channel 20 .
A resilient damping layer 52 is disposed adjacent to the channel segments 26 . The damping layer 52 damps a deflection movement of the channel segments 26 due to the setting fastener movement, and resets the respective channel segment 26 , temporally delayed, into its initial position. A suitable material for the damping layer 52 is an elastomer, for example. However, other materials that have the damping and spring properties described above, are also suitable. It is further preferable to equip the damping layer 52 with a progressive spring characteristic, so that the desired damped deflection of the channel segments and their delayed return occurs as described above in connection with the springs.
A hollow cylinder 54 is optionally disposed between the casing tube 70 and the damping layer 52 . The hollow cylinder 54 in the head piece 3 can be exchanged so that the hollow cylinder 54 can be used with different radial thicknesses. On this basis, the preloading or compression of the damping layer 52 can be adjusted or readjusted. The channel segments 26 resiliently damped in this manner thereby satisfy the function of the braking webs 42 described above. Due to the surfaces in the joining channel 20 , the channel segments 26 offer larger support surfaces for the setting fastener B. In addition, a two-dimensional energy introduction into the damping layer 52 is provided when the channel segments 26 absorb the lateral movements of the setting fastener B. This guarantees a softer damping of the setting fastener B moving through the joining channel 20 .
The method for the setting of setting fasteners implemented with the present invention can be summarized in the following steps. Initially, the auxiliary joining part B is fed loose into the joining channel 20 of the setting device 1 . Then, an air stream to be positioned counter to the joining direction of the auxiliary joining part B in the joining channel 20 is generated by means of suction and/or feeding in air. As soon as this air stream is sufficiently strong, a positioning of the auxiliary joining part B occurs at the punch face side 13 of the punch 10 . When the auxiliary joining part B is appropriately positioned, the joining process starts, and the punch 10 , for joining of the auxiliary joining part B, moves through the joining channel 20 in the direction of the component to be joined. | The invention relates to a setting device for an auxiliary joining part, particularly a setting fastener or a punch rivet, including a driven punch which for a setting movement can be moved in a joining channel to which the auxiliary joining part can be loosely fed. The setting device includes a head piece in which a part of the joining channel runs, further including a plurality of compressed air ducts ending in the joining channel, and an exhaust air channel. The exhaust air channel ends adjacent to the front side of the punch moving the auxiliary joining part into the joining channel of the setting device such that an airflow can be generated in the joining channel in the direction of the front of the punch moving the auxiliary joining part by way of an overpressure which can be generated in the plurality of compressed air channels compared to the atmospheric pressure and by which the auxiliary joining part can be positioned on the front side of the punch. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 62/266,989 filed Dec. 14, 2015, titled “Ruby Blades and Rotating Fiber for Delamination Free Strip Edges,” which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present invention is directed to a method and apparatus for cutting and stripping optical fibers.
[0004] Discussion of the Known Art
[0005] When manufacturing a high power cladding pumped fiber laser, a length of a polymer coating on the fiber is cut and stripped from one end of the fiber, and the stripped end is recoated. When the fiber operates as a laser, substantial optical power is pumped through the fiber cladding and interacts with the coating. Therefore, when the coating is stripped off the end of the fiber, the edge of the coating that remains on the fiber and the underlying cladding must be smooth and clean to keep the operating temperature of the fiber laser relatively low. Defects at an edge of the coating or the recoating, or any particles present on the surface of the fiber cladding, will induce heating and cause the fiber laser to fail.
[0006] While it is possible to use a liquid or acid to remove the coating (see, e.g., U.S. Pat. No. 5,298,105 (Mar. 29, 1994)), acid stripping can raise reliability issues over the long term. Therefore, mechanical tools are typically used for cutting and stripping coated or jacketed optical fibers. Such tools are commercially available from, inter alia, Jonard Tools, Tuckahoe, N.Y. 10707, and Micro Electronics, Inc., Seekonk, Mass. 02771. See also U.S. Pat. No. Re. 30,342 (Jul. 22, 1980), U.S. Pat. No. 4,271,729 (Jun. 9, 1981), and U.S. Pat. No. 6,643,448 (Nov. 4, 2003), and Pub. No. US 2014/0338195 (Nov. 20, 2014), all of which are incorporated by reference.
[0007] As mentioned, after the coating is stripped from the end of the fiber, the edge of the coating left on the fiber must be clean and smooth so the fiber can operate as a laser at high power without overheating. If a mechanical tool is used and the tool blades are not sufficiently sharp, the coating will be crushed rather than cleanly sliced, and regions will be produced where the coating separates or delaminates from the fiber cladding.
[0008] FIG. 1 is a microscope image of an end of a coated fiber 10 , showing a delamination region at a cut edge 18 of the coating 12 after a length of the coating was cut and stripped from the end of the fiber by a conventional tool, leaving a stripped region 14 . After the fiber 10 is spliced to another optical fiber or otherwise processed, the stripped region 14 is typically recoated with a low index polymer. During operation of the fiber 10 as a laser, pump light from a multi-mode optical diode laser or other source is guided by a boundary 16 between the cladding 14 and the coating 12 on the fiber 10 . Therefore, any delamination or tear at the cut edge 18 of the coating will disturb the properties of the boundary 16 and cause the fiber 10 to overheat during laser operation.
[0009] Tools that use ruby or diamond blades to cleave an optical fiber to obtain a mirror flat surface on a terminating end of the fiber, are commercially available from, inter alia, Thorlabs Inc., Newton, N.J. 07860 and Delaware Diamond Knives, Wilmington, Del. 19805. See also U.S. Pat. No. 4,621,754 (Nov. 11, 1986) which is incorporated by reference. Notwithstanding, a need exists for a method and apparatus for cutting and stripping a coating from an end of an optical fiber so that the coating remaining on the fiber is free of tears or delamination.
SUMMARY OF THE INVENTION
[0010] According to the invention, a method of cutting and stripping a coating from an optical fiber, includes supporting a coated optical fiber in confronting relation to a cutting edge of one or more blades, and positioning each blade so that its cutting edge cuts into the coating, while avoiding delaminating the coating from an underlying fiber cladding by providing the cutting edge with sufficient sharpness. The coating around the circumference of the fiber is sliced by either (a) rotating the fiber about its axis while each blade maintains contact with the coating, whereby the cutting edge of the blade slices the coating over a corresponding portion of the circumference of the fiber, or (b) rotating the cutting edge of each blade about the fiber axis while the blade maintains contact with the coating, whereby the cutting edge of the blade slices the coating over a corresponding portion of the circumference of the fiber. A cut length of the coating is then removed from an end of the fiber.
[0011] According to another aspect of the invention, apparatus for stripping a length of a coating from an end of an optical fiber, includes one or more blades each having a cutting edge, a first mount arrangement constructed to support and adjust the position of the blades, and a second mount arrangement constructed to support a length of the fiber in confronting relation to the cutting edges of the blades. The first mount arrangement is operative to position the blades with respect to the length of the fiber, and the cutting edges of the blades are sufficiently sharp to cut the coating to a determined depth without delaminating the coating from an underlying fiber cladding. The second mount arrangement is operative to rotate the fiber about its axis so that, after cutting the coating, the cutting edges of the blades slice the coating around the circumference of the fiber. The second mount arrangement is also operative to translate the fiber in a direction away from the blades so that the blades engage and strip the coating from the end of the fiber without tearing or delaminating the coating remaining on the fiber.
[0012] According to another aspect of the invention, apparatus for stripping a length of a coating from an end of an optical fiber, includes one or more blades each having a cutting edge, a first mount arrangement constructed to support and adjust the position of the blades, and a second mount arrangement constructed to support a length of the fiber in confronting relation to the cutting edges of the blades. The first mount arrangement is operative to (i) position the blades with respect to the length of the fiber, and the cutting edges of the blades are sufficiently sharp to cut the coating to a determined depth without delaminating the coating from an underlying fiber cladding, and (ii) rotate the blades about the axis of the fiber so that the cutting edges of the blades slice the coating around the circumference of the fiber. The second mount arrangement is also operative to translate the fiber in a direction away from the blades so that the blades engage and strip the coating from the end of the fiber without tearing or delaminating the coating remaining on the fiber.
[0013] For a better understanding of the invention, reference is made to the following description taken in conjunction with the accompanying drawing and the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0014] In the drawing:
[0015] FIG. 1 is a microscope view of an end of an optical fiber from which a fiber coating has been cut and stripped by a conventional tool;
[0016] FIG. 2 is a plan view of a first embodiment of apparatus for stripping a coating from an optical fiber, according to the invention;
[0017] FIG. 3 is a plan view as in FIG. 2 , wherein a microscope in the apparatus of FIG. 2 is omitted for clarity, and showing an end length of an optical fiber from which a coating is to be stripped by the apparatus;
[0018] FIGS. 4( a ) to 4( d ) illustrate steps performed by the apparatus of FIGS. 2 and 3 when cutting and stripping the coating from the optical fiber, according to the invention;
[0019] FIG. 5 is a microscope view of an end of an optical fiber from which a fiber coating has been cut and stripped according to the invention;
[0020] FIG. 6 is a plot showing recoat temperatures of fiber lasers that were stripped by the use of a conventional tool, and fiber lasers that were stripped by the use of the inventive apparatus;
[0021] FIG. 7 is a schematic diagram of a pumped laser cavity constructed with optical fibers whose ends were stripped according to the invention;
[0022] FIG. 8 is plot showing signal output power versus pump power for the laser cavity in FIG. 7 ; and
[0023] FIG. 9 is a plan view of a second embodiment of apparatus for stripping a coating from an optical fiber, according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention is directed to a method and apparatus for cutting and stripping a coating from an end of an optical fiber so that the cut edge of the coating remaining on the fiber is not torn, and is not delaminated from the underlying fiber cladding. The invention enables the production of high power, cladding pumped optical fiber lasers having superior thermal performance.
[0025] In a disclosed embodiment, a coated optical fiber is supported lengthwise between cutting edges of a pair of cleaved ruby blades. The blades are positioned to cut into the fiber coating to a determined depth, and are sufficiently sharp to avoid crushing the coating. The fiber is rotated about its axis, or, alternatively, the blades are rotated about the axis of the fiber, so that the cutting edges of the blades slice the coating cleanly over the circumference of the fiber. The fiber is then translated or pulled in a direction away from the blades, so that the blades engage and strip a cut length of the coating from the fiber without tearing or delaminating the coating remaining on the fiber.
[0026] In particular;
[0027] 1. The cutting edges of the blades are sharp enough to cut and slice into the fiber coating without crushing the coating, or inducing a load high enough to delaminate the coating from the underlying fiber cladding.
[0028] 2. The initial cut by the blades into the fiber coating is sufficiently deep to prevent the coating remaining on the fiber from being torn or delaminating from the cladding when the cut length of coating is stripped from the end of the fiber. Direct physical contact between the cutting edges of the blades and the surface of the fiber cladding is preferably avoided so as not to degrade the strength of the cladding.
[0029] 3. A conventional (e.g., USB) microscope and an associated display can be provided to allow an operator to observe the depth of the initial cut into the fiber coating and subsequent steps of the inventive process.
[0030] It may also be preferable in some cases to use a conventional tool to cut and strip less than all of a desired length of the coating from the end of the fiber, and then use the inventive apparatus to cut and strip the remaining length of coating so as to avoid tearing and delaminating the coating remaining on the fiber.
[0031] FIG. 2 is a plan view of apparatus 20 for cutting and stripping, e.g., an acrylate coating 24 from an optical fiber 26 with the aid of a microscope 28 , according to a first embodiment of the invention. FIG. 3 is a plan view of the apparatus 20 wherein the microscope 28 in FIG. 2 is omitted for clarity, and showing an end length 30 of the fiber 26 from which the coating 24 is to be stripped by the apparatus 20 .
[0032] In the apparatus 20 , a pair of blades 32 , 34 are supported on associated translation mounts 36 , 38 so that cutting edges 32 a , 34 a of the blades face one another, and the positions of the edges on the blades relative to the mounts can be finely adjusted. The blades 32 , 34 may be, for example, cleaved ruby blades which are commercially available with associated holders from Thorlabs Inc. of Newton, N.J., wherein each blade is provided with a 30 degree beveled cutting edge and has a 5.2 to 5.5 mm long contact area.
[0033] Apparatus 20 also includes a rotation mount 40 that is constructed and arranged to support the optical fiber 26 to extend lengthwise between the cutting edges 32 a , 34 a of the blades, and to rotate the fiber 26 about its axis during operation of the apparatus 20 . The microscope 28 (see FIG. 2 ) is disposed above the optical fiber 26 and the blades 32 , 34 so that an operator can view and adjust the positions of the cutting edges 32 a , 34 a of the blades with respect to the fiber 26 between them. See FIGS. 4( a ) to 4( d ) and related text below. It will be understood that imaging and/or sensing systems other than the microscope 28 can be used to position the cutting edges 32 a , 34 a of the blades accurately with respect to the fiber 26 when cutting and stripping the fiber.
[0034] Also, because the end length 30 of the fiber 26 from which the coating 24 is to be stripped by the opposed blades 32 , 34 is relatively short, and the fiber 26 is usually stiff enough so that any deflection is minimal, a separate mount or device at the left side of the blades 32 , 34 should not be required to support the end length 30 while being cut. A conventional fiber clamp may be provided, however, if needed to hold the end length 30 steady.
[0035] FIG. 4( a ) depicts the optical fiber 26 supported by the rotation mount 40 , and after a length 42 of the fiber coating 24 has been coarsely cut and removed from an end 46 of the fiber by a commercially available stripper tool. Note the resulting delamination region 48 at the cut edge 50 of the coating 24 that remains on the fiber 26 .
[0036] In the view of FIG. 4( b ) , the cutting edges 32 a , 34 a of the blades 32 , 34 are positioned to contact the fiber coating 24 and to cut radially into the coating to a determined depth that approaches but preferably avoids direct physical contact with the underlying fiber cladding 52 . It has been discovered that the edges of the cleaved blades 32 , 34 disclosed above are sharp enough to cut cleanly through the coating 24 without crushing the coating, or causing the coating to delaminate from the fiber cladding 52 .
[0037] After the blades 32 , 34 initially cut into the fiber coating 24 , the rotation mount 40 is operated to rotate the fiber 26 about its axis, preferably by at least 180 degrees. As shown in FIG. 4( c ) , the cutting edges 32 a , 34 a of the blades together slice through the fiber coating 24 cleanly over the circumference of the fiber 26 without crushing or delaminating the coating. That is, by rotating the fiber 26 about its axis after the blades initially cut into the fiber coating 24 , a clean incision that approaches the fiber cladding 52 is formed through the coating.
[0038] Next, as illustrated in FIG. 4( d ) , while the fiber 26 is held in the rotation mount 40 , the mount 40 is translated in a direction away from the blades 32 , 34 . As a result, the blades 32 , 34 engage and act to strip the cut length 30 of coating 24 including the delamination region 48 as the end 46 of the fiber 26 is withdrawn from beneath the cut length 30 . As seen at the right in FIG. 4( d ) and in FIG. 5 , the cut edge 54 of the coating 24 that remains on the fiber 26 is clean and delamination free.
[0039] The inventive stripping method has been tested and found to work with coated fibers having a wide range of outer diameters (ODs), and with both low index and high index fibers. A test for delamination has also been developed. After cutting and stripping the fiber coating, a drop of alcohol is placed on the cut edge of the coating remaining on the fiber, and the alcohol is observed, e.g., via the microscope 30 . If there is delamination, the alcohol can be seen to wick beneath the coating, and delamination regions will become clearly visible as the alcohol evaporates.
[0040] The thermal performance of low-index coated fibers whose ends were stripped and recoated, was measured in a Yb-doped cladding pumped fiber laser configuration wherein the OD of the fiber was 125 μm. Four fibers were stripped using a conventional mechanical tool and subsequently re-coated with a low index polymer, resulting in delaminated coating edges comparable to the one shown in FIG. 1 . Two fibers were stripped using apparatus according to the invention and subsequently re-coated with a low-index polymer, resulting in smooth and clean coating edges without delamination, like the edge 54 in FIG. 5 .
[0041] FIG. 6 is a graph showing thermal performance of the four low-index recoated fibers whose ends were initially stripped with a conventional tool, and the two recoated fibers whose ends were initially stripped with the inventive apparatus. Note that the thermal performance of the latter two fibers was significantly better than that of the fibers that were stripped conventionally. Significantly, the latter fibers could tolerate a 67% increase in pump power and maintain the same operating temperature.
[0042] Although the inventive process and apparatus as disclosed herein remove a relatively small length of coating at the end of a coated optical fiber to obtain a delamination free edge on the remaining coating, longer lengths of coating may also be removed if desired according to the invention. Moreover, fibers of any OD and having any coating thickness can be stripped using the inventive apparatus 20 by translating the mounts 36 , 38 so as to adjust the positions of the cutting edges 32 a , 34 a of the blades 32 , 34 with respect to a given fiber. Furthermore, it is also possible to use a single blade, in which case the fiber may be supported by a backing surface or substrate to prevent the fiber from deflecting when the fiber and the blade rotate relative to one another, and the cutting edge of the blade slices the coating about the circumference of the fiber.
Example
[0043] About 30 meters of six 125 μm Yb-doped coated fibers, each having 1117 nm gratings, were stripped of their coating according to the invention, and recoated. The fibers were configured as a bi-directionally pumped cavity with 12×55 W nLight 915 nm diodes. See FIG. 7 .
[0044] As shown in FIG. 8 , an output power of 354 W was measured at 1117 nm, for a pump power of 539 W at 915 nm. The measured output power rolled over slightly at 300 W, possibly due to fact that the power meter used in the experiment was only rated to 300 W.
[0045] While the foregoing represents preferred embodiments of the present invention, it will be understood by persons skilled in the art that various changes, modifications, and additions can be made without departing from the spirit and scope of the invention. For example, FIG. 9 is a plan view of apparatus 120 for cutting and stripping a coating from an optical fiber, according to a second embodiment of the invention. Components in the apparatus 120 have the same reference numerals as corresponding components in the apparatus 20 in FIG. 3 , increased by 100.
[0046] A basic difference between the apparatus 20 in FIG. 3 and the apparatus 120 in FIG. 9 is that translation mounts 136 , 138 , which support and adjust the positions of cutting blades 132 , 134 , are constructed and arranged to rotate in unison about the axis of the fiber by at least 180 degrees so that cutting edges 132 a , 132 b of the blades slice cleanly through a fiber coating 124 about the circumference of fiber 126 . Both of the translation mounts 136 , 138 may, for example, be mounted on a common base 200 that is configured to rotate about the axis of the fiber 126 .
[0047] Other than supporting the fiber 126 , the mount 140 in FIG. 9 need only operate to translate the fiber 126 in a direction away from the blades 132 , 134 after the blades initially slice through the coating 124 , so that the blades will act to engage and strip a cut length of coating as the end 146 of the fiber 126 is withdrawn from beneath the length of coating.
[0048] Moreover, as mentioned earlier, a single blade may be used instead of a pair of blades, and the fiber can be supported by a substrate so as to prevent the fiber from deflecting as it and the blade rotate relative to one another and the blade slices the coating around the fiber. Accordingly, the invention includes all such changes, modifications, and additions that are within the scope of the following claims. | A length of a coating on an optical fiber is cut and stripped from an end of the fiber by supporting the fiber in confronting relation to a cutting edge on one or more blades. Each blade is positioned so that its cutting edge cuts into the coating without delaminating the coating from an underlying fiber cladding by providing the cutting edge with sufficient sharpness. The coating is sliced around the circumference of the fiber by either rotating the fiber about its axis so that the cutting edge of each blade slices the coating around a corresponding portion of the circumference of the fiber, or rotating the cutting edge of each blade about the fiber axis so that the cutting edge slices the coating around a corresponding portion of the circumference of the fiber. A cut length of the coating is then removed from the end of the fiber. | 6 |
BACKGROUND OF THE INVENTION
A vibration table upon which is mounted a test specimen or the like is connected with vibrators through couplings. The purpose of the vibration table is to investigate the behavior of a building and test specimens in an earthquake, and the couplings must have the following functions and must accomplish these functions satisfactorily:
(1) The force and the amount of displacement of the vibrator must be transmitted to the vibration table positively and without any time delay. From the theoretical standpoint of analyzing vibration, lost motion and friction in the coupling must be minimized.
(2) The vibrators are generally mounted on a foundation and the vibration table makes two- or three-dimentional movement depending upon its function. To this end, the axial force and displacement of the vibrator must be transmitted to the vibration table and must slide within the bearing strokes against the movements perpendicular to the table. In addition, the sliding frictional resistance must be reduced as much as possible. In general, hydrostatic bearings are used.
(3) The construction must be such that even if the position of the vibration table is distorted under vibrations so that the mounting surface is inclined, no excessive force is exerted to the bearings.
There have been devised various types of couplings which connect such vibrators with the vibration table. For instance, there has been available a hydrostatic bearing type coupling c as shown in FIG. 1 which is interposed between a vibration table a and a vibrator b and includes a spherical body d. The coupling c is rotatably and slidably supported, through the spherical body d, by a supporting member e which extends from the vibration table a. A pressurized oil source f is communicated with the bearing surfaces, whereby the hydrostatic bearing is provided.
In this case, the coupling c is connected to the supporting member e on the vibration table a in a cantilever manner. Therefore, there arises no problem concerning the transmission of the axial force of the vibrator and the absorption of the displacement in the directions perpendicular to the direction of the axial force. However, if "wrenching" occurs due to the distortion of the table a, they cannot slide with small frictional resistances because the spherical surface of the body d does not form a hydrostatic bearing.
There has been also devised and demonstrated a coupling which, as shown in FIG. 2, transmits the force through a connecting rod g whose both ends are terminated by spherical shapes.
With this system, however, when the vibrator b causes the vibration table a to move in one direction, the connecting rods g which support the table a are caused to swing as indicated by the double-pointed arrrows. There must be therefore provided a control for cancelling the displacement due to this swinging motion by the motion of other vibrators. As a result, accurate control of the position of the table is difficult.
One of the objects of the present invention is to provide a coupling device which is simple in construction, has small lost motion and is simple in assembly and mounting.
Another object of the present invention is to provide a coupling device which exhibits minimum frictional resistance to every movement, is free of the influence from other vibrators and obtains correct waveforms by a simple control.
Preferred embodiments of the present invention will be described with reference to the accompanying drawings.
BRIEF EXPLANATION OF THE DRAWINGS
FIGS. 1 and 2 are views used for the explanation of prior art coupling devices;
FIG. 3 is a perspective view of a first embodiment of the present invention;
FIG. 4 is a view as viewed in the direction indicated by the arrows IV--IV of FIG. 3;
FIG. 5 is a view as viewed in the direction indicated by the arrow V--V of FIG. 4;
FIG. 6 is a view used for the explanation of a second embodiment of the present invention;
FIG. 7 is a view as viewed in the direction indicated by the arrows VII--VII of FIG. 6;
FIG. 8 is a view used for the explanation of a hydrostatic bearing;
FIG. 9 is a cross sectional view thereof; and
FIG. 10 is a view illustrating the arrangement of coupling devices.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 3 to 5, a cross-shaft assembly generally indicated by the reference numeral 1 has two co-axial shafts 1a and two co-axial shafts 1b, the axes of the two pairs of shafts crossing each other at right angles so that the shafts are spaced at 90° from each other about the central point. The first pair of co-axial cross shafts 1a are supported by hydrostatic bearings 2 so that the cross shafts 1a can rotate and axially slide in the hydrostatic bearings 2. These hydrostatic bearings 2 are mounted on a bracket or yoke 3 which in turn is mounted on the rod 3a of a vibrator 4. In like manner, the second pair of co-axial cross shafts 1b whose axis is perpendicular to that of the first pair are supported by hydrostatic bearings 2b mounted on a bracket or yoke 6 which in turn is attached to a vibration table 5. As a result, only the vibrations in the direction (Z) of the axis of the rod 3a of the vibrator 4 can be transmitted to the vibration table 5 while the movements in the other two directions (X and Y) perpendicular to the former can be completely absorbed by the hydrostatic couplings.
In FIGS. 8 and 9 are shown in detail the construction of each of the hydrostatic bearings. A lubricating oil under pressure is forced to flow from a lubricating oil source 7 into the space 10 between the spaced bearing surfaces 11 of the cross shaft 1a (or 1b) and the hydrostatic bearing 2 or 2b. Reference numerals 8 and 9 designate shaft covering sleeves.
As shown in FIG. 10, the vibration table 5 is operatively connected to a plurality of vibrators 4 through couplings of the type described above. For example, when an axial force is applied from the vibrator 4 of the coupling device A (in the direction X), the axial force is transmitted through the cross-shaft assembly 1a to the vibration table 5 without being affected by the movements in the other axes (Y and Z). The movements of in the other two directions perpendicular to the direction of the axial force (i.e., the directions Y and Z) as well as tilting movements of the vibration table are also exerted toward the coupling device A from vibrators 4 of coupling devices B or the like; however, such movements are absorbed by the axial sliding movement or rotation of the cross-shaft assembly 1a of the coupling device A, so that these movements are not transmitted to the vibrator 4 of the coupling device A. The axial force from the vibrator 4 of the coupling device A causes the coupling devices B to swing in the directions indicated by the double-pointed arrows θ x . Reference letter m denotes a specimen under test.
The vibrators 4 are so disposed relative to the vibration table 5 that the vibrators 4 vibrate in the X, Y and Z directions with respect to the vibration table 5 as described previously, and the vibrators 4 are connected to the vibration table 5 through the couplings 1a and 1b. As a result, the vibrations generated by a vibrator can be correctly transmitted to the vibration table 5 without being influenced by the vibrations in the other directions generated by the other vibrators 4.
In FIGS. 6 and 7 is shown a second embodiment of the present invention. In distinction to the first embodiment shown in FIGS. 4 and 5, the hydrostatic bearing consists of an inner spherical part 12a through which the shaft 1a (or 1b) slidably passes, and which is received within an outer spherical part 12b. In addition to the bore through which passes the shaft, localized concave pads 20 are provided at the portion at which the spherical concave and convex surfaces slide each other. Thus, the hydrostatic bearing is provided. As a result, even when the force is exerted on the coupling in the direction of the axis of the vibrator so that the shaft 1a is bowed, the hydrostatic bearings 12a and 12b which incorporate the spherical surfaces slide against each other so that excess or partial contact of the shaft 1a (or 1b) with the bore of the inner bearing 12a can be avoided.
According to the present invention, the following effects and advantages can be attained:
(i) In absorbing movements in the two directions perpendicular to the load direction, according to the prior art, plane surfaces slide against each other so that the hydrostatic bearing is large in size. According to the present invention, however, the movements are absorbed by the axial sliding movement of the cylindrical surfaces of each shaft and its hydrostatic bearing so that the coupling can be compact in size.
(ii) Fabrication, assembly and mounting are simplified.
(iii) The hydrostatic bearing portions are cylindrical surfaces, so that it is easy to form the structure so that the collection of discharged oil from the hydrostatic bearings can be effected within the bearing proper.
(iv) When the couplings of the present invention are used, influences between vibrators can be eliminated so that correct waveforms can be obtained, whereby accurate movement are gained by simple controls.
(v) All vibration assemblies are constructed with the hydrostatic bearings so that frictional resistance is small against every movement and lost motion can be reduced.
(vi) Even when the vibration table 5 is inclined in the direction other than θ x shown in FIG. 10, the coupling can absorb such a movement. The coupling of the present invention makes is possible to cause the vibration table to pitch and yaw by controlling every vibrator. | The present invention provides a hydrostatic bearing type coupling for a vibrating machine. The coupling is interposed between a vibration table upon which a test specimen or the like is mounted and a vibrator in such a way that even when the vibration table is caused to vibrate three-dimensionally, there are free movements in the two directions. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to processing methods for adaptive filtering on a source signal for transmission, and more particularly an adaptive filtering method to identify the relationship between a source signal and a received signal.
[0003] 2. Description of the Related Art
[0004] It will be readily appreciated by one skilled in the art that the use of adaptive filtering operations may be required in a variety of different signal processing applications. One example of such an area is that of acoustics and specifically sonar signaling. Adaptive filtering systems for time varying operators have broad applications. For example, echo cancellation, active and passive sonar, and equalization of communication signals employ adaptive filtering modeling regimes for extracting information from signals. These modeling regimes are often limited by available memory, computational resources, and acceptable processing delays.
[0005] Multiresolution models of time varying operators have been promoted with the idea of exploiting the sparsity or “economy” of representation attendant in them. This is a useful concept since many operators that are not shift invariant are often succinctly described in wavelet bases, the basic building block of multiresolution models. Conventional approaches have given a general framework for formulating the multiresolution filter structures and provided a fast least mean square-like estimators with an assumed maximal scale of representation. However, this assumption is often overly optimistic. In which case the maximal scale of representation or the most economical wavelet bases can be jointly estimated.
[0006] With regards to adaptive filtering, multiresolution models naturally allow estimation of the response at a given time instant based on given data. In addition, the model circumvents the need for locally stationary assumptions of time recursive algorithms. Accordingly, a larger amount of information is available for the estimation problem at each time instant. Unlike in-time estimation algorithms that are by their very nature causal or near causal, dependencies across time in the forward looking direction are not accounted for with classic in-time adaptive filtering algorithms. In-time estimation is a powerful paradigm due to its computational efficiencies and memory requirements and it continues to find broad appeal and enjoys superior performance in a variety of applications. Nevertheless in areas where fading and multipath delay do not conform to the wide sense stationary (WSS) assumption the multiresolution model is a viable solution. Other practical considerations related to using multiresolution modeling include signal processing and communication schemes involving strategies based on finite duration signaling. For example, mobile radio and underwater acoustic communications data employ a sequence of finite duration packets to transmit information. Similarly for underwater target localization by active sonar as well as radar applications source signals employ time localized “pings.”
[0007] Accordingly, a need exists for a scale adaptive filtering method that is able to match a received signal based on information from a source signal by estimating a variety of parameters. A channel operator is built up in scale, and the channel operator employs time delays and frequency spreads. For this purpose, each additional incrementation of the Doppler spread is hypothesized and then tested.
BRIEF SUMMARY OF THE INVENTION
[0008] An aspect of the present invention provides a scale adaptive filtering method to produce a match of the received signal based on the source signal, by estimating the channel operator at each scale along with nuisance parameters, for example.
[0009] This and other aspects are substantially achieved by providing a system and method for scale adaptive filtering to identify a relationship between a source signal and an actual received signal. The method includes calculating a scale wherein the scale includes a time delay spread and a frequency spread, estimating at least one wavelet coefficient, determining an estimated received signal at the scale using the wavelet coefficient, determining when the estimated received signal is sufficiently similar with respect to the actual received signal, and recalculating the scale by a factor when the estimated received signal is not sufficiently similar with respect to the actual received signal.
[0010] The above and still further aspects, features and advantages of the present invention will become apparent upon consideration of the following definitions, descriptions and descriptive figures of specific embodiments thereof, wherein like reference numerals in the various figures are utilized to designate like components. While these descriptions go into specific details of the invention, it should be understood that variations may and do exist and would be apparent to those skilled in the art based on the descriptions herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a flow chart representing a scale adaptive filtering method in accordance with an aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] While the invention will be described in detail with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. Accordingly, it is intended that the present invention covers modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
[0013] Scale adaptive filtering is a general estimation method employed to estimate the relation between a received signal and a source signal in a variety of transmission environments. As is well known in the art, signaling information can be lost or distorted between a source signal and the received the signal.
[0014] The present invention is a novel method of applying transform function analysis to the received signal at a specific scale thus forming an estimated received signal. This estimated received signal is then compared to the actual received signal. If the estimated received signal is sufficiently complex to model the actual received signal, then the transform analysis has been successful. However, if the estimated signal is not sufficiently complex to model the actual received signal, then the scale is doubled and the transform analysis is applied again. This process is repeated, iteratively, until the estimated received signal is sufficiently complex to model the actual received signal. Sufficiency is achieved when a suitable measure of error is minimized without increasing the complexity of the channel operator. The complexity is limited such that the noise is not included in the modeled signal. In addition, achieving sufficiently similar signals is also determined by employing the Empirical Bayes estimator (a general statistical method), wherein the estimator provides a particular cost function.
[0015] The flow chart 10 illustrates the operation of an exemplary method of scale adaptive filtering in accordance with the present invention. Block 15 is representative of the start block. Block 20 includes generating a source signal from a source such as a transmitter on a submarine or other underwater vehicle, and receiving an actual received signal at a receiver. Block 25 is descriptive of the step including calculating a minimal scale, such that the scale includes time delay information and frequency spread information.
[0016] Block 30 is descriptive of the step of estimating a wavelet coefficient to be used in a transform analysis to determine an estimated received signal. In wavelet analysis it is helpful to view a signal in terms of a fully scalable modulated window. The window is shifted along the signal and for every position the spectrum is calculated. This process is repeated many times with a slightly shorter (or longer) window for every iteration. In the end the result is a collection of time-frequency representations of the signal. In the case of wavelets, we normally do not speak about time-frequency representations but about time-scale representations, scale being a means of quantifying the time variation in the channel operator.
[0017] Block 35 is descriptive of the step of determining an estimated received signal at the minimal scale, initially chosen in Block 20 and employing the wavelet coefficient of Block 30 .
[0018] Block 40 is descriptive of the step of determining if the estimated received signal is sufficiently similar to the actual received signal. In other words, a sufficiently similar signal is achieved when a suitable measure of error is minimized without increasing the complexity of the channel operator. This takes into account the amount of noise in the signal information. The noise or nuisance parameters in the actual received signal should not be modeled in the estimated received signal. If the estimated received signal is not sufficiently similar, then the method proceeds to Block 45 and the scale is increased by doubling the minimal scale and recalculating the wavelet coefficient by proceeding through Blocks 30 . Block 40 checks the estimated received signal against the actual received signal. If the two signals are sufficiently similar, according to the parameters outlined above, the method proceeds to Block 50 and Ends.
[0019] The flow chart 10 is an overview of the method described by the present invention. The following is an exemplary embodiment of this system and method. Specifically, when the maximal scale/frequency of representation of the most economical wavelet coefficients can not be assumed they are jointly estimated. Accordingly, the present invention exploits sparsity of representation under a priori uncertainty regarding Doppler spread and degree of sparsity of the operator.
[0020] Overall, the present invention employs three estimators. First, the wavelet coefficients of the channel response based on the flexible and adaptable Gaussian mixture model. Second, the estimation of the_minimal_scale of the multiresolution space in which the operator resides. Finally, an estimation of the nuisance parameters associated with the mixture model.
[0021] It is shown that the estimation of the maximal scale synonymous with the Doppler spread, is akin to model order selection and estimators for this parameter are provided. These channel estimators are recursive in scale each relying on the preceeding lower scale estimate as a starting point for the next higher resolution estimate. In this framework the channel is gradually built up in scale, rather than time, with each addition of detail a greater Doppler spread (decreased coherence time) is hypothesized and is tested against the data in a model selection framework. Thus multiple resolutions of the operator are provided in sequence with finer scale details descending from the lower scale estimates starting with the linear time invariant (LTI). The algorithm as presented is limited to filter operators that are underspread (i.e. Bτ max <1 where τ max is the delay spread of the filter, B the maximal Doppler bandwidth associated with any of the scatterers, this requirement excludes the underdetermined parameter estimation case).
[0022] The following provides preliminary notation to address the time varying channel as well as an introduction to the empirical Bayes approach. We review the multiresolution decomposition of a time varying operator and the in-scale maximum likelihood estimator is presented based on the conjugate gradient algorithm for in-scale recursions. We go on to introduce a suitable sparsity prior for the time varying channel and this leads to the posterior mean and variance along with estimators of the nuisance parameters associated with the sparsity model. Lastly, we present Doppler spread estimates and stopping rules based on the maximum a posterior (MAP) criteria and on Laplace's approximation as well as the simple and effective Akaike information criteria (AIC). Finally, the usefulness of these algorithms is demonstrated on a diverse set of simulated channels with various types and degrees of Doppler spread. Improved performance of the empirical Bayes posterior mean estimator over the maximum likelihood estimator is demonstrated.
[0023] The following definitions are provided for ease of reference, and will be used throughout. Without loss of generality all matrices and vectors are assumed real. Denote the M×N matrix A by A M×N and the N×1 vector {right arrow over (a)} by {right arrow over (a)} N . Let {right arrow over (1)} N denote a column vector of 1's, {right arrow over (0)} N denote a column vector of 0's and I N denote the identity matrix of size N by N.
[0000] Definitions:
[0000]
1. For vectors {right arrow over (a)} N define the diagonal matrix with diagonal elements {right arrow over (a)} N by Diag({right arrow over (a)}). For square matrices A N,N , the vector of diagonal elements of the matrix A by diag(A).
2. Stack operator, [•] st acts on a matrix A M×N =[{right arrow over (a)} 1 , {right arrow over (a)} 2 , . . . {right arrow over (a)} N ] yielding [A] st =[{right arrow over (a)} 1 ′, . . . {right arrow over (a)} N ′]′, a stacking of A's component columns into a supercolumn with inverse denoted by [•] ist such that A=[A st ] ist .
3. Kronecker product A M×N {circle around (×)}B L×K is the L M×N K matrix of weighted B blocks, having {m,n} th block entry a m,n B.
4. Elementwise product, (A M×N {circle around (·)}B M×N ) m,n =a m,n b m,n .
5. Vector square root, (√{square root over ({right arrow over (a)})}) n =√{square root over (a)} n .
6. Matrix operator {hacek over (H)}, associated with the matrix array H M×N with n th column H n , has N+M−1 rows and N columns; the n th column is {hacek over (H)} n =[{right arrow over (0)} n−1 , H n , {right arrow over (0)} N−n ]. Paragraphs 58 through 61 list a few useful properties and identities that follow directly from these definitions.
[0030] The empirical Bayes (EB) approach is useful primarily for its computational efficiency. Consider computation of E[h|r], var[h|r] and E[φ|r] where r represents received data, h a parameter set of interest and φ a set of nuisance parameters. Expectations over the joint density p(h, φ|r) are often not easily computed. EB methods leverage a crude assumption p(φ|r)≈δ(E[φ|r]) to approximate expectations via iteration E[h|r] l ≈E[h|r, φ=E[φ|r] l−1 ] and are synonymous with approximations of the posterior marginal density via p[h|r]≈p[h|r, φ=E[φ|r]]. The method is versatile with other suitable estimators in place of {circumflex over (φ)}=E[φ|r] l−1 where their computation is faster or warranted by knowledge of the distribution. The penalty of this approximation is its underestimation of variance since var[h|r]=E φ [var[h|φ, r]]+var φ [E[h|φ, r]]. EB approaches therefore provide a lower bound, var[h|r]≧E φ [var[h|r, φ]] that is useful when var φ [E[h|φ, r]] is relatively small. For adaptive filtering problems where the computational demands of Bayesian analysis are presently out of reach the approach has merit.
[0031] Define two multiresolution (M R) spaces one over time and the other over delay. Let {Ω j ξ } jεZ and {Ω k ψ } kεZ represent these respectively; thus Ω J ξ ={Σ j=0 J Σ lεZ c j,l ξ j,l (t) ∥{right arrow over (c)}∥ 2 <∞} where ξ 0,0 (t)=Σf l ξ ξ 0,0 (2t−l) is the scaling function associated with this MR space, and the lowpass f ξ and highpass g ξ are a QMF pair. The scale index j increases with increasing bandwidth in agreement with the convention on the wavelets that ξ j,l (t)=√{square root over (2 j−1 )}ξ 1,0 (2 j−1 t−l) and ξ 1,0 (t)=Σg l ξ ξ 0,0 (2t−l).
[0032] Following the filter model of Doroslovacki, H B (t, τ)εΩ J ξ ×Ω K ψ implies
H B ( t , τ ) = ∑ j , k J , K ∑ l , m L j , M k ω j , k , l , m ξ j , l ( t ) ψ k , m ( τ )
L j = BT 2 j - J - 1 M k = F τ max 2 k - K - 1 ( 1 )
has approximate Doppler spread B∝2 J /T and represents the time varying filter perfectly on the domain (t, τ)=(0, T)×(0, τ max ). The model (1) implicitly specifies the maximal Doppler spread and is therefore denoted with a subscript B.
[0033] Frequency selectivity in the band [2 K−k−1 , 2 K−k ]F is modeled by the Fτ max 2 k−K basis functions {ψ k,m } k,m at delay shifts 2 K−k+1 m/F. In this way the frequency selectivity of the channel due to diverse scatterer locations and delay spreads is modeled as a superpostion of wavelet bases.
[0034] For moving scatterers Doppler spread is induced and is synonymous with an effective channel modulation over time corresponding to an imparted bandwidth to the impulse response process over time at any given delay. Modulations at time t≈2 −j−1 l T with durations ∝T/2 j are modeled with the basis functions {ξ j,l (t)} j,l . These modulations correspond to each scatterers motion such that scatterers corresponding to greater accelerations will yield a channel operator with projections onto bases at fine scales (i.e. large J).
[0035] Let H B (n, m)=H(n/2 q B, m/F) q>1 be a suitably sampled in time t and delay τ version of H(t, τ). Representing this 2-D array as a single stacked column {right arrow over (h)} B of time invariant filters via paragraph 21, definition 2 each operating to produce F/2 q B samples of the output, express the wavelet coefficients of H(t, τ) (nonzero up to scale J) by
{right arrow over (w)} J =U J ( D ξ −q {circle around (×)}I 2 k ) {right arrow over (h)} B W J =Ψ′ K H B D ξ q Ξ J . (2)
The matrix D ξ q is the 2 J+q by 2 J matrix decimation operator associated with the M R space of ξ. Its adjoint D ξ q′ =D ξ −q is the associated interpolation operator. The columns of Ξ J and Ψ K are respectively the expansion coefficients of the wavelets ξ j,l (t) and ψ k,m (τ) in the bases of the associated scaling functions ξ 0,0 (t) and ψ 0,0 (τ) respectfully. The matrix Ξ J εR BT×BT and Ψ K εR Fτ max ×Fτ max have maximal scales of J=└log 2 B T and K=└ log 2 Fτ max ┘ respectively. The operator U J is the Kronecker product of the two wavelet transforms U J =Ξ′ J {circle around (×)}Ψ′ K . The wavelet coefficients {right arrow over (w)} J ={w j,k,l,m , j=1 . . . J, k=1 . . . . K, l, mεZ 2 } are computable via the fast wavelet transform. The operator H is synthesized from {right arrow over (w)} J with the fast inverse wavelet transform to J+q scales (q interpolation/scaling operators added via zero appending W J )
{right arrow over (h)} B =( D ξ q {circle around (×)}I 2 K ) U′ J {right arrow over (w)} J H B =Ψ K W J Ξ′ J D ξ −q (3)
implying that H B is synthesized as constant at time scales less than 1/2 q B. Clearly then q must satisfy q<log 2 F/B since the channel is LTI at the sampling rate. The LHS of (3) follows from paragraph 58, property 4, with Ξ and Ψ unitary. Compute {right arrow over (h)} B from {right arrow over (w)} J via the RHS of (3) and denote the scaling function expansion of the channel by
{right arrow over (h)} B 0 =U′ J {right arrow over (w)} J . (4)
Lastly define the time varying convolution matrix operator associated with the time varying array structure H B or synonymously its stacked representation {right arrow over (h)} B as {hacek over (H)} B .
[0036] For channels with sparse arrivals that are dispersed and non-stationary the wavelet model offers a represention that is parsimonious. However for filters with peaky features in frequency, Fourier bases or autoregressive models will be more suitable. Fourier bases modeling Doppler spread will be optimal as well for the WSS channel as T→∞. Fourier bases will fail however to capture discontinuities or time localized phenomena. In addition where finite duration segments must be modeled boundaries pose severe penalties to Fourier methods, wavelets on the other hand parsimoniously capture these features. At lower frequencies associated with scatterers with smaller Doppler spread wavelets will offer near Fourier-like performance for the WSS condition. Nevertheless wavelets provide a means to model abrupt changes in channel conditions, localized phenomena in time and delay as well as minimizing boundry effects associated with finite duration signaling. Wavelet models of course are not universally appropriate for delay localized operators. For instance in the case of channels consisting of arrivals that have no dispersion in delay the standard Euclidean bases (in delay) are optimal (i.e. H(t, τ)=Σ n α n (t)δ τ−τ n (t) ). In this case the path delays and amplitudes (associated with the time changing geometry of the environment) are modeled.
[0037] The following paragraphs introduce an in-scale likelihood model from which a recursive in-scale MLE follows. A sparsity prior is then assumed and from this in-scale posterior expectation, variance and Doppler spread B estimates are derived. Empirical Bayes methods are employed throughout.
[0038] The channel response H(t, τ) of (1) with B Hz Doppler spread is observed via the source, s(t) and received signal r(t) through the linear model
r ( t )=∫ H ( t , τ) s ( t −τ) dτ+n ( t ) (5)
where n(t) is a white Gaussian noise process of known power σ 2 F.
[0039] Let N x (μ, Σ)=√{square root over ((2π) −N |Σ| −1 )}exp(−(x−μ)′Σ −1 (x−μ)/2). Assuming H is time-invariant over durations 1/2 q B and that s(t) and r(t) are suitably sampled at the Nyquist rate F let N=F(T+τ max ) the received signal dimension and M=Fτ max the delay spread dimension. The discrete time model associated with (5) using the time varying operator of paragraph 21, definition 6, is
p ( {right arrow over (r)}|{right arrow over (h)} B ,{right arrow over (s)} ,σ)= N {right arrow over (r)} ( {hacek over (H)} B {right arrow over (s)},Iσ 2 ) (6)
where {hacek over (H)} B represents the N by N−M+1 block convolution operator associated with {right arrow over (h)} B in (3). Synonymously using (3) express (6) as a set of stacked wavelet coefficients
p ( {right arrow over (r)}|{right arrow over (w)} J ,{right arrow over (s)} ,σ)= N {right arrow over (r)} ( S 2 q B ( D ξ q {circle around (×)}I 2 K ) U′ J {right arrow over (w)} J , Iσ 2 ) (7)
where J is interchangeable with B as in (3) and for notational simplicity the conditioning on families ξ and ψ are assumed for time and delay respectively. With P=BT the Doppler dimension, S 2 q B is the N×2 q P M block convolution operator associated with the sampled source signal {right arrow over (s)}. The blocks of S 2 q B are proportional to the coherence time of 1/2 q B over which the channel is LTI. S 2 q B operates on a 2 q P long list of stacked M length LTI channel vectors to yield a channel output. To illustrate consider q=0 then S B has the form
S B = [ L 1 0 ⋮ ⋮ ⋮ 0 X 1 0 ⋮ Y 1 L 2 ⋮ 0 X 2 ⋮ 0 Y 2 • ⋮ ⋮ 0 ⋮ • 0 ⋮ 0 ⋮ • L P 0 X P 0 ⋮ ⋮ ⋮ 0 Y P ] ( 8 )
The L's (Y's) are lower (upper) triangular, and are each of size M by M. The X's are full and of size F/B−M by M. Together each [L′, X′, Y′]′ block represents a time invariant filter operator over a duration of 1/2 q B seconds derived from the source signal of this block. The operator (D ξ q {circle around (×)}I 2 K ) maps the N by 2 K+J+q block convolution operator S 2 q B of source samples, to the N by 2 K+J block convolution operator of modulated blocks associated with coefficients in a scaling expansion of ξ. Some useful properties are exposed by considering the case of q large. Define the limiting matrix
S B ξ =lim q→∞ S 2 q B ( D ξ q {circle around (×)}I 2 K ) (9)
which operates on the stacked coefficients of a scaling function expansion of the channel (i.e. {right arrow over (h)} B 0 =U′ J {right arrow over (w)} J ) to produce the expected value of the output of the time varying filter according to (7). The following scaling equation for such block convolution operators is informative S B/2 ξ =S B ξ (D ξ 1 {circle around (×)}I 2 K ). Further observe that for ξ Haar the scaling equation for the operator S B takes the form
S B =S 2B ( D Haar 1 {circle around (×)}I 2 K ) (10)
and while it requires no multiplies it exhibits abrupt discontinuities between blocks. In practice (9) is not computable, the upper bound on q is determined by the bandwidth of the source q<log 2 F/B such that modeling of the channel as anything but LTI over durations smaller than the sampling period is infeasible and unnecessary. For channels with reasonable regularity q>3 is sufficient in practice. For instance with q=5, a B Hz Doppler spread channel is modeled as LTI over durations <1/32 B sec.
[0040] Returning back to (7) the implied likelihood function on {right arrow over (w)} J =U J {right arrow over (h)} B 0 is
p ( r → | w → , s → , J = log 2 BT ) ∝ 𝒩 w ~ J ( w → ~ J , Δ J )
w → ~ J = U J h → ~ B 0 , h → ~ B 0 = ( C B ξ ) - 1 S B ξ ′ r → , Δ J = σ 2 U J C B ξ U J ′ ( 11 )
where the 2 K+J ×2 K+J matrix C B ξ =S B ξ S B ξ is the source covariance matrix associated with the time-varying filter model. To illustrate consider again the simple case q=0 and ξ Haar. It follows that C B =S′ B S B and takes the form
C B = [ T 1 V 1 0 … 0 V 1 ′ T 2 ⋰ ⋮ 0 • 0 0 • 0 ⋮ ⋰ T P - 1 V P - 1 0 … 0 V P - 1 , T P ] ( 12 )
with T p M×M Toeplitz, V p lower triangular Hankel with zeros on the main diagonal having rank M−1 and P=BT. C B is represented either by the 2P vectors of length M corresponding to the first columns of T p and V p , or by the 2M+1 diagonals of C B each being of length P M. Thus C B is non-Toeplitz, banded Hermitian with 2M+1 nonzero diagonals. For ξ≠Haar C B ξ will differ from C B in that it will be banded with width >2M+1. The vector {right arrow over (b)} B =S B ξ′ {right arrow over (r)} in (11) is a block overlapped cross-correlation of source and received data vectors associated with the windowing scaling function ξ 0,0 (t). The weakness of the in-scale likelihood approach is simply that the parameter set grows exponentially with scale, (i.e. PM∝2 J ) a severe penalty for a linear model. Nevertheless for the very limited set of spectrally flat signals the approach has some merit computationally. Signals for which ∥C B ξ −C 0 I PM ∥ is small for some scalar C 0 (e.g. Gaussian white signals, maximal length sequences) ∥{right arrow over (b)} B −{right arrow over (h)} B ∥ will be small as well and close approximations to {right arrow over (h)} B are attained with the fast block correlation {right arrow over (b)} B =S B ξ′ {right arrow over (r)}.
[0041] The in-scale computation is done using the conjugate gradient method. A direct computation of
h → ~ B 0
in (11) requires O((PM) 3 ) a computationally impractical feat. A feasible approach assumes that
h → ~ B / 2 0
is known to a tolerable precision. Compute
h → ~ B 0
starting from
( D ξ 1 ⊗ I 2 K ) h → ~ B / 2 0
via the conjugate gradient (CG) method. Initialization requires only O(M 2 ) since for J=0 the system is Toeplitz. The CG algorithm has found wide application in solving banded and sparse systems. Indeed the CG algorithm has been shown to be synonymous with the multistage Wiener filter. Table 1 lists the operations necessary along with the associated computational demands. Note that only a single matrix multiplication by the sparse banded matrix C B ξ is required per iteration. A multiply is accomplished efficiently from the 2M+1 stored diagonals of length P M. In this framework the inversion of large matrices is avoided by solving much lower (1/2) dimension problems to a given precision then using these as starting points for the next higher hypothesized dimension. The resulting maximum likelihood estimate when the CG algorithm is iterated to machine precision is termed {right arrow over (h)} B mle and is computed via interpolation from {tilde over ({right arrow over (h)})} B 0 as
h → ~ B mle = ( D ξ q ⊗ I 2 K ) h → ~ B 0 ⟺ H B mle = [ h → B 0 ] ist D ξ - q .
[0042] The CG algorithm also allows for flexibilty in the number of iterations. Computation of {right arrow over (h)} B mle to machine precision may not be necessary and a solution slightly more coherent (closer to {right arrow over (h)} B/2 mle ) may be tolerable. For less computation iterate to within a ball of radius proportional to the covariance of the MLE and call such a solution {right arrow over (h)} B a , an approximate MLE. To determine this iteration number an approximate ad-hoc approach is taken. Define κ the ratio of minimum to maximum eigenvalues of C B ξ then at iteration i a , where {right arrow over (h)} B {i a } ={right arrow over (h)} B a the CG solution is within a ball of radius ∥{right arrow over (h)} B a −{right arrow over (h)} B mle ∥=∥Σ i a +1 PM ρ i {right arrow over (d)} i ∥≦2∥{right arrow over (h)} B mle ∥√{square root over (κ)}ω i a where ω=(√{square root over (κ)}−1)/(√{square root over (κ)}+1). The computation of κ is not trivial and must be approximated for the class of source signals that are considered. Further in the case of in-scale computation proposed here the extreme eigenvalues of C B ξ at each B would have to be approximated, at present this is impractical and an approximation is used for ω. The implementation of the CG algorithm presented makes an additional ad-hoc assumption to eliminate ∥{right arrow over (h)} B mle ∥ from the stopping criteria based on the fact that the CG algorithm gives fairly smooth exponential convergence due to dominant eigenvectors not dominating the convergence. For this reason in practice the tightness of the ≦2∥{right arrow over (h)} B mle ∥√{square root over (κ)}ω i a bound does not vary greatly from iteration to iteration. Express the radius as ∥Σ i a +1 PM ρ i {right arrow over (d)} i ∥=G∥ρ i a +1 {right arrow over (d)} i a +1 ∥+∥Σ i a +2 PM ρ i {right arrow over (d)} i ∥ for some constant 0<G<1 (since the innovation components are not orthogonal). Assuming the convergence is fairly well behaved approximate ∥ρ i a +1 {right arrow over (d)} i a +1 ∥≈∥{right arrow over (h)} B a −{right arrow over (h)} B mle ∥(1−ω). A common scenario is that of a white non-fading source signal with variance ζ 2 . The variance of each coefficient w j,k,l,m is simply δ J 2 =Δ j,k =σ 2 /ζ 2 ×B/F. With PM=BTFτ max coefficients this implies {right arrow over (w)} J has variance P×Bτ max /SNR. In this scenario, with G=10 iterate while ∥ρ i+1 {right arrow over (d)} i+1 ∥>10(1−ω)PBτ max /SNR. A conservative approximation of κ=1000 corresponding to ω=0.93 can be made.
TABLE 1 Computation of w ⇀ ~ J via conjugate gradient . P = BT, M = Fτ max , N c = F/B m 0 ∝ length(g ξ ) Initialize x ⇀ 0 = ( D ξ 1 ⊗ I K ) h ⇀ ~ B / 2 0 O(PM × m 0 2 ) C B , b ⇀ B = S B ′ r ⇀ O(PN c logN c ) d ⇀ 0 = e ⇀ 0 , e ⇀ 0 = b ⇀ - C B x ⇀ 0 f ⇀ 0 = C B d ⇀ 0 O(PM 2 ) while ρ i d ⇀ i 2 > ( 1 - ω ) PB τ max δ J 2 η = e ⇀ i ′ f ⇀ i / d ⇀ i ′ f ⇀ i , d ⇀ i + 1 = e ⇀ i - η d ⇀ i O(PM) f ⇀ i + 1 = C B d ⇀ i + 1 O(PM 2 ) ρ i + 1 = e ⇀ i ′ d ⇀ i + 1 / d ⇀ i + 1 ′ f ⇀ i + 1 , v ⇀ i + 1 = v ⇀ i + ρ i + 1 f ⇀ i + 1 O(PM) x ⇀ i + 1 = x ⇀ i + ρ i + 1 d ⇀ i + 1 , e ⇀ i + 1 = b ⇀ - v ⇀ i + 1 O(PM) i = i + 1 end h ⇀ ~ B = x ⇀ i + 1 w ⇀ ~ J = U J x ⇀ i + 1 O(PM × m 0 2 )
[0043] The Gaussian (normal) mixture can be chosen as a sparsity prior for the doppler spread channel. The previous maximum likelihood in-scale estimate of the channel assumes that all delay lags of the channel at each time contribute to the output a priori equally. Synonymously there is in the likelihood model an implicit prior of large and equal variance for each and every time-delay component of the channel operator. This assumption is simplistic for sparse channels and a modification to the likelihood approach is warranted. The prior chosen should give the model flexibility to choose components, associated with frequency selectivity and Doppler spread (time modulation) that are significant and reject those that are not. This problem is synonymous with variable selection and mixture prior assignments have been useful for such problems in both the Bayesian and empircal Bayes methodologies. For this reason the binary discrete mixture normal model
p ( w |π,λ,ε)= M (π,λ,ε) w|π,λ,ε˜πN w (0,λ 2 )+(1−π) N w (0,ε 2 ) (13)
is chosen as a prior. Specify the prior conditional density of {right arrow over (w)} J as
w → J ❘ π j , k , λ j , k , ε j , k ~ ∏ j , k J , K ∏ l , m L j , M k M w j , k , l , m ( π j , k , λ j , k , ε j , k ) . ( 14 )
The mixture normal model can be useful because it captures an attribute of sparsity. For each of the significant arrival paths associated with an operator we have a normal model. For those delays for which no arrival energy is present we model these with small (ε) variance. The hyperparameters necessary to specify the model are summarized in a single parameter {right arrow over (φ)} J ={π j,k , λ j,k , ε j,k } j,k ≦J,K. With the prior and likelihood specified the resulting posterior distribution to be maximized jointly over {right arrow over (w)} J and J (synonymous with {right arrow over (h)} B and B) and hyperparameters {right arrow over (φ)} J is
p({right arrow over (w)}, {right arrow over (φ)},J|{right arrow over (r)},{right arrow over (s)}, σ 2 )∝N {right arrow over (w)} J ({right arrow over ({tilde over (w)})} J ({right arrow over (r)},{right arrow over (s)}), Δ J ({right arrow over (s)},σ 2 ))×p({right arrow over (w)}|{right arrow over (φ)},σ 2 ,J)×p({right arrow over (φ)}|J)×p(J) (15)
The first term, the likelihood assumes independence of wavelet coefficients via the near diagonalizing property of U J on the source covariance C B ξ and the second term the prior, is predicated on this assumption.
[0044] For ease of notation let *=l, m represent an arbitrary wavelet coefficient at time-delay location associated with l, m according to the model of Equation (1) so that w j,k,* =w j,k,l,m . In the spirit of empirical Bayes consider the posterior distribution of wavelet coefficients given all other parameters. This conditional density is shown in Equation 33 to be
w j , k , * | w ~ j , k , * , σ 2 , ϕ → J ~ Π ( w ~ j , k , * ) 𝒩 w j , k , * ( γ ( λ j , k ) w ~ j , k , * , γ ( λ j , k ) δ j , k 2 ) + ( 1 - Π ( w ~ j , k , * ) ) 𝒩 w j , k , * ( γ ( ε j , k ) w ~ j , k , * , γ ( ε j , k ) δ j , k 2 ) ( 16 )
where the posterior mixture coefficient Π({right arrow over (w)} j,k,* ) and the gains γ(•) are defined in the derivation of Equation 33. This posterior (16) has the same mixture normal form as the prior (13). There are however two important distinctions, first the posterior mixture coefficents Π(•) are functions of each individual empirical coefficient {right arrow over (w)} j,k,l,m . Secondly the means of the mixture densities are not equal. For this reason the posterior density is not symetric and therefore its first moment ŵ=E[w|{tilde over (w)},{right arrow over (φ)} J ] is not synonymous with the argument maximizing (16).
[0045] Since the posterior is a mixture the mean is simple to assess as
ω ^ j , k , * = E [ ω j , k , * | ω ~ j , k , * , σ 2 , ϕ → J ] = [ Π ( ω ~ j , k , * ) γ ( λ j , k ) + ( 1 - Π ( ω ~ j , k , * ) ) γ ( ε j , k ) ] ω ~ j , k , * . ( 17 )
The resulting operator {right arrow over (ŵ J =E[{right arrow over (w)}|{right arrow over ({tilde over (w)})} J σ 2 ,{right arrow over (φ)} J ] attenuates smaller coefficients and leaves larger ones relatively unchanged. It is similar in form to a Wiener filter with the noticeable difference of a mixture of Wiener gains, each gain being proportional to the implicit empirical posterior probability of the associated model in the mixture.
[0046] The posterior mean of the channel {right arrow over (h)} B sampled at the rate 2 q B Hz follows directly from (17) and the linearity of the wavelet transform as
{right arrow over (ĥ B =E[{right arrow over (h)}|{right arrow over (r)}, {right arrow over (s)}, σ 2 ,{right arrow over (φ)} J ]=( D q {circle around (×)}I 2 K ) U J {right arrow over (ŵ J Ĥ B =Ψ K [{right arrow over (ŵ J ] ist Ξ′ J D ξ −q .(18)
The posterior mean is useful since for the ensemble of channels associated with the mixture prior on wavelet coefficients no other estimator has smaller mean square error. It is however a biased estimator. The MAP estimate for the posterior is computationally intensive requiring iterations over every wavelet coefficient and for this reason an approximate MAP is worth considering.
w j , k , * amap = { γ ( λ j , k ) w ~ j , k , * if Π ( w ~ j , k , l , m ) > 1 / 2 γ ( ε j , k ) w ~ j , k , * if Π ( w ~ j , k , l , m ) < 1 / 2 ( 19 )
is a simple approximation and has been tested against the actual MAP, computed via Nelder-Mead iteration, and gives comparable performance in terms of MSE on simulated channels.
[0047] The conditional variance of the channel {right arrow over (h)} B is computable directly from the posterior density (16) and gives measure of the uncertainty associated with the channel after observation of the data. The derivation of Equation 34 presents proof of the following
v j , k , * 2 = var [ w j , k , * | w ~ j , k , * , ϕ → J ] = ( Π ( w ~ j , k , * ) γ ( λ j , k ) + ( 1 - Π ( w ~ j , k , * ) ) γ ( ε j , k ) ) δ j , k 2 + = Π ( w ~ j , k , * ) ( 1 - Π ( w ~ j , k , * ) ) ( γ ( λ j , k ) - γ ( ε j , k ) ) 2 w ~ j , k , * 2 . ( 20 )
The above shows that the conditional variance for each coefficient is the sum of two components. The first is a weighted average of the variances associated with the two models of the mixture. The last component represents the uncertainty of the coefficient being associated definitively with either of the two models in the mixture and is maximum for Π(w)=½. For this reason large variance is associated with coefficients with magnitude approximately
w ~ j , k , * = ± ( λ j , k 2 + δ j , k 2 ) ( ε j , k 2 + δ j , k 2 ) λ 2 - ε 2 log ( ( λ j , k 2 + δ j , k 2 ) ( ε j , k 2 + δ j , k 2 ) ( 1 - π j , k ) 2 π j , k 2 ) .
Define {right arrow over (v)} J as the vector of posterior variances (20) associated with {right arrow over (w)} J ; then under the assumption that the wavelet coefficients are uncorrelated, cov[{right arrow over (w)} J ]=Diag[{right arrow over (v)} J ]. The posterior covariance of {right arrow over (h)} B is then, using (3) and paragraph 58, property 2,
Γ B = cov [ h → B ] = ( D ξ q ⊗ I 2 κ ) U J ′ Diag ( v → J ) U J ( D ξ - q ⊗ I 2 κ ) = ( D ξ q Ξ J ⊗ Ψ K ) Diag ( v → J ) ( Ξ J ′ D ξ - q ⊗ Ψ K ′ ) . ( 21 )
Determine the variance of H B at any give t, τ by computing V B =[diag(Γ B )] ist using paragraph 58 to express diag(Γ B )=[(D ξ q Ξ J {circle around (·)}D ξ q Ξ J ){circle around (×)}(Ψ K {circle around (·)}Ψ K )]{right arrow over (v)} J . This implies that the posterior variance field V B defined over t, τ is
V B =(Ψ K {circle around (·)}Ψ K )[{right arrow over (v)} J ] ist ( D ξ q Ξ J {circle around (·)}D ξ q Ξ J ). (22)
Since the operators (Ψ K {circle around (·)}Ψ K ) and (D ξ q Ξ J {circle around (·)}D ξ q Ξ J ) do not obey a scaling recursion they must be computed directly an impractical feat for channels of high dimension BT×Fτ max . For this reason a fast approximate (1−α)% confidence interval for H B is worth pursuing. Proceed as follows; define {right arrow over (w)} J α ={right arrow over ({tilde over (w)})} J +z α √{square root over ({right arrow over (v)} J )} and {right arrow over (w)} J 1−α ={right arrow over (ŵ J −z α √{square root over ({right arrow over (v)} J )} and transform via (3). Here of course P[z>z α ]=α/2, with z˜N(0, 1). These wavelet domain bounds produce an approximate EB high probability region for the channel as
P [ min ( H ^ B α ( t , τ ) , H ^ B 1 - α ( t , τ ) ) < H ( t , τ ) < max ( H ^ B α ( t , τ ) , H ^ B 1 - α ( t , τ ) ) ] ≈ 1 - α
H ^ B α = Ψ K [ w → J α ] ist Ξ J ′ D ξ - q H ^ J 1 - α = Ψ K [ w → J 1 - α ] ist Ξ J ′ D ξ - q . ( 23 )
[0048] In keeping with the empirical Bayes methodology, estimate the hyperparameters {right arrow over (φ)} J={π j,k ,λ j,k ,ε j,k } as follows: first for π j,k use Donoho's threshold argument, namely that z i ˜N(0, δ 2 ) implies that
lim n→∞ P [max i≦n |z i |>δ√{square root over (log(2 πn ))}]=0. Let {right arrow over (1)} S ( x )={1 for xεS, 0 otherwise}.
With the total number of coefficients at the j,k th scale denoted N j,k =2 K−k+J−j BTFτ max then an asymptotically unbiased estimate of π j,k when λ j,k >>δ j,k for the model of (13) is
π ^ j , k = ∑ 1 → S j , k N j , k
where
S j , k = { w j , k , l , m : w j , k , l , m > δ j , k log ( 2 π N j , k ) }
For λ j,k use {circumflex over (λ)} j,k =max * |{right arrow over (w)} j,k,* |/3. Lastly for the ε's use the assumptions that the channel w j,k,* and noise processes are independent with π<<1/2 the median absolute deviation (MAD) estimator of zero-mean iid (independent identically distributed) variates suggests E 2 [mad * {right arrow over (w)} j,k,* ]≈δ j,k 2 +ε j,k 2 leading to the estimator {circumflex over (ε)} j,k 2 =max[δ j,k 2 /20, [mad * {right arrow over (w)} j,k,* ] 2 −δ j,k 2 ].
[0049] In this and the following two paragraphs, inference regarding Doppler spread B or maximum scale J=log 2 BT is shown to be synonymous with model order selection. An EB-MAP estimate as well as rules based on Laplace's approximation and Akaike (AIC) are provided. It is convenient in keeping with the in-scale paradigm to place a prior on B synonymous with an uninformative prior on J, the maximum scale parameter. With this assumption the MAP estimate of the Doppler spread is determined by maximizing the likelihood p({right arrow over (r)}|J); the objective then is
Ĵ=arg min J {−log p ( {right arrow over (r)}|J )},
p ( {right arrow over (r)}|B =2 J /T )=∫ p ( {right arrow over (r)}|{right arrow over (w)} J ) p ( {right arrow over (w)} J ≡|{right arrow over (φ)} J ) p ({right arrow over (φ)} J |J ) d{right arrow over (w)}d{right arrow over (φ)}. (24)
The first term in the integrand is decomposed as
p ( {right arrow over (r)}|{right arrow over (w)} J )=(√{square root over (2π)}) 2 J Fτ max |Δ J | 1/2 ×N {right arrow over (r)} ( {hacek over (H)} B mle {right arrow over (s)},Iσ 2 )× N {right arrow over (w)} J ( {right arrow over ({tilde over (w)})} J ,Δ J )
leading to
p ( r → | B = 2 J / T ) = 𝒩 r → ( H ⋓ B mle s → , I σ 2 ) × ( 2 π ) BTF τ max / 2 Δ J 1 / 2 × ∫ ∏ j , k , l , m ( 𝒩 w j , k , l , m ( w ~ j , k , l , m , δ j , k 2 ) × [ π j , k 𝒩 w j , k , l , m ( 0 , λ j , k 2 ) + ( 1 + π j , k ) 𝒩 w j , k , l , m ( 0 , ε j , k 2 ) ] p ( ϕ → | J ) ) ⅆ w → ⅆ ϕ →
Integrate over {right arrow over (w)} analytically since N w ({right arrow over (w)}, δ 2 )N w (0, λ 2 )=N w (γ(λ){right arrow over (w)}, γ(λ)δ 2 )N {right arrow over (w)} (0, δ 2 +λ 2 ) and over the 3J K parameters of {right arrow over (φ)} J using the asymptotic result of Schwarz (i.e. ∝ (FT) −3JK/2 ). Under the near diagonalizing property of U J approximate |Δ J |≈Π j,k δ j,k2 , and with the EB estimate of {right arrow over (φ)} J and {right arrow over ({tilde over (e)})} r,B =r−{hacek over (H)} B mle {right arrow over (s)}, the MAP criterion is
{circumflex over (B)} MAP =arg min J {Q MAP ( J )} (25)
where
Q MAP ( J ) = ⅇ → ~ r , B ′ ⅇ → ~ r , B 2 σ 2 - ( 2 J F τ max ) 2 log ( 2 πδ j , k 2 ) + 3 JK 2 log FT - ∑ j , k , l , m J , K log ( ℳ w ~ j , k , l , m ( π ^ j , k , λ ^ j , k 2 , + δ j , k 2 , ε ^ j , k + δ j , k 2 ) ) . ( 26 )
It is somewhat striking and counterintuitive that this empirical Bayes MAP estimate of Doppler spread (25) does not require the computation of the MAP or posterior mean (PM), the residual errors being associated with that of the MLE.
[0050] To consider rules based on the residual errors associated with the posterior mean or approximate MAP channel estimate proceed as follows; let lp({right arrow over (w)})=log p({right arrow over (r)}|{right arrow over (w)})p({right arrow over (w)}|{right arrow over (φ)}, J) (noting that this is proportional to the log posterior of {right arrow over (w)} expand about {right arrow over (w)} map ; lp({right arrow over (w)})≈lp({right arrow over (w)} map )+({right arrow over (w)}−{right arrow over (w)} map )′lp″({right arrow over (w)} map )({right arrow over (w)}−{right arrow over (w)} map )/2. Approximate lp″({right arrow over (w)} map )≈−V −1 and substitute the posterior mean {right arrow over (ŵ J and covariance V B yielding
p ( {right arrow over (r)}|J )≈ p ( {right arrow over (r)}|{right arrow over (ĥ B )|2π| BTFτ max /2 V B | 1/2 ∫p ({right arrow over (ŵ J |{right arrow over (φ)} j ,J ) p ({right arrow over (φ)}| J ) d{right arrow over (φ)}.
With |V B | 1/2 =Π{right arrow over (v)} J 1/2 and the asymptotic result of Scharwz applied to {right arrow over (φ)} J the resulting Laplace approximation rule is
{circumflex over (B)} LAP =arg min J {Q LAP ( J )} (27)
where
Q LAP ( J ) = - log p ( r → | w → ^ J ) - log p ( w → ^ | J ) + 3 JK 2 log FT - 1 2 ∑ j , k , l , m log 2 π v j , k , l , m 2 . ( 28 )
The first term −log p({right arrow over (r)}|{right arrow over (ŵ J ) is a measure of the quality of the posterior mean channel estimate to predict the data {right arrow over (r)} and is synonymous with the coding complexity of the data given the estimate of the channel. From this perspective it is proportional to the length of the best code of the residuals of the data predicted by the adaptive filter estimate and source signal. Similarly the sum of the second and third terms is proportional to the information necessary to specify this particular channel estimate {right arrow over (ĥ B from the prior assignment to the resolution associated with the posterior variance.
[0051] A popular and heuristically simple alternative is Akaike's Information Criteria (AIC) (for a reasonable explanation of this ad-hoc measure see Kay). The associated penalty cost in this case is simply one half the number of parameters of the model
{circumflex over (B)} AIC =arg min J {Q AIC ( J )} (29)
where
Q AIC ( J ) = - log p ( r → | w → ^ J ) + 3 JK 2 + 2 J - 1 F τ max . ( 30 )
[0052] These in-scale algorithms were tested on a diverse set of simulated multipath channels to determine their relative performance in jointly estimating the channel operator and its Doppler spread.
[0053] The considered test channels are of the form
H ( t , τ ) = ∑ m = 1 M p α m ( t ) χ m ( τ - d m ( t ) ) ( 31 )
having M p independent component paths. Each path has an associated arrival spreading function x m (•) that is time invariant. Doppler spread is induced by both the path gain processes α m (t) and the path delay processes d m (t). Arrival path delay times d m (t) and amplitudes α m (t) are modeled as correlated Gaussian variates with respective covariances c d m (τ)=c d m (0)(1−τ/T d m ) for |t|<T d m , 0 otherwise and c α m (t)=c α m (0)(1−t/T α m for |t|<T α m , 0 otherwise. A realization of such a channel is then generated given the 3M d parameters: the weight functions χ m (•), and coherence times T d m and T α m . An associated Doppler bandwidth for each of these path processes is termed B α m =2/T α m and B d m =2/T d m . For each test case the Doppler spread is termed the maximum of these constituent Doppler bandwidths. Varying the correlation times associated with the processes d m 's and α m 's as well as the spreading shapes χ m 's allows for the simulation of processes that are diverse and realistic.
[0054] Four channel operators were tested, the number of paths and the maximal Doppler spread for each of the cases is listed in Table 2.
TABLE 2 Test cases for time-varying channel parameters case M d B (Doppler spread) LTI 4 0 Hz TV α's 4 1 Hz TV delay's 4 4 Hz TV delay's & α's 4 4 Hz
[0055] Some channels share a common feature of sparsity in that while each scatterer path exhibits Gaussian uncorrelated scattering each delay lag does not. Thus the channels are not wide sense stationary-uncorrelated scattering (WSS-US).
[0056] Gaussian source {right arrow over (s)} and additive noise signals of the same spectra where used in the simulations. The source signal correlation c {right arrow over (s)} (τ)=E[s(t)s(t+τ)]=ζ 2 (1−2τF) for |τ|<2F, 0 otherwise. c {right arrow over (n)} (τ)=σ 2 c {right arrow over (s)} (τ)/ζ 2 . The channels were simulated for durations of approximately T=8 seconds and a bandwidth F=2k Hz.
[0057] In these simulations C B and S B were used as approximations to C B ξ and S B ξ in the CG algorithm for the computational savings associated with its tight banded structure. In practice the number of C G iterations to compute {right arrow over ({tilde over (h)})} B a starting from (D ξ 1 {circle around (×)}I 2 K ){tilde over ({right arrow over (h)})} B/2 a hB/2 to a chosen precision of 0.1×P×δ J 2 is approximately 5. Further iterations are used to compute the MLE. The algorithm was implemented with Daubechies orthogonal wavelets order 3 (ψ=D(3)) in delay and ξ=D(5) in time for U J under the folded wavelet assumption. The interpolation operator D ξ −q of (3) in this simulation was implemented as a windowed sinc for the simplicity associated with its linear phase and q was set at 4 so that for a given hypothesized J the estimate was assumed LTI over durations of T/2 J+4 .
[0058] The normalized mean square error for the channel estimates
e h 2 2 = [ ( h → ^ B - h → B ) ′ ( h → ^ B - h → B ) h → B ′ h → B ]
is computed for each of the estimators; the approximate MLE {right arrow over ({tilde over (h)})} B a (aMLE), the MLE, {right arrow over (h)} B mle , the posterior mean {right arrow over (ĥ B (PM) and the approximate MAP.
[0059] Granular noise is present in the MLE and represents the cost incured by the use of this unbiased estimator. With the sparsity prior the PM is able to provide a more regular estimate that exhibits better MSE performance. However this performance comes at a cost of bias in the PM estimate. This bias is pronounced in the peaks of the channel response estimate. Indeed it is easily verified by considering near L ∞ loss functions. Tests were conducted with ∥e h ∥ p p=8 to approximate L ∞ loss and demonstrate that the MLE often outperforms the PM even for these sparse test cases.
[0060] To determine the ability of the in-scale approach to accurately determine Doppler spread the algorithm can be tested on an LTI operator. One important attribute of the in-scale approach is that LTI filters can be recognized even at quite low SNR. The in-scale algorithm can identify LTI channels with only the computation of 2 iterations in the scale domain. The first iteration is the LTI estimate. The second is the scale 1 iteration from which the LTI is compared favorably and the in-scale iteration is ceased. This is in stark contrast to in-time recursions where computational resources are distributed over time without respect to the actual coherence time of the channel process. Thus for finite duration signaling the in-scale approach has a distinct advantage. The Doppler complexity measure is a minimum for the J=0 th scale estimate for all three criteria (AIC, LAP, MAP) and does not fall below this at greater resolution estimates. Here each of the Doppler costs are normalized by E[log p({right arrow over (r)}|{right arrow over (h)} B )]=−(1+log σ 2 )FT/2. It is further noted that for sparse channels in delay the mixture normal model is an effective sparsing model affording a 2 dB improvement in performance over the MLE estimate at the 0 th scale estimate. The PM estimate exhibits greater gains at higher scales demonstrating the robustness of the posterior mean and MAP estimates against variance of the Doppler spread rule.
[0061] Monte Carlo simulations reveal slightly greater variability of the MAP stopping rule over that of the AIC or LAP. We can demonstrate that a model of the time varying filter as a process in scale yields estimators that provide joint estimation of channel response and coherence time. Coherence time is modeled in this framework as model order selection.
[0062] An MLE, approximate MLE, approximate MAP and posterior mean were derived along with AIC, Laplace approximation and MAP Doppler estimation procedures based on empirical Bayes assumptions. These algorithms were tested and compared with one and other on a number of simulated time varying channels. As expected the posterior mean demonstrates improvement in performance over the MLE and approximate MAP for time varying channels relative to mean square error.
[0063] All of the estimators presented for in-scale processing rely on the conjugate gradient algorithm to compute approximate MLE estimates from the previous lower scale estimate. From the MLE and conditional variance along with a sparsity prior the posterior mean is a simple adaptive thresholding of wavelet coefficents. In this framework computation is distributed over scale in the estimator and this contrasts with in-time Kalman methods that distribute computation in time for an assumed coherence time. Joint estimation of channel parameters and coherence time is fundamental to in-scale estimation as it provides a stopping rule at which additional computation is unlikely to provide an improved estimate. Lastly covariance estimates of the time varying model are provided and approximate high probability regions are shown to be easily accessible. These present useful computationally efficient empirical Bayes lower bounds on certainty bands of the channel operator.
[0064] The implications for multisensor and multichannel estimation are apparent. Computational resources can be automatically and seemlessly focused on system nodes that exhibit greater Doppler bandwidth. This implies two advantages, first channels that are more coherent will not waste computational resources. Secondly performance degradation is limited since overfitting of data associated with overly complex models is less likely.
[0065] Important issues relating to computation and performance relative to in-time recursions must be addressed. Future work should focus on comparison of in-scale recursions with in-time recursions (e.g. Kalman, RLS) to give bounds on signal duration, channel sparsity and coherence time measures where the in-scale regime is to be favored. The in-scale approach could be broadened to include other scale stepping increments rather than the classic octave band partition presented here. Mixed scale-time methods can also be envisioned for block processing over time.
[0066] The following matrix and Kronecker properties are useful.
[0000] Properties:
[0000]
1. [A H B] st =(B′{circle around (×)}A)[H] st
2. (A C{circle around (×)}B D)=(A{circle around (×)}B)(C{circle around (×)}D)
3. (A{circle around (·)}C){circle around (×)}(B{circle around (·)}D)=(A{circle around (×)}B){circle around (·)}((C{circle around (×)}D) where A M×N C M×N and B L×K D L×K .
4. (A{circle around (×)}B) −1 =A −1 {circle around (×)}B −1 , and (A{circle around (×)}B)′=A′{circle around (×)}B′
5. diag(A B)=[A{circle around (·)}B′]{right arrow over (1)} M where A M×N and B N×M
6. diag(A{circle around (·)}B)=diag(A){circle around (·)}diag(B) where A N×N and B N×N and B L×LM/N
7. A{right arrow over (b)}=A Diag({right arrow over (b)}){right arrow over (1)} N
8. A Diag({right arrow over (b)})=A{circle around (·)}({right arrow over (b)}′{circle around (×)}{right arrow over (1)} M ) where A M×N and {right arrow over (b)} N×1
[0075] The following result is useful when computing the posterior variance of a time varying operator
for: A K×L , C L×K , B M×N , D N×M , {right arrow over (v)} LN×1
if: V =( A{circle around (×)}B )Diag( {right arrow over (v)} )( C{circle around (×)}D )
then: diag( V )=[( A{circle around (·)}C ′){circumflex over (×)}( B{circle around (·)}D ′)] {right arrow over (v)} (32)
Proof:
V = ( ( A ⊗ B ) ⊙ ( v ′ ⊗ 1 → KM ) ) ( C ⊗ D ) property 8 diag ( V ) = [ ( A ⊗ B ) ⊙ ( v ′ ⊗ 1 → KM ) ⊙ ( C ′ ⊗ D ′ ) ] 1 → L N property 5 = [ ( ( A ⊗ B ) ⊙ ( C ′ ⊗ D ′ ) ) Diag ( v → ) ] 1 → L N property 8 = [ ( A ⊗ B ) ⊙ ( C ′ ⊗ D ′ ) ] v → property 7 = [ ( A ⊙ C ′ ) ⊗ ( B ⊙ D ′ ) ] v → property 3
[0076] The following form of the posterior distribution is useful. The prior and likelihood on wavelet coefficients are w j,k,* |π j,k , λ j,k ˜π j,k N w j,k* (0, λ j,k 2 )+(1−π j,k )N(0, ε j,k 2 ) and {tilde over (w)} j,k,* |w j,k* ˜N {tilde over (w)} j,k,* (w j,k,* , δ j,k 2 ) respectively. The marginal density of empirical coefficients is then
p ( w ~ j , k , * | ϕ → J ) = ∫ p ( w ~ j , k , * | w j , k , * ) p ( w j , k , * | π j , k , λ j , k , ε j , k ) ⅆ w j , k , * = π j , k 𝒩 ω ~ j , k , * ( 0 , λ j , k 2 + δ j , k 2 ) + ( 1 - π j , k ) 𝒩 ω ~ j , k , * ( 0 , ε j , k 2 + δ j , k 2 ) .
Since
𝒩 ω j , k , * ( w ~ j , k , * , δ j , k 2 ) 𝒩 ω j , k , * ( 0 , λ j , k 2 ) = 𝒩 ω j , k , * ( γ ( λ j , k ) w ~ j , k , * , γ ( λ j , k ) δ j , k 2 ) 𝒩 ω ~ j , k , * ( 0 , λ j , k 2 + δ j , k 2 )
where γ(λ)=λ 2 /(λ 2 +δ 2 ) is akin to a Wiener gain, a direct application of Bayes theorem p(w|{tilde over (w)})=p({tilde over (w)}|w)p(w)/p({tilde over (w)}) confirms the posterior density to be
w j , k , * | w ~ j , k , * , ϕ → J ~ Π ( w ~ j , k , * ) 𝒩 w j , k , * ( γ ( λ j , k ) w ~ j , k , * , γ ( λ j , k ) δ j , k 2 ) + ( 1 - Π ( w ~ j , k , * ) ) 𝒩 w j , k , * ( γ ( ε j , k ) w ~ j , k , * , γ ( ε j , k ) δ j , k 2 )
where
Π ( w ~ j , k , * ) = [ 1 + 1 - π j , k 𝒩 w ~ j , k , * ( 0 , ε j , l 2 + δ j , k 2 ) π j , k 𝒩 w ~ j , k , * ( 0 , λ j , k 2 + δ j , k 2 ) ] - 1 ( 33 )
[0077] The following form of the variance is useful. For the variance, start with var[w j,k,* |{tilde over (w)} j,k,* , {tilde over (φ)} J ]=E[w j,k,* 2 |{tilde over (w)} j,k,* , {right arrow over (φ)} J ]−E 2 [w j,k,* |{right arrow over (w)} j,k,* , {right arrow over (φ)} J ]. For simplicity denote the modulus square of a coefficient by x 2 =x′x. From the posterior density the second moment E[w j,k,*, 2 |{tilde over (w)} j,k,*, {right arrow over (φ)} J ] is easily evaluated as
E [ w j , k , * 2 | w ~ j , k , * , ϕ → J ] = Π ( w ~ j , k , * ) ( γ ( λ ) δ j , k 2 + γ 2 ( λ ) w ~ j , k , * 2 ) + ( 1 - Π ( w ~ j , k , * ) ) ( γ ( ε ) δ j , k 2 + γ 2 ( ε ) δ j , k 2 + γ 2 ( ε ) w ~ j , k , * 2 )
and of course E 2 [w j,k,* |{right arrow over (w)} j,k,* , {right arrow over (φ)} J ] is taken from (17). The result after simplification is
var [ w j , k , * | w ~ j , k , * , ϕ → J ] = [ Π ( w ~ j , k , * ) γ ( λ ) + ( 1 - Π ( w ~ j , k , * ) ) γ ( ε ) ] δ j , k 2 + Π ( w ~ j , k , * ) ( 1 - Π ( w ~ j , k , * ) ) [ γ ( λ ) - γ ( ε ) ] 2 w ~ j , k , * 2 . ( 34 )
Since lim x→0 Π(x)=0 and lim x→∞ Π(x)=1, it is easily confirmed that for λ>>δ and ε/δ<<1
lim var[w|{tilde over (w)}]=δ 2 lim var[w|{tilde over (w)}]=ε 2 (35)
while the maximum variance attainable is approximately var[w|{tilde over (w)}={tilde over (w)} p ]≈δ 2 (2+log(λ 2 /δ 2 π 2 ))/4 where
w ~ p 2 = arg { Π ( w ~ ) = 1 / 2 } = ( λ 2 + δ 2 ) ( ε 2 + δ 2 ) λ 2 - ε 2 log ( ( λ 2 + δ 2 ) ( ε 2 + δ 2 ) ( 1 - π ) 2 π 2 ) ( 36 ) | A scale adaptive filtering scheme is developed for underspread channels based on a model of the linear time varying channel operator as a process in scale. Recursions serve the purpose of adding detail to the filter estimate until a suitable measure of fidelity and complexity is achieved. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for transporting agitatable material using a vibrator in general and more particularly to such a device used for the purpose of galvanically deposition aluminum from aprotic, oxygen-free and anhydrous aluminum organic electrolytic solution. More specifically, the present invention is related to an improvement in such a device having a vibrator conveyor trough mounted in a spiral around a center tube and surrounded by a tank. This tank contains a liquid into which the vibrator is partially submerged along with the center tube.
It is known that by surface finishing metallic components, their life span can be extended and new fields of application can be developed. For example, coatings of light metal and ferrous material are effective in protecting relatively non-precious metals whose surfaces can corrode under the effects of the atmosphere. By means of appropriate pretreatment, the components receive a polished surface free of unwanted surface film. The metallic coating can be supplemented by a secondary treatment.
During galvanic treatment, the agitatable small parts must be held together so that the individual parts make electrical contact with each other. On the other hand, the agitatable material to be treated should be sufficiently spread out so that metal deposition can take place over as great an article surface area as possible. This also provides an optimally uniform current density on all parts. A further important prerequisite for achieving perfect metal platings with a uniform layer of uniform thickness is the sufficient agitation of the material during the galvanic treatment. The devices for electrolytic surface plating (electroplating) are equipped with conveyors for transporting the agitatable material through an electrolytic solution. A continuous or periodic admission and removal of the material is made possible through the use of corresponding admission and exit sluices. In addition, both the motion of the material, and the mixing as well as transport of the material through the electrolyte should be done so that the material is treated gently and sensitive parts are not mechanically damaged during galvanic treatment. These requirements are not only relevant in the case of electrolytic surface plating (electroplating), in particular in mass electrolytic surface plating, but are also of significance for the electrochemical surface treatment of agitatable material in liquids, e.g. as during chemical and electrolytic pickling in acids or alkaline liquids, as well as during electrolytic degreasing in alkaline baths, and electrolytic polishing. During electrolytic surface treatment, the agitatable material is wired as a cathode or as an anode. For example, the circuit arrangement is applied such that the agitatable material is an anode during electrolytic polishing, whereas the agitatable material is preferably wired as a cathode during the deposition of aluminum.
The prior art discloses a device suitable for the purpose of mass electroplating, in particular for the galvanic deposition of aluminum, in which a vibrator with horizontal and vertical vibrating components is used to transport the agitatable material through the treatment bath. By utilizing inertial force, this vibrator transports the agitatable material in an upward direction within a spiral conveyor trough around a supporting pedestal which is connected to the conveyor trough. The vibrator is placed with the supporting pedestal in a gas-tight vessel which contains an electrolytic solution into which the vibrator is partially submerged. For example, vibrators having a skew effect or tilted guides can serve as motive agents. In addition, gravity conveyors in the form of downspouts can be provided. Such vibrators simply require a relatively low motive force for operation and make the gentle conveyance of the agitatable material possible. One thus obtains an intensive movement of material and good electrolytic exchange as well as a uniform current intake over the entire active surface of the spread out material (U.S. Pat. No. 4,670,120, which corresponds to DE-OS No. 35 24 510).
Another prior art device for the surface treatment of agitatable material includes a spiral conveyor which is secured to a centrally mounted supporting pedestal. This conveyor is provided with several steps, whose step height is calculated so that the material turns while falling, thus providing enhanced mixing. A larger number of such steps at the same slope of the conveyor, however, leads to a corresponding enlargement of the apparatus (EPA No. 0 209 015).
Despite these prior devices, there is a need for simplifying and improving device for transporting agitatable material in a liquid using a vibrator. In particular, there is a need to obtain better intermixing of the agitatable material in the conveyor trough.
SUMMARY OF THE INVENTION
In a device of the type described above, this need is fulfilled by providing at least one product mixer in the conveyor trough, with the mixer mounted radially below the conveyor trough and having nozzle openings which also penetrate the trough. The openings guide a flow of liquid under pressure which aids in the mixing.
The present invention provides uniform exposure of the agitatable material to the electrolytic solution. The product mixers, mounted between transoms supporting the trough, enhance mixing of the material. Furthermore, because of their position between the transoms, the number of such mixers employed is not limited by the slope of the conveyor or by the size of the apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the device for transporting agitatable material via a conveyor trough according to the present invention.
FIG. 2 is a plan view partially in section of the trough of FIG. 1 with the mixer structure of the present invention attached thereto.
FIG. 3 is a sectional view taken along line III--III of FIG. 2.
DETAILED DESCRIPTION
The device according to FIG. 1 for transporting agitatable material, which can be used for the galvanic deposition of aluminum from aprotic, oxygen-free and anhydrous aluminum organic electrolytes, contains a central tube 2 with a floor 3 and a cover 4 which projects out of a tank 6, whose cover 7 makes gas-tight connection with the central tube 2. A gas cushion 10 is contained between the floor 3 of the central tube 2, which is bordered on the side by a hollow cylindrical pipe socket extending from the floor 3 of the central tube 2 and a liquid 12. The floor 3 and pipe socket 5 rest like a diving bell on a lower level 11 of liquid 12. The central tube 2 is partially submerged in this liquid, whose upper level 13 is also shown in FIG. 1. The liquid 12 can be an aprotic oxygen-free and anhydrous aluminum organic electrolytic solution.
A driving mechanism 16 for the central tube 2 and the conveyor trough 20 connected to this central tube 2 is provided above the cover 4 of the central tube 2 and thus outside of the tank 6. The driving mechanism 16 is secured to a bearing block 17. Using a cam structure (not shown in the Figures), the driving mechanism 16 produces a vibrating movement of the central tube 2 and thus of the conveyor trough 20, which is mounted in a spiral around the central tube 2. The conveyor trough 20 can be made of plastic (in particular, laminated plastic). Trough 20 is connected to transoms 22 and 28, which preferable act simultaneously as cathodes and, with the aid of lead-in insulators, are passed through the tank 2 in electrical isolation. The transoms 22 and 28, which are mounted above each other in an axial direction, are connected respectively over a common electrical bus bar 34 or 35 to a cathode terminal 38 or 39. Three anodes 42 are shown in FIG. 1, two of which are secured to the cover of an anode shaft, and whose electrical supply leads are passed through this cover in electrical isolation. The other anode 42 is secured to the wall of the tank 6.
An entry chute 56, which is schematically indicated, serves to supply the agitatable material 40, which is indicated in the Figures simply by dots and which can consist for example of screws or other small parts which are to be electroplated. An outlet sluice 62 contains an outlet port 63 and a chute 64. A supply inlet 66 is provided below the level 13 for the liquid 12.
Springs are provided between the floor 3 of the central tube 2 and the floor 8 of the tank 6, of which only two, 72 and 73 are shown in FIG. 1. A plug-cock 74, which serves the centering alignment, is mounted in a bearing 75 able to move in axial direction of the central tube 2. Preferably, the bearing 75 can be a self-aligning thrust bearing. The bearing 75 is placed in a bearing cartridge 76 which is secured to the floor 8 of the tank 6. The floor 8 is provided with an opening 78, which serves to drain the electrolytic solution 12. The central tube 2 is supported in a centering alignment which is able to move in the axial direction. A gas-tight connection is produced by a bellows-type seal 82 between the cover 7 of the resting tank 6 and the movable central tube 2.
The gas cushion 10 consists of an inert gas. In connection with an electrolytic solution 12, this gas can preferably consist of an oxygen-free gas, in particular nitrogen N 2 , whose supply is not shown in the Figures for the sake of simplicity.
This gas cushion 10 can easily be compressed and decompressed by the upward and downward movements of the system vibrating from the central tube 2 and conveyor trough 20 so that the column of liquid through which passes the agitatable material 40 does not build up disadvantageous pressures.
The agitatable material 40 to be aluminized is introduced through the entry shaft 56 into the lower region of the tank 6, at which place it falls onto the lower end of the conveyor trough 20. The agitatable material 40 is transported on this conveyor trough 20, which is designed as a vibrating trough and which leads upward in a spiral, beyond and upwards above the upper level 13 of the electrolytic solution 12. It then falls into the funnel-shaped upper end of the chute 64 leading out of the tank 6.
By means of the drive mechanism 16, the conveyor trough 20 is made to vibrate with a somewhat spiral movement over the central tube. Due to the skewed movement and the accelerations and speeds arising thereby, a movement is forced upon the agitatable material 40 lying on the spiral conveyor trough 20 leading upwards s that the agitatable material 40 is transported with a continuous increase in height in the direction of the conveyor.
In case multiple traversals of the agitatable material 40 along the trough are desired, the conveyor trough 20 can be provided with a shutter 69, which can be controlled from outside the tank via a shutter control 70. Shutter 69 causes material to drop down from higher to lower sections of the trough.
According to the present invention, at least one product mixer is provided below the conveyor trough 20; preferably, several product mixers are mounted below the conveyor trough 20 at specified distances. Two such product mixers 100 are shown in FIG. 1.
These product mixers 100 are mounted radially below the conveyor trough 20 as shown in FIG. 2 Each product mixer is provided with a bore-hole 12 running in its longitudinal direction and with perpendicular nozzle openings 104, which also pass through the conveyor trough 20. The product mixer is mounted between two transoms 106 and 107, which pass through the central tube with their retaining sockets 108 and 109, respectively, and to which the bus bars 112, 113 are secured. The electrolytic solution can be supplied through a connecting bore-hole 105 and emerges from nozzle openings 104 at a preferably adjustable, increased pressure. This pressurization can be provided by a conventional pump and regulator structure feeding the solution to the bore-hole at 105 as illustrated in FIG. 1. The flow of the electrolytic solution through the nozzle openings 104 provides additional mixing of the material as it moves along the trough, whose further perforation is indicated in FIG. 2 by the openings 114. The floor of the conveyor trough 20 can preferably consist of exchangeable segments 115 to 117, which are secured with clamping screws 118 and 119 to the transoms 106 and 107.
The arrangement of the product mixer 100 below the conveyor trough 20 between the transoms 106 and 107, which simultaneously serve as supporting bars, is shown in section in FIG. 3. The movement of the electrolytic solution emerging from the nozzle openings 104 is directed perpendicularly away from the trough and towards the axial direction of movement of the agitatable material 40. This both produces a good intermixing of the agitatable material 40 and enhances the uniformity of deposition of plating onto the agitatable material. In one specific embodiment, the bore holes 104 need not be perpendicular to the plane of the conveyor trough 20, but rather can be tilted with respect to such a perpendicular plane such that a component in the direction of movement of the agitatable material along the trough results.
In the illustrated embodiment, a device for the electrolytic surface plating of agitatable material 40 is shown in which the material is transported through an electrolytic liquid for this purpose. However, the device can also be used for transporting agitatable material 40 which passes through the device for the purpose of pretreatment, e.g., cleaning or pickling as well as degreasing. The device will then contain a liquid treatment medium in place of the electrolytic liquid , e.g. a cleaning agent or a grease solvent. Further, the device can be used for secondary treatment of an agitatable material, e.g. to extract water. | An apparatus for transporting agitatable material through a liquid treatment bath, comprising a spiral conveyor trough mounted around a central tube in a gas-tight tank which contains a liquid into which a portion of the trough is submerged. The conveyor trough is provided with at least one product mixer mounted radially beneath the trough which is provided with openings which serve to guide the flow of the liquid. The device is especially effective as an electroplater. | 1 |
TECHNICAL FIELD
The present invention relates to a touch panel that detects contact or approach of a finger, a stylus, or the like to a detection surface, and to a display device having such a touch panel function in the display part thereof.
BACKGROUND ART
A touch panel that detects that a finger, a stylus, or the like of a user has come into contact with or approached a detection surface is known. In recent years, electronic devices in which touch panel functions (also referred to as touch sensor functions) that can freely perform various functions just by having a stylus or the like touch the display screen are provided in a liquid crystal display element such as a liquid crystal display screen are starting to become widely used. Such a touch panel is formed onto a display panel, and by displaying various types of buttons on the display screen as images, it is possible to realize data input substituting these displayed buttons for normal buttons. Thus, when applying such a touch panel to a miniature mobile device, it is possible to have the display and buttons share a common space, thus presenting great advantages such as being able to increase the size of the display screen, decreasing the amount of space dedicated to control parts, or reducing the number of parts.
Additionally, a technique is known in which a touch panel shares some of the structure of the display part. For example, a configuration is known in which pixel electrodes or an opposite electrode for liquid crystal display, or the source bus lines double as one of the detection electrodes (detection lines) of a capacitance detection type touch panel. If the configuration is shared in this manner, it is also possible to attain the advantage that the device can be made thin.
However, if the detection electrode doubles as an electrode for display in this manner, the display driving frequency and the detection driving frequency match due to functional reasons. As a result, even if an attempt is made to raise the detection driving frequency because the detection speed is low and the responsiveness to data input is bad, there is a problem that it is not possible to freely change the detection driving frequency due to restrictions in the display driving frequency.
Patent Document 1 discloses a contact detection device in which the detection speed is improved without raising the detection driving frequency. As shown in FIG. 19 , in Patent Document 1, the touch panel 110 has a contact response part that includes driver electrodes E1 and detection electrodes E2, which respond to contact and cause an electrical change, and a contact driver scanning part 111 . The contact driver scanning part 111 scans a detection surface 113 A in one direction by applying drive voltage to the driver electrodes E1, and controls output of the electric change from the detection electrodes E2 in chronological order. At this time, the contact driver scanning part 111 performs a plurality of scans (Re1 and Re2) in parallel for a drive signal source S and a reversed drive signal source Sx for different regions in the touch panel 110 . With this configuration, the detection speed is improved without raising the frequency for contact detection.
Also, as shown in FIG. 20 , in Patent Document 1, the contact driver scanning part performs parallel scanning to two different regions in the contact response part and supplies drive voltages having phases that are 180° apart in phase with respect to each other to the two regions, the contact driver scanning part controlling the output of electric change in chronological order by performing scanning in one direction on the detection surface by applying drive voltages to the contact response part, which causes electrical change in response to an object to be detected coming into contact or approaching the detection surface.
RELATED ART DOCUMENT
Patent Document
Patent Document 1: Japanese Patent Application Laid-Open Publication, “Japanese Patent Application Laid-Open Publication No. 2010-72743 (Published on Apr. 2, 2010)”
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
However, with the configuration of Patent Document 1, if objects to be detected come into contact with (approach) the same line in different contact response part regions, the electrical changes generated in the respective regions cancel each other out, resulting in no output.
In order to avoid this situation, a possible solution is to rely on instantaneous output change resulting from a time difference between the two contact (approach) points. However, this only works when the contact speed (i.e. the time difference) is sufficiently slower than the sensing speed, and if active sensing speed is slow (30 ms to a second, for example) such as when multiple unit output changes accumulate and are used as main output, when reactivating after standby, or the like, then there is a possibility of glitches such as non-detection occurring.
Means for Solving the Problems
The present invention takes into account the above-mentioned problems, and an object thereof is to provide a highly reliable touch panel in which glitches such as non-detection do not occur, and a display device provided therewith.
The inventors of the present invention have found that the above-mentioned object can be attained by mitigating the induction of an inactive charge among parasitic capacitance formed between the driver electrodes and the detection electrodes.
Thus, in order to solve the above-mentioned problems, the touch panel according to the present invention is
a touch panel that detects contact or approach of an object to a detection surface, including a detection electrode and a driver electrode, wherein the touch panel detects the contact or approach of the object on the basis of a change in amount of an electric charge that is induced on the detection electrode in response to a drive signal applied to the driver electrode, and
wherein the touch panel further includes a complementary electrode that forms a capacitance along with the detection electrode, the complementary electrode having applied thereto a complementary signal having a different phase than the drive signal, a voltage change ΔVcm of the complementary signal satisfying a formula below:
Δ Vcm=−ΔVdr ×( Cfo+Ccr )/ Ccm
where, in the formula, ΔVdr represents a voltage change of the drive signal, Cfo represents a capacitance that is primarily a fringe capacitance between the driver electrode and the detection electrode corresponding to a capacitance component that is not affected by the object, Ccr represents a capacitance that is primarily a cross capacitance between the driver electrode and the detection electrode corresponding to a capacitance component that is not affected by the object, Cfo+Ccr represents a total capacitance between the driver electrode and the detection electrode that is not affected by a presence or absence of the object, and Ccm represents a capacitance formed between the complementary electrode and the detection electrode.
According to the configuration above, by providing a complementary electrode, it is possible to form between the complementary electrode and the detection electrode a parasitic capacitance corresponding to capacitance component that does not affect detection, among the parasitic capacitance formed between the driver electrode and the detection electrode.
Specifically, (Cfo+Ccr) in the formula above represents a parasitic capacitance (Cfo) corresponding to a capacitance component between the driver electrode and the detection electrode that is not affected by an object to be detected among fringe capacitances being added to a parasitic capacitance (Ccr) corresponding to a capacitance component between the driver electrode and the detection electrode that is not affected by an object to be detected among cross capacitances. By multiplying this by (−ΔVdr), the resulting value corresponds to inactive charge that is formed regardless of whether or not an object to be detected is in contact or approaches the detection surface, and thus, by dividing this value by the parasitic capacitance (Ccm) formed between the complementary electrode and the detection electrode, it is possible to calculate the amplitude (ΔVcm) of the complementary signal. At the time of detection, by applying the complementary signal having this amplitude (ΔVcm) to the complementary electrode, of the charge induced on the detection electrode, the charge that is not affected by the object to be detected, or in other words, the inactive charge can be minimized.
Also, even if objects to be detected are in contact with (approach) the detection surface on the same line, the electrical changes do not cancel each other out unlike the conventional configuration. Thus, glitches such as non-detection do not occur.
Therefore, according to the configuration of the present invention, it is possible to provide a highly reliable touch panel in which glitches such as non-detection do not occur.
Fringe capacitance refers to capacitance formed between electrodes in the same layer, while cross capacitance refers to capacitance formed between electrodes in different layers from each other.
The present invention also includes a display device provided with the above-mentioned touch panel.
Effects of the Invention
As stated above, a touch panel according to the present invention is
a touch panel that detects contact or approach of an object to a detection surface, including a detection electrode and a driver electrode, wherein the touch panel detects the contact or approach of the object on the basis of a change in amount of an electric charge that is induced on the detection electrode in response to a drive signal applied to the driver electrode,
wherein the driver electrode and the detection electrode are, in portions thereof, in different layers from each other, and
wherein the touch panel further comprises a complementary electrode that forms a capacitance along with the detection electrode, the complementary electrode having applied thereto a complementary signal having a different phase than the drive signal, a voltage change ΔVcm of the complementary signal satisfying a formula below:
Δ Vcm=−ΔVdr ×( Cfo+Ccr )/ Ccm
where, in the formula, ΔVdr represents a voltage change of the drive signal, Cfo represents a capacitance that is primarily a fringe capacitance between the driver electrode and the detection electrode corresponding to a capacitance component that is not affected by the object, Ccr represents a capacitance that is primarily a cross capacitance between the driver electrode and the detection electrode corresponding to a capacitance component that is not affected by the object, Cfo+Ccr represents a total capacitance between the driver electrode and the detection electrode that is not affected by a presence or absence of the object, and Ccm represents a capacitance formed between the complementary electrode and the detection electrode.
Also, the display device according to the present invention includes the above-mentioned touch panel.
According to the configuration of the present invention, it is possible to provide a highly reliable touch panel in which glitches such as non-detection do not occur.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a configuration of a touch panel according to an embodiment of the present invention.
FIG. 2 is a partial magnified view of a touch panel region of the touch panel shown in FIG. 1 .
FIG. 3 shows cross-sectional views of the touch panel region shown in FIG. 2 .
FIG. 4 shows a change in parasitic capacitance due to contact or non-contact of an object to be detected in the touch panel region shown in FIG. 2 .
FIG. 5 schematically shows a relation between widths of an input dynamic range, an induced electric charge Q in a non-contact state, an induced electric charge Q@Touch in a contact state, and a detected signal charge Qsig in the touch panel shown in FIG. 1 .
FIG. 6 is a drawing for explaining the effect of the complementary electrode.
FIG. 7 shows a configuration of a touch panel according to another embodiment of the present invention.
FIG. 8 is a partial magnified view of a touch panel region of the touch panel shown in FIG. 7 .
FIG. 9 shows cross-sectional views of the touch panel region shown in FIG. 8 .
FIG. 10 shows a configuration of a touch panel according to another embodiment of the present invention.
FIG. 11 shows cross-sectional views of the touch panel region shown in FIG. 10 .
FIG. 12 shows a portion of a configuration of a touch panel according to another embodiment of the present invention.
FIG. 13 shows a display device including a touch panel according to an embodiment of the present invention.
FIG. 14 shows a display device including a touch panel according to an embodiment of the present invention.
FIG. 15 shows a display device including a touch panel according to an embodiment of the present invention.
FIG. 16 is a drawing for explaining how a display device including a touch panel according to the present invention is driven.
FIG. 17 is a drawing for explaining how a display device including a touch panel according to the present invention is driven.
FIG. 18 shows modification examples of an electrode configuration of a touch panel according to the present invention.
FIG. 19 is a drawing showing a conventional technology.
FIG. 20 is a drawing showing a conventional technology.
DETAILED DESCRIPTION OF EMBODIMENTS
Embodiment 1
An embodiment of the present invention will be explained below with reference to FIGS. 1 to 6 .
First, an embodiment of a touch panel of the present invention will be explained, and then, an embodiment of a display device of the present invention will be explained.
(1) Configuration of Touch Panel
FIG. 1 shows the touch panel of the present embodiment. FIG. 1( a ) is a top view of the touch panel, and FIG. 1( b ) is a partial magnified view of the touch panel in which the portion in FIG. 1( a ) surrounded by the frame is magnified.
The touch panel of the present embodiment detects that a finger, a stylus, or the like of a user has come into contact with or approached a detection surface. Thus, as shown in FIG. 1( a ), a touch panel 10 of the present embodiment has a touch panel region 1 . In actuality, a protective plate is disposed on the topmost surface of FIG. 1 , which is a detection surface of the touch panel region 1 , but in FIG. 1 , the protective plate is omitted.
A specific configuration of the touch panel region 1 will be described with reference to the touch panel region 1 shown in FIG. 1( b ). The touch panel region 1 includes driver electrodes 2 , detection electrodes 3 , and complementary electrodes 4 .
The portions in FIG. 1( b ) depicted in grey indicate that these portions are on the same surface, or in other words, in the same layer as each other, and the portions depicted in black indicate that these portions are in a different layer from the grey portions but that the black portions are on the same surface, or in other words, in the same layer as each other. The grey portions are in a different layer from the black portions, and the black portions are closer to the detection surface than the grey portions.
As shown in FIG. 1( b ), the driver electrodes 2 have a plurality of driver electrode parts 21 , and the driver electrode parts 21 are interconnected by first bridge parts 22 .
As shown in FIG. 1( b ), the detection electrodes 3 also have a plurality of detection electrode parts 31 , and the detection electrode parts 31 are interconnected by second bridge parts 32 .
The driver electrode parts 21 and the detection electrode parts 31 , as shown in FIG. 1( b ), are in the same layer as each other. The second bridge parts 32 are also in the same layer as the driver electrode parts 21 and the detection electrode parts 31 . On the other hand, the first bridge parts 22 are in a different layer from the driver electrode parts and the detection electrode parts. Specifically, the first bridge parts 22 are in a layer below the driver electrode parts 21 , and, as described below, are in the same layer as the complementary electrodes 4 . The first bridge parts 22 and the driver electrode parts 21 overlap each other with a dielectric layer therebetween, and both are electrically connected to each other in portions thereof by a connecting part that extends in a direction of overlap.
The driver electrode parts 21 are respectively quadrilaterals. The plurality of driver electrode parts 21 are aligned along the row direction such that a diagonal line drawn from one set of opposite corners in each quadrilateral extends in the row direction, and the driver electrode parts 21 that are aligned in the row direction are electrically connected to each other by the first bridge parts 22 . There are a plurality of such rows, which are aligned in the column direction, parallel to each other. The first bridge parts 22 electrically connect driver electrode parts 21 aligned in the row direction. The driver electrode parts 21 and the first bridge parts 22 are described later with reference to FIG. 2 .
The detection electrode parts 31 are, in general, the same shape as the driver electrode parts 21 , and are respectively quadrilaterals. The plurality of detection electrode parts 31 are aligned along the column direction such that a diagonal line drawn from one set of opposite corners in each quadrilateral extends in the column direction, and the detection electrode parts 31 that are aligned in the column direction are electrically connected to each other by the second bridge parts 32 . There are a plurality of such columns, which are aligned in the row direction, parallel to each other.
The driver electrode parts 21 and the detection electrode parts 31 are disposed in an alternating fashion in the row direction and the column direction, respectively. Specifically, the driver electrode parts 21 , as described above, are in the same layer as the detection electrode parts 31 , and as shown in FIG. 1( b ), are disposed along the row direction and the column direction such that the diagonal lines drawn from the sets of opposite corners of the quadrilaterals are individual lines. In other words, in regions other than the edges of the touch panel region 1 , four detection electrode parts 31 are disposed such that four sides of each driver electrode part 21 respectively face the detection electrode parts 31 . In other words, a substantially quadrilateral space is formed in the center by a total of four detection electrode parts 31 in two rows and two columns, and in this space, one driver electrode part 21 is disposed.
The second bridge parts 32 are disposed in the same layer so as to separate driver electrode parts 21 adjacent to each other in the row direction.
Here, the shape of the driver electrode parts and the shape of the detection electrode parts as shown in FIGS. 1 and 2 were described, but the shapes are not limited thereto, and shapes of the driver electrode parts and the detection electrode parts shown in FIG. 18 are also possible as another example.
FIG. 2 shows a portion of FIG. 1( b ). A detailed configuration of the touch panel region 1 of the touch panel 10 will be described using cross-sectional views of the touch panel 10 along the section line A-A′, the section line B-B′, and the section line C-C′ shown in FIG. 2 .
FIG. 3( a ) is a cross-sectional view of the touch panel 10 along the section line A-A′ shown in FIG. 2 . FIG. 3( b ) is a cross-sectional view of the touch panel 10 along the section line B-B′ shown in FIG. 2 . FIG. 3( c ) is a cross-sectional view of the touch panel 10 along the section line C-C′ shown in FIG. 2 .
As shown in FIGS. 3( a ) to 3 ( c ), the respective electrodes described above are disposed between the substrate 11 and the protective plate 12 . A shield 13 is disposed on the substrate on the side thereof opposite to the protective plate 12 .
The shield 13 protects the touch panel 10 from external shocks, and protects the touch panel from external electromagnetic waves that interfere with the touch panel function, or in other words, the touch sensor function. The shield 13 can be made of a conventional material, and disposed using a conventional method.
The touch sensor function of the touch panel 10 of the present embodiment will be described. In the position shown in FIG. 3( a ), an insulating film 14 is formed on the substrate 11 , and on the insulating film 14 , the driver electrode parts 21 and the detection electrode parts 31 are provided. In this position, a voltage (drive signal) is applied to the driver electrode parts 21 , and thus, as shown with the lines of electric force in arrows in FIG. 3( a ), a parasitic capacitance is formed between the driver electrode parts 21 and the detection electrode parts 31 through the insulating film 14 , the substrate 11 , and the protective plate 12 . With such a parasitic capacitance formed, as shown in FIG. 4 , when a finger, for example, comes into contact with or approaches the detection surface, the parasitic capacitance changes, and by having the detection electrodes 3 detect such changes, it is possible to detect contact or approach to the detection surface. This is the principle behind the so-called capacitive touch sensor. Below, only a case in which contact is made is described, but the description applies similarly to approach as well.
When viewing the parasitic capacitance in detail with reference to FIG. 4 , it is possible to see that a parasitic capacitance Cfo that does not change even if a finger comes into contact is present. This parasitic capacitance Cfo is a component that is not affected by an object to be detected.
In other words, between the driver electrode parts 21 and the detection electrode parts 31 in the same layer as each other, there is both a parasitic capacitance Cfo that is not affected by the object to be detected, and a parasitic capacitance Cfs that is affected by the object to be detected.
Also, the parasitic capacitance Cfo is formed between the driver electrode parts 21 and the second bridge part 32 in the same layer shown in FIG. 3( b ). The driver electrode parts 21 and the second bridge part 32 are close to each other, and here as well, a parasitic capacitance Cfo is formed regardless of whether or not a finger has come into contact.
As shown in FIG. 3( b ), a parasitic capacitance Ccr is formed between the first bridge part 22 , which electrically connects driver electrode parts 21 aligned in the row direction, and the second bridge part 32 , regardless of whether or not a finger has come into contact.
As for other parasitic capacitance, a parasitic capacitance Ccm_cr formed between the complementary electrode 4 to be described later and the detection electrode 3 is also present.
To summarize,
Cfo is a component of the fringe capacitance between the driver electrodes and the detection electrodes that is not affected by an object to be detected,
Cfs is a component of the fringe capacitance between the driver electrodes and the detection electrodes that is affected by an object to be detected,
Ccr is a component of the cross capacitance between the driver electrodes and the detection electrodes that is affected by an object to be detected, and
Ccm_cr is a cross capacitance between the detection electrodes and the complementary electrodes. Here, fringe capacitance refers to capacitance formed within the same layer, and cross capacitance refers to capacitance formed in different layers.
To reiterate the explanation of the principle of the touch sensor function, if the capacitance between the driver electrodes and the detection electrodes is Cf, then an electrical charge Q induced on the detection electrode if the driver electrode is driven once at ΔVdr is expressed in the following formula:
Q=ΔVdr×Cf.
Based on FIG. 4 , the non-contact state capacitance Cf and the contact state capacitance Cf are as follows:
in the non-contact state, Cf=Cfo+Cfs+Ccr , and
in the contact state, Cf=Cfo+Ccr.
Where the non-contact state induced charge is Q and the contact state induced charge is Q@Touch,
Q=ΔVdr ×( Cfo+Cfs+Ccr ), and
Q @Touch=Δ Vdr ×( Cfo+Ccr ),
and a charge Qsig representing the detected signal is such that
Q sig= Q−Q @Touch=Δ Vdr×Cfs.
Thus, the circuit receiving the induced charge (integrator or decision circuit) uses, for determination, the width of the detected signal charge Qsig upon obtaining a sufficient width to be able to receive a non-contact state induced charge Q as an input dynamic range.
FIG. 5 schematically shows the relation of the widths of the input dynamic range, the non-contact state induced charge Q, the contact state induced charge Q@Touch, and the detected signal charge Qsig. In FIG. 5 , a represents the input dynamic range margin, and Cj represents the received capacitance value (value of capacitance in which the induced charge is charged).
In FIG. 5 , Qsig/Cj is the width used in order to determine whether or not contact has actually taken place.
Based on FIG. 5 , the real determination width ratio Rd for the dynamic range is as follows:
Rd=Cfs /(( Cfo+Cfs+Ccr )+α Cj/ΔVdr ).
In FIG. 5 , (Qfo+Qcr)/Cj does not contribute to determination. An object of the present invention is to reduce this portion. In other words, the object is to mitigate charge of this portion.
In order to attain this object, in the present embodiment, as shown in FIGS. 1 to 3 , complimentary electrodes 4 are provided.
The complementary electrodes 4 extend in parallel with the driver electrodes 2 (row direction) along the extension direction of the driver electrodes 2 in the touch panel region 1 shown in FIG. 1 . The driver electrodes 2 and the complementary electrodes 4 are aligned along the column direction in an alternating fashion. As shown in FIGS. 1 and 2 , the complementary electrodes 4 are in the same layer as the first bridge parts 22 .
As for the complementary electrode 4 disposed in this manner, where the parasitic capacitance between the complementary electrode and the detection electrode is Ccm (=Ccm_cr), and the complementary signal amplitude (voltage change) is ΔVcm, the amount of charge induced when the complementary electrode and the driver electrode are driven simultaneously is as follows:
Q=ΔVdr ×( Cfo+Cfs+Ccr )+Δ Vcm×Ccm , and
Q @Touch=Δ Vdr ×( Cfo+Ccr )+Δ Vcm×Ccm.
Here, by setting ΔVcm and Ccm (=Ccm_cr) such that
Δ Vcm×Ccm≈−ΔVdr ×( Cfo+Ccr ),
it is possible to mitigate the occurrence of charge that does not contribute to determination.
In other words, the configuration is such that when applying the drive signal to the driver electrodes 2 , a complementary signal at a different phase from the drive signal is applied to the complementary electrodes 4 , and the amplitude (ΔVcm) of the complementary signal satisfies the following formula:
Δ Vcm=−ΔVdr ×( Cfo+Ccr )/ Ccm
Cfo+Ccr in the formula corresponds to Cf−Cfs, and to a capacitance component unnecessary for detection.
The complementary signal is generated by a complementary signal generating circuit, which is not shown in the drawings, included in the touch panel, and a drive signal is inputted to the complementary signal generating circuit. The complementary signal generating circuit reverses the inputted drive signal, thus generating the complementary signal. Thus, an appropriate complementary signal based on the drive signal is generated and applied to the complementary electrodes.
In order to fulfill the formula above, when considering a calibration step for when the touch panel is shipped, for example, one method is to bring a conductive plate into contact so as to cover the touch panel (Cfs=0), and set ΔVcm such that the detection electrode signal output in relation to the driver electrode signal at this time is at a minimum. An adjustment method at this time is to set the Rf in the complementary signal generating mechanism shown in FIG. 12( a ) to be mentioned later as volume resistance, and to manually set ΔVcm while monitoring the detection electrode signal. It is also possible to automate this step by having a similar control function in the complementary signal generating mechanism.
FIG. 6 is a drawing for describing effects by the complementary electrodes 4 . The respective graphs of FIG. 6 have the horizontal axis as time, and the left three graphs of FIG. 6 show a non-contact state and the right three graphs thereof show a contact state. The top two graphs of FIG. 6 show a relation between time “t” and an amount of charge Q (vertical axis) in a configuration of a comparison example in which a complementary electrode is not provided. The middle two graphs of FIG. 6 show a relation between time “t” and a complement amount of a complementary electrode (vertical axis). The bottom two graphs of FIG. 6 show a relation between time “t” and the amount of charge Q (vertical axis) when the complementary electrode and the driver electrode are driven.
In the top two graphs of FIG. 6 , Q0 represents the total signal amount and Qsig0 represents a net signal amount, or in other words, the signal amount for detecting whether or not there is contact. As described above in FIG. 4 , Qsig0 satisfies the following:
Q sig0 =Q−Q @Touch=Δ Vdr×Cfs.
This represents the difference between the amount of charge induced on the detection electrode when there are no objects to be detected, and the amount of charge induced on the detection electrode when an object to be detected has come into contact with (approached) the detection electrode.
The top two graphs of FIG. 6 indicate that the amount of change in the charge (=net signal amount Qsig0) resulting from an object to be detected is small in relation to the total amount of charge (=total signal amount Q0) including charge that is not affected by the object to be detected.
By applying complementary signals shown in the middle two graphs of FIG. 6 to the complementary electrode when applying drive signals shown in the top two graphs of FIG. 6 , the total signal amount Q1 and the net signal amount Qsig1, which are obtained by applying the drive signals, result as shown in the bottom two graphs of FIG. 6 .
The positions indicated with (i) in the bottom two graphs of FIG. 6 are positions in which a difference due to a time constant occurs in the detection electrode. The position indicated with (ii) is a position where a residual effect between ΔVcm×Ccm and ΔVdr×(Cfo+Ccr) appears.
The top two graphs and the bottom two graphs of FIG. 6 have the following relationship:
Q 1 <Q 0,
Q sig1 ≈Q sig0, and
Q sig1 /Q 1 >Q sig0 /Q 0.
Thus, in the touch panel 10 of the present invention, by providing complementary electrodes 4 ,
(1) it is possible to reduce the input dynamic range of the charge receiving circuit depending on the total signal amount, thereby attaining low power consumption by performing low voltage driving, and
(2) it is possible to improve signal resolution (resolution). As an example, if the total signal amount has a 12-bit resolution, then if Qsig1/Q1=½ and Qsig0/Q0=¼, then the resolution of Qsig1 is 11-bit and the resolution of Qsig0 is 10-bit.
(2) Configuration of Display Device
Next, a display device to which the above-mentioned touch panel is installed will be described.
Here, as an example of a display device, first, a configuration of a general liquid crystal display device will be described with reference to FIG. 13 . FIG. 13( a ) is a top view of the liquid crystal display device.
The liquid crystal display device 170 has a configuration in which a plurality of image signal lines SL and a plurality of scanning signal lines GL intersect each other, and includes a driver 173 in a frame 172 of the liquid crystal display device adjacent to the display region 171 , and a flexible substrate 174 provided with lines to connect to the power source and the like. In the display region 171 , pixels 175 are provided at the intersections between the image signal lines SL and the scanning signal lines GL.
Details of the display region 171 will be described with reference to FIG. 13( b ). FIG. 13( b ) is an exploded view of the display region 171 . In FIG. 13( b ), pixel areas not covered by a common electrode are present for ease of description, but in reality, all pixel areas are covered by the common electrode.
The display region 171 includes pixel electrodes 180 arranged in a matrix, a common electrode 181 disposed opposite to the pixel electrodes 180 with a liquid crystal layer therebetween, auxiliary capacitance lines 182 that form an auxiliary capacitance Cs between the pixel electrodes 180 and the auxiliary capacitance lines 182 , and switching elements 183 connected to the image signal lines SL and the scanning signal lines GL and performing switching on the pixel electrodes 180 .
The liquid crystal display device 170 is an active matrix liquid crystal display device that uses a drive method in which, when each of the switching elements 183 is in the on period, an image signal voltage with its signal voltage polarity reversed every field period of the display screen is applied to each of the pixel electrodes 180 , and in the off period of the switching element 183 , a modulated signal in the opposite direction is applied to the auxiliary capacitance lines 182 every field period, thereby changing the potential of the pixel electrodes 180 . This allows the change in potential and the pixel signal voltage to overlap or cancel each other out, and this voltage is applied to the liquid crystal layer. A circuit configuration of one pixel is shown in FIG. 13( c ).
In the display device of the present embodiment, a touch panel (function) is installed on the above-mentioned liquid crystal display device.
Specifically, touch panels can be broadly categorized as an on-cell type or an in-cell type. On-cell type is a type in which a touch panel is attached to the surface of a liquid crystal display device such as that mentioned above. In-cell type refers to a type in which a touch panel function is installed in a liquid crystal display device such as that mentioned above, and in which the touch panel uses some of the electrode configurations used in the display device.
Below, first, an on-cell type liquid crystal display device will be described.
FIG. 14 is a schematic cross-sectional view of an on-cell type liquid crystal display device 90 of the present embodiment.
The liquid crystal display device 90 shown in FIG. 14 includes a liquid crystal display part 70 , and a touch panel part 80 attached to the display surface side of the liquid crystal display part 70 .
The liquid crystal display part 70 has a pair of substrates with a liquid crystal layer therebetween, and on the rearmost surface, a first polarizing plate 71 is provided. This liquid crystal display part 70 has the configuration shown in FIG. 13 . Therefore, various electrodes shown in FIG. 13 are provided between the pair of substrates shown in FIG. 14 . The liquid crystal display part 70 is also provided with a display driver 72 that applies a voltage (signal) to the electrodes.
The touch panel part 80 has the configuration of the touch panel of FIG. 1 already explained in the present embodiment, but on the display side (light-emitting side) substrate of the pair of substrates in the liquid crystal display part 70 , various electrodes 81 (driver electrodes, detection electrodes, and complementary electrodes) shown in FIGS. 1 and 2 are formed.
The touch panel part 80 is provided with a second polarizing plate 73 between the protective plate 12 and the various electrodes 81 . The touch panel part 80 is also provided with a detection driver 82 that applies a voltage (signal) to the various electrodes 81 .
In this manner, an on-cell type liquid crystal display device 90 of the present embodiment can detect that an object to be detected is in contact with or approaching a detection surface (surface of the protective plate 12 ) in the touch panel part 80 in a state in which images are displayed in the liquid crystal display part 70 .
The above-mentioned on-cell type liquid crystal display device is one example and the present invention is not limited thereto; the present invention can be applied to various types of on cell-type liquid crystal display devices.
The present invention is not limited to a configuration in which various electrodes of the touch panel are formed on the substrate of the liquid crystal display part, and a configuration may be used in which the second polarizing plate is provided on the liquid crystal display part, and on the second polarizing plate, everything from the substrate 11 to the protective plate 12 shown in FIG. 3 is attached. However, in order to allow a thinner configuration, a configuration such as one in which the substrate 11 is omitted and the various electrodes are formed on the second polarizing plate may be used.
Next, an in-cell type liquid crystal display device will be described.
FIG. 15 is a cross-sectional view that shows a schematic configuration of an in-cell type liquid crystal display device. In FIG. 15 , various electrodes 81 of the touch panel are formed between the first substrate 74 and the second substrate 75 , which constitute the pair of substrates of the liquid crystal display.
As an example of a configuration of FIG. 15 , the driver electrodes and the detection electrodes are in the same layer, for example, and are disposed on the liquid crystal layer side of the first substrate 74 of the liquid crystal display.
The in-cell type liquid crystal display device is not limited to the configuration of FIG. 15 .
Below, a driving method will be described for an in-cell type, in which the common electrode for display is shared with the driver electrodes and the detection electrodes for the touch panel.
FIG. 16 shows a schematic view of an in-cell touch panel (T/P) display. The common electrode for display is shared with the T/P driver electrodes and the T/P detection electrodes, and thus, a switch for supplying to the common electrode for display any of the common signal, the T/P driving signal, and the T/P detection signal (the detection signal is extracted) is included.
FIG. 17 shows a schematic drive timing chart, and by using the above-mentioned switch, during a display period, a common signal is inputted to the common electrode for display and normal display is performed, and during a vertical blanking period, the T/P drive signal is supplied to the common electrode for display, and the T/P detection signal is extracted. In FIG. 17 , an example is shown in which the common electrode for display is divided into n+m blocks, where blocks 1 to n function as a driver electrode, while blocks n+1 to n+m function as a detection electrode.
The display device according to the present embodiment can be applied as a display device with a touch sensor integrally incorporated therein. Besides this, the display device is suitable to various electronic devices that include touch sensor functionality. This display device can also be applied to personal computers and various portable devices such as mobile phones and laptop computers.
(3) Effects of the Present Embodiment
As stated above, according to the configuration of the touch panel 10 of the present embodiment, by disposing a complementary electrode 4 , it is possible to form between the complementary electrode and the detection electrode a parasitic capacitance corresponding to a capacitance component that does not affect detection, among the parasitic capacitance formed between the driver electrode 2 and the detection electrode 3 .
Specifically, in (Cfo+Ccr) in the above formula, a parasitic capacitance (Cfo) corresponding to a capacitance component that is not affected by the object to be detected among fringe capacitances between the driver electrode 2 and the detection electrode 3 is added to a parasitic capacitance (Ccr) corresponding to a capacitance component that is not affected by the object to be detected among cross capacitances between the driver electrode 2 and the detection electrode 3 . By multiplying this value by (−ΔVdr), the resulting value corresponds to inactive charge that is generated regardless of whether or not an object to be detected is in contact with or approaches the detection surface, and thus, by dividing this value by the parasitic capacitance (Ccm) formed between the complementary electrode and the detection electrode, it is possible to calculate the amplitude (ΔVcm) of the complementary signal. At the time of detection, by applying the complementary signal having this amplitude (ΔVcm) to the complementary electrode 4 , of the parasitic capacitance induced on the detection electrode, the charge that is not affected by the object to be detected, or in other words, the inactive charge can be minimized.
Also, even if objects to be detected are in contact with (approach) the detection surface on the same line, the electrical changes do not cancel each other out unlike the conventional configuration. Thus, glitches such as non-detection do not occur.
Therefore, according to the configuration of the present embodiment, it is possible to provide a highly reliable touch panel in which glitches such as non-detection do not occur.
Also, according to the present embodiment, the complementary electrodes and the driver electrodes have different shapes, and thus, it is possible to independently use optimal shapes to form the parasitic capacitance component necessary for each of the electrodes. For example, it is possible for the complementary electrode to have a shape that can achieve an optimal capacitance value (Cm) in order to minimize the inactive charge induced by the driver electrode on the detection electrode, and to have a shape that can minimize the parasitic capacitance component of the detection electrode that is affected by the object to be detected, and it is possible for the driver electrode to have a shape that can maximize the parasitic capacitance component that is affected by the object to be detected. As for the “different shapes,” the electrodes may have different widths.
Embodiment 2
Another embodiment according to the present invention is as described below with reference to FIGS. 7 to 9 . In the present embodiment, differences from Embodiment 1 above will be described, and for ease of explanation, components having the same functions as those described in Embodiment 1 are given the same reference characters, and the descriptions thereof are omitted.
The difference between the touch panel of Embodiment 1 and the touch panel of the present embodiment is only that the position of the electrodes is different. Thus, only the position of the electrodes will be described below.
FIG. 7 is a drawing that shows a touch panel 10 ′ of the present embodiment. FIG. 7( a ) is a top view of the touch panel corresponding to FIG. 1( a ), and FIG. 7( b ) is a partial magnified view of a touch panel region corresponding to FIG. 1( b ).
In the touch panel region of the present embodiment, as shown in FIG. 7( b ), among driver electrode parts 21 ′, first bridge parts 22 , detection electrode parts 31 , second bridge parts 32 , and complementary electrodes 4 , only the second bridge parts 32 that connect the detection electrode parts 31 in the column direction are shown in grey. In other words, the driver electrode parts 21 ′, the first bridge parts 22 , the detection electrode parts 31 , and the complementary electrodes 4 are in the same layer, and are closer to the detection surface than the second bridge part 32 .
The first bridge parts 22 that connect the driver electrode parts 21 ′ with each other in the row direction extend along the row direction in the same layer as the driver electrode parts 21 ′ and the detection electrode parts 31 . In other words, the detection electrode parts 31 aligned along the column direction are separated by the first bridge parts 22 .
The first bridge parts 22 are constituted of a first bridge part 22 a and a first bridge part 22 b proximal to each other in the column direction. The first bridge part 22 a and the first bridge part 22 b are disposed between detection electrode parts 31 adjacent to each other in the column direction.
The first bridge part 22 a and the first bridge part 22 b are disposed between detection electrode parts 31 adjacent to each other in the column direction, and between the first bridge part 22 a and the first bridge part 22 b , a complementary electrode 4 is formed.
The driver electrode parts 21 ′ differ from those of Embodiment 1 in having a triangular shape. The triangular driver electrode parts 21 ′ are disposed in a substantially triangular space formed by dividing a substantially quadrilateral space formed in the same layer as the detection electrode part 31 by the arrangement of quadrilateral detection electrode parts 31 in FIG. 7( b ) by the first bridge part 22 a and the first bridge part 22 b in the column direction.
FIG. 8 is a partial magnified view of FIG. 7 . As shown in FIG. 8 , the second bridge part 32 is disposed in a layer below the first bridge part 22 a , the first bridge part 22 b , and the complementary electrode 4 , which are between the detection electrode parts 31 adjacent to each other in the column direction.
The first bridge part 22 a and the first bridge part 22 b may be driven separately or driven together.
FIG. 9( a ) is a cross-sectional view of the touch panel 10 ′ along the section line A-A′ shown in FIG. 8 . FIG. 9( b ) is a cross-sectional view of the touch panel 10 ′ along the section line B-B′ shown in FIG. 8 . FIG. 9( c ) is a cross-sectional view of the touch panel 10 ′ along the section line C-C′ shown in FIG. 8 .
Parasitic capacitances Cfs, Cfo, Ccr, and Ccm_cr respectively shown in FIGS. 9( a ) to 9 ( c ) are the same as described in Embodiment 1.
In other words, the configuration is such that when applying the drive signal to the driver electrodes 2 , a complementary signal at a different phase from the drive signal is applied to the complementary electrodes 4 , and the amplitude (ΔVcm) of the complementary signal satisfies the following formula:
Δ Vcm=−ΔVdr ×( Cfo+Ccr )/ Ccm
and the complementary signal with the amplitude (ΔVcm) is applied to the complementary electrode 4 .
Thus, as in Embodiment 1, a highly reliable touch panel in which glitches such as non-detection do not occur is attained.
The touch panel 10 ′ of the present embodiment can also be installed on a display device, as in Embodiment 1.
Embodiment 3
Another embodiment according to the present invention is as described below with reference to FIGS. 10 and 11 . In the present embodiment, differences from Embodiment 1 above will be described, and for ease of explanation, components having the same functions as those described in Embodiment 1 are given the same reference characters, and the descriptions thereof are omitted.
The difference between the touch panel of Embodiment 1 and the touch panel of the present embodiment is only that the position of the electrodes is different. Thus, only the position of the electrodes will be described below.
FIG. 10 shows a touch panel 10 ″ of the present embodiment. FIG. 10( a ) is a top view of the touch panel corresponding to FIG. 1( a ), and FIG. 10( b ) is a partial magnified view of a touch panel region corresponding to FIG. 1( b ).
In the touch panel region of the present embodiment, as shown in FIG. 10( b ), driver electrodes 2 ′ extend in the row direction and complementary electrodes 4 also extend in the row direction, and the driver electrodes 2 ′ and the complementary electrodes 4 are aligned in an alternating fashion in the column direction, in the same layer as each other.
The driver electrodes 2 ′ are not constituted of the driver electrode parts and the first bridge parts unlike Embodiment 1, but have an electrode line shape. Complementary electrodes 4 are the same as in Embodiment 1 and have an electrode line shape.
As shown in FIG. 10( b ), the detection electrodes 3 ′ extend in the column direction and intersect with the driver electrodes 2 ′ and the complementary electrodes 4 . As shown in FIG. 10( b ), only the detection electrodes 3 ′ are black. In other words, the detection electrodes 3 ′ are closer to the detection surface than the driver electrodes 2 ′ and the complementary electrodes 4 .
The detection electrodes 3 ′ have intersections 50 with the complementary electrodes 4 that are wider in the row direction than intersections 60 with the driver electrodes 2 ′. With this configuration, the detection electrodes are made wider on the complementary electrodes, and block lines of electric force from the lower layer outside, thereby minimizing the capacitance component between the complementary electrodes and the detection electrodes being affected by the object to be detected.
FIG. 11( a ) is a cross-sectional view of the touch panel 10 ″ along the line A-A′ shown in FIG. 10 . FIG. 11( b ) is a cross-sectional view of the touch panel 10 ″ along the line B-B′ shown in FIG. 10 .
Parasitic capacitances Cfs, Cfo, Ccr, and Ccm_cr respectively shown in FIGS. 11( a ) and 11 ( b ) are the same as those described in Embodiment 1.
In other words, the configuration is such that when applying the drive signal to the driver electrodes 2 , a complementary signal at a different phase from the drive signal is applied to the complementary electrodes 4 , and the amplitude (ΔVcm) of the complementary signal satisfies the following formula:
Δ Vcm=−ΔVdr ×( Cfo+Ccr )/ Ccm,
and the complementary signal with the amplitude (ΔVcm) is applied to the complementary electrode 4 .
Thus, as in Embodiment 1, a highly reliable touch panel in which glitches such as non-detection do not occur is attained.
The touch panel 10 ″ of the present embodiment can also be installed on a display device, as in Embodiment 1.
In the touch panel 10 ″ of the present embodiment, the shape of overlap of the complementary electrodes and the detection electrodes is different from the shape of overlap of the driver electrodes and the detection electrodes. According to this, among the capacitance between the detection electrode and the driver electrode and between the detection electrode and the complementary electrode, the cross capacitance is not easily affected by the state of the detection surface, or in other words, whether or not an object to be detected as come into contact (approached), compared to the fringe capacitance. This allows an optimal capacitance value (Ccm) to be attained at the complementary electrode for minimizing the inactive charge induced on the detection electrode by the driver electrode, and is suited to minimizing the parasitic capacitance component in the detection electrode that is affected by an object to be detected. Thus, by having different shapes for overlapping portions, a more suitable complementary driving can be performed.
Embodiment 4
Another embodiment according to the present invention is as described below with reference to FIG. 12 . In the present embodiment, differences from Embodiment 1 above will be described, and for ease of explanation, components having the same functions as those described in Embodiment 1 are given the same reference characters, and the descriptions thereof are omitted.
In Embodiment 1 above, a complementary signal generating circuit to which a drive signal is to be inputted generates a complementary signal. The present embodiment, in addition to this, has an amplitude adjusting circuit that adjusts amplitude. This will be explained with reference to FIG. 12 .
FIG. 12( a ) is a drawing for describing a complementary signal generating mechanism in the present embodiment, and FIG. 12( b ) schematically shows the entire touch panel of the present embodiment.
As shown in FIG. 12( a ), in the present embodiment, a reversed signal resulting from a drive signal being inputted into the signal reversing circuit 41 of the complementary signal generating mechanism 40 and being reversed therein is inputted into the amplitude adjusting circuit 42 . As an example of the complementary signal generating mechanism 40 , a circuit using a reversal amplifier shown on the right side of FIG. 12( a ) can be installed.
By providing such an amplitude adjusting circuit 42 , even if a change is made that affects the parasitic capacitance component in the device, such as the shape of various electrodes and the layered structure in the panel, the same circuit can be used with appropriate conditions.
An appropriate complementary signal is generated by the amplitude adjusting circuit 42 , and this generated complementary signal is applied to the complementary electrode 4 in the touch panel region ( FIG. 1 , for example).
The present invention is not limited to the embodiments above. Various modifications can be made to the present invention by those skilled in the art without departing from the scope specified by claims. That is, new embodiments can be obtained by combining technologies that were appropriately modified in the scope specified by claims. That is, the specific embodiments provided in the detailed description of the present invention section are merely for illustration of the technical contents of the present invention. The present invention shall not be narrowly interpreted by being limited to such specific examples. Various changes can be made within the spirit of the present invention and the scope as defined by the appended claims.
SUMMARY OF INVENTION
As stated above, a touch panel according to the present invention is
a touch panel that detects contact or approach of an object to a detection surface, including a detection electrode and a driver electrode, in which the touch panel detects the contact or approach of the object on the basis of a change in amount of an electric charge that is induced on the detection electrode in response to a drive signal applied to the driver electrode, and
in which the touch panel further includes a complementary electrode that forms a capacitance along with the detection electrode, the complementary electrode having applied thereto a complementary signal having a different phase than the drive signal, a voltage change ΔVcm of the complementary signal satisfying a formula below:
Δ Vcm=−ΔVdr ×( Cfo+Ccr )/ Ccm
where, in the formula, ΔVdr represents a voltage change of the drive signal, Cfo represents a capacitance that is primarily a fringe capacitance between the driver electrode and the detection electrode corresponding to a capacitance component that is not affected by the object, Ccr represents a capacitance that is primarily a cross capacitance between the driver electrode and the detection electrode corresponding to a capacitance component that is not affected by the object, Cfo+Ccr represents a total capacitance between the driver electrode and the detection electrode that is not affected by a presence or absence of the object, and Ccm represents a capacitance formed between the complementary electrode and the detection electrode.
According to the configuration above, by providing a complementary electrode, it is possible to form between the complementary electrode and the detection electrode a parasitic capacitance corresponding to a capacitance component that does not affect detection, among the parasitic capacitance formed between the driver electrode and the detection electrode.
Specifically, (Cfo+Ccr) in the formula above represents a parasitic capacitance (Cfo) corresponding to a capacitance component that is not affected by an object to be detected among fringe capacitance between the driver electrode and the detection electrode being added to a parasitic capacitance (Ccr) corresponding to a capacitance component that is not affected by an object to be detected among cross capacitance between the driver electrode and the detection electrode. By multiplying this by (−ΔVdr), the resulting value corresponds to inactive charge that is generated regardless of whether or not an object to be detected is in contact or approaches the detection surface, and thus, by dividing this value by the parasitic capacitance (Ccm) formed between the complementary electrode and the detection electrode, it is possible to calculate the amplitude (ΔVcm) of the complementary signal. At the time of detection, by applying the complementary signal having this amplitude (ΔVcm) to the complementary electrode, of the charge induced on the detection electrode, the charge that is not affected by the object to be detected, or in other words, the inactive charge can be minimized.
Also, even if objects to be detected are in contact with (approach) the detection surface on the same line, the electrical changes do not cancel each other out unlike the conventional configuration. Thus, glitches such as non-detection do not occur.
Therefore, according to the configuration of the present invention, it is possible to provide a highly reliable touch panel in which glitches such as non-detection do not occur.
Fringe capacitance refers to capacitance formed between electrodes in the same layer, while cross capacitance refers to capacitance formed between electrodes in different layers from each other.
In addition to the configuration above, in the touch panel according to the present invention, it is preferable
that the complementary electrodes and the driver electrodes have different shapes.
According to this configuration, the complementary electrodes and the driver electrodes have different shapes, and thus, it is possible to independently use optimal shapes to form the parasitic capacitance component necessary for each of the electrodes. For example, it is possible for the complementary electrodes to have a shape that can attain an optimal capacitance value (Ccm) for minimizing the inactive charge induced by the driver electrode on the detection electrode and that can minimize the parasitic capacitance component of the detection electrode being affected by the object to be detected, and it is possible for the driver electrodes to have a shape by which it is possible to maximize the parasitic capacitance component that is affected by the object to be detected.
As for the “different shape,” the electrodes may have different widths.
In addition to the configuration above, it is preferable that the touch panel of the present invention
include a complementary signal generating circuit that generates the complementary signal when the drive signal is inputted thereto.
According to this configuration, an appropriate complementary signal can be applied to the complementary electrode based on the drive signal.
In addition to the configuration above, it is preferable that the touch panel of the present invention
include an adjusting circuit that adjusts an amplitude of the complementary signal when the complementary signal is inputted thereto.
According to this configuration, by providing an adjusting circuit that adjusts the amplitude of the complementary signal, it is possible to use the same circuits with appropriate conditions even if changes that affect the parasitic capacitance components in the device such as the shape of the various electrodes and the layered structure inside the panel are made.
In addition to the configuration above, in the touch panel according to the present invention, it is preferable
that a plurality of the driver electrodes extend along a row direction, and a plurality of the detection electrodes extend along the column direction so as to intersect with the driver electrodes,
that the complementary electrodes extend along an extension direction of the driver electrodes, and
that a shape of overlap between the complementary electrodes and the detection electrodes differ from a shape of overlap between the driver electrodes and the detection electrodes.
According to this configuration, among the capacitance between the detection electrode and the driver electrode and complementary electrode, the cross capacitance is not easily affected by the state of the detection surface, or in other words, whether or not an object to be detected as come into contact (approached), compared to the fringe capacitance. This allows an optimal capacitance value (Ccm) to be attained at the complementary electrode for minimizing the inactive charge induced on the detection electrode by the driver electrode, and is suited to minimizing the parasitic capacitance component in the detection electrode that is affected by an object to be detected. Thus, by having different shapes for overlapping portions, a more suitable complementary driving can be performed.
In addition to the configuration above, in the touch panel of the present invention it is preferable that the driver electrodes include a plurality of driver electrode parts interconnected by first bridge parts,
that the detection electrodes include a plurality of detection electrode parts interconnected by second bridge parts,
that the driver electrode parts and the detection electrode parts be in the same layer as each other, and
that either of the first bridge parts or the second bridge parts be in the same layer as the driver electrode parts and the detection electrode parts, with the other of the first bridge parts and the second bridge parts being in a layer different from the layer, and the complementary electrodes, at a portion thereof overlapping the detection electrodes, are in the same layer as whichever of the first bridge parts or the second bridge parts is in the layer different from driver electrode parts and the detection electrode parts.
According to this configuration, by forming the driver electrode parts and the detection electrode parts in the same layer, it is possible to efficiently form a capacitance component that is affected by the object to be detected, while by including the complementary electrodes in a different layer from the driver electrode parts and the detection electrode parts, it is possible to minimize the capacitance component that is affected by the object to be detected between the complementary electrodes and the detection electrodes. As in FIG. 1( b ), the complementary electrodes are disposed in a layer below the driver electrode parts and the detection electrode parts, and the driver electrode parts and the detection electrode parts widely cover the complementary electrodes, and thus, it is possible to effectively mitigate the occurrence of lines of electric force, which is shown in FIG. 3( a ) with Cfs, that signify the capacitance component that is affected by the object to be detected, between the complementary electrodes and the detection electrodes.
In addition to the configuration above, in the touch panel of the present invention it is preferable
that the driver electrodes include a plurality of driver electrode parts interconnected by first bridge parts,
that the detection electrodes include a plurality of detection electrode parts interconnected by second bridge parts,
that the driver electrode parts, the first bridge parts, and the detection electrode parts be in the same layer, the second bridge parts being in a layer different from the driver electrode parts and the detection electrode parts, the complementary electrodes, at a portion thereof overlapping the detection electrodes, being in the same layer as the first bridge parts,
that the detection electrode parts be aligned along the column direction,
that the driver electrode parts be between detection electrode parts adjacent to each other in the row direction, and
that the complementary electrodes extend between driver electrodes adjacent to each other in the column direction.
According to this configuration, even if it is necessary to dispose the complementary electrodes in the same layer as the driver electrode parts and the detection electrode parts, it is possible to avoid having the complementary electrodes and the detection electrodes be adjacent to each other, and thus, it is possible to reduce the capacitance component indicated with Cfs in FIG. 9( a ), for example, and as a result, it is possible to minimize the capacitance component that is affected by an object to be detected among the capacitance between the complementary electrodes and the detection electrodes.
In addition to the configuration above, in the touch panel of the present invention it is preferable
that the driver electrodes and the complementary electrodes be arranged in the same layer in an alternating fashion in the column direction,
that the detection electrodes be in a layer different from the driver electrodes and the complementary electrodes, and
that the detection electrodes be wider in the row direction at intersections thereof with the complementary electrodes, than at intersections thereof with the driver electrodes.
According to this configuration, it is not necessary to form a bridge part, thereby resulting in a relatively simple configuration.
Also, according to the configuration above, the capacitance component that is affected by the object to be detected among the capacitance between the driver electrodes and the detection electrodes is a portion of Cfs shown in FIG. 11( a ), for example, or in other words, the component resulting from the lines of electric force that move towards the detection electrodes in a higher layer than the detection electrodes from the lower layer outside. Similarly, with respect to the complementary electrodes disposed in a lower layer, if the detection electrodes in a higher layer have the same shape as the driver electrodes, similar lines of electric force are generated, and thus, parasitic capacitance that is affected by the object to be detected is present (if the width of the driver electrodes and the complementary electrodes are different, then the Cfs is correspondingly different). A method to improve this is shown in FIG. 10( b ) in which the detection electrodes are made wider on the complementary electrodes, and block the lines of electric force from the lower layer outside, thereby minimizing the capacitance component between the complementary electrodes and the detection electrodes being affected by the object to be detected.
The present invention also includes a display device provided with the above-mentioned touch panel.
INDUSTRIAL APPLICABILITY
The present invention can be used for a display device of various types of electronic devices as a display device in which a liquid crystal panel having a display function is combined with a touch panel function.
DESCRIPTION OF REFERENCE CHARACTERS
1 touch panel region
2 driver electrode
3 detection electrode
4 complementary electrode
10 , 10 ′, 10 ″ touch panel
11 substrate
12 protective plate
13 shield
14 insulating film
21 driver electrode part
22 , 22 a , 22 b first bridge part
31 detection electrode part
32 second bridge part
40 complementary signal generating mechanism
41 signal reversing circuit
42 amplitude adjusting circuit
50 intersection
60 intersection
70 liquid crystal display part
71 first polarizing plate
72 display driver
73 second polarizing plate
74 first substrate
75 second substrate
80 touch panel part
81 type of electrode
82 detection driver
90 liquid crystal display device
170 liquid crystal display device
171 display region
172 frame
173 driver
174 flexible substrate
175 pixel
180 pixel electrode
181 common electrode
182 auxiliary capacitance wiring line
183 switching element | The touch panel of the present invention is a touch panel ( 1 ) that applies drive signals to drive electrodes ( 2 ) and carries out detection on the basis of the variation in the amount of charge that has been induced on detection electrodes ( 3 ), and is configured such that when drive signals are being applied to the drive electrodes, complementary signals having a different phase from the drive signals are applied to complementary electrodes ( 4 ), and the complimentary electrodes ( 4 ) are configured such that the amplitude (ΔVcm) of the complimentary signals satisfies the following formula:
Δ Vcm=−ΔVdr ×( Cfo+Ccr )/ Ccm. | 6 |
TECHNICAL FIELD
This invention relates to systems and methods for dispensing multi-component products.
BACKGROUND
Antiperspirants, deodorants, and other personal care products are widely available in the form of solid or semi-solids sticks, gels and creams. The inactive ingredients used in these types of products, such as carriers/vehicles, emollients and structural agents (e.g., fatty alcohols and waxes), may inhibit or inactivate some of the active ingredients that would be desirable to use in the product. Thus, choices of ingredients for use in such products tend to be limited by issues of reactivity, other undesirable interaction between the ingredients, and syneresis (phase separation).
The ingredients selected for use in the product, and their relative proportions, may also be dictated by manufacturing constraints. For example, in order to obtain a product that is easily processed, it may be necessary to set the amount of a particular ingredient, e.g., fragrance, at a level that may not be optimal from a consumer standpoint. Moreover, temperature, shear or mixing may inactivate, entrap or volatilize certain ingredients.
In addition to these constraints, the formulator of personal care products is faced with the dilemma that product characteristics that are desirable to one consumer may be undesirable to another. For instance, different users may require different levels of deodorant or antiperspirant actives, or disagree on the optimal level of aesthetic modifiers such as fragrance. Moreover, different users have different body chemistries, which may result in different levels of effectiveness and comfort for a given product formulation.
SUMMARY
The present invention features dispensing systems that allow a component of a multicomponent product to be maintained separate from other components of the product until the product is applied by a user. The dispensing systems include a dispenser body and a cap constructed to cover a dispensing end of the body. The separated component, which may contain one or more ingredients, is stored in a reservoir in the cap, and is applied by the user to the dispensing end when the user is about to apply the product. For instance, the dispenser body may contain a stick antiperspirant product containing a relatively low level of an antiperspirant active (or even no antiperspirant active), and the cap may contain a supply of the antiperspirant active, e.g., in powdered form. Thus, the composition of the stick may contain inactive substances that are advantageous for production of a stick product, even though such substances would tend to inhibit the antiperspirant active. Moreover, the user can choose whether to apply the antiperspirant active that is in the cap, and in preferred implementations can adjust the amount applied, and thus can tailor the amount of antiperspirant active in the product to suit his or her needs.
Because one component of the product can be separated from others until the product is applied, ingredients can be used in the product that, if mixed and stored, would be reactive or otherwise incompatible. The product can also be formulated to contain a minimal amount of ingredients such as fragrance, which some users may not like, in the body side, and an additional amount in the cap side, so that users can choose whether to augment the amount of that ingredient that is in the product.
In some preferred implementations, the user can select a desired dose of the component to be delivered from the cap. For example, if an antiperspirant active is provided in the cap, a user who expects to be in a hot environment can apply a large dose of the antiperspirant active to the dispensing end, while a user expecting to be in a cooler environment can apply a smaller dose. Similarly, if a fragrance is provided in the cap, the user can adjust the amount of fragrance in the product to suit his or her taste by adjusting the amount dispensed from the cap.
In other preferred implementations, the cap reservoir is empty when the product is sold to the user, and the cap is constructed so that the user can charge the reservoir with a desired component. For example, the component in the body may be fragrance-free, enabling the user to add a favorite perfume or cologne to the cap reservoir and thus obtain a custom-scented product.
Advantageously, the ability to deliver a component to the dispensing end of a dispenser body containing another component can result in increased efficacy of the product, and in enhanced sensory attributes such as improved glide and decreased negative attributes such as stickiness and white residue (because ingredients that enhance glide and reduce stickiness and white residue can be used even if they would ordinarily inactivate the active ingredients of the product). In preferred implementations, product customization is also provided, allowing users to tailor the product attributes to suit their personal tastes, requirements and body chemistries.
In one aspect, the invention features a dispensing system for a multi-component product. The dispensing system includes (a) a body, containing a first component of the product and having a dispensing end constructed to apply a portion of the first component to a surface; and (b) a cap, constructed to cover the dispensing end, containing a reservoir adapted to receive a second component of the product and being constructed to apply a portion of the second component to the dispensing end prior to applying the first component to the surface.
Implementations of this aspect of the invention may include one or more of the following features. The first component is provided in a form selected from the group consisting of liquids, creams, gels, solids and semi-solids. The first component is provided in the form of a solid or semi-solid, and an end surface of the stick is exposed at the dispensing end. The first component is provided in the form of a liquid, and the dispensing end comprises a rolling ball constructed to deliver a film of the liquid to a surface. The first component is provided in the form of a liquid, and the dispensing end comprises a porous applicator, e.g., a foam or a sintered porous material. The first component is provided in the form of a gel, and the body includes a dispensing device for metering a dose of the gel to a dispensing surface at the dispensing end. The product is selected from the group consisting of antiperspirants, deodorants, antiperspirant/deodorants, toothpastes, sun screens, shaving preparations, aftershaves, condiments, soaps, candies, fabric softeners, laundry soaps, cosmetics, medications, paints, shoe polishes, floor cleaners, tub and tile cleaner, hair color treatments, window cleaners, and polishes and waxes. The second component is provided in the form of a powder or liquid. The second component is provided in the form of a compressed powder. The cap includes a dispensing device constructed to remove a portion of the powder using a grating action. The cap is constructed to deliver a predetermined dose of the second component onto the dispensing end when actuated by a user. The cap is constructed to allow the user to adjust the amount of the second component that is constructed to allow the user to adjust the amount of the second component that is delivered when the cap is actuated by a user. The cap, as supplied to the user, contains a supply of the second component in the reservoir. The cap includes an inlet constructed to allow a user to charge the reservoir with a supply of the second component. The second component is selected from the group consisting of antiperspirant actives, fragrances, anti-stain agents, anti-irritants, antiperspirant actives, deodorant actives, antimicrobials, anti-caking agents, film formers, glide enhancers, emollients, anti-whitening agents, absorbents, binders, exfoliants, buffering agents, cooling agents, heating agents, co-salts, encapsulants, antioxidants, skin conditioning materials, humectants, reducing agents, oxidation agents, opacifying agents, and UV absorbing agents. The cap includes a dispensing mechanism for delivering the second component to the dispensing end. The dispensing system further includes an actuator to allow a user to actuate the application of the second component, or, alternatively, an actuator that is constructed to automatically apply the second component, e.g., when the cap is removed. The dispensing mechanism is selected from the group consisting of sprays, atomizers, droppers, and powder delivery devices. The first and second components are reactive with each other. An ingredient in the first component would tend to inactivate an ingredient in the second component during storage. The surface includes human skin, hair, tongue or oral cavity. Alternatively, the surface includes a fabric, leather, or plastic.
The invention also features a method of dispensing a multi-component product from a dispenser having a dispensing end that is covered by a cap when the dispenser is not in use and that is constructed to apply a first component of the product to a surface. The method includes (a) removing the cap, (b) applying a second component, contained in the cap, to the first component at the dispensing end to form the multi-component product; and (c) contacting a surface with the dispensing end to apply the multi-component product to the surface.
Preferred implementations of the method may include one or more of the following features. The surface includes human hair, skin, tongue or oral cavity. The applying step includes adjusting the amount of the second component to be applied to the dispensing end.
Other features and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic perspective view of a dispensing system according to one embodiment of the invention.
FIG. 2 is a perspective view of a cap for a dispensing system according to one aspect of the invention, with the front half removed.
FIG. 3 is an exploded perspective view of the cap shown in FIG. 2 .
FIG. 4 is a cross-sectional view of the cap shown in FIG. 2 .
FIG. 5 is an exploded perspective view of a cap according to an alternative embodiment of the invention.
FIGS. 5A and 5B are schematic perspective views of the cap of FIG. 5, shown in its normal and dispensing positions, respectively.
FIG. 6 is a schematic perspective view of a dispensing system according to an alternate embodiment of the invention in which a liquid is dispensed from the cap.
FIG. 7 is a cross-sectional view of a cap suitable for use in the dispensing system of FIG. 6 .
FIG. 8 is a cross-sectional view of an alternative cap suitable for use in the dispensing system of FIG. 6, with the dispensing mechanism shown schematically.
FIG. 9 is a cut-away perspective view of a cap suitable for dispensing a compressed powder.
FIG. 9A is a top view of a grating plate used in the cap of FIG. 9 .
FIG. 9B is a perspective view of the grating plate.
DETAILED DESCRIPTION
Referring to FIG. 1, a dispensing system 10 includes a dispenser body 12 , containing a stick 14 (e.g., an antiperspirant) and having a dispensing end 16 , and a cap 18 constructed to cover the dispensing end during storage. (While a stick is shown as an example, and discussed below, the body may contain, and the dispensing end may be adapted to dispense, any desired substance, e.g., a gel or liquid.)
The dispenser body includes an actuator (e.g., a rotatable knob) to allow the user to advance the stick towards the dispensing end as the stick is exhausted, as is well known in the antiperspirant art.
The cap includes an actuator 22 to allow the user to deliver a powder from a reservoir in the cap (not shown in FIG. 1) onto the stick 14 at the dispensing end 16 . In this embodiment, pressing the actuator 22 causes a predetermined dose of the powder, set during manufacturing, to be delivered. Thus, while the user cannot deliver an amount that is less than the predetermined amount, the user can nonetheless deliver an amount in excess of the predetermined amount by pressing the actuator more than once, or deliver none of the powder by not pressing it at all. The predetermined amount can be varied by the manufacturer by varying the channel geometry, depth and/or length.
While the dispensing system 10 is shown delivering a powder in FIG. 1, liquids can also be delivered from the cap to the dispensing end, as will be discussed below with reference to FIGS. 6-7.
Alternative powder delivery mechanisms for dispensing powders from the cap are shown in FIGS. 2-4 and FIG. 5 . Many other types of delivery mechanisms may be used, as will be apparent to those of skill in the art.
Referring to FIGS. 2-4, cap 18 ′ includes a powder reservoir 24 that defines a reservoir area 25 , and is constructed to receive in rotatable engagement a cylindrical shaft 26 having a plurality of powder delivery channels 28 . Shaft 26 also includes an actuation wheel 30 having a plurality of spokes 32 . When the cap is assembled, as shown in FIG. 2, the actuation wheel 30 extends from a side surface 34 of the cap 18 ′ and is protected by a shroud 36 .
When the shaft 26 is aligned as shown in FIG. 2, two of the powder delivery channels 28 each contain a dose of powder, and the remaining two channels are empty. One of the full channels is within the reservoir area 25 , and the other is facing the side wall 27 (FIG. 3) of powder reservoir 24 . As a user rotates the wheel 30 , the dose of powder in the delivery channel 28 that is facing side wall 27 is delivered from the cap, the delivery channel that was in the reservoir area 25 moves to face the side wall 27 , and the next delivery channel is positioned in the reservoir area and filled.
As discussed above, while the minimum amount that can be dispensed is predetermined (the volume contained in a single delivery channel), the amount delivered can be varied by delivering multiple doses, i.e., by continuing to turn the wheel 30 . For a wheel that includes four channels 28 , each 90 degree rotation of the wheel would deliver a single dose of powder.
An alternate powder dispensing device is used in cap 18 ″, shown in FIGS. 5-5B. This device includes a first plate 40 that defines the top surface of a powder reservoir 41 (FIG. 5 A), and second and third plates 42 , 44 , each of which includes an array of apertures 46 , 48 . As shown in FIGS. 5A and 5B, plate 42 is mounted on plate 44 with protrusion 50 of plate 44 extending through slot 52 of plate 42 to allow transverse movement of plate 42 relative to plate 44 . Plate 42 is biased towards a normal, “rest” position by spring 54 , which is mounted on shaft 56 of plate 42 . When the powder dispensing device is in its normal position (FIG. 5 A), the apertures 46 are not registered with the apertures 48 , and thus no powder is dispensed from the cap. When actuator 58 is pressed, plate 42 is moved transversely (arrow A, FIG. 5 A), against the returning force of spring 54 , until the apertures 46 and 48 are brought into registration (FIG. 5 B), causing powder to be dispensed from the cap. When the actuator button is released, the spring 54 will return the plate 42 to its normal position, and no further powder will be dispensed. Thus, in this embodiment the user can determine how much powder is to be delivered by pressing the actuator 58 for a longer or shorter period of time.
As shown in FIG. 6, a dispensing system 110 can be used to dispense a liquid 124 from a cap 118 onto the dispensing end 116 of a dispenser body 112 when an actuator 122 is depressed or turned. In this embodiment, cap 118 includes a liquid dispensing device 160 that is constructed to deliver droplets of liquid, e.g., by atomization as will be discussed below.
As shown in FIG. 7, in one embodiment the liquid dispensing device includes a liquid reservoir 162 containing a supply of liquid 124 , and a pump spray device, e.g., a spray pump system commercially available from Seaquist Perfect Dispensing (www.seagperf.com) that has been modified so that the liquid 124 exits from the bottom of the cap. Briefly, the pump spray device includes a hollow shaft 164 and a piston 206 that are connected to an actuator 122 and biased to a normal position (FIG. 7) by spring 166 . An intake tube 168 extends from the lower end of hollow shaft 164 , and is normally sealed off from the shaft 164 by a ball 201 . Within the piston 206 is a tube 210 , which is in fluid communication with an outlet tube 207 , which in turn communicates with a spray orifice 170 . A gasket 204 seals the lower end of tube 210 when the pump spray device is in its normal position. After the pump spray system has been initially primed by depressing the actuator several times (when the dispensing system is used for the first time), the hollow shaft 164 will normally be full of liquid. Upon depressing the actuator 122 , piston 206 presses down on piston base 205 , causing spring 166 to be compressed. The pressure on piston base 205 breaks the seal between the gasket 204 and end of tube 210 , allowing fluid to flow from the hollow shaft 164 into tube 210 , and from tube 210 into outlet tube 207 and thus to spray orifice 170 . When the actuator is released and the spring relaxes, ball 201 moves upward allowing liquid to flow upward through intake tube 168 into the hollow shaft 164 , refilling the hollow shaft 164 .
As shown in FIG. 8, the liquid reservoir 162 may be empty when the dispensing system 110 is supplied to the user, and may include an inlet 172 having a removable cover 174 . Thus, the user may remove the cover 174 and charge the reservoir, e.g., with the user's own perfume 176 , as shown. (Similarly, if the cap is designed to dispense a powder, the user could fill the powder reservoir with a desired powdered substance, e.g., perfumed talcum powder.) The reservoir 162 may also be pre-filled with a supply of a carrier powder (not shown), to which the user adds a supply of a liquid, e.g., the user's own perfume, which is absorbed by the carrier powder. To facilitate charging the reservoir with liquid, the cover 174 may be replaced by a one-way valve if desired.
Alternatively, the substance in the cap may be provided in the form of a compressed powder. In this case, the cap may include a dispensing mechanism as shown in FIG. 9 . In this embodiment, a block 153 of compressed powder is placed in a chamber that is defined by a top plate 151 and a bottom plate 155 that includes a cutting surface 154 that is positioned against the lower surface of the block 153 . The bottom plate 155 is shown in detail in FIGS. 9A and 9B. The cutting surface 154 includes a plurality of grating apertures 152 that have sharp edges that protrude above the cutting surface, as shown in FIG. 9B. A pair of actuators 156 , positioned on the sides of the plate 155 , allow the plate 155 to be pushed back and forward (arrow A, FIG. 9 ), causing the cutting surface 154 to abrade the lower surface of block 153 . The powder that is removed by the grating action of cutting surface 154 drops through grating apertures 152 (which extend through the thickness of plate 155 ) and is thus dispensed from the cap. Top plate 151 is spring-loaded by springs 150 , so that as powder is removed the block 153 remains pressed firmly against the cutting surface 154 .
Many substances may be dispensed from the cap. Suitable substances include glide enhancers, e.g., micronized beads and boron nitride; exfoliants, e.g., abrasive particles, loofa, polyethylene beads, jojoba oil microspheres and nylon; wetness, greasiness and oiliness reducing ingredients, e.g., starches, water lock agents, polypore, microsponge, silicone elastomers and absorbents; anti-caking agents, e.g., calcium phosphate, silicas, aluminosilicates and emollients; and ingredients that provide a sensation of coolness, e.g., menthol, menthyl lactate, and sodium palmitoyl proline.
Other suitable substances include adhesion agents, fragrances, deodorant actives (e.g., ACH, Farnesol and octoxyglycerine), aluminum salts, talcs, efficacy enhancing agents (e.g., calcium chloride, for antiperspirants), odor modifiers (e.g., sodium bicarbonate), anti-irritants (e.g., allantoin), detackifiers (e.g., silicones, emollient esters and oils), water or encapsulated water, and anti-stain agents (e.g., Vitamin E and tocopherols). Many other examples of suitable materials are listed below. However, these are only examples and many others may be used, as will be apparent to those of skill in the art.
If aluminum salts are used, it may be necessary to restrict the level of aluminum salt in the composition to be delivered from the cap if the product is for sale in the United States. This is because aluminum salts are monographed by the FDA, and the FDA monograph requires that “no more than 25% by weight of a formula may be composed of an AP salt.” As a result, if it is necessary to comply with this FDA requirement then a filler powder should be added to the aluminum salt so that the amount of aluminum salt in the composition delivered by the cap is 25% or less. Suitable fillers for this purpose would include co-salts and talc powders, which would advantageously also increase glide and efficacy.
Other embodiments are within the claims.
For example, while the discussion above focuses primarily on antiperspirant and deodorant products, the dispensing system can be used to dispense a wide variety of products, including, e.g., toothpastes, sun screens, shaving preparations, aftershaves, condiments, soaps (e.g., bars, powders and gels), candies (e.g., powders, liquids, gels and sticks), fabric softeners, laundry soaps (e.g., powders, liquids and gels), cosmetics (e.g., lipstick, blush, mascara), medications (e.g., for diaper rash, anti-itch, eczema, anti-sting and wound repair), paints, pet powders (e.g., flea, tick and deodorant treatments), shoe polishes, floor cleaners, tub and tile cleaner, hair color treatments, window cleaners, and polishes and waxes.
In addition, the cap can be used to dispense a wide variety of different materials, examples of which are listed below:
Emollients/Antiwhitening Agents
Acetyl Trioctyl Citrate, Apricot Kernel Oil PEG-6 Esters, Arachidyl Propionate, Avocado Oil, Bay Oil, Behenyl Erucate, Bisphenylhexamethicone, Butyl Acetyl Ricinoleate, Butyl Myristate, Butyl Oleate, Butyl Stearate, C18-36 Acid Glycol Ester, C12-15 Alcohols Benzoate, C12-15 Alcohols Lactate, C12-15 Alcohols Octanoate, C14-15 Alcohols, C15-18 Glycol, C18-20 Glycol Isostearate, C14-16 Glycol Palmitate, C13-14 Isoparaffin, C13-16 Isoparaffin, C20-40 Isoparaffin, C11-15 Pareth-3 Oleate, C11-15 Pareth-3 Stearate, C11-15 Pareth-12 Stearate, C12-15 Pareth-9 Hydrogenated Tallowate, C12-15 Pareth-12 Oleate, C30-46 Piscine Oil, Caprylic/Capric/Diglyceryl Succinate, Caprylic/Capric Glycerides, Caprylic/Capric/Isostearic/Adipic Triglycerides, Cetearyl Alcohol, Cetearyl Isononanoate, Cetearyl Palmitate, Cetyl Acetate, Cetyl Alcohol, Cetylarachidol, Cetyl Esters, Cetyl Lactate, Cetyl Myristate, Cetyl Octanoate, Cetyl Palmitate, Cetyl Ricinoleate, Cetyl Stearate, CocoCaprylate/Caprate, Cocoglycerides, Coconut Alcohol, Corn Oil PEG-6 Esters, Cottonseed Glyceride Cottonseed Oil Cyclomethicone, Decyl Alcohol, Decyl Isostearate, Decyl Oleate, Decyl Succinate, Decyltetradecanol, Dibutyl Adipate, Dibutyl Sebacate, Di-C12-15 Alcohols Adipate, Dicapryl Adipate, Dicetyl Adipate, Diethylene Glycol Dibenzoate, Diethyl Palmitoyl Aspartate, Diethyl Sebacate, Dihexyl Adipate, Dihydrocholesteryl Octyldecanoate, Dihydrophytosteryl Octyldecanoate, Dihydroxyethyl Soyamine Dioleate, Dihydroxyethyl Tallowamine Oleate, Diisobutyl Adipate, Diisocetyl Adipate Diisodecyl Adipate, Diisopropyl Adipate, Diisopropyl Dilinoleate, Diisopropyl Sebacate, Diisostearyl Adipate, Diisostearyl Dilinoleate, Diisostearylmalate, Dilauryl Citrate, Dimethicone Copolyol, Dimethiconol, Dioctyl Adipate, Dioctyl Dilinoleate, Dioctyl Sebacate, Dioctyl Succinate, Dipropylene Glycol Dibenzoate, Ditridecyl Adipate, Dodecyltetradecanol, Ethyl Arachidonate, Ethyl Laurate, Ethyl Linoleate, Ethyl Linoleanate, Ethyl Morrhuate, Ethyl Myristate, Ethyl Palmitate, Ethyl Pelargonate, Ethyl Persate, Ethyl Stearate, Fish Glycerides, Glyceryl Behenate, Glyceryl Caprate, Glyceryl Caprylate, Glyceryl Caprylate, Glyceryl Caprylate/Caprate, Glyceryl Cocoate, Glyceryl Dilaurate, Glyceryl Dioleate, Glyceryl Distearate, Glyceryl Erucate, Glyceryl Hydroxystearate, Glyceryl Isostearate Glyceryl Lanolate, Glyceryl Laurate, Glyceryl Linoleate, Glyceryl Myristate, Glyceryl Oleate, Glyceryl Palmitate Lactate, Glyceryl Ricinoleate, Glyceryl Sesquioleate, Glyceryl Stearate, Glyceryl Stearate Citrate, Glyceryl Stearate Lactate, Glyceryl Triacetyl Hydroxystearate, Glyceryl Triacetyl Ricinoleate, Glyceryl Trioctanoate, Glyceryl Triundecanoate, Glycol Dioctanoate, Glycol Hydroxystearate, Glycol Oleate, Glycol Ricinoleate, Glycol Stearate, Heptylundecanol, Hexyl Laurate, Hydrogenated Coco-Glycerides, Hydrogenated Lard Glyceride, Hydrogenated Lard Glycerides, Hydrogenated Palm Glycerides, Hydrogenated Palm Kernel Glycerides, Hydrogenated Palm Oil Glyceride, Hydrogenated Palm Oil Glycerides, Hydrogenated Palm/Palm Kernel Oil PEG-6 Esters, Hydrogenated Polyisobutene, Hydrogenated Soybean Oil Glycerides, Hydrogenated Soy Glyceride, Hydrogenated Tallow Glyceride, Hydrogenated Tallow Glyceride Citrate, Hydrogenated Tallow Glyceride Lactate, Hydrogenated Tallow Glycerides, Hydrogenated Tallow Glycerides Citrate, Hydrogenated Vegetable Glyceride, Hydrogenated Vegetable Glycerides, Hydrogenated Vegetable Glycerides Phosphate, Hydroxylated Lanolin, Hydroxyoctaconsanyl Hydroxystearate, Isoamyl Laurate, Isobutyl Myristate, Isobutyl Palmitate, Isobuytl Pelargonate, Isobutyl Stearate, Isocetyl Alcohol, Isocetyl Isodecanoate, Isocetyl Palmitate, Isocetyl Stearate, Isocetyl Stearoyl Stearate, Isodecyl Hydroxystearate, Isodecyl Isononanoate, Isodecyl Laurate, Isodecyl Myristate, Isodecyl Neopontanoate, Isodecyl Oleate, Isodecyl Palmitate, Isononyl Isononanoate, Isopropyl Isostearate, Isopropyl Lanolate, Isopropyl Laurate, Isopropyl Linoleate, Isopropyl Methoxycinnamate, Isopropyl Myristate, Isopropyl Oleate, Isopropyl Palmitate, Isopropyl Ricinoleate, Isopropyl Stearate, Isopropyl Tallowate, Isosearyl Alcohol, Isostearyl Benzoate, Isostearyl Isostearate, Isostearyl Lactate, Isostearyl Neopentanoate, Isostearyl Palmitate Isotridecyl Isononanoate, Laneth-9 Acetate, Laneth-10 Acetate, Lanolin, Lanolin Alcohol, Lanolin Oil, Lanolin Wax, Lard Glycerides, Laureth-2 Benzoate, Lauryl Alcohol, Lauryl Glycol, Lauryl Isostearate, Lauryl Lactate, Lauryl Myristate, Lauryl Palmitate, Methyl Acetyl Ricinoleate, Methyl Caproate, Methyl Caprylate, Methyl Caprylate/Caprate, Methyl Cocoate, Methyl Dehydroabietate, Methyl Glucose Sesquioleate, Methyl Glucose Sesquistearate, Methyl Hydrogenated Rosinate, Methyl Hydroxystearate, Methyl Laurate, Methyl Linoleate, Methyl Myristate, Methyl Oleate, Methyl Palmitiate, Methyl Pelargonate, Methyl Ricinoleate, Methyl Rosinate, Methyl Stearate, Mineral Oil, Mink Oil, Myreth-3 Caprate, Myreth-3 Laurate, Myreth-3 Myristate, Myreth-3 Palmitate, Myristyl Alcohol, Myristyleiconsanol, Myristyleicosyl Stearate, Myristyl Isostearate, Myristyl Lactate, Myristyl Lignocerate, Myristyl Myristate, Myristyl Neopentanoate, Myristyloctandecanol, Myristyl Propionate, Myristyl Stearate, Neopentyl Glycol Dicaprate, Neopentyl Glycol Dioctanoate, Nonyl Acetate, Octyl Acetoxystearate, Octyldodecanol, Octyldodecyl Neodecanoate, Octyl Hydroxystearate, Octyl Isononanoate, Octyl Myristate, Octyl Palmitate, Octyl Pelargonate, Octyl Stearate, Oleyl Acetate, Oleyl Alcohol, Oleyl Arachidate, Oleyl Erucate, Oleyl Lanolate, Oleyl Myristate, Oleyl Oleate, Oleyl Stearate, Palm Kernel Alcohol, Palm Kernel Glycerides, Palm Oil Glycerides, PEG-6 Caprylic/Capric Glycerides, PEG-2 Castor Oil, PEG-3 Castor Oil, PEG-4 Castor Oil, PEG-5 Castor Oil, PEG-8 Castor Oil, PEG-9 Castor Oil, PEG-10 Castor Oil, PEG-10 Coconut Oil Esters, PEG-5 Glyceryl Triisostearate, PEG-5 Hydrogenated Castor Oil, PEG-7 Hydrogenated Castor Oil, PEG-5 Hydrogenated Corn Glycerides, PEG-8 Hydrogenated Fish Glycerides, PEG-20 Methyl Glucose Sesquistearate, Pentaerythrityl Rosinate, Pentaerythrityl Tetraoctanoate, Pentaerythrityl Tetraoleate, PPG-4-Ceteth-1, PPG-8-Ceteth-1, PPG-8-Ceteth-2, PPG-10 Cetyl Ether, PPG-10 Cetyl Ether Phosphates, PPG-28 Cetyl Ether, PPG-30 Cetyl Ether, PPG-50 Cetyl Ether, PPG-17 Dioleate, PPG-3 Hydrogenated Castor Oil, PPG-30 Isocetyl Ether, PPG-5 Lanolate, PPG-2 Lanolin Alcohol Ether, PPG-5 Lanolin Alcohol Ether, PPG-10 Lanolin Alcohol Ether, PPG-20 Lanolin Alcohol Ether, PPG-30 Lanolin Alcohol Ether, PPG-5 Lanolin Wax, PPG-5 Lanolin Wax Glyceride, PPG-9 Laurate, PPG-4 Lauryl Ether, PPG-3 Myristyl Ether, PPG-4 Myristyl Ether, PPG-26 Oleate, PPG-36 Oleate, PPG-10 Oleyl Ether, PPG-20 Oleyl Ether, PPG-23 Oleyl Ether, PPG-30 Oleyl Ether, PPG-37 Oleyl Ether, PPG-50 Oleyl Ether, PPG-9-Steareth-3, PPG-11 Stearyl Ether, PPG-15 Stearyl Ether, Propylene Glycol Isostearate, Propylene Glycol Hydroxystearate, Propylene Glycol Laurate, Propylene Glycol Myristate, Propylene Glycol Myristyl Ether, Propylene Glycol Myristyl Ether Acetate, Propylene Glycol Oleate, Propylene Glycol Ricinoleate, Propylene Glycol Soyate, Propylene Glycol Stearate, Silica Silylate, Soybean Oil Unsaponifiables, Soy Sterol, Soy Sterol Acetate, Squalene, Stearoxytrimethylsilane, Stearyl Acetate, Stearyl Alcohol, Stearyl Citrate, Stearyl Lactate, Sucrose Distearate, Sulfurized Jojoba Oil, Sunflower Seed Oil Glycerides, Tall Oil Glycerides, Tallow Glyceride, Tallow Glycerides, Tridecyl Alcohol, Triisocetyl Citrate, Triisostearin PEG-6 Esters, Trimethylsilylamodimethicone, Triolein PEG-6 Esters, Tris(Tributoxysiloxy)Methylsilane, Undecylpentadecanol, Vegetable Glycerides Phosphate, Wheat Germ Glycerides
Humectants
Acetamide MEA, Fructose, Glucamine, Glucose, Glucose Glutamate, Glucuronic Acid, Glutamic Acid, Glycereth-7, Glycereth-12, Glycereth-26, Glycerin, Histidine, Honey, Hydrogenated Honey, Hydrogenated Starch Hydrolysate, Lactose, Maltitol, Mannitol, Methyl Gluceth-10, Methyl Gluceth-20, PCA, PEG-10 Propylene Glycol, Polyamino Sugar Condensate, Propylene Glycol, Pyrisoxine Dilaurate, Saccharide Hydrolysate, Saccharide Isomerate, Sodium Lactate, Sodium PCA, Sorbitol Sucrose, TEA-Lactate, TEA-PCA, Urea, Xylitol Corn Syrup, Fructose, Glucose, Glycerin, Glycol, 1,2,6-Hexanetriol, Inositol, Lactic Acid, PEG-4, PEG-6, PEG-8, PEG-9, PEG-10, PEG-12, PEG-14, PEG-16, PEG-18, PEG-20, PEG-32, PEG-40, PEG-75, PEG-135, PEG-150, PEG-200, PEG-5 Pentaerythritol Ether, Polyglyceryl Sorbitol, Propylene Glycol, Sodium PCA, Sorbitol, Sucrose, Urea, Xylitol
Film Formers
Acrylamide Copolymers, Acrylamide/Sodium Acrylate Copolymers, Acrylate/Acrylamide Copolymers, Acrylate/Ammonium Methacrylate Copolymers, Acrylate Copolymers, Acrylates/Diacetoneacrylamide Copolymer, Acrylic/Acrylate Copolymer, Adipic Acid/Dimethylaminohydroxypropyl Diethylenetriamine Copolymer, Adipic Acid/Epoxypropyl Diethylenetriamine Copolymer, Albumen, Allyl Stearate/VA Copolymer, Aminoethylactylate Phosphate/Acrylate Copolymer, Ammonium Acrylates Copolymer, Ammonium Alginate, Ammonium Vinyl Acetate/Acrylates Copolymer, AMP Acrylates/Diacetoneacrylamide Copolymer, AMPD Acrylates/Diacetoneacrylamide Copolymer, Balsam Canada, Balsam Oregon, Balsam Peru, Balsam Tolu, Benzoic Acid/Plithalic Anhydride/Pentaelythritol/Neopentyl Glycol/Palmitic Acid Copolymer, Benzoin Extract, Butadiene/Acrylonitrile Copolymer, Butylate Urea-Formaldehyde Resin, Butyl Benzoic Acid/Phthalic Anhydride/Trimethylolethane Copolymer, Butyl Ester of Ethylene/Maleic Anhydride Copolymer, Butyl Ester of PVM/MA Copolymer, Calcium Carrageenan, Calcium/Sodium PVM/MA Copolymer Carboxymethyl Hydroxyethylcellulose, Cellulose Gum, Collodion, Copal, Corn Starch/Acrylamide/Sodium Acrylate Copolymer, Damar, Diethylene Glycolamine/Epichlorohydrin/Piperazine Copolymer, DMHF, Dodecanedioic Acid/Cetearyl Alcohol/Glycol Copolymer, Ethylcellulose, Ethylene/Acrylate Copolymer, Ethylene/Maleic Anhydride Copolymer, Ethylene/Vinyl Acetate Copolymer, Ethyl Ester of PVM/MA Copolymer, Flexible Collodion, Gum Benzoin, Gutta Percha, Hydroxybutyl Methylcellulose, Hydroxyethylcellulose, Hydroxyethyl Ethylcellulose, Hydroxypropylcellulose, Hydroxypropyl Guar, Hydroxypropyl Methylcellulose, Isopropyl Ester of PVM/MA Copolymer, Maltodextrin, Melamine/Formaldehyde Resin, Methacryloyl Ethyl Betaine/Methacrylate Copolymer, Nitrocellulose, Octylacrylamide/Acrylate/Butylaminoethyl Methacrylate Copolymer, Octylacrylamide/Acrylates Copolymer, Phthalic Anhydride/Glycerin/Glycidyl Decanoate Copolymer, Phthalic/Trimellitic/Glycols Copolymer, Polyacrylamide, Polyacrylamidomethylpropane Sulfonic Acid, Polyacrylic Acid, Polybutylene Terephthalate, Polychlorotrifluoroethylene, Polyethylacrylate, Polyethylene, Polyethylene Terephthalate, Polyisobutene, Polyquaternium-1, Polyquatemium-2, Polyquaternium-4, Polyquaternium-5, Polyquaternium-6, Polyquaternium-7, Polyquaternium-8, Polyquaternium-9, Polyquaternium-10, Polyquaternium-11, Polyquatemium-12, Polyquatemium-13, Polyquatemium-14, Polyquaternium-15, Polystyrene, Polyvinyl Acetate, Polyvinyl Alcohol, Polyvinyl Butyral, Polyvinyl Imidazolinium Acetate, Polyvinyl Laurate, Polyvinyl Methyl Ether, Potassium Carrageenan, PVM/MA Copolymer, PVP, PVP/Dimethylaminoethylmethacrylate Copolymer, PVP/Eicosene Copolymer, PVP/Ethyl Methacrylate/Methacrylic Acid Copolymer, PVP/Hexadecene Copolymer, PVP/VA Copolymer PVP/Vinyl Acetate/Itaconic Acid Copolymer Rosin, Serum Albumin, Shellac, Sodium Acrylate/Vinyl Alcohol Copolymer, Sodium Carrageenan, Sodium Polymethacrylate, Sodium Polystyrene Sulfonate, Starch/Acrylate/Acrylamide Copolymer, Starch Diethylaminoethyl Ether, Stearylvinyl Ether/Maleic Anhydride Copolymer, Styrene/Acrylate/Acrylonitrile Copolymer, Styrene/Acrylate/Ammonium Methacrylate Copolymer, Styrene/Maleic Anhydride Copolymer, Styrene/PVP Copolymer, Sucrose Benzoate/Sucrose Acetate Isobutyrate/Butyl Benzyl Phthalate Copolymer, Sucrose Benzoate/Sucrose Acetate Isobutyrate/Butyl Benzyl Phthalate/Methyl Methacrylate Copolymer, Sucrose Benzoate/Sucrose Acetate Isobutyrate Copolymer, Toluenesulfonamide/Formaldehyde Resin, Tragacanth Gum, Vinyl Acetate/Crotonates Copolymer, Vinyl acetate/Crotonic Acid Copolymer, Vinyl Acetate/Crotonic Acid/Methacryloxybenzophenone-1 Copolymer, Vinyl Acetate/Crotonic Acid/Vinyl Neodecanoate Copolymer, Zein
Occlusive Film Formers
Acetylated Castor Oil, Acetylated Glycol Stearate, Acetylated Hydrogenated Cottonseed Glyceride, Acetylated Hydrogenated Lard Glyceride, Acetylated Hydrogenated Tallow Glyceride, Acetylated Hydrogenated Vegetable Glyceride, Acetylated Lanolin, Acetylated Lanolin Alcohol, Acetylated Lanolin Ricinoleate, Acetylated Lard Glyceride, Acetylated Palm Kernel Glycerides, Acetylated Sucrose Distearate, Aluminum Isostearates/Laurates/Palmitates, Aluminum Isostearates/Laurates/Stearates, Aluminum Isostearates/Myristates, Aluminum Isostearates/Palmitates, Aluminum Isostearates/Stearates, Aluminum Lanolate, Aluminum Myristates/Palmitates, Aluminum Stearate, Aluminum Stearates, Aluminum Tristearate, Apricot Kernel Oil, Avocado Oil, Avocado Oil Unsaponifiables, Batyl Alcohol, Batyl Isostearate, Batyl Stearate, Bayberry Wax, Biphenylhexamethicone, Butter C18-36 Acid Triglyceride, C30-46 Piscine Oil, C10-18 Triglycerides, Caprylic/Capric/Isostearic/Adipic Triglycerides, Caprylic/Capric/Lauric Triglyceride, Caprylic/Capric/Linoleic Triglyceride, Caprylic/Capric/Stearic Triglyceride, Caprylic/Capric Triglyceride, Castor Oil, Chaulmoogra Oil, Cherry Pit Oil, Cocoa Butter, Coconut Oil, Cod Liver Oil, Corn Oil, Cottonseed Oil, Dihydrogenated Tallow Phthalate, Diisostearyl Silinoleate, Dilinoleic Acid, Dimethicone, Dioctyl Dilinoleate, Ditridecyl Dilinoleate, Egg Oil, Erucyl Arachidate, Erucyl Erucate, Ethiodized Oil, Glyceryl Tribehenate, Glycol Dibehenate, Grape Seed Oil, Hazel Nut Oil, Hexadecyl Methicone, Hexanediol Distearate, Hybrid Safflower Oil, Hydrogenated C6-14 Olefin Polymers, Hydrogenated Castor Oil, Hydrogenated Coconut Oil, Hydrogenated Cottonseed Oil, Hydrogenated Jojoba Oil, Hydrogenated Jojoba Wax, Hydrogenated Lanolin, Hydrogenated Lard, Hydrogenated Menliaden Oil, Hydrogenated Palm Kernel Oil, Hydrogenated Palm Oil, Hydrogenated Peanut Oil, Hydrogenated Rice Bran Wax, Hydrogenated Shark Liver Oil, Hydrogenated Soybean Oil, Hydrogenated Tallow, Hydrogenated Vegetable Oil, Isobutylated Lanolin Oil, Isostearyl Erucate, Isostearyl Stearoyl Stearate, Jojoba Butter, Jojoba Oil, JojobaWax, Lanolin Linoleate, Lanolin Ricinoleate, Lard, Lauryl Stearate, Linseed Oil, Menhaden Oil, Methicone, Mineral Oil, Mink Oil, Mink Wax, Moringa Oil, Neatsfoot Oil, Octyldodecyl Myristate, Octyldodecyl Stearate, Octyldodecyl Stearoyl Stearate, Oleostearin, Oleyl Lanolate, Oleyl Linoleate, Olive Husk Oil, Olive Oil, Olive Oil Unsaponifiables, Palm Kernel Oil, Palm Oil, Paraffin, Peach Kernel Oil, Peanut Oil, Pengawar Djambi Oil, Pentdesma Butter, Pentaeiythrityl Hydrogenated Rosinate, Pentaerythrityl Tetraabietate, Pentaerythrityl Tetrabehenate, Pentaerythrityl Tetrastearate, Pentahydrosqualene, Petrolatum, Phenyl Trimethicone, Pristane, Propylene Glycol Dicaprylate, Propylene Glycol Dicaprylate/Dicaprate, Propylene Glycol Dicocoate, Propylene Glycol Dilaurate, Propylene Glycol Dioctanoate, Propylene Glycol Pipelargonate, Propylene Glycol Distearate, Propylene Glycol Diundecanoate, Rapeseed Oil, Rapeseed Oil Unsaponifiables, Rice Bran Oil, Rice Bran Wax, Safflower Oil, Sesame Oil, Shark Liver Oil, Shea Butter, Shea Butter Unsaponifiables, Shellac Wax, Soybean Oil, Soybean Oil Unsaponifiables, Soy Sterol Acetate, Squalane, Stearoxy Dimethicone, Stearyl Caprylate, Stearyl Caprylate/Caprate, Stearyl Eurcate, Stearyl Heptanoate, Stearyl Octanoate, Stearyl Stearate, Stearyl Stearoyl Stearate, Sunflower Seed Oil, Sweet Almond Oil, Synthetic Jojoba Oil, Synthetic Wax, Tall Oil, Tallow, Tallow Glycerides, Tricaprin, Trihydroystearin, Trisononanoin, Triisopropyl Trilinoleate, Triisostearin, Triisonstearyl Trilinoleate, Trilaurin, Trilauryl Citrate, Trilinoleic Acid, Trilinolein, Trimethylolpropane, Triisostearate, Trimethylolpropane, Trioctanoate, Trimethyl siloxysilicate, Trimyristin, Trioctyl Citrate, Triolein, Trioleyl Phosphate, Tripalmitin, Tristearin, Tristearyl Citrate, Vegetable Oil, Walnut Oil, Wheat Bran Lipids, Wheat Germ Oil
Glide-Enhancing Agents
Micronized beads, polytetrafluoroethylene (PTFE), glass, polyethylene, silicone elastomers (9506 Dow Corning), Dry-Flo PC (National Starch and Chemical)
Exfoliants
Almond Meal, Alumina, Aluminum Silicate, Barley Flour, Calcium Carbonate, Calcium Phosphate, Calcium Pyrophosphate, Calcium Sulfate, Chalk, Corn Cob Meal, Corn Flour, Corn Meal, Corn Starch, Diatomaceous Earth, Dicalcium Phosphate, Dicalcium Phosphate Dihydrate, Fullers Earth, Hydrated Silica, Magnesium Trisilicate, Oat Bran, Oat Flour, Oatmeal, Peanut Flour, Pecan Shell Powder, Pumice, Rice Bran, Rye Flour, Silica, Sodium Silicoaluminate, Soy Flour, Tricalcium Phosphate, Walnut Shell Powder, Wheat Bran, Wheat Flour, Wheat Starch, Zirconium Silicate
Absorbents
Natrasorb absorbent (American Starch), polyacrylamide, hydrogels, polyvinyl acetate, poly aspartate, polyethylene, Methocel absorbent (Dow Chemical) Aluminum Silicate, Aluminum Starch Octenylsuccinate, Bentonite, Calamine, Calcium Silicate, Cellulose, Chalk, Corn Starch, Cotton, Dextrin, Diatomaceous Earth, Fullers Earth, Glyceryl Starch, Hectorite, Hydrated Silica, Kaolin, Magnesium Aluminum Silicate, Magnesium Carbonate, Magnesium Hydroxide, Magnesium Oxide, Magnesium Silicate, Magnesium Trisilicate, Maltodextrin, Microcrystalline Cellulose, Montmorillonite, Oat Bran, Oat Flour, Oatmeal, Potassium Aluminum Polyacrylate, Potato Starch, Silica, Talc, Wheat Starch
Anticaling Agents
Alumina, Aluminum Behenate, Aluminum Caprylate, Aluminum Dilinoleate, Aluminum Distearate, Aluminum Isostearates/Laurates/Palmitates, Aluminum Isostearates/Laurates/Stearates, Aluminum Isostearates/Myristates, Aluminum Isostearates/Palmitates, Aluminum Isostearates/Stearates, Aluminum Lanolate, Aluminum Myristates/Palmitates, Aluminum Silicate, Aluminum Starch Octenylsuccinate, Aluminum Stearate, Aluminum Stearates, Aluminum Tristearates, Ammonium Xylenesulfonate, Calcium Behenate, Calcium Stearate, Distarch Phosphate, Lithium Stearate, Magnesium Aluminum Silicate, Magnesium Cocoate, Magnesium Lanolate, Magnesium Myristate, Magnesium Palmitate, Magnesium Silicate, Magnesium Stearate, Magnesium Tallowate, Magnesium Trisilicate, Microcrystalline Cellulose, Silica, Talc, Zinc Laurate, Zinc Myristate, Zinc Neodecanoate, Zinc Rosinate, Zinc Stearate
Biological Extracts
Acerola, Agrimony Extract, Alfalfa Extract, Algae Extract, Aloe, Aloe Extract, Aloe Vera Gel, Althea Extract, Amniotic Fluid, Amylase, Angelica Extract, Animal Tissue Extract, Anise Extract, Apple Extract, Apricot Extract, Arbutus Extract, Arnica Extract, Artichoke Extract, Asafoetida Extract, Asparagus Extract, Avens Extract, Avocado Extract, Azulene, Balm Mint Extract, Banana Extract, Basil Extract, Bearberry Extract, Benzoin Extract, Berberis Extract, Bilberry Extract, Bioflavinoids, Biotin, Birch Bark Extract, Birch Extract, Birch Leaf Extract, Birch Sap, Bisbolol, Bisstort Extract, Bitter Almond Extract, Blackberry Extract, Black Currant Extract, Black Mustard Extract, Black Walnut Extract, Bladderwrack Extract, Blessed Thistle Extract, Blue Cohosh, Borage Extract, Brain Extract, Broom Extract, Buckbean Extract, Buckthorn Extract, Buckwheat Extract, Bugloss Extract, Burdock Root Extract, Butcherbroom Extract, Cabbage Extract, Cabbage Rose Extract, Cabbage Root Extract, Calendula Extract, Calfskin Extract, Capsicum Extract, Capsicum Oleoresin, Carob Extract, Carrot Extract, Carrot Juice, Carrot Oil, Carrot Seed Extract, Celandine Extract, Chamomile Extract, Chapparel Extract, Chaulmoogra Oil, Chicory Extract, Chinese Tea Extract, Cholecalciferol, Cinchona Extract, Clematis Extract, Clover Blossom Extract, Cocoa Extract, Colocynth Extract, Coltsfoot Extract, Coltsfoot Leaf Extract, Comfrey Extract, Comfrey Leaf Extract, Condurango Extract, Coneflower Extract, Corn Germ Extract, Corn Poppy Extract, Corn Silk Extract, Couch Grass Root Extract, Crane's Bill Extract, Crataegus Extract, Cream, Cucumber Extract, Cucumber Juice, Cumin Extract, Curled Dock Extract, Cutaneous Lysate, Cyanocobalamin, Cypress Extract, Daisy Extract, Dandelion Root, DNA, Drosera, Drosera Extract, Dulcamara Extract, Eggplant Extract, Elm Bark Extract, Embryo Extract, English Oak Extract, Ergocalciferol, Escin, Esculin, Eucalyptus Extract, Euphrasia Extract, Everlasting Extract, Faba Bean Extract, Fennel Extract, Fenugreek Extract, Field Poppy Extract, Fig Extract, Folic Acid, French Rose Extract, Fumitory Extract, Galega Extract, Garlic Extract, Gentian Extract, Geranium Extract, Gingko Extract, Ginseng Extract, Glycyrrhetinic Acid, Goldenrod Extract, Gourd Extract, Goutweek Extract, Grape Extract, Grapefruit Extract, Grapefruit Seed Extract, Grape Juice, Grape Leaf Extract, Great Burnet Extract, Green Bean Extract
Buffering Agents
Aluminum Glycinate, Aluminum Lactate, Ammonium Acetate, Ammonium Carbonate, Ammonium Phosphate, Boric Acid, Calcium Phosphate, Diammonium Citrate, Diammonium Phosphate, Diethanolamine Bisulfate, Disodium Phosphate, Disodium Pyrophosphate, Ethanolamine HCl, Glycine, Potassium Bicarbonate, Potassium Biphthalate, Sodium Acetate, Sodium Aluminum Lactate, Sodium Bicarbonate, Sodium Lactate, Sodium Phosphate, Sodium Tartrate, Sodium Trimetaphosphate, Tetrapotassium Pyrophosphate, Tetrasodium Pyrophosphate
Oil Absorbers
Polytrap absorber (Applied Polymer Systems), Microsponge absorber (Applied Polymer Systems), Sebumase absorber (US Cosmetics), silicone elastomers (e.g., 9506 Dow Corning), Guar Gum, Nylon or other synthetic fibers
Cooling Agents
Menthol, Frescolate, Methyl Salicylate
Heat generating agents
Capsasin, Zeolites
Fragrances
Microencapsulated Fragrances (Giavodan), various fragrance and essential oils
Antiperspirant and/or Deodorant Efficacy Enhancers
Calcium Chloride, Copper Sulfate, Strontium, Aluminum Salts, Tricolsan, Cetyl Pyridinium Chloride, Phenoxyethanol, Phospholipid PTC, Chlorhexidine Salts, Citric Salts
Anti-stain/Anti-oxidants
Vitamin E
Materials to be Added to Fragrance Encapsulants or Aluminum Salts
Adenosine Phosphate, Adenosine Triphosphate, Alanine, Albumen, Aldioxa, Allantoin, Allantoin Ascorbate, Allantoin Biotin, Allantoin Calcium Pantothenate, Allantoin Galacturonic Acid, Allantoin Glygyrrhetinic Acid, Allantoin Polygalacturonic Acid, Aloe, Animal Collagen Amino Acids, Animal Elastin Amino Acids Animal Keratin Amino Acids, Arginine, Asparagine, Aspartic Acid, C10-11 Isoparaffin, C10-13 Isoparaffin, C11-12 Isoparaffin, C11-13 Isoparaffin, C12-14 Isoparaffin, Camphor, Caprylyl/Capryl Glucoside, Casein, Cetyl Betaine, Chlorodeceth-14, Cholesterol, Cocamidoethyl Betaine, Cocamidopropyl Betaine, Cocamidopropyl Hydroxysultaine, Cocamidopropyl Hydroxysultaine, Cocamidopropyl Lauryl Ether, Coco-Betaine, Coco/Oleamidopropyl Betaine, Coco-Sultaine, Cod Liver Oil, Cycteine, Cycteine HCl, Cystine, Decyl Betaine, Desamido Animal Collagen, Dicapryloyl Cystine, Diethyl Aspartate, Diethylene, Tricaseinamide, Diethyl Glutamate, Dihydrocholesterol, Dipalmitoyl Hydroxyproline, Disodium Adenosine Triphosphate, Dried Buttermilk, Dried Egg Yolk, Egg, Egg Oil, Egg Yolk, Egg Yolk Extract, Ethyl Aspartate, Ethyl Ester of Hydrolyzed Animal Protein, Ethyl Glutamate, Ethyl Serinate, Ethyl Urocanate, Folic Acid, Fructose, Glutamic Acid, Glutamine, Glyceryl Lanolate, Glycine, Glycogen, Guanosine, Hexamethyldisiloxane, Hexyl Nicontinate, Histidine, Human Placental Protein, Hyaluronic Acid, Hydrogenated Animal Glyceride, Hydrogenated Honey, Hydrogenated Palm Oil, Hydrogenated Tallow Betaine, Hydrogenated Tallowtrimonium Chloride, Hydrogenated Laneth-5, Hydrolyzed Animal Elastin, Hydrolyzed Animal Keratin, Hydrolyzed Animal Protein, Hydrolyzed Casein, Hydrolyzed Human Placental Protein, Hydrolyzed Mucopolysaccarides, Hydrolyzed Silk, Hydrolyzed Soy Protein, Hydrolyzed Vegetable Protein, Hydrolyzed Yeast Protein, Hydroxylated Lanolin, Hydroxyproline, Isobutylated Lanolin Oil, losleucine, Isostearamindopropyl Betaine, Isostearyl Diglyceryl Succinate, Keratin, Laneth-4 Phosphate, Laneth-5, Lanolinamide DEA, Lanosterol, Lard Glycerides, Lauramidopropyl Betaine, Lauryl Aminopropylglycine, Lauryl Betain, Lauryl Diethylenediaminoglycine, Lauryl sultaine, Lecithin, Leucine, Linoleic Acid, Linolenic Acid, Lysine, Magnesium Aspartate, Magnesium Lanolate, Magnesium Sulfate, MEA-Hydrolyzed Animal Protein Methionine, 2-Methyl-4-Hydroxypyrrolidine, Milk, Mixed Isopropanolamines Lanolate, Mixed Mucopolysaccarides, Monosaccharide Lactate Condensate, Myristamidopropyl Betaine, Myristyl Betaine, Niacinamide, Nonfat Dry Milk, Norvaline, Oleamidopropyl Betaine, Oleamidopropyl Hydroxysultaine, Oleyl Betaine, Orotic Acid, Palmamidopropyl Betaine, Palmitalmidopropyl Betaine, Palmitalmidopropyl Dimethyl amine, Palmitoyl Animal Collagen Amino Acids, PEG-5 Hydrogenated Lanolin, PEG-10 Hydrogenated Lanolin, PEG-2 Milk Solids, PEG-6 Soya Sterol Undecylenated, Phenylalanine, Polyglyceryl-2 Lanolin Alcohol Ether, Potassium Aspartate, Potassium Caseinate, Potassium DNA, PPG-9, PPG-12, PPG-15, PPG-17, PPG-20, PPG-26, PPG-30, PPG-34, PPG-2-Buteth-3, PPG-3-Buteth-5, PPG-5-Buteth-7, PPG-7-Buteth-10, PPG-9-Buteth-12, PPG-12-Buteth-16, PPG-15-Buteth-20, PPG-20-Buteth-30, PPG-24-Buteth-27, PPG-26-Buteth-26, PPG-28-Buteth-35, PPG-33-Buteth-45, PPG-4 Butyl Ether, PPG-5 Butyl Ether, PPG-9 Butyl Ether, PPG-14 Butyl Ether, PPG-15 Butyl Ether, PPG-16 Butyl Ether, PPG-18 Butyl Ether, PPG-22 Butyl Ether, PPG-24 Butyl Ether, PPG-30 Butyl Ether, PPG-33 Butyl Ether, PPG-40 Butyl Ether, PPG-53 Butyl Ether, PPG-2 Isostearate, PPG-10 Methyl Glucose Ether, PPG-20 Methyl Glucose Ether, PPG-20 Methyl Glucose Ether Acetate, PPG-2 Myristyl Ether Propionate, Pregnenolone Acetate, Proline, Pyridoxine, Pyridoxine Dicaprylate, Pyridoxine Dilaurate, Pyridoxine Dioctenoate, Pyridoxine Dipalmitate, Pyridoxine HCl, Pyridoxine Tripalmitate, Resorcinol Acetate, Teinol, Teinyl Acetate, Retinyl Palmitate, Ribonucleic Acid, Ricinoleamidopropyl Betaine, Salicylic Acid, Serine, Serum Albumin, Serum Proteins, Silk, Silk Amino Acids, Silk Powder, Sodium Caseinate, Sodium Chondroitin Sulfate, Sodium DNA, Sodium Gluconate, Sodium Glutamate, Sodium Hyaluronate, Sodium Lactate Methylsilanol, Sodium Laneth Sulfate, Sodium Mannuronate, Methylsilanol, Sodium PCA Methylsilanol, Sodium Riboflavin Phosphate, Sodium Urocanate, Soluble Animal Collagen, Sorbitol, Soyaethyl Morpholinium Ethosulfate, Soy Protein, Seartamidoethyl Diethylamine, Stearamidoethyl Diethylamine Phosphate, Stearamidopropyl Betaine, Stearamidopropyl Dimethyl amine, Stearyl Betaine, Sulfur, Sulfarized Jojoba Oil, Tall Oil Sterol, Tallowamidopropyl Betaine Tallowimidopropyl hydroxysultaine, Thiamine HCl, Thiamine Nitrate, Threonine, Tocopheryl Acetate, Tocopheryl Linoleate, Tocopheryl Niotinate, Tocopheryl Succinate, Tridecyl Salicylate, Tridecyl Stearate, Tryptophan, Tyrosine, Undecylenyl Alcohol, Undecylpentadecanol, Uric Acid, Urocanic Acid Vegetable Oil, Wheat Chermanidopropyl Betaine, Wheat Germanidoproyl Dimethylamine Lactate, Whey Protein Whole Dry Milk, Witch Hazel Distillate, Witch Hazel Extract | A dispensing system is provided for a multi-component product. The dispensing system includes (a) a body, containing a first component of the product and having a dispensing end constructed to apply a portion of the first component to a surface; and (b) a cap, constructed to cover the dispensing end, containing a reservoir adapted to receive a second component of the product and being constructed to apply a portion of the second component to the dispensing end prior to applying the first component to the surface. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a debris stripping device configured for attachment to a rake for stripping debris from the rake head. More particularly, the present invention is directed toward a rake stripper capable of being adjusted for use with rakes and rake heads of varying sizes.
2. Discussion of the Prior Art
Prior art rake attachments for stripping debris from a rake have been known for quite some time. For example, U.S. Pat. No. 695,139 to Benson (the Benson patent) was issued in 1902 and is directed to such a rake attachment. The Benson patent discloses the use of an ejector formed from a metallic wire loop that engages the front and back sides of the rake tines so that as the ejector is moved from a retracted position to an extended position, debris is removed from the tines.
More recently, U.S. Pat. No. 4,165,598 to Kutsi (the Kutsi patent) discloses a rake attachment for stripping debris from a rake. The attachment employs a plate fitted about the tines so that as it is moved from a retracted position to an extended position, the plate urges debris from the tines.
Such prior art devices, however, are constructed to be of a fixed size and do not provide a means for ready adjustment so that the same attachment may be used on rakes of varying sizes. There is a need for an adjustable rake stripping attachment having a relatively simple design for ease of use and construction. The present invention is directed toward such a device.
BRIEF SUMMARY OF THE INVENTION
A new and improved rake stripper for cleaning debris from a rake broadly comprises a cleaning member pivotally coupled with the handle of a conventional rake for movement between a first, retracted position and a second, extended position. The cleaning member includes a pair of cleaning elements positioned relatively close to at least a portion of the tines of the rake so that as the cleaning member is moved between the retracted and extended positions, the debris is cleaned from the rake tines.
The cleaning elements each present a proximal end and a distal end. The distal ends of the elements define the width of the cleaning member. The cleaning member further includes a bracket as an adjustment means for adjusting the width of the cleaning member. The bracket presents a longitudinal axis and is used for selectively positioning the distal ends of the cleaning elements along a line generally parallel to the longitudinal axis of the bracket for adjustment of the width of the cleaning member. As a result, the rake stripper is capable of being fitted to rakes of varying sizes. In addition, a rake stripper constructed in accordance with the present invention having its cleaning member set for use on a relatively large rake may be removed from that large rake, and the cleaning member adjusted to a smaller width for use on a smaller rake, further increasing the utility of the inventive stripper.
A biasing member is used to couple the cleaning member to the rake handle, permitting movement between the retracted and extended positions. In addition, the biasing member is used as a biasing means for biasing the cleaning member toward the retracted position. The rake stripper is deployed by forcing the cleaning member from the retracted position toward the extended position, so that the cleaning elements scrape debris from the tines of the rake. Such deployment may be actuated by rotating the rake 180° about its longitudinal axis and contacting the exposed biasing member with the ground thereby forcing the cleaning member to move from the retracted position to the extended position. Removal of the deployment force permits the biasing member to return the cleaning member to the retracted position for later use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a rake stripper constructed in accordance with a preferred embodiment of the present invention coupled with a rake;
FIG. 2 a is a perspective view of the stripper of FIG. 1 showing the cleaning member in the retracted position;
FIG. 2 b is a perspective view of the stripper of FIG. 1 showing the cleaning member in the extended position;
FIG. 3 a is a perspective view of the stripper of FIG. 1 wherein the cleaning member is adjusted to a relatively narrow width;
FIG. 3 b is a perspective view of the stripper of FIG. 1 wherein the cleaning member is adjusted to a relatively wide width;
FIG. 4 a is an exploded view of the stripper of FIG. 1 ;
FIG. 4 b is an isolated fragmentary view of the stripper on an enlarged scale taken along the line as depicted in FIG. 4 a;
FIG. 5 is a perspective view of the rake stripper constructed in accordance with an alternative embodiment of the present invention; an
FIG. 6 is a perspective view of the rake stripper constructed in accordance with another alternative embodiment of the present invention; and
FIG. 7 is a perspective view of a rake stripper constructed in accordance with another alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIG. 1 depicts a rake stripper 10 constructed in accordance with a preferred embodiment of the present invention attached to a rake 12 having a handle 14 and a rake head 15 with a plurality of tines 16 . The stripper 10 includes a cleaning member 18 having an open-ended, hollow bracket 20 and a pair of cleaning element bars 22 , 24 received in the ends of the bracket 20 . The cleaning bars 22 , 24 are constructed from generally rigid material.
The cleaning member 18 is attached to the rake handle 14 by a biasing member 26 . The biasing member 26 includes a cantilevered-spring 28 and an integral bracket support 30 for supporting the bracket 20 thereby positioning the cleaning member 18 in close proximity to the tines 16 of the rake 12 . The spring 28 is preferably constructed from spring steel having memory, or other suitable material providing appropriate strength and memory. The spring 28 permits movement of the cleaning member 18 between a retracted position, as shown in FIG. 2 a , and an extended position, as shown in FIG. 2 b . In addition, the spring 28 biases the cleaning member 18 toward the retracted position.
The support 30 includes a generally T-shaped end (not shown) for supporting the bracket 20 . The T-shaped end of the support 30 permits relatively easy assembly of the stripper 10 while causing the cleaning member 18 to move between the retracted and extended positions as the spring 28 is deflected and released. The bracket 20 may be fixed to the support 30 by screws, rivets, nuts and bolts or other conventional fastening devices known in the art. It will be appreciated that by providing a T-shaped end, the support 30 presents more surface area and a greater linear length for installation of the fastening devices, thereby strengthening the rake stripper 10 .
The cleaning member 18 is adjustable between a relatively narrow width and a relatively wider width. FIG. 3 a depicts the cleaning member 18 in a narrow condition wherein the cleaning bars 22 , 24 are fully inserted into the bracket 20 . Such a condition may be desired when the stripper 10 is attached to a rake 12 having a relatively narrow head 15 , or to yield more stability to the stripper 10 for concentrated cleaning of the center section of the head 15 .
FIG. 3 b shows the cleaning member 18 adjusted so that the cleaning bars 22 , 24 span the entire width of the rake head 15 . Such a condition may be desired when the rake head 15 is relatively wide, or when the debris stripping capabilities of the stripper 10 are desired over the span of the rake head 15 .
As revealed in FIGS. 4 a and 4 b , the bracket 20 is hollow and presents a generally rectangular-shaped cross section. A plurality of adjustment holes 32 extend through the upper face of the bracket 20 .
The cleaning bars 22 , 24 each present a distal end 34 and a proximal end 36 . The distal end 34 is generally s-shaped so that in use, the end 34 engages the front side of a portion of the tines 16 and the back side of another portion of the tines 16 . The proximal ends 36 of the bars 22 , 24 are received for telescopic movement within the interior of the bracket 20 so that the bars 22 , 24 may be moved between a narrow position, shown in FIG. 3 a , and a wide position, shown in FIG. 3 b.
The proximal ends 36 have a groove 38 defined therein for engaging the support 30 when in the narrow position. A retaining button 40 is also positioned in a recess located on each of the proximal ends 36 of the bars 22 , 24 . The buttons 40 are configured for locking the bars 22 , 24 in a desired position. The grooves 38 provide flexibility at the proximal ends 36 of the bars 22 , 24 when the buttons 40 are depressed such that the bars may be slidably adjusted. The buttons 40 are conventional and are biased toward the extended position shown in FIG. 4 b . The buttons 40 have an outer circumference slightly smaller than the inner circumference of the adjustment holes 32 . As a result, when the bars 22 , 24 are inserted into the bracket 20 , the buttons 40 are configured to reside within a desired adjustment hole 32 locking the bars in position. Depressing the appropriate button 40 permits the bars 22 , 24 to be moved so that the button 40 may be aligned with another hole 32 , thereby adjusting the width of the cleaning member 18 .
When in the narrow position, as shown in FIG. 3 a , the grooves 38 engage the T-shaped end of the support 30 . This construction yields a relatively rigid connection between the support 30 and bracket 20 , while keeping the relative size of the bracket 20 when compared with the cleaning bars 22 , 24 and permitting a larger range of telescopic motion in the bracket 20 than if the bars 22 , 24 did not have the grooves 38 .
In use, the stripper 10 is attached to the handle 14 of a rake 12 so that the cleaning member 18 is adjacent to the rake head 15 . A fastening device is preferably used to secure the biasing member 26 to the handle 14 . Prior to attachment, the cleaning bars 22 , 24 are adjusted to an appropriate length so that the cleaning member 18 is of a similar length to that of the rake head 15 . Once attached, the distal ends 34 of the cleaning bars 22 , 24 are adjacent to the outer-most tines 16 of the rake head 15 . Should the rake 12 become worn or broken and in need of replacement, it will be appreciated that the rake stripper 10 may be easily removed from the rake 12 for use on another rake. Furthermore, the length of the cleaning member 18 of the stripper 10 may be adjusted so that the stripper 10 may be used on a replacement rake having different size than that of the original rake 12 , greatly increasing the utility of the stripper 10 .
In an alternative form the bracket and cleaning bars of the cleaning member may be incorporated in a unitary structure wherein the outer ends of the cleaning member utilize breakaway tabs ( 25 ) to yield adjustability (FIG. 7 ). While such a design would only permit adjustment of the length of the cleaning member downwardly, it would provide a degree of adjustability and relatively lower costs due to fewer parts. The breakaway tabs of such an alternative cleaning member would be broken away at the time of installation so that the cleaning member would be of a suitable size for the rake to which the stripper is attached.
Turning now to FIG. 5 , an alternative rake stripper 42 is depicted attached to the rake 12 . The stripper 42 broadly includes a cleaning member 44 having a plurality of cleaning element wires 46 and a bracket 48 . The wires 46 each present a distal end 50 and a proximal end 52 . The proximal ends 52 are received in a clamp 54 configured for attachment to the rake handle 14 . It will be appreciated that the clamp 54 and bracket 48 keep the wires 46 in a generally co-planar configuration. The wires 46 are of varying lengths with the shortest wires 46 positioned in the center portion of the stripper 42 and the longer wires 46 positioned toward the outer edges of the stripper 42 permitting the wires 46 to be fanned while keeping the distal ends 50 positioned generally along a common line and also aligned with the tines 16 .
The bracket 48 includes opposed, upper and lower halves 56 , 58 that are fastened together by conventional means for clamping the wires 46 adjacent to the distal ends 50 thereof. Deflection flanges 60 , 62 are mounted on the upper half 56 of the bracket 48 .
The bracket 48 and distal ends 50 of the wires 46 cooperatively define the cleaning member 44 , the width of which is defined by the two distal ends 50 that lie along the outer edges of the array of wires 46 . By unfastening the halves 56 , 58 of the bracket 48 , the bracket 48 may be moved back and forth along the wires 46 permitting increased or decreased fanning of the wires 46 . As a result, the bracket 48 provides an adjustment means for adjusting the width of the cleaning member 44 . While movement of the bracket 48 along the wires 46 will not keep the distal ends 50 in perfect alignment due to their geometry, the ends 50 will stay in general alignment while providing various options with regard to the width of the cleaning member 44 .
The proximal ends 52 of the wires 46 are constructed from material that is relatively flexible, with memory. Therefore the proximal ends 52 permit movement of the cleaning member 44 between a retracted position and an extended position, and provide a means for biasing the cleaning member 44 toward the retracted position.
In use, the rake 12 is rotated 180°, and the deflection flanges 60 , 62 are pressed against the ground, thereby moving the cleaning member 44 from the retracted position toward the extended position, scraping debris from the tines 16 of the rake 12 . Removal of the deflection force allows the cleaning member 44 to be brought back to the retracted position.
FIG. 6 shows a rake stripper 63 constructed in accordance with another alternative embodiment of the present invention. The distal ends 50 of the wires 46 of the stripper 63 define loops 64 that loop about the tines 16 when the stripper 42 is attached to the rake 12 . It will be appreciated that the alternative stripper 63 functions in much the same way as the stripper 42 . By incorporating the loops 64 , the stripper 63 provides relatively more surface area for stripping debris from the tines 16 than the stripper 42 of FIG. 5 .
Although the invention has been described in the above preferred embodiment with reference to the drawing figures, it is understood that substitutions may be made and equivalents employed herein with departing from the scope of the invention as set forth in the following claims. | A rake stripper includes a cleaning member pivotally coupled to a rake handle for movement between a retracted position and an extended position. The cleaning member includes a pair of cleaning elements positioned relatively close to the tines of the rake for cleaning debris therefrom as the cleaning member is moved between retracted and extended positions. The cleaning member includes a bracket for telescopically permitting adjustment of the width of the cleaning member. A biasing member couples the cleaning member to the rake handle, permitting movement between retracted and extended positions. The biasing member biases the cleaning member toward the retracted position. The cleaning member scrapes debris from the tines when the cleaning member is forced from the retracted position toward the extended position. Removal of the deployment force permits the biasing member to return the cleaning member to the retracted position. | 0 |
FIELD OF THE INVENTION
[0001] The present invention is directed to an edible emulsion having reduced levels of oil and cholesterol. More particularly, the present invention is directed to an edible emulsion comprising 75.0% by weight oil, or less, and typically less than 4.0% by weight of liquid emulsifier. The edible emulsion of the present invention, unexpectedly, is excellent tasting, able to maintain a viscosity of at least about 4,500 cps in the absence of starch, and substantially free of cholesterol and carbohydrates.
BACKGROUND OF THE INVENTION
[0002] Obesity is a concern for men, women and children in many nations. There is a trend, therefore, for food manufactures to formulate products with reduced levels of fat in order to minimize caloric intake. Reduced fat products, unfortunately, tend to have characteristics (e.g., flavor and texture characteristics) that are inferior to those of full-fat and calorie products. For example, mayonnaise compositions (which traditionally have about 80.0% by weight oil) have been formulated with reduced levels of oil. When the oil content of the composition is less than 65.0% by weight, the mayonnaise composition cannot be classified as real (the standard of identity for real mayonnaise requires at least 65.0% by weight oil) and starch and/or other thickeners are usually required to obtain a consumer acceptable viscosity.
[0003] When the oil levels are reduced within a real mayonnaise range (e.g., 65.0% to 75.0% by weight), emulsifier, like egg yolk, is typically required at a level which is at least (in liquid form) 4.0% by weight of the total weight of the mayonnaise composition so that a product with a consumer acceptable viscosity can be obtained and maintained over the shelf-life of the product. High levels of egg yolk, however, typically result in a mayonnaise composition that is high in cholesterol.
[0004] There is increasing interest to develop an edible emulsion that has reduced levels of oil and cholesterol, but which also has the characteristics of a full-fat emulsion. This invention, therefore, is directed to an edible emulsion comprising 75.0% by weight oil, or less, and less than 4.0% by weight liquid emulsifier. The edible emulsion of this invention is, unexpectedly, excellent tasting, able to maintain a viscosity of at least about 4,500 cps in the absence of starch, and substantially free of cholesterol and carbohydrate.
[0000] Additional Information
[0005] Efforts have been disclosed for making edible emulsions. In U.S. Pat. No. 4,923,707, mayonnaise compositions with corn syrup having a low D.E. are described.
[0006] Other efforts have been disclosed for making edible emulsions. In International Application No. WO 02/39833, described are mayonnaise compositions with levels of liquid egg yolk at 4.0% by weight, or more, and dry matter content of emulsifier at 2.0% by weight, or more.
[0007] Still other efforts have been disclosed for making edible emulsions. In U.S. application No. 2002/0127324, a process for making emulsified spoonable and pourable dressings is described.
[0008] None of the additional information above describes an edible emulsion having reduced levels of oil and cholesterol, and particularly, 75.0% by weight oil, or less, and less than 4.0% by weight of liquid emulsifier whereby the edible emulsion is able to maintain a viscosity of at least about 4,500 cps.
SUMMARY OF THE INVENTION
[0009] In a first aspect, the present invention is directed to an edible emulsion comprising 75.0% by weight oil, or less, and less than 4.0% by weight liquid emulsifier wherein the edible emulsion has a viscosity of at least about 4,500 cps.
[0010] In a second aspect, the present invention is directed to an edible emulsion comprising 75.0% by weight oil, or less, and less than 2.0% by weight dry matter content of emulsifier wherein the edible emulsion has a viscosity of at least about 4,500 cps.
[0011] In a third aspect, the present invention is directed to a method for making the edible emulsions described in the first two aspects of this invention.
[0012] Emulsion, as used herein, means a suspension or dispersion of one liquid within a second immiscible liquid and is preferably an oil-in-water or water-in-oil-in-water emulsion, and most preferably, an oil-in-water emulsion. Substantially free of cholesterol means less than about 6.0 mg of cholesterol in a 15.0 ml serving. Substantially free of carbohydrates means less than about 1.0 g of carbohydrate per 15.0 ml serving. Oil, as used herein, means triglycerides, and especially, those that are liquids at ambient temperature. Emulsifier, as used herein, means an agent suitable to promote the formation of an emulsion, and not egg white. Full-fat, as used herein, means over 75.0% by weight oil, based on total weight of the edible emulsion. Viscosity, as used herein, means rheological properties of a product taken on a Haake Rheometer (Rotovisco RV20) at room temperature using a set of concentric cylinders (or bob-in-cup) with a 1 mm gap, the bob having a diameter of 1.0 cm and length of 1.0 cm. The inner cylinder or bob starts rotating from zero shear rate and ramps up to a shear rate of 134 sec −1 in 542 sec. By way of comparison, the viscosity values refer to the shear rate of 10 sec −1 . Has or is able to maintain a viscosity of at least about 4,500 cps means has a viscosity of at least about 4,500 cps for at least about three weeks after being stored at ambient temperature
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The only limitation with respect to the type of oil used to make the edible emulsion of this invention is that the oil is suitable for human consumption. Illustrative examples of the types of oil which may be used in this invention include, without limitation, those which are liquid at ambient temperature like avocado, mustard, coconut, cottonseed, fish, flaxseed, grape, olive, palm, peanut, rapeseed, safflower, sesame, soybean, sunflower, mixtures thereof or the like.
[0014] Other types of oils which may be used in this invention are solid at ambient temperature. Illustrative examples of the oils which are solid at room temperature and suitable for use in this invention include, without limitation, butter fat, chocolate fat, chicken fat, coconut oil, hydrogenated palm kernel oil, mixtures thereof or the like.
[0015] In a preferred embodiment, the oil used in this invention is a liquid at ambient temperature. In a most preferred embodiment, the oil used in this invention is soybean, sunflower or rapeseed oil or a mixture thereof.
[0016] The amount of oil used in the edible emulsion of this invention is typically at least about 65.0% by weight to 75.0% by weight, based on total weight of the edible emulsion and including all ranges subsumed therein. Preferably, the amount of oil employed in the edible emulsion is from about 65.0% to about 74.0%, and most preferably, from about 65.0% to about 72.5% by weight, based on total weight of the edible emulsion and including all ranges subsumed therein.
[0017] The water used in this invention can be pure water, tap water, bottled water, deionized water, spring water, or a mixture thereof. Thus, the water used in this invention may be an aqueous solution comprising salts or minerals or both. Typically, water makes up the balance of the edible emulsion with reduced fat and cholesterol.
[0018] The emulsifier suitable for use in this invention often has an HLB of greater than about 8.0, and preferably, greater than about 11.0, and most preferably, from about 12.0 to about 18.0, including all ranges subsumed therein. Illustrative examples of the types of emulsifier suitable for use in this invention include protein, like fruit, vegetable, milk (e.g., whey) or soy protein and other natural and synthetic food emulsifiers, or mixtures thereof.
[0019] Other emulsifiers suitable for use in this invention include phospholipid, whole egg (egg white not being emulsifier), egg yolk or a mixture thereof. In a preferred embodiment, the emulsifier comprises egg yolk having been modified with enzymes or by fermentation. In an especially preferred embodiment, the emulsifier is egg yolk or egg yolk in whole egg whereby the same has been modified with phospholipase A2 to convert egg yolk lecithin to lysolecithin. Illustrative examples of the types of enzymes which can be used to convert the egg yolk lecithin to lysolecithin are Lecitase, and Lysomax, made commercially available by Novo Nordisk and Genencor, respectively. An additional description of modified eggs suitable for use in this invention may be found in U.S. Pat. No. 5,028,447, the disclosure of which is incorporated herein by reference.
[0020] In a preferred embodiment, the emulsifier used in this invention is a liquid egg blend comprising enzyme modified egg yolk, egg white and salt wherein the same typically makes up from about 3.5% to about 5.0% by weight of the edible emulsion, including all ranges subsumed therein. In another preferred embodiment, the emulsifier of the present invention is from about 2.0% to about 3.75% by weight liquid egg yolk, and most preferably from about 2.75% to about 3.40% by weight liquid egg yolk, based on total weight of the edible emulsion, and including all ranges subsumed therein. In yet another preferred embodiment, the emulsifier employed in the present invention comprises, in dry form, from about 1.25% to less than 2.00% by weight dry egg yolk (i.e., dry matter content of emulsifier), and most preferably, from about 1.35% to about 1.65% by weight dry egg yolk, based on total weight of the edible emulsion and including all ranges subsumed therein.
[0021] Optional additives suitable for use in this invention include acidulants like acetic acid, citric acid, hydrochloric acid, lactic acid, malic acid, phosphoric acid, glucono-delta-lactone, mixtures thereof or the like. Typically enough acidulant is added to the edible emulsion of this invention to produce an emulsion having a pH from about 2.5 to about 4.5, and preferably, a pH from about 2.8 to about 3.8. In a preferred embodiment, the acidulant employed is vinegar and/or lemon juice, which typically and collectively makes up from about 2.0% to about 3.5% by weight of the total weight of the edible emulsion.
[0022] Additional optional additives suitable for use in this invention include salt (and other spices and seasoning) vitamins, natural and artificial flavors (e.g., mustard flavor) and colors, preservatives, antioxidants, chelators like EDTA, meat like ham and bacon bits or particulates, buffering agents, protein sources, vegetable bits or particulates, fruit bits or particulates, cheese, mixtures thereof or the like. These additional optional additives, when employed, typically and collectively make up less than about 20.0% by weight of the total weight of the edible emulsion.
[0023] Still other optional additives suitable for use in this invention include sweeteners like fructose, lactose, glucose, saccharose, syrups, dextrose, lactose, levelose, maltose, saccharin, aspartame, sucralose, mixtures thereof or the like. The amount of sweetener is such that the resulting edible emulsion has less than about 1.0 g of carbohydrate in a 15.0 ml serving to no carbohydrate in a 15.0 ml serving.
[0024] When making the edible emulsion of the present invention, ingredients (e.g., acidulant, soybean oil, water, liquid egg blend, spices, chelator) are typically added to a mixing tank in no particular order and mixed to produce a premix. Usually, the premix is made at ambient temperature, atmosphere pressure, and under moderate shear. Preferably, some acidulant is mixed with flavor, spices and emulsifier to produce an emulsifier mixture to be added to the mixing tank. The premix is preferably then fed through an emulsifying mixer like a colloid mill, homogenizer (e.g., like those equipped with transversally arranged plates with bores of about 0.5 to 3.5 mm), or preferably, an in-line mixer/emulsifier having a means to vary the gap opening between its stator and rotor and a variable speed motor (such as the one described in U.S. application No. 2002/0127324 A1, the disclosure which is incorporated herein by reference). The resulting edible emulsion which exits the emulsifying mixer employed has oil droplets (at least about 85.0% of all oil droplets) having a diameter from about 2.5 microns to about 10.0 microns. In preferred embodiment, at least about 90.0% of all oil droplets present within the resulting edible emulsion have a diameter from about 3.0 to about 5.5 microns. In yet another preferred embodiment, an inert gas, like nitrogen, can be used to modify product texture and appearance.
[0025] Surprisingly, the viscosity of the edible emulsion of the present invention has (i.e., maintains) a viscosity of at least about 4,500 cps, and preferably, from about 6,000 cps to about 50,000 cps, and most preferably, from about 10,000 cps to about 35,000 cps (including all ranges subsumed therein) when no starch or thickeners, like gums and the like, are employed and less than 4.0% by weight liquid emulsifier (having, when dry, preferably about 1.25% to less than 2.0% by weight dry egg yolk) is used.
[0026] Also, it is within the scope of this invention for the edible emulsion to be a real mayonnaise composition that has the taste and viscosity of conventional real mayonnaise, notwithstanding the fact that the real mayonnaise of this invention has less fat and cholesterol when compared to conventional products.
[0027] It is further noted herein, that even though 75.0%, or less, oil is employed in the edible emulsion of this invention, and only about 1.25% to less than 2.0% by weight dry egg yolk may be used as emulsifier, the edible emulsion of this invention has a consumer acceptable viscosity and is not over-sheared to a point where the desired emulsion's stability is jeopardized.
[0028] The packaging for the edible emulsion of this invention is often a glass or plastic jar, food grade sachet or squeezable plastic bottle. Sachets are preferred for food service applications, and a plastic bottle is preferred for domestic use.
[0029] The examples which follow are provided to facilitate an understanding of the present invention. The examples are not intended to limit the scope of the claims.
EXAMPLE 1
[0030] Edible emulsions (mayonnaise compositions) having the following ingredients were made.
Ingredient Percent by Weight Soybean Oil 69.0-72.0 Modified liquid egg blend 4.3-4.7 Lemon juice 0.11-0.27 Vinegar 2.0-2.5 Salt 1.0-1.5 Sugar 2.0-2.5 Flavor 0.0075-0.0135 Water Balance
[0031] Emulsifier mixtures were made by combining, in no particular order, modified liquid egg blend, salt, sugar, lemon juice (about 50.0% of the total) and flavor. The emulsifier mixture was fed to a premix tank along with an acid phase having vinegar, the remaining lemon juice and the balance of the ingredients. The ingredients were mixed for about 2.0 minutes at ambient temperature and under moderate shear to produce pre-emulsions. The pre-emulsions were fed to an in-line mixer/emulsifier (e.g., Ross Mill) with gaps, of low rates and mill speed adjusted to yield an edible emulsion having at least 85.0% of its oil droplets with a diameter from about 2.5 microns to about 10.0 microns. The resulting edible emulsions were placed in 12 oz. glass jars and left at room temperature. The viscosities of the edible emulsions were about 29,000 cps after being checked at one, three and five week intervals.
EXAMPLE 2
[0032] Approximately 20 panelists tasted and visually assessed the edible emulsions of Example 1, comparing the same to Kraft's real mayonnaise and conventional Hellmann's real mayonnaise. The panelists unanimously concluded that the edible emulsions of this invention had the same texture as Kraft's real mayonnaise and Hellman's real mayonnaise. Unexpectedly, the panel also concluded that the edible emulsions of this invention (having less fat and cholesterol) had an acceptable mayonnaise taste, even with reduced fat and cholesterol. | An edible emulsion with a viscosity of 4,500 cps or higher is described. The edible emulsion has 75.0% by weight oil, or less, and less than 4.0% by weight liquid emulsifier. The edible emulsion has good color, texture and flavor characteristics and is substantially free of cholesterol and carbohydrates. | 0 |
PRIOR APPLICATION
This application is a U.S. national phase application based on International Application No. PCT/SE2004/000287, filed 3 Mar. 2004, claiming priority from Swedish Patent Application No. 0300581-6, filed 5 Mar. 2003.
TECHNICAL FIELD
This application relates to an arrangement for adjusting a rotor position in a rotating sluice.
THE PRIOR ART
It is necessary in pulp mills to sluice chips and other lignocellulose material, such as cooking liquor or other treatment liquors, between lines and vessels that maintain different pressures. Thus chips are sluiced through what is known as a low-pressure feed into a steaming vessel in which a certain vapour pressure is maintained, usually between 150 and 200 KPa. The chips together with cooking liquor are sluiced after the steaming process via a highpressure feed into the high-pressure system of the digester, where a considerably higher pressure is maintained. A high-pressure feed, i.e. a sluice feeder intended for use with large pressure differences, of a conventional type is shown in FIG. 1 and FIG. 2 . This feed corresponds to the type of feed revealed in SE,C,503684. It consists of a feed casing 1 and a rotor 2 , also known as a tap. This tap is divided into a number of pockets 3 in order to sluice in chips through an inlet opening 4 and cooking fluid through an inlet opening 5 via an outlet opening 6 to the pulp digester. The shaft of the tap is denoted by the number 7 . The general shape of the tap is that of a truncated cone, whose surface is denoted by the number 8 . This tap is brought into contact with a correspondingly cone-shaped congruent surface 9 in the feed casing 1 . The surfaces 8 and 9 are worn through friction between the surfaces 8 and 9 during rotation of the tap (means for achieving this rotation are not shown in the drawings). The setting of the tap must therefore be gradually adjusted by an axial displacement relative to the feed casing 1 . Up until the middle of the 1990s, different manually adjustable screw arrangements in adjustment equipment attached to one end of the shaft 7 of the tap have been used for this adjustment. These arrangements have in common that they required relatively large forces to adjust them, while at the same time providing, in many cases, only limited accuracy of adjustment. Systems have been developed in order to adjust the position of the tap automatically.
For example, the Swedish patent SE,C,512305(=U.S. Pat. No. 5,597,446) describes such an arrangement, in which an automatic wear adjustment, which is also dependent on time, of the position of the tap is revealed. An electric motor is used in this case that presses the rotor shaft inwards by a regulatory distance of 0.03-0.4 mm at suitable intervals of time, from 3 times per day to once every four days.
The adjustment concept specified in SE,C,512305 has been installed at approximately 20 pulp mills, and the principle of its execution in practice is shown in FIG. 3 . An electric motor 50 is used in this case, suspended on a ground-based frame 51 . The tap shaft 7 is rotated through a reduction gear 52 , this also being anchored to the ground-based frame, through a first connection 55 and a second connection 56 . The connection 55 is a flexible connection that can absorb vibrations and oblique orientation between the driving unit and the shaft 7 of the tap, where the driving unit (motor and gear) is located in a support fixed to the ground and the feed casing 1 is allowed to have a certain flexibility. The second connection 56 and the shaft 7 of the tap are allowed through a splines connection (the female half of the splines connection is shown cross-hatched in the drawing) to move to the right in FIG. 3 during adjustment for wear.
Detection of the current rotational position is carried out through a toothed wheel 53 that is attached to the shaft of the motor, and by a sensor 54 on the support that detects the rotational position of the disk 53 .
However, the adjustment servo as it is implemented as described in FIG. 3 will be relatively expensive since several different expensive connectors are required in order to connect the shafts between the driving unit that is attached to the ground and the shaft of the tap. In particular, the flexible connection is very expensive since it must be able to absorb the relatively large adjustment torque without any risk for play arising at the rotational position. Adjustment costs will also be unnecessarily high since installation of the adjustment servo requires on-site preparation during the completion of the ground-based frame.
PURPOSE AND AIM OF THE INVENTION
The present invention intends to offer a cheaper, better and considerably simpler adjustment servo for the compensation of wear in the sluice feeder. According to the invention, at least one connector and two expensive connections, relative to the previously known solution, can be eliminated. Preparations for installation and installation costs can be reduced to a minimum since a ground-based frame can be totally eliminated and the complete adjustment servo is instead suspended on the shaft of the tap with torque support in the feed casing. A splines connector can also be eliminated and replaced by a sliding bearing support that is fixed attached to the feed casing. In summary, an adjustment servo is obtained with the simplified design and the simplified installation procedure that costs only ⅓-⅕ of the equivalent cost for a previously known adjustment servo.
In contrast to the prior art, the complete driving package is suspended on the shaft of the tap and accompanies the educated sliding towards the sliding bearing support during adjustment of the position of the shaft of the tap.
DESCRIPTION OF FIGURES
FIG. 1 shows the principle of operation of a known sluice feeder;
FIG. 2 shows a side view of the sluice feeder shown in FIG. 1 ;
FIG. 3 shows how an adjustment servo of known design has been installed on a sluice feeder;
FIG. 4 shows a side view of the adjustment servo according to the invention;
FIG. 5 shows a view of the adjustment servo according to the invention as seen from above in FIG. 4 ;
FIG. 6 shows a view of the adjustment servo according to the invention that is a cross-sectional view perpendicular to VI-VI in FIG. 4 ;
FIG. 7 shows a view of the adjustment servo according to the invention that is a cross-sectional view perpendicular to VII-VII in FIG. 4 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention concerns an arrangement for a sluice feederer equivalent to the one shown in FIG. 1 and as has been previously described.
The sluice feederer is arranged to sluice material from a first upper region 4 with lower pressure to a second lower region 6 with higher pressure, where the sluice feeder comprises a rotor 3 with a rotor shaft 7 arranged in a feed casing 1 where the rotor has the form of a truncated cone arranged with rotational symmetry around the rotor shaft 7 with at least two pockets 3 in the rotor that are open radially towards the perimeter, and where the inner surface of the feed casing has a conical form congruent with that of the rotor with an inlet connected to the first region 4 and an outlet connected to the second region 6 , whereby a pocket on the rotor is initially filled with material from the first upper region and, following rotation of the rotor, delivers material to the second lower region.
The rotor is provided with an adjustment servo in a known manner for adjustment of the axial position of the rotor in the feed casing 1 in order to compensate for wear between the rotor and the feed casing hereby compensation of wear is obtained by adjustment of the axial position of the rotor such that play between the conical form of the rotor and the conical inner surface of the feed casing is reduced to a minimum.
The adjustment servo according to the invention is shown in different views in FIGS. 4 , 5 , 6 and 7 , which adjustment servo comprises a driving unit 60 and a gear 61 , which gear in this embodiment is a worm gear. The driving unit 60 , 61 is arranged directly connected to the rotor shaft 7 without a ground-based frame for the driving unit, through a journal 63 and a shaft sleeve 64 fixed attached to the journal. The shaft sleeve 64 is fixed with respect to rotation to the rotor shaft with a conventional cotter joint. According to the invention, at least one fixed torque support (two torque supports 70 a , 70 b are shown in the drawings) is arranged in the feed casing 1 , which torque support is arranged parallel to the rotor shaft 7 with an extent of the torque support from the feed casing 1 to the driving unit 60 , 61 , and that the driving unit makes contact with the torque support 70 a , 70 b when seen from the direction of rotation of the rotor/rotor shaft 7 .
The torque support is constituted by at least one torsionally rigid beam 70 a , 70 b , fixed arranged in the feed casing, preferably a hollow beam as the cross-sectional views in FIG. 6 and FIG. 7 make clear. Each beam is fixed arranged, appropriately by welding, to the relevant end of the feed casing onto a flange 80 that is attached by screwing to the feed casing using attachment screws 81 . FIG. 6 shows that the beams also have reinforcements 82 that, as is shown in FIGS. 4 and 5 , extend a certain distance from the beam at the free end of the beam. The complete torque support is thus constituted only by the flange 80 , the beams 70 a , 70 b and the reinforcements 82 , which are mounted with attachment screws 81 .
The torsionally rigid beam is designed to have an elongated surface of contact 71 , 72 on the beam that is parallel with the rotor shaft. In the embodiment shown, there are two torque supports in the form of torsionally rigid beams, which are arranged at a distance, in the embodiment shown at equal distances, from the centre of the rotor shaft 7 , and where each beam is located arranged on opposite sides of the centre of the rotor shaft.
Naturally, a different number of torque supports than two may be used, for example three torque supports, which are then appropriately arranged essentially evenly distributed around the rotor shaft, preferably with 120 degrees between the torque supports in the direction around the rotor shaft. As FIG. 5 makes clear, each beam 70 a , 70 b is designed with two parallel elongated contact surfaces 71 a and 71 b on both sides of the beam. In order for the driving unit to be able to absorb torque relative to the feed housing, the driving unit 60 , 61 is designed with a sliding support 73 a , 73 b and 74 a , 74 b that makes contact with the elongated contact surface of the beam. In the embodiment shown, these are constituted by the end surfaces of an adjustment screw.
The sliding support 73 a , 73 b and 74 a , 74 b straddles, in the embodiment shown, the interacting torque-absorbing beam and makes contact with the elongated contact surfaces on each side of the beam. Absorption of torque can in this way take place in both directions without any play arising.
In the embodiment shown, where the sliding support is in the form of the end surfaces of adjustment screws, it is easy to adjust the play between the sliding support of the driving unit and the elongated contact surface of each beam, and to lock the adjustment screws with the locking nut shown.
The complete driving unit will accompany the axial displacement of the rotor shaft during adjustment, while the sliding supports slide along the contact surfaces of the beam or beams 70 a , 70 b.
In accordance with the adjustment known from SE,C,512305 (=U.S. Pat. No. 5,597,446), an automated adjustment of wear can take place on the basis of time, in this case suitably with an adjustment magnitude of 0.03-0.4 mm, as often as an adjustment three times per day and up to an adjustment of once per four days. However, this method of adjustment has proven to be unsuitable and insensitive to changes in the process, since wear in the sluice feeder is far from uniform over a period of time, and depends on the tendency of the material being fed in at any moment to wear down the play between the rotor and the feed casing. Using strictly time-based adjustment, a displacement of the rotor is most often initiated at times when it is not justified, something that means that the sluice feeder is adjusted with too little play, giving not only an increased motor torque, which results in increased operating costs, but also increased wear on the sluice feeder (both rotor and casing). It is preferable that the adjustment be carried out in an adaptive manner depending on a parameter of the sluice feeder that depends on operation, and that is indicative of the degree of wear. This parameter can be constituted by one or several of the following parameters.
Parameter No. 1
The motor torque for driving the rotor of the sluice feeder. By monitoring the motor torque at a pre-determined production (rpm of the rotor), an adjustment can be initiated as soon as the motor torque constantly falls below a pre-determined threshold value during a certain minimum period. It is appropriate if the threshold value is set at a motor torque that lies 5-10% under the nominal motor torque, which nominal motor torque corresponds to the torque required at the relevant rate of revolution and initially measured play between the rotor and the casing. It is appropriate that torque measurement at the shaft or a torque measurement of the driving motor is used for detection of the motor torque, by detection of the instantaneous current supply to the electric motor (for a motor having a controlled rate of revolution).
Parameter No. 2
Sluice feeders of the relevant type most often have a return flow to the sluice feeder in order to compensate for increased wear, and in this way also for leakage of cooking liquor. An adjustment can be initiated by monitoring this return flow, as soon as the flow exceeds a pre-determined threshold value during a certain minimum period. It is appropriate that the threshold value is set to be a flow that lies 10-20% above the nominal flow, which corresponds to the flow required at the relevant rate of revolution and initially measured play between the rotor and the casing.
A feedback-controlled initiation of adjustment using a parameter that indicates wear allows each adjustment to be much smaller, since a subsequent detection of the parameter can be carried once the adjustment has been made. If the relevant parameter still indicates that the wear is too large, a new adjustment can be made after only a few minutes, preferably at least 10 minutes after the previous adjustment. The desired nominal value can be used instead of the threshold value during such a repeated adjustment, if adjustment back to the optimal situation is desired.
While the present invention has been described in accordance with preferred compositions and embodiments, it is to be understood that certain substitutions and alterations may be made thereto without departing from the spirit and scope of the following claims. | The arrangement is for the adjustment of wear of the position of the rotor of a sluice feeder within a feed casing. The rotor has the form of a truncated cone and the play between the rotor and the surrounding casing is adjusted depending on the wear between the rotor and the casing through the rotor being axially displaced a predetermined displacement. A complete driving unit, motor and gear box are suspended on the journal of the rotor. The driving unit receives support from a torque support in the form of a beam fixed in the casing. The complete driving unit accompanies the rotor shaft during adjustment and makes contact with the torque-absorbing beam through sliding bearing supports. | 3 |
This application is a continuation of application Ser. No. 028,822, filed Mar. 20, 1987 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to phenyl-endcapped depolymerizable polymers having increased depolymerization threshold temperatures and reduced residue after depolymerization. More particularly, the invention relates to phenyl-endcapped poly(methyl methacrylate) and poly(alpha-methyl styrene) and their use as lift-off materials and ceramic binders.
Poly(methyl methacrylate) and poly(alpha-methyl styrene) are thermally depolymerizable polymers. These polymers depolymerize by "unzipping," that is they essentially undergo a complete reverse of polymerization, regenerating the gaseous monomer or monomers from which the unzippable polymer was formed.
For use as lift-off materials and binders, an optimal thermally depolymerizable polymer should have the following properties:
(1) It should not depolymerize below a given threshold temperature that is above the highest temperature that the structure is exposed to during intermediate process steps.
(2) It should not leave any residue after depolymerization.
(3) It should have good sheet or film-forming properties.
Lift-off processes are well known in the art, especially for applying metallization patterns to semiconductors. In such a process, a sacrificial layer is deposited and patterned with the inverse of the desired metallurgy pattern. Following blanket metallization, the sacrificial layer is dissolved, "lifting off" the metal in the undesired areas. U.S. Pat. No. 4,519,872, U.S. Pat. No. 4,539,222 and U.S. Pat. No. 4,456,675 describe lift-off layers comprising poly-(methyl methacrylate) or poly(alpha-methyl styrene). These films undergo rapid weight loss at temperatures of 275-315° C. This creates a problem when argon sputter cleaning at 240° C. is used prior to metallization, because the polymers begin to unzip at this temperature.
Binders are normally comprised of simple solvent soluble thermoplastic organic polymers having good film-forming properties which are nonvolatile at moderate temperatures but which will volatilize with other constituents of the resin system on firing of the green sheet to the final sintered state. A commonly used binder resin is poly(vinyl butyral). However, where low temperature systems, such as glass ceramic substrates, are used, the maximum temperature for binder removal is much lower due to the coalescence of the glass particulate at about 800-875° C. Thus, after the glass has coalesced, any remaining binder residue will become entrapped in the glass body. Failure to completely remove the binder in the initial stages of the heat treatment process can result in the evolution of gas during the final sintering stage. This gives rise to pores in the material or, in extreme cases, to blow holes.
Glass ceramic substrates are typically used with copper metallurgy. Copper metallurgy precludes the use of oxidizing ambients during binder burn-off. As disclosed in U.S. Pat. No. 4,234,367, it has been found that conventional binder resins, such as poly(vinyl butyral), are not easily burnt out in these non-oxidizing atmospheres. This can result in black or darkened substrates that are not fully sintered. The black or darkened color is generally attributed to carbon residue. The carbon remaining in the ceramic can form conduction paths which lead to lower insulation resistance by many orders of magnitude and to increased dielectric losses.
The use of unzipping polymers such as free radical polymerized poly(methyl methacrylate), poly(alpha-methyl styrene) and polyisobutylene, has been disclosed in IBM Technical Disclosure Bulletin, July 1979, p. 542 to Anderson, et al. and in U.S. Pat. No. 4,598,107. These polymers have cleaner burn-out and minimal residue formation in an inert atmosphere as compared to poly(vinyl butyral). A problem with these polymers is that as a result of the free radical polymerization process by which they are formed, there is rather limited control in molecular weight distribution and end groups. Furthermore, the reactive terminal vinyl group promotes cross-linking which leads to carbonaceous residues. This residue will not be removed in low temperature or non-oxidizing systems.
U.S. Pat. No. 4,550,061 discloses the use of alpha-substituted styrene polymers or polymers derived from alpha-substituted acrylate monomer as binders for electro-erosion printing media. The materials have decreased residue after decomposition (less than 2%).
U.S. Pat. No. 4,474,731 discloses a process for the removal of carbon residues formed during sintering of ceramics.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to improve the materials used for lift-off and as binders.
It is a further object of the invention to increase the depolymerization temperature of the polymers used for lift-off.
It is another object of the invention to eliminate residues produced when depolymerizable polymers unzip.
In accordance with these and other objects, the present invention discloses phenyl-endcapped thermally depolymerizable polymers. Such polymers generally fall within a class having the following regular structure: ##STR1## X=CH 3 , CN, CF 3 tert-butyl, etc. Y= ##STR2## where X is as above defined, etc.
X and Y represent substituents that are thermally stable and cannot be cleaved from the polymer backbone upon heating at conditions as are used in the present invention to unzip the polymer and n is selected so as to provide the desired molecular weight. Currently preferred thermally depolymerizable polymers include poly(methyl methacrylate) and poly(alpha-methyl styrene).
The phenyl endcap eliminates the reactive terminal vinyl group. This decreases the vapor pressure of the bulk polymer at constant temperature and increases the depolymerization temperature. In addition, this eliminates a reactive site from possible reactions which form residues. The phenyl endcap stabilizes the terminal group thermally and quenches the radical/anion on the terminus. If unquenched, the terminal group "quenches" itself via elimination resulting in a terminal vinyl group. ##STR3##
where R=phenyl, a phenyl derivative, or methyl, wherein a phenyl is preferred in this equation. This vinyl moiety can then become a new site for radical initiation upon heating via H abstraction. The vinyl group is not a thermally stable group. The vapor pressure of the bulk appears to increase upon heating and what results is radically induced chain scission and "unzipping." The radically induced unzipping of the polymer results in a wide variety of by-products with an accompanying wide variation in by-product volatility. Some of the by-products have very high volatilities which can cause problems in particular applications while other of the by-products are non-volatile and result in formation of undesirable residues during processing. By contrast, the phenyl-endcapped polymers have increased depolymerization temperatures (by 20-50° C.) and decreased residues as compared to the same polymers without phenyl endcaps.
A mask of the phenyl-endcapped polymer can be applied to a desired substrate, overlaid with a photo-resist, patterned lithographically so as to remove the mask material in the desired pattern areas or vias, and a blanket conductive layer such as a metallization layer can be applied. Because of the increased depolymerization temperature, the phenyl-endcappped polymer does not unzip during sputter cleaning of surfaces such as argon sputter cleaning or deposition of the conductive layer such as the metallization layer. Upon heating the substrate to a higher temperature than that achieved during sputter cleaning or metallization, the polymer unzips. Adhesion of the blanket metal film is deteriorated sufficiently so that the metal spontaneously delaminates and metal stress causes it to roll up. At this point the metal may be blown away. Alternatively, the depolymerized polymer can be rapidly swelled and/or dissolved in a suitable solvent, due to its substantial reduction in MW and increased solubility of the smaller chain length fragments.
In another application, the phenyl-endcapped polymer can be used as a binder resin in forming ceramic compositions. The phenyl-endcapped polymers according to the present invention have improved "binder burn-out" when compared to such commonly used binders as poly(methyl methacrylate) or poly(vinyl butyral). Binder burn-out is the process step in which the green ceramic is heated to volatilize and remove the binder resin system. During binder burn-out, the phenyl-endcapped polymers decompose uniformly and completely, with little or no residue.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1-5 show the lift-off process resulting in metal structures embedded in a passivating layer with a planarized surface.
FIG. 6 shows an alternative embodiment of the lift-off process in which the metal structures are not embedded.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The phenyl endcapping represents a method of stabilizing polymers derived from vinyl monomers. These polymers fall within a class having the following regular structure: ##STR4## X=CH 3 , CN, CF 3 tert-butyl. etc. Y= ##STR5## where X is as above defined, etc.
X and Y represent substituents that are thermally stable and cannot be cleaved from the polymer backbone upon heating at conditions as are used in the present invention to unzip the polymer and n is selected so as to provide the desired molecular weight. Use of a phenyl endcap on such polymers stabilizes the polymer relative to reversal of the polymerization process, i.e. radical depolymerization, or the direct reversal of the reaction mechanism for polymerization. Polymer synthesis and endcapping can be either radical or anionic.
PREPARATION OF PHENYL-ENCAPPED POLYMERS
Synthesis of the polymers can be achieved via either radical or anionic polymerization using a variety of commercially available, common catalysts and/or heat, as is well known in the art: ##STR6## where X=CH 3 and Y=COOCH 3 for poly(methyl methacrylate) or where X=CH 3 and Y=C 6 H 5 for poly(alpha-methyl styrene), and where R=phenyl, a phenyl derivative or methyl, wherein a phenyl is preferred.
Fractionation of the polymer to remove low MW oligomers and impurities will increase the depolymerization temperature (T D ) of the polymer, Addition of 1% Irganoz radical trapping agent to scavenge radicals formed prior to main chain polymer depolymerization will also increase T D . Molecular weight of the polymer should be 50,000 to 150,000, with the preferred range being about 60,000 to 90,000.
The endcapping is achieved by quenching the growing, reactive polymer chain with a radical or anionic trapping agent: ##STR7## where R, X. and Y are as defined above.
Lift-off process
A multilevel metal process using the phenyl-endcapped polymers of the present invention comprises the following generalized sequence of steps.
1. Forming a cured organic polymer layer 3 such as polyimide on a substrate 1 which is typically monocrystalline silicon with a dielectric layer 2 which is typically a silicon oxide or silicon nitride, having contact openings (not shown here) for contact with active and passive devices. (FIG. 1) The material for this organic polymer layer can be a polyimide such as Pyralin (trademark of E. I. duPont deNemours), which is applied in thicknesses of 1-5 microns. For device fabrication the preferred thickness of the organic polymer layer is about 1-2 microns while for packaging about 4-5 micron thick films can be employed. For packaging applications, layers 1 and 2 would be replaced by dielectric layers such as ceramic, glass ceramic, glass or other insulating materials which can be employed according to the processes described herein to form conductive patterns on a module comprising integrated circuit devices and associated circuitry.
2. Deposition of a thin masking layer 4 by plasma or PECVD (plasma enhanced chemical vapor deposition), e.g., silicon nitride, silicon oxide or plasma polymerized organosilicons. (FIG. 2) Solution coated glass resin type materials may also be used.
3. Application of a layer of the phenyl-endcapped polymer 5 according to the present invention by spin-coating of a solution of the typically 10-40% by weight polymer in a suitable solvent such as diglyme or 2-methoxy ethyl ether (FIG. 2). Thickness of the layer will be of the order of about 0.5-2.0 microns for devices and about 5-10 microns for packaging. This is followed by a bake cycle of about 85° C. for 15 minutes for device fabrication or about 150-260° C. for 1 hour for packaging fabrication.
4. Deposition of an oxygen reactive ion etch resistant layer 6 of the type described in Step 2 above, to serve as a barrier during image transfer into the underlying layers by RIE (Reactive Ion Etching) in an O 2 containing ambient. (FIG. 2)
5. Deposition of a resist layer 7 by spin coating, followed by prebake at an appropriate temperature. The thickness of the film is typically on the order of 1-3 microns. (FIG. 2) The resist can be any of those well known in the art, including novolak resist materials.
6. Exposure and image development of the resist according to techniques well known in the art to delineate the desired conductive pattern. (FIG. 2) Depending on the resist, exposure can be by optical, E-beam, X-ray or ion beam.
7. Replication of the resist pattern in the underlying layers by RIE in CF 4 containing ambients to etch the barrier layers and in O 2 containing ambients to etch the lift-off layers. (FIG. 3)
8. An optional step of sputter cleaning of the substrate may be used at this time.
9. Deposition of a conductive material, such as evaporation of a metal layer 8, such as Al/Cu or Cr-Cu-Cr alloy by E-beam or RF evaporation. (FIG. 4) The thickness of layer 8 is preferably approximately equal to that of layer 3.
10. Brief thermal treatment of the structure to depolymerize the phenyl-endcapped polymers. Phenyl-endcapped poly(methyl methacrylate) depolymerizes completely in 3-4 minutes at 350° C. or 6-8 minutes at 330° C. TD (the temperature at which depolymerization occurs) is 320° C. and no depolymerization is seen at 300° C. Adhesion of the blanket metallic film is deteriorated sufficiently so that the metallic film spontaneously delaminates and metal stress causes it to roll up. At this point the metal may be blown away. Alternatively, solvent assisted lift-off may be used. (FIG. 5) If sufficient time is spent above T D the thermal depolymerization can be complete to the point of leaving no residue provided that the polymer was very pure and did not contain any branched groups or residual vinyl groups on the backbone.
11. Steps 1-10 can be repeated to give further levels of metallurgy.
UV analysis has indicated a small shift of 2-5% in the UV absorbance of phenyl-endcapped poly(methyl methacrylate) as compared to unsubstituted poly(methyl methacrylate). Therefore, resist properties and high temperature lift-off properties can be combined in a single 2 micron thick film. Taking advantage of this property, Step 5 can be eliminated and the phenyl-endcapped poly(methyl methacrylate) can be directly patterned. In this case, exposure will be by E-beam. This greatly simplifies the lithographic process and permits a totally dry development and lift-off sequence.
Steps 1-10 result in metal structures embedded in a passivating layer with a planarized surface. In an alternative embodiment, Steps 1 and 2 can be eliminated to provide metal structures which are not embedded, as shown in FIG. 6.
Binder Resin Process
The depolymerizable polymers of the present invention are particularly useful as binder resins in the fabrication of glass ceramic substrate carriers for mounting of semiconductor or integrated circuit chips. Glass ceramics allow sintering at lower temperatures (less than 1000° C.) than that possible with alumina-based ceramics, which require sintering temperatures in excess of 1400° C. This allows less refractory metallurgies, such as copper and gold, to be used.
The ceramic slurry for manufacture of ceramic green sheets from glass ceramic is formulated, in accordance with usual practice, from ground glass, a binder resin system and a solvent system. The function of the binder resin system is to provide adhesive and cohesive forces to hold the ground glass together in its green sheet configuration. The solvent system is a volatile composition whose role is to dissolve the binder resin system into solution, to aid in uniformly mixing the binder resin with the ground glass, and to provide the necessary viscosity to the resultant ceramic slurry for subsequent casting. The sintered ground glass forms the substrate material in the ultimately fired structure.
Starting materials for formulation of ceramic slurry in accordance with the present invention comprise liquid solvents (e.g. isopropyl alcohol, acetone, ethyl acetate, hexane, 1-butanol), phenyl-endcapped poly(methyl methacrylate) or poly(alpha-methyl styrene) as prepared above, a resin plasticizer (e.g. dibutyl phthalate), and a glass ceramic. Typical glass ceramic can have either beta-spodumene (Li 2 .Al 2 O 3 .4SiO 2 ) or cordierite (2MgO.2Al 2 O 3 .5SiO 2 ) as the main crystalline phase. The general composition ranges for such glass ceramics are described in U.S. Pat. No. 4,301,324, assigned to the assignee of the present invention and incorporated herein by reference.
The substrate fabrication process involves the following illustrative basic steps:
1. The cullet of the chosen crystallizable glass is ground to average particle sizes in the range of 2 to 7 micrometers. The grinding can be done in two stages, a preliminary dry or wet grinding to 400 mesh particle size followed by further grinding with suitable organic binders and solvents until the average particle size is reduced to between 2 and 7 micrometers and a castable slurry is obtained. A single stage prolonged grinding of cullet in the medium of the binder and solvent, until the desired particle sizes are obtained can also be used. In the latter case, a filtering step may be necessary to remove oversized particles.
The actual quantities of solvent and polymer are chosen to provide the necessary viscosity in the ceramic slurry to form on casting a cohesive ceramic sheet. Generally, this can be obtained by maintaining the ratio, in parts by weight, of the polymer to solvent system in the general range of 1:2 to 1:12, and preferably 1:5 to 1:7. The specific quantity of the solvent system in the ceramic slurry will normally be that which will provide a viscosity in the broad range of about 500 to about 2,000 mPa.s at a temperature of about 25° C., preferably from about 800 to about 1,000 mPa.s at a temperature of about 25° C.
Generally, the ceramic slurry will comprise from about 40 to about 60 wt. percent of ceramic glass and from about 60 to about 40 wt. percent of binder resin system and solvents. The binder resin system will comprise from about 0-10% plasticizer, with the remainder of the system being phenyl-endcapped polymer and solvents. A preferred embodiment comprises about 52.7% ceramic glass, about 4.4% phenyl-endcapped polymer, about 1.9% dibutyl phthalate, about 16.3% isopropyl alcohol and about 24.7% acetone.
2. After blending of the ceramic slurry, it is filtered, deaerated and cast on a removable flexible supporting tape, such as Mylar (a glycol terephthalic acid polyester) or Teflon (polytetrafluoroethylene) (both trademarks of E. I. duPont deNemours). The slurry may be slightly compressed, spread and leveled by use of a doctor blade to provide on drying green ceramic sheets having a thickness in the range of 1-15 mils.
3. The cast ceramic slip is dried by evaporation of the solvent system at temperatures providing controlled volatilization in accordance with well-known principles in the art, which minimize bubbling, cracking, buckling, volatilization of plasticizer, and the like, of the drying ceramic slip. The drying temperature is typically 25-50° C. and the drying time depends on the thickness of the cast ceramic slip and the air or ambient flow across the evaporation surface during drying.
4. The resulting green sheet, after removal of the mylar supporting tape, is cut into green sheet units of the desired size and via holes are punched through them in the required configuration. A metallizing paste of copper is extruded into the via holes in the individual sheets.
5. A copper paste or ink is then screen printed on selected units in the patterns desired for electrical conduction. The solvent is evaporated from the coated composition.
6. The green sheet units are stacked on each other in proper relation. The assembly is then laminated in a laminating press. The temperature and pressure employed for lamination should be such as to cause the individual green sheets to bond to each other and to cause the green ceramic to sufficiently flow and enclose the conductor patterns.
7. After lamination the green laminate is cut to final shape and fired in a furnace under an exidizing, neutral or reducing atmosphere for burn-off of the phenyl-endcapped polymer, sintering or coalescence of the glass particles, and conversion to a glass ceramic by crystallization with concurrent sintering of the metal particles in the conductor patterns. Burn-off of the phenyl-endcapped polymer occurred between 250-450° C.
While the invention has been particularly shown and described with reference to preferred embodiments, it will be understood by those skilled in the art that changes in form and detail may be made without departing from the spirit and scope of the invention. For example, the phenyl-endcapped polymers may be used as binders with other systems, such as alumina-based ceramics. Furthermore, phenyl endcapping of PMMA photoresist will improve its resistance to dry etch processing, allowing it to be used in a greater variety of manufacturing environments. | Phenyl-endcapped depolymerizable polymers are disclosed. The phenyl endcap eliminates the reactive terminal vinyl group resulting in increased depolymerization threshold temperatures and reduced residue after depolymerization. A multilevel metal lift-off process using the phenyl-endcapped polymers is disclosed. Additionally, the polymers are improved ceramic glass binder resins. | 2 |
BACKGROUND-FIELD OF INVENTION
The present invention relates to torque converters and transmissions, specifically to automotive torque converters and transmissions that utilize gyrating inertial masses.
BACKGROUND-CROSS REFERENCE TO RELATED APPLICATIONS
The present application is related to my application filed on Sep. 1, 1988, entitled INERTIA TORQUE CONVERTER/TRANSMISSION, having a Ser. No. of 07/239,608, abandoned due to lack of detail in specifications.
BACKGROUND-DISCUSSION OF PRIOR ART
Heretofore automotive torque converters and transmissions are overly complicated, inefficient, difficult to use in some cases, and expensive to manufacture and maintain. Traditional geared transmissions cannot maintain at all times perfect matches between engines and loads. The so called continuously variable transmissions may provide a better match, but have other problems in durability and reliability. There were a few attempts to use gyrating masses to convert torque from a rotatable energy source to a rotatable load, but the designs are unnecessarily complicated and inefficient, due to a lack of understanding of the exact mechanism of the conversion of torque by gyrating masses. One of such attempts is disclosed in U.S. Pat. No. 4,742,722 issued to Wallace in 1988, which discloses an inertial transmission using gyrating inertial masses. The disclosure explains how torque is converted to angular velocity and how angular velocity is converted to torque within one object, but never explains in full how torque is transmitted from one object to another, i.e. from the input shaft to the output shaft. It is obvious that the mechanism of transmitting torque from one object to another through gyrating masses was not fully understood. This lack of understanding produces a machine that is inefficient and overly complicated, exemplified by complicated and unnecessary three-dimensional movements of inertial masses, complicated and inefficient crank links, and unnecessary one-way clutches. Furthermore, the quantitative relationship between the output torque and input rate of rotation is not established.
Another attempt to utilize gyrating masses in a transmission is disclosed in U.S. Pat. No. 4,336,870 issued to Shea in 1982, which describes a torque exchange coupling for transmitting rotational mechanical power, wherein a set of gyrating extendable members of inertial nature are used to generate torque on a solid track which, through its contact surface, is contacted by the extendable members. Using a solid track is not the best way to derive torque from gyrating masses because of friction between the solid track and the gyrating masses. Furthermore, the extendable members will bounce back from the contact surface of the solid track and the machine will not operate smoothly.
Still another attempt to utilize gyrating masses in a torque converter is disclosed in U.S. Pat. No. 3,581,584 issued to Williams in 1971, which describes a torque converter that utilizes gyrating masses to generate oscillating torque. This oscillating torque is in turn converted into an one-directional torque through an one-way clutch, and applied to a load. Again, this is a case where lack of understanding of how torque is transmitted through gyrating masses leads to a design that is overly complicated and inefficient. If the device was properly designed and constructed, the one-way clutch would not have been necessary.
Unless the mechanism of transmission of torque through gyrating masses is fully understood, a simpler and more efficient design is impossible. The mechanism of such a transmission of torque will be explained in detail later in this application.
OBJECTS AND ADVANTAGES
It is an object of this invention to provide a transmission which is simple, rugged, practical, and easy to manufacture.
It is another object of this invention to provide a transmission which is extremely efficient with minimal heat loss.
It is still another object of this invention to provide a transmission which does not shift between gears yet matches engine and load automatically.
It is still another object of this invention to provide a transmission which has a wide range of torque output.
It is still another object of this invention to provide a transmission wherein magnitude of torque output is very easy to manipulate. A desirable amount of torque can be obtained by simply adjusting engine rate of rotation.
It is still another object of this invention to provide a transmission wherein rotational energy is recyclable. Instead of generating heat, unused rotational energy is recycled. For example, rotational energy of a set of gyrating masses generates an adequate amount of torque to keep an automobile from rolling down a steep grade, yet since the automobile is not moving, rotational energy is not consumed, most of the rotational energy is recycled to continue generating torque, as a result, torque is maintained and the automobile is kept in place with very little energy consumed. This is not a perpetual movement. The operation is analogous to the gyration of a satellite, which keeps on producing centrifugal forces almost indefinitely. But in a down-to-earth environment where this rotational energy coupler operates, energy loss due to friction is inevitable, hence a continuous energy infusion is necessary. But unlike a frictional torque converter or a fluidic torque converter, friction here does not play any functional role.
SUMMARY OF THE INVENTION
The transmission disclosed is comprised of 3 parts: a rotatable input unit with drive arms mounted radially thereon; a set of inertial masses drivably coupled to the drive arms; and a rotatable output unit having trackless guiding means mounted thereon to guide said inertial masses to travel in a path along which the distance to the axis of rotation of the rotatable output unit varies.
There are two types of drive arms: sliding drive arms and swinging drive arms. The sliding drive arms are fixedly and radially mounted on the input shaft. The inertial masses are drivably and slidably coupled to the sliding drive arms so that they can slide along the length of the drive arms either inward or outward with respect to the axis of rotation of the input unit. To increase efficiency, the sliding drive arms can also be mounted in a way so that they tilt to the direction of rotation of the input unit, so that when the inertial masses slide outward they also slide forward.
The swinging drive arms are pivotally and radially mounted on the input shaft. The inertial masses are drivably coupled to the swinging drive arms so that together with the swinging drive arms they swing either outward or inward with respect to the axis of rotation of the input unit. To make it more efficient, the pivots that mount the swinging drive arms on to the input shaft are forwardly tilted so that when swinging outward the inertial masses also swing forward.
It is one of the novel features of this invention that there is no solid track to guide the inertial masses. The inertial masses are guided by guiding means mounted on the output unit, to follow intangible paths so as to keep friction to a minimum.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 explains the theory of how torque is generated by a gyrating inertial mass.
FIG. 2 is a schematic, three-dimensional, exploded view of a workable example of the theory explained in FIG. 1.
FIG. 3 shows in detail a connecting device of the embodiment in FIG. 2.
FIG. 4 shows in detail an inertial mass of the embodiment in FIG. 2.
FIG. 5 shows a longitudinal section of first preferred embodiment having sliding drive arms, taken from line 5--5 of FIG. 6.
FIG. 6 shows a cross section of first preferred embodiment having sliding drive arms, taken from line 6--6 of FIG. 5.
FIG. 7 is a schematic, three-dimensional, exploded view of first preferred embodiment having sliding drive arms, without showing a casing.
FIG. 8 schematically shows the path of an inertial mass of first preferred embodiment.
FIG. 9 is a schematic, three-dimensional, exploded view of first preferred embodiment having swinging drive arms, without showing a casing.
FIG. 10 schematically shows a set of non-biased sliding drive arms.
FIG. 11 schematically shows a set of first version of forward biased sliding drive arms.
FIG. 12 schematically shows a set of second version of forward biased sliding drive arms.
FIG. 13 schematically shows a set of non-biased swinging drive arms.
FIG. 14 schematically shows a set of forward biased swinging drive arms.
FIG. 15 explains how offsetting effect of torque occurs with a non-biased drive arm.
FIG. 16 explains how offsetting effect of torque diminishes with a forward biased drive arm.
FIG. 17 is a longitudinal section of second preferred embodiment taken from line 17--17 of FIG. 18.
FIG. 18 is a cross section of second preferred embodiment taken from line 18--18 of FIG. 17.
FIG. 19 schematically shows the path of an inertial mass of second preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
This invention is based on a theory illustrated in FIG. 1, wherein 31 is a drive arm, 32 is the axis of rotation of drive arm 31, 33 is an inertial mass slidably mounted on drive arm 31, 34 is a natural path of inertial mass 33 when driven by drive arm 31 without a guiding track, 35 is an eccentrically mounted circular guiding track to guide inertial mass 33. Track 35 does not exist in the preferred embodiments. It is incorporated here for the purpose of teaching the theory. Track 35 is also rotatable around axis of rotation 32. F is a net force exerted on track 35 by inertial mass 33. D is the distance between force F and axis of rotation 32.
Drive arm 31 is rotatable around its axis of rotation 32, inertial mass 33 is slidably mounted on drive arm 31 so that it can slide along the length of drive arm 31 either inward or outward with respect to axis of rotation 32. When drive arm 31 is driven by a rotational energy source (not shown) to rotate around its axis of rotation 32 in a clockwise direction, and when there is no guiding track to guide inertial mass 33, inertial mass 33 will follow a path depicted by a broken line 34 which is designated the natural path of inertial mass 33. When inertial mass 33 is forced into going an eccentrically circular path by eccentrically mounted circular track 35, the left half of circular track 35 substantially coincides with natural path 34 of inertial mass 33, while the right half of circular track 35 deviates markedly from natural path 34. It does not require much force to guide inertial mass 33 into going the left half of track 35, while much force is needed to guide inertial mass 33 into going the right half of track 35. As a result, there is a net reactive force F exerted on the right side of track 35 by inertial mass 33. A net torque is generated on track 35, with a magnitude equal to force F times distance D, represented by an equation T=FD where T is the net torque generated on guiding track 35, F is the net force exerted on guiding track 35 by inertial mass 33, D is the distance between force F and axis of rotation 32.
There is a misconception that leads to a conclusion that an unidirectional torque will not be generated the way described in FIG. 1. This misconception is that the right side and left side of the guiding track are symmetrical, if there is a force exerted on the right side of the track when the inertial mass travels through the right side of the track, there will also be a force with a same magnitude but opposite direction exerted on the left side of the track when the inertial mass travels through the left side of the track, and in average these two forces cancel out each other. According to this misconception, there will not be any continuous and unidirectional torque generated. Instead there will be a so called "oscillating torque" generated, because these two forces do not occur at the same time. Unless one-way clutches are used to convert this so called "oscillating torque" into unidirectional torque, this "oscillating torque" is useless. The prior art clearly has the misconception just described, evidenced by the utilization of one-way clutches. The reason for this misconception is that the prior art failed to recognize that although the left and right sides of the track are symmetrical, the effects of the inertial mass on these two sides of the track are not symmetrical. The inertial mass has far less effect on the left side of the track than has it on the right side of the track, because the left side of the track substantially coincides with the natural path of the inertial mass while the right side of the track substantially deviates from the natural path of the inertial mass, as explained above in FIG. 1.
The relationship between the magnitude of force F thus generated and the rate of rotation of inertial mass 33 is exponential, namely: the magnitude of force F is proportional to the square of the rate of rotation of inertial mass 33. If guiding track 35 also rotates, the magnitude of force F is proportional to the square of the rotation rate difference between inertial mass 33 and guiding track 35. A small change in rate of rotation of inertial mass 33 will cause a big change in magnitude of force F, for example, if track 35 is stationary, a 5-fold change in rate of rotation of inertial mass 33 will cause the magnitude of force F to change 25 folds, resulting in an extremely wide range of torque output.
The guiding track in FIG. 1 does not have to be circular in shape as long as along the track the distance to the axis of rotation varies. This is because of the fact that when said distance is increasing along the track, the shape of that part of the track is more conformed to the natural path of the inertial mass than when said distance is decreasing. Hence, the inertial mass has a greater force exerted on the track when travelling along the part of the track where distance to the axis of rotation is decreasing than when travelling on the part of the track where distance to the axis of rotation is increasing. As a result, an unidirectional torque is generated on the track around the axis of rotation. The theory can then be generalized as: when an inertial mass is driven by a drive arm to rotate around an axis of rotation and is forced into going a path along which the distance to the axis of rotation varies, an unidirectional torque is generated around the axis of rotation by the inertial mass on those that forces the inertial mass into the path, the torque thus generated having a magnitude proportional to the square of the rotation rate difference between the inertial mass and those that forces the inertial mass into the path.
FIG. 2 schematically shows a workable example of the theory in a three-dimensional, exploded manner. The embodiment in FIG. 2 is not a preferred embodiment because it is not dynamically balanced and it has a less efficient tangible track. It is cited here only to exemplify, and thus for better understanding of the above described theory. The embodiment in FIG. 2 is divided into three parts for ease of description. The first part is an input unit which comprises an input shaft 42 which is rotatably mounted on a casing 41 through a bearing 43, and is rotatable around an axis of rotation 55; and a pair of identical drive arms 44 radially and fixedly mounted on input shaft 42. The second part is the inertial media comprising a pair of identical inertial masses 46 and a pair of identical connecting devices 45 which drivably couple inertial masses 46 onto drive arms 44. The third part is an output unit which comprises an output shaft 48 which is rotatably mounted on casing 41 through a bearing 49, and is rotatable around axis of rotation 55; and a circular track 47 eccentrically and fixedly mounted on output shaft 48.
FIG. 3 shows a connecting device 45 in detail wherein 51 is a bore for slidably fitting connecting device 45 onto a drive arm 44, 52 is a cylindrical connecting shaft for rotatably mounting connecting device 45 onto an inertial mass 46.
FIG. 4 shows an inertial mass 46 in detail wherein 53 is a cylindrical bore for receiving cylindrical connecting shaft 52 of connecting device 45, 54 is an arc-shaped groove having a same curvature as the curvature of circular track 47. Through said arc-shaped groove 54, inertial mass 46 is snugly and slidably seated onto eccentrically mounted circular track 47.
Bore 51 on connecting device 45 has a non-circular cross-sectional shape substantially the same as the cross-sectional shape of drive arm 44, so that when fitted snugly and slidably onto drive arm 44, connecting device 45 does not rotate axially around drive arm 44.
Cylindrical connecting shaft 52 is integrated into connecting device 45 as an integral part thereof. The outer end of cylindrical connecting shaft 52 is fitted into cylindrical bore 53 to rotatably couple inertial mass 46 onto connecting device 45.
Since circular track 47 is eccentrically mounted, when sliding along circular track 47, the position of inertial mass 46 relative to a corresponding drive arm 44 keeps on changing both angularly and linearly. The function of connecting device 45 is to keep inertial mass 46 and said corresponding drive arm 44 travelling at a same angular speed, while accommodating different positional relationships between said inertial mass 46 and said drive arm 44.
Input shaft 42 imports rotational energy from a rotational energy source (not shown) and causes drive arms 44 to rotate around axis of rotation 55. Drive arms 44 in turn through connecting devices 45 drive inertial masses 46 to gyrate around axis of rotation 55. The path of inertial masses 46 is set forth by circular guiding track 47 which is eccentrically and fixedly mounted on output shaft 48. Since guiding track 47 is an eccentrically mounted circular track, said path will be an eccentric circle along which the distance to axis of rotation 55 varies. As a result an unidirectional torque is generated on guiding track 47 around axis of rotation 55, causing guiding track 47 and hence output shaft 48 to rotate around axis of rotation 55. Since this torque is unidirectional, it is exported directly through output shaft 48 to a load (not shown), without aid of one-way clutches.
FIG. 5, FIG. 6, and FIG. 7 show a preferred embodiment of the invention wherein FIG. 5 is a longitudinal section taken from line 5--5 of FIG. 6, FIG. 6 is a cross section taken from line 6--6 of FIG. 5, and FIG. 7 is a schematic illustration of said embodiment without showing the casing in an exploded, three-dimensional manner. The embodiment is divided into three parts for ease of description: an input unit, inertial mass media, and an output unit. The input unit comprises an input shaft 60 which is rotatably mounted on a casing 76 through a bearing 71, and is rotatable around an axis of rotation 73; and four identical sliding drive arms 61 fixedly and radially mounted on input shaft 60. The inertial mass media comprises four identical inertial masses 62 each of which has a bore 77 thereon for slidably and drivably coupling said inertial mass 62 onto a sliding drive arm 61; and four identical cylindrical connecting rods 63. The output unit comprises an outer drum guiding gear 64; an output shaft 65 which is rotatably mounted on casing 76 through a bearing 72, and is rotatable around axis of rotation 73; four identical inner guiding gears 66 each of which is rotatable around its axis of rotation 74, having a cylindrical bore 75 in between its circumference and its axis of rotation 74; a pair of identical inner guiding gear supporting members 67; another pair of identical inner guiding gear supporting members 70 (only shown in FIG. 7); four identical inner guiding gear mounting shafts 68; and two identical inner guiding gear supporting member mounting sleeves 69.
Input shaft 60 is rotatably mounted on casing 76 through bearing 71. Sliding drive arms 61 are fixedly and radially mounted on input shaft 60. Each of inertial masses 62 is slidably coupled to a drive arm 61 through bore 77 so that inertial mass 62 is slidable along the length of drive arm 61. Sliding drive arm 61 and bore 77 have substantially same shape of cross sections that are not circular, so that when slidably and snugly mounted onto sliding drive arm 61 through bore 77, inertial mass 62 will not rotate axially around drive arm 61. Outer drum guiding gear 64 is fixedly mounted on output shaft 65, having a same axis of rotation 73 as that of output shaft 65. Outer drum guiding gear 64 has teeth constructed on the inner cylindrical surface thereof. Each pair of inner guiding gear supporting members 67, 70 are rotatably mounted on output shaft 65 through a mounting sleeve 69. Each of mounting sleeves 69 is fixedly mounted on a pair of inner guiding gear supporting members 67, 70, and rotatably mounted on output shaft 65. Each of inner guiding gears 66 is rotatably mounted on an inner guiding gear supporting member 67, 70 through an inner guiding gear mounting shaft 68. Each of inner guiding gears 66 engages outer drum guiding gear 64, and has axis of rotation 74 parallel to axis of rotation 73 of output shaft 65. Mounting shafts 68 are fixedly mounted on supporting members 67, 70. One end of each of cylindrical connecting rods 63 is fixedly mounted on an inertial mass 62. The other end of said connecting rod 63 is rotatably fitted into a bore 75 which is at an area between the circumference and axis of rotation 74 of an inner guiding gear 66. Cylindrical connecting rods 63 are mounted in a position parallel to axis of rotation 73 of output shaft 65. The function of a connecting rod 63 is to keep the connected bore 75 of an inner guiding gear 66 and the connected inertial mass 62 rotating at a same angular speed, while accommodating the ever changing positional relationship between said inner guiding gear 66 and said inertial mass 62. Output shaft 65 is rotatably mounted on casing 76 through bearing 72.
In FIG. 7, a pair of inner guiding gear supporting members 70 are clearly shown which is not shown in FIG. 5 and FIG. 6. As clearly shown in FIG. 7, bores 75 on inner guiding gears 66 carried by inner guiding gear supporting members 70 are closer to axis of rotation 73 than bores 75 on inner guiding gears 66 carried by the other inner guiding gear supporting members 67. It is preferred to arrange so that all bores 75 do not reach the near point to axis of rotation 73 at the same time, but rather, when two opposite bores 75 reach the near point, the other two opposite bores 75 reach the far point, as clearly shown in FIG. 6 and FIG. 7.
In FIG. 6, although not in the plane of the section, the relative positions of input shaft 60, sliding drive arms 61, and inertial masses 62 are also shown, but in broken lines.
As clearly shown in FIG. 6 and FIG. 7, four drive arms 61 are perpendicular to each other so that they are evenly separated.
It is also preferred that outer drum guiding gear 64 has an even number of teeth so that each pair of opposite inner guiding gears 66 operate in a symmetrical manner.
Input shaft 60 imports rotational energy from a rotational energy source (not shown) and causes sliding drive arms 61 to rotate. Sliding drive arms 61 in turn cause inertial masses 62 to gyrate. Inertial masses 62 in turn through cylindrical connecting rods 63 and bores 75 cause inner guiding gears 66 to rotate around axis of rotation 73 of output shaft 65. The path along which an inertial mass 62 travels is illustrated in FIG. 8, wherein one inner guiding gear 66 is shown engaging outer drum guiding gear 64. When the input rotation is clockwise and outer drum guiding gear 64 is stationary, inner guiding gear 66 rotates around axis of rotation 73 of output shaft 65 in a clockwise direction, and at the same time, due to the engagement with outer drum guiding gear 64, rotates about its own axis 74 in a counter clockwise direction. Bore 75 on inner guiding gear 66 will follow a path depicted by a broken line 78, along which the distance to axis of rotation 73 of output shaft 65 varies. Since one end of connecting rod 63 is rotatably mounted inside bore 75 and the other end of said connecting rod 63 is fixedly mounted on an inertial mass 62, said inertial mass 62 will travel in exactly the same path as that of said bore 75. Hence broken line 78 also represents the path along which an inertial mass 62 travels. The arrow in FIG. 8 indicates the direction of movement of bore 75 and inertial mass 62. Without outer drum guiding gear 64, inner guiding gear 66 will not rotate about its own axis 74, and said path of bore 75 and inertial mass 62 will become a circle along which the distance to axis of rotation 73 of output shaft 65 will not change. A causal relationship is then obvious: Outer drum guiding gear 64 causes inertial mass 62 to travel in a path along which the distance to axis of rotation 73 of output shaft 65 varies. As a result, an unidirectional torque is generated on outer drum guiding gear 64 around axis of rotation 73. Since said torque is unidirectional and outer drum guiding gear 64 is fixedly mounted on output shaft 65, said torque can be exported through output shaft 65 directly without aid of one-way clutches.
It is obvious that the guiding system that guides inertial mass 62 in the embodiment shown in FIG. 5, FIG. 6, and FIG. 7 is trackless. Inertial mass 62 is guided into going a designated path 78 (in FIG. 8) not by a guiding track.
To avoid running into each other of inner guiding gears 66, and to ensure the smoothness of path 78 in FIG. 8, it is preferred that the diameter of inner guiding gear 66 is not greater than a third of the diameter of outer drum guiding gear 64, and the distance from the center of cylindrical bore 75 to axis of rotation 74 of inner guiding gear 66 is not more than a quarter of the diameter of inner guiding gear 66.
To reduce friction, swinging drive arms can be used in place of sliding drive arms. Without showing the casing, FIG. 9 schematically illustrates an embodiment wherein swinging drive arms are used, in an exploded, three-dimensional manner. The embodiment in FIG. 9 has a swinging drive arm mounting plate 80, four identical swinging drive arm mounting pivots 81, four identical swinging drive arms 82, four identical inertial masses 83, four identical inertial mass mounting pivots 84, four identical cylindrical connecting rods 85. All other parts of the embodiment in FIG. 9 are shared by the embodiment shown in FIG. 5, FIG. 6, and FIG. 7.
Swinging drive arms 82 are pivotally mounted to input shaft 60 through swinging drive arm mounting plate 80 and swinging drive arm mounting pivots 81. Mounting plate 80 is fixedly mounted on input shaft 60. Inertial masses 83 are pivotally mounted on swinging drive arms 82 through mounting pivots 84 so that each of inertial masses 83 is rotatable around a pivot 84 but will not move linearly against a corresponding swinging drive arm 82. One end of each of cylindrical connecting rods 85 is fixedly mounted on an inertial mass 83. The other end of said connecting rod 85 is rotatably and slidably fitted into bore 75 on an inner guiding gear 66 to keep both bore 75 of said inner guiding gear 66 and said inertial mass 83 rotating at a same angular speed, while accommodating an ever changing positional relationship between said inner guiding gear 66 and said inertial mass 83. Cylindrical connecting rod 85 has to be slidably fitted into bore 75 on inner guiding gear 66, because the distance between inertial mass 83 and output shaft 65 is not constant. Cylindrical connecting rod 85 has to slide in and out bore 75 to accommodate the variation of said distance. Since connecting rod 85 is slidably fitted into bore 75, connecting rod 85 has to be long enough to remain at all times inside bore 75. This is the difference between cylindrical connecting rod 85 and cylindrical connecting rod 63 of the embodiment shown in FIG. 5, FIG. 6, and FIG. 7.
While the distance between inertial mass 83 and output shaft 65 keeps on changing, there is nothing to prevent inner guiding gears 66 and mounting sleeves 69 from sliding axially. The amount of possible axial sliding of inner guiding gears 66 and mounting sleeves 69 is the same as the amount of distance variation between inertial mass 83 and output shaft 65. When swinging drive arm 82 is substantially long as shown in FIG. 9, said distance variation is small and hence said axial sliding of inner guiding gears 66 and mounting sleeves 69 is small. A small axial sliding of inner guiding gears 66 and mounting sleeves 69 does not affect the operation of the embodiment. But if swinging drive arm 82 is short, said axial sliding will be substantial, and means should be provided to prevent such axial sliding. Said means could be a pin (not shown) or a collar (not shown) attached to the end of inner guiding gear mounting shaft 68 and the end of output shaft 65.
The swinging drive arms impart less frictional loss than the sliding drive arms do, but take up a little bit more room.
To make it more efficient, the drive arms can be made forward biased so that when the inertial mass goes outward, it also goes forward. A forward biased drive arm is defined as a drive arm that causes the inertial mass to go forward to the direction of rotation when said inertial mass is going outward away from the axis of rotation. FIG. 10 schematically shows a set of non-biased sliding drive arms just for comparison, wherein 90 is an input shaft, 91 is an axis of rotation, 92 is a non-biased sliding drive arm. FIG. 11 schematically shows a set of forward biased sliding drive arms, wherein 90 is the input shaft, 91 is the axis of rotation, 93 is a forward biased drive arm, and an arrow indicates the direction of rotation. It is obvious that forward biased drive arm 93 bends to the direction of rotation so that when an inertial mass (not shown) slides outward, it also slides forward. FIG. 12 schematically shows a set of another version of forward biased sliding drive arms, wherein 90 is the input shaft, 91 is the axis of rotation, 94 is a drive arm mounting plate, 95 is a forward biased sliding drive arm, and an arrow indicates the direction of rotation. It is also obvious that drive arm 95 bends to the direction of rotation.
FIG. 13 schematically shows a set of non-biased swinging drive arms just for comparison, wherein 90 is the input shaft, 91 is the axis of rotation, 96 is a drive arm mounting plate, 97 is a nonbiased swinging drive arm, and 98 is a pivot that mounts swinging drive arm 97 onto drive arm mounting plate 96. FIG. 14 schematically shows a set of forward biased swinging drive arms, wherein 90 is the input shaft, 91 is the axis of rotation, 99 is a drive arm mounting plate, 100 is a forward biased swinging drive arm, 101 is a pivot that mounts forward biased swinging drive arm 100 onto drive arm mounting plate 99, and an arrow indicates the direction of rotation. It is also obvious that when drive arm 100 swings outward, it also swings forward to the direction of rotation, bringing an inertial mass (not shown) with it.
The reason for the higher efficiency of forward biased drive arms is explained in FIG. 15 and FIG. 16. FIG. 15 schematically shows a non-biased sliding drive arm in operation, wherein 91 is the axis of rotation, 103 is a non-biased sliding drive arm, 102 is an inertial mass, 104 is an eccentrically mounted circular track, 107 is the center of circular track 104, and an arrow indicates the direction of rotation. As indicated in FIG. 15, inertial mass 102 is travelling through a portion of track 104 where the distance to axis of rotation 91 is decreasing. Inertial mass 102 is forced to decelerate by drive arm 103. A force 105 is exerted on inertial mass 102 by drive arm 103. Force 105 has a divisional force 106 that points to center 107 of circular track 104, offsetting the effect of inertial mass 102 on track 104. In other words, this divisional force 106 is counter productive, because it reduces the torque that can be produced by inertial mass 102 on track 104.
FIG. 16 schematically shows a forward biased sliding drive arm in operation, wherein 91 is the axis of rotation, 102 is the inertial mass, 108 is a forward biased sliding drive arm, 104 is the eccentrically mounted circular track, 107 is the center of circular track 104, and an arrow indicates the direction of rotation. As indicated in FIG. 16 inertial mass 102 is traveling through a portion of track 104 where the distance to axis of rotation 91 is decreasing. Inertial mass 102 is forced to decelerate by drive arm 108. A force 109 is exerted on inertial mass 102 by drive arm 108. Since drive arm 108 is forward biased, force 109 will point to a direction so that it will not have a divisional force that points to center 107 of track 104. In other words, there is no offsetting of the torque produced on track 104 by inertial mass 102.
Forward biased drive arms are more efficient in a way that they make it possible to reduce the size of the transmission or reduce the rate of rotation without reducing the magnitude of the torque generated.
FIG. 17 and FIG. 18 show another preferred embodiment of the invention, wherein FIG. 17 is a longitudinal section taken from line 17--17 of FIG. 18 and FIG. 18 is a cross section taken from line 18--18 of FIG. 17. The embodiment in FIG. 17 and FIG. 18 has an input shaft 110, four identical sliding drive arms 111, four identical inertial masses 112, four identical cylindrical connecting rods 113, a central guiding gear 114, four identical peripheral guiding gears 115, a pair of identical peripheral guiding gear supporting members 116 shown (there is another pair not shown), four identical peripheral guiding gear mounting shafts 117, two identical peripheral guiding gear supporting member mounting sleeves 118, an output shaft 119, a casing 122, a bearing 123 for rotatably mounting input shaft 110 onto casing 122, a bearing 124 for rotatably mounting output shaft 119 onto casing 122, an axis of rotation 120 of output shaft 119 and input shaft 110, an axis of rotation 121 of each of peripheral guiding gears 115, a cylindrical bore 125 on each of peripheral guiding gears 115 for rotatably coupling a cylindrical connecting rod 113 to a peripheral guiding gear 115, a bore 127 on each of inertial masses 112 for slidably and drivably coupling an inertial mass 112 onto a sliding drive arm 111.
Input shaft 110 is rotatably mounted on casing 122 through bearing 123. Sliding drive arms III are radially and fixedly mounted on input shaft 110. Inertial masses 112 are slidably and snugly fitted onto drive arms 111 through bores 127. Drive arm 111 has a non-circular cross section that has substantially same shape as that of bore 127, so that when slidably and snugly fitted onto said drive arm 111 through bore 127, inertial mass 112 will not rotate axially around drive arm 111. Central guiding gear 114 is fixedly mounted on output shaft 119, having an axis of rotation common to axis of rotation 120 of output shaft 119. Peripheral guiding gear supporting members 116 are rotatably mounted on output shaft 119 through mounting sleeves 118 which are fixedly mounted on supporting members 116 and rotatably mounted on output shaft 119. Peripheral guiding gears 115 are rotatably mounted on supporting members 116 through peripheral guiding gear mounting shafts 117, engaging central guiding gear 114, having axes of rotation 121 parallel to axis of rotation 120 of output shaft 119. Mounting shafts 117 are fixedly mounted on supporting members 116. Cylindrical bore 125 on a peripheral guiding gear 115 is located in an area between the circumference and axis of rotation 121 of said peripheral guiding gear 115, for rotatably coupling one end of a connecting rod 113 to said peripheral guiding gear 115. The other end of said connecting rod 113 is fixedly mounted on an inertial mass 112. Said connecting rod 113 is mounted in a position parallel to axis of rotation 120 of output shaft 119. The function of a connecting rod 113 is to keep the connected cylindrical bore 125 of a peripheral guiding gear 115 and the connected inertial mass 112 rotating at a same angular speed, while accommodating the ever changing positional relationship between said guiding gear 115 and said inertial mass 112. Output shaft 119 is rotatably mounted on casing 122 through bearing 124.
In FIG. 18, although not in the plane of the section, the relative positions of input shaft 110, sliding drive arms 111, and inertial masses 112 are also shown, but in broken lines. As clearly shown in FIG. 18, the four drive arms 111 are perpendicular to each other; central guiding gear 114 has an even number of teeth to accommodate symmetrical operation of peripheral guiding gears 115; and two inertial masses 112 in opposite sides of axis of rotation 120 reach the far points to said axis of rotation 120, while the other two inertial masses 112 reach the near points to said axis of rotation 120.
It is preferred that the diameter of peripheral guiding gear 115 is not greater than the diameter of central guiding gear 114, and the distance between the center of bore 125 and axis of rotation 121 of peripheral guiding gear 115 is not greater than one-fourth of the diameter of peripheral guiding gear 115, to prevent running into each other of peripheral guiding gears 115.
Input shaft 110 imports rotational energy from a rotational energy source (not shown) and causes sliding drive arms 111 to rotate. Sliding drive arms 111 in turn cause inertial masses 112 to gyrate. Inertial masses 112 in turn through cylindrical connecting rods 113 and cylindrical bores 125 cause peripheral guiding gears 115 to rotate around axis of rotation 120 of output shaft 119. The path along which an inertial mass 112 travels is illustrated in FIG. 19, wherein one peripheral guiding gear 115 is shown engaging central guiding gear 114. When the input rotation is clockwise and central guiding gear 114 is stationary, peripheral guiding gear 115 rotates around axis of rotation 120 of output shaft 119 in a clockwise direction, and at the same time, due to the engagement with central guiding gear 114, rotates about its own axis of rotation 121 in a clockwise direction. Bore 125 on peripheral guiding gear 115 will follow a path depicted in a broken line 126, along which the distance to the axis of rotation 120 of output shaft 119 varies. Since one end of connecting rod 113 is rotatably mounted inside said bore 125 and the other end of said connecting rod 113 is fixedly mounted on an inertial mass 112, said inertial mass 112 will travel in exactly the same path as that of said bore 125. Hence broken line 126 also represents the path along which said inertial mass 112 travels. The arrow in FIG. 8 indicates the direction of movement of said bore 125 and said inertial mass 112. Without central guiding gear 114, peripheral guiding gear 115 will not rotate about its own axis of rotation 121, and said path of bore 125 and inertial mass 112 will become a circle along which the distance to axis of rotation 120 of output shaft 119 will not change. A causal relationship is then obvious: central guiding gear 114 causes inertial mass 112 to travel in a path along which the distance to axis of rotation 120 of output shaft 119 varies. As a result, an unidirectional torque is generated on central guiding gear 114 around axis of rotation 120. Since said torque is unidirectional and central guiding gear 114 is fixedly mounted on output shaft 119, said torque can be exported through output shaft 119 directly without aid of one-way clutches.
It is obvious that the guiding system that guides inertial mass 112 in the embodiment shown in FIG. 17 and FIG. 18 is trackless. Inertial mass 112 is guided into going a designated path 126 (in FIG. 19) not by a tangible guiding track.
Thus the reader will see that the inertial masses mediated rotational energy coupler of the invention provides a very simple, very rugged, highly functional, and highly efficient device for automobiles and wherever transmission of rotational energy is needed.
While my above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of a few preferred embodiments thereof. Many other variations are possible. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents. | A rotational energy coupler generally regarded to as a transmission is described, wherein rotational energy is transmitted through inertial media. An input unit transmits rotational energy to a set of inertial masses by driving the inertial masses to gyrate. An output unit recovers rotational energy from the gyrating inertial masses by altering their natural travelling paths through a guiding system that guides the gyrating inertial masses into paths along which the distance to the axis of rotation of the output unit is not constant. As a result, an unidirectional torque is generated on the output unit. If the output unit rotates, rotational energy is consumed, if not, rotational energy is conserved. The magnitude of the torque so generated is related to the rotation rate difference between the input unit and the output unit in an exponential manner, namely: the magnitude of the torque is proportional to the square of the rotation rate difference. The range of the magnitude of the torque is much wider than the range of the rate difference. The guiding system of the output unit has an unique feature of having no tangible track to guide the inertial masses so as to reduce friction. The output torque is unidirectional so that one-way clutches that convert oscillating torque into unidirectional torque are unnecessary. | 8 |
BACKGROUND OF THE INVENTION
The inherent torque and vibration characteristics of internal combustion engines make it desirable to provide flexible mounts for such power units. Usually exhaust headers are applied rigidly to the engine for movement therewith, but in many installations the headers must be connected to exhaust tail pipes or other exhaust components that are relatively more constrained than the engine itself. These movement and vibration characteristics present a special problem in connection with the design and fabrication of a connector that will satisfactorily interconnect exhaust header components and other exhaust components for particular installations. When the engine and exhaust system are intended for aircraft use, the problem is even greater. Since the vibration and torque movement patterns for the engine are increased, it is even more desirable that these influences be isolated from the air frame. The high performance characteristics of aircraft engines contribute to a further air safety problem, since a defective connector can burn out in flight to cause a serious fire hazard or to release carbon monoxide gases into the aircraft cabin.
The duty and service requirements for such connectors is increased when exhaust gas turbines are provided for use with aviation engines. In order to minimize precession influences that would act adversely on the rapidly spinning rotor, the turbine is usually mounted on the air frame, and, accordingly, it is relatively restrained when compared with the movement pattern for the engine itself. The engine exhaust gases, at usually higher temperature and pressure, must still be safely and efficiently interconnected to the turbine. Previously used bellows type connectors have a high failure incidence when used for such purpose, and, accordingly, an improved connector is desirable.
SUMMARY OF THE INVENTION
In order to provide an improved connector for engine exhaust systems, the present inventors essentially provide telescoping tube sections that may move reciprocally and rotationally open with respect to the other. To avoid inherent problems of translational and torsional friction where mating cylindrical sections are used and the fretting and galling results thereof and to reduce the characteristic channelization of escaping gases past mating cylindrical surfaces, a modified construction is provided. The potential area of contact between the interfitted and mated cylindrical surfaces is reduced and purposely disposed in a space separated, regulated pattern through provision of a plurality of circumferential ribs on one of the cylindrical sleeves. The limiting surfaces of the circumferential ribs are in close contact with a mating cylindrical surface, but areas of non-contact are preserved between said ribs. Reduction in the total area of contact reduces both translational and torsional friction so that the freedom for relative movement between the sleeves is improved. At the same time it is noted that the leakage characteristics are minimized through use of such arrangement, since the areas of non-contact between the ribs provide circumferential chambers for the collection and retention of exhaust gases that may have passed an upstream rib. In use, the pressure of exhaust gases in each of such successive chambers will be gradually reduced in the downstream direction. This stepped gradient of pressure in the separate chambers tends to minimize the pressure differential across each of the separate ribs, and, accordingly, the escape of gases across the rib to cylindrical surface seal interface is minimized.
When the connector is used with aircraft engine installations at a position disposed within the engine nacelle, it is desirable to provide a pressure collar that will be disposed exteriorally of the interfitted sleeves and over the terminal end of the outer sleeve of such combination. The loosely fitting pressure collar then is disposed to minimize loss of any escaping gases, but it additionally provides a chamber in communication with the last of said pressure seal zones whereby such zone is itself subjected to the superatmospheric pressure influences existent within the engine nacelle. Either or both of the inner or outer sleeves may be provided with ball socket joints and flanges as necessary to join the connector to the exhaust headers of the engine or to any installed turbine compressor or exhaust tail pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side schematic illustration showing use of the invention in connection with an aircraft installation,
FIG. 2 is an end elevation taken from the right end of FIG. 3, and
FIG. 3 is a side cross-sectional elevation through the length of the connector showing details thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the invention is shown in the accompanying Figures, in which FIG. 1 illustrates use of a connector 11 made in accordance with this invention to interconnect the exhaust system 12 of an engine 13 to an exhaust discharge tail pipe 14 beneath the wing 15 of an aircraft, or alternately to an exhaust turbine compressor unit 20 that is disposed in position above the wing but still within the nacelle 16 of the aircraft. In such usage the connector provides a flow passage for the hot exhaust gases of the engine. Moreover the connector 11 operates to isolate the exhaust tail pipe 14 and/or the turbine from the vibration and movement influences acting on the engine and the propeller to which it is connected.
The preferred construction of the exhaust gas connector 11 is shown in FIGS. 2 and 3. In FIG. 2, which is an end view from the socket joint or inlet end of the connector, the inside of the socket joint 17 is seen with seven-hole flange 18 being disposed about the socket joint at a position behind the entrance angle flare 19 on the terminal end of the spherical shaped surface 21 for the socket joint 17. The seven-hole flange 18 has a leg section 22 formed integrally therewith which cooperatively engages the exterior spherical shaped surface 21. In use the flange 18 is connected to a flange of similar shape, size and hole pattern provided by the exhaust system 12 of the aircraft engine. When through bolts are inserted through the holes 23, the interior surface 21 of socket joint 17 is moved into contact with a ball joint (not shown) provided by the exhaust system 12. The flange 18 and the similar flange on the exhaust system will hold the exhaust gas connector 11 securely engaged to the engine exhaust system 12.
Downstream the socket joint component 17 is joined, as by welding, along the line 24 to an inner sleeve 25 which is itself telescopically received within an outer sleeve 26. Outer sleeve 26 is joined by welding along the line 27 to a ball joint end 28 through which the engine exhaust gases pass for conductance to an engine turbo compressor (shown schematically at 20) or alternately to the exhaust discharge tail pipe 14 used by the aircraft. A second flange 29 is disposed about the exterior spherical surface 31 of the ball joint 28. This flange 29, which may be of construction identical with that of the seven-hole flange 18, again has a leg segment 32 that engages the spherically contoured exterior surface of the ball joint end 28. The flange 29 is used in similar manner to connect the connector 11 to the turbine inlet pipes (not shown) or to the exhaust discharge tail pipe 14.
One further component completes the construction for the connector. This component is a pressure collar 33 which is welded to the inner sleeve 25 at a position so that the open free end 34 of the pressure collar 33 will be disposed exteriorally of the outer sleeve 26. In fact, the inner end 36 of the outer sleeve 26 terminates at a position intermediate the free end 34 for the pressure collar 33 and the point of weld attachment 37 for the pressure collar 33 and the inner sleeve 25. With this arrangement the outer sleeve 26, which is of telescoped arrangement with respect to the inner sleeve 25 disposed therein, is itself in a somewhat telescoped arrangement with respect to the pressure collar 33 that surrounds the outer sleeve 26. Since all of such elements must be all closely fitted together in order to provide the low leakage characteristic, it is essential that all of the pieces be of true circular contour. A roll bead 38 is formed in the pressure collar 33 so that the contour and concentricity of this element can be better maintained. In addition to the provision of such roll bead 38, the entire free end of the pressure collar is expanded when compared to the welded end thereof. This arrangement provides a shoulder 39, as shown by the drawings.
In order to provide a combined structure that will have zero or low leakage while still maintaining a telescoping relationship to accommodate vibration and position changes, it is obvious that the inner and outer sleeves 25 and 26 must be closely fitted together. While tubing of sizes that would closely interfit one another in the as-manufactured condition might be obtained, it would be difficult to maintain the close interfit required over a contact length equal to or greater than the diameter of the tubing without running into conditions where the inner and outer tubing pieces would be securely locked or seized together in a manner that would transmit vibration influences to the detriment of the engine exhaust system or the aircraft structure. This is especially true where the fitted tubing pieces are to be subjected to widely varying temperatures.
To avoid the corrosion and fretting conditions that might be encountered with closely interfitted straight walled tubing pieces, the present invention provides a ribbed construction for at least one of the interfitting components. For the embodiment illustrated, a plurality of rib sections 41, 42 and 43 are provided. The rib segments are derived by expanding the material of the inner sleeve 25 at the rib positions 41, 42 and 43 to a size such that the exterior surfaces of the ribs will then closely engage the interior surface 46 of the outer sleeve 26. Sections of the inner sleeve 25 that are disposed intermediate the rib sections 41, 42 and 43 then have their outer surfaces out of contact with the inner surface 46 of the outer sleeve 26, and in effect, chambers, such as the spaced chambers 47 and 48, then exist between the inner sleeve 25 and outer sleeve 26. The described arrangement decreases the total contact area between the inner and outer sleeves and tends to prevent the seizing of such elements one to the other so that telescoping freedom is maintained. It is also found that the tendency of exhaust gases to escape is minimized by this arrangement even when compared to relatively tightly fitting inner and outer straight wall tube sections. Exhaust gases escaping past the terminal end 49 of the inner sleeve 25 that would cross back along the inner surface 46 of the outer sleeve 26 must successively pass each of the raised ribs 43, 42 and 41 before being received in the chamber 51 between the inner sleeve 25 and the pressure collar 33. Flow and passage along such course is not only resisted by the contact between raised rib segments and the outer sleeve, but it is also noted that different pressures exist in the chambers 47 and 48. With the differential pressures across any of the raised segments 41, 42, 43 being reduced, the tendencies for flow thereacross is minimized. Importantly, a low differential pressure across any of the raised segments likewise tends to minimize the channelization of such flow at concentrated zones, and, accordingly, the tendency for the creation of hot spots and for increased burning is also minimized.
Beneficially the interior of the nacelle 16 for aircraft engine installations of the described type is itself subjected to a superatmospheric pressure by reason of ram air due to forward movement of the aircraft or by other pressurizing influences. This raised pressure influence is introduced into the chamber 51 disposed between the pressure collar 33 and inner sleeve 25. Since this pressure is greater than the free air pressure at the exhaust tail pipe 14, any leakage potential is minimized.
In the manufacture of the inner sleeve, it should be noted that the upstream end thereof is of expanded size in order to butt directly with the cylindrical section of the socket joint 17. Accordingly, these similarly sized segments may be butt-welded together at 24. The initial tube stock for the inner sleeve is of an exterior cylindrical size that would easily slip and turn within the outer sleeve 26. The desired friction engagement between the inner sleeve and outer sleeve is obtained by expanding the inner sleeve to provide the rib sections 41, 42 and 43. A multi-segment expanding die is used to provide these rib sections, and it is desirable that the inner sleeve and die be rotated one with respect to the other as the rib sections are expanded so the derived circumferential contact surface 46 will be continuous and smoothly contoured.
The provision of the seven-hole flange makes it possible for this connector unit 11 to be applied to various existing aircraft exhaust systems. The bolt circle diameter for all of the holes 23 is the same, but it should be noted that the actual spacing of the used holes is in equiangular patterns when three bolts or five bolts are used. Accordingly, either of the seven-hole flanges 18 or 29 could be joined to existing three or five bolt flanges that have the same bolt circle diameter.
With usage at widely varied temperatures and under vibration and movement conditions, the further requirement that leakage of exhaust gases be minimized makes it important that the connector utilized be accurately built of materials that have an extended service life. The exhaust gas connector shown in FIGS. 2 and 3 is fabricated of a plurality of parts wherein all of the parts and components are of corrosion and heat resistant materials. Desirably, the components are formed of stainless steel materials that are compatible with their intended uses and also of types that may be efficiently welded together to provide the desired connector assembly. As an example of adequate materials, the tubular components, inclusive of inner and outer sleeves, pressure collar and also the end flanges, may be made of Type T-321 stainless steel. The socket and ball joint connectors at the respective inlet and outlet ends of the connector may be made of Type T-347 stainless steel. Additionally, stainless steel Types 62, 601 and 625 and Inconel may be used as substitute materials. | A connector for interengaging the exhaust header components of an internal combustion engine that are subjected to movement and vibration to a turbine compressor and/or tail pipe components that are constrained and relatively unmoving wherein inner and outer sleeves of generally telescoping type are separately joined to said moving and constrained components by angular misalignment compensating ball socket joints held in assembled relation with said components by mating flanges. Said inner and outer sleeves further cooperatively provide a close interfitting engagement between a smooth cylindrical surface on one sleeve and a plurality of spaced circumferential ribs on the other sleeve to provide spaced apart pressure sealing zones whereby the pressure of any escaping exhaust gases are reduced by stepped gradients. A pressure collar disposed exteriorally of the interfitted sleeves and in communication with at least one of said zones is itself subjected to superatmospheric pressure to minimize loss of exhaust gases past said seal zones and pressure collar. | 5 |
CLAIM FOR PRIORITY
[0001] This non-provisional application is a national phase entry of International Application No. PCT/RU2008/000151, filed on Mar. 18, 2008, entitled “Pharmaceutical composition for preventing dysbiosis associated with enteral administration of antibiotics”. The priority of International Application No. PCT/RU2008/000151 is hereby claimed and its disclosure incorporated herein by reference in its entirety.
FIELD OF INVENTION
[0002] The group of inventions relates to medicine, namely to pharmaceutics and the development of compositions of pharmaceutical preparations, containing antibiotics and prebiotics, for correcting the composition of the intestinal microflora during antibiotic therapy.
BACKGROUND OF THE INVENTION
[0003] The therapeutic action of broad-spectrum antibiotics is as a rule accompanied by disturbances involving the gastrointestinal tract, connected with negative action of the antibiotic on the microflora of the large intestine. Antibiotics have a strong negative influence on the permeability of biological membranes to ammonium ions in the large intestine. As a result, antibiotics suppress not only pathogenic, but also useful microflora of the digestive tract, lead to disturbance of homeostasis and promote the development of dysbiosis and allergies. Disturbed equilibrium in the microbiocenosis of the intestine leads in many cases to disturbances of the immune system and active multiplication of unicellular fungi, which actively colonize the intestine. The normal intestinal microflora is a necessary condition for digestion of food and assimilation of nutrients, as well as it serves as a barrier to exogenous infection; it participates in detoxication of toxic metabolites, restriction of the multiplication of pathogenic and opportunistic microorganisms that have got into the intestine.
[0004] The most favorable conditions for the activity of microflora in the gastrointestinal-tract arise starting from the distal part of the small intestine, where the secretions of the stomach and pancreas do not reach, as well as the components of the bile, the bacteriostatic and bactericidal effects of which become weaker as the large intestine is approached. Against a background of dysbiosis, pathogenic agents of intestinal infections or opportunistic microorganisms that enter the body can quickly colonize the mucosa of the small and large intestine, destroying epithelial cells and displaying pronounced antagonism with respect to the indigenous microflora. Inflammation develops, leading to reduced production of short-chain fatty acids, which inhibit the growth of pathogenic microorganisms. This occurs during antibiotic therapy with broad-spectrum preparations. Even partial loss of the intrinsic intestinal microflora leads to serious consequences for the organism and requires specific treatment.
[0005] Such treatment can be carried out, in particular, by prescribing various probiotics, which are not always compatible with the normal microflora and over a period of several days they may be eliminated from the intestine. As for the manifestation of undesirable effects when using these preparations, they include at first and foremost the ability of probiotics to modulate immune inflammation. For example, it is known that about 10% of workers of factories producing bacterial and immunobiological preparations (probiotics), after several years of the work get allergic diseases.
[0006] A more physiological way to maintain the normal intestinal microflora in active state is intake of prebiotics. Prebiotics are indigestible components of food, which promote improvement of health by selective stimulation of the growth and/or metabolic activity of one or more groups of bacteria living in the large intestine. Carbohydrate prebiotics, in contrast to probiotics, are not digested in the stomach and are not absorbed, but reach the large intestine unchanged, because their structure has unusual beta-glycosidic bonds, which are not hydrolyzed by the human organism owing to the absence of specific beta-glycosidases. But prebiotics can selectively stimulate the growth and multiplication of lactobacilli and bifidobacteria, i.e. species that predominate in the composition of the normal microflora of the human gut. Prescribing combination therapy including prebiotics mean to eliminate atrophic processes in the mucosa of the large intestine and dystrophic changes of the epithelium with restoration of its functionality. However, in not less than in half of cases, taking antibiotics and prebiotics at different times we cannot completely preclude damage of the intestinal microflora by the antibiotics. Most often prebiotics are prescribed when the symptoms of dysbiosis have already appeared, particularly in the form of diarrhea and flatulence. As a result, by the time prebiotics begin to be taken after antibiotic therapy has been carried out, the useful microflora has been strongly disrupted or is practically unviable.
[0007] Accordingly, it is desirable to provide selective advantages for the useful microflora over pathogenic or opportunistic species of bacteria during treatment with antibiotics. Therefore there have been attempts to provide protection for the indigenous intestinal microflora by simultaneous ingestion of an antibiotic and a prebiotic in the form of a single pharmaceutical composition.
[0008] There is a known pharmaceutical composition, the method of preparation and the method of use thereof, containing the prebiotic lactulose and an antibiotic from the group comprising penicillins, cephalosporins, tetracyclines, lincosamides, macrolides. See RU No. 2284832, publ. Oct. 10, 2006, the disclosure of which is incorporated herein in its entirety.
[0009] A drawback of this composition is that the commonly used lactulose preparations contain a considerable amount of admixtures (lactose, galactose, fructose), which can stimulate the growth of pathogenic and opportunistic species of microorganisms living parasitically in the intestine.
[0010] One more negative factor in this case is the laxative action of lactulose, which shortens the transit time of the chyme and reduces the absorption and assimilation of nutrients, and furthermore, the laxative effect of lactulose in combination with antibiotics may be falsely clinically assessed as a sign of dysbacteriosis. Moreover, it is known that some preparations of dry lactulose are extremely hygroscopic, and this creates serious technical difficulties in production of the compositions, and packaging and storage of finished pharmaceutical preparations containing lactulose.
[0011] There is a known pharmaceutical form—pharmaceutical composition, method of preparation and method of use thereof—containing an antibiotic and the fructanprebiotic, which, in addition to antibacterial action and to some, more slowly developing maintenance of the intestinal microflora, increases calcium absorption and bone mineralization. See EP 1166800, 2002, the disclosure of which is incorporated herein in its entirety.
[0012] Drawbacks of this composition are a narrow range of application, low specificity of stimulant action on the main species of the indigenous microflora, nonoptimal weight ratio (lack of balance) of antibiotic and fructan, nonoptimal degree of dispersion (particle size), nonoptimal degree of polymerization of the prebiotic, at which the level of fermentation of carbohydrates and the antibacterial action of the product are reduced. There is reduced therapeutic-prophylactic effect from using the composition, as well as reduced calcium absorption and bone mineralization. Moreover, said composition is characterized by complexity of the production process and insufficient efficacy in application.
[0013] The drawbacks of this composition are largely due to the high degree of polymerization and low purity of the fructan, which hamper the process of fermentation of the polysaccharide by lactobacilli and bifidobacteria, as well as necessity to use a larger amount of prebiotic in the composition. As mentioned above negative feature is presence in lactulose preparations from the majority of domestic manufacturers of admixtures (up to 40%) that stimulate the growth of pathogenic and opportunistic bacteria of the intestinal group, the presence of side action on the blood coagulation system (mainly prolongation of the partial prothrombin time and decrease in level of fibrinogen), and high frequency of allergic reactions.
BRIEF DESCRIPTION OF THE INVENTION
[0014] The technical object of the group of inventions, bound by a common inventive concept, is the creation of an effective pharmaceutical composition and a method of preventing dysbiosis, while extending the arsenal of pharmaceutical compositions and methods of preventing dysbiosis.
[0015] The technical result that enables this object to be achieved comprises expanding the range of application of a composition of prebiotics and antibiotics, by the inclusion of more effective antibacterial preparations for oral administration (fluoroquinolones, ansamycins etc.) in the composition and the elimination of side-effects. Effective utilization of the prebiotic component of the composition in the intestine is provided by administering oligosaccharides with an optimal degree of polymerization and optimal proportions of the components with the necessary degree of dispersion (particle size).
DETAILED DESCRIPTION OF THE INVENTION
[0016] This invention is described in detail below with reference to several embodiments and examples. Such discussion is for illustration only.
[0017] The essence of the invention with respect to a pharmaceutical composition for preventing intestinal dysbiosis during antibiotic therapy, destined for oral use, according to a first embodiment contains an antibiotic and a prebiotic, moreover the antibiotic and the prebiotic are incorporated in the form of powder, and the prebiotic comprises an oligosaccharide selected from the group comprising fructooligosaccharides, galactooligosaccharides, xylooligosaccharides, maltooligosaccharides and isomaltooligosaccharides with degree of polymerization from 2 to 10, particle size up to 0.3 mm and purity of at least 95%, and antibiotic with particle size from 20 to 200 μm, moreover the antibiotic and the oligosaccharide are incorporated in a fixed composition at a weight ratio from 1:1 to 1:100, respectively.
[0018] Preferably it contains pharmaceutically acceptable amounts of excipients, for improving the organoleptic and consumer properties, selected from the groups: fillers, taste correctants, flavorings, and odoriferous substances. The composition is produced in a pharmaceutical form suitable for oral use, selected from the group comprising capsules, tablets, powders, pills, sugar-coated pills, granules, sachets, gels, pastes, syrups, emulsions, suspensions, solutions.
[0019] The essence of the invention with respect to a pharmaceutical composition for preventing intestinal dysbiosis during antibiotic therapy, destined for oral use, according to a second embodiment contains an antibiotic and a prebiotic, said antibiotic and said prebiotic being included in the form of powder, moreover the antibiotic, selected from the group comprising beta-lactams, including combinations of beta-lactams with inhibitors of bacterial beta-lactamases, azalides, fluoroquinolones, amphenicols, glycopeptides, ansamycins, nitrofurans, derivatives of phosphonic acid, cycloserine, trimetoprim, is included with particle size from 20 to 200 μm, and oligosaccharide with degree of polymerization from 2 to is included as prebiotic, moreover the antibiotic and the oligosaccharide are included in the composition at a weight ratio from 1:1 to 1:100. Preferably it contains pharmaceutically acceptable amounts of excipients, for improving the organoleptic and consumer properties, selected from the group comprising fillers, taste correctants, flavorings, and odoriferous substances. The composition is prepared in a pharmaceutical form suitable for oral use, selected from the group comprising capsules, tablets, powders, pills, sugar-coated pills, granules, sachets, gels, pastes, syrups, emulsions, suspensions, solutions.
[0020] The essence of the invention with respect to the method of preventing intestinal dysbiosis during antibiotic therapy according to first variant comprises administration of a fixed pharmaceutical composition containing an antibiotic and a prebiotic, said antibiotic and said prebiotic being included in the form of powder, moreover an oligosaccharide prebiotic selected from the group comprising fructooligosaccharides, galactooligosaccharides, xylooligosaccharides, maltooligosaccharides or isomaltooligosaccharides with degree of polymerization from 2 to 10, with particle size up to 0.3 mm and purity of at least 95%, and the antibiotic has a particle size from 20 to 200 μm, moreover the antibiotic and the oligosaccharide are included in a fixed composition at a weight ratio from 1:1 to 1:100, respectively, which is administered orally.
[0021] The essence of the invention with respect to the method of preventing intestinal dysbiosis during antibiotic therapy according to mentioned mode comprises administration of a pharmaceutical composition containing an antibiotic and a prebiotic, said antibiotic and said prebiotic being included in the form of powder, the antibiotic being selected from the group comprising beta-lactams, including combinations of beta-lactams with inhibitors of bacterial beta-lactamases, azalides, fluoroquinolones, amphenicols, glycopeptides, ansamycins, nitrofurans, derivatives of phosphonic acid, cycloserine, trimetoprim and included with particle size from 20 to 200 μm, and an oligosaccharide with degree of polymerization from 2 to 10 is included as prebiotic, moreover the antibiotic and the oligosaccharide are included in the composition at a weight ratio from 1:1 to 1:100, which is taken orally.
[0022] Use of this combination greatly increases calcium absorption and increases bone mineralization in patients. Additionally the oligosaccharides—fructooligosugars, galactooligosugars, xylooligosugars, maltooligosugars and isomaltooligosugars—not only create conditions for growth of useful bacteria, but also effectively improve the composition of the blood, and the state of the cardiovascular and immune systems.
[0023] It has to be borne in mind that the human body is a multiorgan system, the cellular elements of which are specialized for performing various functions. Interaction inside the body is based on complex regulating and coordinating mechanisms involving neurohumoral and other factors. The many separate mechanisms regulating intracellular and intercellular interactions perform opposing functions, which balance one another. This leads to the establishment of a dynamic physiological balance in the body and enables the system as a whole to maintain relative dynamic equilibrium, despite changes in the surroundings and shifts arising during the activity of the organism. Disturbance of physiological balance, including that connected with disturbance of equilibrium in microbiocenosis, may be manifested as diseases of various organs. The proposed composition and method of use are directed to prevention or effective decrease of deviations of physiological balance, with respect to the state of the intestinal microbiocenosis under the influence of a “disturbing” factor in the form of antibiotics.
[0024] Oligosaccharides are carbohydrates whose molecules are predominantly formed by not more than 10 monosaccharide residues. They are divided into disaccharides, trisaccharides and so on. In living organisms oligosaccharides are formed during enzymatic cleavage of polysaccharides. The microorganisms in the gut utilize oligosaccharides with the aid of their own glycosidases, and oral administration of oligosaccharides leads to increased production and intensification of the saccharolytic activity of these enzymes.
[0025] Since the prebiotic —oligosaccharide in the form specified according to the present invention—is used in the proposed composition simultaneously with the antibiotic and in the necessary proportions by weight, although the antibiotic suppresses pathogenic bacteria, the intrinsic microflora of the large intestine does not perish, but synchronously with the supply of oligosaccharide, hydrolyzes (ferments) the latter with formation of an effective amount of short-chain fatty acids (predominantly lactic, partially formic and acetic). The osmotic pressure in the large intestine increases to 6.6-8.0 atm and the pH falls below 5.0, i.e. in the direction of increasing acidity, which leads to reliable maintenance of the normal selective permeability of the biological membranes of the intestine and retention of ammonium ions therein, removal of ammonia from the blood into the intestine and its ionization. Thus, in the lumen of the large intestine, conditions develop that are completely unfavorable for the development of pathogenic species of bacteria, e.g. salmonella.
[0026] The accumulated acid products and some metabolites suppress the development of a wide range of putrefactive microflora. As a result, in the lumen of the intestine there is a decrease in the quantity of pathogenic bacteria and toxic metabolites (ammonia, skatole, indole etc.). Against a background of effective maintenance of homeostasis, there is unhindered provision of sufficient multiplication and stimulation of growth of the natural useful intestinal microflora that is to be preserved. As the acidity of the medium increases, the acids react with the amino groups of protein and, by removing OH ions, promotes development of electropositive protein, which suppresses inflammatory processes that might occur in the intestine owing to external causes and as a complication of the main disease.
[0027] Any nonliving and living matter (organism, system, organ, tissue, cell, cellular organelles and substrates etc.) has its particular spectrum of electromagnetic vibrations in a wide range from hundredths of a hertz to kilo- and mega-hertz and more complex harmonics. In normal conditions, it is accepted to call these vibrations harmonic (physiological), whereas in pathologic conditions, disharmonic (pathological) vibrations appear. Oligosaccharides, in the form specified according to the present invention, being vegetable components, have energy components that initiate super-weak electromagnetic vibrations, which are superposed on the disharmonic vibrations introduced by the antibiotics, and at selected proportions by weight of the ingredients there is, as it were, “obliteration” of this potentially pathologic information.
[0028] This action of oligosaccharides is evidently also connected with an immunostimulating effect, which increases the body's nonspecific resistance to infections and preserves “biological equilibrium”. There is then restoration of self-regulating processes and intensification of the harmonic vibrations that stimulate the processes of regeneration of the intestinal mucosa.
[0029] The process for preparation of the proposed composition comprises preparing specified amounts of powdered antibiotic and powdered prebiotic with a supplier-guaranteed purity of at least 95%, predrying to 2-3% moisture and mixing in the proportions specified by the present invention. The mixture also includes anticaking additives, flavorings, and taste correctants, and static electric charges are removed.
[0030] Next, packaging of the finished product is carried out, according to the dosage and the pharmaceutical form.
[0031] Compositions with the following combinations of ingredients were prepared.
[0032] Fructooligosugars with one of the amphenicols, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 130-200 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:1.5.
[0033] Fructooligosugars with one of the fluoroquinolones, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 30-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:2.
[0034] Fructooligosugars with one of the glycopeptides, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size 20-90 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:4.
[0035] Fructooligosugars with one of the ansamycins, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 4 to 10, and with the antibiotic in the form of powder with particle size of 20-140 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:15.
[0036] Fructooligosugars with one of the amphenicols, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 20-90 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:30.
[0037] Fructooligosugars with one of the nitrofurans, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 8, and with the antibiotic in the form of powder with particle size of 20-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:70.
[0038] Fructooligosugars with one of the sulfanilamide preparations (biseptol), with the oligosaccharide in the form of powder with particle size of 0.2-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 20-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:100.
[0039] Galactooligosugars with one of the amphenicols, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 5 to 15, and with the antibiotic in the form of powder with particle size of 50-150 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:2.
[0040] Galactooligosugars with one of the fluoroquinolones, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 4 to 12, and with the antibiotic in the form of powder with particle size of 20-90 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:3.
[0041] Galactooligosugars with one of the glycopeptides, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 5 to 15, and with the antibiotic in the form of powder with particle size of 30-100 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:40.
[0042] Galactooligosugars with one of the ansamycins, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 3 to 10, and with the antibiotic in the form of powder with particle size of 20-110 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:60.
[0043] Galactooligosugars with one of the derivatives of phosphonic acid (fosfomycin), with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 4 to 12, and with the antibiotic in the form of powder with particle size of 20-90 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:90.
[0044] Galactooligosugars with one of the nitrofurans, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 3 to 10, and with the antibiotic in the form of powder with particle size of 90-200 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:55.
[0045] Galactooligosugars with one of the sulfanilamide preparations (Streptocid), with the oligosaccharide in the form of powder with particle size of 0.2-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 40-150 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:45.
[0046] Xylooligosugars with one of the amphenicols, with the oligosaccharide in the form of powder with particle size of 0.2-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 20-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:45.
[0047] Xylooligosugars with one of the fluoroquinolones, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 8, and with the antibiotic in the form of powder with particle size of 20-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:80.
[0048] Xylooligosugars with one of the glycopeptides, with the oligosaccharide in the form of powder with particle size of 0.2-0.3 mm and with degree of polymerization from 4 to 10, and with the antibiotic in the form of powder with particle size of 160-200 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:100.
[0049] Xylooligosugars with one of the ansamycins, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 8, and with the antibiotic in the form of powder with particle size of 20-100 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:65.
[0050] Xylooligosugars with one of the derivatives of phosphonic acid (fosfomycin), with the oligosaccharide in the form of powder with particle size of 0.2-0.3 mm with degree of polymerization from 4 to 10, and with the antibiotic in the form of powder with particle size of 20-100 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:5.5.
[0051] Xylooligosugars with one of the nitrofurans, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 30-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:3.5.
[0052] Xylooligosugars with one of the sulfanilamide preparations, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 20-90 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:2.
[0053] Maltooligosugars with one of the amphenicols, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 120-180 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:1.
[0054] Maltooligosugars with one of the fluoroquinolones, with the oligosaccharide in the form of powder with particle size of 0.2-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 20-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:6.
[0055] Maltooligosugars with one of the glycopeptides, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 6, and with the antibiotic in the form of powder with particle size of 20-90 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:25.
[0056] Maltooligosugars with one of the derivatives of phosphonic acid (fosfomycin), with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 8, and with the antibiotic in the form of powder with particle size of 20-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:60.
[0057] Maltooligosugars with one of the ansamycins, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 5 to 15, and with the antibiotic in the form of powder with particle size of 20-90 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:70.
[0058] Maltooligosugars with one of the monobactams, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 4 to 12, and with the antibiotic in the form of powder with particle size of 40-140 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:100.
[0059] Maltooligosugars with one of the sulfanilamide preparations, with the oligosaccharide in the form of powder with particle size of 0.1-0.3 mm and with degree of polymerization from 2 to 8, and with the antibiotic in the form of powder with particle size of 20-120 μm, the antibiotic and the oligosaccharide being used in a weight ratio of 1:6.
[0060] The composition was prepared in pharmaceutical forms suitable for oral use, in particular in the form of capsules, tablets, powders, pills, sugar-coated pills, granules, sachets, gels, pastes, syrups, emulsions, suspensions, solutions. The composition included pharmaceutically acceptable amounts of excipients for improving the organoleptic and consumer properties, in particular fillers, taste correctants, flavorings etc.
[0061] To investigate the action of the preparations obtained and to confirm their suitability to serve as prophylactic and therapeutic pharmaceutical agents, their effects on the physical state of patients with various infectious diseases were investigated. The action of the preparations on general state, physical activity, sleep, appetite, progression of atherosclerosis, neurologic status and the course of chronic somatic diseases (diabetes mellitus) was assessed.
[0062] The test group under observation comprised 157 patients in the age range from 19 to 70 years: 75 men and 82 women. The diagnosis was established in outpatient conditions based on medical examination, results of laboratory and biochemical tests, ECG data, echocardiography etc.
[0063] There were 48 patients with a diagnosis of gastric ulcer, 45 patients with a diagnosis of chronic bronchitis and bronchiectatic disease, 40 patients with a diagnosis of acute or chronic pneumonia, and 24 women with gynecological diagnoses. Many of these patients had had symptoms of gastrointestinal disturbances for a long time (colitis, enterocolitis, IBS etc.), as well as symptoms of atherosclerosis of varying severity.
[0064] Before starting intake of combination of antibiotics andprebiotics a general blood analysis and biochemical indices of the blood serum of all patients were investigated: namely AST and ALT activity, concentration of serum creatinine, glucose, calcium, total bilirubin, protein, serum iron, TIBC, sodium, potassium, cholesterol, uric acid, urea, albumin, activity of alkaline phosphatase and GGT, content of triglycerides, β-lipoproteins, and in addition urine analysis, microbiologic analysis of the intestinal contents and investigation of the feces were carried out.
[0065] The patients took the preparations 2-3 times a day, during or after a meal in amounts specified in the instructions for use of the antibiotics and the clinical standards for treatment of the particular infectious diseases. On average, antibiotics with oligosaccharides according to each of these embodiments were taken by patients in test subgroups of 5-6 patients. Monitoring tests were carried out for 2 months, every 8-10 days.
[0066] Moreover, the first control group—64 patients of similar age and physical condition, with the same diseases—received antibiotics plus placebo (instead of oligosaccharide), and the second control group—54 patients of similar age and physical condition, with the same diseases—received antibiotics with oligosaccharides sequentially, with an interval of 1-1.5 hours.
[0067] For the patients in both groups, during the first days of taking the preparations their state was assessed as unsatisfactory, there were observed fever, depression, chill, tinnitus, flatulence, constipation or diarrhea (the latter arose, as a rule, after previous courses of treatment with antibiotics). Improvement in general state was marked for most patients in the test group after taking the preparations for 6-8 days.
[0068] At 7 th -9 th day after the start of treatment, the condition of the patients in the control group had also started to improve with respect to the main disease, but 75% of patients in the first group and 50% in the second group had clear symptoms of negative effects of the antibiotics on the intestinal microbiocenoses (dysbiosis), manifested as discomfort, slight pains in the region of the large intestine, flatulence and diarrhea. In some patients the dysbiosis led to reduced appetite and sleep disturbance.
[0069] By the end of the course of treatment with the preparations, there was overall improvement of condition for all the patients in the test group. There was a dramatic improvement in the state of 46 patients, and for the other patients in this group the symptoms of the main disease had practically disappeared. In 28 patients with various symptoms of atherosclerosis, headaches decreased in 22 cases, dizziness in 13, tinnitus in 16, cardiac pains in 18, and arterial blood pressure had normalized in 17 cases.
[0070] For the gynecological patients in the test group, the efficacy of the treatment was assessed before its start, during the treatment and after completion, using: biopsy of cervical mucosa, cytologic and microbiological investigation. After the first four weeks of taking the preparation, appearance of the first regions of marginal epithelization of erosions was noted, and lactobacilli and bifidobacteria appeared in the microbiocenoses of the vagina, discharges decreased considerably and painful sensations had disappeared completely. The data from morphological investigation after stopping intake of the preparation indicated almost complete replacement of columnar epithelium with squamous epithelium. Smears indicated a decrease in signs of inflammation.
[0071] In nearly all the patients in the test group, the functional state of the gastrointestinal tract had normalized, and the amount of muscle fibers, fat, fatty acids, and undigested cellulose in the stool specimen was in the normal range.
[0072] Analysis of the dynamics of a number of biochemical indices showed a significant decrease in bilirubin, P-lipoproteins, triglycerides, ALT, AST. The structural-functional changes in the plasma proteins indicated enhancement of albumin binding capacity, and increase in the activity of antibodies and proteins of the complement system. The results of biochemical investigation and cell counts of the peripheral blood also indicated positive dynamics of the process.
[0073] At the same time there was an increase in the amount of urea synthesized, indicating improvement of the processes of reamination and transamination of amino acids in the liver, i.e. normalization of metabolic detoxication processes.
[0074] Nearly all patients in the test group noticed improvement in quality of life through increase in physical activity, improvement of mood and sleep, normalization of appetite and of the working of the intestines. No adverse side-effects from taking the preparation appeared during treatment or follow-up.
[0075] In the first control group, among patients who received the antibiotic plus placebo, despite the decrease in severity of the symptoms of the main disease (under the influence of the antibiotic), 88% did have no clear tendency toward improvement in the indices of intraintestinal homeostasis. In the second control group, patients who received the antibiotic and oligosaccharides sequentially, the indices of intraintestinal homeostasis were similar to the indices in the test group in 55% of cases.
[0076] Observation of the state of the majority of patients in the test group, who received the proposed preparation, was continued over the next 4-9 months and confirmed the overall decrease in incidence of respiratory diseases, decrease in level of anxiety, increase in physical capacity for work, normalization of sleep, decrease in frequency of relapses of the underlying disease and steady improvement in quality of life, especially in the bowel function.
[0077] The results presented above confirm the efficacy of prophylaxis and treatment of dysbiosis during antibacterial therapy.
[0078] As a result, variants of an effective pharmaceutical composition and variants of an effective method of preventing dysbiosis have been created, and the arsenal of pharmaceutical compositions and methods of preventing dysbiosis has been expanded.
[0079] Moreover, the range of application of a composition of prebiotics and antibiotics has been expanded by including the most effective antibacterial preparations for oral administration (fluoroquinolones and ansamycins) in the composition and by eliminating side-effects. Effective utilization of the prebiotic component of the composition in the intestine was provided by introducing oligosaccharides with an optimal degree of polymerization and optimal proportions of the components with the necessary degree of dispersion (particle size).
SUITABILITY FOR INDUSTRIAL APPLICATION
[0080] The present invention is implemented using universal equipment, which is widely used in industry.
[0081] While the invention has been described in detail, modifications within the spirit and scope of the invention will be readily apparent to those of skill in the art. In view of the foregoing discussion, relevant knowledge in the art and references discussed above in connection with the Background and Detailed Description, the disclosures of which are incorporated herein by reference, further discussion is deemed unnecessary. | In the first variant, the pharmaceutical composition comprises antibiotic and prebiotic in the form of oligosaccharide of a group comprising fructooligosaccharides, galactooligosaccharides, maltooligosaccharides and isomaltooligosaccharides the polymerisation degree of which ranges from 2 to 10, the particle size is equal to less than 0.3 mm and the purity is of at least 95%, wherein the antibiotic particle size ranges from 20 to 200 mkm and the antibiotic and oligosaccharide are contained with a mass ratio ranging from 1:1 to 1:100 respectively. In the second variant, the pharmaceutical composition comprises antibiotic which is in the form of a powder with the particle size ranging from 20 t0 200 mkm and is selected form a group consisting of beta-lactams, including the combination thereof with bacterial betalactamase inhibitors, azalides, fluoroquinalones, amphenicols, glycopeptides, ansamycins, nitrofurans, phosphonic acid derivatives, cycloserine and trimetoprim. The prebiotic is in the form of a powder oligosaccharide, the polymerisation degree of which ranges from 2 to 10, the particle size is equal to less than 0.3 mm and the purity is of at least 95%, wherein the antibiotic and oligosaccharide are contained with a mass ratio ranging from 1:1 to 1:100 respectively. The above-mentioned compositions are used for preventing intestinal dysbiosis during antibiotic therapy and are perorally administered. The inventive composition produces a stimulating effect on intestinal lactobacilli and bifidobacteria simultaneously inhibiting the growth and proliferation of extraneous or pathogenic microflora. | 0 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to the field of seismic data acquisition systems and methods of using same. More specifically, the invention relates to methods and systems for determining one or more orientation parameters of nodes in or attached to seismic cable apparatus, such as seismic streamer and seabed seismic cables.
2. Related Art
Marine seismic exploration investigates and maps the structure and character of subsurface geological formations underlying a body of water. For large survey areas, a seismic spread may have vessels towing multiple seismic streamer cables through the water, and one or more seismic sources by the same or different vessel. The seismic sources typically comprise compressed air guns for generating acoustic pulses in the water. The energy from these pulses propagates downwardly into the geological formations and is reflected upwardly from the interfaces between subsurface geological formations. The reflected energy is sensed with seismic instruments attached to or internal of the seismic streamer cables, and data representing such energy is recorded and processed to provide information about the underlying geological features. So-called “ghost” signals, which reflect off of the surface of the water, may be problematic. Typically, it is necessary to “de-ghost” seismic signals received by seismic instruments. Seismic data may also be acquired using one or more so-called seabed seismic cables, and on land using a variety of seismic techniques. While this discussion focuses on art related to towed streamer seismic data collection, the invention is not so limited.
The orientation of seismic receivers is critical for the purpose of de-ghosting using multiple seismic instruments. Ghost signals may be separated from the directly reflected seismic signal if the ghost signal is recorded by two or more seismic instruments in seismic streamer cables with known fixed separation. Unfortunately, due to seismic streamer cable rotation, snaking and other irregularities, the distance between any two seismic instruments in a streamer are almost constantly changing. Accelerometers may be used for measuring streamer cable rotation, but accelerometers are subject to drift, add weight to the streamer, and are therefore not ideal. An alternate method of measuring orientation of seismic cable apparatus would be beneficial to the de-ghosting effort. The methods and systems of the present invention address this problem, as well as providing other advantages in certain embodiments.
SUMMARY OF THE INVENTION
In accordance with the present invention, methods and systems for determining one or more orientation parameters of a seismic cable apparatus or system are described. As used herein the phrase “orientation parameter” includes, but is not limited to rotational movement or change in position, relative inline local directional heading, and the like. As used herein the “seismic cable apparatus or system” includes seismic streamers and seismic seabed cables, as well as “streamer-related” items such as streamer section connectors, sensors in or on the streamers, connectors between streamers (for example connectors facilitating so-called over/under streamer arrangements, as described in our co-pending application serial number 11/055,481, tiled Feb. 10, 2005, incorporated by reference herein), “positioning streamers” as described in our co-pending application serial number 11/086,030, filed Mar. 22, 2005, incorporated by reference herein, streamer deflectors, separation cables, steerable and non-steerable tail buoys, and the like, including control surfaces and bodies of such devices, and one or more instruments integral with or attached to any of these, such as hydrophones, GPS receivers, compasses, inertial measuring devices, and the like. In certain embodiments, methods and systems of the invention may be used to estimate rotation and/or directional heading of a marine seismic streamer cable, or rotational movement of a seabed seismic cable. In certain embodiments, other information may be obtained as well, such as local sound velocity in the vicinity of a seismic cable apparatus. The methods and systems of the invention reduce or overcome problems using accelerometers, and may increase the ability to de-ghost reflected seismic signals received by seismic instruments attached to or within seismic streamer cables. Methods and systems of the invention may be used to collect marine seismic data, for example 3-D and 4-D marine seismic data, while allowing improved ghost separation from directly reflected seismic signals. The invention provides methods and systems for determining one or more orientation parameters, and optionally other parameters, of a seismic cable apparatus by analysis of one or more acoustic signals. Other signals, such as electromagnetic (EM) signals, may be used to transfer data to and/or from the acoustic transmitter, to transmit power, and/or to receive instructions to operate equipment. The acoustic signal impinges upon the seismic cable apparatus, or portions thereof. In certain embodiments the impinged signals may be received and transmitted to a calculation unit by a signal receiver apparatus, and in other embodiments the signals may be reflected or otherwise directed to other apparatus able to interpret the reflected signals.
A first aspect of the invention comprises methods, one method comprising:
a) initiating an acoustic signal from a transmitter, the signal impinging upon at least two nodes on or in one or more seismic cable apparatus, the nodes separated by a fixed distance; b) measuring a first and a second difference in arrival times at the nodes for the signal; and c) using change in the second difference from the first difference to estimate one or more orientation parameters of at least a portion of the seismic cable apparatus.
As used herein the term “node” is used generically to denote a component able to detect a signal, or to be detected remotely by a signal impinging on it and being reflected to another device. Methods of the invention include those wherein the signal comprises a wavelength shorter than the fixed distance between the two nodes, which may be two seismic instruments, such as hydrophones. Certain methods of the invention are those wherein the estimate of the at least one orientation parameter comprises measuring orientation of a seismic streamer, the method comprising estimating parameters selected from an angle of rotation of the streamer, inline heading of a streamer, and the like. Methods of the invention include those wherein the signal is an acoustic signal initiated from within a seismic spread, wherein the marine seismic spread comprises one or a plurality of streamers, and each streamer may have a plurality of seismic instruments, such as hydrophones, therein or attached thereto. Three or more seismic instruments may exist in a seismic instrument plane that is substantially vertical and perpendicular to a longitudinal axis of the seismic cable apparatus. The angle of rotation may be in a plane defined by three or more seismic cable apparatus. Certain methods of the invention may use one or more signals recorded at orthogonally situated seismic instruments to estimate orientation of the seismic cable apparatus. Differences in phase measured at the seismic cable apparatus provide their relation to one another with regard to orientation of the plane they sit in. Since the fixed distance between nodes is known, orientation parameters may be estimated. Further, more precise distance measurements and signal propagation rates may be possible using high-frequency signals, which may be measured with multiple instruments. High-frequency signals (e.g., wavelengths smaller than the distance between nodes) provide phase differences with higher resolution than lower-frequency acoustic signals. Continuous cycle counting and phase tracking may be employed to measure small orientation changes. For example, techniques common to tracking position relationship of GPS satellites and receivers may be employed. In certain methods, integer ambiguity resolution in GPS comprises making a first good estimate of relation between transmitters (GPS satellites) and receivers. The phase of the carrier signal is tracked and a search performed of a volume within which the receiver probably is located. Typically there are a number of locations within the volume where the partial waves could fit together, and the method evaluates the most likely location of this set. This then is used as a starting place for relative change. Successive events of phase tracking lead to more and more certainty for which of the set is the most likely one. In some embodiments, use of a large number of measurements may ensure high resolution and accuracy in the determination of cycle ambiguity.
Yet other methods of the invention include estimating relative inline local heading of a seismic cable apparatus, for example a seismic streamer cable. An estimate of an inline local heading may be obtained as long as there is a fixed distance separation between nodes parallel to the seismic apparatus. Both the shape and absolute bearing with respect to a fixed reference frame are useful for seismic hydrophone positioning. Acoustic signal recordings at nodes such as hydrophones or other receivers rigidly aligned with an inline axis of a seismic cable apparatus may provide a local apparatus heading at their locale, and these local headings may optionally be interpolated using some assumed shape between these locales to give a better estimation of shape of a seismic cable apparatus, such as a streamer cable, that may be available today. These headings may be related to an absolute reference when the nodes aligned with the inline axis of the seismic cable apparatus are positioned in an acoustic network with a reference to an absolute reference frame, the GPS reference frame WGS-84 for example. If the axis between two inline nodes, integral to the seismic cable apparatus, is rigid, a further use for these two nodes capable of recording a signal is to determine the local sound velocity propagation over the distance separating the two nodes.
Exemplary methods of the invention comprise multiple acoustic transmitters transmitting acoustic signals. In certain methods of the invention the difference in acoustic arrival times at two acoustic receivers on a seismic cable apparatus may be combined with monitoring of acoustic signal phase change. This combination may provide the orientation of a plane containing the receivers when the relative positions of receivers in the plane are known, as it is an ultra-short baseline acoustic system. In yet other methods of the invention, the earth-based positions of the transmitters, the seismic cable apparatus or portions thereof may be determined from trilateration in reference to satellite receiver control points spaced regularly or randomly as desired in the spread to make an insea network. Estimating of seismic cable apparatus orientation (rotation, inline heading, and the like) may be performed by a calculation performed by a computer and one or more software algorithms. Optionally, streamer parameters and characteristics of streamer steering devices, such as force exerted by wings of steerable birds having one or more wings, may be used in the calculation. As used herein the phrase “streamer parameters” includes, but is not limited to, tension in the streamer, the angle of incidence of the streamer to the flow direction, streamer relative water speed, streamer diameter, streamer density, and the like. Methods of the invention include those wherein at least one seismic cable apparatus position, or a node thereon, is known, and the position of a neighboring seismic cable apparatus, or neighboring node, is estimated. The estimation of position of at least a portion of a seismic cable apparatus, such as a section of a seismic streamer cable, may include use of the equations of motion, and may include other information and/or calculations and algorithms. Other methods of the invention may employ nodes integrated into a seismic streamer cable and/or other seismic devices, and using the estimate as an inline orientation (heading) estimate.
A second aspect of the invention are systems for carrying out the inventive methods, one system comprising:
a) two or more nodes separated by a fixed distance in a seismic cable apparatus; b) a transmitter emitting an acoustic signal; c) a measuring unit for measuring a first and a second difference in arrival times at the nodes for the signal; and d) a calculation unit using change in the second difference from the first difference to estimate one or more orientation parameters of at least a portion of the seismic cable apparatus.
Systems of the invention include those wherein the transmitter is an acoustic transmitter that emits an acoustic signal having a wavelength shorter than the fixed distance between the nodes. Other systems of the invention include those wherein the calculation unit calculates a parameter selected from an angle of rotation, inline heading, and the like. Systems of the invention include those wherein the measuring unit and calculation unit are combined in one unit, and systems where they are separate units. Systems of the invention may include other sensors, instrumentation, and equipment such as temperature sensors, pressure sensors, depth sensors, salinity sensors, inertial sensors such as accelerometers, acoustic positioning instrumentation (transmitters, receivers, and/or transceivers), steering devices, connectors and the like. A transceiver is a dual functioning unit that both transmits and receives acoustic signals. Systems of the invention may also utilize buoy-mounted transmitters and/or receivers wherein the buoys are tethered to something other than seismic cable apparatus, such as a buoy anchored in a channel.
Systems of the invention may include satellite-based global positioning control points (satellite receivers) spaced as desired, either regularly or randomly spaced. The satellite receivers may be stationed on floatation devices, for example buoys, tethered to a streamer. A satellite receiver may be stationed near a quarter point between a midpoint and a tail of one or more seismic streamers. It is also within the invention to station a satellite receiver near a quarter point between the midpoint of the seismic streamer and the towing vessel. As with acoustic transmitters and receivers, the invention contemplates usage of buoy-mounted satellite receivers in conjunction with one or more streamer mounted satellite receiver, wherein some of the buoys are not attached to any spread element, but anchored to some other location.
Systems of the invention include those systems wherein the seismic cable apparatus are seismic streamers positioned in over/under arrangement, with or without rigid or semi-rigid connectors, or offset horizontally. It is not necessary that streamers follow any defined path or trajectory, as long as it is possible for the nodes to receive the signal emitted from the transmitter to calculate arrival time differences and use this information in calculating one or more orientation parameters. Systems of the invention may comprise inertial positioning components, which may supplement the inventive systems in embodiments when satellite communication is blocked or unavailable. Systems of the invention may include means for communicating positions of seismic cable apparatus to a vessel or other information repository or controller (such as steering device controllers) requiring the information.
Methods and systems of the invention will become more apparent upon review of the brief description of the drawings, the detailed description of the invention, and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which the objectives of the invention and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
FIG. 1 illustrates a simplified schematic plan view of a towed streamer seismic spread that may benefit from the methods and systems of the invention;
FIGS. 2 and 3 illustrate detailed, highly schematic cross-sectional views of a seismic streamer cable, illustrating methods of the invention;
FIG. 4 is a schematic perspective view of a series of seismic streamer cables employing a method of the invention;
FIG. 5 is a schematic illustration of measurement and calculation units in a system useful in implementing methods of the invention; and
FIGS. 6 and 7 are schematic perspective views of other methods of the invention.
It is to be noted, however, that the appended drawings are not to scale and illustrate only typical embodiments of this invention, and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
All phrases, derivations, collocations and multiword expressions used herein, in particular in the claims that follow, are expressly not limited to nouns and verbs. It is apparent that meanings are not just expressed by nouns and verbs or single words. Languages use a variety of ways to express content. The existence of inventive concepts and the ways in which these are expressed varies in language-cultures. For example, many lexicalized compounds in Germanic languages are often expressed as adjective-noun combinations, noun-preposition-noun combinations or derivations in Romantic languages. The possibility to include phrases, derivations and collocations in the claims is essential for high-quality patents, making it possible to reduce expressions to their conceptual content, and all possible conceptual combinations of words that are compatible with such content (either within a language or across languages) are intended to be included in the used phrases.
As illustrated schematically in FIG. 1 , in order to perform towed marine seismic surveys, one or more marine seismic streamers 6 , 8 , each typically several thousand meters long and containing a large number of seismic instruments and associated electronic equipment distributed along its length, is towed at about 5 knots behind a seismic survey vessel 2 using tow cables 3 and 5 , which also may tow one or more seismic sources 4 comprising source members, typically air guns. Streamers 6 and 8 may be outer-most streamers of a greater number of streamers than depicted in FIG. 1 , and then might be diverted by streamer diverters 7 and 9 . Acoustic signals produced by seismic sources 4 are directed down through the water into the earth beneath, where they are reflected from the various strata. The reflected signals may be received by numerous acoustic receivers (seismic instruments) in the streamers, as indicated at 20 , digitized and then transmitted to the seismic survey vessel, where they may be recorded and at least partially processed with the ultimate aim of building up a representation of the earth strata in the area being surveyed. In recent years, seismic streamers have included acoustic ranging systems, wherein acoustic transmitters and receivers (or transducers performing both functions of transmitting and/or receiving) are stationed strategically in the streamers and dedicated to determining position of the streamers. Satellite receivers stationed at the tow vessel and the end of the streamers on buoys 12 , 14 , 16 , and 18 help determine the earth-oriented position.
As mentioned, ghost signals may be problematic in towed streamer marine seismic surveying, and de-ghosting is necessary. The orientation of a seismic streamer cable is critical for the purpose of de-ghosting using multiple seismic instruments. Ghost signals may be separated from the directly reflected seismic signal if the ghost signal is recorded by two or more seismic instruments in seismic streamer cables with known fixed separation distance. Unfortunately, a current indicated by arrow C tries to force streamers off the path intended by the survey operators, and numerous steering devices 10 may be used to keep the streamers close to their intended paths. In an effort to correct for the current C and other natural forces exerted on the streamers, streamer steering devices 10 may be employed. Unfortunately, the steamer then assumes a shape that is bowed between steering members 10 , and steering efforts by streamer steering devices 10 may cause seismic streamer cables 6 and 8 to rotate about their longitudinal axis, perhaps first in one rotational direction, and then in the opposite rotational direction, in a kind of torsion spring fashion. Therefore, in reality the positions of seismic instruments in a streamer are almost constantly changing, increasing the difficulty of de-ghosting the seismic signals. Accelerometers may be used for measuring streamer cable rotation, but accelerometers are subject to drift, requiring recalibration, add weight to the streamer, and are therefore not ideal. Similar cable rotation problems may be experienced by seabed seismic cables.
In accordance with the present invention, methods and systems for determining one or more orientation parameters of a seismic cable apparatus are described. The methods and systems of the invention reduce or overcome problems using accelerometers, and may increase the ability to de-ghost reflected seismic signals received by seismic instruments attached to or within seismic streamer cables, although the invention is not so limited, and may be employed in conjunction with seabed seismic methods using seabed cables. Methods and systems of the invention may be used to collect towed streamer marine seismic data, for example 3-D and 4-D marine seismic data, while allowing improved ghost separation from directly reflected seismic signals. The invention provides methods and systems for determining the orientation of seismic instruments such as seismic streamer cables and/or instruments contained within or on the cable using one or more acoustic signal transmissions and analysis of the difference in arrival times of the signals at the streamer cable and/or instruments on or in the cable. In certain embodiments, the signals may be short wavelength (high-frequency) relative to the separation distance between the seismic instruments. Differences in phase measured at the seismic instruments give their relation to one another with regard to orientation of the plane they sit in. Since the distance between and relative orientation of the seismic instruments is known, cable orientation may be determined. More precise distance measurements and propagation rates are possible since the acoustic signals may be measured with multiple seismic instruments. High-frequency signals (e.g., wavelengths smaller than the distance between nodes) may be useful to provide phase difference with high resolution, and continuous cycle counting and phase tracking may be employed to provide small orientation changes. In certain methods and systems of the invention, a large number of measurements may ensure high resolution and accuracy in the determination of cycle ambiguity. Illustrated in FIG. 1 are one or more acoustic transmitters 24 attached to streamers 6 , 8 . Transmitters 24 are illustrated as attached to streamers 6 , 8 , but this is not a requirement of the invention. Essentially all that is required is that transmitters 24 be able to emit acoustic signals from a position that allows seismic instruments 20 to pick up their signal. Thus, transmitters 24 could, for example, be placed on source 4 , or buoys 12 , 14 , 16 , and/or 18 .
FIGS. 2 and 3 illustrate detailed, highly schematic cross-sectional views of a seismic streamer cable, illustrating methods of the invention. FIG. 2 illustrates determining the orientation of a seismic streamer cable 6 and/or the seismic instruments 26 , 27 , and 28 contained within a streamer cable 6 using an acoustic signal transmission 32 from a transmitter 24 . Signal 32 is recorded by instruments 26 , 27 , and 28 as evidenced by vertical dashed lines 34 , 38 , and 36 , respectively, in other words at orthogonally situated nodes in streamer cable 6 to determine cable orientation, which may be expressed as a rotation angle “α” from a vertical axis. Nodes 26 , 27 , and 28 are electronically connected to data acquisition hardware through electrical connections 29 , 30 , and 31 , respectively. Signal 32 may comprise a short wavelength relative to the separation distance between the nodes. FIG. 3 illustrates an embodiment wherein high-frequency signals 32 (e.g., wavelengths smaller than the distance between nodes) provide phase difference with high resolution, and continuous cycle counting and phase tracking may be employed to provide small orientation changes (small rotation angle, α). In certain methods and systems of the invention, such as embodiment 50 illustrated schematically in FIG. 4 having multiple streamers 6 , 6 a , 6 b , 8 and 8 a , and a plurality of high-frequency signal transmitters 24 , which may be the same or different in terms of signal frequency, a large number of measurements may ensure high resolution and accuracy in the determination of cycle ambiguity.
FIG. 5 is a schematic illustration of measurement, calculation and other sub-systems of a system useful in implementing methods of the invention. As illustrated in FIG. 5 , one or more measurement units 43 supply, via a wire or wireless transmission 45 , signal arrival times, signal phase changes, and the like to a calculation unit 33 , which may be used to estimate streamer cable rotation and relative positions of nodes in or on a seismic apparatus such as a streamer cable. Seismic system characteristics 41 , such as streamer diameter and material of construction, steerable bird wing angles and wing areas, current vector information, GPS coordinates of one or more buoys and nearby receivers, and the like, may optionally be supplied to calculation sub-unit 33 via wire or wireless transmission 39 . Calculation unit 33 may include software and hardware allowing the implementation of one or more equations of motion, as well as other algorithms and operations as required, as well as access databases 58 , data warehouses and the like, via wire or wireless transmission 56 . A data deghosting sub-unit 55 may receive streamer cable rotation and relative positions of seismic instruments in or on the streamer cable, and de-ghost seismic data being received by these seismic instruments. De-ghosted data may be transmitted to database 58 , navigation system 57 , or other sub-units not illustrated, through wire or wireless transmissions 60 , 61 , and 62 .
FIG. 6 illustrates schematically another method of the invention, wherein two nodes 26 and 27 , which may be seismic hydrophones or other nodes dedicated receivers integrated into or attached to streamer 6 , receive an acoustic signal 32 . FIG. 6 illustrates determining the orientation of a seismic streamer cable 6 and/or seismic instruments 26 , 27 contained within a streamer cable 6 using a signal 32 from an acoustic transmitter 24 , which may be on an adjacent streamer 6 ′. Signal 32 is recorded by nodes 26 , 27 as in the embodiment illustrated in FIG. 2 , however, nodes 26 , 27 need not be orthogonally situated in streamer cable 6 to determine cable orientation. This embodiment may be used to measure inline heading of the streamer cable, and change of distance between nodes 26 , 27 . Nodes 26 , 27 are electronically connected to data acquisition hardware through electrical connections in the streamer cable, as previously indicated, but not illustrated in FIG. 6 . This arrangement may also be used to estimate a local streamer heading in the vicinity of nodes 26 , 27 by determining X-Y coordinates of nodes 26 and 27 . Since they are rigidly separated by a known distance, the local tangent of the streamer or other seismic apparatus may be estimated by taking the arctangent (Dy/Dx), giving local reference frame bearing. A large number of measurements would ensure higher resolution and accuracy in the determination of the relative position of the two nodes. This technique may be used with other seismic cable apparatus as well, such as seabed seismic cables, streamer steering devices, deflectors, streamer connectors, positioning streamers, and the like, as long as a fixed distance between any two nodes on a seismic cable apparatus, or between two nodes on separate seismic cable apparatus, is known.
FIG. 7 illustrates yet another method of the invention, wherein sound velocity may be determined directly by time of flight measurements through a seismic cable apparatus, such as a seismic streamer cable 6 . The illustrated methods are deemed streamer-integrated or seismic cable apparatus-integrated methods of estimating local sound velocity. An acoustic signal 32 traverses through the streamer until reaching receivers 26 and 27 , positioned at a known fixed distance apart through a portion of the streamer.
In certain exemplary embodiments, the ratio of the signal wavelength to fixed distance between nodes may range from 0.1 or less to 0.95, although the invention is not so limited, and the signal may have wavelengths longer than the fixed distance between nodes. In both the short- and long-wavelength embodiments, one or more signal processing techniques may be used, such as digital signal processing, mathematical transforms such as Fourier transforms to generate Fourier transformed data, applying a spatial wavenumber estimation based on a parametric algorithm to the Fourier transformed data, generating a wavenumber spectrum from the parametric algorithm, and using the wavenumber spectrum in one or more calculations. Differences in phase measured at the nodes give their relation to one another with regard to one or more orientation parameters, for example rotation in the plane they sit in. Since the distance between and relative orientation of the nodes is known, one or more orientation parameters may be determined. More precise distance measurements and propagation rates are possible since the signals may be measured with multiple instruments.
Other optional features may be provided with systems of the invention. For example, in cases where the seismic cable apparatus, for example a seismic streamer cable, is slightly heavy (slightly negative buoyancy), and winged streamer steering devices thus need to produce lift to maintain the streamer at the desired depth, this lift may be produced by the flow of the water over the wings of the bird, resulting from the towing speed of the streamer through the water, and can be changed by changing the angle of attack of the wings with respect to the flow. The magnitude of the lift required may depend on seismic instrument positions, and how far the streamer is off of target depth and/or lateral position. If the streamer needs to be moved laterally, the angular position of one wing of the bird may first be adjusted to increase its lift, while the angular position of the other wing is adjusted to decrease its lift, thus causing the bird to roll clockwise or counterclockwise as desired. This roll continues until the bird reaches a steady state condition, where the vertical component of the lift produced by the wings is equal to the lift required to maintain the streamer at the desired depth, while the much larger horizontal component moves the streamer laterally as desired.
While adjusting the angular positions of the wings of the bird, a control circuit may continuously receive signals representative of the actual angular positions of the wings from the stepper motors, as well as a signal representative of the actual roll angle of the bird from an inclinometer, and actual rotation angle of a streamer cable using the methods described herein, to enable the control circuit to determine when the calculated wing angular positions and bird roll angle have been reached. The control circuit may repeatedly recalculate the progressively changing values of the roll angle of the bird, the angular positions of the wings required for the bird and streamer to reach the desired depth and lateral position, and the rotation angle of the streamer cable, until the bird and streamer actually reach the desired depth and lateral position.
The body of steerable birds may or may not rotate with respect to the streamer; if the body does not, it will twists the streamer as it rolls. The streamer resists this twisting motion, so acting as a kind of torsion spring which tends to return the bird to its normal position (i.e. with the wings extending horizontally). However, this spring returning action, though beneficial, is not essential, and the bird can if desired be designed to rotate to a certain extent with respect to the axis of the streamer.
In order to optimize seismic data acquisition, such as during towed streamer marine seismic acquisition and seabed seismic data acquisition, accurate position estimates of seismic receivers are required. For towed streamer seismic data acquisition, force models of the streamers may provide better receiver position estimates by giving more information to calculation units used in previous methods. The direction and speed of the water flow past a streamer, (i.e., current relative to the streamer, and to wings of steering devices) may be determined within a common absolute reference frame, such as the World Geodetic System—1984 (WGS-84). For example, the combined vectors for ocean current and vessel motion give the water flow vector. Estimates of varying precision and accuracy for the streamer orientation exist. The streamer orientation uncertainty is due to at least two model errors; the streamer shape model between the steering devices and the unmodeled misalignment of the steering device relative to the longitudinal streamer axis.
Several methods may be used to advantage to calculate forces on a streamer in the absence of this information. The least precise is to assume the angle of attack of a streamer does not change and use a reasonable value and accept the accompanying error. An improvement on this method is to assume that the streamer is straight. A refinement again is to accept that the streamer is not straight and to use a function that approximates the streamer shape. These methods provide a more precise orientation estimate for the streamer than simply assuming the streamer is straight, however they are still estimates. Rather than using a streamer shape model, the best way to determine forces on a streamer is by measuring one or more characteristics of the steering devices and using this information to calculate the forces the steering devices are exerting on the streamer or portions thereof. This invention describes how to do this through several measurement mechanisms and calculating the forces using the equations of motion.
Knowing the respective wing surface areas, wing shapes, streamer cable rotation angle, and the water flow vector over the wings, one can calculate the forces exerted by the wings, and thus by the steering devices. Tension in the streamer cable may be measured using suitable devices, and the diameter and materials of construction of the streamer are known. It is then possible to calculate the position of a portion of the streamer, such as a seismic instrument, at time t 1 relative to a known position of a seismic instrument at time t 0 using this information and the equations of motion. Examples of using the equations of motion relative to towed flexible cylinders was addressed by Dowling in at least two articles, which are incorporated by reference herein: Dowling, A. P., “The Dynamics of Towed Flexible Cylinders Part I. Neutrally Buoyant Elements”, J. Fluid Mechanics, V. 187, pp 507-532 (1988); and Dowling, A. P., “The Dynamics of Towed Flexible Cylinders Part II. Negatively Buoyant Elements”, J. Fluid Mechanics, V. 187, pp 533-571 (1988). Mathematical treatment of wings, including spanning area and lift and drag coefficients, was address by Tritton in 1988: Tritton, D.J., “Physical Fluid Dynamics”, Second Ed., Chapter 3, pp 153-161, Oxford Science Publications (1988), which is also incorporated by reference herein.
The initial lateral position of one or more steerable birds in a marine seismic spread that is close to a GPS receiver in the spread may be determined for instance by using GPS alone or combined with an acoustic positioning system, such as a short-baseline (SBL) or ultra-short baseline (USBL) acoustic system. By further using measured arrival times of high-frequency acoustic signals in accordance with the invention, and/or phase changes of the high-frequency acoustic signals, along with characteristics of steering devices and streamer cables, and calculating the forces exerted on the streamer or portions thereof by the steering devices, it is possible to calculate the position of a portion of the streamer, such as an acoustic receiver, at times t 1 , t 2 , . . . , t n , at least relative to a known position, as well as rotational angle of the streamer. All receivers in or on a streamer cable, including receivers on birds, and other sensors and portions of a streamer, can this way be tracked for the purpose of deployment precision, increased operational safety, and increased efficiency.
It is within the invention to combine systems of the invention with other position control equipment, such as source array deflecting members, and streamer deflectors. Some of these may include bridle systems, pneumatic systems, hydraulic systems, and combinations thereof. Methods and systems of the invention may also be used to estimate one or more orientation parameters of these apparatus, or portions thereof, such as control surfaces.
In certain embodiments, regardless of the acoustic environment, a higher density of global positioning control points throughout the spread will improve overall accuracy by decreasing the distance between these points and the associated degradation of accuracy.
Other steerable birds useful in the invention include battery-powered steerable birds suspended beneath the streamer and including a pair of laterally projecting wings, the combination of streamers, orientation members (steerable birds) being arranged to be neutrally buoyant. Clamp-on steerable birds, as discussed previously, may also be employed. Steerable birds useful in the invention, including suspended birds, in-line birds, and clamp-on birds may include on-board controllers and/or communications devices, which may be microprocessor-based, to receive control signals representative of desired depth, actual depth, desired lateral position, actual lateral position and roll angle of the steerable bird. The bird on-board controllers may communicate with local controllers mounted on or in other birds, and/or communicate with other local controllers and/or remote controllers, such as a supervisory controller.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, no clauses are intended to be in the means-plus-function format allowed by 35 U.S.C. § 112, paragraph 6 unless “means for” is explicitly recited together with an associated function. “Means for” clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. | Methods and systems for estimating one or more orientation parameters of a seismic apparatus are described. One method comprises initiating an acoustic signal from an acoustic transmitter in a marine seismic spread comprising a streamer, the streamer having at least two nodes separated by a fixed distance; measuring a first and a second difference in acoustic arrival times at the nodes for the acoustic signal; and using change in the second difference from the first difference to estimate orientation of the streamer. It is emphasized that this abstract is provided to comply with the rules requiring an abstract, which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b). | 6 |
BACKGROUND OF THE INVENTION
This invention was made for the purpose of constructing a flexible tube element for the exhaust systems of combustion engines in vehicles with a helically or annularly corrugated bellows made of metal, with a stripwound metal hose in a coaxial position to the bellows and with coaxial, mostly cylindrical connection fittings installed at the ends of the bellows and/or the hose.
Such flexible tube elements are, as a rule, installed as an intermediate part in an automotive exhaust system which consists of rigid elements, for the purpose of absorbing such movements and vibrations as are caused by the elastically supported engine, by shock, by changes of length due to thermal effects, etc., and of insulating adjacent components from such movements and vibrations. The tube elements therefore not only have to have sufficient heat-insulating and sound absorbing properties and have to be tight to exhaust gases, they especially have to have suitable vibration damping properties.
Whereas the bellows, together with the connection fittings which are at least indirectly fixed to the bellows usually by welding, provides gas-tightness of the metal hose element, the stripwound metal hose is the part on which the damping properties are based. The damping of movements by this helically stripwound metal hose made of an, in general, pre-profilated metal strip by interlocking adjacent strip edges and by forming several layers with interlocked profile, is achieved by the conversion of the movements into friction, the so-called lost work of deformation, between the adjacent strip edges or layers with interlocked profile, for an angular, axial, lateral or torsional deflection. The friction values depend on the rate of winding or interlocking.
For an optimum damping of movements, the winding rate must be defined thus that there is neither almost no friction between the said hose edges due to a too loose winding which will reduce the obtainable damping properties to a very low value, nor that the winding is so tight that the friction in the metal hose is too high due to its rigidity, with the damping properties of the metal hose being reduced to a rate almost equal to the very low damping properties of a rigid pipe.
Even if a stripwound metal hose of optimum design is installed in the flexible tube element, there are still applications in which the damping properties of the metal hose cannot take full effect or in which its damping properties are yet not sufficient. The damping properties can be diminished at certain operating temperatures of the stripwound metal hose, i.e. at high temperatures of the hose due to a longer operating period of the exhaust system. One reason for this effect is the so-called thermal stiffening occurring especially in the bending zones of the stripwound hose due to the different material tensions induced during the winding process trying to relax and expanding at different rates in this process. As a result, there is an increase in friction between the adjacent strip edges or layers with interlocked profile, which will cause a restriction of the mobility of the hose or an increase in wear of the hose areas which are in contact with each other and, finally, a deterioration of the damping properties.
SUMMARY OF THE INVENTION
On the basis of the foregoing facts, this invention was made for the purpose of providing a flexible tube element of the kind mentioned in the beginning, whose advantages are an improvement of the damping properties and their persistence for a longer operating period regardless of the application and installation conditions.
In respect to the flexible metal hose element described hereinbefore, these requirements are met by providing a second stripwound metal hose in a coaxial position to the first stripwound metal hose already mentioned. The advantage of this design is the distribution of the respective requirements to two metal hoses, thus guaranteeing that, in any case, both metal hoses will achieve a maximum lost work of deformation for the purpose of optimum damping, and the reduction of thermal energy as only one example for the possible additional functions of the interior metal hose which works like an insulating device, protecting the first metal hose and the bellows from the heat of the exhaust gases.
This application allows the use of a stripwound hose with a loose winding for the reduction of temperatures, since the lost work of deformation it has to provide is only a secondary effect. The flexibility of this hose will avoid negative influences on the damping behavior of the first metal hose which will be subject to higher stress, requiring a tighter winding. This means that, due to the distribution of functions between the two hoses, made possible by the second stripwound metal hose, the first hose, whose task is damping, can always be designed with preference to optimum damping properties, whereas the second hose has to cover only a low lost work of deformation but has to carry out the task of protecting the first metal hose from conditions which may deteriorate its damping properties.
This combination of two metal hoses allows a high positioning variety, with the only precondition being at least an indirect firm connection of the two stripwound metal hoses with the connection fittings, since there is no other way of guaranteeing the desired damping between access and exit of the flexible tube element. According to this design, both metal hoses extend over at least a high percentage of the length of the metal hose element. It would also be possible to fix only the metal hose to the two connection fittings whose task is the damping of movements, whereas the second metal hose would still be able to provide insulation without a direct connection with the connection fittings, but the additional damping facility provided by this second hose would then not exist.
The two stripwound metal hoses can, e.g., be installed by insertion of one hose into the other under direct contact between them, or at a distance to each other due to the insertion of one spacer element. This design still allows both alternatives of installing both hoses either inside or outside the metal bellows. Furthermore, the bellows can also be placed between the two stripwound hoses.
The insulating effect of the interior metal hose allows the application of appropriate materials for the additional metal hose as well as for the bellows with regard to corrosion resistance, etc., which would alone be inappropriate for a temperature range existing under the influence of exhaust gases. The resistance of the metal hoses to thermal stiffening can be increased by the application of ferritic steel, whose expansion coefficient is only half the coefficient of austenitic steel.
In order to achieve an utmost damping of movements, it is recommended to select at least one hose with engaged profile for installation. A favorable feature of this hose type is the extension of the contact surfaces between adjacent strip layers providing an increase in friction or lost work of deformation.
In respect to the shape of the cross-sectional areas of the metal hoses, it is possible to use hoses with either polygonal or round cross-sectional areas. Regardless of these shapes, it is recommendable to select a diameter as high as possible for these metal hoses, i.e. to install them on the exterior surface of the bellows whenever possible, in order to provide a higher lost work of deformation rate by an increase in circumference and in the size of the contact surfaces of adjacent strip edges/layers with interlocked profile.
Finally, the equipment of the flexible tube element with a braiding hose consisting of metal wires, which is applied particularly if the two metal hoses are installed on the interior surface of the bellows and the bellows corrugations can be protected by this braiding hose from, e.g., influences from the environment, allows a high number of further modifications in respect to the positioning of the individual components in the metal hose element.
The foregoing series of examples makes it easy to get an idea of the possibilities and methods of designing the tube element by selection of the appropriate metal hose positions, winding rates etc., always allowing an optimum and long-lasting damping of movements. The only precondition to be complied with is the installation of the metal hose whose task is the damping of movements outside the critical temperature zone which would cause the thermal stiffening effects already mentioned, with the other metal hose providing the insulation of this metal hose and the bellows from these critical temperatures, and also being able to participate in the damping of movements.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of this invention are given in the following descriptions of design examples according to the drawings.
FIGS. 1 to 6 show design alternatives for a flexible tube element based on this invention, for installation in exhaust system, being presented in a lateral view, partly with axial section.
FIG. 7 shows a further alternative for the tube element, presented in a cross-sectional and in a lateral view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a flexible tube element 1 which consists of a helically or annularly corrugated metal bellows 2, whose axial ends are equipped with cylindrical connection fittings 3, 4, thus forming a gas-tight connection. The tube element 1 also includes helically stripwound metal hoses 5, 6 of engaged profile, in coaxial positions to the bellows. These hoses extend between the two connection fittings 3 and 4 at a low distance to each other and are fixed there, with the bellows 2 being installed between them as an intermediate part. Whereas the bellows has the task of guaranteeing the gas tightness of the tube element, at least one of the two stripwound hoses with interlocked profile 5, 6 provides the required damping characteristics of the flexible tube element.
Presuming that the interior hose with interlocked profile is installed in the critical temperature zone, it is the task of this hose to insulate the hose with interlocked profile 5 and the bellows 2 from this critical temperature. As a consequence, the hose with interlocked profile 5 is designed and applied in a way which provides the highest percentage of the damping rate.
FIG. 2 presents a tube element 11 which, in addition to the components of the element shown in FIG. 1 (with identical components being marked with identical references), is equipped with a braiding hose 17 which consists of metal wire and is installed on the exterior surface of the bellows, protecting the bellows from influences of the environment.
In any other respect, the tube elements 1 and 11 are equal.
FIG. 3 shows a flexible tube element 21, consisting of the components of metal hose element 1, with the only additional feature being the installation of the hoses with interlocked profile 5 and 6, one of which is inserted into the other, at a distance to each other. This distance is achieved by spacer rings 28, 29, which are installed at the axial ends of the hoses in the zones of their connection fittings. These spacer rings avoid direct contact between the hoses for low angular movements, which excludes, e.g., the production of noise due to such contact. In any other respect, the tube elements 21 and 1 have equal designs and functions.
The difference between the tube element presented in FIG. 4 differs and the metal hose element shown in FIG. 3 is the equipment of the metal bellows 2 with a braiding hose 37 of metal wires on its exterior surface, similar to the braiding hose 17 installed in the tube element shown in FIG. 2.
FIG. 5 shows a tube element 41 which differs to a higher extent from the tube elements presented in FIGS. 1 to 4. The metal hose element 41 consists of a metal bellows 42 whose ends are equipped with connection fittings 43, 44 and is equipped with a stripwound metal hose 46 with interlocked profile which is installed in the interior of this element and is fixed to the metal bellows in the zones of the connection fittings. The second metal hose 45 is equipped with two end sleeves 47, 48, each of them being provided for establishing a firm connection of one of the exterior ends of the hose with the corresponding connection fitting.
The metal bellows 42 is installed at a distance to both the first stripwound metal hose 46 and the second stripwound metal hose 45, thus avoiding a direct contact between the individual components under low angular movements between the two tube elements which would cause undesirable frictions and sounds.
In respect to the metal hose 45 installed on the exterior surface of the bellows it has to be mentioned that its diameter is, of course, larger than the diameter of metal hose 46, thus guaranteeing better damping properties due to the increase in the contact surface size of adjacent strip edges or layers with interlocked profile.
In the tube element 41, the two stripwound hoses are installed at a certain distance approximately equal to the height of the bellows corrugations, thus excluding a common connection in the zone of the connection fittings due to the cylindrical design of the stripwound hoses. The connection fittings 43, 44 are therefore bent at an angle which adapts them approximately to the exterior diameter of the interior stripwound hose 45 in the zone of their lower diameter, which provides a connection type between connection elements and stripwound hoses guaranteeing the transfer of movements.
FIG. 6 shows a tube element 51 making use of the higher damping effect due to a larger diameter of the stripwound hoses on the principle of an arrangement of both stripwound hoses 55, 56 on the exterior surface of a bellows 52. Due to this design, the interior surface of the bellows 52 is directly subject to the influence of the exhaust gases and their temperatures. This fact restricts the application of this design to such engines or to such positions in the exhaust system in which the exhaust gas temperatures are uncritical for the function of the metal bellows 52.
Whereas in the tube elements shown in FIGS. 1 to 5, the connection fittings are connected with the bellows ends at the level of their interior diameters, the metal bellows 52 in FIG. 6 is connected with the end of the stripwound hose 55 in the diametrical zone of its corrugation crests. The connection fittings 53, 54 are located on the exterior surface of the stripwound hose 55, so that, in this version, there is only an indirect connection between bellows and connection fittings, with the stripwound hose 55 being installed as an intermediate part.
The second stripwound hose 56 is fixed to the exterior surfaces of the connection fittings 53, 54 which are, in this version, used as spacer elements similar to those shown in FIGS. 3, 4. This hose runs in a coaxial position to the first stripwound hose, with a distance between the two hoses due to these connection fittings. The exterior surface of the stripwound hose 56 is also equipped with two end sleeves which are used in welding the outward stripwound hose to the connection fittings, similar to the application of the end sleeves 47, 48 in FIG. 5.
To summarize, this invention provides the advantage of a distribution of functions made possible by the second metal hose which is installed in addition to the first stripwound metal hose. This distribution of function guarantees the persistent ability of insulating one metal hose and/or the bellows from critical exhaust gas temperatures by means of the other metal hose, thus allowing the selection of a metal hose version with optimum damping properties.
FIG. 7 shows a tube element 5 which has a polygonal cross-sectional outline. | A flexible tube element for an exhaust pipe of a vehicle engine includes a first end and an opposite, second end; a circumferentially corrugated metal bellows extending between the first and second ends; a first stripwound metal hose arranged coaxially with the bellows between the first and second ends; a second stripwound metal hose arranged coaxially with the bellows and the first stripwound metal hose between the first and second ends; and first and second generally cylindrical connection fittings arranged at the first and second ends, respectively, and being coaxial with the bellows. | 5 |
FIELD AND BACKGROUND OF THE INVENTION
This invention relates in general to the joining of composite parts into a finished product and in particular to a new and useful method of sewing a seat cover into a foamed plastic panel of honeycombed cells.
A similar process for fabrication of seat covers with honeycomb cells is described in German patent DE-PS No. 33 04 343, in which striplike segments of foam plastic provides the filling of cells. It is introduced between a lower piece of material and an upper piece of material by means of guide channels, the upper piece of material lying around the lengthwise edges of the segments of foam plastic. Then, the cells are simultaneously sewn up on a multiple needle sewing machine. With seat covers manufactured in this way, the two seams lying in each recess between two cells will always be openly visible, so that this process is not suitable for manufacture of seat covers with cells in which the seams are to be concealed for optical reasons or for better durability.
U.S. Pat. No. 2 183 249 indicates a machine for the manufacture of seat covers which comprises prefabricated upper material segments, a bottom material fed from a supply reel, and many striplike elastic insert pieces lying between the layers of material. The layers of material are folded riblike between the insert pieces and the edges of the fold project on the lower piece of material. Then, the projecting portion of the fold is sewn up with a blind stitch by an appropriate number of sewing heads at the same time, so that many adjoining padded cells are formed on the upper side of the finished seat cover and the seams are quite invisible.
A serious defect of the seat covers made in this way is the fact that the seams under prolonged and heavy use are permanently stretched, so that gaps are formed between the originally adjacent segments of upper material in the region of the seam and as a result the threads of the seam become visible.
SUMMARY OF THE INVENTION
The invention provides a process for the manufacture of seat covers with honeycomb cells in which the seams are fully concealed and the threads of the seam do not become visible, even under stretching of the seam.
By using a foam plastic panel provided with prefabricated grooves as the elastic cushioning material instead of individual striplike insert pieces, this process dispenses with the exact placement of insert pieces between the upper and lower layers of material. Since the foam plastic panel is provided with a glued backing, it possesses great form stability to begin with, and there is no need for it to be sewn to the bottom material.
By virtue of the fact that after each sewing procedure the cover material to be used in the next folding and sewing procedure is folded back over the previously formed seam, the seams are entirely concealed and even remain invisible when the seat cover or the seams are stretched.
The inventive process enables an automatic operation of the individual process steps. Prior to each feeding motion of a new fold segment of the cover material into a groove, a portion of the cover material lying on the fold forming traveler is pushed together into a loose wave, large enough so that during the feeding motion it is again pulled flat without exerting any sizeable tension on the segment of material connected to the previously produced seam. This avoids any moving or uneven shifting of the already sewn portion of the seat cover.
An advantageous aspect of the inventive process creates a precondition for the needle rail always to advance the exactly required length of cover material on the traveler. Preferably the already sewn portion of the seat cover is held fast during feeding motion of the folding blade, so that the already sewn portion of the seat cover is additionally secured against being moved or unevenly shifted.
Accordingly it is an object of the invention to provide an improved method to forming a seat cover or similar article by joining a cover to a panel of foam plastic material which has transversely and longitudinally extending raised foam plastic portions separated by recesses and which includes directing the cover material so that a folded edge is introduced into the first row of recesses, held in position there and sewn or otherwise secured while a further portion of the cover is formed into a loop which is directed into the next adjacent recess and over the top of the raised foam honeycomb cells and the next folded edge is joined to the panel by sewing it along the recess and including repeating the process until the complete cover and panel are joined together.
A further object of the invention is to provide an apparatus for effecting the sewing of seat covers which includes a base plate which has a cross rail cooperative therewith which facilitates the positioning of the foam plastic panel so that its alternate rows of recesses in raised portions are oriented in respect to a traveler plate which carries a cover material which is folded over an edge of the traveler plate and directed by the traveler plate into the first row of recesses between the raised honeycomb portions of the cells and located in position so that it may be sewn by reciprocating sewing needles and which further includes means for forming a loop on the traveler plate of the cover material of an extent which permits it to cover the next adjacent row of cells and including means to direct this traveler plate so that the next formed edge of the cover material is directed into the second row of recesses at which this edge is again sewn in position and in which the process is repeated until the complete cover is sewn to the panel.
A further object of the invention is to provide a machine which permits the placing of a foam plastic material in a precise orientation to permit joining of a cover thereto which is sewn into the panel along recesses formed between raised foam cells of the cover.
A further object of the invention is to provide an apparatus for forming seat covers which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims and annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a partial top perspective view of a machine for the manufacture of seat covers constructed in accordance with the invention;
FIG. 2 is a top plan view of the machine;
FIGS. 3-8 are enlarged schematic sectional views of the inventive steps showing the principle of the successive work phases;
FIG. 9 is a sectional view of a finished seat cover.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in particular, in accordance with the inventive method a seat cover assembly is formed with a foam plastic panel (S) which has a plurality of rows of transversely and longitudinally spaced raised cells designated (T) and recesses (N). In accordance with the invention the foam panel (S) is placed on a base plate (68) which includes a tilted base plate portion (67) and it is precisely oriented on plate (68) by means of a cross rail (57) which moves downwardly and enters into a selected recess (N) of the foam panel (S). The cover material (B) is fed onto a traveler (34) so that an edge overlaps the traveler and forms a joining edge (K) which is directed by movement by the traveler (34) to the first row of recesses (N). The cover material is then held by a holding plate which is moved onto the marginal edge of the cover which has been folded and a pressing member (51) is moved downwardly over the top of the first folded edge which is then sewn by a needle 9 which is positioned at the location of the recess (N).
In accordance with the invention the next length of cover material which is to be formed over the next raised cell (T) is formed by advancing a needle rail (44) along the cover material (B) to form a loop (W) which would be of a precise length to cover the next adjacent raised cell (T). Thereafter the traveler (34) is again moved to direct the next folded length of cover material into the next adjacent row of recesses (N). The material of the cover (B) is again held by the holding plate (64) and by the pressing rail (51) to effect a sewing in the next recess by the sewing needle (9). The base plates (67) and (68) are moved to position the material in the locations so that the sewing needle (9) is effective to sew along the recesses (N).
On a frame (1) there is secured to table top (2), which carries a sewing machine (3). The sewing machine (3) has a base plate (4), set into the table top (2), a pedestal (5), and an arm (6), which passes into a head (7). In the head (7) is a needle bar (8), carrying a needle (9), which is actuated in the usual manner, (not shown).
A naturally rigid frame (10) comprise two cross bars (11), a rear lengthwise bar (12) joining these together, and a front lengthwise bar (13), which is joined to the cross bars (11) across two short vertical bars (14). The frame (10) rests on an angle rail (16), secured to the table top (2) and extending transverse to the lengthwise direction of the sewing machine (3), across several traveling rolls (15) able to turn on the rear lengthwise bar. The frame (10) is further supported and at the same time guided by several profile rolls (18), each turning in a holder (17), on guide rails (19) fastened to the frame (1) and extending parallel to the angle rail (16), so that the frame (10) can move in the direction transverse to the lengthwise direction of the sewing machine (3). The frame (10) is connected to the upper segment of a toothed belt or gear belt (21) across an angle piece (20), fastened to the front lengthwise bar (13). The toothed belt (21) travels across two gear wheels (22, 23), one of which is connected to a drive motor (24).
On the two cross bars (11) there is arranged a rotating shaft (25) extending between these bars, and on the shaft there are fastened two carrier plates (26) adjacent to the cross bars (11). On one end of the rotating shaft (25) is secured a crank (27), which is coupled to the piston rod of a pneumatic cylinder (28), fastened to the frame (10). On the upper end of each carrier plate (26), fashioned as a fork, there is secured a slide rod (29), extending parallel to the cross bars (11). On each slide rod (29) is arranged a cradle (30), U-shaped in top view, which has two transversely projecting legs (31, 32). The two cradles (30) are solidly joined together by a rod (33). On the rod (33) is secured a fold forming traveler (34) in the shape of a plate. To move the traveler (34), there is a pneumatic cylinder (35) assigned to each cradle (30), of which for better visibility in FIGS. 1 and 2 only the pneumatic cylinder (35) of the right cradle (30) is shown.
On each of the two slide rods (29) there is arranged an additional movable cradle (36), which is shorter than the particular cradle (30) located on the same slide rod (29) and which is located between the two projecting legs (31, 32) of the latter. On the two cradles (36) there are arranged two rotating shaft (37, 38), which at the same time join these cradles together. The shaft (37) is connected by a crank (39), fastened to it, with the piston rod of a pneumatic cylinder (40), which is arranged on the left cradle (36) in FIGS. 1 and 2. The shaft (38) is joined by a crank (41), fastened to it, with the piston rod of a pneumatic cylinder (42), which is also arranged on the left cradle (36) in FIGS. 1 and 2.
On the rotating shaft (37) there are secured two arms (43) (FIG. 2), which carry a needle rail (44) that is moved up and down by the pneumatic cylinder (40). On the rotating shaft (38) there are secured two arms (45) (FIG. 2), which carry a brush rail (46) that is moved up and down by the pneumatic cylinder (42). The two cradles (36) on the slide rods (29) are moved by two pneumatic cylinders (47), of which for better visibility in FIGS. 1 and 2 only the pneumatic cylinder (47) of the left cradle (36) is shown. This pneumatic cylinder (47) is arranged on a holding plate (48) which, in turn is fastened to the adjacent carrier plate (26).
There is a pneumatic cylinder (50) arranged on each of the two angle pieces (49), fastened to the two cross bars (11). Arranged on the piston rods of the two pneumatic cylinders (50) is a pressing rail (51), extending transverse to the lengthwise direction of the sewing machine.
On each cross bar (11) there are arranged two shoulders (52), which carry a slide rod (53). On the slide rods (53) are arranged the cradles (54), each L-shaped from the side view. On the end of each cradle (54) facing the pressing rail (51) is a movably mounted arm (55 and 56). The free ends of the arms (55, 56) are joined together by a cross thrust rail (57), extending parallel to the pressing rail (51). The arm (56) is joined to a lever (58) in one piece. The lever (58) is engaged by the piston rod of a pneumatic cylinder (59), which is linked to a shoulder (60) of the corresponding cradle (54). The two cradles (54) are moved by two pneumatic cylinders (61), shown only in FIG. 2, which are fastened to the cross bars (11), the piston rods of the cylinders being connected to the side projections (62) of the cradles (54).
Mounted on the front end of the two cross bars (11) and extending between them is a rotating shaft (63), shown only in FIG. 1, on which is secured a holding plate (64), extending basically in the horizontal direction. On one end of the shaft (63) is secured an angle lever (65), to which is coupled the piston rod of a pneumatic cylinder (66), arranged on the frame (10).
Arranged on the frame (10) are two base plates (67, 68), which have a small spacing from the table top (2). The front base plate (67), shown only in FIG. 1, extends beneath the holding plate (64) in basically the horizontal direction and has an upwardly curved section in its forward region. The rear base plate (68) is located beneath the cross thrust rail (57) and extends in a tilted plane.
The mode of operation is as follows:
On the base plate (68) there is placed a foam plastic panel (S), which contains a number of rectangular grooves (N) with an identical mutual spacing. The foam panel (S) is arranged as in FIG. 3 such that the third groove (N) is located beneath the cross thrust rail (57). After setting down the foam panel (S), the cross thrust rail (57) is lowered into the groove (N) lying beneath it by the pneumatic cylinder (59) and in this manner the foam panel (S) is secured to the base plate (68).
Then, a segment of cover material B with the intended upper side facing downward is placed on the raised traveler (34) and a segment projecting beyond the edge of the traveler as in FIG. 3, is placed beneath the raised holding plate (64) on the front part of the foam plastic panel (S).
After the placement of the cover material (B), the needle rail (44) is lowered onto the cover material (B) by the pneumatic cylinder (40), while the brush rail (46) is still kept in the raised position.
Then the travelers (34) is pushed beneath the pressing rail (51), held in the lifted position, by the pneumatic cylinder (35). As soon as the front edge of the traveler (34) is located above the first groove (N), it is moved down by the pneumatic cylinder (28). At the end of the swiveling and pushing motion of the traveler (34), the edge (K) of the fold of cover material (B) formed by its front edge, as in FIG. 4, lies in the corner of the groove (N) closer to the cross thrust rail (57), while the portion of the foam plastic panel bordering this groove (N) and facing the direction of the holding plate (64) is pressed flat.
During the pushing movement of the traveler (34), which occurs by the shifting motion of the respective cradles (30) on the particular slide rods (29), the cradles (36) arranged on the same slide rods between the legs (31, 32) of the cradles (30) are moved along from the start of the motion by the leg (31), acting as a driver in this respect, so that the rotating shafts (37, 38) arranged on the cradles (36) and the brush rail (46) are moved along in synchronization with the traveler (34).
As soon as the traveler (34) reaches the end position shown in FIG. 4, the pressing rail (51) is lowered by the pneumatic cylinder (50) with light horizontal distance from the edge of the fold (K) onto the cover material (B) lying on the traveler (34). Then, by the pneumatic cylinder (47), the two cradles (36) are moved along the slide rode (29) in the direction of the pressing rail (51), until they come to stop against the legs (32) of the cradles (30). In this way, the needle rail (44) is pushed into the position on the traveler (34) shown in FIG. 5. As a result of this movement of the needle rail (44), the segment of cover material (B) gripped between the needle rail and the pressing rail (51) is pushed together into a loose wave (W).
After formation of the wave (W), the traveler (34) along with the needle rail (44) and the brush rail 946) is retracted to the position shown in FIG. 6.
Meanwhile, the cover material (B) is held firmly by the pressing rail (51), so that the edge (K) of the fold remains in the corner of the groove (N). Then, the motor of the sewing machine (3), which is not shown, and the drive motor (24) for the frame (10) are simultaneously activated, whereupon the fold of cover material (B) located in the groove (N) is joined to the foam plastic panel (S) by a seam (F) formed between the edge (K) of the fold and pressing rail (51).
After making the seam (F), the frame (10) is withdrawn into the starting position and the cross thrust rail (57) is swung up by the pneumatic cylinder (59) and moved back by the pneumatic cylinder (61) to the next, i.e., the fourth groove (N), after which the cross thrust rail (57) is swung down into this groove (N). Then, the traveler (34) and the pressing rail (51) are raised, upon which the cross thrust rail (57) pushes the foam panel (S) into the position shown in FIG. 7.
As soon as the foam panel (S) is in the new position, the holding plate (64) is swung down by the pneumatic cylinder (66), by which the portion of the cover material (B) lying between this plate and the base plate (67) and the foam panel (S) are pinched together and held fast. Then, the traveler (34) in its raised position is pushed by the pneumatic cylinder (35) underneath the raised pressing rail (51), whereby the segment of cover material (B) formed into a wave (W) on the traveler (34) is moved along over the groove (N) and the ridge (T) of the foam panel (S) situated between the first and the second groove (N) and thereby pulled flat. During this movement of the traveler (34), the pneumatic cylinders (47) hold the cradles (36) against the legs (32) of the cradles (30), whereby the needle rail (44) and the brush rail (46) are moved together with the traveler (34). As soon as the front edge of the traveler (34) is located above the second groove (N), the traveler (34), the needle rail (44) and the brush rail (46) are together swung downward by the pneumatic cylinder (28). At the end of the swinging and pushing motion of the traveler 934), the edge (K) of the fold of cover material (B) formed by the front edge of the traveler lies in the corner of the second groove (N) closer to the cross thrust rail (57), as in FIG. 8, while the portion of the foam panel (S) bordering this groove (N) and facing the holding plate (64) is pressed flat.
As soon as the traveler (34) reaches the end position shown in FIG. 8, the brush rail (46) is lowered by the pneumatic cylinder (42) onto the cover material (B) and the needle rail (44) is lifted by the pneumatic cylinder (40) enough so that it no longer pulls along the cover material (B). After this, the cradles are pushed by the pneumatic cylinder (47) along the slide rods (29) until they strike against the legs (31) of the cradles (30).
By this relative motion between the brush rail (46) and the cover material (B) held securely in the groove (N) by the traveler (34), the portion of cover material (B) lying on the traveler (34) is pulled completely flat and at the same time the edge (K) of the fold is also stretched taut. Subsequently, the needle rail (44) and the brush rail (46) are together retracted into their starting position shown in FIG. 3.
When the needle and the brush rails (44, 46) have reached their initial position, the pressing rail (51) is lowered again, as in FIG. 5, a new wave (W) is formed in the cover material (B) by the needle rail (44), and then the traveler (34) is retracted as shown in FIG. 6, whereupon the fold of cover material (B) located in the second groove (N) is connected to the foam panel (S) by a seam in the previously described manner.
With the formation of the second seam, the first foam plastic filled cell (P) of the seat cover (A) shown in FIG. 9 is complete. Subsequently, the folding movements of the cover material (B), the feeding movements of the foam panel (S), and the seams (N) necessary for the remaining cells (P) are carried out in the manner shown in FIGS. 5-8.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | In the process for manufacture of seat covers with honeycomb cells, a plain and folded segment of a cover material is introduced by means of a fold forming traveler into a first of several grooves of a foam plastic panel and after the traveler is retracted, the fold of cover material is sewn to the foam panel. Then, a new segment of the cover material is folded back over the seam by the traveler in the direction of the adjacent second groove and, after forming a fold, is sewn in this groove. In the seat covers produced by this process, the seams are fully concealed by the cover material. | 3 |
BACKGROUND OF THE INVENTION
When a pipe is to be joined to a fitting having an internal shoulder it is common for the free end of the pipe to be inserted into the fitting to an extent sufficient to enable the end of the pipe to abut the shoulder. The pipe and fitting may not be welded together in such relative positions, however, because of the likelihood that the weld will crack or break due to thermal expansion and contraction of the pipe and fitting. Accordingly, it is the practice to provide a clearance between the free end of the pipe and the shoulder of the fitting, such clearance amounting to at least 1/16 inch according to most welding standards. If welds are to comply with such standards it is essential that the welder have some means of ensuring that the spacing between the shoulder of the fitting and the end of the pipe is not less than the minimum prior to and during welding of the pipe and fitting. To attain this objective welders heretofore have utilized many techniques with varying degrees of success. One technique is disclosed in U.S. Pat. No. 3,973,765 which makes use of a jig in which the fitting and the pipe are positioned prior to and during welding. Another technique heretofore employed utilizes a tool having a pair of clamping jaws between which a pipe to be welded to a fitting may be gripped. Associated with such jaws are a pair of pivoted fingers which may be swung to a position in which they are interposed between the associated clamp jaw and the free end of the fitting. In this construction, however, interference between the blade and the pipe could be encountered during movement of the fingers into their spacing position. Moreover, the fingers are exposed to the likelihood of being bent. Further, such tool is unable to accommodate pipes of significantly different diameters.
SUMMARY OF THE INVENTION
A tool constructed according to the invention comprises a hand held clamp having a pair of jaws movable toward and away from one another so as to clamp and unclamp, respectively, a pipe that is to be joined in telescoping relation to a fitting. The jaws are of V-shaped trough configuration, and of different size, and arranged so that the open sides of the jaws confront one another so as to receive a pipe therebetween. Corresponding ends of the jaws are coplanar and each jaw supports a mounting bracket on which is mounted at least one shim blade for sliding movements toward and away from the pipe. One side of each shim blade lies in the plane of the ends of the jaws and the thickness of the blade corresponds to the spacing to be provided between the free end of the pipe and an internal shoulder formed on the fitting. Each shim may include a plurality of blades of the same or different thicknesses, each of such blades being independent of the remainder.
DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention is disclosed in the following description and in the accompanying drawings, in which:
FIG. 1 is a side elevational view of a tool illustrating it clamped to a pipe, the pipe being shown in section;
FIG. 2 is a view of the apparatus shown in FIG. 1 as viewed from the right of the latter, a fitting being shown in section;
FIG. 3 is a view similar to FIG. 1, but with some of the parts in adjusted positions;
FIG. 4 is a view similar to FIG. 2, but illustrating the parts as they appear in FIG. 3; and
FIG. 5 is a view similar to FIG. 4, but illustrating an optional feature.
DETAILED DESCRIPTION
A tool constructed in accordance with the invention is designated generally by the reference character 1 and comprises a clamp 2 of known construction, such as disclosed in U.S. Pat. No. 2,641,149, having a handle 3 to one end of which is fixed an arm 4. A second arm 5 is pivoted to the handle 3 as at 6 so as to enable relative movement of the arms toward and away from one another. A link 7 has one end pivoted to the arm 5 as at 8 and its other end slidably fitted to the handle 3 for adjustment longitudinally of the latter by means of an adjusting screw 9. The link 7 also is pivoted as at 10 to an operating lever 11 which also is pivoted at 8 to the arm 5. The arrangement is such that the arms 4 and 5 may be moved toward one another so as to provide between the confronting ends of the arms a preselected spacing and the arms then may be latched in such position so as to prevent inadvertent extension of the spacing between the confronting ends on the arms.
The free end of the arm 4 is welded or otherwise suitably fixed to a V-shaped jaw 12 and the free end of the arm 5 is similarly fixed to a V-shaped jaw 13. The jaws 12 and 13 thus are trough-like in configuration with their open sides confronting one another. The limbs forming the jaw 13 preferably are substantially longer than the limbs of the jaw 12, for a purpose presently to be explained, but the length of each jaw preferably is uniform and the jaws are so arranged that corresponding ends 14 and 15, respectively, are coplanar.
Adjacent the end 14 of the jaw 12 is fixed an upstanding mounting bracket 16 and a similar mounting bracket 17 is fixed to the jaw 13 adjacent the end 15. The bracket 16 has an opening therein through which extends the shank of a bolt 18 and a similar bolt 19 extends through a similar opening in the bracket 17. A compression spring 20 reacts between the bracket 16 and the head of the bolt 18 and a similar spring 21 reacts between the bracket 17 and the head of the bolt 19.
In face to face linearly sliding movement with the bracket 16 is a shim blade 22 and a similar shim blade 23 is in linearly sliding face to face engagement with the bracket 17. The blades 22 and 23 have elongate slots 24 and 25, respectively, through which the shanks of the bolts 18 and 19 project, the bolt 18 having at its free end a washer 26 and an anchor nut 27. The bolt 19 has at its free end a similar washer 28 and a similar anchor nut 29. Each blade 22 and 23 thus is capable of limited sliding adjustment toward and away from one another and each blade will be frictionally retained in a selected position of adjustment by means of the biasing face exerted thereon by the associated springs 20 and 21. The nuts 27 and 29 may be removed from the associated bolts so as to enable blades of different thicknesses to be substituted for the blades 22 and 23.
The thickness of each blade 22 and 23 has a predetermined dimension to which reference will be made hereinafter, and the thickness of each blade preferably is uniform.
The width of the blade 22 preferably corresponds to the width between the limbs of the jaw 12 and that edge or end of the blade 22 which confronts the blade 23 preferably has a V-shaped notch 30 which matches the trough formed by the jaw 12. The blade 23 has a width corresponding to the width between the limbs of the jaw 13 and and end or edge having a V-shaped notch 31 which matches the trough formed by the jaw 13. A finger loop 32 is welded to the opposite sides of the blade 22 and extends beyond the latter so as slidingly to embrace the bracket 16, thereby providing a guide to ensure linear movement of the blade 22. A similar finger piece 33 is welded to that side of the blade 23 which confronts the bracket 17 and embraces the bracket 17 so as to provide a similar guide.
The construction shown in FIG. 5 is the same as that previously described with the exception that, in the embodiment of FIG. 5, the shims include additional blades 22a, 23a similar to the blades 22, 23 and which are slidable either with or independently of the associated blades 22 and 23. The thickness of the blades 22a, 23a preferably is uniform and may be either the same as or different from the thickness of the blades 22, 23.
Apparatus constructed in accordance with the invention is especially adapted for use in the welding of a pipe 34 to a fitting 35. The fitting may be a sleeve fitting, as shown, or it may be a tee, elbow, cross over, or any other kind of conventional fitting. The fitting 35 comprises a cylindrical body 36 having opposite ends 37 and 38 extending inwardly from which are bore portions 39 and 40. Between the ends of the body is a bore portion 41 of reduced diameter which forms shoulders 42 between the bore portions 39 and 40. The bore portion 39 is of such size as snugly to accommodate the end of the pipe 34 with the end 43 thereof abutting the adjacent shoulder 42.
To condition the apparatus for operation the arms 4 and 5 of the tool 1 are spread apart and the shim blades 22 and 23 are moved apart. The pipe 34 is fitted into the bore portion 39 of the fitting 35 so that the end 43 of the pipe abuts the shoulder 42. The jaws 12 and 13 then are moved toward one another so as to cause them to engage the pipe 34 with the ends 14 and 15 of the jaws abutting the end 37 of the fitting. The operating lever 11 is then actuated to clamp the jaws 12 and 13 against the pipe 34 so as to preclude inadvertent relative movement between the jaws and the pipe.
Following the clamping of the jaws 12 and 13 against the pipe 34, the latter may be slid outwardly of the bore 39. The shim blades 22 and 23 (as well as the blades 22a, 23a, if desired) then may be slid toward one another, or radially of the pipe, to their operative positions in which their notched edges are flush with the jaws 12 and 13 bear against the pipe, following which the pipe 34 may be slid into the bore 39 toward the shoulder 42 until such time as the shim blades 22 and 23 abut the end 37 of the fitting. See FIG. 4. In this position of the pipe 34 a gap 44 will be provided between the shoulder 42 and the end 43 of the pipe and the axial length of the gap will correspond to the thickness of the shim blades. The pipe then may be tack welded to the fitting 35 in the peripheral spaces between the jaws 12 and 13 so as to ensure maintenance of the gap 44. Thereafter, the tool may be removed from the pipe 34 and the welding of the latter to the fitting completed.
Of particular advantage in a tool constructed according to the invention is the utilization of a clamp jaw 13 of greater size than that of the jaw 12. The larger jaw makes possible the accommodation of pipes of greatly differing diameters, the maximum diameter of the pipe being limited only by the maximum distance than the jaws 12 and 13 may be spaced from one another. A single tool, therefore, can be utilized by a pipe fitter in the coupling of pipes and fittings of greatly varying size.
The disclosed embodiment is representative of a presently preferred form of the invention, but is intended to be illustrative rather than definitive. The invention is defined in the claims. | A tool for use by pipefitters in joining a length of pipe to a fitting in which one end of the pipe is accommodated with a predetermined spacing between the end of the pipe and an internal shoulder within the fitting. The tool comprises jaws which may be clamped on the pipe when the end of the latter abuts the shoulder and includes shims movable from a position spaced from the pipe toward the latter to occupy a position between the jaws and the adjacent free end of the fitting, thereby providing for a predetermined spacing between the free end of the pipe and the shoulder of the fitting. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a 35 U.S.C. §§371 national phase conversion of PCT/ES2010/000415, filed Oct. 14, 2010, which claims priority of Spanish Application No. P200930865, filed Oct. 19, 2009, the contents of which are incorporated by reference herein. The PCT International Application was published in the Spanish language.
OBJECT OF THE INVENTION
The present invention relates to a system and a method for identifying documents or any another paper supports, such as paper money, equipment, consumption goods or other supports such as liquids.
The object of the invention involves a system and a method for identifying and verifying a number of markers made up of embedded nanoparticles or nanoparticles that form a coating on the support.
BACKGROUND OF THE INVENTION
Amongst the previous uses given to nanoparticles composed of a dielectric nucleus and a metal shell, different research groups worldwide have used them in medicine for the thermal ablation of tumour cells: they are injected in a tumour and a laser in the near-infrared region (NIR), with the wavelength whereat the particles are absorbed and diffracted, is externally applied; the particles are heated, resulting in the death of the tumour tissue due to temperature elevation, as reflected in patents US2002103517-A1 and U.S. Pat. No. 6,530,944-B2, and in several popular science documents.
Some types of nanoparticles have also been patented as filling material for paints, to obtain thermal insulation paints, as disclosed in U.S. Pat. No. 6,344,272-B1 held by UNIV RICE WILLIAM MARSH.
Also well-known are their plasmon optical resonance properties, which make them of interest to be used as contrast agents in medical .imaging (by means of photoacoustic tomography), and their use is disclosed in various documents, such as patents US2002187347-A1 and U.S. Pat. No. 7,144,627-B2. They have also been used to activate an optically activated sensor in patents US2004214001-A1 and U.S. Pat. No. 7,371,457-B2.
Other similar applications also consider the use of nanoparticles as optically activated valves; this use is reflected in documents such as Optically controlled valves for microfluidics devices. Sershen, S R., Ng, M. A., Halas, N. J., Beebe, D., West, J. L. Advanced Materials, 17 (2005): 1366-1368.
Currently, there are other inorganic nanoparticles the use whereof is aimed at optical labelling. However, these nanoparticles are based on carbon (e.g. carbon nanotubes) or quantum dots (semiconductor nanostructures that confine the movement, in the three spatial directions, of conduction band electrons, valence band gaps or excitons (binding pairs of conduction band electrons and valence band gaps, CdSe, CdS, CdTe, etc.)) (e.g. ©Evident Technologies, Inc.). Said materials emit at a single wavelength within the near-infrared region.
Invention patent US20070165209 discloses a method and a device for applying security labels or identifiers to documents or banknotes in order to prevent the counterfeiting thereof. Said identifiers may have the form of nanolabels, which may be Raman-active metal nanoparticles.
More specifically, gold nanoparticles may heat an area of up to 1000 times their size when they are excited with a laser of a given wavelength. Said property has been used to produce the photothermal ablation of tumours in vitro and in vivo, as previously mentioned. These nanoparticles are formed by a dielectric nucleus (silica) and a shell made of gold or any other noble metal (i.e. silver, platinum, copper). By changing the relative dimensions between the materials that make up the nucleus and the shell, it is possible to modify the properties of the resonant plasmon (wavelength of optimal optical extinction) of gold, causing them to absorb light in the near-infrared region (NIR). This near-infrared region (between 800 and 1200 nm) is of interest in biomedical applications, since tissues are transparent in said region, and do not absorb light from the incident beam. It is the so-called “water window”. Thus, if a tissue is irradiated with any laser of a wavelength within that range, the temperature of said tissue will not rise. However, if the tissue is infiltrated with gold/silica nanoparticles, the application of a laser in the area would cause cell death by hyperthermia. Some authors have studied the effect .of different nanoparticle geometries and shapes/thicknesses on the absorption of IR radiation, but always from the standpoint of biomedical use, in phototherapy and thermal ablation.
DESCRIPTION OF THE INVENTION
A system is proposed for the authentication of various objects (identification documents, banknotes, paper money, luxury item labels, etc.), which is based on the use of nanoparticles that have a characteristic radiation absorption pattern in the near-infrared region (NIR). To this end, hybrid nanoparticles have been synthesised, composed of a dielectric nucleus made of silica and coated with a layer of gold, which present absorption patterns that may be modified as a function of the dimensions of the dielectric nucleus and the thickness of the metal layer. A given combination of dimensions provides a defined absorbance at a given wavelength (e.g. 808 nm) and at no other region of the spectrum.
Moreover, in that region of the spectrum, called “water window”, few materials absorb light. I.e., below this region of the spectrum (between 800 and 1200 nm), light is absorbed by materials carrying chromophores, and, above this region, it is absorbed by materials containing water. For example, if we apply laser radiation of a wavelength within this region between 800 and 1200 nm to our skin, our skin and our bones would not absorb it and would be transparent thereto, as previously mentioned. This is obviously of great interest in medical applications: as discussed in the preceding section, and, for this reason, many works have attempted to develop this type of nanoparticles for various biomedical scenarios (cell labelling, hyperthermia, etc.), where the particles act as radiation targets.
The application of the object of the invention is clearly different; in this invention, the nanoparticles composed of a dielectric nucleus and a metal shell are used to authenticate objects whereto the aforementioned nanoparticles have been incorporated, since said nanoparticles absorb in this NIR region and absorb exclusively at a given wavelength. The practical interest and the advantages thereof are evident, since these particles are highly sophisticated and their manufacturing is beyond the reach of most research laboratories, and, of course, counterfeiters; nonetheless, they may be manufactured at a low cost; given their nanometric size, they are invisible to the eye and .even to optical microscopes; they do not change the essential properties of the material; they provide a means of authentication based on easy-to-read properties (light absorption at a given wavelength, supplemented, when applicable, with magnetic measurements); they may be easily introduced in both paper-based materials (e.g. cellulose, cotton, linen, etc.) and textile fibres and polymers; they may be dispersed in a liquid to be used as ink; unlike other nanoparticle-based systems, which usually work with fixed absorption characteristics for a given system, the system proposed in this invention presents high flexibility in its light absorption configuration, and an infinite number of absorbance patterns are possible, depending on the characteristics of the nanoparticles used.
A first embodiment of the object of the invention proposes the use of a combination of these nanoparticles to obtain an optical label (and, if applicable, a magnetic label, if they are used combined with magnetic nanoparticles) which is characteristic and exclusive, in order to make it impossible to copy items that are labelled or embedded with said nanoparticles. This application is clearly different from those already known, since the nanoparticles composed of a dielectric nucleus and a metal shell disclosed in this invention are used to authenticate objects due to the fact that they absorb in this NIR region and absorb exclusively at a given wavelength.
Another embodiment of the object of the invention also proposes the possible use: of a combination of several types of nanoparticles to obtain an optical label (or, if applicable, a magnetic or a combined label) which is characteristic and exclusive, in order to make it practically impossible to copy items that are labelled or embedded with said nanoparticles; the ratio between the size of the nucleus and the size of the shell, to obtain optical tracks which are characteristic and exclusive, in order to prevent the counterfeiting not only of paper money, but also of equipment, high-value-added consumption goods, etc. In some embodiments, the present invention provides for a method able to authenticate fluids such as perfumes.
DESCRIPTION OF THE DRAWINGS
In order to complement the description being made and to contribute to a better understanding of the characteristics of the invention, in accordance with a preferred practical embodiment thereof, a set of drawings is attached to said description as an integral part thereof, wherein the following has been represented for illustrative, non-limiting purposes:
FIG. 1 .—Shows a TEM image of the nanoparticles synthesised.
FIG. 2 .—Shows an absorbance graph of silica/gold nanoparticles with a nucleus size of 50 nm and an absorbance maximum at 826 nm.
FIG. 3 .—Shows an absorbance graph of silica/gold nanoparticles with a nucleus size of 100 nm and an absorbance maximum at 713 nm.
PREFERRED EMBODIMENT OF THE INVENTION
In light of the figures, below we describe a preferred embodiment of the process of this invention.
For the embodiment of the object of the invention, two types of silica/gold nanoparticles were synthesised, with different relative sizes, in order to obtain different absorption properties of the resonant plasmon thereof. To this end, classic wet chemistry techniques are used to synthesise the materials. The sol-gel technique is used for the dielectric nucleus made of silica, by means of the Stöber method, and seeding and secondary growth is used to obtain the gold shell in accordance with the method described by Oldenburg et al.
Thus, siliceous nanoparticles are obtained that are functionalised with amino groups in order to achieve the heterogeneous crystallisation, on the surface thereof, of gold particles (prepared separately) which grow to form layers of said material following successive regrowth steps with a gold precursor (chloroauric acid).
In some embodiments, the nucleus of the nanoparticles may be porous. In some embodiments, the nucleus of the nanoparticles may be adapted to house a third species inside the pores.
In some embodiments, the dielectric nucleus may be an inorganic oxide.
Examples of inorganic oxides include, but are not limited to, SiO 2 or TiO 2 .
In some embodiments, the nanoparticles may form linear chains and/or multi-dimensional matrices.
In some embodiments, the nanoparticles may have a nanosphere, nanothread, nanorod, tetrahedral, and/or cube geometry.
Once obtained, the nanoparticles are characterised by means of:
Transmission electron microscopy, to determine the size of the nanoparticles. The Dual. Beam (Nova™ 200 NanoLab) equipment was used to distinguish the dielectric nucleus from the shell made of gold. High-resolution transmission electron microscopy, to perform electron diffraction and corroborate the crystalline nature of the gold shell surrounding the amorphous silica nucleus. To this end, HRTEM equipment from TEI Instruments was used. Nitrogen adsorption/desorption, to determine the specific surface area of the materials synthesised, by means of a Nitrogen adsorption equipment from Micromeritis. Photon correlation spectroscopy, to determine the hydrodynamic size of the nanoparticles in dispersion in different media and at different pHs, in a Malvern Zeta Sizer 2000 equipment. Thermogravimetry, to determine the quantity of amino groups on the surface prior to having the gold shell grow on the dielectric nuclei. Atomic Absorption and Emission Analytical Spectrometry (ICP), to determine the elementary composition of the materials. X-ray spectroscopy (XPS), to determine the atomic number of the elements that make up the surface of the nanoparticles, as well as the bonds found. Fourier Transform Infra-red Spectroscopy (FTIR) in a catalytic chamber (DRIFT), to determine the bonds and interactions between the materials, and the coatings and functionalisations thereof. UV-VIS-NIR spectroscopy, to evaluate the extinction coefficients and determine whether the nanoparticles synthesised absorb or disperse light within the near-infrared range, between 800 and 1200 nm. Study of the reproducibility of the synthesis and the stability of the nanoparticles formed through time, under standard storage conditions in the presence and in the absence of light.
FIG. 1 shows the morphology of the nanoparticles synthesised.
FIGS. 2 and 3 show how, by changing the proportions between the size of the nucleus and the size of the shell, absorption spectra in the near-infrared region are obtained which are characteristic of each nanoparticle. | An identification and verification system and a process for said identification and verification of documents is disclosed, which is based on the use of nanoparticles embedded or adsorbed in the document support, utilizing the different optical reflectance characteristics thereof in order to obtain, by combining several nanoparticles with specific characteristics, a high effectiveness in the identification of counterfeits. | 6 |
CROSS REFERENCE TO PRIORITY APPLICATIONS
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
BACKGROUND
1. Field
The present description relates in general to the field of inductor-based switching-mode direct current-to-direct current (DC-DC) converters and more specifically to a DC-DC converter of that kind operating in a discontinuous conduction mode (DCM).
2. Description of the Related Art
Inductive DC-DC converters are typically characterized by long times in which the inductor current falls down. If the available power is very low, the converter has to work in discontinuous conduction mode, which means that for a certain interval of time the inductor current remains equal to zero. In order to prevent a current to an energy storage element connected to the DC-DC converter from becoming negative, that is, the DC-DC converter circuit takes current from that energy storage element, an inductor zero current crossing condition has to be detected.
An exemplary DC-DC converter operating in a discontinuous mode is described in U.S. Pat. No. 6,847,197, which comprises an electronic circuit for detecting a zero current condition flowing through an inductor, the entire contents of which are herein incorporated by reference. In such a DC-DC converter an inductor is charged by coupling the inductor to a voltage source for a predetermined amount of time; thereafter, the inductor is discharged by coupling the inductor to a ground until the current flowing through the inductor equals zero; and a method for detecting a zero current flowing through the inductor includes coupling the inductor to a transistor and comparing the output of that transistor to a transistor coupled to ground.
Another example of an inductor-based DC-DC converter is described in EP Patent Application 2 251 966 A1, which comprises a switch control circuit, and a switch controllable to cause the DC to DC converter to alternate between a magnetization phase in which an inductor current in the inductive component increases, and a demagnetization phase in which the inductor current decreases, the entire contents of which are herein incorporated by reference. The switch control circuit compares an inductor current to an intermediate threshold below a maximum inductor current, and compares an output voltage to a voltage threshold. The converter switches from the demagnetization phase to the magnetization phase when the inductor current has dropped below the intermediate threshold, and dependent on the output of the second comparator. This intermediate current threshold enables the conduction mode to be continuous at high loads and discontinuous at light loads.
A problem with the current state of the art inductor-based DC-DC converters is its speed, power consumption and/or precision performance in, for example, low power applications, e.g. in which the input available power can vary from a few microwatts to several milliwatts. The control circuit used in such inductor-based DC-DC converters needs to turn on and off the switches at the right time, and to improve the precision, speed and/or dynamic range in such control circuits there is still a need for high power consumption.
SUMMARY OF CERTAIN INVENTIVE ASPECTS
The following description discloses embodiments of a DC-DC converter and a method for controlling a DC-DC converter in a discontinuous conduction mode (DCM). In the disclosed embodiments, the DC-DC converter can provides a better speed, precision and/or power consumption trade-off performance.
According to one embodiment, a method of controlling an inductor-based switching-mode DC-DC converter, comprises an inductor, a first switching element and a second switching element, the switching elements being operationally coupled to the inductor so that the inductor is charged and completely discharged in each conversion cycle thereby operating the DC-DC converter in a discontinuous conduction mode, and the method comprising: in each conversion cycle, first, turning on the first switching element, while maintaining the second switching element in off state, thereby increasing the current through the inductor; second, turning off the first switching element, while maintaining the second switching element in off state; third, detecting when a voltage signal at one connection node of the inductor reaches a first threshold value for the first time after the start of the conversion cycle, and triggered by the first threshold value detection, turning on the second switching element, while maintaining the first switching element in off state, thereby decreasing the current through the inductor; fourth, detecting when the voltage signal reaches a second threshold value, and triggered by the second threshold value detection, turning off the second switching element, while maintaining the first switching element in off state; and fifth, maintaining the first and the second switching element in off state until the end of the conversion cycle.
Advantageously, according to one embodiment, a method of controlling an inductor-based switching-mode DC-DC converter makes use of the knowledge about the behavior of the inductor voltage, so that the switching elements can be turned on and off based on a precise detection of the inductor voltage reaching a certain first and second threshold value. Advantageously, the detection can take in consideration the specific signal characteristics of the inductor voltage when reaching a first and a second threshold value in a first and a second inductor voltage signal transition event respectively.
According to another embodiment, the method of controlling the DC-DC converter, further comprises, after detecting when the inductor voltage signal reaches a second threshold value, and triggered by the second threshold value detection, detecting when the inductor voltage signal reaches a third threshold value, and triggered by the third threshold value detection, turning off the second switching element, while maintaining the first switching element in off state. Advantageously this allows further precision for turning off the second switching element based on the specific characteristics of a second inductor voltage signal transition event.
According to another aspect, there is provided an inductor-based switching-mode DC-DC converter comprising an inductor, a first switching element and a second switching element, the switching elements being operationally coupled to the inductor so that the inductor is charged and completely discharged in each conversion cycle thereby operating the DC-DC converter in a discontinuous conduction mode, and further comprising switch control circuitry controlling the turn-on and turn-off period of the first and the second switching element so as to cause the DC-DC converter to operate in a discontinuous conduction mode in which an inductor is charged and completely discharged in each conversion cycle, wherein, the switch control circuitry is configured to, in each conversion cycle, first, turn on the first switching element, while maintaining the second switching element in off state, in order to cause the current through the inductor to increase; second, turn off the first switching element, while maintaining the second switching element in off state; third, detect when a voltage signal at one connection node of the inductor reaches a first threshold value for the first time after the start of the conversion cycle, and triggered by the first threshold value detection, turn on the second switching element, while maintaining the first switching element in off state, in order to cause the current through the inductor to decrease; fourth, detect when the voltage signal, after reaching the first threshold value, reaches a second threshold value, and triggered by the second threshold value detection, turn off the second switching element, while maintaining the first switching element in off state; and fifth, maintain the first and the second switching element in off state until the end of the conversion cycle.
According to still another embodiment, the switch control circuitry may comprise two signal transition event detection circuits: a first signal transition event detection circuit comprising a first comparator circuit and configured to detect when the voltage signal reaches the first threshold value for the first time after the start of the conversion cycle; a second signal transition event detection circuit comprising a second comparator circuit and configured to detect when the voltage signal reaches the second threshold value; and the first and the second signal transition event detection circuits being so configured to, triggered by the first threshold value detection, turn on the second switching element, and triggered by the second threshold value detection, turn off the second switching element. Advantageously, by using two different comparator circuits optimized for detecting independently a first and a second inductor voltage transition signal event, overall system efficiency is increased and power consumption is reduced.
According to still another embodiment the switch control circuitry may be further configured to, after detecting when the voltage signal reaches a second threshold value, and triggered by the second threshold value detection, detect when the voltage signal reaches a third threshold value, and triggered by the third threshold value detection, turn off the second switching element, while maintaining the first switching element in off state. The switch control circuitry may comprises, for example, two signal transition event detection circuits: a first signal transition event detection circuit comprising a first comparator circuit and configured to detect when the voltage signal reaches the first threshold value for the first time after the start of the conversion cycle; and a second signal transition event detection circuit comprising a second and a third comparator circuit, the second comparator circuit adapted for detecting when the voltage signal reaches the second threshold value and the third comparator circuit adapted for detecting when the voltage signal reaches the third threshold value; and the first and the second signal transition event detection circuits being so configured to, triggered by the first threshold value detection, turn on the second switching element, and triggered by the second and third threshold value detection, turn off the second switching element. Advantageously, by using two comparator circuits for detecting an inductor voltage second signal transition event, overall system efficiency can be increased and power consumption can be further decreased.
According to another embodiment, the first signal transition event detection circuit may be configured to activate the first comparator circuit for a period of time between the moment in which the first switching element is turned off and the moment of the first threshold value detection, and the second signal transition event detection circuit may be configured to activate the second comparator circuit for a period of time between the moment of the first threshold value detection and the moment in which the second switching element is turned off. Further, the first signal transition event detection circuit may configured to activate the first comparator circuit for a period of time between the moment in which the first switching element is turned off and the moment of the first threshold value detection, and the second signal transition event detection circuit is configured to activate the second comparator circuit for a period of time between the moment of the first threshold value detection and the moment in which the second switching element is turned off, and activate the third comparator circuit for a period of time between the moment of the second threshold value detection and the moment in which the second switching element is turned off. Advantageously, by precisely activating the comparator circuits at the time they need to do the detection, reduces overall power consumption.
According to one embodiment of a DC-DC converter, the first, the second or the third threshold values is either a voltage value of zero or a value close to zero designed to take internal circuit operating delays into account. According to another embodiment of a DC-DC converter, the first, the second or the third threshold values is either a voltage value equal to the value of the output voltage signal of the DC-DC converter or a value close to the value of the output voltage signal designed to takes internal circuit operating delays into account. Advantageously, the invention can be used with both step-up and step-down DC-DC converters.
The description also relates to an electronic system comprising a DC-DC converter according to any of the embodiments of the invention.
Certain objects and advantages of various inventive aspects have been described above. It is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment. Those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages without necessarily achieving other objects or advantages as may be taught or suggested herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate one or more exemplary embodiment(s) of the present disclosure and, together with the description, further serve to explain the principles and to enable a persona skilled in the art to make and use of the invention.
FIG. 1 shows a schematic general block diagram of a first exemplary embodiment of a DC-DC converter circuit.
FIG. 2 shows a schematic general block diagram of a second exemplary embodiment of a DC-DC converter circuit.
FIGS. 3A , 3 B illustrate time graphs of a plurality of voltage and current signals provided in an exemplary embodiment of a DC-DC converter circuit according to FIG. 1 .
FIG. 4 illustrates time graphs of another plurality of voltage and current signals provided in an exemplary embodiment of a DC-DC converter circuit according to FIG. 2 .
FIG. 5 shows a more detailed block diagram of an exemplary embodiment of a DC-DC converter circuit according to FIG. 1 .
FIG. 6 shows a more detailed block diagram of another exemplary embodiment of the DC-DC converter circuit according to FIG. 1 .
FIG. 7 illustrates time graphs of another plurality of voltage signals provided in an exemplary embodiment of a DC-DC converter circuit according to FIGS. 5 and 6 .
FIG. 8 illustrates time graphs of another plurality of voltage and current signals provided in an exemplary embodiment of a DC-DC converter circuit according to FIG. 6 .
FIG. 9 shows a more detailed block diagram of an exemplary embodiment of a DC-DC converter circuit according to FIG. 2 .
FIG. 10 shows a more detailed block diagram of another exemplary embodiment of a DC-DC converter circuit according to FIG. 2 .
DETAILED DESCRIPTION
In the following, it should be appreciated that in the description of exemplary embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This is however not to be interpreted as the invention requiring more features than the ones expressly recited in each claim, with each claim standing on its own as a separate embodiment of this invention. Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those skilled in the art. In the description of the embodiments, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these non-essential specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure the understanding of this description.
FIG. 1 shows a general block diagram of a first exemplary embodiment of a DC-DC converter circuit 100 , comprising a pulse generation circuit CP which provides a pulse signal VP, a first switch control circuit CS 1 which provides a first switch control signal VS 1 to a first switching element S 1 , a second switch control circuit CS 2 which provides a second switch control signal VS 2 to a second switching element S 2 . The DC-DC converter circuit 100 may receive an input voltage signal VIN and may provide an output voltage signal VO to an energy storage element ESS connected to the circuit by an inductor L. An inductor current IL may circulate through the inductor L and change in value depending on an inductor voltage signal VC. It shall be understood that the DC-DC converter circuit 100 according to certain embodiments may not comprise all the elements showed in FIG. 1 and that some of the shown elements and/or signals may be external and/or provided to the DC-DC converter circuit 100 . It shall be also understood that although the switch control functionality has been split in different circuits for clarity purposes, a plurality of switch control circuits comprising whole or part of the functionality of the first switch control circuit CS 1 , and/or the second switch control circuit CS 2 and/or the pulse generation circuit CP can be envisaged as embodiments of the present disclosure and of the DC-DC converter circuit 100 .
According to an embodiment, the DC-DC converter circuit 100 of FIG. 1 has a topology of a step-down DC-DC converter, also known as a buck converter, which converts a certain DC input voltage signal V IN to a certain lower DC output voltage signal VO. The first switch control circuit CS 1 controls the turn-on and turn-off period of the first switching element S 1 by means of the first switch control signal VS 1 . The second switch control circuit CS 2 controls the turn-on and turn-off period of the second switching element S 2 by means of the second switch control signal VS 2 . The first and the second switch control circuits CS 1 , CS 2 are configured to turn on and off the first and the second switching elements S 1 , S 2 respectively, so that the inductor L is charged during a certain first period of time and discharged into the energy storage element ESS during a certain second period of time. In that manner, the energy storage element ESS, which may be, for example a battery, can be charged by the DC-DC converter circuit 100 . According to an embodiment, the DC-DC converter circuit 100 of FIG. 1 is configured to operate in discontinuous conduction mode so that the inductor L is completely discharged and the inductor current IL falls to zero.
The pulse generation circuit CP may be, for example, an oscillator circuit or any electronic circuit that generates a pulse-like voltage or digital signal VP, which is used to define the start and the end of the conversion cycle and is used by the first and the second switch control circuits CS 1 , CS 2 to drive the switching elements S 1 , S 2 . The oscillator circuit may be, for example, a low power relaxation oscillator, which can be designed based on charging and discharging a single or a plurality of capacitors. A precise and low power relaxation oscillator for generating an impulse signal of variable width and period can be designed based on charging a first capacitance with a first current and discharging a second capacitance with a second current.
According to an embodiment, the first switching element S 1 may be a pMOS transistor and the second switching element S 2 may be a nMOS transistor, but it shall be understood that other equivalent switching elements or switches may be used instead which can be turned on and off in order to electrically connect and disconnect respectively a certain connection point to another. Such switching elements may include electromechanical or electrical switches.
According to an embodiment, when the digital pulse signal VP transitions to an active state, e.g. a digital “1” voltage, indicating the start of a new conversion cycle, the first switch control circuit CS 1 generates a first switch control signal VS 1 that turns on (or closes, in order to conduct) the first switching element S 1 , while the second switching element S 2 is maintained in an off state (or open or not conducting state). Then the inductor voltage signal VC rises to a value close to the DC value of the input voltage signal V IN and causes the inductor current IL to ramp up at a rate which is proportional to the value of the input voltage signal V IN . The digital pulse signal VP may remain active during a certain period of time and when the pulse signal returns to inactive state or digital “0” voltage, the first switch control circuit CS 1 generates a first switch control signal VS 1 that turns off the first switching element S 1 (or causing the first switching element S 1 to open), while the second switch control circuit CS 2 maintains the second switching element S 2 in open state. The first switching element S 1 will be maintained in an open or off state until the next conversion cycle starts. It shall be understood that although the above exemplary embodiment shows a first way to indicate, by means of the pulse signal VP, the start of a new conversion cycle and the turn off time of the first switching element S 1 , a person skilled in the art will understand that other embodiments are possible to achieve the same purpose without departing from the scope of this disclosure. For example, with more than one pulse signal, with digital or analogue signals, and considering different transitions of the pulse signal or signals.
According to an embodiment, the second switch control circuit CS 2 is configured to detect specific signal transition events in which the inductor voltage signal VC reaches a threshold value close or equal to zero in each conversion cycle. Also according to an embodiment, the second switch control circuit CS 2 is configured to detect two of such signal transition events in each conversion cycle. According to yet another embodiment, the second switch control circuit CS 2 is configured to detect each of the two signal transition events independently. According to an embodiment, when the first switch control circuit CS 1 opens the first switching element S 1 , while the second switching element S 2 is still open, the inductor voltage signal VC falls, crossing zero, to a negative value, defining a first signal transition event TVC 1 (in FIGS. 3A , B). When the second switch control circuit CS 2 detects such first signal transition event TVC 1 after a start of a new conversion cycle, the second switch control circuit CS 2 generates a second switch control signal VS 2 that turns on the second switching element S 2 (or causing the second switching element S 2 to close or conduct). After the second switching element S 2 closes, the inductor current IL ramps down with a rate proportional to the output voltage signal VO and the value of the inductor voltage signal VC increases, reaching at a certain moment a value of zero volts, defining a second signal transition event TVC 2 (in FIGS. 3A , B). The second switch control circuit CS 2 keeps precisely sensing the inductor voltage signal VC so that when the second switch control circuit CS 2 detects such second signal transition event TVC 2 after a start of a new conversion cycle, the second switch control circuit CS 2 generates a second switch control signal VS 2 that turns off the second switching element S 2 (or causing the second switching element S 2 to open). After the second switching element S 2 is opened, the second switch control circuit CS 2 is configured to neglect all further transitions of the inductor voltage signal VC crossing zero or close to zero and to maintain such second switching element S 2 in open state until the start of the next conversion cycle.
FIG. 2 shows a general block diagram of a second exemplary embodiment of a DC-DC converter circuit 101 , comprising a pulse generation circuit CP which provides a pulse signal VP, a first switch control circuit CS 1 which provides a first switch control signal VS 1 to a first switching element S 1 , a second switch control circuit CS 2 which provides a second switch control signal VS 2 to a second switching element S 2 . The DC-DC converter circuit 101 may receive an input voltage signal V IN which is connected to the circuit by an inductor L and may provide an output voltage signal VO to an energy storage element ESS. An inductor current IL may circulate through the inductor L and change in value depending on an inductor voltage signal VC. It shall be understood that the DC-DC converter circuit 101 according to certain embodiments, may not comprise all the elements showed in FIG. 2 and that some of the shown elements and/or signals may be external and/or provided to the DC-DC converter circuit 101 . It shall be also understood that although the switch control functionality has been split in different circuits for clarity purposes, a plurality of switch control circuits comprising whole or part of the functionality of the first switch control circuit CS 1 , and/or the second switch control circuit CS 2 and/or the pulse generation circuit CP can be envisaged as embodiments of the present disclosure and of the DC-DC converter circuit 101 .
According to an embodiment, the DC-DC converter circuit 101 of FIG. 2 has a topology of a step-up DC-DC converter, also known as a boost converter, which converts a certain DC input voltage signal V IN to a certain higher DC output voltage signal VO. The first switch control circuit CS 1 controls the turn-on and turn-off period of the first switching element S 1 by means of the first switch control signal VS 1 . The second switch control circuit CS 2 controls the turn-on and turn-off period of the second switching element S 2 by means of the second switch control signal VS 2 . The first and the second switch control circuits CS 1 , CS 2 are configured to turn on and off the first and the second switching elements S 1 , S 2 respectively, so that the inductor L is charged during a certain first period of time and discharged into the energy storage element ESS during a certain second period of time. In that manner, the energy storage element ESS, which may be, for example a battery, can be charged by the DC-DC converter circuit 101 . According to an embodiment, the DC-DC converter circuit 101 of FIG. 2 is configured to operate in discontinuous conduction mode so that the inductor L is completely discharged and the inductor current IL falls to zero.
According to an embodiment, the pulse generation circuit CP may be implemented as in the DC-DC converter circuit 100 of FIG. 1 , the first switching element S 1 may be a nMOS transistor and the second switching element S 2 may be a pMOS transistor, but it shall be understood that other equivalent switching elements or switches may be used instead, as explained above.
According to an embodiment, when the digital pulse signal VP transitions to an active state, indicating the start of a new conversion cycle, the first switch control circuit CS 1 generates a first switch control signal VS 1 that turns on (or closes, in order to conduct) the first switching element S 1 , while the second switching element S 2 is maintained in off state (or open or not conducting state). Then the inductor voltage signal VC falls to a value close to zero while the input voltage signal V IN causes the inductor current IL to ramp up by a rate which is proportional to that value of the input voltage signal V IN . The digital pulse signal VP may remain active, e.g. a digital “1” voltage, during a certain period of time and when the pulse signal returns to inactive state or zero voltage the first switch control circuit CS 1 generates a first switch control signal VS 1 that turns off the first switching element S 1 (or causing the first switching element S 1 to open), while the second switch control circuit CS 2 maintains the second switching element S 2 in open state. The first switching element S 1 will be maintained in open state until the next conversion cycle starts. It shall be understood that although the above exemplary embodiment shows a first way to indicate, by means of the pulse signal VP, the start of a new conversion cycle and the turn off time of the first switching element S 1 , a person skilled in the art will be able to easily derive other embodiments to achieve the same purpose, for example, with more than one pulse signal, with digital or analogue signals, and considering different transitions of the pulse signal or signals.
According to an embodiment, the second switch control circuit CS 2 is configured to detect specific signal transition events in which the inductor voltage signal VC reaches a threshold value close or equal to the output voltage signal VO in each conversion cycle. Also according to an embodiment, the second switch control circuit CS 2 is configured to detect two of such signal transition events in each conversion cycle. According to yet an embodiment, the second switch control circuit CS 2 is configured to detect each of the two signal transition events independently. According to an embodiment, when the first switch control circuit CS 1 opens the first switching element S 1 , while the second switching element S 2 is still open, the inductor voltage signal VC rises to a value close or equal to the output voltage signal VO, defining a first signal transition event TVC 1 (in FIG. 4 ). When the second switch control circuit CS 2 detects such first signal transition event TVC 1 after a start of a new conversion cycle, the second switch control circuit CS 2 generates a second switch control signal VS 2 that turns on the second switching element S 2 (or causing the second switching element S 2 to close or conduct). After the second switching element S 2 closes, the inductor current IL ramps down with a rate proportional to the difference between the output voltage signal VO and the input voltage signal VIN and the value the inductor voltage signal VC decreases, reaching at a certain moment the value of the output voltage signal VO, defining a second signal transition event TVC 2 (in FIG. 4 ). The second switch control circuit CS 2 keeps precisely sensing the inductor voltage signal VC so that when the second switch control circuit CS 2 detects such second signal transition event TVC 2 after a start of a new conversion cycle, the second switch control circuit CS 2 generates a second switch control signal VS 2 that turns off the second switching element S 2 (or causing the second switching element S 2 to open). After the second switching element S 2 is opened, the second switch control circuit CS 2 is configured to neglect all further transitions of the inductor voltage signal VC close to the value of the output voltage signal VO and to maintain such second switching element S 2 in open state until the next conversion cycle starts.
FIGS. 3A and 3B show time graphs of the inductor current IL, the inductor voltage current VC and the first and second switch control signals VS 1 , VS 2 provided in an exemplary embodiment of a DC-DC converter circuit 100 shown in FIG. 1 . FIG. 3B shows a detailed view of the specific signal transition events that are detected by the second switch control circuit CS 2 according to an embodiment, namely a first signal transition event TVC 1 and a second signal transition event TVC 2 .
According to an embodiment, the first signal transition event TVC 1 occurs when the inductor voltage signal VC falls to a negative value for the first time after the start of a new conversion cycle at a cycle starting time TS. Also according to an embodiment, the second signal transition event TVC 2 occurs after the first signal transition event TVC 1 and in the same conversion cycle, when the inductor voltage signal VC increases and reaches the value of zero or a certain value close to zero. After the second signal transition event TVC 2 , the inductor voltage VC will resonate around the level of the output voltage signal VO due to the small energy which is still remaining in the inductor and which will be lost (due to parasitic losses) before the next conversion cycle starts.
As can be appreciated in FIG. 3B a first voltage signal peak of the inductor voltage signal VC below the zero value at the time of the first signal transition event TVC 1 has a faster characteristic than a second voltage signal peak of the inductor voltage signal VC below the zero value at the time of the second signal transition event TVC 2 , that is, the two signal peaks are substantially different in terms of speed. The first negative voltage peak occurs when the inductor voltage signal node is floating and discharged by the peak current in the inductor. Typical falling times of the inductor voltage signal VC are in the order of one volt per nanosecond and depend on the total parasitic capacitance of the inductor voltage signal node. There is a small delay for second switching element S 2 to close due to the speed of the detection mechanism sensing the inductor voltage signal VC. After the second switching element S 2 closes, the inductor voltage signal VC becomes zero minus a voltage drop, for example 100 mV, of the second switching element S 2 . The falling time of the inductor current IL is proportional to the peak current and to the inverse of the voltage of the energy storage element ESS connected to the circuit. If the time period in which the first switching element S 1 is closed is constant, the peak current is proportional to the difference between the input voltage signal VIN and the output voltage signal VO. Hence the falling time of the inductor current is dependent on the input and output voltages. The falling time of the inductor current is always much larger than the falling time of the inductor voltage VC. The second negative voltage peak occurs when the second switch control circuit CS 2 changes the state of the second switching element S 2 from closed to open. At that point the inductor current IL is still a little positive and the inductor voltage VC a little bit negative, and it will result in a negative kick back of the inductor voltage VC.
According to an embodiment, the second switch control circuit CS 2 is configured to detect the first and the second signal transition events TVC 1 , TVC 2 in each conversion cycle using independent detection mechanisms, one for detecting the first signal transition event TVC 1 , and another for detecting the second signal transition event TVC 2 .
During the first signal transition event TVC 1 , if the second switching element S 2 is turned on too early, the charge on the parasitic capacitance seen on the inductor voltage signal node will be discharged to ground instead of recharging the energy storage element ESS. On the other hand, if the second switching element S 2 is turned on too late, the inductor voltage VC would decrease below ground, causing conduction of the substrate diode, resulting in efficiency losses. During the second signal transition event TVC 2 , if the second switching element S 2 is turned off too early, it will produce an increase of the power losses, because the substrate diode will start to conduct. On the other hand, if the second switching element S 2 is turned off too late, the inductor current will start to flow from the energy storage element ESS to ground. Advantageously, according to an embodiment, the second switching element S 2 is controlled by the second switch control circuit CS 2 to a very precise on and off switching time.
According to an embodiment, the second switch control circuit CS 2 of the DC-DC converter circuit 100 shown in FIG. 1 is configured to detect the first signal transition event TVC 1 when the inductor voltage signal VC reaches a first threshold detection value, of zero or close to zero, after a new start of a conversion cycle at a cycle starting time TS. Also according to an embodiment, such second switch control circuit CS 2 is configured to detect the second signal transition event TVC 2 when the inductor voltage signal VC reaches a second threshold detection value, of zero or close to zero, after the first signal transition event TVC 1 and in the same conversion cycle. The threshold value close to zero may be a positive or negative voltage value substantially close to zero. According to another embodiment, the threshold value close to zero is a positive or negative voltage value which is chosen considering operational delays of the second switch control circuit CS 2 , so that such circuit is operative when the inductor voltage signal VC reaches a certain designed value.
FIG. 4 shows time graphs of the inductor current IL, the inductor voltage signal VC and the first and second switch control signals VS 1 , VS 2 provided in an exemplary embodiment of a DC-DC converter circuit 101 shown in FIG. 2 . FIG. 4 also indicates the specific signal transition events that are detected by the second switch control circuit CS 2 according to an embodiment, namely a first signal transition event TVC 1 and a second signal transition event TVC 2 .
According to an embodiment, the first signal transition event TVC 1 occurs when the inductor voltage signal VC rises and reaches a value close or equal to the output voltage signal VO for the first time after the start of a new conversion cycle at a cycle starting time TS. Also according to an embodiment, the second signal transition event TVC 2 occurs after the first signal transition event TVC 1 and in the same conversion cycle, when the inductor voltage signal VC decreases and reaches a value close or equal to the output voltage signal VO.
As can be appreciated in FIG. 4 , a first voltage signal peak of the inductor voltage signal VC over the value of the output voltage signal VO at the time of the first signal transition event TVC 1 has a faster characteristic than a second voltage signal peak of the inductor voltage signal VC over the value of the output voltage signal VO at the time of the second signal transition event TVC 2 . Similar to what happens in FIG. 3B , the two signal peaks are substantially different in terms of speed.
According to an embodiment, the second switch control circuit CS 2 of the DC-DC converter circuit 101 shown in FIG. 2 is configured to detect the first signal transition event TVC 1 when the inductor voltage signal VC reaches a first threshold detection value, being equal or close to the output voltage signal VO, for the first time after the start of a new conversion cycle at a cycle starting time TS. Also according to an embodiment, such second switch control circuit CS 2 is configured to detect the second signal transition event TVC 2 when the inductor voltage signal VC reaches a second threshold detection value, being equal or close to the output voltage signal VO, after the first signal transition event TVC 1 and in the same conversion cycle. The threshold value close to the value of the output voltage signal VO may be a voltage value higher or lower than the value of the output voltage signal VO. According to another embodiment, the threshold value close to the value of the output voltage signal VO may be a voltage value higher or lower than the value of the output voltage signal VO which is chosen considering operational delays of the second switch control circuit CS 2 , so that such circuit is operative when the inductor voltage signal VC reaches a certain designed value.
FIG. 5 shows a more detailed block diagram of an exemplary embodiment of a DC-DC converter circuit 100 according to FIG. 1 , comprising a pulse generation circuit CP which provides a pulse signal VP, a first switch control circuit CS 1 which provides a first switch control signal VS 1 to a first switching element S 1 , a second switch control circuit CS 2 which provides a second switch control signal VS 2 to a second switch element S 2 . The DC-DC converter circuit 100 may receive an input voltage signal VIN and may provide an output voltage signal VO to an energy storage element ESS connected to the circuit by an inductor L. An inductor current IL may circulate through the inductor L and change in value depending on an inductor voltage signal VC. The second switch control circuit CS 2 according to an embodiment comprises a first signal transition event detection circuit and a second signal transition event detection circuit.
According to an embodiment, the first signal transition event detection circuit comprises a first digital circuit L 1 which provides an enabling signal VEN and a first comparator circuit ZVD which provides a first transition event signal VTVC 1 . The first digital circuit L 1 receives the pulse signal VP from the pulse generation circuit CP and the first transition event signal VTVC 1 from the first comparator circuit ZVD and generates the enabling signal VEN to activate/enable or deactivate/disable the first comparator circuit ZVD. For example, when the pulse signal VP has a transition from inactive to active state, e.g. from a digital “0” to “1” (the first switching element S 1 is turned on), the first digital circuit L 1 detects the start of a new conversion cycle and waits until the pulse signal VP has a transition from an active to an inactive, e.g. from the digital “1” to “0” (the first switching element S 1 is turned off), for causing the enabling signal VEN to transition to active state (e.g. to a digital “1”) in order to enable the first comparator circuit ZVD. Afterwards, when the first transition event signal VTVC 1 transitions to active state (e.g. a high value voltage or a digital “1”), the first digital circuit L 1 causes the enabling signal VEN to transit again to inactive state (e.g. to a digital “0”) in order to disable the first comparator circuit ZVD until the start of a new conversion cycle. The first comparator circuit ZVD may be connected to a first reference voltage, which may be the voltage at the inductor voltage signal node, and to a second reference voltage or having a first threshold detection value, which may be ground or a zero voltage value or a value close to zero, the latter, for example, in case the internal delays of the circuits are taken into account, and therefore compensated for designing the threshold detection value. The first comparator circuit ZVD is configured to detect the first signal transition event TVC 1 when the inductor voltage signal VC reaches the first threshold detection value for the first time after the start of a new conversion cycle. When the first comparator circuit ZVD detects the first signal transition event TVC 1 , it will cause the first transition event signal VTVC 1 to transition to active state, e.g. to a high voltage value. Advantageously, the first signal transition event detection circuit is fast enough to follow the inductor voltage signal first signal transition event falling slope, which can be as fast as one volt per nanosecond. To limit its power consumption, the first comparator circuit ZVD is disabled immediately after it detects the first signal transition event TVC 1 . According to another embodiment, the first comparator circuit ZVD may be substituted by an inverter (e.g. for peak values of the inductor voltage VC lower than the gate breakdown voltage) or a voltage limiter followed by an inverter (e.g. for high voltage converters and the limiter being able to keep the input voltage of the inverter lower than the output voltage signal VO).
According to an embodiment, the first signal transition event detection circuit is optimized for detecting the first signal transition event TVC 1 . Advantageously, the first signal transition event detection circuit is able to detect the fast falling transition of the inductor voltage VC with negligible power consumption. A dedicated first signal transition event detection circuit for the first signal transition event TVC 1 can be fast and low power, and does not need to be extremely precise. Even if the first comparator circuit ZVD needs to consume a lot of power to be fast, the first digital circuit L 1 is used to enable the first comparator circuit ZVD only for a short period of time, between the moment in which the first switching element S 1 is turned off and the moment the first comparator circuit ZVD detects the first signal transition event TVC 1 , which could be, for example, less than 135 nanoseconds, and for that reason the power consumption is negligible.
Also according to an embodiment, the second signal transition event detection circuit comprises a second comparator circuit ZCD which provides a second transition event signal VTVC 2 and a second digital circuit L 2 which provides the second switch control signal VS 2 . The second digital circuit L 2 receives the first transition event signal VTVC 1 from the first signal transition event detection circuit and the second transition event signal VTVC 2 from the second comparator circuit ZCD and generates the second switch control signal VS 2 to turn on or off the second switching element S 2 and to activate/enable or deactivate/disable the second comparator circuit ZCD. For example, when the first transition event signal VTVC 1 transitions from inactive to active state, e.g. from a low to a high voltage value, the second digital circuit L 2 causes the second switch control signal VS 2 to transit to active state in order to turn on the second switching element S 2 and to enable the second comparator circuit ZCD. When enabled, the second comparator circuit ZCD causes the second transition event signal VTVC 2 to transit from inactive to active state, e.g. from a low to a high voltage value. Afterwards, when the second transition event signal VTVC 2 transitions from an active to an inactive, e.g. from a high to a low voltage value, the second digital circuit L 2 causes the second switch control signal VS 2 to transit to inactive state in order to turn off the second switching element S 2 and to disable the second comparator circuit ZCD. Afterwards, the second digital circuit L 2 maintains the second switch control signal VS 2 in inactive state (the second switching element S 2 is turned off) and the second comparator circuit ZCD disabled until it receives a new rising transition (from inactive to active state) of the first transition event signal VTVC 1 . The second comparator circuit ZCD may be connected to a first reference voltage, which may be the voltage at the inductor voltage signal node VC, and to a second reference voltage or having a second threshold detection value, which may be ground or a zero voltage value or a value close to zero, the latter, for example, in case the internal delays of the circuits are taken into account, and therefore compensated for designing the threshold detection value. The second comparator circuit ZCD is configured to detect the second signal transition event TVC 2 when the inductor voltage signal VC reaches the second threshold detection value, after the first signal transition event detection circuit has detected the first signal transition event TVC 1 and in the same conversion cycle. In case the first threshold detection value of the first signal transition event detection circuit is designed to be equal to the second threshold detection value of the second signal transition event detection circuit, for example zero volts, then the second comparator circuit ZCD can be configured to detect the second signal transition event TVC 2 when the inductor voltage signal VC reaches zero volts for the second time after the start of a new conversion cycle. When the second comparator circuit ZCD detects the second signal transition event TVC 2 , it will cause the second transition event signal VTVC 2 to transition from an active to an inactive, e.g. from a high to a low voltage value.
According to an embodiment, the second signal transition event detection circuit is optimized for detecting the second signal transition event TVC 2 . Advantageously, the second signal transition event detection circuit is able to compare the negative inductor voltage signal value with the second threshold detection value with a reasonable speed and precision and consuming low power. A dedicated second signal transition event detection circuit for the second signal transition event TVC 2 may be advantageously designed to be precise and to work for a longer period of time, for example tens of microseconds, for slower slopes of the inductor voltage VC, in order to maximize the overall efficiency. According to another embodiment, the second comparator circuit ZCD may be implemented by a level shifter followed by a comparator.
It shall be understood that although in the exemplary embodiments of FIG. 5 , the first comparator circuit ZVD and the second comparator circuit ZCD are directly connected to the inductor voltage signal node VC and to ground, other voltage references that relate to the falling or rising slope of the inductor voltage signal VC and to its crossing through a certain threshold value, positive or negative, close to zero can be also used. Alternatively, the comparator circuits may be connected to ground but implemented with an intrinsic internal voltage offset.
FIG. 6 shows a more detailed block diagram of another exemplary embodiment of a DC-DC converter circuit 100 according to FIG. 1 . Its structure is the same as the one explained in the exemplary embodiment of FIG. 5 , but for the fact that the second signal transition event detection circuit now comprises two different comparators, a first comparator circuit, hereinafter called a low power comparator circuit LPC, and a second comparator circuit, hereinafter called a high power comparator circuit HPC. The low power comparator circuit LPC is connected to a first reference voltage, which may be the voltage at the inductor voltage signal node VC, and to a second reference voltage or having a second threshold detection value, which may be ground or a zero voltage value or a value close to zero, the latter, for example, in case the internal delays of the circuits are taken into account, and therefore compensated for by designing a threshold detection value. As an example, the low power comparator circuit LPC may have an intrinsic internal offset voltage designed to consider the delays for turning off the second switching element S 2 in all operating conditions, and thus advantageously avoiding switching delays that can cause efficiency losses. In a specific embodiment, the intrinsic internal offset voltage is proportional to the turning on time of the high power comparator circuit HPC. In an embodiment, the low power comparator circuit LPC advantageously enables the high power comparator circuit HPC a bit before the zero crossing time of the inductor voltage signal VC. In an embodiment, when the first transition event signal VTVC 1 transitions from inactive to active state, e.g. from a low to a high voltage value, the second digital circuit L 2 causes the second switch control signal VS 2 to transit to active state in order to turn on the second switching element S 2 and to enable the low power comparator circuit LPC. When enabled, the low power comparator circuit LPC causes the second transition low power event signal VLPC 2 , the second transition high power event signal VHPC 2 and the second switch control signal VS 2 , to transit from inactive to active state, e.g. from a low to a high voltage value. The low power comparator circuit LPC is configured to detect the second signal transition event TVC 2 when the inductor voltage signal VC reaches the second threshold detection value, after the first signal transition event detection circuit has detected the first signal transition event TVC 1 and in the same conversion cycle. When the low power comparator circuit LPC detects the second signal transition event TVC 2 , it will cause the second transition low power event signal VLPC 2 to transition from an active to an inactive, e.g. from high to a low voltage value, in order to enable the high power comparator circuit HPC. The high power comparator circuit HPC is connected to a first reference voltage, which may be the voltage at the inductor voltage signal node VC, and to a second reference voltage or having a third threshold detection value, which may be ground or a zero voltage value or a value close to zero. In an exemplary embodiment, when enabled by the low power comparator circuit LPC and when it detects that the inductor voltage signal VC reaches the third threshold detection value, it will cause the second transition high power event signal VHPC 2 to transition from an active to an inactive, e.g. from a high to a low voltage value. At that time, when the second transition high power event signal VHPC 2 transitions from an active to an inactive, the second digital circuit L 2 causes the second switch control signal VS 2 to transit to inactive state in order to turn off the second switching element S 2 and to disable both the low power comparator circuit LPC and the high power comparator circuit HPC.
According to an embodiment, the second signal transition event detection circuit of FIG. 6 is optimized for detecting the second signal transition event TVC 2 , so that the detection is performed as precisely as possible to maximize the overall efficiency. Advantageously, the second signal transition event detection circuit comprises two different comparator circuits; one (the low power comparator circuit) that consumes low power and works for the most of the operation time, and another (the high power comparator circuit) that is more precise and consumes more power but which is operated for a shorter period of time. In this manner it is also advantageous that the detection operation of the second signal transition event TVC 2 is performed with negligible effect on the efficiency of the DC-DC converter even at low input power (e.g. 10 μW).
FIG. 7 shows time graphs of the enabling signal VEN, the inductor voltage signal VC and the first transition event signal VTVC 1 , provided in exemplary embodiments of DC-DC converter circuits according to FIGS. 5 and 6 . When the first digital circuit L 1 causes the enabling signal VEN to transition to active state, the first comparator circuit ZVD is enabled, so that the first comparator circuit ZVD is able to detect the first signal transition event TVC 1 . After detection, the first comparator circuit ZVD causes the first transition event signal VTVC 1 to transition to active state. Afterwards, when the first transition event signal VTVC 1 transitions to active state, the first digital circuit L 1 causes the enabling signal VEN to transit again to inactive state in order to disable the first comparator circuit ZVD until the start of a new conversion cycle.
FIG. 8 shows time graphs of the second transition low power event signal VLPC 2 , the second transition high power event signal VHPC 2 , the inductor current IL and the first transition event signal VTVC 1 and the second switch control signal VS 2 , provided in an exemplary embodiment of a DC-DC converter circuit according to FIG. 6 . When the first signal transition event detection circuit detects the first signal transition event TVC 1 , and the first transition event signal VTVC 1 transitions from inactive to active state, the low power comparator circuit LPC is enabled and causes the second transition low power event signal VLPC 2 , the second transition high power event signal VHPC 2 and the second switch control signal VS 2 , to transit from inactive to active state. At the first transition event TVC 1 the high power comparator HPC is not enabled, but its output signal VHPC 2 is already preset to an active state in order to avoid missing a transition in case of fast inductor current changes. When the low power comparator circuit LPC detects the second signal transition event TVC 2 , it will cause the second transition low power event signal VLPC 2 to transition to transition from an active to an inactive, which enables the high power comparator circuit HPC. When the high power comparator circuit HPC detects that the inductor voltage signal VC reaches the third threshold detection value, it will cause the second transition high power event signal VHPC 2 and the second switch control signal VS 2 to transition from an active to an inactive.
FIG. 9 shows a more detailed block diagram of an exemplary embodiment of a DC-DC converter circuit 101 according to FIG. 2 , comprising the same structural elements as the ones explained in the exemplary embodiment of FIG. 5 . It will become apparent for a person skilled in the art that the functionality of the first signal transition event detection circuit (the first digital circuit L 1 and the first comparator circuit ZVD) and the second signal transition event detection circuit (the second comparator circuit ZCD and the second digital circuit L 2 ) is similar and can be derived from the embodiments explained in FIG. 5 , together with the facts explained in FIGS. 2 and 4 and particularly considering that the first threshold detection value and the second threshold detection value of the first comparator circuit ZVD and the second comparator circuit ZCD respectively, may equal or close to the value of the output voltage signal VO. The threshold value close to the value of the output voltage signal VO may be a voltage value higher or lower than the value of the output voltage signal VO, in case the internal delays of the circuits are taken into account, and therefore compensated for by designing the threshold detection value.
FIG. 10 shows a more detailed block diagram of another exemplary embodiment of a DC-DC converter circuit 101 according to FIG. 2 , comprising the same structural elements as the ones explained in the exemplary embodiment of FIG. 9 . but for the fact that the second signal transition event detection circuit now comprises two different comparators, a low power comparator circuit LPC and a high power comparator circuit HPC. It will become apparent for a person skilled in the art that the functionality of the first signal transition event detection circuit (the first digital circuit L 1 and the first comparator circuit ZVD) and the second signal transition event detection circuit (the low power comparator circuit LPC, the high power comparator circuit HPC and the second digital circuit L 2 ) is similar and can be derived from the embodiments explained in FIG. 6 , together with the facts explained in FIGS. 2 and 4 and particularly considering that the first threshold detection value, the second threshold detection value and the third threshold detection value of the first comparator circuit ZVD, the low power comparator circuit LPC and the high power comparator circuit HPC respectively, may equal or close to the value of the output voltage signal VO. The threshold value close to the value of the output voltage signal VO may be a voltage value higher or lower than the value of the output voltage signal VO, in case the internal delays of the circuits are taken into account, and therefore compensated for by designing the threshold detection value.
The DC-DC converters according to any of the embodiments herein described may be used, but not limited to, for ultra-low power wireless sensing applications, as interface between energy harvesters and a battery element that is charged and stores the energy obtained from the harvester. The DC-DC converters according to one or more of the embodiments herein described may be advantageously efficient for low input powers between 10 and 1000 microwatts and for a large input voltage range between 5 and 60 V. The DC-DC converters works in Discontinuous Conduction Mode (DCM) to achieve high efficiency even at low input powers. Thanks to its low power consumption and to its asynchronous implementation, the DC-DC converters work efficiently also at extremely low input powers (of the order of few microwatts) and the measured efficiency is high (61% to 91%) in a wide range of input powers (10 μW-1 mW) and input voltages (5V to 60V). The control circuits and power switches of any of the DC-DC converters according embodiments of the description can be integrated in the same integrated circuit. The inductor and a rechargeable battery may be added as discrete components. | A DC-DC converter and a method of controlling an inductor-based switching-mode DC-DC converter in a discontinuous conduction mode are disclosed. In one aspect the method includes providing a DC-DC converter having a first and second switching elements, and, in each conversion cycle, first, turning on a first switching element, while maintaining a second switching element in off state, thereby increasing the current through an inductor. The method also includes detecting when a voltage signal at one connection node of the inductor reaches a first threshold value for the first time after the start of the conversion cycle, and turning on the second switching element, while maintaining the first switching element in off state, thereby decreasing the inductor current. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a coaxial transmission, especially hollow shaft transmission for industrial drive engineering, having high power density, with a drive element, with an element and with an output element, a step-up and a transfer of a drive torque between the drive element and output element taking place via a plurality of radially movable toothed segments, the at least one toothed segment having a supporting element in the range of action with respect to the drive element.
Conventional transmissions are known and obtainable commercially in any form and version.
Essentially three different technologies of transmissions are employed commercially. On the one hand, epicyclic transmissions are known commercially, in which, for example within a ring wheel, one or more planet wheels are provided coaxially, by means of a mostly centrally arranged sunwheel, with the transfer of a torque to a planet wheel carrier or an output element.
In planetary or epicyclic transmissions of this type, they cannot run at high transfer speeds and, because generally there are only very small possible hollow shaft diameters, they cannot transfer high torques. Moreover, transmissions of this type suffer from low rigidity and low robustness and have a low overload capacity.
Furthermore, there is the disadvantage that, especially in case of high drive-side rotational speeds, a step-up or a step-up ratio is restricted.
Furthermore, eccentric transmissions are known in which, mostly, a planet wheel is provided within an internally toothed ring wheel for transferring the torques and for effecting step-ups.
The disadvantage of eccentric transmissions is that these require high separating forces in very large bearing elements, especially in hollow shaft versions, and are suitable only for hollow shaft versions having a smaller diameter. Even here, these eccentric transmissions have low overload capacities and low robustnesses.
Moreover, the step-up ranges are restricted to about i=30 to i=100, and only at low drive rotational speeds. At higher drive rotational speeds, eccentric transmissions of this type are subject to high wear and therefore have a short service life, which is undesirable.
Moreover, eccentric transmissions of this type have high frictional losses and therefore low efficiencies when clutches or the like follow eccentric transmissions in order to shift eccentric output movement to a centric movement. Efficiency of the eccentric transmission is therefore very low.
Especially at high rotational speeds, serious vibration problems arise which are likewise undesirable.
Furthermore, harmonic drive transmissions are known, which, indeed, can also be implemented as hollow shaft transmissions, there being arranged between the drive element of mostly oval design and an internally toothed ring wheel a flexible spline, as it is known, which is designed to be soft and resilient and which transfers the corresponding torque between the drive and ring wheel and allows a step-up.
The flexible spline, as it is known, is subject to permanent loads and often fails under high torques. Moreover, the flexible spline does not have overload capacity and often quickly breaks off when torques are too high. Furthermore, the harmonic drive transmission has poor efficiency and low torsional rigidity.
DE 31 21 64 represents the prior art closest to the present invention. Said document relates to a self-locking shift transmission in which a plurality of arms, which are arranged in a stellate fashion around a shaft, are mounted with their inner ends eccentrically on the shaft. The arms are designed as two-armed levers, their centers of rotation are guided in a crossed fashion and their inner ends rest independently of one another on the driving eccentric, such that the outer ends perform a connecting rod movement. Here, said ends engage in succession into the gearwheel and drive the latter in the opposite direction to the rotation of the driveshaft. The contact surfaces are widened in relation to the tooth roots. However, said contact surfaces are fixedly connected, not connected loosely or in a joint-like manner, to the tooth or toothed wheel.
The object on which the present invention is based, therefore, is to provide a coaxial transmission of the type initially mentioned, which eliminates said disadvantages of the hitherto known coaxial transmissions, epicyclic transmissions, eccentric transmissions and harmonic drive transmissions, while force transfer between the drive element and toothed segment is to be improved markedly with the transfer of very high forces.
Moreover, the coaxial transmission is to have very high compactness and complexity, with the smallest possible installation space and lowest possible weight at a certain power rating.
The fact that the supporting element is movable, in particular in an articulated manner, in a joint-like manner, pivotably connecting or supported slidably, with respect to a basic body of the respective toothed segment and that the supporting segments together result in a segmented mounting leads to the achievement of this object.
SUMMARY OF THE INVENTION
In the present invention, it has proved advantageous to provide a coaxial transmission in which a plurality of toothed segments are linearly guided radially outward within an element.
The individual toothed segments have at one end corresponding tooth flanks which engage into corresponding tooth spaces of an outer ring wheel.
The toothed segments are moved into the toothing of the ring wheel by means of a drive element which possesses an outer profiling and an outer contour, in order to effect a stepped-up rotational movement by means of a corresponding rotational drive movement.
In this case, it has proved especially advantageous, in the present invention, to form enlarged supporting elements in the root region of the toothed segments, in order to transfer very high radially acting forces of the drive element, especially of its profiling, to the toothed segment.
In this case, the supporting elements may be connected to the toothed segment in a joint-like manner directly or indirectly, via intermediate elements, intermediate bearings or joints, or directly in one piece via corresponding contractions, narrowings or the like.
As a result of a greater length of the supporting elements in relation to the thickness of the toothed segment, the contact area of the supporting elements is markedly enlarged, so that there, in this region, a plurality of bearing elements transfer the forces of the drive element to the toothed segment. High load distribution occurs, and therefore even very high rotational speeds of the coaxial transmission, along with high torque transfer, can be ensured.
Furthermore, it has proved especially advantageous that the individual supporting elements adjacent to one another engage one in the other on the end faces and allow a certain play in the circumferential direction and in the radial direction.
However, an axial play is ensured by a corresponding engagement of end-face projections into corresponding adjacent recesses of the adjacent supporting elements.
The bearing elements are preferably needle rollers or balls which can be inserted, fully fitted or spaced apart individually, in cages or spacers with positive guidance.
In this case, it is also to come within the scope of the present invention that an additional distribution of the forces becomes possible, for example via an additional elastic bearing outer ring, between an underside of the supporting element and the bearing elements.
Overall, the present invention provides a coaxial transmission, in which extremely high forces can be transferred at very high speeds from the drive element to the radial movement of the toothed segments and therefore to the toothing of the ring wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention may be gathered from the following description of preferred exemplary embodiments and with reference to the drawing, in which:
FIG. 1 a shows a diagrammatically illustrated cross section through a coaxial transmission;
FIG. 1 b shows a perspective top view of part of the coaxial transmission in the region of the drive element and toothed segments;
FIG. 1 c shows a part cross section, illustrated enlarged, of the coaxial transmission according to FIG. 1 a;
FIG. 2 shows a diagrammatically illustrated perspective illustration of a further exemplary embodiment of a coaxial transmission in the region of toothed segments and the drive element;
FIGS. 3 a to 3 c show cross-sectionally enlarged illustrations of individual toothed segments with different directly or indirectly connected and adjoining supporting elements for support on bearing outer rings or needle bearings;
FIG. 4 shows a diagrammatically illustrated perspective illustration of part of a further exemplary embodiment of a coaxial transmission with toothed segments and supporting elements;
FIG. 5 shows a perspective bottom view of an exemplary embodiment of a supporting element for transferring the thrust movement of the toothed segments.
DETAILED DESCRIPTION
According to FIG. 1 a , a coaxial transmission R 1 has a ring wheel 1 which possesses an internal toothing 2 with a plurality of tooth spaces 2 ′. An element 3 is inserted in an annulus-like manner within the ring wheel 1 , a plurality of toothed segments 5 being inserted radially next to one another and into corresponding guides 4 in the annulus-like element 3 . The toothed segments 5 are mounted so as to be displaceable radially to and fro within the guide 4 and have a tooth flank 6 .
Within the element 3 having received toothed segments 5 is provided a drive element 7 designed as a shaft or as a hollow shaft and having an outer profiling 8 which, for example with a contour 9 , may be designed as an elevation in the polygonal or cam-like manner.
Bearing elements 10 are likewise provided between the outer contour 9 of the profiling 8 of the drive element 7 and the toothed segments 5 , as is indicated especially in FIGS. 1 b and 1 c.
In the present invention, it has proved especially advantageous, particularly with regard to the coaxial transmission R 1 , that a supporting element 11 of enlarged design adjoins the toothed segment 5 .
As is evident especially from FIGS. 1 a , 1 b and 1 c , a joint 12 connects the toothed segment 5 to the supporting element 11 in a joint-like manner.
Furthermore, in the present invention, it has proved to be advantageous that adjacent supporting elements 11 can be connected in a chain-like or link-like manner in each case in the end-face region of the supporting elements 11 , while at the same time a play is possible in the direction of the double arrow x illustrated, that is to say with respect to the movement of the circumferential surface, and a play is possible in the y-direction, that is to say in the radial direction, as illustrated in FIG. 1 c.
In this case, it has proved especially advantageous that the supporting element 11 can be adapted to the contour 9 of the profiling 8 by means of the joint 12 and is thereby at the same time tied to the positively guided position of the toothed segment 5 inserted in the guide 4 .
The supporting element 11 can therefore easily be adapted in a joint-like manner, during the rotation or rotational movement of the drive element 7 with respect to the ring wheel 1 and/or to the element 3 , to the contour 9 of the drive element 7 , said contour changing as a result of rotation.
In the present exemplary embodiment, according to FIGS. 1 a , 1 b and 1 c , the supporting elements 11 lie directly on the bearing elements 10 which, in turn, are supported on the outside on the contour 9 of the drive element 7 .
A plurality of rolling bodies, in particular needle rollers or balls, are preferably used as bearing elements 10 .
With regard to the functioning of the coaxial transmission, reference is made to German patent application DE 10 2006 042 786. The functioning is described exactly there.
The present application relates to a further development and an improvement in the kinematics between the drive element 7 and element 3 , especially in the region of the mounting of the toothed segments 5 .
FIG. 1 b illustrates part of the coaxial transmission R 1 in perspective. It can be gathered there, how the individual supporting elements 11 engage one in the other by corresponding projections 13 and recesses 14 next to one another on the end faces and, as illustrated in FIG. 1 c , allow play in the x- and y-direction. By the projection 13 of one supporting element 11 engaging into the recess 14 of the adjacent supporting element 11 , good guidance and, at the same time, mounting and hold in the axial direction are ensured.
It is also important in the present invention, however, that, because the supporting elements 11 are enlarged, they are supported and cushioned via a plurality of individual bearing elements 10 , in particular needle bearings, so that very high radial forces can be absorbed by the toothing 2 for operating the coaxial transmission R 1 .
In the present invention, furthermore, it has proved advantageous that, as is not illustrated in any more detail here and is indicated merely in FIG. 3 a , a bearing outer ring 15 ( FIG. 3 a ) can be inserted between the supporting element 11 and the bearing element 10 or directly between the supporting element 11 and a contour 9 of the drive element 7 . The bearing outer ring 15 is of the elastic type and assists force distribution between the supporting element 11 and bearing element 10 or force distribution between the supporting elements 11 and the outer contour 9 of the drive element 7 .
In the exemplary embodiment of the present invention according to FIG. 2 , a coaxial transmission R 2 is shown, in which spacers 16 are provided between the supporting elements 11 and the drive elements 7 , especially its contours 9 , and between individual adjacent bearing elements 10 , especially needle rollers. The spacers 16 in each case engage radially and on the end faces onto the bearing elements 10 , preferably on both sides, and space these apart from one another in a chain-like or link-like manner.
Thus, the individual needle rollers can be spaced radially apart from one another around the contour 9 of the drive element 7 , a guidance of the individual supporting elements 11 in each case being ensured laterally.
FIG. 3 a illustrates, enlarged, a toothed segment 5 with a supporting element 11 , a corresponding profiling 18 of the supporting element 11 being provided in a recess 17 in the root region of the toothed segment 5 , so that a joint-like movement of the supporting elements 11 with respect to the toothed segment 5 is also ensured.
As illustrated in FIG. 3 c , it may also be conceivable to form the corresponding profiling 18 from the root region of the toothed segment 5 , said profiling then cooperating in a joint-like manner with a corresponding recess 17 of the supporting element 11 .
If, for example, the use of a bearing outer ring 15 , as illustrated in FIG. 3 a , is dispensed with, it has proved advantageous if the supporting elements 11 have introduction chamfers 20 on their underside 19 directed toward the bearing element 10 , particularly in the end-face regions.
Thus, for example without an interposed bearing outer ring 15 , the load can be transferred via the bearing elements 10 directly to the supporting element 11 and therefore directly to the toothed segment 5 .
Furthermore, in the present invention, it is advantageous that the supporting elements 11 have on the end faces corresponding overlaps 13 , 14 , for example as a projection 13 or recess 14 or as a setback, in order in the circumferential direction to ensure, as a segmented bearing outer ring, a guidance of the bearings 10 in the circumferential direction.
Moreover, a defined gap 26 is established between two supporting elements 11 , spaced apart on the end faces, as a function of the contour 9 or profiling 8 of the drive element 7 , in order to compensate different radii of the drive element 7 during a rotational movement in cooperation with the supporting elements 11 .
In the exemplary embodiment according to FIG. 3 b , it is illustrated that the supporting element 11 and toothed segment 5 are formed in one piece, the contraction 21 , as a taper, being formed in the root region of the toothed segment 5 , in order to allow an articulated or joint-like pivoting of the supporting elements 11 with respect to the toothed segment 5 , as indicated in the direction of the double arrow.
In the present invention, however, it is important, as is also illustrated clearly in FIGS. 3 a to 3 c , that a length L of the supporting elements 11 is greater than a thickness D of the toothed segment 5 .
The length L of the supporting elements 11 may amount to 1.5 to 4 times the thickness D of the toothed segment 5 . This is likewise to come within the scope of the present invention.
Furthermore, it has proved to be especially advantageous in the present invention, as is clear particularly from the exemplary embodiment according to FIG. 4 , that a plurality of supporting elements 11 are arranged, spaced apart radially next to one another, on an outer contour 9 of the drive element 7 . In this case, the bearing elements 10 are embedded in a bearing groove 23 on the outside in the contour 9 or profiling 8 , so that said bearing elements cannot emerge axially either in one direction or the other.
A plurality of supporting elements 11 arranged next to one another are laid onto the bearing elements 10 and likewise possess corresponding bearing grooves 24 on their underside, so that, as illustrated in FIG. 5 , corresponding flanges 25 engage over the bearing elements 10 on the end faces, with the result that the bearing element 11 is held, secured axially, on the bearing elements 10 , particularly the needle rollers, and allows optimal mounting radially.
The supporting element 11 possesses laterally a projection 13 which is preferably triangle-like and is shaped as an obtuse triangle, and engages into a corresponding matching recess 14 of an adjacent supporting element 11 . The supporting element possesses, on the one hand, a corresponding projection 13 and, on the other hand, a corresponding recess 14 which serves for the engagement of the projection 13 of the adjacent supporting element 11 .
Furthermore, the corresponding recess 17 is preferably designed to be continuous, so that at least one toothed segment 5 can engage there in its root region 22 .
In the present invention, it has proved to be particularly advantageous for a plurality of individual supporting elements 11 with bearing elements 10 to have a segment-like design and, as segment-like bearing outer rings, to surround the actual drive element 7 , in particular its profiling 8 . At the same time, the supporting element 11 serves for distributing the forces to the toothed segments 5 , the toothed segments 5 being separately mounted or supported within the supporting elements 11 . A bearing outer ring segmented in this way and formed from a plurality of segment-like supporting elements 11 is highly rigid and can transfer very high forces at high circumferential speeds to the individual toothed segments.
It has proved advantageous in the present invention to insert a plurality of, preferably two, cylindrically designed toothed segments 5 arranged next to one another in the axial direction into the element 3 , in particular into the output element, into a corresponding, matching, cylindrical guide 4 , said toothed segments then being supported together in one supporting element 11 . | A coaxial transmission, especially a hollow shaft transmission for industrial drive engineering, having a high power density. The transmission comprises an input element ( 7 ), an element ( 3 ) and an output element, a drive torque being multiplied and transmitted between the input element ( 7 ) and the output element via a plurality of radially mobile toothed sections ( 5 ). At least one toothed section ( 5 ) has a bearing element ( 11 ) which is enlarged in its effective zone with respect to an input element ( 7 ). | 5 |
BACKGROUND OF THE INVENTION
The present invention relates in general to switching regulators, and in particular to a method and circuitry for a constant on-time switching regulator.
Many of today's battery powered consumer products such as notebook computers and cellular phones operate with more than one power supply voltage level. For example, a central processing unit (CPU) for a portable personal computer may be designed to operate at 2.9 volts while the hard disk drive operates at 5 volts. Instead of providing several sources of power, these systems typically use a single power supply source and generate the others with DC--DC converters. The DC--DC conversion is typically performed by the power supply regulator circuitry that is almost universally provided in battery operated electronic products.
There are basically two types of power supply regulators, linear and switching regulators. Linear regulators rely on a linear control element (typically the effective resistance of a pass transistor) with feedback to regulate or obtain a constant voltage. When a linear regulator is used as a DC--DC converter, there is always an appreciable amount of power dissipation the average value of I out (V in -V out )!.
In a switching regulator, a transistor operating as a switch periodically applies the input voltage across an inductor for short intervals. Since the input voltage is switched on and off to transfer just enough charge to the load without going through energy dissipating elements, an ideal switching regulator dissipates zero power. There are several types of switching regulators, step-down, step-up, and inverting regulators. Although there are different ways to realize switching conversion, the most common method uses inductor and capacitor as energy storage elements and a MOSFET as the switching element.
FIG. 1 shows an example of a typical step-down switching regulator. When switch 100 is closed, V out -V in is applied across inductor 102, causing a linearly increasing current (dI/dt=V/L) to flow through inductor 102 and smoothing capacitor 104. When switch 100 opens, inductor current continues to flow in the same direction, with clamp diode 106 starting to conduct. Diode 106 clamps the voltage across the inductor causing the inductor current to decrease linearly. A switch control circuit 108 includes an error amplifier that compares the output voltage with a reference voltage and generates a signal with either controlled pulse width (pulse width modulation PWM) or controlled frequency (pulse frequency modulation PFM) to drive switch 100.
In PWM switching regulators the switching frequency is constant but the pulse width (therefore the duty cycle) is changed. A DC step-down conversion is achieved by adjusting the proper duty cycle of the switch control signal. For example, to obtain a 3 volt output from a 5 volt input, the duty cycle of the switch control signal will be 3/5 or 60% . The duty cycle of the switch control signal is changed according to the line and load conditions as well. For example, the duty cycle decreases as the load current decreases.
In PFM switching regulators, typically, the off-time of the switching element is kept constant and the frequency of the control signal is varied depending on the input and output conditions. This approach, commonly referred to as constant off-time switching, has the advantage that the system operates mostly in continuous mode, reducing noise and ripple.
FIG. 2 is a timing diagram demonstrating the control signal for PWM and PFM step-down switching regulators. A 50% duty cycle signal with an exemplary 40 μs period is shown at line 200. A switch control signal for a step-down PWM regulator is shown at line 202. To reduce the duty cycle to 40%, the pulse width of the control signal is reduced but the frequency is maintained constant. Signal 204 shows a step-down constant-off PFM regulator switch control signal. In this example, the PFM signal provides the same 40% duty cycle. The constant-off time regulator keeps the duration of the low half cycle at 20 μs but reduces the width of the high half cycle to 13.3 μs to achieve a duty cycle of 40%. The frequency of the signal thus is increased significantly.
While the switching regulators provide an improvement over the linear regulators, their performance does suffer under lower load conditions. This is generally due to a proportional increase in switching loss through parasitic capacitors attendant at the control terminal of the switching transistor. The switching transistor is typically a large power MOSFET with sizable gate-to-source (C gs ) and gate-to-drain (C gd ) capacitances. In the case of the PWM switching regulators, the switching frequency remains constant resulting in a constant switching loss that is independent of output current. At lower load currents, the switching loss through C gs /C gd becomes a significantly larger percentage of the overall power. For the constant off time PFM switching regulators, at lower load currents the frequency of the control signal is increased. The switching loss through C gs /C gd increases as the switching frequency at the gate terminal of the transistor increases. Thus, the efficiency of both types of switching regulators is low under low load current conditions.
An improvement for the lower load current performance has been to introduce a sleep (or idle) mode to the operation of the PFM and PWM switching regulators. A sensor inside the switch control circuitry detects the load current, and when it drops below a threshold level, the circuit operates to block most of the switching pulses resulting in a much lower effective switching frequency. Thus, the effective switching frequency is reduced as the load current decreases, reducing the overall switching loss. The transition between sleep mode and regular mode, however, causes larger output ripple and degrades the load regulation. Further, the implementation of the sleep mode requires extra circuitry which adds to circuit complexity and chip area.
There is therefore a need for a switching regulator that can provide DC--DC conversion and operate at all load current conditions without performance degradation and chip area compromise.
SUMMARY OF THE INVENTION
The present invention provides a method and circuitry for a pulse frequency modulated switching regulator whose switching frequency decreases as the load current is reduced. By keeping the on-time of the switch constant, the circuit of the present invention operates to reduce the switching frequency under lower load currents. This in turn reduces switching loss and improves the efficiency of the regulator at low currents. The present invention eliminates the need for a sleep or idle mode. As a result, the load regulation and ripple performance are improved and the corresponding sleep mode circuitry is eliminated.
Accordingly, in one embodiment, the present invention provides for use in a switching regulator a current-controlled oscillator (CCO) circuit including a comparator with a first input coupled to a threshold voltage and an output for providing an output signal, a first current source for controlling an off time of the output signal, and a second current source for controlling the on time of the output signal. The first and the second current sources couple to a second input of the comparator. The control circuit also includes a feedback circuit coupled between the output of the comparator and one of the current sources to switch the current source on and off. The amount of current flowing through the first current source varies while an amount current flowing through the second current source remains constant. Thus, the CCO circuit generates an output signal with constant on-time and variable off-time.
In another embodiment, the present invention provides a method for controlling a switch in a switching regulator comprising the steps of: (A) sensing an output signal of the switching regulator; (B) comparing the output signal with a reference signal; (C) generating an error signal representing a difference between the output signal and the reference signal; and (D) maintaining a constant on-time and adjusting an off-time of the switch in response to the error signal.
A better understanding of the nature and advantages of the constant on-time switching regulator of the present invention may be had with reference to the detailed description below and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a conventional step-down switching regulator circuit;
FIG. 2 is a timing diagram illustrating the switch control signals for step-down PWM and PFM switching regulators;
FIG. 3 is a simplified block diagram of a current-controlled oscillator according to the present invention, for use in the constant on-time switching regulator of the present invention;
FIG. 4 is one example of a circuit implementation for the current-controlled oscillator of FIG. 3; and
FIG. 5 is a block diagram of the constant on-time step-down switching regulator according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The switching regulator of the present invention is designed such that as the load current decreases the frequency of the switching decreases. This is accomplished by maintaining a fixed duration for the high portion of the switch control signal and adjusting the duration of the low portion of the cycle. In one embodiment, the present invention implements this constant on-time switching by a current-controlled oscillator circuit.
Referring to FIG. 3, there is shown a simplified block diagram of current-controlled oscillator (CCO) 300 according to the present invention. CCO 300 includes a first current source 302 that sources current I1 into a node 308. A second current source 304 sinks current I2 from node 308 to ground. A timing capacitor C306 connects between node 308 and ground, and is charged and discharged by the two current sources 302 and 304. Node 308 also connects to one input of a comparator 310 whose other input connects to a threshold voltage Vt. The output of comparator 310 provides the CCO output (CCO out ) that can directly drive the switching element (power transistor not shown). The threshold voltage Vt has two levels Vth and Vt1 controlled by the CCO out signal. Hysteresis is thus provided by setting Vt at its high level Vth when CCO out is high, and its low level Vt1 when CCO out is low. The CCO out signal is also fed back to both current sources 302 and 304 via on/off control blocks 312 and 314, respectively. The two current sources are turned on and off with opposite polarity signals from the on/off control blocks 312 and 314. An error circuit 316 generates an error signal I err driving current source 302 to adjust the magnitude of I1. It is the magnitude of I1 that sets the off time.
In operation, when the timing capacitor C306 is charged up (by I1) to a voltage above Vth (i.e., when the voltage at node 308 or V 308 is greater than Vth), CCO out switches low turning on the switching element. When CCO out turns low, control block 314 turns on current source 304 and control circuit 312 turns off current source 302, and Vt is switched from Vth to Vt1. Timing capacitor C306 is discharged by I2 until V 308 drops below Vt1, at which time the comparator output switches high, turning off the switching element, turning off current source 304, turning on current source 302, and switching Vt from Vt1 to Vth. Thus, the capacitor C306 is charged by I1 until V 308 rises above Vth. Thus, the discharge time determined by I2 sets the length of time COO out remains low which determines the on time of the switching element, and the charge time determined by I1 sets the length of time CCO out remains high which determines the off time of the switching element. Given a constant magnitude for I2, the on time remains constant. The magnitude of I1, and therefore the off time, on the other hand, is varied by I err depending on the input/output condition of the regulator. The charging and the discharging of C306 and the toggling of the comparator output repeats cyclically to generate the desired constant on-time switching signal.
An exemplary transistor level schematic for the CCO of FIG. 3 is shown in FIG. 4. The same reference numerals are used for the corresponding blocks in FIGS. 3 and 4. Transistors Q400 (current source 302) and Q402 (current source 304) provide I1 and I2 currents, respectively. A pair of emitter-coupled transistors Q404 and Q406 form comparator 310. The output of comparator 310 is tapped off the base terminal of transistor Q406, is buffered by two emitter-follower transistors Q408 and Q410, and provided at the output terminal CCO out . Transistors Q412, Q413 and Q414 implement the feedback control block 312 for I1 current source 302 (transistor Q400), and transistors Q416, Q418, and Q420 implement the feedback control block 314 for I2 current source 304 (transistor Q402). The error signal I err connects to the I1 control circuitry 312 via transistor Q422. Timing capacitor C306 connects to the C ext terminal that connects to the base terminal of comparator transistor Q404.
This circuit implementation of the CCO adds hysteresis to the comparator function. A string of diode connected transistors Q424, Q426, and Q428 set up a fixed threshold voltage Vt (three diode drops) above ground. A hysteresis network made up of the parallel connection of a diode-connected transistor Q430 and a resistor R432 converts Vt to either Vth or Vt1 at the base terminal of comparator transistor 406. Transistors Q434 and Q436 provide a buffering action for the mid-reference voltage V mr that is supplied to the rest of the circuitry to calibrate the mid-supply voltage level for the entire circuit. The MAX -- I input terminal supplies an active low control signal that provides protection against high current conditions. A bias network 438 sets up the bias currents for the circuit through transistors Q440, Q442, Q444, and Q446.
FIG. 5 shows a block diagram of a step-down switching regulator using the CCO according to the present invention. The output of the current-controlled oscillator 300 connects to a driver amplifier 500 whose output drives the gate terminal of a power transistor 502. Power transistor 502 acts as a high speed saturated switch with one terminal connected to the input signal Vin. The other terminal of transistor switch 502 connects to the step-down network including an inductor 504 coupled in series to a resistor 506, a capacitor 508 and a diode 510. The output Vout of the regulator goes through a resistive voltage divider 512 and connects to an input of an error voltage amplifier 514. The other input of the error amplifier 514 connects to an output of a reference voltage generator 516. Reference voltage generator 516 is preferably a very stable reference voltage such as a bandgap reference voltage. Resistor 506 acts as a sense resistor that detects current through inductor 504 and sends the inductor current information to a current amplifier 518. The output of current amplifier 518 also drives the control input of CCO 300. This current feedback improves system stability and line regulation.
The switching regulator of the present invention generates switching pulses only when needed. The lower the load current, the fewer pulses is required to generate the regulated output. Since the on time of the switch is constant and it is the off time that is adjusted, the frequency of the switching is reduced when fewer pulses are required. Therefore, for lower load currents the power consumption of the circuit is reduced and the overall efficiency is improved.
In conclusion, the present invention provides a circuit and method for an improved switching regulator. The switching regulator uses a current-controlled oscillator to implement constant on-time switching. The constant on-time switching results in reduced frequency of switching at lower load currents, and improved overall efficiency of the regulator. Compared with the existing PWM and PFM controllers, the overall performance is improved while the circuitry and chip area is reduced. While the above describes specific embodiments of the present invention, it is possible to use various alternatives, modifications and equivalents. The constant on-time architecture of the present invention, for example, is not limited to the step-down type of switching regulators, and other types of switching regulators may be designed which use a similar technique without departing from the inventive concept. Also, while FIG. 4 shows a circuit implementation of the CCO using bipolar transistors, the CCO can be implemented in CMOS technology. An alternative implementation of the constant on-time architecture of the present invention may, for example, include only the on/off control circuitry (314) for the adjustable current source (304) with a large sinking current that overrides that of the adjustable current source (302), without having to provide for a separate on/off circuitry for the adjustable current source (302). Therefore, the scope of the present invention should be determined not with reference to the above description but should, instead, be determined with reference to the appended claims, along with their full scope of equivalents. | A switching voltage regulator whose switching frequency decreases with reduced load currents is disclosed. The switching voltage regulator includes a current-controlled oscillator that varies the frequency of switching by changing the off-time of the switch and maintaining a constant on-time. The lower frequency as a result of the constant on-time switching reduces switching loss and power consumption at lower load currents. The constant on-time architecture of the present invention significantly improves the overall efficiency of the switching voltage regulator, while reducing component count and die size. | 7 |
This application is a regular National application claiming priority from Provisional Application, U.S. application Ser. No. 60/108,703 filed Nov. 17, 1998. The entirety of that provisional application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a novel 1,2-dioxetane substrate for use in a chemiluminescent assay for the detection of neuraminidase. This invention takes advantage of the high sensitivity of chemiluminescent 1,2-dioxetane reagents to overcome sensitivity problems encountered in the prior art. Additionally, this invention pertains to methods and kits employing such dioxetanes.
2. Background of the Prior Art
A wide variety of diseases and infections are caused by viruses. Of all of these known diseases and infections, respiratory infections such as those caused by influenza viruses are the most common. Acute respiratory infections can be fatal, especially in elderly patients. Consequently, the development of assays for the detection of viruses and viral infections has become increasingly important.
In general, influenza viruses express surface glycoproteins that have neuraminidase activity. The enzyme neuraminidase, also known as sialidase, is a well-characterized hydrolytic enzyme that has an optimum pH at 5.5 and hydrolyzes substrates that contain 2-ketosidically linked n-acetylneuraminic acids (Neu5ac, also known as sialic acid). This low optimum pH (5.5) for the neuraminidase enzyme makes it difficult to obtain an assay for neuraminidase that has adequate sensitivity.
The detection of neuraminidase is important because neuraminidase is implicated in a variety of biological events. For example, a deficiency in this enzyme leads to sialidosis, an autosomal recessive trait. Additionally, it is known that the release of neuraminidase mediates the penetration of cells by influenza viruses.
Because the early detection of influenza viruses allows for a more effective treatment, it is desirable to have a highly sensitive assay for the early detection of influenza viruses. However, it is very difficult to detect influenza viruses at an early stage using conventional technology because the clinical samples obtained often do not have a sufficient amount of neuraminidase present to be able to be detected by current technology.
A chromogenic/fluorogenic neuraminidase substrate has been developed and is reported in U.S. Pat. No. 5,719,020, Liav, et al. The same is incorporated herein by reference. While the substrate and assay provided in this reference offers some enhancement of specificity and reliability in detection, in fact, the use of chromogenic or fluorogenic reporter molecules suffers from a variety of drawbacks in detection mechanisms, note, for instance, the detailed collection and assessment steps necessary in the assay described in U.S. Pat. No. 5,719,020. A simpler, more reliable, quantifiable detection system is desirable. The problems with specificity for this specific assay are also discussed in Reinhard et al., Biol. Chem., Volume 373, pages 63-68 (1992).
Chemiluminescent substrates release light for a positive indication of the presence of a particular substance in a sample. Chemiluminescent assays which utilize these chemiluminescent substrates are attractive assays because they avoid the need for special procedures for using and discarding radioactive materials. Additionally, chemiluminescent assays typically do not require complicated or involved apparatus for detection of the assayed substance. Further, chemiluminescent assays may be enhanced by water soluble enhancers to enhance the total luminosity. Typical enhancers are set forth in U.S. Pat. No. 5,145,772, incorporated herein by reference.
The assignee of this application, Tropix, Inc., has developed a wide array of chemiluminescent enzyme substrates for use in detection assays, many of which utilize 1,2-dioxetanes. Representative patents addressing these chemiluminescent enzyme substrates include U.S. Pat. Nos. 4,931,223; 4,931,569; 4,952,707; 4,956,477; 4,978,614; 5,032,381; to 5,112,960; 5,145,772; 5,220,005; 5,225,584; 5,326,882; 5,330,900; 5,336,596; 5,869,699; 5,538,847; and 5,871,938, all of which are incorporated herein by reference.
The above-referenced patents address 1,2-dioxetanes which are stabilized by a polycyclic group bonded to one of the carbons in the four membered ring portion of the dioxetane by a Spiro linkage. An electron-rich moiety, typically an aryl group, a phenyl, or a naphthyl group, is bonded to the remaining carbon of the dioxetane ring. Attached to this moiety is an enzyme-cleavable group. When this group is cleaved, an anion is generated which decomposes, causing the dioxetane to release light. In addition, the carbon that bears the above-identified electron-rich moiety may also bear an alkoxy or other electron-active group.
As disclosed in U.S. Pat. No. 5,112,960, an enzyme-triggerable dioxetane such as 3-(4-methoxy-spiro[1,2-dioxetane-3,2′-tricyclo[3.3.1.1 3,7 ]decan]-4-yl-phenyl phosphate and its salts (AMPPD®) is a highly effective reporter molecule. Superior performance can be obtained by selective substitution on the polycyclic group. For example, substitution with an electron-active species, such as chlorine, has been shown to dramatically improve reaction speed and signal-to-noise ratio (S/N). The chlorine-substituted counterpart of AMPPD®, CSPD®, has been widely commercialized by Tropix, Inc. “Third-generation” dioxetane compounds of similar structure, wherein the phenyl or naphthyl moiety also bears an electron-active substituent, such as chlorine, offer further improvements in performance. These “third generation” dioxetanes have also been commercialized by Tropix, Inc. The phosphate moieties are available under the trademarks CDP® and CDP-STAR®. These reporter molecules, which are chemiluminescent in nature, are referred to as enzyme-triggerable dioxetanes. To date, alkaline phosphatase has been the dominant enzyme of interest as a triggering agent.
Although much is known about chemiluminescent assays generally, the existing literature does not describe a triggerable dioxetane which is specific for the neuraminidase enzyme. Furthermore, the existing literature does not disclose a chemiluminescent detection assay, or a substrate for use in such an assay, for the sensitive detection of neuraminidase. Accordingly, a need exists for a 1,2-dioxetane compound which can be used to detect the presence of neuraminidase. Thus, it remains a goal of one of ordinary skill in the art to find an assay to detect the presence of the neuraminidase enzyme which is highly sensitive and employs reagents which can be obtained through simplified procedures.
SUMMARY OF THE INVENTION
The above objects, and other discussed in more detail below, are met by a chemiluminescent assay which relies on chemiluminescent 1,2-dioxetanes. Other dioxetanes, developed by the assignee here, Tropix, Inc., are the subject of a wide variety of United States patents. The 1,2-dioxetane substrates useful in the present invention are generally represented by the following formula:
wherein T is a substituted or unsubstituted polycycloalkyl group bonded to the 4-membered ring portion of said dioxetane by a spiro linkage, said substituents being independently selected from the group consisting of a hydroxyl group, fluorine, chlorine, an unsubstituted straight or branched chain alkyl group of 1-6 carbon atoms, a 1-6 carbon alkyl group mono-, di- or tri- substituted with a hydroxy or 1-3 halogen atoms, a phenyl group, a cyano group and an amide group;
wherein X is selected from the group consisting of phenyl, naphthyl and other heteroaryls, and wherein X bears 1-3 electron active substituents, each electron active substituent being independently selected from the group consisting of halogen (particularly F and Cl), alkoxy, aryloxy, trialkylammonium, alkylamido, arylamido, arylcarbamoyl, alkylcarbamoyl, cyano, nitro, ester, alkylsulfonamido, arylsulfonamido, triphorylmethyl, aryl, alkyl, trialkyl, triarylsilyl, alkylarylsilyl, alkylamidosulfonyl, arylamidosulfonyl, alkylsulfonyl, arylsulfonyl, alkylthioether and arylthioether, and wherein, each alkyl or aryl moiety comprises 1-12 carbon atoms;
wherein Z is an enzymatically cleavable group of formula II:
and R 1 -R 3 are hydrogen or alkyl groups (straight chain or branched) of 1-4 carbon atoms;
and wherein R is an alkyl, aryl, aralkyl or cycloalkyl of 1-20 carbon atoms, which may contain 1-2 hetero atoms selected from the group consisting of phosphorus, nitrogen, sulfur and oxygen; and wherein R can bear at least one halogen substituent.
It is another object of this invention to provide diagnostic kits and methods for detecting neuraminidase employing such substrates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a neuraminidase substrate.
FIG. 2 is a flowchart illustration of a synthesis of a neuraminidase substrate.
FIG. 3 is a flowchart illustration of the mechanism for a neuraminidase-induced light emission.
FIG. 4 provides graphic illustration of the chemiluminescent signal obtained by neuraminidase triggering of a 1,2-dioxetane neuraminidase substrate from Experiment 1.
FIG. 5 provides graphic illustration of the background noise obtained from 5 μl of dioxetane stock diluted with 250 μl of glaxo buffer with no enzyme.
FIG. 6 provides graphic illustration of the chemiluminescent signal obtained from Experiment 2.
FIG. 7 provides graphic illustration of the chemiluminescent signal obtained from Experiment 3.
FIG. 8 provides graphic illustration of the background noise from 5 ml of dioxetane stock diluted with 250 ml of sodium phosphate buffer with no enzyme.
FIG. 9 provides graphic illustration of the chemiluminescent signal obtained from Experiment 5.
FIG. 10 provides graphic illustration of the chemiluminescent signal obtained from Experiment 6.
FIG. 11A is a graph showing chemiluminescence (RLU) as a function of sialidase dilution for a substrate according to the invention in a 0.05 M sodium acetate/0.1M NaCl buffer.
FIG. 11B is a graph showing signal to noise ratio (S/N) as a function of sialidase dilution for a substrate according to the invention in a 0.05 M sodium acetate/0.1M NaCl buffer.
FIG. 12A is a graph showing chemiluminescence (RLU) as a function of sialidase dilution using a methylumbelliferyl-N-acetylneuraminic acid salt fluorescent substrate in a 0.05 M sodium acetate/0.1M NaCl buffer.
FIG. 12B is a graph showing signal to noise ratio (S/N) as a function of sialidase dilution for a methylumbelliferyl-N-acetylneuraminic acid salt fluorescent substrate in a 0.05 M sodium acetate/0.1M NaCl buffer.
FIG. 13A is a graph showing chemiluminescence (RLU) as a function of sialidase dilution for a substrate according to the invention in a 0.05 M phosphate/0.1M NaCl buffer.
FIG. 13B is a graph showing signal to noise ratio (S/N) as a function of sialidase dilution for a substrate according to the invention in a 0.05 M phosphate/0.1M NaCl buffer.
FIG. 14A is a graph showing chemiluminescence (RLU) as a function of sialidase dilution for a substrate according to the invention using two different buffer systems.
FIG. 14B is a graph showing signal to noise ratio (S/N) as a function of sialidase dilution for a substrate according to the invention using two different buffer systems.
FIG. 15A is a graph showing chemiluminescence (RLU) as a function of sialidase dilution for a substrate according to the invention in a 0.05 M phosphate/0.1M NaCl buffer at a pH of 7.7.
FIG. 15B is a graph showing signal to noise ratio (S/N) as a function of sialidase dilution for a substrate according to the invention in a 0.05 M phosphate/0.1M NaCl buffer at a pH of 7.7.
FIG. 16A is a graph showing chemiluminescence (RLU) as a function of sialidase dilution for a substrate according to the invention with a quaternary polymeric onium enhancer.
FIG. 16B is a graph showing chemiluminescence (RLU) as a function of sialidase dilution for a substrate according to the invention without a quaternary polymeric onium enhancer.
FIG. 16C is a graph showing signal to noise ratio (S/N) as a function of sialidase dilution for a substrate according to the invention with and without a quaternary polymeric onium enhancer.
DETAILED DESCRIPTION OF THE INVENTION
The structure, synthesis, and use of preferred embodiments of the present invention will now be described.
Structure
The present invention employs 1,2-dioxetanes of the general formula:
which is capable of producing light energy when decomposed;
wherein T is a substituted or unsubstituted polycycloalkyl group bonded to the 4-membered ring portion of said dioxetane by a spiro linkage, said substituents being independently selected from the group consisting of a hydroxyl group, fluorine, chlorine, an unsubstituted straight or branched chain alkyl group of 1-6 carbon atoms, a 1-6 carbon alkyl group mono-, di- or tri- substituted with a hydroxy or 1-3 halogen atoms, a phenyl group, a cyano group and an amide group;
wherein X is selected from the group consisting of phenyl, naphthyl and other heteroaryls, and wherein X bears 1-3 electron active substituents, each electron active substituent being independently selected from the group consisting of halogen (particularly F and Cl), alkoxy, aryloxy, trialkylammonium, alkylamido, arylamido, arylcarbamoyl, alkylcarbamoyl, cyano, nitro, ester, alkylsulfonamido, arylsulfonamido, triphorylmethyl, aryl, alkyl, trialkyl, triarylsilyl, alkylarylsilyl, alkylamidosulfonyl, arylamidosulfonyl, alkylsulfonyl, arylsulfonyl, alkylthioether and arylthioether, and wherein, each alkyl or aryl moiety comprises 1-12 carbon atoms;
wherein Z is an enzymatically cleavable group of formula II:
and R 1 -R 3 are hydrogen or alkyl groups (straight chain or branched) or 1-4 carbon atoms; and wherein R is an alkyl, aryl, aralkyl or cycloalkyl of 1-20 carbon atoms, which may contain 1-2 hetero atoms selected from the group consisting of phosphorus, nitrogen, sulfur and oxygen; and wherein R can bear at least one halogen substituent.
Any one of X, T or R, most preferably R can bear one or more groups which enhance the solubility of the dioxetane reagent in aqueous preparations. Typical moieties of this type include sulfonyl groups, carboxylic acid moieties such as COOH, fluorine or halogen based groups, including trifluoro substituent and the like. In some preferred embodiments, two solubility enhancing groups may be present.
The 1,2-dioxetanes according to the present invention are unusual in that the 1,2-dioxetane aglycone is constructed such that the pKa of the leaving group upon enzyme cleavage may be low enough so that light may be produced concomitantly with enzyme action. The neuraminidase enzyme has pH optimum ranges which vary from 5.5 to 7.8, depending on the type and medium. The thermal stability of the neuraminidase substrate of the present invention is greater at a higher pH.
Specifically, in circumstances where the aryl moiety X bears electron active substituents, such as a chlorine moiety in the para or meta position, as reflected in FIG. 1, the pKa of the leaving group upon cleavage is sufficient such that at the optimum pH of the neuraminidase enzyme of 5.5-7.8, sufficient light is produced to achieve a sustained glow characteristic of dioxetane chemiluminescent emission, which sustained glow is desirable for high speed throughput and automation. In this case, a one step assay (contact with the enzyme) is employed. It may frequently be desirable, however, to control the speed and performance of the assay by using a substrate which requires the addition of base to elevate the pH to achieve the sustained glow emission. In this situation, the aryl ring (in the case of FIG. 1, a phenyl moiety) does not bear additional electron active substituents, other than the oxygen linkage. The resulting oxyanion gives a sustained glow at a pH above the active range of the enzyme, e.g., above about 8.5, and thus, detection can be separated from reaction and conditions of the assay can be controlled. Thus, the invention provides for either a one or two step assay, depending on the users preference. A two step assay is illustrated in FIG. 3, using the molecule of FIG. 1 . The same assay could be performed without the addition of base, and a glow of lower intensity, but nonetheless sustained emission, would be detected, depending on the actual pH employed.
The substrates provided by the present invention are capable of providing a continuous chemiluminescence-based assay at a pH which is in concert with both enzyme action and the triggering of the fragment to allow either a one step or two step assay. This flexibility offers significant advantages and format compatibility.
This invention lends itself to the use of enhancer detection of chemiluminescence. The enhancers are based, in general, on polymeric onium salts, particularly quaternary salts based on phosphonium, sulfonium and, preferably, ammonium moieties. The polymers have the general formula III shown below:
In this formula each of R 1 , R 2 and R 3 can be a straight or branched chain unsubstituted alkyl group having from 1 to 20 carbon atoms, inclusive, e.g., methyl, ethyl, n-butyl, t-butyl, hexyl, or the like; a straight or branched chain alkyl group having from 1 to 20 carbon atoms, inclusive, substituted with one or more hydroxy, alkoxy, e.g., methoxy, ethoxy, benzyloxy or polyoxethylethoxy, aryloxy, e.g., phenoxy, amino or substituted amino, e.g., methylamino, amido, e.g., acetamido or ureido, e.g., phenyl ureido; or fluoroalkane or fluoroaryl, e.g., heptafluorobutyl groups, an unsubstituted monocycloalkyl group having from 3 to 12 carbon ring carbon atoms, inclusive, e.g., cyclohexyl or cyclooctyl, a substituted monocycloalkyl group having from 3 to 12 ring carbon atoms, inclusive, substituted with one or more alkyl, alkoxy or fused benzo groups, e.g., methoxycyclohexyl or 1,2,3,4-tetrahydronaphthyl, a polycycloalkyl group having 2 or more fused rings, each having from 5 to 12 carbon atoms, inclusive, unsubstituted or substituted with one or more alkyl, alkoxy or aryl groups, e.g., 1-adamantyl or 3-phenyl-1-adamantyl, an aryl, alkaryl or aralkyl group having at least one ring and from 6 to 20 carbon atoms in total, unsubstituted or substituted with one or more alkyl, aryl, fluorine or hydroxy groups, e.g., phenyl, naphthyl, pentafluorophenyl, ethylphenyl, benzyl, hydroxybenzyl, phenylbenzyl or dehydroabietyl; at least two of R 1 , R 2 and R 3 , together with the quaternary nitrogen atom to which they are bonded, can form a saturated or unsaturated, unsubstituted or substituted nitrogen-containing, nitrogen and oxygen-containing or nitrogen and sulfur-containing ring having from 3 to 5 carbon atoms, inclusive, and 1 to 3 heteroatoms, inclusive, and which may be benzoannulated, e.g., 1-pyridinium, 1-(3-alkyl or aralkyl)imidazolium, morpholino, alkyl morpholinium, alkylpiperidinium, -acylpiperidinium, piperidino or acylpiperidino, benzoxazolium, benzthiazolium or benzamidazolium.
The symbol X − represents a counterion which can include, alone or in combination, moieties such as halide, i.e., fluoride, chloride, bromide or iodide, sulfate, alkylsulfonate, e.g., methylsulfonate, arylsulfonate, e.g., p-toluenesulfonate, substituted arylsulfonate, e.g., anilinonaphthylenesulfonate (various isomers), diphenylanthracenesulfonate, perchlorate, alkanoate, e.g., acetate, arylcarboxylate, e.g., fluorescein or fluorescein derivatives, benzoheterocyclic arylcarboxylate, e.g., 7-diethylamino-4-cyanocoumarin-3-carboxylate, organicdianions such as p-terephthalate may also be represented by X − .
The symbol n represents a number such that the molecular weight of such poly(vinylbenzyl quaternary ammonium salts) will range from about 800 to about 200,000 (weight average), and preferably from about 20,000 to about 70,000, as determined by intrinsic viscosity or LALLS techniques.
Methods for the preparation of these polymers, related copolymers and the related starting materials where M is nitrogen are disclosed in G. D. Jones et al, Journal of Polymer Science, 25, 201, 1958; in U.S. Pat. Nos. 2,780,604; 3,178,396; 3,770,439; 4,308,335; 4,340,522; 4,424,326 and German Offenlegunsschrift 2,447,611.
The symbol M may also represent phosphorous or sulfur whereupon the corresponding sulfonium or phosphonium polymers have been described in the prior art: U.S. Pat. Nos. 3,236,820 and 3,065,272.
Methods of preparation of the two polymers of this invention are set forth in the referenced U.S. patents, and do not constitute any aspect of this invention, per se.
Copolymers containing 2 or more different pendant onium groups may also be utilized in the invention described herein:
The symbols X − , M, R 1 , R 2 , R 3 are as described above. The symbols y and z represent the mole fraction of the individual monomers comprising the copolymer. The symbols y and z may thus individually vary from 0.01 to 0.99, with the sum always equaling one.
As preferred moieties, M is N, and R 1 -R 3 are individually, independently, cycloalkyl, polycycloalkyl (e.g. adamantane), aralkyl or aryl, having 1 to 20 carbon atoms, unsubstituted or further substituted with hydroxyl, amino, amido, ureido groups, or combine to form via a spiro linkage to the M atom a heterocyclic (aromatic, aliphatic or mixed, optionally including other N, S or O hetero atoms) onium moiety.
X is preferably selected to improve solubility and to change ionic strength as desired, and is preferably a halogen, a sulfate, or a sulfonate. In copolymers, each of R 1 -R 3 may be the same as or different from the corresponding R 1 -R 3 . Examples of preferred polymers include the following:
polyvinylbenzylphenylureidoethyldimethyl ammoniumchloride (PUDMQ);
polyvinylbenzyldimethyl hydroxyethylammonium chloride (DMEQ);
polyvinylbenzylbenzoylaminoethyldimethylammonium chloride (BAEDMQ);
polyvinylbenzylbenzyldimethyl ammonium chloride (BDMQ);
polyvinylbenzyltributyl ammonium chloride (TBQ);
copolyvinylbenzyltrihexylammoniumchloride-polyvinylbenzyltributyl ammonium chloride (THQ-TBQ); and
copolyvinylbenzylbenzyldimethylammonium chloride-polyvinyl aminoethyldimethylammonium chloride (BDMQ-AEDMQ).
These vinylbenzyl quaternary ammonium salt polymers can be prepared by free radical polymerization of the appropriate precursor monomers or by exhaustive alkylation of the corresponding tertiary amines with polyvinylbenzyl chloride, or copolymers containing a pendant benzyl chloride function. This same approach can be taken using other polymeric alkylating agents such as chloromethylated polyphenylene oxide or polyepichlorohydrin. The same polymeric alkylating agents can be used as initiators of oxazoline ring-opening polymerization, which, after hydrolysis, yields polyethyleneimine graft copolymers. Such copolymers can then be quaternized, preferably with aralkyl groups, to give the final polymer. These polymers are described, in detail, as membranes in U.S. Pat. No. 5,593,828, incorporated herein by reference. In the alternative, the dicationic enhancer of U.S. Pat. No. 5,650,099, incorporated herein by reference, can be used.
Synthesis of Dioxetane Neuraminidase Substrates
The following example is a representative synthesis of a 1,2-dioxetane as shown in FIG. 2 and should not limit the scope of the claims.
Methyl (5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-D-glycero-β-D-galacto-nonulopyranosyl chloride)onate (compound 3 in FIG. 2)
Methyl (5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-D-glycero-β-D-galacto-nonulopyranosyl chloride)onate was prepared in two steps from the commercially available N-acetylneuraminic acid (compound 1 in FIG. 2) according to the procedure set forth in Kuhn, R., Lutz, P. and McDonald, D. C., Chem. Ber., 99 (1966) 611-617. The crude methyl (5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-D-glycero-β-D-galacto-nonulopyranosyl chloride)onate obtained was purified by a silica gel plug and eluted with 200 ml of 80-90% EtOAc in hexanes. After concentrating the filtrate, 1.24 g (2.43 mmole) of methyl (5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-D-glycero-β-D-galacto-nonulopyranosyl chloride)onate was obtained as an off-white powder. This product was then immediately used in the following coupling reaction.
Methyl (2-chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenl 5 -acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-α-D-glycero-D-zalacto-2-nonulopyranosid)onate (compound 4 in FIG. 2)
2-Chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenol (1.65 g, 4.86 mmole) and the phase transfer catalyst tetrabutylammonium hydrogensulfate (0.83 g, 2.43 mmole) were placed in a 100 ml round-bottomed flask and treated with 12.5 ml of CH 2 Cl 2 and 17.5 ml of 0.5 N NaOH at room temperature. The resulting two-phase mixture was added to a solution of the product set forth above (1.24 g 2.43 mmole) of methyl (5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-D-glycero-β-D-galacto-nonulopyranosyl chloride)onate) in 5 ml of CH 2 Cl 2 .
After an hour of vigorous stirring, the reaction mixture was diluted with CH 2 Cl 2 and poured into a separatory funnel containing a saturated sodium bicarbonate solution. After the organic layer was separated, the aqueous layer was extracted two additional times with CH 2 Cl 2 . The combined organic layer was then washed with H 2 O and dried over anhydrous Na 2 SO 4 . TLC (80% EtOAc in hexanes) showed the coupling product methyl (2-chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenyl 5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate at Rf=0.48 with faint shadows above and below. The organic solution was then treated with 10 drops of ET 3 N and concentrated.
Next, the crude product was purified by silica gel chromatography and eluted with 20% EtOAc in hexanes to recover the unreacted enol ether phenol (compound 7 in FIG. 2 ), followed by 80-90% EtOAc in hexanes, thereby affording 1.242 g (62.9%) of methyl (2-chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenyl 5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate as a light yellow, crispy foam.
IR(CHCl 3 cm −1 ): 3432, 3040,2936, 1750, 1688, 1372, 1235 and 1040. The 1 H NMR (CDCl 3 ) spectrum was complicated, but it still could reveal that the sample actually was a mixture of about 4:3:1 of the desired product (compound 4)and glycal from the dehydrochlorination of the chloride (compound 3).
A clean sample was obtained by removing the O-acetyl groups with NaOMe in MeOH followed by reacylation with acetic anhydride in pyridine to remove the glycal. The resulting 1 H NMR spectrum clearly showed that methyl (2-chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenyl 5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate existed as a 1:1 mixture of two isomers, based on the equal splitting of the methyl ester and O- and N-acetyl methyl signals. The presence of two triplets at 2.82 ppm and 2.86 ppm for H-3e of the neuraminic acid ring indicated that both of the isomers were α-pyranosides.
1 H NMR (CDCl 3 ): δ 7.35 (d, J=8.2 Hz, 1H), 7.21 (m, 1H), 6.99 (m, 1H), 5.25-5.34 (m, 3H), 4.98-5.10 (m, 1H), 4.14-4.31 (m, 3H), 4.03 (m, 1H), 3.75 and 3.747 (2s. 3H, Me ester), 3.43 (broad s, 1 H), 3.30 (s, 3H, OMe), 2.86 and 2.82 (2t, J=4.3 Hz, 1H), 2.13, 2.12, 2.10 and 2.07 (4s, 6H), 2.04 (s, 3H), 2.03 (s, 3H) and 1.91 (s, 3H).
The same phase-transfer coupling reaction was performed on 3-(methoxytricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenol (compound 8 in FIG. 2) to yield the corresponding coupled product.
IR (CHCl 3 ,cm 1 ): 3440, 3018, 2920, 2860, 1795, 1690, 1375, 1238, 1138, 1045; 1 H NMR (CDCl 3 ): δ 7.26 (t, J=7.9 Hz), 7.04-7.10 (m, 2H), 6.97 (m, 1H), 5.27-5.37 (m, 4H), 4.97 (m, 1H) 3.68 (s, 3H, Me ester), 3.28 (s, 3H, OMe), 3.24 (broad s, 1H), 2.72 (dd, J=12.9, 4.6 Hz, 1H, H-3e), 2.60 (broad s, 1H), 2.22 (t, J=12.7 Hz), 2.14, 2.12, 2.05, 2.04 and 1.91 (5s, 15H, O- and N-Ac methyl groups).
Sodium (2-chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenyl 5-acetamido-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate (compound 5 in FIG. 2)
The impure pyranoside methyl (2-chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenyl 5-acetamido-4,7,8,9-tetra-O-acetyl-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate (1.76 g, 2.1 mmole) was deprotected in a mixture of 6.5 ml of THF and 6.5 ml of MeOH with 12 ml of 1 N NaOH at 0° C. After sitting for 5 minutes at 0° C., the mixture was stirred at room temperature for one hour. Next, the pH was lowered by the addition of 1.05 g of solid sodium bicarbonate. Although most of the bicarbonate did not go into solution, a clear solution was ultimately obtained by dilution with water, which yielded a total volume of 100 ml.
Next, the solution was filtered through a Buchner funnel, rinsed with a small volume of water, and purified by reverse phase prep HPLC with a one-inch column packed with polystyrene. The column was eluted with an acetonitrile-water gradient. The fractions containing the product were then pooled and lyophilized to yield 658.9 mg (46.6%) of sodium (2-chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenyl 5-acetamido-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate as a white fluffy powder.
1 H NMR (D 2 O): δ 7.42 (d, J=8.1 Hz, 1H), 7.32 (broad s, 1H), 7.02 (d, J=8.1 Hz, 1H), 3.72-3.93 (m, 5H), 3.59-3.68 (m, 2H), 3.31 (s, 1H), 3.31 (s, 3H, OCH 3 ), 2.90-2.99 (m, 1H, H-3e), 2.67 (broad s, 1H), 2.08-2.30 (m, 6H, adamantyl), 2.02 (s, 3H, N-Ac), 1.66-2.0 (m, 5 adamantyl H and 1-H-3a).
Sodium (2-chloro-5-(4-methoxyspiro{1,2-dioxetane-3,2′-(5-chloro)tricyclor[3.3.1.1 3,7 }decan}-4-yl-phenyl 5-acetamido-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate (compound 6 in FIG. 2)
Photooxygenation of a solution of sodium (2-chloro-5-(methoxy-5-chlorotricyclo[3.3.1.1 3,7 ]dec-2-ylidenemethyl)phenyl 5-acetamido-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate (414.5 mg, 0.635 mmole) in 20 ml of 15% MeOH in CH 2 Cl 2 in the presence of 20 drops of TPP stock solution (2 mg/ml CHCl 3 ) was carried out by irradiation with a 400 w sodium vapor lamp for 25 minutes at a temperature of from 3-5° C while continuously bubbling oxygen through the solution. The reaction was monitored using the UV spectrum, i.e., the maximum absorptions of the product shifted from 260.5 nm to 277.5 nm as the reaction proceeded. Next, the mixture was concentrated on a rotovap at a low temperature and pumped in vacuo until a purple glassy foam was obtained. The crude product obtained was soluble in 30 ml of H 2 O containing 2 ml of a saturated NaHCO 3 solution. The product was then filtered through a Buchner funnel and rinsed with water which yielded a final volume of 50 ml. The solution was then injected in 5 separate 10 mL portions on the reverse phase HPLC column described above. The column was eluted with an acetonitrile-water gradient. HPLC revealed that a broad peak eluted just before the sharp major peak. These fractions were pooled and lyophilized separately to yield 68.4 mg and 350 mg respectively, as white powders. Both product fractions exhibited chemiluminescence upon treatment with neuraminidase enzyme (recombinant from E. Coli ) obtained from Oxford Glycosciences.
Sodium (5-(4-methoxyspiro{1,2-dioxetane-3,2′tricyclo[3.3.1.1 3,7 ]decan}-4-yl-phenyl 5-acetamido-3,5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosid)onate was prepared from the corresponding acetate-protected, phase-transfer coupled enol ether in the same manner as described above and then de-protected and photooxygenated. Spotting the product on a TLC plate from an aqueous solution exhibited blue chemiluminescence when the plate was heated in the dark. This phenomenon indicated the presence of a 1,2-dioxetane product.
The synthesis set forth above is a representative example of the formation of a 1,2-dioxetane substrate according to the present invention which is capable of detecting the presence of neuraminidase in a sample and should not be construed as limiting the scope of the present invention. Other 1,2-dioxetanes, such as longer wave length emitting dioxetanes with naphthalene or heteroaryl emitters are considered within the scope of the invention. Additionally, the presence of stabilizing groups such as dialkyl dioxetanes and adamantyl or substituted adamantyl groups are also contemplated within the scope of the present invention.
The 1,2-dioxetanes of the present invention are engineered to detect the presence of neuraminidase in a two-step assay as is set forth in FIG. 3 . In the two-step assay, the neuraminidase acts in step 1. In step 2, the liberated dioxetane is triggered with a base alone or with a base and a monometric or oligomeric enhancer moiety which may additionally contain an energy acceptor device for additional amplification of light emission, or the shifting of its wave length. Suitable bases include metal hydroxides, carbonates and the like, to as well as ammonia and amine bases. The two step assay for the detection of neuraminidase is derived from the basic protocol disclosed by M. Potier, et al., Anal. Biochem., 94, 287-296, 1979, which indicates a first step at a pH below 7 followed by the application of an upward pH shift to about pH 10 (or higher) will produce a fluorescent signal from the enzyme product.
EXPERIMENT 1
1.5 mg of dioxetane 489-102 (the compound of FIG. 1) (molecular weight of 684.5) was dissolved in 0.5 ml of 0.51 M sodium acetate buffer at a pH of about 8.3 to form a dioxetane stock solution. FIG. 5 is a plot indicating the noise obtained from 5 microliters of the dioxetane stock diluted with 250 microliters of a glaxo pH 5.5 buffer (no enzyme). As shown, there was essentially constant noise at approximately 0.2 RLU.
Next, 0.2 units of Oxford Enzyme were diluted with 400 microliters of Oxford Enzyme. 200 microliters of the enzyme (0.1 units) were then treated with 10 microliters of the dioxetane stock and incubated at 37° C. for 15 minutes. The solution was then placed in a Turner luminometer. Light was detected at a constant 80 RLU at a pH of 5.5. All Turner readings were calibrated to 31.5° C. 400 microliters of 0.1 AMP with a pH of 10 was then injected into the tube to produce a peak light emission of greater than 10,000, decaying with a half life of about 1.25 minutes. The form of the curve in FIG. 4 indicates a near complete substrate consumption during the incubation time.
EXPERIMENT 2
5 microliters of the dioxetane stock prepared in Experiment 1 was added to 0.05 units of Oxford sialidase in 200 microliters of the pH 5.5 buffer. The solution (approximately a 110 micromolar substrate) was incubated at 37° C. for 15 minutes. The solution was then placed in a Turner luminometer, and steady light emission at about 55 RLU was noted (see FIG. 6 ). This light emission is about 275 times greater than the “no enzyme” noise at pH 5.5 as shown in FIG. 5 . Next, 400 microliters of AMP pH 10 buffer was injected to produce an off-scale light spike (i.e., greater than 10,000 RLU).
EXPERIMENT 3
Experiment 2 was repeated with a 110 micromolar substrate in the presence of 0.025 units of the enzyme. FIG. 7 illustrates that at a pH of 5.5, the light level obtained (56 RLU) was similar to that obtained in Experiment 2. From these results it was determined that the light emission at pH 5.5 did not correlate with enzyme concentration. Next, an additional 400 microliters of the AMP pH 10 buffer was added, which produced a light peak at 8860 RLU and similar decay kinetics as in Experiment 2.
EXPERIMENT 4
A 120 micromolar sodium phosphate buffer with a pH of 7.7 was prepared from stock solutions of monobasic and dibasic salts. 250 microliters of this buffer and 5 microliters of the dioxetane stock solution prepared in Experiment 1 were incubated in a Turner luminometer at 31.5° C. FIG. 8 demonstrates a steady noise level at about 2 RLU at a pH of 7.7. This is 10 times the noise level at pH 5.5 (no enzyme) as shown in Experiment 1.
EXPERIMENT 5
The experimental conditions are the same as those set forth in Experiment 4, except that a pH 10 AMP buffer was used in place of the sodium phosphate buffer. This experiment showed noise at 31.5° C., with a maximum value of about 2.3 RLU. As can be seen in FIG. 9, the noise slowly decreased over a time period of 20 minutes to approximately 1.3 RLU. The substrate used in this Experiment did not receive up-front incubation other than cold storage in the acetate buffer.
EXPERIMENT 6
A pH 7.7 solution of 5 microliters of dioxetane stock and 200 microliters of the phosphate buffer was made and incubated for several minutes at 31.5° C. After incubation, 0.25 units of Oxford sialidase in 50 microliters of 50 micromolar acetate buffer was added. Chemiluminescence was spontaneously produced, rising to a maximum of 1380 RLU at 3.25 minutes (see FIG. 10 ). The approximate half life in the decay portion of the curve was about 5.5 minutes.
EXPERIMENT 7
A two step assay was conducted with the Oxford X-501 neuraminidase enzyme utilizing a quaternary onium polymeric enhancer and a base in step two. These conditions permitted the detection of 2.7×10 −7 units of enzyme and a signal-to-noise ratio of approximately 2.0. The enzyme exhibited 300 units of activity per mg and had a molecular weight of 41,000. The unoptimized, lower detection limit was 2.19×10 −15 moles of enzyme. This corresponds to a 1:125,000 dilution of the Oxford enzyme solution. The assay was carried out in 0.05 M sodium acetate/0. 1 M NaCl buffer solution at a pH of 5.5, 6.0, and 6.5. The results and conditions are summarized in Table A and depicted graphically in FIGS. 11A and 11B.
TABLE A
Units sialidase
pH 5.5
pH 6.0
pH 6.5
per well
Dilution
RLU
S/N
RLU
S/N
RLU
S/N
Blank
5791.00
5507.00
4244.00
4708.00
2047.00
2085.50
Blank
5223.00
5172.00
2124.00
1.70667E-11
1953125000
5515.50
1.00
4580.50
0.97
2110.50
1.01
8.53333E-11
390625000
6057.00
1.10
4809.50
1.02
2141.50
1.03
4.26667E-10
78125000
5226.50
0.95
4830.00
1.03
2316.00
1.11
2.13333E-09
15825000
4024.50
0.73
4801.00
1.02
2301.00
1.10
1.06667E-08
3125000
3926.50
0.71
5341.00
1.13
2374.00
1.14
5.33333E.08
625000
4875.50
0.89
7005.50
1.49
3277.00
1.57
2.66667E-07
125000
9278.50
1.68
14161.00
3.01
7106.00
3.41
1.33333E-06
25000
32671.00
5.93
48058.00
10.21
26764.50
12.83
6.66667E.06
5000
133228.00
24.19
180955.50
38.44
106454.00
51.04
3.33333E-05
1000
463115.00
84.10
656939.00
139.54
412963.50
198.03
Experiments with Sigma's Methylumbelliferyl-N-acetylneuraminic acid salt as a fluorescent substrate gave a signal-to-noise ratio of 1.79 at a dilution of 1:40,000, indicating inferior sensitivity compared to that obtained with the chemiluminescent neuraminidase-Star substrate. The results and conditions are summarized in Table B and depicted graphically in FIGS. 12A and 12B.
TABLE B
Dilution
RLU
S/N
1000
4209078
153.62
5000
1171002
42.74
25000
263218
9.61
125000
75078
2.74
625000
32200
1.18
3125000
27538
1.01
15625000
28231
0.96
EXPERIMENT 8
The two step assay of Experiment 7 was carried out using a 0.05 M phosphate/0.1 M NaCl buffer in place of the 0.05 M sodium acetate buffer. The assays were carried out at a pH of 7.7, 7.3, 7.0, and 6.5. The results and conditions are summarized in Table C and depicted graphically in FIGS. 13A and 13B.
TABLE C
Sialidase,
Sialidase
units/well
dilution
pH 7.7
S/N
pH 7.3
S/N
pH 7.0
S/N
pH 6.5
S/N
3.33333-05
1000
348406.00
152.41
448301.00
115.07
502029.00
94.68
6.66667E-06
5000
81881.00
35.82
121922.00
31.29
140195.00
26.44
21972.00
2.85
1.33333E-06
25000
20034.50
8.76
27813.00
7.14
33429.50
6.30
10740.00
1.40
2.66667E-07
125000
5923.50
2.59
8416.50
2.16
10673.00
2.01
8240.00
1.07
5.33333E-08
625000
2920.50
1.28
4816.50
1.24
6462.50
1.22
7744.50
1.01
1.06667E-08
3125000
2593.00
1.13
4113.50
1.06
5743.50
1.08
7626.50
0.99
2.13333E-09
15625000
2327.50
1.02
3910.50
1.00
5536.50
1.04
7440.50
0.97
4.26667E-10
78125000
2332.50
1.02
3748.00
0.96
5468.50
1.03
7763.00
1.01
8.53333E-11
390625000
2339.50
1.02
3719.50
0.95
5274.00
0.99
7908.00
1.03
1.70667E-11
1953125000
2353.50
1.03
3731.50
0.96
5162.00
0.97
8090.00
1.05
2341.50
3820.50
5341.50
7683.00
2354.50
3971.50
5265.00
7709.00
EXPERIMENT 9
A two step assay was conducted with the Oxford X-501 neuraminidase enzyme utilizing a quaternary onium polymeric enhancer and a base in step 2. The conditions were the same as in Experiment 7, except that two different buffer systems were used as a means of comparison: MES at a pH of 6.5 and sodium acetate at a pH of 5.5. The results and conditions are summarized in Table D and depicted graphically in FIGS. 14A and 14B.
TABLE D
Sialidase,
Sialidase
S/N
S/N,
units/well
dilution
RLU, pH 6.5
pH 6.5
RLU, pH 5.5
pH 5.5
3.33E-05
1000
523391.00
58.08
890934.00
56.37
6.67E-06
5000
131643.33
14.61
252815.67
16.00
1.33E-06
25000
76867.67
8.53
14715.33
0.93
2.67E-07
125000
22911.67
2.54
15090.33
0.95
5.33E-08
625000
11516.00
1.28
15294.67
0.97
1.07E-08
3125000
10015.00
1.11
15327.00
0.97
2.13E-09
15625000
9234.67
1.02
15527.67
0.98
4.27E-10
78125000
8863.67
0.98
15369.00
0.97
8.53E-11
390625000
9128.00
1.01
15455.67
0.98
1.71E-11
1953125000
9096.00
1.01
15361.33
0.97
9027.00
9011.17
15733.33
15804.00
8995.33
15874.67
EXPERIMENT 10
A two step assay was conducted with the Oxford X-501 neuraminidase enzyme utilizing a quaternary onium polymeric enhancer and a base in step 2. The neuraminidase substrate was incubated at 37° C. in a 0.05 M phosphate/0.1 M NaCl, pH 7.7 buffer solution for 30 and 60 minutes. The results and conditions are summarized in Table E and depicted graphically in FIGS. 15A and 15B.
TABLE E
Sialidase,
Sialidase
30 minutes at 37 degrees
60 minutes at 37 degrees
units/well
dilution
Ave RLU
S/N
Ave RLU
S/N
3.33E-05
1000
167304.8
66.65183
153543.8
57.03176
6.67E-06
5000
38770.25
15.44551
36162.75
13.43217
1.33E-06
25000
10236.5
4.078076
9611.75
3.570155
2.67E-07
125000
4264.25
1.698816
4308.5
1.600334
5.33E-08
625000
3312
1.319454
3248.25
1.206519
1.07E-08
3125000
2646
1.054129
2985.75
1.109017
2.13E-09
15625000
2970.75
1.183504
3361.25
1.248491
4.27E-10
78125000
2667.75
1.062794
2964.75
1.101216
8.53E-11
390625000
2705.5
1.077833
3002.25
1.115145
1.71E-11
1953125000
2676
1.06608
2731.25
1.014486
2510.125
2692.25
EXPERIMENT 11
A two step assay was conducted with the Oxford X-501 neuraminidase enzyme in both the presence and absence of a quaternary onium polymeric enhancer. The results and conditions are summarized in Table F and depicted graphically in FIGS. 16A-16C.
TABLE F
No enhancer
Plus Enhancer
Sialidase,
Sialidase
Average
Average
units/well
dilution
RLU
S/N
RLU
S/N
3.33E-05
1000
8785.00
106.06
527184.00
91.42
6.67E-06
5000
1701.67
20.54
163132.33
28.29
1.33E-06
25000
421.00
5.08
34451.00
5.97
2.67E-07
125000
144.00
1.74
11151.33
1.93
5.33E-08
625000
99.00
1.20
6414.33
1.11
1.07E-08
3125000
84.33
1.02
6021.33
1.04
2.13E-09
15625000
81.00
0.96
5839.33
1.01
4.27E-10
78125000
85.33
1.03
5811.00
1.01
8.53E-11
390625000
81.00
0.96
5742.00
1.00
1.71E-11
1953125000
80.33
0.97
5689.00
0.99
82.83
5766.83
The invention of this application is described above both generically and with regard to specific embodiments. A wide variety of alternatives known to those of ordinary skill in the art can be selected within the generic disclosure, and examples are not to be interpreted as limiting, unless specifically so indicated. In particular, variations of the identity of the dioxetane, buffer compositions, signal detecting apparatus, protocol time, temperatures, and conditions and the like will occur to those of ordinary skill in the art. These variations are intended to remain within the scope of the invention. The invention is not otherwise limited, except for the recitation of the claims set forth below. | The present invention discloses chemiluminescent 1,2-dioxetane substrates capable of reacting with a neuraminidase to release optically detectable energy. These 1,2-dioxetanes have the general formula:
wherein Z is
and the variables are selected so as to induce decomposition of said dioxetane accompanied by chemiluminescence where Z is cleaved by neuraminidase present. | 2 |
FIELD OF THE INVENTION
The present invention pertains to a process for producing combination patterns consisting of a plurality of individual sewing patterns by means of an electronically controlled sewing machine including a memory storing greatly different individual sewing patterns as well as a plurality of individual stitches with different feed directions and to a sewing machine for carrying out the process.
BACKGROUND OF THE INVENTION
West German Patent Specification No. DE-PS 32,25,078 (corresponding to U.S. Pat. No. 4,607,585) discloses an electronically controlled sewing machine which has a random access memory (RAM), in which various access data of individual patterns stored in a read-only memory (ROM) of the sewing machine can be stored in different sequences in order to enable these sewing patterns to be sewn in this sequence. Using this sewing machine, it is possible to carry out a sewing process in which one or several forward or reverse stitches, which are also available in the read-only memory, can be inserted between two consecutive individual sewing patterns in order to thus produce new pattern structures deviating from the existing individual sewing patterns. Only combination patterns whose width is limited essentially to the width of the largest possible format of the individual sewing pattern being stored can be produced with the prior-art sewing machine and the process described. In contrast, broader sewing pattern combinations can be achieved only by repeated parallel sewing of the combination pattern set, which not only requires a considerable effort, but also leads to a displacement of the patterns sewn next to one another due to differences in the feed characteristics of the sewing machine and inaccurate guiding by the sewing machine operator.
SUMMARY AND OBJECTS OF THE INVENTION
It is an object of the present invention to produce combination patterns in a simple manner, whose width is not subject, in principle, to any limitations, from the existing individual sewing patterns.
According to the invention, a process is provided for producing combination patterns including providing an electronically controlled sewing machine with a memory and storing greatly different individual sewing patterns in the memory as well as a plurality of individual stitches with different feed directions. At least one of the individual stitches is inserted in a selectable manner between the formation of a last needle touchdown of a first individual sewing pattern and a formation of a first needle touchdown of a second individual sewing pattern. The fabric to be sewn is fed at least partially at right angles to a normal feed direction for a predeterminable number of individual stitches to prepare a combination pattern of increased width.
The electronically controlled sewing machine memory includes a read-only memory and a programmable working memory such as a random access memory. The initial address of a selectable number of stored individual sewing patterns can be consecutively stored by actuating a program entry key using a microprocessor for consecutively reading the individual sewing patterns associated with the initial address from the read-only memory to the working memory. The sewing machine includes a stitch forming arrangement including a needle and a feed mechanism with a feed dog. A stitch forming controlling device is provided for controlling the stitch forming arrangement. The stitch forming controlling device includes a first stepping motor controlling a lateral deflection of the needle bar rocker, a second stepping motor controlling a forward and reverse movement of the feed dog (in the normal direction), and another stepping motor controlling a lateral movement of the feed dog (at right angles to the normal direction). The control acts as means for producing combination patterns in which the width of the individual sewing patterns can be controlled essentially by a deflection of the needle and the length of the individual sewing patterns can be controlled by the movement of the feed dog in the normal feed direction, and the offset of the individual sewing patterns can be controlled by a combination of the movement of the feed dog in the normal feed direction and in the direction at right angles to the normal feed direction.
It is thus possible, in a simple manner, to produce new combination patterns or border patterns whose width depends only on the wishes of the sewing machine operator or the width of the fabric to be processed from the existing individual sewing patterns having a limited width.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a partially sectional view of a sewing machine with electronic control device according to the invention;
FIG. 2 is an enlarged schematic representation of the drive unit for driving a feed dog according to the invention;
FIG. 3 is a block diagram of a control system of the electronically controlled sewing machine according to the invention;
FIG. 4 is a greatly enlarged representation of the direction and the stitch length of the individual stitches being stored, and
FIGS. 5 and 6 show schematic representations of combination patterns according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The sewing machine shown in FIG. 1 has an arm 1 that is connected to a base 3 via a stand 2. The base 3 is carried by a bottom plate 4 and is expanded in the forward direction compared with the stand 2 and the arm 1. The base is equipped with a fabric support arm 5, which is displaced to the rear in relation to the center line of the base 3, in which the lower stitch-forming tools, especially the looper of the sewing machine, are mounted.
A main shaft 6 mounted in the arm 1 of the sewing machine drives, via a gear 7 and a toothed belt 8, a lower shaft 9 (see
A main shaft 6 mounted in the arm 1 of the sewing machine drives, via a gear 7 and a toothed belt 8, a lower shaft 9 (see FIG. 2), which is used to drive the shuttle in the known manner (not shown).
A stepping motor 10, which is connected to a needle bar rocker 13 via a crank 11 and a connecting rod 12, is provided in the arm 1. The needle bar rocker 13 is hinged to a bolt in the arm 1 and carries a vertically movable needle bar 14 with a needle 15. The needle bar 14 is rigidly connected to a pin 16, on which a connecting rod 17 acts, which is hinged to a crank 18 fastened to the main shaft 6.
A stepping motor 20 (see FIG. 2), whose shaft 21 drives a toothed segment 24 fastened on an adjusting shaft 23 via a pinion 22, is fastened in the base 3. A connecting link guide 25 is fastened at the free end of the adjusting shaft 23.
An eccentric 30, which is surrounded by an eccentric rod 31, which is hinged to the middle part of a push rod 32, is fastened on the shaft 9. One end of this push rod 32 is connected via a pin 33 to a sliding block 34, which is mounted rotatably on the pin 33 and cooperates with the connecting link guide 25 in the known manner. The other end of the push rod 32 is connected to a rocker arm 35a of a feed rocker 35, which is carried by a shaft 36 mounted in the lower arm 3.
A shaft 37 is fastened by means of screws 38 in a bore of the feed rocker 35. A support 39 is mounted pivotably and displaceably on the shaft 37. The support 39, which is supported on a lifting cam 41 fastened to the shaft 9, is rigidly connected to a feed dog 42.
To feed the fabric to be sewn, the feed dog 42 is provided with feed webs 42a, which act on the fabric to be sewn through openings 43 (see FIG. 1) provided in a needle plate 44 covering the fabric support arm 5 in the area of the stitch formation site. The openings 43 are designed such that the feed webs 42a of the feed dog 42 are able to perform shifting movements both in the feed direction and at right angles to the feed direction.
A stepping motor 46, on the driving shaft 47 of which a pinion 48 is fastened, is fastened with screws in a plate 45 (FIG. 1) carried by the fabric support arm 5. This pinion 48 is in driving connection with a toothed segment 50a of a rocker 50 which is mounted on a pin 51 fastened on the plate 45. A shoulder of the rocker 50 surrounding the pin 51 is designed as an eccentric 52, whose shaft extends outside the shaft of the pin 51. A sleeve 53, against which a lateral surface 39b of the support 39 abuts under the effect of a tension spring 56, is rotatably mounted on the eccentric 52. One end of this tension spring 56 is suspended on a pin 57 fastened on the support 39, and its other end is suspended on a bolt 58, which is fastened in the shaft of the eccentric 52.
A microcomputer 61 (FIG. 3), which is connected via lines 62 to a pulse generator 63 driven synchronously by the main shaft 6 of the sewing machine, is accommodated in the housing of the sewing machine. During each revolution of the machine, the pulse generator 63 sends an impulse to the microcomputer 61 when the needle 15 has left the fabric being sewn, and the stepping motor 10 is able to adjust the position of the needle bar; in addition, it also sends a signal when the feed dog 42 has completed its feed movement and the stepping motors 20 and 46 are able to perform the control of a new feed amount. A stitch position control unit 65, which is connected via lines 66 to the stepping motor 10, is connected to the microcomputer 61 via lines 64. Via lines 67, the microcomputer 61 is connected to a forward/reverse feed control unit 68, and the latter is connected to the stepping motor 20 via lines 69. Finally, the microcomputer 61 is connected via lines 70 to a transverse feed control unit 71 for carrying out a cross feed, and this cross feed or transverse feed control unit 71 is connected via lines 72 to the stepping motor 46.
A read-only memory (ROM) 74 is connected to the microcomputer 61 via lines 73, a working memory (RAM) 76 is connected to the microcomputer 61 via lines 75, and a display unit 78 is connected to the microcomputer 61 via lines 77. In addition, a selection unit 80 is connected to the microcomputer 61 via lines 79, a program entry key 82 is connected via line 81, and a repeat key 84 is connected via line 83.
The designs and the general control of the three stepping motors 10, 20, and 46 are identical. The stepping motor 10 is used to control the lateral movement of the guide rocker 13; the stepping motor 20 is used to control the pushing movement of the feed dog in its normal feed direction; and the stepping motor 46 is used to control the displacing movement of the feed dog 42 at right angles to its normal feed direction.
A control panel 85 (FIG. 1) is fastened on the front side of the housing of the sewing machine. A display unit (78) is accommodated in this control panel 85. It consists of a section 86 with two display elements and one section 87 with eleven display elements. The sewing patterns to be selected are displayed by a two-digit number in the section 86. Two rocker switches 88 and 89, which form the selection unit 80, are arranged in the section 86. The right-hand rocker switch 89 is used to switch upward (+) or downward (-) the number formed by the two display elements. The left-hand rocker switch 88 is used to switch the numbers formed with the left-hand display element up (+) or down (-) independently.
The program entry key 82 and the repeat key 84 are arranged under the rocker switches 88 and 89.
The display elements of the display unit 78 are connected via the lines 77 to the microcomputer 61, which is able to connect them to a program memory formed by part of the working memory 76.
The electronic control unit of the sewing machine is designed to be such that the control commands for the stepping motors 10, 20, and 46 of every individual sewing pattern are stored in coded form as control segments in the read-only memory 74 of the microprocessor 61, and can be entered from there into the program memory contained in the working memory 76 in a desired sequence on the basis of the pattern number.
To select a desired combination of individual sewing patterns, the decimal number associated with the first individual sewing pattern, which number is taken from a table, is set in the display elements of the section 86 of the display unit 78 by means of the two rocker switches 88 and 89. Immediately after the setting process, the basic data corresponding to the individual sewing pattern selected are taken over by the microcomputer 61 from the read-only memory 74 into the working memory 76. When the program entry key 82 is actuated, this pattern number is entered into the program memory part of the working memory 76. Further individual sewing patterns can also be called from the read-only memory 74 in the same manner, and stored in the program memory part by means of the program entry key 82. It is thus possible to store sewing sequences containing an arbitrary sequence of individual sewing patterns.
After completion of the data entry, the machine is switched over to the "Sewing of the sewing patterns stored" mode by means of the repeat key 84, and the contents of the pattern numbers stored are displaced at the same time by the section 87 of the display unit 78.
During sewing, the coded control data of the corresponding individual sewing patterns contained in the control unit are consecutively called in the known manner each time after a pattern number is called by the microcomputer 61. The microcomputer 61 now controls the stepping motor 10 for the lateral rocking movements of the guide rocker 13 via the stitch position control unit 65, the stepping motor 20 for the normal feed movement of the feed dog 42 via the forward/reverse feed control unit 68, as well as the stepping motor 46 for the transverse movement of the feed dog 42 via the cross feed control unit 71, corresponding to the programed sequence, which is then repeated.
To perform the stitch formation, the stepping motor 10 pivots the guide rocker 13 into the new stitch position for the needle 15 via the crank 11 and the connecting rod 12, as soon as the needle has left the fabric being sewn. The stepping motor 20 will adjust the connecting link guide 25 via the pinion 22 and the toothed segment 24. During the swinging-out movement of the bolt 33 brought about by the eccentric rod 31, the sliding block 34 is pushed to and from in the connecting link guide 25. Corresponding to the angular position of the connecting link guide 25, which is imposed on it by the stepping motor 20, the sliding block 34 will pivot the feed rocker 35 via the push rod 32, thus imparting to the feed dog 42 feed movements, whose amount and direction depend on the angular position of the connecting link guide 25.
Synchronously with the rotation of the main shaft 6, the lifting cam 41 is driven via the shaft 9, and imparts lifting movements to the feed dog 42.
To displace the fabric being sewn at right angles to the normal fabric feed, the stepping motor 46 drives the rocker 50 via the pinion 48, as a result of which the eccentric 52 will laterally displace the support 39 against the action of the tension spring 56 via the sleeve 53. The feed webs 42a of the fed dog 42 connected to it will now carry the material to be sewn at right angles to the normal feed direction during their lateral displacement. This displacement takes place synchronously with the normal feed movement of the feed dog 42, i.e., during the phase in which the feed webs 42a of the feed dog 42 are raised above the needle plate 44.
Besides a great number of sewing patterns consisting of a plurality of individual stitches, whose individual stitches are produced from combinations of the lateral oscillation of the needle and the feed of the material being sewn in the feed direction or simultaneously in the feed direction and at right angles to the feed direction, the read-only memory 74 also contains so-called offset stitches. These offset stitches consist of 8 individually selectable individual stitches V1 through V8 (FIG. 4), whose feed in the normal feed direction is zero or 1 mm forward or backward, and whose feed in the transverse direction is also zero or 1 mm to the right or left. Thus, there are two individual stitches V1 and V5 in the normal feed direction and opposite the normal feed direction; two individual stitches V3 and V7 at right angles to the normal feed direction; as well as four individual stitches V2, V4, V6, and V8, which latter are produced by a combination of the drive of the feed dog 42 in the normal feed direction and at right angles to this [direction]. The respective individual stitch and the fabric feed needed for it correspond to the line connecting a first needle touchdown point (filled circle in FIG. 4) to a second needle touchdown point (one of the empty circles in FIG. 4).
By combining one or more of the normal individual sewing patterns being stored in the read-only memory 74, e.g., a lozenge pattern R, with a number of offset stitches, e.g., 10 individual stitches V2 and V8, it is possible to produce, as is shown in FIG. 5, a very broad combination pattern, without this combination pattern having to be stored in the read-only memory 74.
The combination pattern shown in FIG. 5 is composed by consecutively programing the lozenge pattern R and the individual stitches V2 or V8. To do so, the number 64, which corresponds to the lozenge pattern R, is set in the section 86 of the display unit 78 by means of the selection unit 80, after which it is entered into the working memory 76 by means of the program entry key 82. The number 92, which corresponds to the individual stitch V2, is subsequently set analogously in the section 86, and 10 of these individual stitches V2 are entered into the working memory 76 by depressing the program entry key 82 ten times. This is followed by another insertion of the lozenge pattern R with subsequent entry of new individual stitches V2, etc., until the entire program sequence of the combination pattern has been set up. After subsequently actuating the repeat key 84, the programed combination pattern can then be sewn.
The other combination pattern represented as an embodiment in FIG. 6 is composed by consecutively programing the arc-shaped pattern B and the individual stitches V7 and V3 analogously to the above-described combination pattern.
By directed entry of the individual stitches V1 through V8 together with the individual sewing patterns present in the read-only memory, it is thus possible to produce combination patterns of any desired length, and the combination patterns can be formed either from a sequence of the same individual sewing pattern, which sequence is connected by individual stitches, or from a sequence of different individual sewing patterns.
The preparation of the individual stitches is not limited, of course, to the stitch length and direction of preparation shown as an example in FIG. 4.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | In a process for producing combination patterns consisting of a plurality of individual sewing patterns by means of an electronically controlled sewing machine, which has a memory for the greatly different individual sewing patterns as well as for a plurality of individual stitches with different feed directions, wherein at least one individual stitch is prepared in a selectable manner between the formation of a last needle touchdown of a first individual sewing pattern and the formation of a first needle touchdown of a second individual sewing pattern. The fabric being sewn is fed at least partially at right angles to the normal feed direction or both in the normal feed direction and at right angles to this normal feed direction for a predeterminable number of individual stitches in order to produce a combination pattern of increased width. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International Application No. PCT/FR2012/051045, filed on May 11, 2012, which claims the benefit of FR 11/54809, filed on Jun. 1, 2011. The disclosures of the above applications are incorporated herein by reference.
FIELD
The present disclosure relates to a nacelle for an aircraft bypass turbojet engine.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
An aircraft is moved by several turbojet engines each housed in a nacelle also housing a set of related actuating devices connected to its operation and performing various functions when the turbojet engine is running or stopped. These related actuating devices in particular comprise a mechanical thrust reverser actuating system.
A nacelle generally has a tubular structure along a longitudinal axis comprising an air inlet upstream from the turbojet engine, a midsection intended to surround a fan of the turbojet engine, and a downstream section housing the thrust reverser means and intended to surround the combustion chamber of the turbojet engine. The tubular structure generally ends with a jet nozzle, the outlet of which is situated downstream from the turbojet engine.
Modern nacelles are intended to house a bypass turbojet engine capable of generating, by means of the rotating fan blades, a hot air flow (also called “primary flow”) coming from the combustion chamber of the turbojet engine, and a cold air flow (“secondary flow”), that circulates outside the turbojet engine through an annular passage, also called “annular flow path”.
The term “downstream” here refers to the direction corresponding to the direction of the cold air flow penetrating the turbojet engine. The term “upstream” designates the opposite direction.
The annular flow path is formed in a downstream section by an outer structure, called outer fixed structure (OFS), and a concentric inner structure, called inner fixed structure (IFS), surrounding the structure of the engine strictly speaking downstream from the fan. The inner and outer structures are part of the downstream section. The outer structure may include one or more cowls sliding along the longitudinal axis of the nacelle between a position allowing the reversed airflow to escape and a position preventing such an escape.
A variable-section nozzle at the outlet of the annular flow path is formed by movable elements configured so as to allow a decrease or increase in the discharge section of the air flow at the outlet of the annular flow path so as to optimize the section of the latter based on the flight phase of the aircraft.
However, the devices for actuating said movable elements are cumbersome and make the nacelle heavier.
SUMMARY
The present disclosure provides a nacelle for an aircraft bypass turbojet engine, comprising downstream, an inner fixed structure intended to surround part of the bypass turbojet engine, and an outer structure at least partially surrounding the inner fixed structure, so as to define an annular flow path along which an air flow circulates, the outer structure comprising at least one movable flap positioned at the downstream end of the outer structure and positioned facing the annular flow path, each movable flap being able to rotate so as to move into a position that increases or reduces the height of the cross-section of the annular flow path in relation to an idle position, only in response to the pressure exerted on the movable flap by the air flow circulating through the facing annular flow path, said movable flap being able to return from the aforementioned cross-section-increasing or -reducing position to another position under the effect of an elastic return means.
Owing to the nacelle according to the present disclosure, the movable flap(s) allow the cross-section of the downstream end of the annular flow path, commonly called “variable section nozzle”, to have a variable height without a cumbersome or heavy actuating device. In fact, said movable flaps are able to go from one position to another solely under the effect of the pressure exerted by the air flow circulating in the annular flow path.
The present disclosure therefore obtains a variable section nozzle simply, effectively, inexpensively and compactly.
According to other features of the present disclosure, the nacelle includes one or more of the following optional features, considered alone or according to any technically possible combination(s):
the elastic return means are positioned at the upstream end at the pivot axis of the movable flap(s), which allows good pivoting of each movable flap; the elastic return means comprise one or more springs configured to oppose the momentum exerted by the pressure of the air flow in the annular flow path, which simply and reliably allows proper positioning of each flap; the elastic return means include two springs placed in opposition so as to obtain a desired stiffness; the elastic return means comprise two springs placed in parallel, which makes it possible to obtain, depending on the stiffness of each spring, a variable section nozzle with three or more positions; the spring(s) comprise one or more torsion spring(s); the spring(s) comprise a torsion bar; one or more movable flaps are made from a shape memory material, chosen from among a family of existing superelastic alloys, in particular such as Nitinol, alloy of Nickel and Titanium, or future alloys, etc., which makes it possible to avoid resistance torque at the elastic return means and to limit the sensitivity of the movable flaps to gale-type winds; reference may in particular be made to document US 2011/003038891; each movable flap is associated with one or more radial stops positioned so as to limit the angular movements of said movable flap; the nacelle further includes blocking means configured to block a movable flap in at least one of the increasing and reducing positions; at least one part of a movable flap is substantially covered by a part of the outer structure, which makes it possible to increase the size of the movable flap and therefore facilitate its rotation; and the upstream end of one movable flap is fixed to the downstream end of another movable flap, the two movable flaps being aerodynamically continuous.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
FIG. 1 is a partial diagrammatic cross-section of one form of a nacelle according to the present disclosure;
FIG. 2 is a partial diagrammatic cross-section of an enlargement of zone II of FIG. 1 , whereof the nacelle includes one form of a movable flap in an increasing position;
FIG. 3 is a partial diagrammatic cross-section of the form of FIG. 2 , in which the movable flap is in its position decreasing the height of the section of the annular flow paths;
FIG. 4 is a partial diagrammatic cross-section of an alternative of the form of FIG. 2 ;
FIG. 5 is a partial diagrammatic cross-section of one alternative of the form of FIG. 3 ;
FIG. 6 is a partial diagrammatic cross-section of another alternative of the form of FIG. 2 ;
FIG. 7 is a partial diagrammatic cross-section of another alternative of the form of FIG. 3 ;
FIGS. 8 and 9 are perspective views of the flap/stationary structure assembly provided with a torsion bar-based elastic system;
FIG. 10 is a longitudinal cross-sectional diagrammatic illustration of a first form of a flap system of FIGS. 8 and 9 ;
FIG. 11 is a longitudinal cross-sectional diagrammatic illustration of a second form of a flap system of FIGS. 8 and 9 using torsion springs;
FIG. 12 is a diagrammatic view of one form of blocking means for the flap, made up of one or more active locking fingers entering dedicated piercings;
FIG. 13 is a diagrammatic view of one form of stops, limiting the rotation of the flap and comprising two pairs of stops on the stationary structure and on the movable flap, each stop pair limiting the rotation of the flap in one direction; and
FIG. 14 shows a curve illustrating the typical behavior of two springs having two different stiffnesses, said stiffnesses being obtained by having either one or two active springs on each segment.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
As shown in FIG. 1 , a nacelle 1 according to the present disclosure has a substantially tubular shape along a longitudinal axis A. The nacelle according to the present disclosure 1 comprises an upstream section 2 with an air inlet lip 13 forming an air inlet 3 , a midsection 4 surrounding a fan 5 of a turbojet engine 6 , and a downstream section 7 . The downstream section 7 comprises an inner structure 8 (generally called “IFS”) surrounding the upstream part of the turbojet engine 6 , and an outer structure (OFS) 9 that can support a moving cowl including thrust reverser means.
The IFS 8 and the OFS 9 delimit an annular flow path 10 allowing the passage of a flow of air 12 penetrating the nacelle 1 at the air inlet 3 .
The nacelle 1 ends with a jet nozzle 21 , called primary nozzle, comprising an outer module 22 and an inner module 24 . The inner 24 and outer 22 modules define a flow channel for a hot air flow 25 leaving the turbojet engine 6 .
As shown in FIG. 2 , the outer structure 9 comprises at least one movable flap 101 positioned at the downstream end of the outer structure 9 and across from the annular flow path 10 , each movable flap 101 being rotatable so as to go from a position increasing or reducing the height h of the section of the annular flow path 10 relative to an idle position solely under the action of the pressure exerted on said movable flap 101 by the airflow 112 circulating in the annular flow path 10 across from said movable flap 101 and the airflow 113 circulating outside the nacelle, said movable flap 101 being able to return from one increasing or reducing position to another position owing to the elastic return means.
The nacelle 1 according to the present disclosure can therefore have an output section of the variable-section nozzle based solely on the pressure exerted by the air flow 112 circulating in the annular flow path 10 and the outer air flow 113 , or in other words, based on the flight phase.
In fact, the pressure exerted by the air flows 112 and 113 depends on the load case. Thus, during takeoff, the pressure on the flap 101 is increased to become maximal at a typical reference value of 50,000 Pa.
During the cruising phase, this pressure is lower and is typically comprised between 35,000 and 25,000 Pa. During the landing phase, this pressure decreases further to reach a pressure comprised between 15,000 and 5,000 Pa.
According to these flight and therefore pressure conditions of the air flow 112 , the movable flap 101 pivots along its pivot axis 120 , typically situated at the upstream end 121 of the movable flap 101 . As a result, the height h of the section of the annular flow path 10 is increased or reduced under the combined action of the pressure and the elastic return systems.
More specifically, the pressure exerted by the air flow of the flow path 112 and the different components of the outer air flow 113 (for example: airplane speed, angle of attack, gusts, etc.) on the flap can therefore have an effect on the movable flap 101 greater than that of elastic return systems, such that said flap 101 pivots to increase the height h. Likewise, the effect of these pressures can therefore have an effect on the movable flap 101 lower than that of the elastic return systems, such that said flap 101 pivots to decrease the height h.
The present disclosure therefore makes it possible to obtain a variable-section nozzle not actuated by a cumbersome and heavy device outside the movable flap 101 . Likewise, savings are thus obtained in terms of mass and space.
Furthermore, advantageously, the movable flap 101 can assume continuous and non-discrete positions that are only influenced by the value of the pressure exerted by the air flow 112 and 113 as well as by the stiffeners of the elastic system. Consequently, the height h of the section of the annular flow path 10 is adjusted precisely based on the needs of the nacelle 1 to improve the performance of the latter.
Typically, the movable flap 101 is mounted aerodynamically continuously at the downstream end of the outer structure 9 so as not to have an impact on the performance of the nacelle 1 . To that end and as shown in FIGS. 2 and 3 , an upstream part of the flap 101 can be positioned in a cavity 130 provided in the outer structure 9 .
The angular travel of each flap 101 may typically be comprised between −4° and +4° relative to the idle position. The variation of the height h can therefore be comprised between +30 mm and 30 mm. The length of each movable flap 101 can be comprised between 300 mm and 1000 mm. These values are provided purely for information and are not limiting on the performance and characteristics of the present disclosure.
The elastic return means can be positioned at the upstream end 121 at the pivot axis 120 of the movable flap(s), which allows good pivoting of each movable flap 101 .
The elastic return means can comprise one or more springs configured to oppose the momentum exerted by the pressure of the air flow 112 in the annular 10 and outer 113 flow path, which makes it possible to position each movable flap 101 properly, simply and reliably.
The elastic return means can include two springs placed in opposition so as to obtain a desired stiffness, the stiffness profile in particular optionally being able to include an operating zone with a non-active spring so as to have a non-constant slope of the stiffness curve and thus define different operating ranges ( FIG. 14 , for example). This makes it possible to obtain a variable section nozzle with three or more positions based on the stiffness of each spring.
The elastic return means can include two springs placed in parallel optionally including an operating area with a non-active spring so as to have a non-constant slope of the stiffness curve, which makes it possible to obtain a variable-section nozzle with three positions based on the stiffness of each spring.
Of course, the nacelle 1 may comprise elastic return means in the form of one or more springs, as previously described, as well as one or more movable flaps.
Each movable flap 101 can be associated with one or more radial stops positioned so as to limit the angular movements of said movable flap. A stop can, for example, assume the form of a protuberance on which the movable flap 101 can abut.
The nacelle 1 can further include blocking means configured to block a movable flap 101 in at least one of the increasing and reducing positions. The blocking means can for example assume the form of locking fingers, in particular having specific actuation.
As shown in FIGS. 4 and 5 , at least part of the movable flap 201 is substantially covered by part 209 of the outer structure, which makes it possible to increase the size of the movable flap 101 and therefore facilitate its rotation.
As shown in FIGS. 6 and 7 , the upstream end 302 of one removable flap 101 b can be fastened to the downstream end 301 of another movable flap 101 a , the two movable flaps 101 a , 101 b being in aerodynamic continuity.
The movable flap 101 b positioned furthest downstream can be shorter than that of the movable flap 101 a positioned furthest upstream form the outer structure 9 .
According to specific forms shown in FIGS. 8 to 10 , these elastic return means can for example be a torsion bar 140 . This torsion bar 140 is blocked in rotation on the stationary structure 9 and on the movable flap 101 , for example using splines, flats, pins, keys, friction via a collar, etc. (means not shown). This torsion bar may be solid or hollow. In the illustrated example form, this torsion bar is associated with a hollow pivot axis 120 , the function of which is to transmit the forces from the movable flap 101 to the stationary structure 9 , other than the torsion moment reacted by the torsion bar 140 . It should be noted that this pivot axis 120 can be mounted with a ball joint (not shown).
As shown in FIG. 11 , one alternative of these elastic return means can be a torsion spring 151 , associated with a pivot axis 120 . In this alternative, the spring is fixed at one of its ends on the stationary structure 9 and at the other end on the movable flap 101 . The pivot axis 120 transmits the forces from the movable flap 101 to the stationary structure 9 , other than the torsion moment reacted by the spring. This pivot axis 120 can be mounted with a ball joint (not shown).
The elastic return means can be a combination of several elementary means, including (non-limiting list) a spring, torsion bar, flexibility of the structure, etc.
As shown in FIG. 12 , the flap(s) 101 can be equipped with blocking means, locking the function of the variable nozzle and for example comprising one or more active locking fingers 142 entering dedicated piercings of the outer structure 9 .
As shown in FIG. 13 , the flap 101 can be equipped with stops 143 , 144 so as to limit the rotation of the flap 101 and/or allow it to adopt discrete positions. To that end, two sets of stops 143 , 144 are provided on the movable flap 101 and the stationary structure, respectively, each stop pair limiting the rotation of the flap in one direction.
The elementary elastic return means can be combined to have several stiffnesses per bearing as shown diagrammatically in FIG. 14 , for example by having angular sectors on which the springs are not active. This function may be obtained by stops for stressing the springs.
Of course, the features described in the context of the forms described above can be considered alone or combined with each other without going beyond the scope of the present disclosure. | A nacelle for an aircraft bypass turbojet engine includes downstream, an internal stationary structure surrounding part of the bypass turbojet engine, and an external structure surrounding the internal stationary structure, defining an annular flow path along which an air flow circulates. The external structure includes a mobile flap disposed at the downstream end of the external structure and positioned facing the annular flow path. Each mobile flap can rotate such as to move into a position that increases or reduces the height of the cross-section of the annular flow path in relation to an idle position, in response to the pressure exerted on the mobile flap by the air flow circulating through the facing annular flow path. The mobile flap can return from the cross-section-increasing or -reducing position to another position under the effect of an elastic return means. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to nip presses used to exert pressing forces on moving webs for the formation of, for example, paper, textile material, plastic foil and other related materials. In particular, the present invention is directed to methods and apparatus for measuring and removing the effects of rotational variability from the nip pressure profile of nip presses which utilize imbedded sensors in covered rolls. While prior art presses which utilize rolls with imbedded sensors may be capable of detecting variations in pressure along the length of the roll, these same imbedded sensors may not be capable of measuring and compensating for rotational variability that can be generated by the high speed rotation of the covered roll. The present invention provides a method and apparatus for measuring and removing rotational variability from the nip pressure profile of the covered roll so as to obtain a more true profile of the nip pressure being developed in the nip region.
Nipped rolls are used in a vast number of continuous process industries including, for example, papermaking, steel making, plastics calendering and printing. The characteristics of nipped rolls are particularly important in papermaking. In the process of papermaking, many stages are required to transform headbox stock into paper. The initial stage is the deposition of the headbox stock, commonly referred to as “white water,” onto a paper machine forming fabric, commonly referred to as a “wire.” Upon deposition, the a portion of the white water flows through the interstices of the forming fabric wire leaving a mixture of liquid and fiber thereon. This mixture, referred to in the industry as a “web,” can be treated by equipment which further reduce the amount of moisture content of the finished product. The fabric wire continuously supports the fibrous web and advances it through the various dewatering equipment that effectively removes the desired amount of liquid from the web.
One of the stages of dewatering is effected by passing the web through a pair or more of rotating rolls which form a nip press or series thereof, during which liquid is expelled from the web via the pressure being applied by the rotating rolls. The rolls, in exerting force on the web and fabric wire, will cause some liquid to be pressed from the fibrous web. The web can then be advanced to other presses or dry equipment which further reduce the amount of moisture in the web. The “nip region” is the contact region between two adjacent rolls through which the paper web passes. One roll of the nip press is typically a hard steel roll while the other is constructed from a metallic shell covered by a polymeric cover. However, in some applications both roll may be covered. The amount of liquid to be pressed out of the web is dependent on the amount of pressure being placed on the web as it passes through the nip region. Later rolls in the process at the machine calender are used to control the caliper and other characteristics of the sheet. Covered rolls are at times used at the calender. The characteristics of the rolls are particularly important in papermaking as the amount of pressure applied to the web during the nip press stage can be critical in achieving uniform sheet characteristics.
One common problem associated with such rolls can be the lack of uniformity in the pressure being distributed along the working length of the roll. The pressure that is exerted by the rolls of the nip press is often referred to as the “nip pressure.” The amount of nip pressure applied to the web and the size of the nip can be important in achieving uniform sheet characteristics. Even nip pressure along the roll is important in papermaking and contributes to moisture content, caliper, sheet strength and surface appearance. For example, a lack of uniformity in the nip pressure can often result in paper of poor quality. Excessive nip pressure can cause crushing or displacement of fibers as well as holes in the resulting paper product. Improvements to nip loading can lead to higher productivity through higher machine speeds and lower breakdowns (unplanned downtime).
Conventional rolls for use in a press section may be formed of one or more layers of material. Roll deflection, commonly due to sag or nip loading, can be a source of uneven pressure and/or nip width distribution. Worn roll covers may also introduce pressure variations. Rolls have been developed which monitor and compensate for these deflections. These rolls generally have a floating shell which surrounds a stationary core. Underneath the floating shell are movable surfaces which can be actuated to compensate for uneven nip pressure distribution.
Previously known techniques for determining the presence of such discrepancies in the nip pressure required the operator to stop the roll and place a long piece of carbon paper or pressure sensitive film in the nip. This procedure is known as taking a “nip impression.” Later techniques for nip impressions involve using mylar with sensing elements to electronically record the pressures across the nip. These procedures, although useful, cannot be used while the nip press is in operation. Moreover, temperature, roll speed and other related changes which would affect the uniformity of nip pressure cannot be taken into account.
Accordingly, nip presses were developed over the years to permit the operator to measure the nip pressure while the rolls were being rotated. One such nip press is described in U.S. Pat. No. 4,509,237. This nip press utilizes a roll that has position sensors to determine an uneven disposition of the roll shell. The signals from the sensors activate support or pressure elements underneath the roll shell, to equalize any uneven positioning that may exist due to pressure variations. The pressure elements comprise conventional hydrostatic support bearings which are supplied by a pressurized oil infeed line. The roll described in U.S. Pat. No. 4,898,012 similarly attempts to address this problem by incorporating sensors on the roll to determine the nip pressure profile of a press nip. Yet another nip press is disclosed in U.S. Pat. No. 4,729,153. This controlled deflection roll further has sensors for regulating roll surface temperature in a narrow band across the roll face. Other controlled deflection rolls such as the one described in U.S. Pat. No. 4,233,011, rely on the thermal expansion properties of the roll material, to achieve proper roll flexure.
Further advancements in nip press technology included the development of wireless sensors which are imbedded in the sensing roll covers of nip presses as is disclosed in U.S. Pat. Nos. 7,225,688; 7,305,894; 7,392,715; 7,581,456 and 7,963,180 to Moore et al. These patents show the use of numerous sensors imbedded in the roll cover, commonly referred to as a “sensing roll,” which send wireless pressure signals to a remote signal receiver. U.S. Pat. No. 5,699,729 to Moschel discloses the use of a helical sensor for sensing pressure exhibited on a roll. Paper machine equipment manufacturers and suppliers such as Voith GmbH, Xerium Technologies, Inc. and its subsidiary Stowe have developed nip presses which utilize sensors imbedded within the sensing roll cover. These nip press generally utilize a plurality of sensors connected in a single spiral wound around the roll cover in a single revolution to form a helical pattern. An individual sensor is designed to extend into the nip region of the nip press as the sensing roll rotates. In this fashion, the helical pattern of sensors provides a different pressure signal along the cross-directional region of the nip press to provide the operator with valuable information regarding the pressure distribution across the nip region, and hence, the pressure that is being applied to the moving web as it passes through the nip region.
Control instrumentation associated with the nip press can provide a good representation of the cross-directional nip pressure (commonly referred to as the “nip pressure profile” or just “nip profile”) and will allow the operator to correct the nip pressure distribution should it arise. The control instruments usually provide a real time graphical display of the nip pressure profile on a computer screen or monitor. The nip profile is a compilation of pressure data that is being received from the sensors located on the sensing roll. It usually graphically shows the pressure signal in terms of the cross-directional position on the sensing roll. The y-axis usually designates pressure in pounds per linear inch while the x-axis designates the cross-directional position on the roll.
While a single line of sensors on the sensing roll may provide a fairly good representation of nip pressure cross-directional variability, these same sensors may not properly take into account the variability of pressure across the nip region caused by the high speed rotation of the sensing roll. The dynamics of a cylinder/roll rotating at a high angular speed (high RPMs) can cause slight changes to the pressure produced by the cylinder/roll that are not necessarily detectable when the cylinder/roll is at rest or rotating at a low speed. Such dynamic changes could be the result of centrifugal forces acting on the cylinder/roll, roll flexing, roll balance, eccentric shaft mounting or out-or round rolls and could possibly be influenced by environmental factors. The dynamic behavior of a typical high speed rotating cylinder/roll is often characterized by a development of an unbalance and bending stiffness variation. Such variations along the cylinder/roll are often referred to as rotational variability. Unbalance can be observed as a vibration component at certain rotating frequencies and also can cause unwanted bending of the flexible cylinder/roll as a function of the rotating speed. Since the lengths of the sensing rolls used in paper manufacturing can be quite long, unbalance in the rotating rolls can pose a serious problem to the paper manufacturer since a less than even nip pressure profile may be created and displayed by the control equipment. Any unwanted bending of the sensing roll can, of course, change the amount of pressure being exerted on the web as it travels through the nip roller. Again, since even nip pressure is highly desired during paper manufacturing, it would be highly beneficial to correctly display the nip pressure profile since any corrects to be made to the rotating roll based on an inaccurate nip pressure profile could certainly exacerbate the problem. A single sensor located at an individual cross-directional position on the sensing roll may not be able to compensate for the effect of rotational variability at that sensor's position and may provide less than accurate pressure readings. There are three primary measurements of variability. The true nip pressure profile has variability that can be term cross-directional variability as it is the variability of average pressure per cross-direction position across the nip. Each sensor in a single line of sensors may have some variability associated with it that may be calculated as the data is collected at high speed. This particular variability profile represents the variability of the high speed measurements at each position in the single line of sensors. This variability contains the variability of other equipment in the paper making process including the rotational variability of the roll nipped to the sensing roll. The third variability profile is the nip profile variability of multiple sensors at each cross-directional position of the roll. This variability represents the “rotational variability” of the sensing roll as it rotates through its plurality or sensing positions.
One of the problems of rotational variability is the creation of “high spots” and “low stops” at various locations along the sensing roll. A single sensor located at a cross-directional position where a high spot or low spot is found could provide the processing equipment with an inaccurate pressure reading being developed at that location. This is due to the fact that the overall pressure that is developed at the sensor's location as the roll fully rotates through a complete revolution will be lower that the measured “high spot” reading. Accordingly, a nip pressure profile which is based on the reading of a sensor located at a high or low spot will not be indicative of the average pressure being developed that that location. The processing equipment, in relying on this single, inaccurate reading, will calculate and display a nip pressure profile which is at least partially inaccurate. If a number of single sensors are located at numerous high or low spots, then the processing equipment will display a nip pressure profile which has numerous inaccuracies. The operator of the papermaking machinery may not even be aware that the processing system is displaying an inaccurate nip pressure profile. Further, attempts to correct the sensing roll based on an inaccurate nip pressure profile could lead to even greater inaccuracies.
Therefore, it would be beneficial if the manufacturer could detect and measure any rotational variability along the length of the covered roll of a nip press and compensate for it when a real time nip pressure profile is being calculated and displayed. The present invention provides a better measurement of the true nip pressure profile and is also capable of providing a previously unmeasured nip profile variability of the rotation (rotational variability). Furthermore, certain arrangements of sensing elements will provide information on the wear of the cover. Compensation for any rotational variability should produce a nip pressure profile which is a more accurate representation of the pressure being developed along the nip region of the press. The present inventions satisfy these and other needs.
SUMMARY OF THE INVENTION
The present invention provides apparatus and methods for accurately detecting, measuring and at least partially removing any effects of rotational variability from a covered roll (also referred to as a “sensing roll”) used in nip presses. The present invention compensates for this effect allowing a more accurate display of the nip pressure profile to be calculated and displayed. The present invention thus provides the machine operator with a more accurate representation of the actual pressure distribution across the nip press. The present invention could be used in collaboration with correcting instrumentation which can eliminate or compensate for pressure variability at locations across the sensing roll of the press. The data obtained from the arrangement of sensors along the sensing roll allows for the calculation and display of a rotational variability profile which can provide the operator with additional real time information concerning the dynamics of the pressure readings in order to obtain a more accurate nip pressure profile. The present invention can compensate for rotational variability in the sensing mechanism by calculating, for example, an average pressure value at each cross-directional (“CD”) position along the sensing roll. The present invention also could calculate and obtain a more accurate nip pressure profile utilizing other models, such as curve fitting.
The present invention uses multiple sensors circumferentially spaced at various cross-directional positions along the sensing roll in order to cancel the effects of rotational variability which may, or may not, be acting on the sensing roll. These strategically-placed sensors are designed to measure the pressure being placed against the web that is being advanced through the nip press. Previous work has demonstrated that roll rotational variability principally occurs at 1 times the rotational frequency of the roll and occasionally at 2 times the rotational frequency, primarily near the edges of the roll. Higher frequencies are rarely seen and then normally only at the extreme edges of the roll. In additional, cycles at each cross-directional position may be in phase where the highs and lows occur simultaneously across the entire roll width (known as “barring”) or the phasing of the highs and lows may vary across the roll as it rotates. Analysis of these variability patterns has demonstrated that the average of measurements of two sensors spaced 180° circumferential apart at a cross-directional position of a covered roll should provide a good measurement of the actual pressure being developed and would cancel, or at least partially cancel, any rotational variability of 1 times the rotational frequency that might develop at this position. Similarly the average of measurements of three sensors spaced 120° or four sensors spaced 90° circumferential apart at a cross-directional position of a covered roll should provide a good measurement of the actual pressure being developed and would cancel, or at least partially cancel, any rotational variability of 2 times the rotational frequency that might develop at this position. Alternate positioning of multiple sensors to remove the effect of rotation is possible. In this manner, a more true measurement of the pressure distribution across the nip region should be obtainable. Information on higher frequency barring which is indicative of cover wear and has been seen at calender stacks may be obtained by spacing the sensing elements at different rotational positions. The difference between individual sensing elements and the average of the group of sensing elements at the same cross-direction progression provides a measure of the roundness of the roll and shape of the cover. The progression of this difference as the cover ages is an indicator of cover wear.
The present invention provides advantages over sensing rolls and system which utilize a single sensor assigned to measure the pressure at a particular cross-directional position. Sensing rolls which just utilize a single sensor disposed at a cross-directional position on a roll lack the ability to take secondary measurements at the same cross-directional position for purposes of comparison to determine if there is any unbalance at that particular cross-directional position. As a result, such a sensing roll may provide inaccurate readings for calculating and displaying the nip profile. If the single sensor is placed at a position where there is a high or low spot, caused by rotational imbalance, then that sensor's pressure reading will not be quite accurate and its reading would lead to the calculation of an inaccurate nip pressure profile. Additionally, the use of single sensors at each CD position cannot generate the necessary data to allow for the calculation and display of a rotational variability profile which could provide the operator with additional real time information in order to obtain a more accurate nip pressure profile. The present invention allows for the calculation and display of such a rotational variability profile, along with the nip pressure profile.
In one aspect, the sensing roll for use in a nip press includes strategically-placed sensors including a first set of sensors disposed in a particular configuration along a roll cover that overlies a cylindrical member. Each sensor of this first set is located at a particular lateral position (cross-directional position) on the roll cover. The sensing roll further includes additional sets of sensors which are likewise disposed in a particular configuration on the roll cover, each sensor of the second set being likewise disposed at a particular cross-directional position. Each sensor of the first set of sensors has a corresponding sensor in the additional sets to define the CD group of sensors that are utilized to take the pressure readings at a particular cross-directional position. Again, each sensor at the cross-directional position is spaced circumferentially apart from the other. Multiple corresponding sensors can be strategically placed at different cross-directional positions along the length of the sensing roll, each pair of sensors designed to measure the pressure being developed at that cross-directional position. Each sensor will measure the pressure as it enters the nip region of the press. In theory, each corresponding sensors of a CD group should measure the same pressure at the particular cross-directional position if the sensing roll is truly balanced. If the pressure measurements for the two corresponding sensors are significantly different, then the measurements would indicate some variability that may be caused by the dynamics of the rotating sensing roll. The present invention allows the sensing roll to take multiple, not just one, pressure measurements at each cross-directional position during each 360° revolution of the sensing roll. These multiple measurements are utilized to obtain a more accurate nip pressure profile and a rotational variability profile. In one aspect of the invention, the readings at each sensor can be averaged to determine an average pressure measurement at that particular cross-directional position. This averaged measurement can then be used in computing and displaying the nip pressure profile. The same readings can be used to calculate and display the rotational variability profile of the operating nip press. The variability of the readings at each position will be monitored and displayed to determine if the roll rotational variability is stable or increasing. There are many possible measures of this variability including variance, standard deviation, 2 sigma, percent of process, co-variance, peak to peak. Increasing variability using any measure may be indicative of a potential failure in the bearings or roll cover or other roll problems.
In another aspect, multiple sets of sensors are disposed so as a particular pattern of lined-up sensors are created. For example, the pattern could be a continuous helical configuration which extends around the sensing roll in one revolution forming a helix around the sensing roll. The sensors of several sets can be aligned in a number of different patterns along the length of the sensing roll in order to develop a good representative nip pressure profile. In another aspect, the continuous line of sensors can extend only partially around the sensing roll, for example, in one half (½) revolution. A second set of sensors would also extend around the sensing roll in one half (½) revolution. In this manner, only a partial helix is formed around the sensing roll 10 . This arrangement of sensors still allows a pair of sensors to be assigned to a particular CD position. These sets of sensors would be spaced 180° circumferential apart from each other. In a similar manner three helixes may be wound 120° each, four 90° each or n helixes 360°/n each. The particular advantage of this arrangement of sensors is in sensing short wavelength bars that may be associated with cover wear as each sensing element is at a different rotational position.
In another aspect, a system for calculating and displaying a nip pressure profile and rotational variability profile for a nip press includes a sensing roll configured with a second roll in a nip arrangement, the sensing roll and the second roll adapted to rotatingly press matter therebetween in a nip region. The sensing roll has a plurality of cross-directional positions defined along its length. The sensing roll including a first set of pressure-measuring sensors and additional sets of pressure-measuring sensors, each sensor of the plural sets of sensors being disposed at a particular cross-directional position along the sensing roll. Each sensor is configured to sense and measure pressure when the sensor enters the nip region of the nip press. Again, each sensor of the first set has corresponding sensors in the additional sets which are located at the same cross-directional position but are spaced apart circumferentially on the sensing roll to provide multiple pressure readings at each cross-directional position. The plurality of readings can be used to calculate and formulate the nip pressure profile and rotational variability profile for the press. In one aspect, an average pressure reading at each location can be calculated to obtain a more accurate nip pressure profile.
A transceiver can be attached to the sensing roll and to each of the sensors of the multiple sets for transmitting data signals from the sensors to a receiver unit. A processing unit for calculating the nip pressure distribution based on the pressure measurements of each CD group of corresponding sensors of the first and additional sets of sensors can be coupled to the sensing roll. A display unit also could be coupled to the processing unit to provide a visual display of the nip pressure profile and the rotational variability profile.
A method for sensing and removing the effects of rotational variability from the nip pressure profile of a sensing roll of a nip press includes providing a sensing roll having a working length and a number of cross-directional positions disposed along the working length. Multiple pressure-measuring sensors are placed at each of the cross-directional positions, the sensors of each cross-directional position being spaced apart circumferentially from each other. The pressure being exerted on each sensor of each CD group as the sensor moves into the nip region of the nip press is then measured with the pressure measurements of each sensor at that cross-directional position being calculate to obtain an average pressure measurement at the respective cross-directional position. The obtained pressure measurements calculated at each cross-directional position can then be utilized to create a nip pressure profile for the nip press.
In yet another aspect, a method for measuring and removing the effects of rotational variability from the nip pressure profile of a sensing roll of a nip press includes measuring the pressure exerted on a first sensor disposed at a particular cross-directional position on the sensing roll of the nip press as the first sensor enters the nip region of the press. The pressure exerted on additional sensors is also measured as the second sensor enters the nip region of the press. The additional sensors are located at the same cross-directional position as the first sensor but spaced apart circumferentially from the first sensor. The pressure measurements of the multiple sensors are used to calculate and display the nip pressure profile and rotational variability profile. Multiple pluralities of sensors could be placed at various cross-directional positions along the sensing roll in order to measure pressures at multiple offset locations for each cross-directional position. The pressure measurements from the multiple sensors for each cross-directional position are averaged and used to calculate and display the nip pressure profile that is developed across the nip region. The method may include providing corrective procedures to the sensing roll in order to adjust for high or low pressure spots along the nip pressure profile.
These and other advantages of the present invention will become apparent from the following detailed description of preferred embodiments which, taken in conjunction with the drawings, illustrate by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a nip press which utilizes a particular embodiment of a sensing or covered roll made in accordance with the present invention.
FIG. 2 is an end, schematic view of the nip press of FIG. 1 showing the formation of a web nipped between the nip rolls, the nip width of the nip press being designated by the letters “NW.”
FIG. 3A is a side elevational view of a particular embodiment of a sensing roll made in accordance with the present invention which shows the placement of two sets of sensors along the length of the roll.
FIG. 3B is an end view of the sensing roll of FIG. 3A showing the placement of the first and second sets of sensors some 180° apart circumferentially on the sensing roll.
FIG. 4 is a side elevational view showing the placement of the two lines of sensors along the length of the sensing roll with sensors disposed within the nip region which is designated by a pair of dotted lines.
FIG. 5 is a side elevational view showing the placement of the two lines of sensors along the length of the sensing roll after the sensing roll has rotated 180° from its initial position shown in FIG. 4 .
FIG. 6A is a side view of a particular embodiment of a sensing roll made in accordance with the present invention which shows the placement of three sets of sensors along the length of the roll.
FIG. 6B is an end view of the sensing roll of FIG. 6A showing the placement of the first, second and third sets of sensors some 120° apart circumferentially on the sensing roll.
FIG. 7A is a side view of a particular embodiment of a sensing roll made in accordance with the present invention which shows the placement of four sets of sensors along the length of the roll.
FIG. 7B is an end view of the sensing roll of FIG. 7A showing the placement of the first, second, third and fourth sets of sensors some 90° apart circumferentially on the sensing roll.
FIG. 8A is a side view of a particular embodiment of a sensing roll made in accordance with the present invention which shows the placement of two sets of sensors wound 180° circumferentially along the length of the roll.
FIG. 8B is an end view of the sensing roll of FIG. 8A showing the placement of the first and second sets of sensors some 180° apart circumferentially on the sensing roll.
FIG. 9A is a side view of a particular embodiment of a sensing roll made in accordance with the present invention which shows the placement of three sets of sensors wound 120° circumferentially along the length of the roll.
FIG. 9B is an end view of the sensing roll of FIG. 9A showing the placement of the sets of sensors some 120° apart circumferentially on the sensing roll.
FIG. 10A is a side view of a particular embodiment of a sensing roll made in accordance with the present invention which shows the placement of four sets of sensors wound 90° circumferentially along the length of the roll.
FIG. 10B is an end view of the sensing roll of FIG. 10A showing the placement of the sets of sensors some 90° apart circumferentially on the sensing roll.
FIG. 11 is a schematic drawing showing the basic architecture of a particular monitoring system and paper processing line which could implement the sensing roll of the present invention.
FIG. 12 is a graphical display showing a plot of normalized error versus profile position for a single sensor array and two sensor array showing a helical pattern of in-phase variability over one cycle.
FIG. 13 is a graphical display showing a plot of normalized error versus profile position for a single sensor array and two sensor array (180°) showing a helical pattern of out of phase variability over one cycle.
FIG. 14 is a graphical display showing a plot of normalized error versus profile position for a single sensor array, a two sensor array (180°) and three sensor array (120°) showing a helical pattern of out of phase variability over one cycle/rotation center and 2 cycles/rotation edges.
FIG. 15 is a graphical display showing a comparison of nip pressure versus profile position for 3 sensor arrays for array 1 (0°), array 2 (90°) and array 3 (180°).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to rolls for use particularly in nipped roll presses, in which rolls exert pressing forces on webs for forming paper, textile material, plastic foil and other related materials. Although the present invention may be used in the above industries, the discussion to follow will focus on the function of rolls for use particularly in the manufacture of paper and particularly to a nip press for dewatering a fibrous web, comprising a sensing roll disposed so as to rotatingly cooperate with another roll in the nip press. FIGS. 1-5 depict the embodiment wherein two sensors are positioned 180° circumferentially across the width of the roll at each cross-directional location as this provides the simplest illustration. Additional embodiments with multiple sensors at each CD location can be extrapolated, as is shown in FIGS. 6-8B .
As shown in FIG. 1 , a schematic perspective view shows a sensing roll 10 made in accordance with the present invention as a portion of a nip press 12 which includes a second roll 14 that cooperates with the sensing roll 10 to produce pressure on a fibrous web 16 that is advanced between the two rolls 10 , 14 . The sensing roll 10 and second roll 14 rotate, as is indicated by arrows in FIG. 2 , and are spaced apart at a nip region 18 where the two rolls 10 , 14 somewhat meet in order to place pressure on the fibrous web 16 so as to remove some of the liquid suspended in the web 16 . The letters NW in FIG. 2 indicate the formed “nip width” of the nip region 18 . This nip region 18 extends along the entire cross-directional length of the sensing roll 10 and second roll 14 . The sensing roll 10 may include an inner base roll 20 and the outer roll cover 22 may comprise materials suitable for use in making a press roll. The inner base roll 20 may include one or more lower layers, with the outer roll cover 22 being the top layer. This composite sensing roll 10 with the roll cover 24 is commonly known as a “covered roll” in the industry. The second roll 14 may be an uncovered roll or also comprise of a number of layers of materials and a base roll as well. If multiple covered rolls are contained in the nip, each may have sensors and produce nip profiles and variability profiles. The nip profiles or the two covered rolls may be averaged together for greater accuracy in making nip profile adjustments. However, the variability profiles of each covered roll provide information about the condition of that specific roll. It should be appreciated that while the present embodiments focuses only in a single nip, it is possible to utilize single rolls involved in bi-nip, tri-nip or multi-nip interactions which are common in the paper industry. One two rolls 10 , 14 are depicted to more clearly describe the advantages associated with the present invention. However, multiple nip profiles can be generated with each independent sensing roll utilizes in the nip press.
Referring now to FIGS. 1 and 3 , a first set 24 of sensors 26 is associated with the sensing roll 10 along with a second set 28 of sensors 30 . Sensors 26 of the first set 24 are designated by a circle while sensors 30 of the second set 28 are designated by a square. Circles and squares have been used for ease in identify the sensors constituting the first set 24 of sensors from the second set 28 of sensors. However, in practice, these sensors 26 and 30 can be the exact same sensing device. Also, one or both of the rolls 10 , 14 may have sensors associated with the roll. For purposes of illustration, however, this discussion will focus on only one of the rolls having sensing and measuring capabilities.
These sensors 26 and 30 may be at least partially disposed within the roll cover 22 which forms the portion of the sensing roll 10 . Each of the sensors 26 and 30 are adapted to sense and measure a particular data parameter, such as, for example, the pressure that is being exerted on the sensor when it enters the nip region 18 . As can be best seen in FIG. 3A , the first set 24 of sensors 26 is shown disposed in a particular configuration along the sensing roll 10 , each sensor 26 being located at a particular lateral position (referred to as the “cross-directional position” or “CD position”) on the sensing roll 10 . Each cross-directional position is a particular distance from the first end 32 of the sensing roll 10 . As can be seen in the particular embodiment of FIG. 3A , the first set 24 of sensors 26 are disposed along a line that spirals around the entire length of the sensing roll in a single revolution forming a helix or helical pattern. The second set 28 of sensors 30 is likewise disposed along a line that spirals around the entire length of the sensing roll in a single revolution creating the same helix or helical pattern except that this second set 28 of sensors 30 is separated apart from the first set 24 some 180° circumferentially around the sensing roll 10 . FIG. 3B shows an end view of the first set 24 spaced approximately 180° apart from the second set 28 . The use of these two lines of sensors 26 , 30 allows a large amount of the outer surface of the sensing roll 10 to be measured while the roll 10 is rotating. While the particular pattern of the first set 24 and second set 28 is shown herein in a helical pattern around the roll 10 , it should be appreciated that these sets 24 , 28 of sensors can be disposed in other particular configurations to provide pressure measurements all along the sensing roll 10 .
Each sensor 30 of this second set 28 is disposed at a particular cross-directional position on the sensing roll 10 . Each sensor 26 of the first set 24 has a corresponding sensor in the second set 28 with each corresponding sensor of the first and second set being located at the same cross-directional position along the sensing roll. In this manner, each cross-directional position of the sensing roll has a pair of sensors which measure the pressure at two different circumferential positions. Each pair of corresponding sensors are located along the sensing roll 10 at a cross-directional position to provide two sensor readings when the sensing roll completes a full 360° rotation. The average of these two readings can then be utilized to calculate and display the nip pressure profile that is being developed on the rotating nip press 12 .
The manner in which the pressure measurements can be made is best explained by referring to FIGS. 4 and 5 . FIGS. 4 and 5 show side elevational views of the sensing roll 10 as it would be viewed looking directly into the nip region 18 which is depicted by a pair of dotted lines. FIG. 4 shows a typical view in which the sensing roll 10 has a pair of sensors 26 , 30 directly in the nip region ready to take a pressure measurement. A grid located at the bottom of the sensing roll 10 for illustrative purposes shows fourteen (14) individual cross-directional positions along the working length L of the sensing roll 10 . In FIG. 4 , the first set 24 of sensors 26 can be seen depicted positioned at cross-directional positions numbered 1 - 7 . Likewise, the second set 28 of sensors 30 are shown in cross-directional positions numbered 8 - 14 in FIG. 4 . The other sensor 26 of the first set 24 are disposed in cross-directional positions 8 - 14 but cannot be seen in FIG. 4 . Likewise, the remaining sensors 30 of the second set 28 are in positions 1 - 7 but cannot be seen in FIG. 4 since they are at the reverse side of the sensing roll. It should be appreciated that only fourteen cross-directional positions are shown in these drawings to provide a simple explanation of the manner in which the present invention operates. In actual operation, there can be many more cross-directional positional positions associated with a sensing roll given the long lengths and widths that are associated with these rolls.
Only the sensor 26 located in the 4 th cross-directional position and the sensor 30 located in the 11th cross-directional position are in proper position for taking the pressure measurement as they are located in the nip region NR. Once these two sensors 26 , 30 enter the nip region NR, the pressure being exerted on the sensor is measured. As the sensing roll 10 continues to rotate, the other sensors in the 5 th and 12 th cross-directional positions will then be located in the nip region NR and will be able to measure the pressure at these particular positions. Further rotation of the sensing roll 10 places the sensors in the 6 th and 13 th cross-directional positions into the nip region NR for pressure measurements. Eventually, the sensing roll 10 rotates 180° from its initial position shown in FIG. 4 and will again have sensors in the 4 th and 11 th cross-directional positions. This arrangement of sensors 26 , 30 is shown in FIG. 5 . The only difference is that a sensor 30 of the second set 28 is now in the 4 th cross-directional position and a sensor 26 of the first set 24 is in the 11 th cross-directional position. These sensors 26 and 30 shown in FIGS. 4 and 5 are corresponding sensors which read the pressure at the 4 th cross-directional position. Likewise, sensor 26 of the first set 24 in FIG. 5 is now in the 11 th cross-directional position ready to measure the pressure at that location. The sensor 30 in the 11 th cross-directional position shown in FIG. 4 and the sensor 26 in the 11 th cross-directional position of FIG. 5 constitute corresponding sensors which provide pressure readings at that particular location on the sensing roll. The system which processes the pressure measurements can take the average of the readings of each pair of corresponding sensors at a particular cross-directional position and calculate the nip profile at that position based on an average reading. For example, if the sensors 26 , 30 in the 4 th cross-directional position both read 200 lbs per linear inch (PLI) then their average would be 200 PLI. This would indicate that there is little, or no, pressure variation caused by the rotation of the sensing roll 10 . The average 200 PLI reading would then be used to calculate and display the nip pressure profile at that particular cross-directional position. For example, if the sensor 30 in the 11 th cross-directional position, as shown in FIG. 4 , reads 240 PLI and the sensor 26 in the 11 th position shown in FIG. 5 reads 160 PLI, then the average pressure would be 200 PLI. These two different readings at the 11 th cross-directional position would indicate a pressure variation that most likely would be attributed to the high speed rotation of the sensing roll 10 . However, in processing the nip pressure profile for the 11 th cross-directional position, the average pressure measurement of 200 PLI would be utilized since this average will cancel, or nearly cancel, the effect of rotational variability that is occurring along the sensing roll 10 . The average of the two measurements will result in a more accurate representation of the pressure being developed at that particular cross-directional position.
In prior art sensing rolls which utilize a single sensor at each cross-directional position, the processing unit would have single sensors at each cross-directional positions. A prior art sensing roll which has a single sensor at the 11 th cross-directional position in the illustrated example above could only rely on a single reading at that position in order to calculate and display the nip pressure profile. A prior art roll would then use either the 240 PLI or 160 PLI reading for determining and displaying the nip pressure profile at this location. Such a reading would be less than accurate as the sensing roll full rotates in a 360° revolution. Accordingly, the calculated nip pressure at this position will be less than accurate. However, the processing unit would display a nip pressure profile would appear to be accurate but in reality would be less than accurate. If adjustments are made to the sensing roll by the machine operator or through automatic adjustment equipment to compensate for high or low pressure readings, then the sensing roll could be adjusted to develop even more incorrect pressures at various locations in the nip region.
As the roll 10 rotates placing different sensors into the nip region, the respective sensors measure the pressure which is then transmitted to the processing unit. The processing unit associated with each sensing roll 10 can then calculate the average pressure of each pair of corresponding sensors at the various cross-directional positions and produce a nip pressure profile which can be visualized on a monitor or other visual screen. Computer equipment well known in the art could be utilized to process the pressure readings that are being made in milliseconds.
One method of the present invention for sensing and removing the effects of rotational variability from the nip pressure profile of a sensing roll of a nip press thus includes providing a sensing roll having a working length and a plurality of cross-directional positions disposed along the working length and the placement of pairs of pressure-measuring sensors at each cross-directional positions. In the particular embodiment shown in FIGS. 3A-5 , the method utilizes sensors being spaced apart 180° circumferentially from each other. This allows for two different pressure measurements to be made at each cross-directional position. The pressure exerted on each sensor of each pair as the sensor moves into the nip region of the nip press can then be measured and the average of each of the two sensors at each cross-directional position can be calculated to determine an average pressure measurement. The average pressure measurements at each cross-directional position can then be used to provide a nip pressure profile for the nip press.
It should be appreciated that while the present invention discloses mathematical modeling that utilizes the direct averaging of the measurements taken by each corresponding sensor, it could be possible to obtain a composite average measurement utilizing other types of models which can obtain and calculate an averaged measurement at each cross-directional position. For example, the operating equipment (data processors) could utilize another model such as “curve fitting” which also can provide the more accurate nip pressure profile. Still other models known in the art could be utilized with the multiple pressure readings from the various sensors to obtain the more accurate nip pressure profile.
Variations of the sensing roll are disclosed in FIGS. 6-8 . Referring initially to FIGS. 6A and 6B , three different sets of sensors are utilized and extend around the sensing roll 10 . As can be seen in the disclosed embodiment of the sensing roll 10 , a first set 24 of sensors 26 , a second set 28 of sensors 30 and a third set 32 of sensors 34 are shown as continuous lines of sensors which extend around the sensing roll in one full revolution, each set 24 , 28 , 32 forming a helix around the sensing roll 10 . Sensors 34 are shown as a triangle to distinguish that particular sensor from the sensors 26 , 30 of the other two sets 24 , 28 . Adjacent sets 24 , 28 and 30 of sensors are spaced 120° circumferential apart from each other (see FIG. 6B ) at a cross-directional position of the sensing roll 10 to provide a good measurement of the actual pressure being developed and would cancel, or at least partially cancel, any rotational variability of 2 times the rotational frequency that might develop at this CD position. Again, the measurements from each of the corresponding sensors at each CD position can be averaged to provide an averaged measurement which provides a more accurate representation of the nip pressure being developed at that CD position.
It should be appreciated that the working length of the sensing roll can be quite long and may require each set of sensors to be wound more than one times around the roll. Again, such a pattern is satisfactory as long as the pattern allows for three sensors to be use at each cross-directional position (spaced 120° apart) in order to produce three separate pressure readings which are then processed to produce a base reading.
Referring now to FIGS. 7A and 7B , a fourth set 36 of sensors 38 has been added to the sensing roll 10 to provide yet another sensor at each CD position. Adjacent sets 24 , 28 , 30 , 36 are spaced 90° circumferential apart from each other (see FIG. 7B ) at a cross-directional position of the sensing roll 10 to provide a good measurement of the actual pressure being developed and would cancel, or at least partially cancel, any rotational variability of 2 times the rotational frequency that might develop at this CD position. Again, it should be appreciated that the working length of the sensing roll can be quite long and may require each set of sensors to be wound more than one times around the roll. Such a pattern is satisfactory as long as the pattern allows for four sensors to be use at each cross-directional position (spaced 90° apart) in order to produce four separate pressure readings which are then processed to produce a base reading.
Referring now to FIGS. 8A and 8B , a first set 24 of sensors 26 is shown as a continuous line of sensors which extend around the sensing roll in one half (½) revolution. Likewise, a second set 28 of sensors 30 extend around the sensing roll in one half (½) revolution. In this manner, only a partial helix is formed around the sensing roll 10 . This arrangement of sensors 26 , 30 still allows a pair of sensors to be assigned to a particular CD position. Like the sensing roll 10 shown in FIGS. 3A-5 , adjacent sets 24 , 28 are spaced 180° circumferential apart from each other (see FIG. 8B ). The resulting structure creates a sensing roll that has only one sensor entering the nip region at any given time. This particular embodiment of the sensing roll 10 should provide a good measurement of the actual pressure being developed and would cancel, or at least partially cancel, any rotational variability of 2 times the rotational frequency that might develop at this CD position.
In a similar manner three helixes may be wound 120° each, four 90° each or n helixes 360°/n each. The particular advantage of this arrangement of sensors is in sensing short wavelength bars that may be associated with cover wear as each sensing element is at a different rotational position. FIGS. 9A and 9B show three continuous lines 24 , 28 and 32 of sensors 26 , 30 and 34 which extend around the sensing roll in a partial revolution (a 120° revolution). In this manner, only a partial helix is formed around the sensing roll 10 by each set 24 , 28 and 32 . This arrangement of sensors 26 , 30 and 34 allows group of sensors to be assigned to a particular CD position. Like the sensing roll 10 shown in FIGS. 6A and 6B , adjacent sets 24 , 28 and 32 are spaced 120° circumferential apart from each other along the roll (see FIG. 9B ). FIGS. 10A and 10B show four continuous lines 24 , 28 , 32 and 36 of sensors 26 , 30 , 34 and 38 which extend around the sensing roll in a partial revolution (a 90° revolution). Again, only a partial helix is formed around the sensing roll 10 by each set 24 , 28 , 32 and 36 . This arrangement of sensors 26 , 30 , 34 and 38 allows group of sensors to be assigned to a particular CD position. Like the sensing roll 10 shown in FIGS. 7A and 7B , adjacent sets 24 , 28 , 32 and 36 are spaced 90° circumferential apart from each other (see FIG. 10B ). The resulting structure creates a sensing roll that has only one sensor entering the nip region at any given time. This particular embodiment of the sensing roll 10 should provide a good measurement of the actual pressure being developed and would cancel, or at least partially cancel, any rotational variability of 2 times the rotational frequency that might develop at this CD position. Similar lines of sensors could be disposed along the length of the sensing roll 10 such that n lines of sensors forming partial helixes are formed and placed 360°/n along the length of the roll 10 . Adjacent lines of sensors would be spaced 360°/n circumferentially apart from each other along the roll.
The methods for sensing and removing the effects of rotational variability from the nip pressure profile of a sensing roll of a nip press utilizing the embodiments of FIGS. 6A-10B includes providing a sensing roll having a working length and a plurality of cross-directional positions disposed along the working length and the placement of pairs of pressure-measuring sensors at each cross-directional positions. The method will calculate an average pressure measurement utilizing the number of sensors placed at each CD position. In the embodiments of FIGS. 6A and 6B and FIGS. 9A and 9B , three sensors located a CD position are averaged. Likewise, the readings from the four sensors of the embodiments of FIGS. 7A and 7B and FIGS. 10A and 10B are utilized to produce an average pressure measurement. The embodiment of FIGS. 8A and 8B , like the embodiment of FIGS. 3A-5 , utilize a pair of sensor measurements at each CD position. The average pressure measurements at each cross-directional position can then be used to provide a nip pressure profile for the nip press.
The sensors used in the various sets can be electrically connected to a transmitter unit 40 which also can be attached to the sensing unit 10 . The transmitter unit 40 can transmit wireless signals which can be received by a wireless receiver located at a remote location. The wireless receiver can be a part of a system which processes the signals, creates the nip profile and sends corrective signals back to the sensing roll 10 . Sensors may be collected in the same collection period and average together for immediate use. However, the additional wireless transmission may reduce the battery life of the wireless unit. As the rotational variability changes slowly, alternating the collection between the sensors and averaging together the collections in the alternate collection periods will provide comparable information and may save battery life.
One particular system for processing the signals is shown in FIG. 11 and will be discussed in greater detail below. Wireless transmission can be carried out via radio waves, optical waves, or other known remote transmission methods. If a direct wired transmission is desired, slip ring assemblies and other well-known electrical coupling devices (not shown) could be utilized.
FIG. 11 illustrates the overall architecture of one particular system for monitoring of a product quality variable as applied to paper production. The system shown in FIG. 11 includes processing equipment which calculates and displays the nip pressure profile. For example, the pressure measurements can be sent to the wireless received from the transmitter(s) located on the sensing roll. The signals are then sent to the high resolution signal processor to allow the average pressure measurements to be calculated and utilized to create and display the nip pressure profile. Data can be transferred to the process control which can, for example, send signals back to the sensing roll to correct pressure distribution across the nip region. One such nip press which is capable of real time correction is described in U.S. Pat. No. 4,509,237, incorporated herein by reference in its entirety. This nip press utilizes a roll that has position sensors to determine an uneven disposition of the roll shell. The signals from the sensors activate support or pressure elements underneath the roll shell, to equalize any uneven positioning that may exist due to pressure variations. Other known equipment which can correct the roll cover could also be used.
The sensors can take any form recognized by those skilled in the art as being suitable for detecting and measuring pressure. Pressure sensors may include piezoelectric sensors, piezoresistive sensors, force sensitive resistors (FSRs), fiber optic sensors, strain gage based load cells, and capacitive sensors. The invention is not to be limited to the above-named sensors and may include other pressure sensors known to those of ordinary skill in the art. It should be appreciated that data relating to the operational parameter of interest, other than pressure, could be utilized with the present invention. In this case, the sensors could be used to measure temperature, strain, moisture, nip width, etc. The sensors would be strategically located along the sensing roll as described above. Depending on the type of sensor, additional electronics may be required at each sensor location. The design and operation of the above sensors are well known in the art and need not be discussed further herein.
The processor unit is typically a personal computer or similar data exchange device, such as the distributive control system of a paper mill that can process signals from the sensors into useful, easily understood information from a remote location. Suitable exemplary processing units are discussed in U.S. Pat. Nos. 5,562,027 and 6,568,285 to Moore, the disclosures of which are hereby incorporated herein in their entireties.
Referring now to FIGS. 12-15 , graphical displays are provided which further explains and presents typical mapping of roll variability which can develop during operation. Roll surfaces were mapped pursuant to the methods and apparatus described in U.S. Pat. No. 5,960,374 using paper properties sensors that were related to nip pressure. The mappings used an array of 5,000 elements broken into 100 CD positions and 50 rotational positions. The mappings confirmed that most roll variability occurs in 1 cycle per revolution in-phase across the roll or out-of-phase (the phase shifts with profile position). A 2 cycle per revolution pattern is sometime noted at the edges of the roll. Higher frequencies (such as 3 cycles per revolution) are rarely seen and then only at the extreme edges and have little impact. Three roll surface maps were normalized (scaled on 0-100%) and helical scan paths were superimposed over the surface maps. The true nip pressure profile was determined by averaging the 50 rotational positions at each of the 100 CD positions. The helical scan paths and the averages of two or more of these paths at various separation angles were used to develop estimates of the nip pressure profile. These estimates were then subtracted from the true nip profile to obtain the error in each estimate. FIGS. 12 and 13 demonstrate that two sensor arrays across the width of the roll and separated by 180° circumferentially are sufficient to remove most of the rotational variability when the variability is 1 cycle per revolution. FIG. 14 demonstrates that 2 arrays are not sufficient to handle the 2 cycle per revolution variability at the edges as the estimate difference from the true nip profile is an large at the edges as the single helical scan. For this case a minimum of 3 arrays separated by 120° would be needed. A larger number of arrays per revolution may further reduce the measurement error, but at a higher cost. Therefore, the embodiment of three (3) arrays (lines) of sensors separated by 120° circumferentially insures that all 1 cycle/revolution and 2 cycle/revolution variability is reduced. However, 2 arrays may be sufficient for many rolls without 2 cycle/revolution variability and more than 3 arrays may give superior variability measurement and reduction but at a higher cost.
FIG. 15 shows nip pressure profiles collected on a roll using the various embedded sensors. The data show clear differences in the profile between the 3 arrays. Most notably, arrays 1 & 3 (separated by 180°) show a significant difference in shape, especially in profile position 14 - 20 .
While there have been described herein what are considered to be preferred and exemplary embodiments of the present invention, other modifications of the invention shall be apparent to those skilled in the art from the teachings herein and, it is therefore, desired to be secured in the appended claims all such modifications as fall within the true spirit and scope of the invention. Thus, any modification of the shape, configuration and composition of the elements comprising the invention is within the scope of the present invention. Accordingly, what is desired to be secured by Letters Patent of the United States is the invention as defined and differentiated in the following claims. | Multiple groups of sensors are circumferentially spaced apart at each cross-directional position along a sensing roll of a nip press to measure and cancel or nearly cancel the effects of rotational variability which may be acting on the sensing roll. The strategically-placed sensors are designed to measure the pressure being placed against the web that is being advanced through the nip press. The average of the measurements of multiple sensors spaced circumferential apart provides a good cancellation of any rotational variability that might be found at a cross-directional position on the sensing roll. In this manner, a more true measurement of the nip pressure profile can be obtained and better adjustments made to reduce nip pressure profile variability. In addition, the nip variability profile may be used as a predictor of cover or bearing failures, resonant frequencies and other roll anomalies. | 3 |
The present invention concerns a method for controlling the amount of ionised gases and/or particles suspended in the air above roads, streets, open spaces or the like.
THE STATE OF THE ART
The term surface refers to surfaces used for roads, streets, open spaces, including airports, as well as surfaces in the vicinity of roads, streets, open spaces and marking on roads, streets and open spaces. Surfaces of roads, streets and open spaces usually consist of a binding agent mixed with an additive material such as sand, gravel and stones with a certain grain size. The binding agent usually completely surrounds the additive material. The binding material is usually bitumen, which may also be mixed with asphalt, gas tar, bituminous polymers and plastic materials. In the present description the word bitumen is employed, even though the bitumen may be mixed with one or more of the above-mentioned materials. Surfaces in the vicinity of roads, streets and open spaces together with marking on roads, streets and open spaces consist of known per se commercial products.
Bitumen is a very good electrical insulator and is used among other things for encapsulating electrical components. A road surface with a binding agent of bitumen will be an electrical insulator and thus it will not conduct electrical current. It is known that insulating materials such as ebonite, glass and the like can be electrically charged, for example by rubbing against other materials. In the same way the insulating surface on roads, streets and open spaces will be electrically charged by friction due to moving traffic, it will be charged by solar radiation and heating of air molecules which are ionised and which will flow from the surface, and it will be charged by thermal expansion and contraction of the surface. The binding agent in the surface will lose electrons, thus giving the surface a positive charge. In consequence the surface will receive a positive charge relative to the ground which is negatively charged.
It is previously known, e.g. from U.S. Pat. No. 5,707,171 to make a road surface electrically conductive. This, however, has previously only been employed for heating the road surface by passing electric current through it in order to prevent ice formation.
Exhaust gas flows from an internal combustion engine and the gas is normally ionised and has a positive charge. Particles in exhaust gas are similarly positively charged. Dust particles in the air above a roadway are also normally positively charged. The dust particles may come from, amongst other things, the top layer of the roadway, industrial and/or private emission.
An electrically charged surface will act as a pole in an electrostatic system. The surface charge in a road surface which is positive will have the same polarity as the charge of gas ions and/or particles in exhaust gas above roads, streets, open spaces, etc. The surface will therefore repel the said gases and/or particles. The result is that the ionised gases and/or particles above the surface will remain in suspension over roads, streets and open spaces. An electrical Coloumb force has been created which acts on the ionised gases and/or particles. The direction of the force is away from the top layer, thus counteracting gravity. An electrical suspension force has been created.
Ionised gases and/or particles above roads, streets and open spaces, etc. have been shown to represent an ever-increasing health risk. The object of the invention is to control the ionised gases and/or particles. This is achieved by means of an electrical field which is established between the surface as mentioned above and the ionised gases and/or particles which are to be controlled, as indicated in claim 1 . The other claims indicate further advantageous features and embodiments of the invention.
According to the invention at least the top layer of the surface and the ionised gases and/or particles will form two electrodes in a capacitor.
DESCRIPTION OF THE INVENTION
The surprising discovery has been made that by using a surface for roads, streets, open spaces, etc. wherein at least the top layer is electrically charged and in electrical contact with earth or a negative voltage source, positively charged gases and positively charged dust particles will be attracted to the surface. This means that harmful and polluting materials will be bound to the surface. The positively charged gases and/or particles will moreover be neutralised by contact with the electrically charged surface. In addition an earthed surface will not be charged by friction due to moving traffic or by solar radiation and heating and ionising of air molecules flowing from the surface or by expansion and contraction of the surface. In addition reduced electrical friction between a vehicle and the surface will be capable of reducing the vehicle's fuel consumption and thereby the discharge of exhaust gases.
By means of the invention the result has been achieved that, instead of being suspended above a surface, exhaust gases and particles from internal combustion engines together with dust particles are attracted to the surface with the result that the air over the surface remains clean. This is of great importance for the task of reducing pollution which is due among other things to exhaust gases from internal combustion engines and the invention therefore is of vital importance for the environment. Large areas of the earth's surface are at present covered by an insulating surface such as bitumen. The extent of this surface is so great that in addition to being important for the environment it may be of importance for the climate and life on earth.
Due to combustion in industry and private households and car traffic, large amounts of ionised gases and/or particles will be formed over roads, streets, open spaces, etc. In such places an electrically charged surface will establish an electrical field, thereby controlling the amount of noxious ionised gases and/or particles. The surface is charged by adding to the currently used binding agent, at least in a top layer of the surface, a conductive material such as, e.g. carbon powder. The surface is then placed in contact with earth or a negative voltage source. This makes the surface a cathode in a capacitor where the positively charged ionised gases and/or particles represent the anode. The electrical field which is created between the anode and the cathode will draw the ionised gases and/or particles towards the top layer, thereby ionising them as well as preventing them from being suspended.
In order to make the surface electrically charged, a network of conductive metal or a piezoelectric material may also be employed under the top layer which is placed in contact with earth or a negative voltage source. The electrically charged top layer may also be composed or a coating which is laid on top of the entire or parts of the surface, for example in the form of road marking or the like.
An electrically charged surface which is in electrical contact with earth will be electrically neutral. It will be capable of emitting or absorbing electrons and by means of friction caused by car wheels a vehicle will remain electrically neutral. The result of this is that neither the vehicle nor the people in the vehicle will be charged, and obtain an electrical voltage relative to the environment. This will prevent unpleasant electric shocks when entering and leaving a vehicle due to potential differences which are common when a vehicle travels on standard insulating surfaces. In the same way an electrically conductive surface will reduce the risk of sparking due to potential differences between a vehicle and the surface. Accidents which can occur due to ignition of inflammable and explosive chemicals and gases which are transported on roads with an electrically conductive surface will thereby be reduced.
Research has shown that car sickness and a feeling of tiredness while driving are due to the build-up of static electrical fields in the vehicle. This will be reduced by the use of an electrically charged surface which is in electrical contact with earth and is thereby electrically neutral. The invention will therefore also be important for traffic safety.
DESCRIPTION OF FIGURES
The invention will now be illustrated in more detail with reference to the drawings which illustrate embodiments of the invention and which are not limiting for the concept of the invention.
FIGS. 1 and 2 show a section and a sectional elevation respectively of an electrically conductive surface with grounding points.
FIGS. 3 and 4 show a section and a sectional elevation respectively of an electrically conductive surface laid as a top layer on an existing road and with earthing points.
FIG. 5 is a sectional elevation of an electrically conductive surface where a voltage source is connected between the surface and the earthing point.
FIG. 6 a illustrates the electrostatic image without the use of the present invention.
FIG. 6 b illustrates the electrostatic image with the use of the present invention.
We now refer to FIGS. 1 and 2 which illustrate a section and a sectional elevation respectively of an electrically conductive surface 1 for roads, streets, open spaces, where the binding agent mixture 2 is electrically conductive. The electrically conductive binding agent mixture 2 surrounds an additive material 3 which may be sand, gravel or stones with specific grain sizes. The surface 1 is usually laid over coarse stones or a layer of crushed stones which will act as an insulator. In modern road building insulation is normally used and such plastic layers will be good electrical insulators. In order to ensure good electrical connection to earth it will therefore be necessary to have earth connections in the surface 1 . In the surface 1 , one or more uninsulated conductors 5 are inserted at specific intervals. The conductor 5 may also consist of a flexible uninsulated metal network of a certain width. Such conductors 5 are inserted across the longitudinal direction of the surface 1 at specific intervals and connected to earth at earthing point 6 . An earthing rod can be used as an earthing point 6 . In addition earth conductors may be inserted in the longitudinal direction of a surface 1 as illustrated in FIGS. 3 and 4.
At places where an electrically conductive surface 1 is laid over areas where the base has good electrical conductivity, with the result that it will act as an earth connection, earthing points 6 will be unnecessary and may be omitted.
FIGS. 3 and 4 illustrate a section and a sectional elevation respectively of an existing road, street, open space 10 . On an existing road 10 an electrically conductive surface 11 is laid as a top layer. The already existing surface 12 may be of a standard commercial type of bitumen, asphalt or oil gravel, or of concrete. By laying an electrically conductive surface 11 in the form of a top layer on already existing roads, streets, open spaces which at present have insulating surfaces 12 , they will be converted into electrically conductive surfaces.
The electrical conductive surface 11 may consist of an electrically conductive binding agent mixture 2 and can be used with or without additive materials 3 such as sand or gravel with a certain grain size. The surface 11 can be laid directly on the existing roadway 10 as a thin top layer with a thickness from a few millimetres to several centimetres. The advantage is thereby obtained that the electrically conductive surface does not alter the existing roadway's 10 characteristic with regard to elasticity and mechanical properties. It is also possible to let this surface 11 cover only parts of the existing road, for example in the form of road marking. In this case in a preferred embodiment of the invention there will be employed known per se materials, with the possible addition of an electrically conductive material such as, for example a carbon powder or metal powder.
At one or more points in the electrically conductive surface 11 there are inserted one or more uninsulated electrical conductors 5 . At specific intervals the conductor or conductors are connected to earth at earthing point 6 . An earthing rod may be used as earthing point. Already existing earthing points may also be used. The distance between each earthing point 6 is dependent on whether conductors are employed on one or both sides of the surface, on the conductivity in the electrically conductive surface and on the traffic density on the road, street or open space, which will determine how great a volume of exhaust gas has to be conveyed to the surface and neutralised per time unit. The distance between each earth connection can be determined in the most expedient manner by measurements. In tests it has been found that distances from 1 to 1000 metres can be employed, but it will be most preferred to employ distances from 20 to 200 metres.
FIG. 5 is a sectional elevation of an electrically conductive surface 1 for roads, streets, open spaces etc., where the binding agent mixture 2 is electrically conductive. The electrically conductive surface 1 may be laid as a new road or as a top layer on an already existing road. One or more uninsulated conductors 5 are inserted in the surface 1 . Such conductors can be inserted both along and across the longitudinal direction of the surface 1 and connected to earth at earthing point 6 . An earthing rod can be employed as earth point. A direct voltage source 7 is connected to the earth conductor 5 between the surface 1 and the earthing point 6 . The voltage source 7 is connected to the negative pole of the surface 1 and the positive pole to the earthing point 6 . The surface 1 thereby obtains negative potential relative to earth. The voltage or the potential difference between the surface 1 and earth 6 is dependent on how great a volume of exhaust gas has to be conveyed to the surface and neutralised per time unit. The potential difference can be determined in the most expedient manner by means of measurements. In tests it has been found that potential differences between 1 V and 1000 V can be employed, but it is most preferred to employ potential differences between 1 V and 100 V.
In order to obtain an electrically charged surface for roads, streets, open spaces or the like, a binding agent mixture is used which consists primarily of bitumen to which electrically conductive materials such as carbon powder or metal powder are added. Asphalt, gas tar, bituminous polymers, plastic materials, etc. can be added to the bitumen. In the present invention the word bitumen is used for the main component even though the above-mentioned materials may be added to the bitumen.
In order to obtain an electrically conductive road surface for surfaces in the vicinity of roads, streets and open spaces, and marking on roads, streets and open spaces, known per se materials are employed to which an electrically conductive material such as carbon powder or metal powder is added.
It is important that the materials which are employed to make the bitumen electrically conductive should be easily mixed with bitumen and not detract from the bitumen's properties as a binding agent in a road surface. It has been found that carbon powder, which is a conductive material, has these properties. All types of carbon powder can be used, such as carbon black, or powder of graphite, coal, coke or charcoal. Carbon fibre may also be used since, in addition to providing electrical conductivity it will also give the bitumen mixture great mechanical strength.
In addition to carbon powder metal powder can be used either alone or together with carbon powder. Metal powder is particularly applicable where the metal grains are in the form of flakes or thin fibres. Aluminium pigments in the form of flakes are one example.
In a binding agent mixture the electrical conductivity will vary with the amount of carbon powder mixed in. The electrical resistance, which is the inverse value of the conductivity, is simpler to measure with commercial measuring instruments. Measurements have been carried out which show that the electrical resistance in a conductive surface should lie within those values which are measured for samples taken of different types of earth. Earth samples are measured from 2 Mohn/cm to 50 Mohm/cm. The resistance in earth samples is probably highly dependent on the moisture content in the sample and on the content of sales which are soluble in water and form ions.
We now refer to FIG. 6, which illustrates an example of application of the invention on a road. FIG. 6 a shows the electrostatic image without the use of the invention, where ionised gases and/or particles 8 and the road surface 1 are both positively charged, thereby repelling each other. FIG. 6 b shows the electrostatic image with the use of the present invention. The surface 1 is connected via conductors 5 to earth 6 or to one pole of a voltage source 7 whose other pole is connected to earth. Thus the surface 1 will represent a cathode and the ionised gases and/or particles 8 will represent an anode. Together they will form a capacitor. In the field between the anode and the cathode an electrical field will be created and thereby an electrostatic force on the ionised gases and/or particles. The result of this is that the surface has an attractive effect, thus preventing air-borne dust.
Tests have been carried out which demonstrate that ionised exhaust gases and particles from internal combustion engines have a substantially longer suspension time over an insulating surface than over an electrically conductive surface connected to earth. In this context suspension time refers to the time required for a gas mixture to pass from the original gas composition until it is naturally converted in the ambient air or the time it takes for particles to fall to the ground.
Two closed glass boxes were filled with a specific volume of exhaust gas from an internal combustion engine with known gas and particle concentration. The volume was measured at 50 litres and the gas mixture was measured at: 18 vol %O 2 , 0.9 vol %CO 2 , 0.5 vol % CO and 350 ppm hydrocarbons and with N 2 as residue. One box was placed on an electrically conductive surface which was not supplied with a charge. One box was placed on an electrically conductive surface connected to earth. Measurements with an ion-meter showed that the gas over an insulated surface kept its original composition for a much longer time than the gas over an electrically conductive surface. The suspension time for ionised exhaust gases over the insulating surface was approximately double the length of the suspension time over an electrically conductive surface connected to earth. In this experiment no account was taken of the fact that an insulating surface will usually have a positive charge, which would have caused the suspension time for ionised gas and particles over such a surface to be considerably longer.
Measurements have been performed over different surfaces with different electrical conductivity. The conductivity has varied from a semi-conductive binding agent to a surface consisting of a conductive plate. The tests show that the suspension time of ionised gases and particles is reduced when the electrical conductivity in a surface increases. | There is described a method for controlling the amount of ionized gases and/or particles suspended in the air above roads, streets, open spaces or the like. This is done by establishing an electrical field between the top layer of a road, street, open space or the like, and the said ionized gases and/or particles. By means of controlling the electrical field we will be able to control the amount of ionized gases and/or particles. The invention also indicates how the electrical field can be established between surfaces in the immediate vicinity of a road, street, open space or the like, for example in tunnel walls. The electrical field is established by making at least the top layer of the surface concerned electrically conductive and connecting it to earth or to one pole of an electrical voltage source. | 4 |
TECHNICAL FIELD
The present invention relates to a lifting and lowering device for a toilet seat or toilet cover provided in a Western-style toilet, and a transmission unit for composing the lifting and lowering device.
BACKGROUND ART
A conventional Western-style toilet has a simple structure, in which a toilet seat and a toilet cover are pivotally supported so as to rise and fall on the top face of a rim on the back side of a toilet bowl main body. In recent years, however, a toilet seat device with a function of cleansing the bottom with warm water or a heated toilet seat device has been installed in the toilet. In such a toilet, the toilet seat and the toilet cover are pivotally supported by a container case, which is disposed in the top surface of the rim. As the container case contains electrical components and the like for operating and controlling the cleansing function with warm water and the function of heating the toilet seat, the container necessarily protrudes from the top face of the rim. As a result, the pivotally supported positions of the toilet seat and the toilet cover are higher than those of the conventional Western-style toilet.
When the pivotally supported positions of the toilet seat and the toilet cover are high, as described above, it becomes difficult to keep the toilet seat and the toilet cover in raised positions in a case where a man urinates. Thus, there is a possibility that the toilet seat and the toilet cover fall down during urination.
To prevent such inconvenience, in the toilet having the warm-water cleansing toilet seat device, a lifting and lowering control unit is fixed in the container case of the debit toilet seat device. In the lifting and lowering control unit, a torsion spring for urging the toilet seat and the toilet cover in a lifting direction is integrated into an automatic lifting and lowering device or a damper device. The automatic lifting and lowering device automatically lifts and lowers the toilet seat and the toilet cover by a user detection signal, a remote control operation, or the like. The damper device is provided to gently lower the toilet seat and the toilet cover. Such structure makes it possible to lightly lift the toilet seat and the toilet cover, and securely keeps the toilet seat and the toilet cover in a lifted state (a state in which the toilet seat and the toilet cover are raised) while preventing the toilet seat and the toilet cover from being undesirably lowered.
By the way, the scene of product development aims to efficiently produce a product group with wide variations in order to meet various market needs. Therefore, products with several variations are often developed based on, for example, one type of basic specifications in accordance with various requirements of a customer.
Accordingly, also in the automatic lifting and lowering devices and the damper devices for the warm-water cleansing toilet seat device, it is necessary to develop various devices corresponding to different self weight torque properties of a plurality of types of toilet seats and toilet covers in different product variations. Thus, in the automatic lifting and lowering device, products with many variations are developed by, for example, increasing torque of a drive motor, varying a speed reducing ratio of a gear in a drive system, or varying the specifications of the torsion spring. The damper devices are also developed in accordance with the different product variations by, for example, increasing and decreasing the capacity of a damper chamber, or varying the specifications of the torsion spring.
Thus, the types of parts increase in accordance with an increase in the product variations, so that not only huge manufacturing cost and management cost are required, but also a long period of time is needed for the manufacturing of the parts. An increase in the variations also increases assembly cost and management cost during manufacture.
In the conventional warm-water cleansing toilet seat device, the torsion spring for urging the toilet seat and the toilet cover to the lifting direction is provided in the automatic lifting and lowering device or the damper device. Thus, these devices necessarily become large due to space for attaching the torsion spring. This is one of the hindrances to the weight reduction and size reduction of the warm-water cleansing toilet seat device.
The present invention aims to solve the foregoing problems. An object of the present invention is to provide a relatively small lifting and lowering device for a toilet seat or toilet cover which can stably hold the toilet seat or toilet cover in a raised position, and achieve commonality of structural parts in accordance with the magnitude of self weight torque of the toilet seat or toilet cover, and to provide a transmission unit for composing the lifting and lowering device.
SUMMARY OF THE INVENTION
A lifting and lowering device for a toilet seat or toilet cover according to the present invention comprises a lifting and lowering control unit, and a transmission unit. The lifting and lowering control unit has an axial member disposed on a swing center line of the toilet seat or toilet cover, which is lifted and lowered pivotally about base end portions. The lifting and lowering control unit is indirectly fixed to a toilet bowl main body or the base end portion of the toilet seat. The transmission unit has a swing shaft and urging means. The swing shaft disposed on the swing center line is coupled to the axial member of the lifting and lowering control unit. The urging means urges the toilet seat or toilet cover in a lifting direction. According to this structure, the lifting and lowering control unit for carrying out the lifting and lowering operation of the toilet seat or toilet cover is separated from the transmission unit for urging the toilet seat or toilet cover in the lifting direction, so that it is possible to miniaturize the lifting and lowering device. The toilet seat or toilet cover can be stably held in a raised position. It is also possible to achieve the commonality of the structural parts in accordance with the magnitude of the self weight torque of the toilet seat or toilet cover.
The lifting and lowering control unit may be indirectly fixed on the toilet bowl main body. The transmission unit may be disposed in the base end portion of the toilet seat or toilet cover, and one end portion of the swing shaft may be detachably coupled to the axial member of the lifting and lowering control unit. According to this structure, it becomes possible to detach the transmission unit from the lifting and lowering control unit together with the toilet seat or toilet cover, so that workability in cleaning or the like is improved. It is also possible to exchange the transmission unit while leaving the lifting and lowering control unit on a toilet, so that it is possible to achieve the commonality of the structural parts in accordance with the magnitude of the self weight torque of the toilet seat or toilet cover.
If the lifting and lowering control unit has a power source for rotating the axial member, it is possible to automatize the lifting and lowering operation of the toilet seat or toilet cover, thereby making it possible to eliminate a load of a user. If the lifting and lowering control unit is a damper unit having the function of controlling the swing of the swing shaft of the transmission unit in the direction of lowering the toilet seat or toilet cover, the toilet seat or toilet cover is slowly lowered after use without using manual power. Therefore, it is possible to prevent the occurrence of noise and damage to the structural parts.
To detachably couple the lifting and lowering control unit to the transmission unit, it is preferable to provide a fitting means. The fitting means can improve the attachment and detachment workability of the transmission unit with respect to the lifting and lowering control unit, and can stabilize a coupled state.
As the fitting means, it is preferable that one of the lifting and lowering control unit and the transmission unit be provided with a protruding section, and the other be provided with a nipper section for nipping the protruding section. According to this structure, it is possible to carry out attaching/detaching operations between the lifting and lowering control unit and the transmission unit by a simple operation, that is, by fitting/detaching the protruding section into/from the nipper section, without using any tools.
Also, it is preferable that a guide face, which guides the protruding section into the fitting position of the nipper section, be provided in a part of the protruding section. In particular, the guide face makes it possible to smoothly guide the protruding section into the predetermined position of the nipper section by a slide on the guide face. Therefore, coupling workability is significantly improved, and it is possible to obtain a secure coupled state.
As coupling means between the axial member of the lifting and lowering control unit and the swing shaft of the transmission unit, on the other hand, it is preferable that one of axial end faces of the axial member and the swing shaft be provided with a protruding section, and a cutout section be formed on an axial end face of the other. The protruding section can be fitted into the cutout section. The coupling means makes it possible to attach/detach the axial member to/from the swing shaft by a simple operation, that is, by fitting the protruding section formed on the axial end face of one of the axial member and the swing shaft into the cutout section of the other of the axial member and the swing shaft, without using any tools.
In this case, a guide face that guides the protruding section into the fitting position of the cutout section may be provided in a part of the cutout section, as with above. The guide face makes it possible to smoothly guide the protruding section formed on the axial end face of one of the axial member and the swing shaft into the predetermined position of the cutout section formed on the axial end face of the other of the axial member and the swing shaft, by a slide on the guide face. Therefore, coupling workability is improved, and it is possible to obtain a secure coupled state.
Furthermore, an urging force generation mechanism that generates urging force on the swing shaft of the transmission unit by the coupling between the axial member of the lifting and lowering control unit and the swing shaft of the transmission unit may be provided. According to this structure, the urging force can be immediately generated on the swing shaft of the transmission unit by coupling the axial member of the lifting and lowering control unit to the swing shaft of the transmission unit. Accordingly, it is possible to improve the function of preventing the toilet seat or toilet cover from falling down.
Next, a transmission unit according to the present invention comprises a swing shaft, a container cylinder, and urging means. The swing shaft has coupling means coupled to an axial member of a lifting and lowering control unit, which is indirectly fixed to a toilet bowl main body or a base end portion of the toilet seat. The container cylinder rotatably contains the swing shaft. The urging means disposed in the container cylinder urges the swing shaft in a constant direction. According to this structure, a lifting and lowering device is composed of a combination of a lifting and lowering control unit that carries out the lifting and lowering operation of the toilet seat or toilet cover, and the toilet seat or toilet cover, so that it is possible to miniaturize the lifting and lowering device. When the lifting and lowering device for the toilet seat or toilet cover is structured, the toilet seat or toilet cover can be stably held in the raised position. Also, it is possible to achieve the commonality of the structural parts in accordance with the magnitude of the self weight torque of the toilet seat or toilet cover.
To keep the swing shaft in an urged state, it is preferable to provide a stopper for determining the swing start position of the swing shaft. According to this structure, when a lifting and lowering device is composed of a combination of the transmission unit, the lifting and lowering control unit, and the toilet seat or toilet cover, the urging force can be immediately generated on the swing shaft of the transmission unit, upon coupling the axial member of the lifting and lowering control unit to the swing shaft of the transmission unit. Therefore, it is possible to improve the function of preventing the toilet seat or toilet cover from falling down.
If a plurality of torsion springs are disposed in the container cylinder of the transmission unit, the urging force is changeable by selecting the torsion springs. Thus, it becomes possible to properly meet the variety of the self weight torque of the toilet seat or toilet cover. Stress applied to the torsion springs and support members for supporting the torsion springs is dispersed, so that it is also possible to increase the durability of the torsion spring and the support members.
The transmission unit may have an intermediate swing shaft and two springs. The intermediate swing shaft is contained in the container cylinder coaxially with the swing shaft. One end of one of the torsion springs is fixed to the container cylinder, and the other end thereof is fixed to the intermediate swing shaft. One end of the other torsion spring is fixed to the intermediate swing shaft, and the other end thereof is fixed to the swing shaft. According to this structure, even if enough space for disposing the springs cannot be secured, it is possible to increase the number of windings of the torsion spring inside the container cylinder. Accordingly, a spring with a relatively small spring constant is usable, and it is possible to reduce variation in torsion spring torque. Therefore, the lifting and lowering operation of the toilet seat or toilet cover becomes smooth, and it is possible to prevent the toilet seat from being incompletely lowered.
Furthermore, if water-proof means is provided to prevent water from getting into the container cylinder, it is possible to protect a metal part, such as the torsion spring contained in the container cylinder, from rust and corrosion. Therefore, reliability and durability are improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a warm-water cleansing toilet seat device, in which a lifting and lowering device for a toilet seat or toilet cover according to a first embodiment of the present invention is installed;
FIGS. 2 to 4 are explanatory views for explaining a method for detaching the toilet seat and the toilet cover from the warm-water cleansing toilet seat device shown in FIG. 1 ;
FIG. 5 is a partial perspective view showing a state in which left base end portions of the toilet seat and the toilet cover of the warm-water cleansing toilet seat device are detached from a container case;
and FIG. 6 is an explanatory view which shows a state in which right base end portions of the toilet seat and the toilet cover of the warm-water cleansing toilet seat device shown in FIG. 1 are detached from the container case.
FIG. 7 is a side view shown in a direction of an arrow Q in FIG. 6 ;
FIG. 8 is a perspective view of the right base end portion of the toilet seat detached from the container case;
FIG. 9 is a perspective view showing a state in which the toilet seat and the toilet cover detached from the container case are separated from each other;
FIGS. 10 to 11 are perspective views which show the left base end portion of the toilet seat detached from the container case;
FIGS. 12 and 13 are perspective views which show the right base end portion of the toilet seat detached from the container case;
FIG. 14 is a perspective view which shows the left base end portion of the toilet cover detached from the container case; and
FIG. 15 is a perspective view which shows the right base end portion of the toilet cover detached from the container case.
FIG. 16 is a longitudinal sectional view of a section which is indicated by an arrow P in FIG. 1 ;
FIG. 17 is an exploded sectional view which shows the vicinity of a toilet seat transmission unit;
FIG. 18( a ) is an exploded perspective view of the toilet seat transmission unit; and FIG. 18( b ) is a view shown in a direction of an arrow R in FIG. 18( a ).
FIG. 19 is a graph showing the relation between a “toilet seat swing angle” and “toilet seat self weight torque” in two types of toilet seat devices (product A and product B) with different toilet seat self weight torque;
FIG. 20 is a graph showing the relation between the “toilet seat swing angle” and “spring torque” of the toilet seat transmission unit in each of the products A and B; and
FIG. 21 is a graph showing the relation between the “toilet seat swing angle” and “composite torque” of the self weight torque of the toilet seat and the spring torque of the toilet seat transmission unit in each of the products A and B.
FIG. 22 is a conceptional view showing combinations of a single lifting and lowering control unit or damper unit, a plurality of transmission units, and a plurality of types of toilet seats (toilet covers).
FIG. 23 is a sectional view of a transmission unit according to a second embodiment of the present invention.
FIG. 24 is a sectional view of a transmission unit according to a third embodiment of the present invention.
FIG. 25 is a sectional view showing a state in which a damper unit is disposed in the lifting and lowering device for the toilet seat or toilet cover shown in FIG. 16 , instead of the lifting and lowering control unit; and
FIG. 26 is a partly omitted sectional view taken along the line Y-Y in FIG. 25 .
FIG. 27 is a schematic view showing a state in which a toilet seat transmission unit in right base end portions of the toilet seat and the toilet cover is engaged with the lifting and lowering control unit;
FIG. 28 is an explanatory view which schematically shows the procedure of engaging the toilet seat transmission unit with the lifting and lowering control unit; and
FIGS. 29 and 30 are sectional views showing a state in which the toilet seat transmission unit is engaged with the lifting and lowering control unit.
DETAILED DESCRIPTION OF THE INVENTION
A first embodiment of the present invention will be described on the basis of FIGS. 1 to 22 .
Referring to FIG. 1 , a warm-water cleansing toilet seat device 1 is attached to a toilet bowl main body 30 , in such a manner that a container case 2 for composing the device 1 is fixed on the top face of a rim 30 a on the back side of the toilet bowl main body 30 . A toilet seat 3 and a toilet cover 4 are attached to the container case 2 rotatably with respect to base end portions 3 l , 3 r , 4 l , and 4 r , respectively. The base end portions 3 l , 3 r , 4 l , and 4 r of the toilet seat 3 and the toilet cover 4 can be separated from the container case 2 by a mechanism, which will be described later.
When the toilet cover 4 and the toilet seat 3 are in a lifted state (raised state), as shown in FIG. 2 , a lever section 36 of a first engagement member 32 and a cord 71 are visible between the base end portion 3 r on the left side of the toilet seat 3 and the container case 2 . A lever section 65 of a lock section 62 is visible between the base end portion 3 l on the right side of the toilet seat 3 and the container case 2 .
Referring to FIG. 3 , the right and left lever sections 36 and 65 are moved upward as shown by arrows, to make an opening of the first engagement member 32 and an opening of a second engagement member 33 into an open state, respectively.
Then, as shown in FIG. 4 , the toilet seat 3 and the toilet cover 4 are lifted upward above the container case 2 while holding the vicinities of the right and left base end portions 3 l , 4 l , 3 r , and 4 r of the toilet seat 3 and the toilet cover 4 with right and left hands, respectively. Then, the first engagement member 32 is detached from a first swing shaft 16 with the base end portions 3 r and 4 r on the left side. The second engagement member 33 and a toilet seat transmission unit 9 are detached from a second swing shaft 17 with the base end portions 3 l and 4 l on the right side. Therefore, as shown in FIG. 5 , the first swing shaft 16 , a cap 45 , and the cord 71 appear on the side of the container case 2 . In the right base end portions 3 l and 4 l of the toilet seat 3 and the toilet cover 4 , the toilet seat transmission unit 9 and the second engagement member 33 become visible. On the right side of the container case 2 , as shown in FIG. 7 , a protruding section 15 a of a second lifting and lowering control unit 15 , which is contained in the container case 2 , and the swing shaft 17 appear.
Then, as shown in FIG. 8 , the toilet seat transmission unit 9 is slid to the center of the right base end portion 3 l of the toilet seat 3 in the direction of the center of an axis, by use of a rib 54 of the toilet seat transmission unit 9 . The rib 54 is exposed from a cutout section 55 in the right base end portion 3 l of the toilet seat 3 . Thus, an end portion of an output shaft 12 of the toilet seat transmission unit 9 can be pulled out of a collar section 29 of the right base end portion 4 l of the toilet cover 4 , which is shown in FIG. 15 described later.
Accordingly, an insertion section 25 (refer to FIG. 8 ) provided on the right base end portion 3 l of the toilet seat 3 is detached from a fitting section 27 (refer to FIG. 15 ) provided in the right base end portion 4 l of the toilet cover 4 . Then, an insertion section 44 (refer to FIG. 11 ) provided on the left base end portion 3 r of the toilet seat 3 is pulled out of a fitting section 26 (refer to FIG. 14 ) provided in the left base end portion 4 r of the toilet cover 4 . Therefore, as shown in FIG. 9 , the toilet seat 3 and the toilet cover 4 that are detached from the container case 2 are separated from each other.
Referring to FIGS. 10 and 11 , the substantially C-shaped insertion section 44 , being a first swing shaft for the toilet cover, is formed in the left base end portion 3 r of the toilet seat 3 . Referring to FIGS. 12 and 13 , the substantially round shaped insertion section 25 , recessed sections 60 , and a fixing hole 61 a are formed in the right base end portion 3 l of the toilet seat 3 . The insertion section 25 functions as a second swing shaft for the toilet cover. Protruding sections 58 of a retaining section 56 , which will be described later, are fitted into the recessed sections 60 . The insertion sections 44 and 25 protrude outward in the directions of the center of an axis of the base end portions 3 r and 3 l of the toilet seat 3 , respectively.
Referring to FIG. 14 , the substantially C-shaped fitting section 26 , having a predetermined depth, is formed in the left base end portion 4 r of the toilet cover 4 . Referring to FIG. 15 , the fitting section 27 , the outside shape of which is half round and the depth of which is predetermined, is formed in the right base end portion 4 l of the toilet cover 4 . The fitting sections 26 and 27 protrude inward in the directions of the center of an axis of the base end portions 4 r and 4 l of the toilet cover 4 , respectively.
Each of the fitting sections 26 and 27 has such a depth that the insertion sections 44 and 25 in the base end portions 3 r and 3 l of the toilet seat 3 , respectively, and the fitting sections 26 and 27 provided inside the base end portions 4 r and 4 l of the toilet cover 4 , respectively, are not misaligned, when the insertion sections 44 and 25 are rotatably fitted into the fitting sections 26 and 27 , respectively. Here, the center of an axis of the base end portions 4 l and 4 r of the toilet cover 4 is the same as that of the base end portions 3 l and 3 r of the toilet seat 3 .
The collar section 28 , which is open substantially in the shape of U, is fixed inside the left fitting section 26 of the toilet cover 4 , in such a manner that the opening position of the collar section 28 is aligned with the opening position of the fitting section 26 . The collar section 28 is engageable with an end portion of the first swing shaft 16 . A collar section 29 , which is open substantially in a round shape, is fixed inside the right fitting section 27 , so that the rotation of the second swing shaft 17 is not transmitted to the toilet cover 4 .
The left insertion section 44 of the toilet seat 3 is fitted into the left fitting section 26 of the toilet cover 4 , and then the right insertion section 25 of the toilet seat 3 is fitted into the right fitting section 27 of the toilet cover 4 to rotatably fix the right insertion section 25 . Thus, the toilet cover 4 and the toilet seat 3 are integrated with each other, and can be swung separately. On the left side, the opening position of the insertion section 44 and that of the fitting section 26 are overlapped with each other, when the toilet cover 4 and the toilet seat 3 are integrated. Accordingly, it is possible to integrally attach/detach the toilet cover 4 and the toilet seat 3 to/from the first swing shaft 16 through the opening positions.
The right base end portion 3 l of the toilet seat 3 shown in FIG. 12 , on the other hand, has a swing block insertion section 3 a , into which a toilet seat transmission unit 9 is inserted movable in an axial direction as shown in FIG. 6 . The toilet seat transmission unit 9 engages with the base end portion 3 l of the toilet seat 3 , and urges the toilet seat 3 to a lifted side (raised direction).
FIG. 16 is a longitudinal sectional view of a section which is indicated by an arrow P in FIG. 1 , and FIG. 17 is an exploded sectional view which shows the vicinity of the toilet seat transmission unit. Referring to FIGS. 16 and 17 , a lifting and lowering device 31 according to this embodiment comprises the lifting and lowering control unit 15 , and the toilet seat transmission unit 9 . The lifting and lowering control unit 15 has the swing shaft 17 (an axial member), and is indirectly fixed on the toilet bowl main body 30 . The swing shaft 17 is disposed on the swing center line C of the toilet seat 3 and the toilet cover 4 , which are lifted and lowered with respect to the base end portions 3 l and 4 l , respectively. The toilet seat transmission unit 9 contains an output shaft 12 (a swing shaft) and a torsion spring 13 . The output shaft 12 is disposed on the swing center line C. One end of the output shaft 12 is detachably connected to the swing shaft 17 of the lifting and lowering control unit 15 , and the other end thereof is detachably connected to the base end portion 3 l of the toilet seat 3 . The torsion spring 13 urges the output shaft 12 to the lifting direction of the toilet seat 3 .
As described above, the container case 2 is attached to the toilet bowl main body 30 by being fixed on the top face of the rim 30 a on the back side of the toilet bowl main body 30 . In the container case 2 , the lifting and lowering control unit 15 is fixed. Therefore, the lifting and lowering control unit 15 is indirectly fixed on the toilet bowl main body 30 through the container case 2 .
Referring to FIG. 16 , a base end portion of the toilet seat transmission unit 9 is coupled to the swing shaft 17 and the protruding section 15 a of the lifting and lowering control unit 15 , protruding from the container case 2 . The base end portion 3 l of the toilet seat 3 is fixed to the output shaft 12 of the toilet seat transmission unit 9 , and the base end portion 4 l of the toilet cover 4 is rotatably supported by the output shaft 12 .
The lifting and lowering control unit 15 may include a motor with a speed reducer, such that the motor lifts and lowers, or only lifts the toilet seat 3 by an electric operation. The lifting and lowering control unit 15 may include a soft lowering mechanism (an example of a damper mechanism), which regulates the speed of the toilet seat 3 lowered from a lifted state to a lowered state into a gentle speed. The lifting and lowering control unit 15 may include a combination of the motor with the speed reducer and the soft lowering mechanism. The motor with the speed reducer has a drive motor (for example, a DC brush motor, an AC motor, a stepping motor, or the like), a transmission gear, a planetary gear mechanism, a torque limiter mechanism, an angle detection sensor, and the like.
The lifting and lowering control unit 15 has the swing shaft 17 protruding from a case 22 . The case 22 contains a drive motor 46 , which is a DC brush motor, a transmission gear 18 , a planetary gear mechanism 19 , a torque limiter mechanism 20 , and an angle detection sensor 21 . The transmission gear 18 and the planetary gear mechanism 19 transmit the rotation of the drive motor 46 while successively reducing its speed. The torque limiter mechanism 20 prevents the application of an excessive load to the drive motor 46 . The angle detection sensor 21 detects the turning angle of the swing shaft 17 .
In the lifting and lowering control unit 15 , the transmission gear 18 decelerates the rotation of the drive motor 46 . Its torque is transmitted to the planetary gear mechanism 19 in the last stage, and is transmitted to the swing shaft 17 through the torque limiter mechanism 20 . After the torque of the swing shaft 17 of the lifting and lowering control unit 15 is transmitted to the output shaft 12 of the toilet seat transmission unit 9 , the torque is transmitted to the base end portion 3 l of the toilet seat 3 . Thus, the toilet seat 3 is lifted or lowered pivotally about the base end portion 3 l to open or close the top face of the rim 30 a of the toilet bowl main body 30 . In the course of this process, the toilet seat 3 is always urged in the lifting direction by the twisting force of the torsion spring 13 , which is contained in the toilet seat transmission unit 9 .
In the lifting and lowering control unit 15 , the angle detection sensor 21 comprising a magnet and a Hall IC detects the turning angle of the swing shaft 17 to detect the lifting angle of the toilet seat 3 . This detection signal is fed back to control the rotation of the drive motor 16 , so that it is possible to realize the gentle lifting and lowering operation of the toilet seat 3 . A turning direction may be detected by a two-phase output encoder having a slit and a photo interrupter, or determined by angle information from a potentiometer, instead of the multi-pole magnet and the Hall IC provided in the swing shaft 17 . The soft lowering mechanism using the viscosity of oil exercises a damping force by the function of a valve.
Referring to FIGS. 17 and 18 , the structure and function of the toilet seat transmission unit 9 will be described in detail. FIG. 17 is an exploded sectional view which shows the vicinity of the toilet seat transmission unit. FIG. 18 is an exploded perspective view which shows the vicinity of the toilet seat transmission unit.
As shown in FIGS. 17 and 18 , the toilet seat transmission unit 9 comprises a container cylinder 11 , the output shaft 12 , the torsion spring 13 (coil spring), and a container cover 14 . Functional parts are contained in the container cylinder 11 . The output shaft 12 is rotatably disposed in the container cylinder 11 . The torsion spring 13 is disposed in the container cylinder 11 in such a manner as to surround the swing shaft 12 . The container cover 14 closes an opening section of the container cylinder 11 .
Since one end of the torsion spring 13 is inserted into an attachment hole 11 e formed inside the container cylinder 11 , the torsion spring 13 is fitted in the container cylinder 11 in such a state as to urge the toilet seat 3 in the lifting direction. Since the other end of the torsion spring 13 is inserted into an attachment hole 12 c formed in the outer periphery of the output shaft 12 , the torsion spring 13 is fixed on the swing shaft 12 . An O-ring 53 is disposed in each of a sliding section between the container cylinder 11 and the output shaft 12 , and a sliding section between the output shaft 12 and the container cover 14 , in order to prevent moisture from getting into space formed by the container cylinder 11 and the output shaft 12 . The torsion spring 13 has enough urging force to maintain the toilet seat 3 in the lowered state.
The rib 54 is formed on the periphery of the container cylinder 11 of the toilet seat transmission unit 9 . The cutout section 55 is formed in a part of the right base end portion 3 l of the toilet seat 3 , into which the toilet seat transmission unit 9 is rotatably fitted, so that the rib 54 is always exposed from the cutout section 55 , as shown in FIGS. 8 and 12 .
Referring to FIG. 18( b ), a U-shaped cutout 12 b , the width of which is magnified toward an opening section, is formed on the left side of the output shaft 12 of the toilet seat transmission unit 9 (a section connected to the lifting and lowering control unit 15 ). The cutout 12 b can be fitted over the swing shaft 17 of the lifting and lowering control unit 15 from above, in the following procedure. Accordingly, the output shaft 12 is fixed unrotatably with respect to the swing shaft 17 of the lifting and lowering control unit 15 .
A right side of the output shaft 12 (a section connected to the toilet seat 3 ), on the other hand, protrudes from the container cover 14 . A base portion of the output shaft 12 is round in cross section, and a distal end portion thereof is in the shape of serrations in cross section. Since the end portion having the serration cross section has a round outer shape, it is rotatably fitted into the collar section 29 of the base end portion 4 l of the toilet cover 4 . A part of the teeth of the serrations is formed into a different shape, or the width of part of the teeth is widened, to align the retaining section 56 , which will be described later, in fitting the retaining section 56 .
Referring to FIG. 18( a ), the retaining section 56 is substantially in an L-shape. The retaining section 56 has a guide on which the toilet seat transmission unit 9 is mounted to be slidable. A through hole 57 is provided in one part of the retaining section 56 , and is engaged with the output shaft 12 of the toilet seat transmission unit 9 . Eight protruding sections 58 are formed at equiangular positions on the outer periphery of the retaining section 56 to be engaged with the toilet seat 3 .
The through hole 57 is in the shape of the serrations in cross section, as with the distal end portion of the output shaft 12 fitted therein. A part of the teeth of the serrations is formed into a different shape, or the width of part of the teeth is widened for alignment. A stopper section 59 is provided in the middle of the other part of the retaining section 56 . The stopper section 59 can make contact with the rib 54 , when the toilet seat transmission unit 9 is slid in the direction of the center of the axis of the base end portion 3 l of the toilet seat 3 . As shown in FIG. 12 , the recessed sections 60 are formed in the inner wall of the right base end portion 3 l of the toilet seat 3 , so that each of the protruding sections 58 of the retaining section 56 is fitted into each of the recessed sections 60 .
The procedure of fixing the toilet seat transmission unit 9 on the right base end portion 3 l of the toilet seat 3 will be described. As shown in FIG. 18( a ), the engagement member 33 is fitted over an external cylinder section 11 a of the toilet seat transmission unit 9 . The internal diameter of the external cylinder section 11 a is slightly larger than that of a ring section 33 a of the engagement member 33 . Thus, when the ring section 33 a surmounts the external cylinder section 11 a and is fitted over a small diameter section 11 b , the toilet seat transmission unit 9 and the engagement member 33 are integrated. The ring section 33 a and the external cylinder section 11 a prevent the engagement member 33 from being dropped in the direction of the center of the axis.
Then, the output shaft 12 of the toilet seat transmission unit 9 is engaged with the through hole 57 of the retaining section 56 . The protruding sections 58 of the retaining section 56 are fitted into the recessed sections 60 formed in the right base end portion 3 l of the toilet seat 3 . Then, a fixing hole 61 formed in a pole of the retaining section 56 is overlapped with a fixing hole 61 a formed in the base end portion 3 l , and a self-tapping screw is screwed in these holes to fasten. Thus, the toilet seat transmission unit 9 is disposed inside of the right base end portion 3 l of the toilet seat 3 . Accordingly, the toilet seat transmission unit 9 is slidable in the direction of the center of the axis of the base end portion 3 l of the toilet seat 3 , and the toilet seat transmission unit 9 is prevented from falling off the right base end portion 3 l of the toilet seat 3 .
Since the retaining section 56 is elastically deformable outward before being fixed on the base end portion 3 l of the toilet seat 3 , the toilet seat transmission unit 9 is detachable from the retaining section 56 . After the retaining section 56 is fixed on the base end portion 3 l of the toilet seat 3 , the base end portion 3 l of the toilet seat 3 restrains the outward deformation of the retaining section 56 . Therefore, the toilet seat transmission unit 9 is prevented from falling off in a thrust direction. A clearance between the retaining section 56 and the external cylinder section 11 a is narrow, and hence the engagement section 33 cannot be deformed to the extent of surmounting the external cylinder section 11 a . Therefore, it is also possible to prevent the engagement section 33 from falling off in the direction of the center of the axis, in a like manner.
The toilet seat transmission unit 9 is disposed between the lifting and lowering control unit 15 and the base end portion 3 l of the toilet seat 3 , as described above. Thus, the toilet seat 3 is urged in the lifting direction by the torsion spring 13 contained in the toilet seat transmission unit 9 through the swing shaft 12 .
Accordingly, when the toilet seat 3 and the toilet cover 4 are lifted up in a case where a man urinates, the toilet seat 3 and the toilet cover 4 can be stably held in the raised positions, without undesirably falling during urination. When the toilet seat 3 is lowered to the horizontal state, the self weight torque of the toilet seat 3 becomes larger than the urging force of the torsion spring 13 . Therefore, the toilet seat 3 is not lifted up from the toilet bowl main body 30 .
FIG. 19 is a graph showing the relation between a “toilet seat swing angle” and “toilet seat self weight torque” in two types of toilet seat devices (product A and product B), which have different toilet seat self weight torque. FIG. 20 is a graph showing the relation between the “toilet seat swing angle” and “spring torque” of the toilet seat transmission unit in each of the products A and B. FIG. 21 is a graph showing the relation between the “toilet seat swing angle” and “composite torque” in each of the products A and B. The “composite torque” refers to a composition of the toilet seat self weight torque and the spring torque of the toilet seat transmission unit.
Referring to FIG. 19 , the “toilet seat self weight torque” of the product A is larger than the “toilet seat self weight torque” of the product B over the whole range of the “toilet seat swing angle.” In such products A and B, suppose the case where toilet seat transmission units with torsion springs having different torque characteristics, as shown in FIG. 20 , are used. In this case, when torque for urging the toilet seat in the lifting direction is applied to the products A and B, the “composite torque” (composite torque of the toilet seat self weight torque and the spring torque of the toilet seat transmission unit) becomes almost equal between the products A and B, as shown in FIG. 21 .
Accordingly, a plurality of types of toilet seat transmission units, which contains a torsion spring with different torque characteristics, are prepared in advance. Of such a toilet seat transmission unit group, an appropriate toilet seat transmission unit is selected and mounted in accordance with a difference in toilet seat self weight torque in various product variations. Thus, it is possible to provide almost the same “composite torque” composed of “toilet seat self weight torque” and “spring torque” of the toilet seat transmission unit, even if the toilet seat self weight torque differs from one product to another.
As described above, the toilet seat transmission unit containing the torsion spring having the torque characteristics appropriate to each toilet seat is selected and used. Thus, it is possible to provide almost the same “composite torque” composed of “toilet seat self weight torque” and “spring torque” of the toilet seat transmission unit, even if the toilet seat self weight torque differs in accordance with the types of the toilet seats. Therefore, for composing the lifting and lowering unit 31 , one type of the lifting and lowering control unit 15 or one type of damper device is available in all products, so that it is possible to achieve commonality of structural parts. The torque characteristics of the torsion spring 13 contained in the toilet seat transmission unit 9 are changeable by adjusting a spring constant. To adjust the spring constant, the diameter of a wire of the torsion spring 13 , the diameter of the center thereof, the number of winding, or the like is changed. Therefore, it is relatively easy to prepare the plurality of types of toilet seat transmission units.
Taking a case where, as shown in FIG. 22 , there are four types of toilet seats (toilet covers) with different shapes and sizes, for example, four types of transmission units 1 to 4 are prepared in accordance with self weight torque different from one toilet seat (toilet cover) to another. In this case, four types of lifting and lowering devices can be composed of a combination of the one type of lifting and lowering control unit (or damper unit) and one of the four types of transmission units 1 to 4 . Thus, the one type of lifting and lowering control unit (or damper unit) is applicable to the four types of toilet seats (toilet covers). In other words, it is possible to achieve commonality of the lifting and lowering control unit (or the damper unit), and hence the manufacturing cost and management cost of the lifting and lowering device are reduced.
In this embodiment, the toilet seat transmission unit 9 is inserted into the swing block insertion section 3 a of the base end portion 3 l of the toilet seat 3 . Thus, it is unnecessary to provide space for disposing the toilet seat transmission unit 9 within the lifting and lowering control unit 15 or the like, and hence it is possible to miniaturize a warm-water cleansing toilet seat device 1 . In FIG. 16 showing the first embodiment, the toilet seat transmission unit 9 is provided only for the toilet seat 3 , but a toilet cover transmission unit may be used in the toilet cover 4 . In such a case, the toilet cover transmission unit is contained in space inside of the left base end portion 3 r of the toilet seat 3 .
Next, a transmission unit according to a second embodiment of the present invention will be described with reference to FIG. 23 . The same reference numbers refer to parts which have the same function and effect as those of the structural parts of the foregoing toilet seat transmission unit 9 .
A toilet seat transmission unit 29 according to this embodiment comprises a container cylinder 11 , a swing shaft 12 , torsion springs 13 a and 13 b , and a container cover 14 . One end of the torsion spring 13 a is inserted into an attachment hole 11 c , so that the torsion spring 13 a is fixed to the container cylinder 11 . The other end of the torsion spring 13 a is inserted into an attachment hole 12 e , so that the torsion spring 13 a is fixed to the swing shaft 12 . One end of the torsion spring 13 b is inserted into an attachment hole 11 d , so that the torsion spring 13 b is fixed to the container cylinder 11 . The other end of the torsion spring 13 b is inserted into an attachment hole 12 d , so that the torsion spring 13 b is fixed to the swing shaft 12 .
In the toilet seat transmission unit 29 , one end of each of a plurality of torsion springs 13 a and 13 b contained in the container cylinder 11 is fixed to the swing shaft 12 , and the other end is fixed to the container cylinder 11 . Thus, the amount of twist torque for urging the swing shaft 12 in the lifting direction of the toilet seat is larger than that in the case of the toilet seat transmission unit 9 . Therefore, the toilet seat transmission unit 29 is appropriate as a structural part of a lifting and lowering mechanism for a toilet seat that has larger self weight torque than the foregoing toilet seat 3 .
By changing the number of the torsion springs contained in the toilet seat transmission unit, as described above, the present invention is applicable to the self weight torque characteristics of the toilet seat or a toilet cover in further various product variations. Since the toilet seat transmission unit 29 contains the plurality of torsion springs 13 a and 13 b , it is possible to reduce a load per single torsion spring. Furthermore, both ends of the torsion springs 13 a and 13 b are fixed at a plurality of points, so that it is possible to disperse occurring stress to the attachment holes 11 c , 11 d , 12 d , and 12 e . Therefore, the container cylinder 11 and the swing shaft 12 can be made of a resin, and hence it is possible to promote reduction in manufacturing cost and weight.
Next, a transmission unit according to a third embodiment of the present invention will be described with reference to FIG. 24 . The same reference numbers refer to parts which have the same function and effect as those of the structural parts of the foregoing toilet seat transmission unit 9 .
A toilet seat transmission unit 39 according to this embodiment comprises a container cylinder 11 , a swing shaft 12 , torsion springs 13 c and 13 d , an intermediate swing shaft 23 , and a container cover 14 . One end of the torsion spring 13 c is inserted into an attachment hole 11 c , so that the torsion spring 13 c is fixed to the container cylinder 11 . The other end of the torsion spring 13 c is inserted into an attachment hole 23 a , so that the torsion spring 13 c is fixed to the intermediate swing shaft 23 . One end of the torsion spring 13 d is inserted into an attachment hole 23 b , so that the torsion spring 13 d is fixed to the intermediate swing shaft 23 . The other end of the torsion spring 13 d is inserted into an attachment hole 12 f , so that the torsion spring 13 d is fixed to the swing shaft 12 .
Of a plurality of torsion springs 13 c and 13 d , as described above, the one end of the one torsion spring 13 d is fixed to the swing shaft 12 , and the other end is fixed to the intermediate swing shaft 23 . Also, the one end of the other torsion spring 13 c is fixed to the intermediate swing shaft 23 , and the other end is fixed to the container cylinder 11 . Accordingly, even if there is not enough space for containing the torsion springs, it is possible to obtain relatively strong torsion force by coupling a plurality of torsion springs through the intermediate swing shaft 23 . Therefore, it is possible to properly set the torque of the torsion springs, which urge a toilet seat or toilet cover in a lifting direction, in accordance with the self weight torque characteristics of the toilet seat or toilet cover in various product variations.
As shown in FIGS. 23 and 24 , O-rings 27 a and 27 b are provided in sliding sections between the container cylinder 11 and the swing shaft 12 , and between the container cover 14 and the swing shaft 12 , so that water, cleaning solution, or the like does not enter the transmission unit 29 , 39 . Therefore, since the toilet seat 3 or the toilet cover 4 is immersible for cleaning, the torsion spring 13 does not corrode by the cleaning, and hence reliability and durability are improved.
Furthermore, even when space for the swing block insertion section 3 a in the base end portion 3 l of the toilet seat 3 cannot be sufficiently secured, it is possible to increase the number of winding of the torsion spring inside the container cylinder 11 . Accordingly, a spring constant can be reduced, and it is possible to reduce variation in torsion spring torque within the range of a toilet seat swing angle. Therefore, the lifting and lowering operation of the toilet seat becomes smooth, and it is possible to prevent the toilet seat from being incompletely leveled.
In the foregoing embodiments, the lifting and lowering control unit 15 is disposed in the container case 2 as a lifting and lowering control unit. A damper unit (the so-called gentle lowering mechanism) which has the function of making the lowering operation of the toilet seat 3 gentle may be disposed instead of the lifting and lowering control unit 15 . By use of the transmission unit 9 , as described above, the same lifting and lowering control unit is applicable to a plurality of types of toilet seats and toilet covers with different sizes and shapes, so that it is possible to achieve commonality of parts.
Next, referring to FIGS. 25 and 26 , a case where a damper unit is provided instead of the lifting and lowering control unit 15 will be described. In a damper unit 49 , two blades 12 w are provided on the outer periphery of a swing shaft 12 at an interval of 180 degrees, and two partition walls 24 c are provided on the inner periphery of a container cylinder 24 at an interval of 180 degrees. The container cylinder 24 is charged with viscous oil such as silicon oil. When the blades 12 w of the damper unit 49 rotate in the direction of an arrow R, the oil smoothly flows from an oil containing chamber 24 a into an oil containing chamber 24 b through clearance between the blade 12 w and the inner periphery of the container cylinder 24 . When the blades 12 w of the damper unit 49 rotate in the direction of an arrow L, the oil flows from the oil containing chamber 24 b into the oil containing chamber 24 a little by little.
Then, a method for reinstalling the base end portions 3 l , 4 l , 3 r , and 4 r of the toilet seat 3 and the toilet cover 4 , which were detached from the container case 2 by a procedure shown in FIGS. 2 to 4 in the foregoing first embodiment, in the container case 2 will be described.
First, the insertion section 44 provided in the left base end portion 3 r of the toilet seat 3 is fitted into the fitting section 26 provided in the left base end portion 4 r of the toilet cover 4 . Then, the insertion section 25 provided in the right base end portion 3 l of the toilet seat 3 is fitted into the fitting section 27 provided in the right base end portion 4 l of the toilet cover 4 . Thus, the base end portions 4 l and 4 r of the toilet cover 4 are coaxially aligned with the base end portions 3 l and 3 r of the toilet seat 3 . The engagement member 33 is slid along the retaining section 56 to an end of the base end portion 3 l of the toilet seat 3 in the direction of the center of the axis, by use of the rib 54 of the toilet seat transmission unit 9 exposed from the cutout section 55 . An end of the output shaft 12 of the toilet seat transmission unit 9 is fitted into the collar section 29 of the toilet cover 4 , to integrate the toilet cover 4 and the toilet seat 3 in such a manner as to be separately rotatable.
The overlapped toilet cover 4 and the toilet seat 3 are lowered downward from an area above the container case 2 , and the first swing shaft 16 and the second swing shaft 17 are fitted into the openings of the engagement members 32 and 33 , respectively. At this time, since the first engagement member 32 is rotatable, an inclined section 34 b of a main body 34 of the first engagement member 32 guides the swing shaft 16 into the center of the axis, in fitting the swing shaft 16 .
Next, a method for reinstalling the base end portions 3 l and 4 l of the toilet seat 3 and toilet cover 4 in the container case 2 will be described with reference to FIGS. 27 to 30 . Referring to FIG. 27 , in the toilet seat transmission unit 9 , guide faces 11 g of a pair of nipper sections 11 x are oppositely disposed in parallel with each other. In a state where the transmission unit 9 is detached from the container case 2 , the parallel direction of the guide faces 11 g is not in parallel with the longitudinal direction 121 of the cutout section 12 b of the swing shaft 12 . The parallel direction of the guide faces 11 g and the longitudinal direction 121 of the cutout section 12 b are displaced approximately 25 to 35 degrees with respect to each other. This aims to maintain the twist torque, which is applied to the swing shaft 12 by the torsion spring contained in the container cylinder 11 , at a constant value or more, even in a state where the transmission unit 9 is detached from the container case 2 .
Accordingly, when the end portion 17 a of the swing shaft 17 of the lifting and lowering control unit is engaged and coupled with the cutout section 12 b of the output shaft 12 , as shown in FIGS. 29 and 30 , the parallel direction of the guide faces 11 g becomes in parallel with the longitudinal direction 121 of the cutout section 12 b of the output shaft 12 . Therefore, the twist torque applied to the swing shaft 12 is applied to the base end portion 3 l of the toilet seat 3 , and hence the toilet seat 3 is urged in the lifting direction.
First, as shown in FIG. 28( a ), the toilet seat transmission unit 9 in an unlocked state is gradually pressed down to the protruding section 15 a protruding from the container case 2 and the end portion 17 a of the swing shaft 17 , while the cutout section 33 b of the engagement member 33 is pointed downward. Then, the lower end portion of one of the nipper sections 11 x makes contact with a guide slope 15 b of the protruding section 15 a as shown in FIG. 28( b ).
When the base end portions 3 l and 4 l are continuously pressed downward, the nipper section 11 x moves downward along the guide slope 15 b . The nipper sections 11 x rotate in a counterclockwise direction as shown in FIG. 28( c ), so that the parallel direction of the guide faces 11 g of the nipper sections 11 x corresponds with the direction of the protruding section 15 a , and the protruding section 15 a is fitted between the pair of the nipper sections 11 x as shown in FIG. 28( d ), thus comprising a fitting portion. The protruding section 15 a is finally brought into a state shown in FIG. 28( e ). The nipper sections 11 x nip the protruding section 15 a , and the container cylinder 11 is fixed in the container case 2 . At the same time, the coupling between the end portion 17 a of the swing shaft 17 and the cutout section 12 b of the output shaft 12 is completed.
At this time, guide faces 12 g , which are formed in the opening section of the cutout section 12 b of the output shaft 12 in such a manner as to magnify the width of the cutout section 12 b , guide the end portion 17 a of the swing shaft 17 . Therefore, it is possible to securely fit the end portion 17 a into the cutout section 12 b.
According to the steps described above, the base end portions 3 l and 4 l of the toilet seat 3 and toilet cover 4 are coupled to the protruding section 15 a and the swing shaft 17 of the lifting and lowering control unit through the toilet seat transmission unit 9 . After that, the lever section 65 of the engagement member 33 is manually operated to rotate the whole engagement member 33 in the toilet cover lowering direction. Then, the cutout section 33 b of the engagement section 33 moves to a back side as shown in FIG. 30 , and the toilet seat transmission unit 9 is brought into a locked state. Therefore, the toilet seat transmission unit 9 cannot be detached upward from the protruding section 15 a of the container case 2 , and attachment is completed.
Accordingly, when the toilet seat 3 and the toilet cover 4 are completely coupled to the container case 2 through the transmission unit 9 , the toilet seat 3 is urged in the lifting direction. Therefore, the toilet seat 3 and the toilet cover 4 do not undesirably fall down, if the toilet seat 3 and the toilet cover 4 are lifted up when a man urinates.
Since the engagement member 33 is lock means to the container case 2 , it is possible to unlock the lock means when cleaning the toilet or the like by rotating the lever section 65 of the engagement member 33 . By carrying out the above-described procedure in reverse, the toilet seat 3 and the toilet cover 4 are detached from the container case 2 . Therefore, it is possible to easily clean the toilet, and workability is improved.
INDUSTRIAL APPLICABILITY
As described above, the lifting and lowering device for the toilet seat or toilet cover, and the transmission unit for the lifting and lowering device according to the present invention are available as a lifting and lowering mechanism for a toilet seat or toilet cover in a warm-water cleansing toilet seat device, a heated toilet seat device, or the like installed in a Western-style toilet. | A lifting and lowering device ( 31 ) for a toilet seat or a toilet cover has a swing shaft ( 17 ) provided on a swing center line (C) of a toilet seat ( 3 ) or a toilet cover ( 4 ) that swings around base end portions ( 3 l, 4 l ), respectively, and rises. The device includes a lifting and lowering control unit ( 5 ) indirectly fixed to a toilet bowl main body ( 30 ); an output shaft ( 12 ) that is provided on the swing center line (C), one end portion of which shaft being removably connected to the swing shaft ( 17 ) of the lifting and lowering control unit ( 5 ) and the other end portion being detacheably connected to the base end portion ( 3 l ) of the toilet seat ( 3 ); and a toilet seat transmission unit ( 9 ) containing a tortion spring ( 13 ) that urges the output shaft ( 12 ) in a lifting direction of the toilet seat ( 3 ). The lifting and lowering device ( 31 ) for the toilet seat of toilet cover is relatively small in size and able to stabely hold the toilet seat or toilet cover in a raised position. Commonality of structural parts can be achieved depending on the magunitude of torque caused by the self weight of the toilet seat or toilet cover. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 12/776,132 filed on May 7, 2010 and entitled METHODS AND SYSTEMS FOR PLASMA DEPOSITION AND TREATMENT, which claims priority from U.S. Provisional Patent Application No. 61/176,715 filed on May 8, 2009 and entitled METHODS AND SYSTEMS FOR PLASMA DEPOSITION AND TREATMENT, both of which applications are incorporated by reference herein.
BACKGROUND
The present invention generally relates to methods and systems for deposition of materials on substrates using plasmas and the treatment of objects using microwave radiation and plasma.
Deposition technologies include physical vapor deposition (PVD), chemical vapor deposition (CVD) (either at atmospheric pressure (APCVD) or reduced pressure (LPCVD)), electroplating, evaporation, thermal flame spray, and thermal plasma spray. Many of these deposition technologies are used for the manufacture of materials layers such as semiconductors, carbon-nanotubes, industrial coatings, biomedical coatings, and the like. Oftentimes a balance has to be struck between technical concerns such as layer adhesion, contamination from undesirable elements, deposition rates, and uniformity (both on a global and on a microscopic scale), and commercial concerns such as the cost of performing such a deposition (materials costs and the effective use of the materials) as well as the cost of the manufacturing equipment deployed.
Generally, processes that employ a vacuum or reduced pressure environment are subject to higher capital equipment costs and demonstrate lower deposition rates. However, the benefit of operating in a reduced pressure environment is often a reduction of contamination and an increase in uniformity and adhesion effectiveness. Furthermore, some processes may not work at all at higher pressures and therefore require a lower pressure or vacuum level operating regime.
Plasma deposition technologies such as PVD and CVD are commonly deployed in areas such as the manufacturing of semiconductor devices. Several methods for generating plasmas are known in the art. Arc plasmas create a plasma by applying a DC voltage between two elements such as an anode and a cathode. The resulting stream of electrons (arc) is responsible for creating very high temperatures in their path through collisions with other molecules and atoms in the arc discharge region. A common problem with arc discharge plasmas is that they consume their electrodes over time. In other words, the arc sputters material from the electrodes, which is subsequently co-deposited or entered into the plasma area. In several processes such as in the deposition of materials that are required to remain very pure, such co-deposition can be detrimental, even at very low contamination levels. As an example, even small amounts of co-deposited metals can be detrimental to the functioning of semiconductors and solar photovoltaic materials.
Inductively Coupled Plasma (ICP) sources typically employ an electrical coil powered by radio frequency signal (around 1-13 MHz is common range of frequencies). The RF signal generates a rapidly changing electromagnetic field. This field can be coupled into a chamber to produce a plasma.
Electron Cyclotron Resonance or ECR plasma sources are commonly used to support deposition chemistries for various materials. ECR sources combine a microwave source (typically operated between 1 and 10 GHz) and a permanent- or electro-magnetic field, in which the microwave source supplies power to the plasma discharge region and where the magnetic field is responsible for the creation of helical paths for charged particles such as electrons and ions. Thus, because of the helical paths, the collision probability between charged particles and neutral particles is significantly increased, resulting in much longer residence times for the charged particles in the plasma region and an enhanced interaction time between the charged particles and other particles in the plasma. This enhanced residence time allows the charged particles (particularly the electrons) to create additional ionized particles in the plasma, resulting in much higher charge concentrations in the plasma region. These higher charge concentrations result in higher extraction rates of the desired particles. This is particularly useful in processes such as ion assisted deposition or in ion doping processes. Furthermore, the longer residence time of the electrons allows for an overall increase of the plasma temperature.
ECR plasmas are very common in the manufacturing of semiconductor devices. Most ECR plasma systems require vacuum levels well below atmosphere to be able to operate, and thus require expensive equipment. However ECR phenomena have been observed at elevated pressures as well.
In general, plasmas exhibit some unique characteristics such as the formation of (meta) stable surface waves in which plasma waves can be emitted over long distances away from their source of origin. Plasma sources that deliberately enhance the formation of waves are Surface Wave Plasma sources (SWPs). They are also referred to as “Surfatrons”. Surfatrons are plasma sources that are deliberately designed to create enhanced plasma wave operations.
Flame Spray Plasmas (FSPs) create a plasma flame, which is created by the chemical reaction of one or more gasses (usually the combination of a carrier gas such as methane and a reaction gas such as air or pure oxygen) while coming out of an instrument such as a torch. The material that is to be deposited is introduced into the flame, typically in powder or sometimes in solid form, whereby rapid melting of the material occurs. The molten material/plasma stream is then aimed at the substrate or surface to be coated. The plasma temperature of a FSP system is typically in the range of 2,000-5,000° C.
Thermal Spray Plasmas (TSPS) do not rely on a chemical reaction, but rather rely on physical processes to create a plasma and a molten particle stream. A typical TSP will use either a DC plasma arc (also called a DC Plasmatron) or a radio-frequency induced plasma (also called an inductively coupled Plasmatron). In either case, a plasma is created and the to-be-coated material is introduced into the plasma stream, where it is rapidly melted. The plasma/material stream is then aimed at a substrate where the material deposits and re-solidifies. The plasma temperature of a TSP system is typically in the range of 5,000-12,000° C.
The above mentioned processes for plasma generation such Inductively Coupled Plasmas, ECR plasmas, Flame Spray Plasmas, and Thermal Spray Plasmas are all commonly known in the art and have all been used or attempted to be used for the deposition of materials used in semiconductor manufacturing as well as for the deposition of photovoltaic active layers and other areas where deposition of materials is desired.
Common problems with the application of these plasmas to materials and substrates involve the co-deposition of undesirable materials that are introduced through either the erosion of the chamber that contains the plasma, or by the use of starting materials that already contain such contamination. The very high temperature of plasmas essentially evaporates some material of the chamber and electrodes surrounding it. Strategies such as the use of shielding or liners, or the use of chamber materials that are not contaminating when co-deposited are a common practice. One disadvantage of shielding and liners is that they too eventually get coated with the to-be-deposited materials or with other residual process effluents. Such depositions ultimately may result in the materials flaking off and falling on the substrate that is in process. These unintended particles or flakes are generally very destructive to the semiconductor devices in process, and great care is typically taking to minimize any risk of particles falling on the substrate. Oftentimes monitoring and periodic cleaning processes are employed to ensure that the flaking of materials is very limited or prevented as much as possible.
Low pressure plasmas have a tendency to also have low deposition rates. Low deposition rates can mean long process times, which means low equipment throughput. The cost of vacuum equipment is typically very high and the combination of long deposition times and high equipment cost is usually not desirable. However, vacuum based processes typically exhibit good adhesion to the substrate because of the absence or lowering of surface contamination (water molecules are a primary culprit in poor adhesion). Furthermore, vacuum chambers typically allow for the creation of stable, large area plasmas which allow for good uniformity across a substrate. Uniformity of the deposited layer is important because the performance of the layer is oftentimes critically dependent on the layer thickness. Uniformities where the layer thickness varies less than a few percent of the overall layer thickness across the substrate are often the goal. Various strategies have been employed to ensure layer uniformity, oftentimes involving moving either the deposition source or the substrate in a pattern across a target area. Other strategies involve the design of the source and gas injection system in such a way that diffusion of the deposition occurs over a large, uniform area.
BRIEF SUMMARY
In accordance with one or more embodiments of the invention, methods and systems are provided for material deposition using a plasma for the creation of multilayer structures for various applications, including photovoltaic applications and the manufacturing and implementation of such layers into photovoltaic panels and integrated into building energy management systems. While the methods and systems can be used for the deposition of semiconductor materials such as used in semiconductor manufacturing or in the manufacturing of photovoltaic panels, it should be clearly understood that these methods and systems can be used in all manner of deposition technologies, including but not limited to the deposition of materials for catalytic converters, thin film batteries, film based capacitors, proton-exchange membranes, films using bone material for the preparation of implants into the human body, coatings for increasing the hardness or wear resistance of components such as turbine blades or drill bits, and films for the coating of the interior or exterior of pipes and the like. Furthermore, the methods and systems described herein can be used for the coating and curing of layers such as the curing of plastics and inks onto paper or the adhesion of metal to plastics as well as for the creation of multilayer structures used for the manufacturing of quantum well devices, superconducting layers and light emitting diodes. In addition, many applications exist for the methods and system described herein for the sterilization and/or heating of surfaces such as needed for many biomedical applications. Also described herein are methods and systems used for the creation of microwave patterns such as used in the detection of objects (RAdio Detection And Ranging or RADAR). Furthermore, the methods and systems described herein can be applied to plasma propulsion systems such as used in space vehicles.
In no way is the description of the applications of the present invention intended to limit the invention to these applications. In general, substantially any process that uses microwaves for the deposition of materials can benefit from the present invention.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwaves from a source and transmits these microwaves through slots in the side of the waveguide that are sufficiently large to allow for the passage of the microwaves in a plane primarily perpendicular to the primary axis of the waveguide into a plasma chamber. In some embodiments, the waveguide has slots on one or more of its sides. In some embodiments, these slots are cut at an angle to the primary axis of the waveguide. In some embodiments, the angle between the primary axis of the waveguide and the main axis of the slots can range between 0 and 90 degrees. In some embodiments, the angle is cut at 45 degrees.
In accordance with one or more embodiments, methods and systems are provided wherein the waveguide is penetrated on a side opposite the slots by one or more pipes or tubes. In some embodiments, such tubes are constructed from metals or ceramics suitable for operation at elevated temperatures. In some embodiments, such pipes are use to transport materials across the microwave tube into the slots that lead to a plasma chamber. In other embodiments, each of the pipes contains different materials or combinations of materials.
In accordance with one or more embodiments, methods and systems are provided wherein the plasma chamber is equipped with permanent or electromagnets in order to allow for the creation of an Electron Cyclotron Resonance (ECR) effect. In some embodiments, the magnets have orientations suitable for the creation of high magnetic fields along the wall of the chamber and a substantially low magnetic field along the primary axis of the plasma chamber. In some embodiments, the magnets are permanent magnets. In some embodiments, the magnets are arranged in a logical pattern in between the microwave slots. In some embodiments, the magnets are arranged along an axis primarily parallel to the main axis of the plasma chamber. In some embodiments, the magnets are arranged at an angle to the main axis of the plasma chamber. In some embodiments, the magnets are arranged at an angle of 45 degrees to the main axis of the microwave chamber. In some embodiments, the magnets are mounted in cavities in the walls of the ECR chamber to keep them from being exposed to the plasma in the chamber. In some embodiments, the short walls of the ECR chamber are created to be primarily parallel to the microwave slots.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has slots cut into one or more of its sides to allow the microwave radiation to enter an ECR plasma chamber and wherein there are pipes or tubes on the opposite side of the microwave slots to allow for the introduction of materials such as gasses, powders, liquids, solids or any combination of these. In some embodiments, the materials are mixes of materials. In some embodiments, the materials are powders that are coated with other materials so that the core of the powder has a lower melting temperature than the coating and so that the internal material melts away while in the plasma discharge region and thereby leaves a hollow shell that can be deposited on the substrate. In some embodiments, such pipes can be individually controlled as to how much material to introduce into such a plasma chamber and as to at what time. In some embodiments, the material is provided through the pipes in a pulsed fashion. In some embodiments, such material pulses allow for the very rapid deposition of alternating materials similar to a process known as “Atomic Layer Deposition” or ALD. In some embodiments, the pipes contain physical features such as tapered openings or bends that allow for directional flows of the materials into the plasma chamber. In some embodiments, the materials directed into the plasma chamber are heated by the ECR plasma and partially or fully melted or even evaporated. In some embodiments, such melted or evaporated materials are directed to a surface where they are deposited to form a layer. In yet another embodiment, the pipes are very small and emit very narrow streams of materials which are used to create individual lines of the material onto the substrate being treated. In some embodiments, individual pipes are independently controlled such as is common in inkjet printer technology.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has slots cut into one or more of its sides to allow the microwave radiation to enter an ECR plasma chamber and wherein there are pipes or tubes on the opposite side of the microwave slots to allow for the introduction of materials such as gasses, powders, liquids, solids or any combination of these and wherein the plasma chamber is outfitted by a set up magnets to create an ECR effect. Furthermore, methods and systems are provided wherein the ECR chamber is enclosed by a cover that allows for a more complete containment of the ECR plasma such that the plasma can be operated at a pressure that is different from the environment around the chamber. In some embodiments, the cover contains slits predominantly parallel and coincident to the microwave slots. In some embodiments, the space between the slits contains additional magnets. In some embodiments, a secondary slit or multiple sets of slits are provided that can be held at an electrical voltage that is substantially different from the plasma chamber's voltage. In some embodiments, such secondary slits are used to extract ions or electrons or other charged particles from the ECR plasma chamber. In further embodiments, such charged particles are used to implant into or treat surfaces of a substrate.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has slots cut into one or more of its side to allow the microwave radiation to enter an ECR plasma chamber and wherein there are pipes or tubes on the opposite side of the microwave slots to allow for the introduction of materials such as gasses, powders, liquids, solids or any combination of these and wherein the plasma chamber is outfitted by a set up magnets to create an ECR effect. In some embodiments, the waveguide and plasma chamber are shaped in a bend to conform to the surface of the object to be coated such as a cylinder or such as a pipe. The waveguides and/or plasma chambers can be constructed to assume many different shapes and configurations so as to effectively coat a non-planar surface. In some embodiments, the waveguide is circular in shape. In yet another embodiment, the waveguide is helical in shape. In a further embodiment, the waveguide is shaped to direct microwaves to a part of a human anatomy, wherein one advantage is that the microwave guide may provide a focal point inside the human body where as a result, the concentration of microwaves is much higher than at any point on the surface of the body. In another embodiment, the microwave guide is shaped to concentrate microwave radiation in a single point or along a single line so that the local microwave power is substantially higher than the power emitted from the individual slots.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has slots cut into one or more of its sides to allow the microwave radiation to exit the waveguide through appropriately sized slots. In some embodiments, the exit slots are generally evenly spaced along one or more sides of the waveguide, whereby the spacing of the slots is designed to be approximately ¼ of the wavelength of the microwaves in the waveguide. In some embodiments, the waveguide is terminated by a plunger that is moveably mounted at the end of the waveguide. Such a plunger effectively allows the end of the waveguide to be tuned so that the power of the microwave radiation exiting the slots can be optimized. In some embodiments, such a waveguide is used for to emit radiation for the purpose of range finding (RADAR).
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has primary slots cut into one of its sides to allow the microwave radiation to exit the waveguide through appropriately sized slots and wherein the waveguide is terminated by a moveable first plunger, and wherein furthermore additional secondary slots are cut approximately equal in size to the first set of slots but located in the opposite wall of the waveguide. In some embodiments, such secondary slots are fitted with a secondary set of plungers called “ejectors.” In some embodiments, such secondary sets of ejectors are used to create an amplification of the emitted radiation through the primary slots, resulting in a significant increase of emitted microwave power and an increase in the narrowness of the emitted microwaves beams. In some embodiments, such secondary plungers are used to optimally tune the emittance of each individual slot. In further embodiments, such secondary plungers are used to create a second standing microwave exiting the waveguide's primary openings. In some embodiments, the primary slots and the secondary plungers are used to emit radiation into a plasma chamber. In a further embodiment, such emitted radiation is used to create a surface wave plasma in the plasma chamber. In further embodiments, the emittance of surface wave plasma is used to impart momentum on a space vehicle. In yet another embodiment, the surface wave plasma is combined with a magnetic field to create both a surface wave plasma as well as an ECR plasma in the plasma chamber region.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has primary slots cut into one of its sides to allow the microwave radiation to exit the waveguide through appropriately sized slots. In some embodiments, multiple waveguides and sources are arranged in a pattern. In some embodiments, a pattern is designed in such a way that each microwave guide's exit slots face a common area. In some embodiments, such a pattern is a target object.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has primary slots cut into one of its sides to allow the microwave radiation to exit the waveguide through appropriately sized slots and wherein the waveguide is terminated by a moveable first plunger, and wherein furthermore additional secondary slots are cut approximately equal in size to the first set of slots but located in the opposite wall of the waveguide and wherein such secondary plungers are made hollow to allow for the passage of materials through the body of the plunger into the primary exit slots of the waveguide. In some embodiments, such hollow secondary plungers are used to deliver materials to a plasma chamber approximately connected to the primary exit slots of the wave guide. In some embodiments, such materials are delivered to an ECR plasma chamber which uses magnetic fields to create plasma conditions. In yet another embodiment the plasma chamber contains additional covers and extraction slits to extract specific charged particles from the plasma in the plasma chamber. In another embodiment, such a secondary plunger and the primary slots in the waveguide cooperate together to create a surface wave plasma and the materials moving through the secondary plunger is directly fed into the surface wave plasma.
In accordance with one or more embodiments, methods and systems are provided wherein multiple waveguides receive microwave radiation from one or more microwave sources and wherein such waveguides contain primary slots for the passage of microwave radiation into plasma chambers and wherein the plasma chambers are equipped with magnets to create ECR plasma conditions. In some embodiments, multiple configurations are setup in serial fashion where some configurations are used for powders or solids, others for gasses, others for the extraction of ions and or electrons and yet others for combinations of the all of the above. In some embodiments, such configurations are used for the deposition of multilayered structures such as those used for the creation of films for the manufacturing of photovoltaic modules. In some embodiments, such arrangement of multiple microwave sources is used for the formation of multilayer structures such as those used in thin film batteries, medical devices, electronic devices, coatings on components and other applications as previously discussed.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has primary slots cut into one of its sides to allow the microwave radiation to exit the waveguide through appropriately sized slots. In some embodiments, the primary slots in the waveguide are closed off by a vacuum tight surface that is permeable by microwave radiation but not for the atmospheric environment. In some embodiments, the vacuum tight surface allows for the passage of pipes into the region beyond the waveguide. In some embodiments, the waveguide is proximately mounted to a vacuum chamber where the plasma connectably located at the primary slots. In some embodiments, such a plasma chamber is an ECR chamber. In further embodiments such a plasma chamber is equipped with extraction slots to extract charged particles from the plasma. In some embodiments, such extracted particles are used for ion implantation or ion treatment of surfaces.
In accordance with one or more embodiments, methods and systems are provided wherein a waveguide receives microwave radiation from a source and wherein the waveguide has primary slots cut into one of its sides to allow the microwave radiation to exit the waveguide through appropriately sized slots. In some embodiments, the waveguide has small pipes on the side opposite the primary slots which penetrate through the waveguide into the primary slots. In some embodiments, such primary pipes are physically shaped to provide directionality to the stream of material going through the pipes. In yet another embodiment, the shape of the pipes conforms to the surface being treated such as the surface of a glass substrate with a corrugated or wavy shape. In further embodiments, the wavy glass substrate is coated with photovoltaic materials.
Various embodiments of the invention are provided in the following detailed description. As will be realized, the invention is capable of other and different embodiments, and its several details may be capable of modifications in various respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not in a restrictive or limiting sense, with the scope of the application being indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a Thermal or Flame Spray Plasma coating system in accordance with the prior art.
FIG. 2 illustrates a DC arc Thermal Spray Plasma system in accordance with the prior art.
FIG. 3 illustrates an inductively coupled, radio frequency Thermal Spray Plasma system in accordance with the prior art.
FIG. 4 illustrates a prior art DC arc Thermal Spray Plasma system disclosed in U.S. Patent Application Publication No. US20080220558, in which certain elements have been replaced with silicon or silicon coated components.
FIGS. 5A and 5B (collectively referred to herein as FIG. 5 ) illustrate a prior art Electron Cyclotron Resonant plasma chamber as disclosed in U.S. Pat. No. 7,305,935, in which longitudinal magnets placed along the axis of a microwave guide where microwave radiation is transmitted through longitudinal slots in the microwave guide to generate an Electron Cyclotron Resonant plasma.
FIGS. 6A and 6B illustrate a system for generating of a surface wave plasma known in accordance with the prior art.
FIG. 7 illustrates a system including a microwave guide and plasma chamber in accordance with one or more embodiments of the present invention in which material feed pipes are arranged along the top of a microwave guide in a diagonal pattern to feed material into a plasma chamber.
FIG. 8 illustrates the assembly of FIG. 7 , wherein the plasma chamber and the microwave guide have been separated, and where the diagonal slots and the interspaced magnets placed along the surface of the plasma chamber are visible.
FIG. 9 illustrates penetration of the material feed tubes through the microwave guide so that material and microwaves enter into the plasma chamber through the same openings in accordance with one or more embodiments.
FIG. 10 illustrates the assembly of the microwave tube and plasma chamber in accordance with one or more embodiments.
FIG. 11 illustrates a waveguide plunger and an extraction system for ions or electrons mounted to the plasma chamber in accordance with one or more embodiments. Several components have been moved to allow an easier view at the assembly.
FIG. 12 illustrates a different view of FIG. 11 where the extraction slit set has been separated from the main plasma chamber to allow a better view of the assembly.
FIG. 13 illustrates an alternate embodiment of the present invention where small, individual feed pipes allow for precise deposition patterns through the plasma chamber.
FIGS. 14A-14D illustrate several patterns emitted by several plasma systems in accordance with one or more embodiments.
FIGS. 15A and 15B illustrate a small composite particle comprising two or more layers before and after it passing through the plasma chamber.
FIGS. 16A-16E illustrate variations of magnet placements along the surfaces of the various embodiments of the present invention.
FIGS. 17A and 17B illustrate various possible implementations of material feed pipe systems into the plasma chamber assembly in accordance with one or more embodiments.
FIGS. 18A and 18B show cross sectional views of the material feed system and the plasma chamber/charge particle extraction system in accordance with one or more embodiments.
FIGS. 19A and 19B illustrate variations in which the wave guide and plasma chamber are shaped in a fashion to complement the shape of an object to be treated in accordance with one or more embodiments.
FIGS. 20A and 20B illustrate an alternative arrangement which allows for uniform emission of microwave radiation along the surface of an annular wave guide in accordance with one or more embodiments.
FIG. 21 illustrates an alternate arrangement of a wave guide allowing for a controllable uniform or directional emission of microwave radiation along a helical waveguide in accordance with one or more embodiments.
FIG. 22 illustrates a dual plunger waveguide system with material feed system in accordance with one or more embodiments.
FIG. 23 shows a close-up view of a section of FIG. 22 illustrating the secondary plunger and material feed system in accordance with one or more embodiments.
FIG. 24 illustrates a cross sectional view of the system of FIG. 22 allowing a view into the interior arrangement of the major components of a dual plunger microwave generator system.
FIG. 25 illustrates a close-up cross-sectional view of the primary and secondary microwave plungers of FIG. 24 .
FIG. 26 illustrates an alternative embodiment of the present invention with the orientation of the secondary plunger and material injection systems along a primary axis of the waveguide.
FIG. 27 illustrates a cross sectional view through an assembly of the dual plunger microwave system and an ECR plasma chamber in accordance with one or more embodiments.
FIGS. 28A and 28B illustrate a dual plunger microwave emission system, where the primary objective of the secondary plunger is to amplify and improve the directionality of the microwave emission from the slots in the microwave guide in accordance with one or more embodiments.
FIG. 29 shows a cross-sectional view of the microwave system of FIG. 28 .
FIG. 30 illustrates a close up view of the dual plunger system of FIG. 28 .
FIG. 31 illustrates a system combining multiple microwave or plasma sources arranged so as to provide a concentrated beam location in accordance with one or more embodiments.
FIGS. 32A and 32B show a layered structure of a thin-film photovoltaic system in accordance with the prior art.
FIG. 33 illustrates a multistep deposition system using multiple configurations to create a multilayer deposition structure in accordance with one or more embodiments.
FIG. 34 demonstrates the deployment of a plasma system in accordance with one or more embodiments in a vacuum chamber for treatment of materials.
FIG. 35 illustrates a “see through” image showing a variation of the plasma system in accordance with one or more embodiments using pre-bend exit elements of the material feed system to allow for deposition on uneven surfaces.
FIG. 36 shows an implementation of FIG. 35 into a system for coating wavy or corrugated surfaces in accordance with one or more embodiments.
FIG. 37 illustrates an embodiment in which the ejected ions are deflected using a number of magnets in order to separate out various differences in ion mass and charge.
FIG. 38 is a cross-sectional view of the drawing in FIG. 37 , wherein the injector and the exiting ion beam can be seen going through the deflector magnet.
FIG. 39 illustrates an alternative technique for ion deflection wherein the ions are deflected and separated by mass and charge using electrostatic deflection.
FIG. 40 is a cross sectional view of the deflector of FIG. 39 .
DETAILED DESCRIPTION
FIG. 1 is a simplified diagram of components of a Thermal Spray Plasma (TSP) system as is commonly known in the art. A plasma source 101 generates a high temperature plasma environment, typically with temperatures ranging from 5,000 to 12,000° C. The temperature of the plasma is determined by a number of operating parameters, such as the power supplied to the plasma source, the powder or solid material feed rates that are supplied to the source region, the amount of gas that is introduced, the environmental pressure, etc. The introduction of gasses into the plasma chamber results in a plasma jet 102 being emitted from the plasma source. An injector 105 can inject additional materials into the plasma chamber 101 or into a convenient location in the plasma jet 102 that is emitted from the chamber. The materials that are injected into the plasma stream can be in almost any form, whether they are gaseous, liquid, solids, powders and combinations thereof. Common materials that are used in the art include ceramics, silicon, metals, plastics, bone etc. The temperature of the plasma jet and the velocity in which materials are fed into the jet, will determine the detailed behavior of the materials while they are being melted in the plasma jet. The plasma beam 102 is directed towards a substrate 104 where the injected material results in a deposition layer 103 on the substrate. Oftentimes the plasma source 101 and injector 105 are movably mounted with respect to the substrate. In some embodiments, the substrate 104 is movably mounted in respect to the plasma source 101 and injector 105 . In other embodiments, both the substrate and the plasma source are movably mounted.
FIG. 2 depicts a schematic diagram commonly known in the art as a DC-Arc Thermal Spray Plasma system. A cylindrical cathode 201 commonly has a small pipe 202 fitted through its center. The pipe 202 is used to introduce materials such as gasses, solid, liquids, powders and the like into the plasma generation area 208 . In addition to, or instead of using the pipe 202 , materials can also be introduced into the plasma through entry ports on the side of the plasma chamber by pipe 203 and into the stream of the plasma coming out of the plasma chamber by pipe 205 . Moveable material injection systems 206 have also been used to introduce materials into the plasma area. A DC power supply 207 is used to create a DC arc discharge between the anode 204 and the cathode 201 . This DC arc creates a large current between the anode and the cathode which in turn allows for the creation of plasma in the discharge region 208 . It is commonly known that DC arc plasmas also introduce some materials that are removed from the anode and cathode by the high electron flux and the exposure to the high plasma temperatures. Since the anode and cathode are commonly constructed using copper or other suitable metals, these metals are as a result introduced into the plasma stream and co-deposited onto the substrate being treated. In many applications this small amount of co-deposited material is not in problem, however in semiconductor applications such a co-deposition can be detrimental the semiconducting function of the material, significantly altering the materials' desirable properties, even at very low contamination levels.
FIG. 3 shows an alternate approach for the creation of a thermal spray plasma system using a Radio Frequency (RF) coil for the generation of power. In the figure, a cathode 301 contains a small pipe 302 that allows for the introduction of materials into the plasma region 308 . The coil 303 receives a RF signal and creates a rapidly alternating magnetic field in the discharge region, which leads to the creating of plasma in the center of the structure. The RF signal is coupled to the plasma by emitting radio waves from the coil into the plasma region 308 . The coil 303 is typically enclosed in a housing 307 that is made from a suitable material able to withstand the exposure to the plasma and the high temperatures that are created. In some cases, in addition to or instead of materials being introduced through the pipe 302 , materials can also be introduced into the plasma region 308 through pipes 304 , 305 or through movable pipes 306 or in any convenient combination of the above.
FIG. 4 shows a view of the main assembly from of a DC arc Thermal Spray Plasma system from U.S. Patent Application Publication No. 20080220558, wherein the components that are exposed to the plasma area of the discharge chamber have been replaced by parts made from silicon, doped silicon, or from materials that are coated with silicon layers or doped silicon layers. The concept of replacing components that are normally made with metals such as copper, stainless steel, or brass with materials that have been clad with silicon or that are made out of silicon is intended to reduce the contamination from those metals surrounding the discharge chamber. Thus, where normally brass, copper, or stainless steel is exposed to the plasma in the chamber, now instead the plasma only sees silicon and hence it will only be silicon that is introduced into the plasma. In this way, the discharge plasma is still contaminated, but the contamination is now silicon, which is essentially not a contaminant for a silicon deposition. Other materials that are essentially not contaminants could also have been chosen, such as graphite, quartz or other suitable materials.
FIG. 5 shows a drawing from U.S. Pat. No. 7,305,935 in which an ECR plasma chamber 50 is connectably mounted against a microwave tube 52 . The ECR chamber contains magnets 58 , 60 and 62 that are placed parallel to the major axis of the chamber to create a high magnetic field near the walls of the chamber and a substantially reduced magnetic field near the center of the chamber. Furthermore, longitudinal openings 59 are placed in two rows along the microwave guide to allow for the passage of microwave from the guide into the ECR chamber region 51 . These openings have been spaced and sized such that the microwave energy is able to exit into the plasma chamber.
FIG. 6 shows a rectangular microwave guide at the end of which a plunger has been inserted “waveguide plunger” and through which a coaxial section has been cut with a secondary plunger “coaxial plunger” as is known in the prior art. The coaxial section contains a secondary plunger which faces an opening on the opposite wall of the waveguide. This opening functions as a launching gap through which a Surface Wave Plasma (SWP) is emitted. A discharge tube is inserted through the coaxial section in order to bring gasses into the discharge area. Plasma is created on the inside of the discharge tube and is sustained by the microwaves emitted from the launcher gap. FIG. 6A shows a perspective view of the SWP Surfatron, whereas FIG. 6B shows a cross-sectional view of the Surfatron.
FIG. 7 illustrates a microwave waveguide body 703 in accordance with one or more embodiments where microwave radiation 701 is introduced from a microwave source (not shown). A flange 702 is used to connect the present section of the microwave guide to the source or through additional sections of microwave guide. The microwave guide body 703 is penetrated by one or more pipes 704 through which materials can pass into a plasma chamber 705 . The plasma chamber 705 can be covered with a number of magnets 706 . The resulting ECR plasma 708 is used to melt or evaporate materials that are coming through the pipes 704 into the plasma chamber 705 . The materials are directed from the plasma region 708 onto a substrate 707 , which can be moved with respect to the plasma source. Multiple arrangements of pipes, magnets and ECR chamber shapes are possible in accordance with various embodiments. Furthermore, the ECR/Waveguide assembly can be moveably mounted to coat a substrate or the substrate can be moved along a stationary ECR/Waveguide assembly, or that both of the assemblies are movable in a suitable pattern with respect to each other. It can also been seen from the figure that a pattern of pipes 704 can be created that is primarily at an angle with respect to the main axis 709 of the waveguide 703 . The advantage of such a pattern is that there can be an overlap of the exiting plasma jets in the plasma region 708 such that a much more uniform plasma discharge can be created.
FIG. 8 shows another aspect of the elements of FIG. 7 in which the plasma chamber 705 has been separated from the microwave guide 703 so that the orientation and pattern of magnets 802 , 803 and slots 801 can be more readily seen. As can be seen from the figure, the pipes 704 follow the same pattern as the slots 801 in the body of the ECR chamber 705 . Furthermore, it can be seen from the figure that the magnets on the top of the chamber are at an angle to the primary axis 709 of the waveguide. In fact, the magnets 802 in the top of the chamber are aligned with the slots 801 in the chamber. As can also be seen from the figure, the magnets 706 that are mounted to the ECR chamber are mounted in small cavities on the exterior of the chamber. The reason for this is that the magnets should not be exposed to the plasma in the chamber directly because they are typically unable to withstand the high temperatures associated with plasmas and neither should they be exposed to the plasma in the chamber for fear that they might contaminate the deposition process when small particles are removed from the magnets by the plasma. The arrangement shown in FIG. 8 shows that the magnets can be shielded from the plasma by the ECR chamber itself. The ECR chamber could be made out of materials that if removed into the plasma would not matter to the contamination of the plasma. For depositions involving semiconductor materials one could think of using, without limitation, materials for the ECR chamber such as silicon, graphite, quartz, alumina or silicon coated materials.
FIG. 9 shows the underside waveguide from FIGS. 7 and 8 with the ECR chamber completely removed from the figure. As illustrated, the pipes 704 penetrate the waveguide 703 and are arranged such that they end near the slots that allow for passage of the microwaves into the plasma chamber. It can be seen from the figure that this arrangement allows for materials 901 and microwaves 701 to be introduced at the same approximate location 903 into the ECR plasma chamber through the slots 902 . The pipes and slots may be arranged in many different patterns and that each pipe may contain different materials.
FIG. 10 depicts the combined microwave guide 703 and ECR plasma chamber 705 from FIGS. 7, 8 and 9 . In the present view, the material pipes 704 can be seen exiting the slots for the microwaves 1001 . The internal side of the ECR plasma chamber 1002 does not expose any undesirable materials to the plasma itself, except for the material that the ECR chamber is constructed out of. The magnets 706 and 803 are kept separate and away from the plasma area, however, the magnetic field lines can easily penetrate the plasma area if the ECR chamber is constructed from non-magnetic materials such as for example graphite.
FIG. 11 illustrates an alternative embodiment of the present invention. The microwave guide 703 is terminated at one end by a moveable wave guide plunger 1101 . An adjustment screw 1102 or similar convenient mechanism can be used to move the plunger 1101 into a position where the maximum of microwave power exits through the slots 902 . Different operating conditions may require different positions of the plunger to optimize power output through the slots. A combination of shorter straight pipes 1103 supports a pipe 1104 with a tapered exit opening. In some embodiments, the straight pipes 1103 carry gasses to the plasma chamber, and the tapered pipes carry powders into the plasma chamber. The ECR chamber 1105 has short angled walls with respect to the major axis of the system rather than the rectangular wall as seen in FIG. 7 through 9 . Such an arrangement keeps the walls of the ECR chamber 1105 approximately at equal distance from the slots 902 whereas a rectangular chamber such as was shown the earlier figures has one end of the slot closer to the short walls of the ECR chamber, thereby potentially creating a non-uniformity in the corner furthest away from the slot. Referring again to the figure, the ECR chamber 1105 is covered by a plate 1106 . The cover plate 1106 is outfitted with slits 1109 that allow for passage of plasma or particles from the ECR plasma region into the exterior environment of the source. It will be understood that commonly such slits are located opposite the slots 902 that allow for passage of microwaves into the ECR chamber; however other arrangements can easily be envisioned. Additional magnets 1108 can be located in the cover plate, again arranged in various ways. Such magnets 1108 are arranged to prevent plasma from getting in close proximity to the internal side of the cover 1106 which is closest to the plasma region.
Furthermore, as can be seen in the figure it is possible to add a second cover 1110 , also equipped with slits 1111 . The second cover 1110 can be mounted on insulators 1107 so that the cover 1110 can be electrostatically charged to a different potential than the source itself. Such a positive potential or negative potential can be used to extract electrons or ions or other charged particles from the plasma region. It should be understood that covers with different slit arrangements as well as additional covers with slits and other electrostatic or magnetic field components can be arranged to shape the extracted beams of particles or to select certain particles over other particles such as is commonly done in mass separators in ion implanters, whether done electrostatically or magnetically.
FIG. 12 shows the same elements from FIG. 11 with the components now mostly assembled in the configuration in which it would be commonly used. The secondary cover 1110 is still shown somewhat removed from the normal position to allow the reader a better view of the primary slits 1109 . It should be clear from the figure that the internal area of the ECR chamber 1105 is almost completely isolated from the exterior environment, safe for the openings in the slits 1109 .
FIG. 13 shows the ECR chamber from the earlier figures with very small pipes 1302 projected in an opening 1301 in the ECR chamber. By way of non-limiting example, the pipes 1302 can each have a diameter ranging from about 1 micron to about 1 mm. Such an arrangement of very small pipes can be useful for the deposition of patterns such as used for deposition of lines of metals on substrates. Furthermore, it will be understood that materials may be injected simultaneously to create mixtures inside the plasma region for co-deposition of materials that are otherwise difficult to mix. It will also be understood that the material flow through the pipes may be deposited in a pulsed fashion so that thin, alternating layers can be deposited onto a substrate. These arrangements could be convenient when depositing thin alternating layers of materials such as commonly done during Atomic Layer Deposition or for patterned deposition of materials.
FIGS. 14A-14D show patterns of the deposition of various slot arrangements of various plasma deposition sources. In FIG. 14A , the exit opening of a common DC Arc plasma is depicted on the right side and a matching deposition pattern is shown on the left, which shows a deposition pattern primarily in a circular pattern similar to a pattern created by a spray paint can. In order to attain very uniform layers over large areas the plasma source is typically moved over a pattern using a scanning motion. Oftentimes the pattern is repeated multiple times so that several layers are deposited on top of each other to create a thicker layer with better uniformity, since non-uniformities can be averaged out in this way. In FIG. 14B the slot pattern of an ECR chamber is shown on the right side and the corresponding deposition pattern is shown on the left side of the figure. Depending on the length of slots, the deposition patterns may, or may not overlap with each other. In FIG. 14C the slot pattern of an ECR chamber with diagonal slots is shown on the right and the corresponding deposition pattern is depicted on the left. In the right side of FIG. 14D a slot pattern is shown with slots perpendicular to the primary axis of the system and the corresponding deposition pattern is shown on the left. It should be evident from the figures that the length and angles of the slots can be carefully chosen so that a substrate that is coated receives a uniform overall coating pattern. It should also be clear that the plasma source as well as the substrate can be moved to create multiple layers with better uniformity properties.
FIG. 15A shows a small particle comprising a core 1501 made out of a first material covered by a shell 1502 made out of a second material. During the heating of the particle in a plasma such as described in accordance with various embodiments of the present invention, the core 1501 which can have a lower melting temperature as the shell 1502 , can evaporate or evolve, thereby creating a hollow structure 1503 and openings 1504 in such as structure. In FIG. 15B the resulting structure of such a process is sketched. It would be possible to create very complex structure with very large surface areas in this fashion, which can be of significant advantage for example for the making of catalytic converters or membranes.
FIGS. 16A-16E show a number of embodiments for the placement of magnets on the side of the ECR chamber. FIG. 16A shows the magnet placement such as substantially disclosed in U.S. Pat. No. 7,305,935. FIG. 16B shows the magnet placement such as substantially shown in FIG. 7 . FIG. 16C shows the magnet placement such as was substantially shown in FIGS. 11, 12 and 13 . In another embodiment shown in FIG. 16D the magnets on the side walls of the ECR chamber are placed at an angle to the surface of the chamber. In another embodiment shown in FIG. 16E , circular magnets are used to create a pattern of magnets on the sides of the ECR chamber. It should be understood that the primary purpose of the magnets is twofold: 1) to create a high magnetic field close to the walls of the ECR chamber and low in its center, and 2) to create helical paths of charged particles to enhance their collision probability with the other particles in the plasma.
FIG. 17A shows a cross sectional view of the assembly of wave guide 1702 with the material feed pipes 1701 feeding material into the plasma region 1705 in accordance with one or more embodiments. The ECR chamber 1703 is properly covered with magnets 1704 intended to prevent the created plasma from coming in touch with the ECR chamber walls. The emitted plasma jets 1706 can be directed towards a substrate to be treated (not shown). FIG. 17B shows alternate embodiments of the material feed pipes 1707 entering from the sides of the wave guide or feed pipes 1708 coming in from the side through the ECR chamber walls. In addition, the feed pipes 1709 and 1710 can be moveably located to inject materials in various locations in the plasma chamber. It should be understood that various combinations and arrangements of feed pipes can be implemented to supply materials to the plasma region.
FIG. 18A shows a cross sectional view of the plasma chamber from FIG. 11 with the primary cover 1801 and optional magnets 1802 installed in the cover. The ejected beam 1803 can now enter a region 1804 wherein the pressure is substantially different than the pressure in the ECR chamber 1805 because of the flow restriction provided by the slot 1806 . In the right hand of the FIG. 18B , a cross sectional view of the same system with an extraction plate 1808 is shown. The extraction plate 1808 is mounted on standoffs 1807 that are electrical insulators. The extraction plate 1808 can then be electrostatically charged to extract charged particles 1803 from the plasma region.
In FIG. 19A , a wave guide 1901 in accordance with one or more embodiments is shaped in a circular or semicircular shape in conformance to a cylindrical object 1904 that is to be coated. The ECR chamber 1902 in turn is also circular or semi-circular in shape. Plasma jets 1903 are emitted towards the center of the system to treat the cylindrical substrate 1904 . In FIG. 19B a waveguide 1901 now has an ECR chamber 1906 on the outside of the waveguide and plasma jets 1907 are directed outwards from the center of the system. The jets are directed towards an internal cylindrical surface 1908 in order to treat or coat the inside surface of such cylindrical pipe. It will be clear to those skilled in the art that many other shapes of waveguide can be employed either with or without a correspondingly shaped ECR plasma chamber. In some embodiments, these systems can be employed to coat the inside surfaces of pipelines such as are commonly used for oil and gas transportation. In some embodiments, these systems can be used to create concentrates microwaves in parts of a human body. In some embodiments, such systems can be used to coat cylindrical objects such as drills.
In FIG. 20A , a waveguide in accordance with one or more embodiments is shown that has a circular shape. Microwave radiation enters the system at 2001 and transmitted through a short section of waveguide 2002 to circularly shaped waveguide 2004 . Slots 2003 cut in the side of the circular waveguide 2003 can be used to transmit microwave radiation into an optional ECR plasma chamber (not shown in the figure). On the right side of the figure an alternate configuration of the waveguide is shown where a short section of the waveguide is removed so that a plunger 2005 can be inserted at the end of the waveguide. The plunger allows for adjustment of the end of the waveguide in order to maximize the power transmitted through the slots 2006 cut in the sides of the waveguide. This is similar in function as the wave plunger discussed in FIG. 11 .
FIG. 21 shows another embodiment of a waveguide 2103 which has been shaped in a helical shape. Microwaves enter the waveguide at the flange 2101 and travel along the waveguide. The end of the waveguide is terminated again by a plunger 2104 that can be moved by an adjustment screw or mechanism 2105 in order to maximize the power emitted through the slots 2102 . The waveguide shown in the figure could be used to emit microwaves into a helically shaped optional ECR chamber (not shown). In some embodiments that utilize such an ECR chamber, such an assembly can be used to create depositions on the inside of pipes as was shown, for example in FIG. 19 . In some embodiments, the secondary sleeves 2109 are penetrated by one or more conduits to allow materials to pass thru to create a materials emission system (as, e.g., shown in FIG. 24 ) to allow material to be entered into an ECR chamber.
The waveguide could also be used to emit microwave radiation in an Omni-directional fashion such as used in (plasma) RADAR systems. It should be clear to those skilled in the art that the system of FIG. 21 could be used either with or without the secondary plunger assembly comprising the secondary plunger housing 2107 , the secondary plunger 2108 and the secondary sleeve 2109 . It should also be understood that the secondary plunger assembly can be adjusted to maximize or—if desired—minimize the power ejected through each slot. In some embodiments the secondary plungers are adjusted to create radially uniform emittance of radiation away from the central axis 2110 . In other embodiments the secondary plungers are adjusted to create emittance in one particular direction and not in other directions. In some embodiments, the secondary plungers face towards the inside of the microwave tube (in the opposite direction as is shown in the figure). One advantage of such an arrangement is that microwave radiation can be highly concentrated along a primary axis of the system 2110 . In another embodiment, such a concentration of microwaves can be used to generate a linear plasma region or to generate a deposition on a cylindrical object such as shown for example in FIG. 19 .
In FIG. 22 , microwaves are entered into a waveguide 2202 . The microwaves enter the wave guide at 2206 . The wave guide is terminated by a plunger (not shown) at the end of the waveguide. Adjusting the plunger through an adjustment mechanism 2201 allows the creation of wave maxima at or near a set of primary slots that are cut into the bottom of the waveguide (not shown). Opposite these slots a secondary plunger assembly is present. The secondary plunger assembly (the “ejector” assembly) includes a housing 2203 , a secondary plunger 2204 which is movably connected to the housing and a sleeve 2205 . The sleeve 2205 can have one or more passages cut through its center to allow for the convenient transport of materials to an optional plasma chamber (not shown in the figure). The sleeve 2205 can also be coated by a metal jacket or similar shield.
The first plunger is able to create a first standing wave inside the microwave guide along the primary axis of the microwave guide. Adjusting the first plunger allows tuning of the microwave guide to emit maximum through the slots. The secondary plunger 2204 is able to create a second standing wave in the chamber in a direction perpendicular to the primary axis of the wave guide and in the direction of the primary slots. The secondary plunger can be tuned to optimize a secondary standing wave to emit a maximum amount of power through a slot. The arrangement of a primary and a secondary plunger system can allow for the creation of a Surface Wave Plasma to exit around the exit of the primary slot.
FIG. 23 shows a close up view of the secondary ejector system from FIG. 22 . In the figure, the housing 2203 is mounted to the wave guide housing 2202 . The secondary plunger 2204 is movable mounted with respect to the housing 2203 . A sleeve 2205 is mounted in a fixed orientation with respect to the housing 2203 . The movable plunger 2204 can be adjusted in a direction perpendicular to the central axis of the wave guide 2202 in such a way that a secondary standing wave is create that is emitted on the side of the waveguide opposite the ejector assembly.
FIG. 24 shows a cross sectional view of the system from FIGS. 22 and 23 . As can be seen from the figure, the primary plunger 2401 can be moveable adjusted by the mechanism 2201 . The primary slots 2402 are cut in the side of the waveguide. On the opposite side of the slots 2402 , a secondary plunger assembly (the “ejector” assembly) is located that comprises the housing 2203 , a secondary plunger 2204 and a sleeve 2205 . The sleeve 2205 is sized so that a small gap exists between it and the cut in the wave guide. The small opening sets up strong electromagnetic fields between the sleeve and the edge of the slots 2402 . Such an arrangement can lead to the ejection or launching of standing plasma waves also known as Surface Wave Plasma (SWP) waves.
FIG. 25 shows the cross sectional view of FIG. 24 in a close up so that the gap 2501 between the sleeve 2205 and the slot 2402 is more easily visible. It should be understood that multiple slots can be created in various shapes and sizes. It will also be clear that the sleeve 2205 can have one or several openings cut into it for the transportation of materials.
FIG. 26 shows an arrangement of ejector assemblies 2601 that are arranged in two rows along the major axis of the wave guide 2202 . In this arrangement the ejectors will each eject a Surface Wave Plasma jet on the opposite side of the surface that the ejectors are mounted to.
FIG. 27 shows a cross sectional view of the wave guide and plunger assembly of FIG. 22 combined with an ECR plasma chamber. The wave guide plunger 2401 and adjuster 2201 set up a primary standing wave inside the wave guide 2202 . The ejectors ( 2203 , 2204 and 2205 ) set up a secondary standing surface wave plasma that is augmented by the ECR function of the plasma chamber. The combination of the two effects allows for a much stronger mixing and emission of higher radiation from the plasma chamber as well as an easier ignition of the initial plasma discharge, however it should be understood that the optional magnets 2701 , 2702 , and 2703 are not required to create a plasma, rather, the Surface Wave Plasma (SWP) effect is adequate to ignite and maintain a plasma discharge in the chamber. The magnets 2701 , 2702 , and 2703 can be arranged in such as way that the magnetic field strength is high near the plasma chamber walls, and significantly lower near the plasma chamber's center. Optional extraction slits 2704 allow for the creation of well defined beam profiles as well as for an increase in pressure inside the plasma chamber. An optional secondary extraction slit 2705 cut into a plate 2706 can be deployed with a proper electrostatic voltage applied to allow for the extraction of ions or electrons from the plasma region.
FIGS. 28A and 28B show another embodiment of a dual plunger system, wherein the primary plunger 2201 sets up a standing microwave along the primary axis of a microwave guide 2202 . The secondary ejector assemblies 2801 are arranged in such a way as to generally maximize the microwave emission from slots cut into the side of the waveguide. In such an arrangement microwaves have the potential to emit radiation much more strongly from the slots as compared to a system that does not employ the secondary ejector system.
FIG. 29 shows a cross sectional view of the arrangement of FIG. 28 . The sleeves 2901 are functioning as secondary antennae to help increase the emission of microwaves from the slots 2902 . Such an arrangement may be employed to increase the operating efficiency of microwave systems such as used for RADAR.
FIG. 30 shows a close up of the cross sectional view of FIG. 29 . The secondary ejector assembly comprises a housing 3001 , a secondary plunger 3002 as well as the sleeve 2901 . Sleeve 2901 can also be moveably located to help optimize the emission of microwave radiation from the microwave waveguide 2202 .
FIG. 31 shows a set of microwave guides 3101 positioned on a mounting mechanism or frame 3102 . The mounting mechanism or frame is positioned in such a way that the exit slots of the microwave guides face towards a common focal area 3103 . Microwave or plasma beams 3104 emitted from the microwave guides 3101 all converge on one or more focal areas. It should be understood that many arrangements or patterns can be conceived each with particular advantages for aiming radiation at a target area or target object.
FIGS. 32A and 32B depict the common layers used in a thin film photovoltaic structures as are known in the art. In the figure labeled 32 A, the layer 3201 is typically a transparent glass cover layer. Layer 3202 is commonly a Transparent Conductive Oxide or TCO layer used to create a conductive film on the back of the glass. Layer 3203 is an amorphous Silicon (a-Si) layer, usually deposited with a high concentration of Hydrogen. A back-side contact 3204 provides a metallic, electrically conductive layer. An encapsulation layer 3205 is usually a polymeric film that provides adhesion and environmental sealing to the back glass 3206 . Incident photons pass through the front glass and TCO layer and can be absorbed by the silicon layer wherein the photon may create an electron hole pair. The structure of layers is such that these charges can be collected on the front and rear contact layers, where they create a voltage that can be used to power devices.
As shown in FIG. 32B , the layers are augmented by an additional layer 3207 also known as a Micromorph layer. A Micromorph layer usually comprises microcrystalline silicon, which is formed using a CVD processes. A Micromorph layer allows photons of longer wavelengths that are not captured in the amorphous silicon layer, to potentially still be captured, thereby increasing the overall efficiency of photon-energy conversion. It is well known in the art that additional layers can be designed and integrated, each with the objective of converting a different section of the solar energy spectrum to electricity.
Such thin film structures however, still mostly require vacuum processing, which as discussed before uses expensive equipment, and has usually the disadvantage of slow growth rates, particularly for thick layers such as the Micromorph layer.
FIG. 33 illustrates a series of plasma sources in a variety of configurations set up to construct a photovoltaic structure in a very simple and continuous process flow in accordance with one or more embodiments. The source 3301 could be set up as a source for the deposition of a TCO layer on a substrate 3303 . Source 3302 could be set up to deliver a doped silicon deposition to the substrate, whereas source 3304 may provide an intrinsic silicon layer. Subsequently source 3305 may provide another silicon layer that is later doped by a different material in source 3306 . Finally source 3307 may provide small printed contact lines or some other metallic contact layer to complete the structure. It should be understood that different sequences or variations of sources can be conceived, and it should also be clear that such sources can provide a partial set of process steps where other steps may be performed in traditional deposition equipment or process equipment.
In some embodiments, such sequence of sources deposits the layers in a similar order and thickness as provided in FIG. 32 .
In another embodiment, a set of sources is set up by way of example to deposit layers of iron-oxide powder, which can be subsequently heated to form small droplets on the surface of a material. Another second source can provide a flow of heated hydrocarbons for the creation of what is commonly know in the art as carbon-nanotubes. Such manufacturing processes can be very useful in the creation of high quality capacitors and batteries.
It should be understood that numerous films can be created in an appropriate sequence to coat a variety of substrates.
Referring again to the figure, substrates 3303 can be transported underneath the series of sources by convenient means such as rollers 3308 or other methods of material transport. It should be understood that continuous films or webs can also be a potential substrate for deposition by such deposition and treatment sources.
In FIG. 34 a plasma source in accordance with one or more embodiments is mounted in a portion of a vacuum chamber 3403 . Microwaves enter a micro wave guide at a flange 3407 and are ejected through openings in the wave guide 3405 into a plasma chamber 3409 . As described before, the microwave can be tuned for maximum power output by a plunger assembly 3408 , and materials can be inject by an injection system 3406 . An optional set of extraction plates 3404 allows for the creation of an ion or electron curtain such as is commonly used in applications for ion treatment or ion implantation of substrates. Materials such as sheets of glass 3401 or films or other suitable substrates can be moved into the treatment region for processing through the openings 3402 .
In FIG. 35 , a cross sectional view is shown wherein the material transport pipes 3506 are going through a microwave guide 3505 into a plasma chamber 3503 . The ends of (some of) the pipes 3504 are mechanically bent to direct streams of material into the plasma at a suitable angle. A substrate 3502 is transported underneath the plasma treatment source by rollers 3501 or any other suitable transport system. The angle of the bent pipes 3504 is designed such that the materials deposit uniformly across a wavy surface of the substrate 3502 . In traditional coating systems it is sometimes hard to get uniform coating coverage across a non-planar surface, resulting in different and oftentimes undesirable characteristics of the deposited film. The present system is able to shape the direction of the deposition to conform to surface contours such as shown in the figure. The use of bent pipes allows for a more uniform deposition without the need for complex movement of the source or the substrate.
FIG. 36 illustrates how a plasma source 3602 can be used to treat a large wavy surface such as a wavy glass plate 3601 in accordance with one or more embodiments. It should be understood that multiple sources and various geometries of surfaces can be employed to coat multiple layers on non-planar surfaces. It should furthermore be understood that the combination of a shapeable wave guide base plasma source that can be combined with a deposition system that is shapeable as well will allow for low cost, high throughput uniform coatings with a much better control over both uniformity and deposition contamination as compared to systems that are currently in use today.
FIG. 37 illustrates a plasma source in accordance with some embodiments further equipped with mass/charge separation system using magnets. As is commonly known, ions can be mass separated using magnetic fields perpendicular to the ion's trajectory. Ions with different masses and/or different charge (single, double or multiple charged ions) will follow different trajectories in such a magnetic field. In the figure, each of the extraction holes in the extraction plate 1808 line up to holes in the ECR source cover plate 1801 . The extraction plate 1808 is held at an appropriate voltage to extract ion beams 3706 through the holes in the plates. The injector assembly in this case can comprise a cylindrical pipe 3701 that is lined with a sleeve 3705 . The secondary plunger 3703 is movably connected between the sleeve 2205 and the housing 3704 . The plasma beam exiting from the ejector is aimed directly at the openings in the extractor plates. As illustrated, the ion beam is diverted by electromagnets (or permanent magnets in some embodiments) comprising pole piece 3708 and coils 3707 . The thus created electromagnetic field bends the ion beam that was extracted from the plasma.
FIG. 38 shows a cross sectional view through the extraction plane of FIG. 37 . As can be seen in the figure, the magnet assembly is made of pole piece 3708 and coils 3707 and can be rotationally mounted around the centerline 3803 . The ion beam 3706 that is extracted enters the magnetic field created by the coils 3807 . Because the extracted beam will contain ions of different masses, such an arrangement causes the lighter ions to follow a tighter trajectory and exit the magnet as indicated in 3801 , whereas heavier ions will follow a larger radius and exit the system around 3802 . It will be clear to those skilled in the art that such an arrangement can be used to perform isotope isolation such as is needed for the purification of Uranium for fuel enrichment. One advantage of the embodiment of FIG. 38 over other methods currently in use is that the plasma density and separation will result in much larger material flows and hence in a faster system for isotope isolation.
It should also be clear to those skilled in the art that the above arrangement could be use to create propellant beams comprising ionized matter such as can be use to direct space craft. The magnets could be rotationally mounted around the apertures in the extraction plate such that the ion beams can be set to point in any direction necessary to drive the space craft. The force exerted on the space craft will be in the opposite direction of the exiting ion beams 3801 and 3802 .
In FIG. 39 a different method for deflection of the extracted ions is shown. In the figure a set of electrostatic deflectors is employed that comprises oppositely charged plates 3901 and 3902 . As is commonly known, an electrostatic deflector also will result in the separation of ions by mass and ion charge. As a result the exiting ion beams 3903 and 3904 will contain different ion masses, where the beam 3904 will contain the heavier ions and the beam 3903 will contain the lighter ions. It should be clear to those skilled in the art that any convenient arrangement of slot shapes and extractor shapes could be conceived. The slots could be parallel to the main axis of the system, perpendicular or at an angle such as is shown in the figure.
FIG. 40 shows a cross sectional view of FIG. 39 wherein the cross section is taken through the injector and extraction slits. One advantage over a slotted extractor such as shown in FIGS. 39 and 40 is that a wider beam can be accommodated as compared to the magnetic separator in FIGS. 37 and 38 , resulting potentially larger material transport capabilities. Potential disadvantages of this approach are that rotation of the exiting beams becomes more challenging and the use of electrostatic deflectors is known to cause “space-charge” blow-up of positively charged ion beams. The space-charge blow-up is caused because electrons in the positively charged beam (which are normally present and prevent the beam from expanding under its own ion charges) are deflected to the opposite side of the deflectors 3901 and 3902 . As a result the beam passing through the deflector is no longer space-charge neutral and rapid beam expansion occurs, which makes mass separation more difficult. In practice mass separation through magnetic separation such as illustrated in FIGS. 37 and 38 is more favorable since space-charge problems do not typically occur in magnetic fields.
Having thus described several illustrative embodiments, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to form a part of this disclosure, and are intended to be within the spirit and scope of this disclosure. While some examples presented herein involve specific combinations of functions or structural elements, it should be understood that those functions and elements may be combined in other ways according to the present invention to accomplish the same or different objectives. In particular, acts, elements, and features discussed in connection with one embodiment are not intended to be excluded from similar or other roles in other embodiments. Accordingly, the foregoing description and attached drawings are by way of example only, and are not intended to be limiting. | An apparatus for separating ions having different mass or charge includes a waveguide conduit coupled to a microwave source for transmitting microwaves through openings in the waveguide conduit. The outlet ends of pipes are positioned at the openings for transporting material from a material source to the openings. A plasma chamber is in communication with the waveguide tube through the openings. The plasma chamber receives through the openings microwaves from the waveguide tube and material from the pipes. The plasma chamber includes magnets disposed in an outer wall thereof for forming a magnetic field in the plasma chamber. The plasma chamber includes a charged cover at a side of the chamber opposite the side containing the openings. The cover includes extraction holes through which ion beams from the plasma chamber are extracted. Deflectors coupled to one of the extraction holes receive the ion beams extracted from the plasma chamber. Each deflector bends an ion beam and provides separate passages for capturing ions following different trajectories from the bending of the ion beam based on their respective mass or charge. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for electrophoresis depositing carbon nanotube on cathode strip for a field emission display, especially to a method for electrophoresis depositing carbon nanotube with certain powders such as glass powder or conductive powder.
[0003] 2. Description of Prior Art
[0004] The field emission display uses cathode electron emitter to generate electron by electrical field. The emitted electron excites phosphor on anode plate for illumination. The field emission display has compact size and flexible viewable area. The field emission display does not have view angle problem encountered in LCD.
[0005] Conventional triode field emission display includes an anode structure and a cathode structure. There is a spacer disposed between the anode structure and the cathode structure, thereby providing a space and a support for the vacuum region between the anode structure and the cathode structure. The anode structure includes an anode substrate, an anode conducting layer, and a phosphorus layer. The cathode structure includes a cathode substrate, a cathode conducting layer, an electron emission layer, a dielectric layer and a gate layer. The gate layer provides a voltage difference to induce the emission of electrons from the electron emission layer. The conducting layer of the cathode structure provides a high voltage to accelerate the electron beam, such that the electron beam can have enough kinetic energy to impinge and excite the phosphorous layer on the anode structure, thereby emitting light. Accordingly, in order to maintain the movement of electrons in the field emission display, a vacuum apparatus is required to keep the vacuum degree of the display being below 10 −5 torr. Therefore, the electrons can have appropriate mean free paths. Meanwhile, the pollution and toxication of the electron emission source and the phosphorous layer should be prevented from happening. Furthermore, in order for the electrons to accumulate enough energy to impinge the phosphorous powder, a predetermined gap is required between the two substrates. Consequently, the electrons can be accelerated to impinge the phosphorous layer, thereby exciting the phosphorous layer and emitting light therefrom.
[0006] The electron emission layer is composed of carbon nanotubes. Since carbon nanotubes, proposed by Iijima in 1991 (Nature, 354, 56 (1991)), possess very good electronic properties that can be used to build a variety of devices. The carbon nanotubes also has a very large aspect ratio, mostly larger than 500, and a very high rigidity of Young moduli larger than 1000 GPn. In addition, the tips or defects of the carbon nanotubes are of atomic scale. The properties described above are considered an ideal material for building electron field emitter, such as an electron emission source of a cathode structure of a field emission display. Since the carbon nanotubes comprise the physical properties described above, a variety of manufacturing process can be developed, e.g. screen printing, or thin film processing.
[0007] However, the art of manufacturing the cathode structure employs carbon nanotubes as an electron emission material, which is fabricated on the cathode conducting layer. The manufacturing process can employ chemical vapor deposition (CVD) process, or any kind of process that can pattern the photosensitive carbon nanotube solution on any pixel of the cathode conducting layer. Moreover, the cathode structure can also be manufactured by coating the carbon nanotubes solution while incorporating with a mask, or depositing the carbon nanotubes on the cathode conducting layer by an electrophoresis method. However, it is still difficult to fabricate carbon nanotube in the cathode electrode in each pixel by above-mentioned processes. Especially for large-size FED display.
[0008] Recently, an electrophoresis deposition process is proposed, for example, US pre-grant publication No. 2003/0102222 discloses an electrophoresis deposition process. An alcohol suspension for carbon nanotube is prepared and charger such as Mg, La, Y and Al is used to form an electrophoresis solution. The cathode electrode substrate to be deposited is connected to an electrode in the electrophoresis solution. A DC or AC voltage is applied to provide electrical field in the electrophoresis solution. The charger is dissolved in the electrophoresis solution and attached to the carbon nanotube powder. The electrical field will facilitate the carbon nanotube powder to deposit on an electrode. This electrophoresis deposition process can easily deposit the carbon nanotube on the electrode layer without the limit of forming triode field emission display on electrode. Therefore, the electrophoresis deposition process is extensively used on the fabrication of cathode plate.
[0009] Moreover, the applicant of the present invention had also proposed a pulse electrophoresis deposition process to enhance uniformity of carbon nanotube. The deposition amount in unitary area is enhanced and the process can be used for aqueous solution. However, the current pulse electrophoresis deposition process still have following problems.
[0010] 1. The area electrophoresis is difficult for electrophoresis solution with complicated carbon nanotube suspension. Some particles are added to the electrophoresis solution to enhance the adhesion ability of carbon nanotube and the effect of manufacturing electron emission source. The carbon nanotube suspension is sensitive to electrical field distribution, and to concentration and thickness of the display. This problem is more serous for large-size display.
[0011] 2. The pulse electrophoresis deposition process has good effect for aqueous solution. However, the property of solution is critical to some carbon nanotube. For example, some non-aqueous solution such as alcohol solution has good property for most carbon nanotube. However, the pulse electrophoresis deposition process uses larger current and has burning risk for alcohol solution.
[0012] 3. The impedance distribution of cathode strip depends on distribution variation of strip length. Therefore, the impedance variation is serious, especially for large-size display. The end of the cathode strip close to power source encounters larger current and has greater deposition concentration. The electrophoresis deposition is not uniform.
SUMMARY OF THE INVENTION
[0013] The present invention is to provide a method for sequentially electrophoresis depositing carbon nanotube of field emission display. In prior art electrophoresis depositing process for large-size anode/cathode plate, the current is large and the deposition is spares. Therefore, the electrophoresis deposition is not uniform for solution with complicated composition. In the present invention, the electrophoresis deposition is localized to one single cathode strip at one time. The complicated particles in the solution is deposited on the single cathode strip, and the remaining cathode strips are conducted successively and individually for global electrophoresis deposition.
[0014] Accordingly, the present invention provides a method for sequentially electrophoresis depositing carbon nanotube of field emission display. The anode ends of a power source are connected to anode strips of an anode plate. The cathode ends of the power source are connected to one input ends of a plurality of controllers. The output ends of the controllers are connected to a plurality of cathode strips of a cathode plate. A signal generator is connected to another input ends of the controllers.
[0015] An electrophoresis tank is provided with electrophoresis solution therein and the anode plate and the cathode plate are placed parallel in the electrophoresis tank. The voltages from anode ends of the power source is output to the anode strips. The signal generator sends pulse voltage signal to one of the controllers such that one of the cathode strip is conducted while the remaining cathode strips are not conducted, whereby only one electrical field is present for one pixel at one time and carbon nanotube is formed at that pixel. The next cathode strip is conducted successively and the remaining cathode strips are non-conducted to fabricate carbon nanotube electron emission source in sequential manner.
BRIEF DESCRIPTION OF DRAWING
[0016] The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself however may be best understood by reference to the following detailed description of the invention, which describes certain exemplary embodiments of the invention, taken in conjunction with the accompanying drawings in which:
[0017] FIG. 1 shows a schematic diagram of the anode plate and cathode plate according to a preferred embodiment of the present invention.
[0018] FIG. 2 shows the schematic diagram of connection of the anode plate and cathode plate to the electrophoresis deposition equipment.
[0019] FIG. 3 shows the schematic diagram of connection of the anode plate and cathode plate to the electrophoresis deposition equipment during fabrication.
[0020] FIG. 4 shows a simplified schematic diagram of connection of the anode plate and cathode plate to the electrophoresis deposition equipment.
DETAILED DESCRIPTION OF THE INVENTION
[0021] With reference to FIGS. 1 and 2 , in the method for electrophoresis depositing carbon nanotube on cathode strip for a field emission display according to the present invention, sequential electrophoresis deposition localizes current to a single pixel to fabricate carbon nanotube electron emission source. Therefore, the peak current can be reduced and the method can be applied to manufacture of large display.
[0022] According to the method of the present invention, a cathode plate 1 is prepared with a plurality of cathode strips 11 (such as 32 cathode strips). The cathode strips 11 are already formed with gate and semi-finished sacrifice layer. The sacrifice layer is used to prevent unwanted deposition (such as gate, dielectric) on the non-electrophoresis deposition area. The sacrifice layer is removed after electrophoresis deposition process.
[0023] Moreover, an anode plate 2 is prepared and the anode plate 2 is formed by platinum, titanium plate or screen-printing plate.
[0024] A power source 3 is connected to the anode plate 2 by anode ends 31 thereof and is connected to input ends of controllers 4 by cathode ends 32 thereof The controller 4 is connected to the cathode strips 11 by output ends thereof.
[0025] Another input end of the controller 4 is connected to a signal generator 5 to complete the connection for electrophoresis depositing. The signal generator 5 provides sequential signal for the cathode strips 11 . The controller 4 controls a conducting and an un-conducting state for the cathode strips 11 and can be realized by signal amplifier or switch. The signal amplifier decides to amplify or not to amplify the output signal from the signal generator 5 . A potential difference is present between the cathode strip 11 and the anode plate to provide an electrical field. Therefore, carbon nanotube electron emission source can be fabricated on a single cathode strip 11 .
[0026] The above-mentioned switch is a timing switch and conducts a predetermined time period such that the signal generated by the signal generator 5 is applied to one cathode strip 11 . A potential difference is present between the cathode strip 11 and the anode plate to provide an electrical field. Therefore, carbon nanotube electron emission source can be fabricated on a single cathode strip 11 . When the predetermined time period is elapsed, the switch is turned off and a next conduction period is provided for a next single cathode strip 11 for fabricating carbon nanotube electron emission source successively.
[0027] With reference to FIGS. 3 and 4 , after the connection for the cathode plate 1 , the anode plate 2 , the scanning power source 3 , the signal amplifier 4 and the signal generator 5 is completed, an electrophoresis solution is prepared for the electrophoresis tank 6 . Alcohol is used for solution and carbon nanotube is used for electron emission source and manufactured by arc discharge. The carbon nanotube has average length below 5 μm and average diameter below 100 nm. The carbon nanotube has multiple wall, the carbon nanotube has an additive concentration of 0.1%-0.005% (preferably 0.02%). The charger uses metal salt is conductive after electrophoresis, for example, the metal salt is one of InCl and indium nitride or other salt with tin. The charger is with 0.1-0.005% weight concentration and glass powder with at 5% weight concentration to enhance adhesion. Preferably the charger is with 0.01% weight concentration.
[0028] The cathode plate 1 and the anode plate 2 are placed in the electrophoresis tank 6 with 3-5 cm separation therebetween. The power source 3 provides a DC or a DC pulse voltage to the anode strip with 120V or 100-300V and with pulse frequency of 250 Hz. The signal 5 sends a continuous square-wave signal to the controller 4 acting as a signal amplifier. The controller 4 amplifies the continuous square-wave signal and sends the amplified continuous square-wave signal to the first one of the cathode strips 11 , while the remaining cathode strips 11 are not conducted. Therefore, an electrical field is established between the first cathode strip 11 and the first anode strip 21 due to a potential difference. A carbon nanotube can be fabricated on the position to be deposited with electron emission source on the first cathode strip 11 . The remaining cathode strips 11 are conducted one by one and other cathode strips 11 are not conducted. In this manner, the electron emission source can be fabricated. The duty cycle for the cathode strips 11 are 1/32 (frequency 32 Hz) or higher frequency provided that the electrophoresis deposition time period is 1 second. The electrophoresis deposition is 10 minutes and an electron emission source with 5-10 um thickness can be formed by one electrophoresis deposition operation.
[0029] Alternatively, the signal generator 5 generates a signal to a plurality of signal amplifiers, where one of the signal amplifiers does not provide signal amplification. Therefore, the first cathode strip 11 is in low level while other cathode strips 11 are in high level, which level is the same as that of anode strips 21 . An electrical field is present in the first cathode strip 11 and the anode plate 2 such that carbon nanotube will be formed on the first cathode strip 11 and can be formed on other cathode strips 11 successively.
[0030] When the controller 4 is timing switch, the signal generator 5 generates a continuous square wave signal to a plurality of timing switches, where the first timing switch is turned on and the remaining timing switches are turned off. Thereof, the first cathode strip 11 is conducted and an electrical field is present in the first cathode strip 11 and the anode plate 2 . A carbon nanotube will be formed on the first cathode strip 11 . When the electrophoresis deposition is performed, the first timing switch counts the deposition time. After a predetermined time period is over, the first timing switch is turned off and the second timing switch is turned on, while other timing switches are turned off. In this manner, the carbon nanotube will be formed on the remaining cathode strip 11 successively.
[0031] To sum up, the scanning-matrix type electrophoresis deposition method according to the present invention has following advantages:
[0032] 1. The electrophoresis deposition method can be used for solution with complicated composition. The distribution is good and various particles can be effectively deposited.
[0033] 2. The electrical field intensity can be increased for a unitary electrophoresis deposition area.
[0034] 3. The cost and electrical current consumption can be reduced for large-size display.
[0035] Although the present invention has been described with reference to the preferred embodiment thereof, it will be understood that the invention is not limited to the details thereof. Various substitutions and modifications have suggested in the foregoing description, and other will occur to those of ordinary skill in the art. Therefore, all such substitutions and modifications are intended to be embraced within the scope of the invention as defined in the appended claims. | A method sequentially performs electrophoresis depositing carbon nanotube of field emission display. Only one cathode strip is subjected to electrical field at one time during electrophoresis deposition. Therefore, the electrophoresis deposition is confined to local area. A cathode plate includes a plurality of cathode strips and the cathode strips sequentially have potential difference with respect to the anode strips, whereby only one electrical field is present for one pixel at one time and carbon nanotube is formed at that pixel. The cathode strips are sequentially applied with voltage for global electrophoresis deposition. | 2 |
RELATED APPLICATIONS
[0001] This application claim priority to U.S. Provisional Patent Application Ser. No. 61/703,379, filed Sep. 20, 2013 and titled TIP RESISTANT REFUSE TOTE, which is incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] The current invention relates to a system of weights and ballasts that are configured to ensure lid closure and prevent tipping of a refuse tote. In particular, the present invention comprises a lid weight and a container ballast that are positioned at precise locations on a refuse tote to prevent tipping of the refuse tote and to prevent the lid from remaining in an opened position following emptying of the tote.
[0003] A refuse tote is a container that is used to store garbage, recyclables, and green waste prior to disposal. Conventional refuse totes are formed of relatively light-weight polymer materials. Some refuse totes include a container having a lid hingedly attached thereto. The interior of the container is accessed by lifting and temporarily removing the lid from an opening of the container. The contents of the tote are protected from the elements and animals by repositioning the lid onto the opening of the container.
[0004] The refuse container is typically emptied by a garbage truck having a clamp that picks up and inverts the tote into a hopper. The inverted position of the tote causes the lid to open under the force of gravity thereby releasing the contents of the tote into the truck. As the tote is returned to its upright position and returned to the ground, the lid of the refuse tote is commonly swung into an opened position. In some instances, the path of swinging lid causes the lid to contact and damage an item in proximity to the tote, such as a car, a person, or a vinyl fence. Further, the momentum created by the swinging lid may result in the tote tipping backwards and falling onto its side. Wind and animals may also cause the emptied refuse tote to tip over, further inconveniencing the owner and causing damage to nearby items.
[0005] Thus, while system and methods currently exist for disposing refuse, challenges still exist. Accordingly, it would be an improvement in the art to augment or even replace current techniques with other techniques.
BRIEF SUMMARY OF THE INVENTION
[0006] In order to overcome the limitations discussed above, the present invention relates to a tip resistant refuse tote having a system of weights and ballasts that stabilize the refuse tote and ensure proper closure to the tote's lid following emptying of the refuse tote. Thus, the present invention provides a refuse tote that eliminates damage due to tipping and uncontrolled swinging of the tote's lid.
[0007] In some instances, a refuse tote is provided having a lid that is hingedly coupled to a container. The container further comprises a front, a rear, a left side, a right side, and an interior having a base. The base of the interior comprises a center of gravity. In some instances, a ballast is provided that is secured to the base at a position that is between the center of gravity and the front of the container, or at a position that is forward of the center of gravity. In some instances, the ballast comprises a weight that weighs approximately 40% of the weight of the emptied refuse tote.
[0008] The lid of the refuse container further comprises a front, a rear, a left side, a right side, an outer surface and an inner surface. In some instances, a weight is secured to the front of the lid, at a position that is opposite the hinged connection of the lid to the container, and at a position that is adjacent the front of the container. In some instances, the lid weight comprises a weight that weighs approximately 40% of the weight of the refuse tote lid.
[0009] The container ballast and the lid weight may include any size, shape, configuration that is compatible for placement on the refuse tote, as described herein. For example, in some instances a lid weight is provided that comprises a handle. Further, the container ballast and the lid weight may include any material sufficient to achieve the weight ratios described herein. For example, in some instances the container ballast and lid weight materials comprise metal, sand, concrete, water, and/or a polymer material.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] In order that the manner in which the above-recited and other features and advantages of the invention are obtained will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. These drawings depict only typical embodiments of the invention and are not therefore to be considered to limit the scope of the invention.
[0011] FIG. 1 illustrates a perspective view of a refuse tote having a lid weight in accordance with a representative embodiment of the present invention.
[0012] FIG. 2 illustrates a cross-section side view of a refuse tote having a lid weight and a container ballast in accordance with a representative embodiment of the present invention.
[0013] FIG. 3 , shown in parts A and B, illustrates a cross-section top view of a container portion of a refuse tote having a container ballast in accordance with various representative embodiments of the present invention.
[0014] FIG. 4 , shown in parts A and B, illustrates various views of a refuse container having a lid weight handle in accordance with a representative embodiment of the present invention.
[0015] FIG. 5 illustrates a cross-section side view of a refuse tote having an integrated container ballast and lid weight in accordance with a representative embodiment of the present invention.
[0016] FIG. 6 illustrates a cross-section side view of a refuse tote having an imbedded container ballast and lid weight in accordance with a representative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The presently preferred embodiment of the present invention will be best understood by reference to the drawings, wherein like reference numbers indicate identical or functionally similar elements. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description, as represented in the figures, is not intended to limit the scope of the invention as claimed, but is merely representative of presently preferred embodiments of the invention.
[0018] As used herein, the term “refuse tote” is understood to include any container having a hinged lid that is capable of containing refuse, such as garbage, recyclables, yard debris, green waste and other items for disposal.
[0019] A used herein, the term “center of gravity” is used to describe a coordinate position in the bottom of the container portion of the refuse tote from which the weight of the refuse tote is considered to act. In some embodiments, the center of gravity for the refuse tote is a center or central point on the bottom of the tote. In other embodiments, the center of gravity for the refuse tote is a point on the bottom of the tote at which the weight distribution between the front, rear, left side and right side of the refuse tote is balanced.
[0020] Referring now to FIG. 1 , a refuse tote 10 is shown. In general, refuse tote 10 comprises a base container 20 having a lid 30 hingedly attached thereto. In some instances, lid 30 is hingedly coupled to a rear side 40 of container 20 . Lid 30 and container 20 are configured to enclose an internal volume 50 that is designed to receive refuse, as shown in FIG. 2 .
[0021] In some embodiments, refuse tote 10 comprises one or more weights that are strategically positioned to prevent tipping of tote 10 and maintain a closed position of lid 30 . For example, in some embodiments tote 10 comprises a lid weight 32 that is attached to lid 30 at a position towards the front 34 of lid 30 , and further at a position that is opposite the hinged connection 12 of lid 30 to container 20 . Further still, in some embodiments, lid weight 32 is coupled to lid 30 at a position that is adjacent the front 42 of container 20 , as shown in FIGS. 1 and 2 . In general, it is desirable to position lid weight 32 at a position maximally distanced from hinged connection 12 .
[0022] The precise position of lid weight 32 is generally centered on lid 30 at a position that is at the front 34 of lid 30 . Lid weight 32 may include any material and/or shape that is compatible for use on a refuse container. In some instances, lid weight 32 comprises a metallic material, such as steel, aluminum, lead, iron and/or stainless steel. In other instances, lid weight 32 comprises a polymer material having sufficient density and/or weight. Further still, in some embodiments lid weight 32 comprises a composite material or a cementitious material.
[0023] In some instances, lid weight 32 comprises an outer plate 36 positioned on an outer surface of lid 30 , and an inner plate 38 positioned on an inner surface of lid 30 , wherein the outer and inner plates 36 and 38 sandwich a portion of lid 30 between the two plates. Outer and inner plates 36 and 38 may be secured to lid 30 by any compatible means. In some embodiments, outer and inner plates 36 and 38 are secured to each other and lid 30 via one or more fasteners 70 , such as a bolt and nut fastener.
[0024] Lid weight 32 comprises an overall weight that is approximately 40% of the weight of lid 30 . In other embodiments, lid weight 32 comprises an overall weight that is from approximately 15% to approximately 60% of the weight of lid 30 . For example, in some embodiments lid weight 32 weighs approximately 4 pounds. In other embodiments, lid weight 32 weighs from approximately 2 pounds to approximately 10 pounds.
[0025] With continued reference to FIG. 2 , some embodiments of the present invention further include a container ballast 22 that is attached to the bottom 44 of tote 20 at a position forward of the center of gravity 100 . In some instances, ballast 22 is positioned such that a minority portion of ballast 22 is positioned at or rearward of center of gravity 100 , and a majority portion of ballast 22 is positioned forward of center of gravity 100 . In other embodiments, ballast 22 is positioned such that a rearward surface of ballast 22 is approximately equal with center of gravity 100 , and the remaining ballast extends forward of center of gravity 100 towards front 42 of tote 20 . Further, in some embodiments ballast 22 is approximately centered between center of gravity 100 and front 42 of tote 20 . Further still, in some embodiments ballast 22 is secured to bottom 44 at a position that is maximally forward of center of gravity 100 .
[0026] Container ballast 22 may include any material and/or shape that is compatible for use on a refuse container. In some instances ballast 22 comprises a metallic material, such as steel, lead, iron, aluminum, and/or stainless steel. In other instances, ballast 22 comprises a polymer material having sufficient density and/or weight. Further still, in some embodiments ballast 22 comprises a composite material or a cementitious material.
[0027] In some instances, ballast 22 comprises an outer plate 24 positioned on an outer surface of container 20 , and an inner plate 26 positioned on an inner surface of container 20 , wherein the outer and inner plates 24 and 26 sandwich a bottom portion 44 of container 20 between the two plates. Outer and inner plates 24 and 26 may be secured to container 20 by any compatible means. In some embodiments, outer and inner plates 24 and 26 are secured to each other and container 20 via one or more fasteners 70 , such as a bolt and nut fastener.
[0028] Container ballast 22 comprises an overall weight that is approximately 40% of the weight of lid weight 32 and refuse tote 10 , when empty. In other embodiments, ballast 22 comprises an overall weight that is from approximately 15% to approximately 60% of the weight of lid weight 32 and refuse tote 10 , when empty. For example, in some embodiments container ballast 22 weighs approximately 20 pounds. In other embodiments, ballast 22 weighs from approximately 10 pounds to approximately 30 pounds.
[0029] Referring now to FIG. 3A , a cross-section top view of container 20 is shown. In some embodiments, center of gravity 100 comprises an x-axis component 100 a and a y-axis component 100 b, wherein the intersection of the two axes 100 a and 100 b is the center of gravity 100 . One having skill in the art will appreciate that the design of refuse tote 10 will necessarily shift the x-axis 100 a and y-axis 100 b components of center of gravity 100 , thereby changing the possible positions of container ballast 22 . Generally, where refuse tote 10 is symmetrical across the y-axis 100 b, container ballast 22 may be centered on y-axis 100 b, as shown.
[0030] In some embodiments, ballast 22 is U-shaped and configured for placement along front 42 and side walls 46 and 48 of container 20 , as shown in FIG. 3B . In this configuration, ballast 22 is positioned in a maximally forward position and maximally outward position with respect to x-axis 100 a and y-axis 100 b.
[0031] Referring now to FIGS. 4A and 4B , in some embodiments lid weight 32 comprises a handle 60 . Handle 60 may include any size and shape that achieves the teachings of the present invention. In some instances, handle 60 comprises a bar 62 that is attached to front 34 of lid 30 via one or more tabs 64 and one or more fasteners 70 . The position of bar 62 extends the distance between hinged connection 12 and lid weight 32 . Further, the position of bar 62 shifts the weight of lid weight 32 to a position maximally forward of the x-axis 100 a of center of gravity 100 , thereby further assisting the function of container ballast 22 . Thus, in some embodiments, lid weight 32 provides a utilitarian function as a handle 60 to assist a user in opening lid 30 .
[0032] Referring now to FIG. 5 , in some embodiments container ballast 22 and/or lid weight 32 comprise an integrated weight. For example, in some embodiments ballast 22 and lid weight 32 comprise a thickened portion of bottom 44 of container 20 and a thickened portion of lid 30 . In some instances, the thickened portions of bottom 44 and lid 30 comprise a polymer material having a greater density than the remaining polymer material of refuse tote 10 . In other embodiments, the thickened portions comprise the same polymer material as the remaining portions of refuse tote 10 , however the dimensions of the thickened portions are selected to achieve the desired weight ratios, discussed above.
[0033] Referring now to FIG. 6 , in some embodiments container ballast 22 and/or lid weight 32 comprise a compartment 80 into which a weighted material 82 is inserted and stored. Compartment 80 may further include a spout or other opening whereby to insert weighted material 82 into compartment 80 . In some embodiments, compartment 80 may be accessed by a user, such as by removing a cap or covering (not shown). Following access to compartment 80 , the user may reclose compartment 80 to retain weight material 82 in compartment 80 .
[0034] Weighted material 82 may comprise any material that is compatible for use with a refuse tote. For example, in some embodiments weighted material 82 comprises a liquid, such as water or antifreeze. In other embodiments weighted material 82 comprises a cementitious material. Further, in other embodiments weighted material 82 comprises a metallic material in the form of lead shot or another type of shot material.
[0035] The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A refuse container having a system of weights and ballasts to prevent tipping and maintain a closed position of the container's lid following emptying of the refuse container. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Divisional Application of Non-Provisional application Ser. No. 11/061,559 entitled ‘Hydraulic Steering’ to Bendt Porskrog, et al. filed Feb. 18, 2005 and claiming priority to German Patent Application No. 10 2004 009 672.4, filed on Feb. 27, 2004, and German Patent Application No. 10 2004 021 531.6 filed on May 3, 2004, the contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
The invention concerns a hydraulic steering with a steering initiator.
BACKGROUND OF THE INVENTION
One type of a steering is known from EP 0 244 418 B1. Such steerings are particularly used in driven machines, for example mobile agricultural equipment. The steering unit activated by the steering initiator, for example a steering handwheel, is used to permit a driver to steer the vehicle. This mode of operation is particularly useful in the road traffic. The auxiliary-force activated steering valve can be used for automatic steering of the vehicle, for example along a path defined from the outside.
In a steering unit, which has feedback properties, it is not absolutely necessary to have a mechanical connection between the steered wheels and the steering initiator, for example the steering handwheel. However, a hydraulic connection is continuously available from the steering motor to the steering unit, so that forces, which act upon the wheels steered by means of the steering motor, can also be felt on the steering handwheel. As soon as the steered wheels are loaded from the outside, pressures are generated in the steering motor, which propagate up to the steering unit thus reaching the measuring motor, which again transfer them to the steering handwheel.
In a steering having a steering unit with feedback properties, it can therefore frequently be seen that the steering initiator moves, when the vehicle is steered by means of the auxiliary-force activated steering valve. When the steering initiator exists in the form of a steering handwheel, this steering handwheel can turn at an activation of the steering by the steering valve, which can be very disturbing for the driver.
Therefore, a change-over valve has been provided in the known steering, which in a first position connects the working connection arrangement with the steering motor and in a second position connects the working connections with each other and separates them from the steering motor. In this case, the steering of the vehicle takes place merely via the steering valve.
This, in fact, prevents a feedback from the steering motor to the steering handwheel, when the vehicle is steered via the steering valve. However, it is not possible for the driver of the vehicle to intervene in the steering behaviour of the vehicle via the steering handwheel, when this is necessary or desired. This can lead to dangerous situations.
SUMMARY OF THE INVENTION
The invention is based on the task of providing a simple manner of ensuring the priority of the steering initiator over the steering valve.
With a steering as mentioned in the introduction, this task is solved in that the steering initiator interacts with an activation sensor, which deactivates the feedback suppressing device on an activation of the steering initiator.
This relatively simple embodiment ensures that in any operating situation the steering handwheel has priority over the effect originating from the steering valve. The activation sensor continuously determines if the steering initiator is activated. As soon as the steering initiator is activated, it is assumed that the driver wishes to enable a direction change by means of the steering initiator. In this case, the steering initiator immediately deactivates the feedback suppressing device, so that it is immediately possible for the steering unit to act upon the steering motor. As the pressures acting upon the steering motor via the steering unit are always larger than the pressures supplied by the steering valve, it is ensured that an activation of the steering initiator will give the steering unit priority over the steering valve.
It is preferred that the steering initiator exists in the form of a steering handwheel, which is connected with the steering unit via a steering shaft, the activation sensor determining an activation of the steering handwheel. When a steering handwheel is activated, this is a unique signal that a direction change of the vehicle is desired. An activation of the steering handwheel is relatively easily determined.
It is preferred that the activation sensor interacts with the steering shaft. This means that the activation sensor is located in a position, in which it does not disturb the driver. The access to the steering handwheel is not impeded in any way. A rotation by a small angle in the range from 1 to 5° can already be determined on the steering shaft, which indicates that a steering activation via the steering handwheel is desired.
Preferably, the activation sensor is a torque sensor. A torque sensor determines when a force is acting in the rotation direction. This force does not yet have to be followed by a movement.
Alternatively, the activation sensor can also be a rotation angle sensor. Already small rotation angles are sufficient to indicate that the steering handwheel has been activated. It is relatively easy to determine a rotary movement of the steering handwheel.
Preferably, the feedback suppressing device has a brake, which acts upon the steering initiator. Thus, the steering initiator is simply retained, when the vehicle is steered via the steering valve. A movement of the steering initiator is thus reliably prevented.
Preferably, the brake acts upon the steering handwheel via the steering shaft. Thus, the steering shaft merely has to be prevented from turning to avoid that the feedback from the steering motor on the steering handwheel can be felt by the driver. This does not require changes of the feedback properties of the steering unit.
Preferably, the activation sensor is located between the brake and the steering handwheel. In spite of an activated brake, the activation sensor can determine when someone turns the steering handwheel. Such a rotary movement of the steering handwheel can at least propagate to the brake, and then leads to a distortion of the steering shaft. Such a distortion does not have to be large to be determined.
It is preferred that the brake is an electrically activated brake. An electrically activated brake is easily activated or deactivated. It can, for example, work electro-magnetically.
It is preferred that the brake generates a maximum braking torque of 8 Nm. Such a braking torque can easily be overcome by a driver, that is, in spite of an activated brake the steering handwheel can be turned without much effort. The effect of the brake is sufficient to prevent the steering initiator from moving along at an activation of the steering valve and the resulting activation of the steering motor.
In an alternative or additional embodiment, it can be ensured that the feedback suppressing device has a change-over valve acting upon the working connection arrangement. This change-over valve changes its switching position to block or permit the feedback from the steering motor to the steering initiator.
In a preferred embodiment it is ensured that in its activated position the change-over valve blocks at least one working connection. When a working connection is blocked, the circuit between the steering motor and the steering arrangement is interrupted, so that influences of the steering motor can no longer penetrate to the steering initiator via the steering valve or via external forces.
Additionally or alternatively, the change-over valve can, in its activated position connect the steering valve with a steering motor, and in its deactivated position connect the steering unit with the steering motor. In the activated position, the working connection arrangement is then interrupted. In the deactivated position of the change-over valve the connection arrangement of the steering valve is interrupted.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention is described on the basis of preferred embodiments in connection with the drawing, showing:
FIG. 1 is schematic diagram of a hydraulic steering with a first embodiment of a feedback suppressing device;
FIG. 2 is a modified form of a hydraulic steering with a different feedback suppressing device; and
FIG. 3 is a third embodiment of a hydraulic steering.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A hydraulic steering according to FIG. 1 has a steering motor 2 , which is provided for steering wheels, not shown in detail. In vehicles with articulated steering, the steering motor can also be provided to swing the front part and the rear part of a vehicle in relation to each other.
The steering motor 2 can be activated in two different ways. Firstly, a steering unit 3 is provided, which is activated by a steering handwheel 4 via a steering shaft 5 . The steering unit 3 has a supply connection arrangement with a pressure connection P and a tank connection T, as well as a working connection arrangement with two working connections L, R. The working connections L, R are connected with the steering motor 2 . The pressure connection P is connected with a pump 7 via a priority valve 6 . The tank connection T is connected with a tank 8 .
The steering unit has a measuring motor 9 and a directional valve 10 . The steering unit 3 has feedback properties, that is, a so-called “reaction” steering unit, in which a pressure change at the working connection L, R can be felt at the steering handwheel 4 . In the hydraulic diagram, this is shown by means of a connecting rod 11 , which does not exist in reality or not in this way. Further, in the neutral position of the directional valve 10 , a hydraulic connection exists between the working connection arrangement L, R and the measuring motor 9 . This means that, when the wheels steered by the steering motor 2 are influenced by jerks or other external forces, such jerks can be felt by the driver on the steering handwheel 4 . Such a feedback can, however, be advantageous for the driving comfort.
Further, the steering motor is connected with a working connection arrangement LV, RV of a steering valve 12 , and can thus be activated by the steering valve 12 . The steering valve 12 can be activated via a control device 13 . The control device 13 can have different embodiments, for example, it can be a radio receiver, via which the vehicle can be remote-controlled, it can be a scanner, by means of which the vehicle can be led along a predetermined path, or it can be a device located somewhere else in the vehicle, by means of which the vehicle can be steered from a second position.
The control device 13 is connected with a drive 14 of a proportional valve 15 . The proportional valve 15 has a slide 16 , which can be displaced more or less in one direction or the other by a control signal generated by the control device 13 , releasing more or less a flow path from the pump connection P to the steering motor 2 and from the steering motor 2 to the tank connection T in dependence of the direction and the size of the deflection.
However, between the pump connection P and the proportional valve 15 a bleed or a throttle 17 is further provided, which ensures that the pressure at the outlet of the proportional valve 15 is always smaller than the pressure at the outlet of the directional valve 10 , also when both the directional valve 10 and the proportional valve 15 are activated simultaneously. This throttle 17 can be avoided, when at simultaneous activation of the steering unit 3 and the steering valve 12 it is ensured that the steering unit 3 has priority over the steering valve 12 .
In a manner known per se, the steering unit 3 is provided with a load-sensing outlet LSE and the steering valve 12 is provided with a load-sensing outlet LSV. Both load-sensing outlets are connected with the pump 7 via a change-over valve 18 with a load-sensing inlet LSP. Here, the pump 7 is shown as a displacement pump. However, the displacement pump can also be replaced by a pump arrangement, in which it is otherwise ensured that the pressure supplied by the pump corresponds to the demand.
Usually, the steering motor is steered either via the steering unit 3 or via the steering valve 12 . When, now, the steering motor 2 is activated via the steering valve 12 , a pressure difference occurs between the working connections L, R, which can, due to the feedback properties of the steering unit 3 , cause that the steering handwheel 4 turns. This can be disturbing or unpleasant for the driver.
To prevent such a turning of the steering handwheel 4 , a brake 19 is provided, which acts upon the steering shaft 5 . The brake 19 is activated via a brake drive 20 . The brake drive 20 can, for example, be a magnet, which draws brake pads towards the steering shaft 5 . The braking torque exerted by the brake does not have to be particularly large. It can, for example, be in the range between 5 and 8 Nm. Such a braking torque is sufficient to prevent a movement of the steering handwheel in spite of the feedback properties of the steering unit 3 .
The brake 19 is activated by the control device 13 , when the control device 13 activates the proportional valve 15 . For this purpose, a line B is provided.
In order to be able to ensure, also during steering of the vehicle via the steering valve 12 , that the driver can steer by means of the steering handwheel 4 , which may be required in connection with an emergency, an activation sensor 21 is provided, which interacts with the steering shaft 5 . The activation sensor 21 determines if the steering handwheel 4 has been turned. Due to the relatively small braking torque provided by the brake 19 , such a turning is possible without problems, however, requires a slightly large force to be provided by the driver. Also with engaged brake 19 , a small turning of the steering shaft is usually possible. In this case, the activation sensor 21 can exist in the form of a rotation angle sensor, which determines the rotation movement of the steering shaft 5 being turned against the force of the brake 19 .
An alternative position of the activation sensor 21 is shown by means of dotted lines. The activation sensor 21 is namely located between the steering handwheel 4 and the brake 19 . Also in this case, the activation sensor 21 can, of course, be a rotation angle sensor. However, it can also be a torque sensor. When namely, the steering handwheel 4 is turned, when the brake 19 is engaged, this will cause a small distortion of the steering shaft 5 , which can be determined by the torque sensor. Of course, also other determination methods for a torque can be imagined.
In the embodiment shown, the activation sensor 21 acts immediately upon the braking drive 20 , thus overriding the order of the control device 13 . When the activation sensor 21 establishes that the steering handwheel 4 is turned, and that thus also the steering shaft 5 must turn, the brake 19 is immediately disengaged.
However, it is also possible to let the activation sensor 21 interact with the control device 13 , so that the disengagement of the brake 19 is caused by the control device 13 .
As soon as the driver turns the steering handwheel 4 , the steering unit 3 is activated. As the steering unit 3 provides a larger outlet pressure at the working connection arrangement L, R than the steering valve 12 , the vehicle is steered by means of the steering handwheel 4 as long as the driver finds this necessary.
The directional valve 10 usually has a slide set with an inner slide and an outer slide, as known per se. When the steering motor 2 is activated via the steering valve 12 , a pressure difference occurs between the measuring motor and the slide set. As, however, the inner slide is retained, the slide set will only open slightly to balance this pressure difference. This gives a balanced situation with no significant oil flow through the steering unit 3 .
Thus, the brake 19 forms a feedback suppressing device, which can be activated at start-up of the steering valve 12 and deactivated via the activation sensor 21 .
FIG. 2 shows a modified embodiment in which the same or functionally the same elements have the same reference numbers.
Instead of the brake 19 (or additionally to it), a change-over valve 22 is connected between the working connection arrangement L, R and the steering motor 2 . In the switching position shown, the change-over valve 22 connects the working connection arrangement LV, RV of the steering valve 12 with the steering motor 2 . When changed over, it connects the working connection arrangement L, R of the steering unit 3 with the steering motor 2 .
Thus, the change-over valve 22 ensures that always only either the steering unit 3 or the steering valve 12 can act upon the steering motor 2 . A parallel operation of the two units 3 , 12 is not possible.
The change-over valve 22 is changed to the position shown by the control device 13 , as soon as the steering motor 2 has to be activated by the steering valve 12 .
If, however, the activation sensor 21 determines that the steering handwheel 4 and thus the steering shaft 5 are turned, this is reported via a line S to the control device 13 , which then activates a drive 23 , for example a magnet drive, of the change-over valve 22 and changes the change-over valve 22 to the other switching position, in which the working connection arrangement L, R of the steering unit 3 is connected with the steering motor 2 . This change can take place relatively fast, as it is supported by a spring 24 . Further, the pressure at the load sensing outlet LSE of the steering unit 3 , which builds up relatively fast, also acts upon the change-over valve 22 via an inlet LSU.
As soon as the steering handwheel 4 is turned, the activation of the steering motor 2 takes place exclusively via the steering unit 3 .
In relation to FIG. 2 , FIG. 3 shows a simplified embodiment, in which the change-over valve 22 merely either releases (switching position shown) or interrupts a working line between a working connection L and the steering motor 2 . When the change-over valve 22 assumes the switching position shown, a feedback from the steering motor 2 on the steering handwheel 4 is possible, but on the other hand also a control of the steering motor 2 by the steering handwheel 4 . When the change-over valve 22 is switched to the other position, the fluid circuit through the steering unit 3 is interrupted and thus also the feedback.
Thus, in the embodiments according to FIGS. 2 and 3 , the change-over valve 22 forms the feedback suppressing device.
In all three embodiments, a small turning of the steering shaft 5 , for example in the range from 1 to 5°, is sufficient to signal the wish for controlling the vehicle via the steering unit 3 . Such a small turning of the steering shaft 5 is reliably determined by the activation sensor 21 , which then immediately deactivates the feedback suppressing device 19 , 22 .
In the embodiments according to FIGS. 1 and 3 it will be expedient to displace the steering valve 12 , which can be a proportional valve, to its neutral or blocking position, when the steering handwheel is activated. In this case, it is avoided that, under unfavourable circumstances, hydraulic fluid, which was to drive the steering motor 2 , can flow off to the tank via the steering valve 12 .
While the present invention has been illustrated and described with respect to a particular embodiment thereof, it should be appreciated by those of ordinary skill in the art that various modifications to this invention may be made without departing from the spirit and scope of the present invention. | The invention concerns a hydraulic steering with a steering initiator, a steering unit with feedback properties, which can be activated by the steering initiator, the steering unit having a supply connection arrangement with a pressure connection (P) and a tank connection (T) and a working connection arrangement with two working connections (L, R), an auxiliary-force operated steering valve, which is located in parallel with the steering unit between the supply connection arrangement (P, T) and the working connection arrangement (L, R), and a feedback suppressing device, which is active, when the steering valve is active. It is endeavored to find a simple manner of ensuring the priority of the steering initiator over the steering valve. For this purpose, the steering initiator interacts with an activation sensor, which deactivates the feedback suppressing device on an activation of the steering initiator. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a signal processing system for a magnetic flowmeter, and in particular to such a system which automatically maintains the internal accuracy of the system over a wide range of flow rates, and in particular at low flow rates.
In a magnetic flowmeter system, the output of the meter is a voltage proportional to the rate of flow of a fluid flowing through the meter body. This signal is generally of rather low level, and is amplified by a signal processing system to provide an output signal. In presently known magnetic flowmeter systems, the accuracy of the signal processing system, in terms of percentage of flow, decreases dramatically as the flow rate decreases below, say, ten percent of full scale. To compensate for this effect, the signal processing system includes a manual "range" setting which permits the system to operate in a "normal" range for flow rates of between ten percent of full-scale and full-scale, and in a "low" range for flow rates below ten percent. This arrangement has a number of drawbacks. For example, it requires operating personnel to keep watch over the output of the system and make the appropriate change in setting when the flow rate reaches the critical setting. It does not maintain as high a degree of accuracy as desirable in either operating range. It requires calibration of both scales. It requires conversion of the displayed output of the system from one range into the units of the other range (e.g. dividing by ten).
SUMMARY OF THE INVENTION
One of the objects of this invention is to provide a magnetic flowmeter signal processing system which automatically maintains the accuracy of the output signal throughout an extended range without requiring any intervention from without the system.
Another object is to provide such a system which provides an output signal which varies continuously with the flow-dependent input signal.
Another object is to provide such a system which is capable of maintaining greater accuracy throughout an extended flow range than presently known systems.
Other objects will become apparent to those skilled in the art in the light of the following description.
In accordance with this invention, an automatic ranging system is provided for a magnetic flowmeter which includes a body adapted to be connected in a flow system for measuring the flow of a fluid therethrough, means for generating a magnetic field in the fluid flowing through the body, means for producing a flow-dependent signal dependent on the electric field generated in the fluid flowing through the magnetic field, and amplifier means for amplifying the flow-dependent signal to produce an amplified flow-dependent signal, and further signal processing means for receiving the amplified flow-dependent signal and producing an output signal dependent thereon, wherein the automatic ranging means comprises first means for increasing the gain of the amplifier means as the flow-dependent signal decreases and second means for producing a signal in the further signal processing means indicative of the increase in gain.
By making the second means decrease the magnitude of the output signal proportionally to the increase in the gain of the amplifier means, an output is produced which is substantially continuous with respect to the flow-dependent signal while preserving internal accuracy.
Preferably, the first means comprise means for sensing the magnitude of the amplified flow-dependent signal and maintaining the magnitude within a predetermined range over an extended range of values of the flow-dependent signal. Also preferably, the amplifier means comprise an operational amplifier and the first means comprise a plurality of resistors and means for switching the resistors into and out of circuit with the operational amplifier to vary its gain in steps.
Also preferably, the further signal processing means comprise means for producing a variable frequency signal dependent on the amplified flow-dependent signal and the second means comprise a digital divider circuit which varies the frequency of the variable frequency signal by integral steps.
Other aspects of the invention will be better understood with reference to the following description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a schematic diagram of a magnetic flowmeter system including the preferred embodiment of automatic ranging system of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, reference numeral 1 indicates a magnetic flowmeter system incorporating the present invention. The flowmeter system 1 includes a flow tube 3, a pair of oppositely disposed electromagnetic coils 5 energized from a source 7, and a pair of electrodes 9 which sense a voltage generated by the flow of an electrically conductive fluid through the magnetic field produced by the coils 5 across the tube 3. The voltage across the electrodes 9 is amplified by a preamplifier 11. All of these components may be conventional.
The output of the preamplifier 11 is rectified by the rectifier 13 and is amplified by an amplifier 5. The amplifier 15 preferably includes an operational amplifier and a feedback amplifier. The input to the operational amplifier is periodically zeroed, and the feedback amplifier is switched into circuit between the operation amplifier output and its input reference, to reduce the output offset of the operational amplifier to a fixed minimum value. Such circuits are well known in the art. A suitable circuit is described in our co-pending application Ser. No. 82,762, filed concurrently herewith. The gain of the operational amplifier 15 is controlled by the ratio of the feedback resistance to the input resistance. These resistance values are set by a network 17 of feedback resistors 17a, 17b, 17c and 17d, controlled by a bank 19 of semiconductor switches 19a, 19b, 19c and 19d respectively, and by a network 21 of input resistors 21a, 21b, 21c and 21d, controlled by a second bank 23 of semiconductor switches 23a, 23b, 23c and 23d respectively. The resistor networks 17 and 21 may be precision ratio matched resistors, such as a 0.1 percent matched resistor package sold by Beckman Instruments, Inc. as its number 699-3-R100K-D and 699-3-R20K-D respectively. The semiconductor switches 19 and 23 may be integrated circuits such as Motorola MC14066BCP. The control pins of the switches 19 and 23 are connected to a gain control circuit 25. The output of the amplifier 15 is applied to an analog to digital converter 27. Numerous suitable converters are known. In the preferred embodiment, the converter 27 is a voltage to frequency converter. The output of the analog to frequency converter 27 is connected through a divide-by-N circuit 29 to an output 31 for display or control. The value of N is controlled by the gain control 25 as described hereinafter. Suitable divide-by-N and output circuits are well known in the art.
The output of the amplifier 15 is also fed to a high-low sense circuit 33. The sense circuit 33 compares the output of the amplifier 15 with a high and a low reference voltage and signals the gain control 25 when the output of the amplifier 15 is out-of-range. Suitable comparators are well known in the art.
In the operation of the system, in the no-flow condition all of the input resistors are connected in parallel to provide minimum resistance in the input path to the amplifier 15. This is accomplished by providing gating signals through a first control line 35 and second control line 37 to switches 23a, 23b and 23c of the switch network 23. The fourth switch 23d is connected to a voltage source and is always closed. Three switches 19a, 19b, and 19c controlling current flow through parallel feedback resistors 17a, 17b and 17c, respectively, are kept open by the gain control circuit 25 in the no-flow condition. The fourth switch 19d is connected to a voltage source and is always closed. The feedback resistor network 17, therefore, provides maximum resistance, and the gain of the amplifier 15 is at its maximum value of twenty.
As flow through the flow tube 3 increases, the magnitude of the output signal from the amplifier 15 increases until it reaches the high threshold of the high-low sense circuit 33. By way of example, this threshold voltage may correspond to an average velocity of about two feet per second. At this point, the high-low sense circuit 33 signals the gain control 25 to decrease the gain of the amplifier 15. The gain control 25 thereupon removes the control signal from line 35, thereby opening the switches 23a and 23b and doubling the input resistance to the amplifier 15. The gain of the amplifier 15 is therefore halved to ten.
When the average velocity of the flow through the meter 3 doubles, the output of the amplifier 15 again exceeds the upper threshold of the high-low sense circuit 33. This circuit then signals the gain control to lower the gain by removing the control signal from line 37, thereby opening switch 23c and doubling the input resistance and halving the gain of the amplifier 15.
In like manner, as the flow rate again doubles, a signal is applied through line 39 to halve the effective feedback resistance. As the flow rate again doubles and approaches maximum flow, a signal through control line 41 closes switches 19a and 19b and again halves the effective feedback resistance to reduce the gain of the amplifier is to a value of 1.25.
As the flow rate decreases to a point that the low threshold value of the high-low sense circuit 33 is reached, the signals applied to the control lines are sequentially reversed, starting with line 41, to double the gain of the amplifier 15. It will be apparent that the high and low theshold values are preferably set such that the high-low sense device 33 provides hysteresis and prevents oscillation of the gain control.
It will be seen that the portion of the system of this invention ahead of the analog to digital converter 27 in the signal processing chain provides at least two major advantages. First, the output of the amplifier 15 is maintained at a sufficiently high value to minimize any residual offset error not compensated by automatic zeroing. Second, the input to the analog to digital converter is maintained within a relatively narrow range, so that the converter 27 may operate in its range of optimum accuracy.
The output of the analog to digital converter is divided by an integer N which is also set by the gain control circuits. It will be apparent that with the gain of the amplifier 15 set at its minimum value, the most convenient value of N is one. As the gain of the amplifier 15 is doubled, the value of N is doubled, so that at maximum gain the value of N is sixteen. The signal provided to the output 31 is therefore continuous with the input signal provided by the preamplifier 11, hence with flow rate. The automatic ranging system of the invention is not observable from outside the signal processing chain, except, possibly, for an extremely brief transient at the switching points. Such transients are easily suppressed at the output.
Numerous variations in the automatic ranging system of the present invention will occur to those skilled in the art in light of the foregoing disclosure. Merely by way of example, the values of the matched resistors 17 and 21 may be different from those of the preferred embodiment, and more or fewer levels of amplification may be utilized. As previously noted, various low offset or automatically zeroed amplifiers may be used for the amplifier 15. Other analog to digital converters may be used, such as those having a digital word output rather than a frequency output, although the frequency output is presently preferred for its ease of transmission and ease of utilization by existing output devices. These variations are merely illustrative. | The internal accuracy of a magnetic flowmeter signal processing chain is preserved throughout an extended flow range by means of an automatic ranging system which automatically multiplies the gain of an amplifier in the chain as the flow rate decreases, and simultaneously divides its output to produce an essentially continuous output signal. The automatic ranging system eliminates manual range setting and is not observable from outside the system in the steady state. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/041,189 filed on Jan. 21, 2005 by Morten Mernoe, which is a continuation of International Application No. PCT/DK2003/000507 filed Jul. 21, 2003, which claims priority to Denmark Patent Application No. PA200201133 filed on Apr. 24, 2002. The disclosures of these previous applications are incorporated herein by reference.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] The present invention generally relates to the technical field of infusing a liquid to a patient or person by means of an infusion pump, e.g. at a hospital. The present invention also relates to infusion of liquid to an animal. More precisely, the present invention relates to an infusion pump system and an infusion pump unit of a universal applicable structure for infusing a liquid into a patient or person.
[0004] At hospitals or nurse houses, it is often necessary to supply medication or body liquids to a person by means of an infusion pump in which instance the medication or the body liquids are infused into the body of the patient or person in question through a catheter which is connected to the blood transportation system of the patient or person, e.g. a vein or a venule. The usual technique of supplying medication by means of an infusion system to a patient or person involves the supply of physiologic liquid to the patient which physiologic volume is supplied at a specific rate and which serves as a diluting liquid as the medication is supplied to the physiologic liquid also at a specific rate such as one or two drops of medication per time period varying from a second or a few seconds to several minutes or even hours. The medication of a patient or person may in some applications involve the supply of the medication directly to the patient or person by means of the infusion pump.
[0005] U.S. Pat. No. 6,270,478 discloses an infusion pump system allowing the patient or person using the infusion pump system to shift from a position sitting or lying in a bed and move around without necessitating the substitution or shift of the stationary infusion pump to a portable infusion pump as the infusion pump system constitutes a universally applicable or combined portable and stationary infusion pump system.
[0006] An advantage of this known system relates to the fact that the infusion pump system may be used in different pumping modes as the infusion pump system includes several programmes for different operational modes and further preferably includes input means for input of different operational programmes. U.S. Pat. No. 6,270,478 is hereby incorporated herein by reference.
[0007] The pump actuator of the infusion pump units of this known system comprises a magnetic core and a solenoid coil. This actuator is rather bulky, noisy and heavy and requires a relatively large input of electrical energy.
SUMMARY
[0008] It is an object of the present invention to provide an infusion pump system, an infusion pump unit for said system and an infusion pump in general were the pump actuator is lighter, smaller, quieter and less power consuming.
[0009] According to one aspect of the invention this object is achieved by providing a shape memory alloy actuator as the pump actuator, and said shape memory actuator comprises:
a body arranged displaceable between a first and a second position,
releasable holding means adapted for holding said body in said first position,
at least one first and at least one second wire made of a shape memory alloy such as nitinol, said first wire being at one end connected to said body such that shortening of the length of said first wire exerts a force on said body for moving said body from said second to said first position, and a biasing means, such as a tension spring, a compression spring, a straight or arcuate flat spring or a piston and cylinder mechanism, arranged and adapted for biasing said body for moving said body from said first to said second position,
said second wire having one end connected to said holding means such that shortening of the length of said second wire releases said holding means for allowing said biasing means to move said body from said first position to said second position.
[0015] According to another aspect this object is obtained by providing a shape memory alloy actuator as the pump actuator, and said shape memory actuator comprises:
a body arranged displaceable between a first and a second position, at least one first wire made of a shape memory alloy such as nitinol, said first wire being at one end connected to said body such that shortening of the length of said first wire exerts a force on said body for moving said body from said second to said first position, a biasing means, such as a tension spring, a compression spring, a straight or arcuate flat spring or a piston and cylinder mechanism, and a rotatably arranged intermediate member such as a lever or a disc connected to said body and to said biasing means, said biasing means being adapted for exerting a rotation force on said intermediate member for rotating said intermediate member around an axis of rotation in a first direction of rotation from a first angular position to a second angular position, said intermediate member being connected to said body such that rotation of said intermediate member in said first direction of rotation displaces said body from said first position to said second position, and said biasing means and said intermediate member being arranged and adapted such that the lever or moment arm of said rotation force with respect to said axis of rotation is larger when said intermediate member is in said second angular position than when said intermediate member is in said first angular position such that said lever or moment arm of said rotation force increases when said intermediate member rotates in said first direction of rotation.
[0022] According to a yet further aspect of the invention this object is achieved by providing a shape memory alloy actuator as the pump actuator, and said shape memory actuator comprises:
a body arranged displaceable between a first and a second position,
at least one first wire made of a shape memory alloy such as nitinol, said first wire being at one end connected to said body such that shortening of the length of said first wire exerts a force on said body for moving said body from said second to said first position, a biasing means, such as a tension spring, a compression spring, a straight or arcuate flat spring or a piston and cylinder mechanism, and a rotatably arranged intermediate member such as a lever or an arm connected to said body at a force transmission point on said body and connected to or integral with said biasing means,
said biasing means being adapted for exerting a rotation force on said intermediate member for rotating said intermediate member around an axis of rotation in a first direction of rotation from a first angular position to a second angular position, said intermediate member being connected to said body such that rotation of said intermediate member in said first direction of rotation displaces said body in from said first position to said second position, and
said intermediate member and said body being arranged and adapted such that said rotation force is transmitted to said body as a displacement force applied at said force transmission point for moving said body from said first to said second position, and such that the lever or moment arm of said displacement force with respect to said axis of rotation is larger when said intermediate member is in said first angular position than when said intermediate member is in said second angular position such that said lever or moment arm of said displacement force with respect to said axis of rotation
[0027] Hereby a quiet, light, mechanically efficient and compact infusion pump is obtained.
[0028] In a yet further aspect the present invention relates to a fluid pump, preferably for use in an infusion pump system, an infusion pump unit or as an infusion pump, said fluid pump comprising:
a flexible tube connected to a fluid inlet at one end and connected to a fluid exit at the opposite end, at least three flattening bodies for flattening said tube against an abutment element and arranged along the length of said tube, said bodies being arranged displaceable between a first position, wherein said body is pressed against said abutment element with said tube flattened between said body and said abutment element, and a second position spaced so far from said abutment element that said tube at least partly has regained an open configuration, at least one first wire for each flattening body and made of a shape memory alloy, said first wire being at one end connected to said body such that shortening of the length of said first wire exerts a force on said body for moving said body from said first to said second position, and a biasing means, such as a tension spring, a compression spring, a straight or arcuate flat spring or a piston and cylinder mechanism, for each of said flattening bodies and connected to said flattening body such that a biasing force is exerted on said flattening body in a direction from said second position to said first position.
[0033] Hereby an exceptionally light, simple and quiet infusion pump is obtained where the elements that are to be replaced for each infusion are relatively inexpensive and easy to replace.
[0034] In a yet further aspect the present invention relates to an infusion pump for infusing a fluid or a paste in a patient, preferably a portable infusion pump and preferably for use in infusing insulin or a pain killer fluid in a patient, said infusion pump comprising:
a housing,
a cartridge, ampoule or syringe containing said fluid or paste and removably arranged in said housing and having an outlet aperture and a piston element slidably arranged inside said syringe such that said piston is displaceable towards said outlet aperture, a spindle connected to said piston element and arranged such that rotation of said spindle in a first rotational direction displaces said piston towards said outlet aperture a shape memory alloy actuator incorporated in a shape memory alloy motor comprising: said shape memory alloy actuator having:
a body arranged displaceable between a first and a second position, at least one first wire made of a shape memory alloy such as nitinol, said first wire being at one end connected to said body such that shortening of the length of said first wire exerts a first displacement force on said body for moving said body from said second to said first position, a biasing means, such as a tension spring, a compression spring, a straight or arcuate flat spring or a piston and cylinder mechanism arranged and adapted for exerting a second displacement force on said body for moving said body from said first to said second position,
and a gear having a first and second rotation direction,
said body having a portion adapted to fit between two adjacent teeth of said gear, and said body and said gear being adapted and arranged such that in said first position said portion is located between a pair of teeth of said gear and in said second position said portion is located between the adjacent pair of teeth of said gear reckoned in said second rotation direction of said gear such that said second displacement force will cause said body to rotate said gear in said first direction, and
said gear being connected to said spindle, preferably via at least one further gear such that rotation of said gear in said first direction causes said spindle to rotate in said first rotational direction.
[0045] In a yet further aspect the present invention relates to an infusion pump for infusing a fluid or a paste in a patient, preferably a portable infusion pump and preferably for use in infusing insulin or a pain killer fluid in a patient, said infusion pump comprising:
a housing,
a cartridge, ampoule or syringe containing said fluid or paste and removably arranged in said housing and having an outlet aperture and a piston element slidably arranged inside said syringe such that said piston is displaceable towards said outlet aperture, said shape memory alloy actuator, having
a body arranged displaceable between a first and a second position, at least one first wire made of a shape memory alloy such as nitinol, said first wire being at one end connected to said body such that shortening of the length of said first wire exerts a first displacement force on said body for moving said body from said second to said first position, a biasing means, such as a tension spring, a compression spring, a straight or arcuate flat spring or a piston and cylinder mechanism arranged and adapted for exerting a second displacement force on said body for moving said body from said first to said second position,
and a rack having a first and second displacement direction and abutting said piston such that displacement of said rack in said second displacement direction displaces said piston towards said outlet aperture,
said body having a portion adapted to fit between two adjacent teeth of said rack, and said body and said rack being adapted and arranged such that in said first position said portion is located between a pair of teeth of said rack and in said second position said portion is located between the adjacent pair of teeth of said gear reckoned in said second displacement direction of said rack such that said second displacement force will cause said body to displace said rack in said first direction.
[0054] In a final aspect the present invention relates to an infusion pump system, comprising:
at least one infusion pump unit, comprising: a housing of a size allowing said infusion pump unit to be carried by a user as a portable infusion pump unit, said housing defining an exterior surface, a fluid inlet provided accessibly at said exterior surface for establishing fluid communication from an external infusion bag to said fluid inlet, a fluid outlet provided accessibly at said exterior surface for establishing fluid communication to an infusion site, a controllable pumping system included within said housing and having an inlet and an outlet, said inlet being connected to said fluid inlet and said outlet being connected to said fluid outlet for allowing transfer of fluid from said fluid inlet to said fluid outlet through activating said controllable pumping system, an electronic control means received within said housing for controlling the operation of said controllable pumping system, said electronic control means including at least two preset pumping programs for allowing said controllable pumping system to be controlled in at least two alternative infusion pumping operations, and a power supply unit housed within said housing for supplying power to said controllable pumping system and to said electronic control means and connectable through exterior terminals provided at said exterior surface of said housing to external electric energy supply means,
[0062] a stationary receptor system including:
at least one receptor means for receiving and fixating one of said infusion pump unit therein so as to maintain said infusion pump unit in a stationary mode and exposing said fluid inlet and fluid outlet of said infusion pump unit for allowing access thereto and having first terminals connectable to said exterior terminals for supplying said electric energy to said power supply unit of said at least one infusion pump unit and further having second terminals connectable to third terminals of a second receptor means for supplying power to said second receptor means, a mains supply unit for receiving electric energy from the mains supply and having second terminals connectable to said third terminals for supplying said electric energy to said receptor means and thereby to said power supply unit of said at least one infusion pump unit, said mains supply unit constituting said external electric supply means, and fastening means for fastening said receptor means adjacent one another and for fastening said mains supply unit adjacent one of said receptor means.
[0066] In the currently preferred embodiment, said system further comprises a carrier frame for carrying one infusion pump unit and provided with receiving means for receiving said infusion pump unit and preferably with releasable holding means for holding a container of infusion fluid communicating with said fluid inlet of said infusion pump unit, said receptor means and said carrier frame having cooperating connection means for allowing said frame to be connected to said receptor means such that said external terminals are connected to said first terminals.
[0067] Hereby a flexible system is obtained where an optional number of receptor means may be arranged adjacent one another and where great flexibility is achieved as to the transport of an infusion pump unit with the corresponding patient.
BRIEF DESCRIPTION OF THE DRAWINGS
[0068] In the following the invention will be explained more in detail in connection with various embodiments thereof shown, solely by way of example, in the accompanying drawings in which
[0069] FIG. 1 is a perspective and schematic view of a first embodiment of a portable infusion pump unit according to the present invention,
[0070] FIG. 2 is an elevational and partly sectional view of the first embodiment of the portable infusion pump unit illustrated in FIG. 1 ,
[0071] FIG. 3 is a schematic view of the interior of the first embodiment of the portable infusion pump unit illustrated in FIGS. 1 and 2 , disclosing the flow path thereof,
[0072] FIG. 4 is a schematic view illustrating a possible application of the first embodiment of the portable infusion pump unit illustrated in FIGS. 1, 2 and 3 ,
[0073] FIG. 5 is a perspective and schematic view illustrating the application of the first embodiment of the portable infusion pump unit illustrated in FIGS. 1-4 in a stationary charger and fixation system for providing a stationary infusion pump system,
[0074] FIGS. 6 and 7 are schematic illustrations of a first embodiment of a pump actuator according to the invention in two different positions, namely with the activating pin fully retracted in FIG. 6 , and with the activating pin fully extended in FIG. 7 ,
[0075] FIGS. 8 and 9 are schematic illustrations of a second and third embodiment, respectively, of a pump actuator according to the invention,
[0076] FIGS. 10-12 are schematic illustrations of three stages in the operation of a fourth embodiment of an actuator according to the invention,
[0077] FIG. 13 is a graph showing two curves of Contraction versus Force for shape memory alloy wires for different biasing systems for the actuators according to the invention, and
[0078] FIG. 14 is a graph showing the relationship between various forces in Newton and the distance of displacement of a piston pump plunger in mm by the actuator shown in FIGS. 10-12 .
[0079] FIGS. 15 and 16 are schematic illustrations similar to FIG. 2 of a second embodiment of an infusion pump unit according to the invention illustrating the use of the shape memory alloy actuators of FIGS. 6-7 and FIGS. 10-12 , respectively, as the pump actuators
[0080] FIG. 17 is a sequence of schematic illustrations showing various stages in the pumping cycle of a fluid pumping system according to the invention utilising SMA actuators,
[0081] FIG. 18 schematically illustrates two stages in the operation of an SMA actuator incorporated in the pumping system in FIG. 17 ,
[0082] FIG. 19 is a schematic illustration of a first embodiment of a shape memory alloy actuator motor for use in an infusion pump according to the invention,
[0083] FIG. 20 is a schematic illustration of a second embodiment of a shape memory alloy actuator motor for use in an infusion pump according to the invention,
[0084] FIG. 21 is a schematic, partly sectional view of an infusion device according to the invention particularly well suited for dispensing insulin to a diabetes patient,
[0085] FIG. 22 is a schematic view of the actuator and dispensing syringe of the device in FIG. 21 ,
[0086] FIG. 23 is a schematic view of a second embodiment of an actuator and a dispensing syringe for incorporation in the device in FIG. 21
[0087] FIG. 24 is a schematic view of a rack-type SMA actuator for incorporation in the device in FIG. 21 ,
[0088] FIG. 25 is a perspective and schematic view illustrating an alternative application of the first embodiment of the portable infusion pump unit illustrated in FIGS. 1-4 in a stationary charger and fixation system for providing a stationary infusion pump system, and
[0089] FIG. 26 is a perspective and schematic view of the components of the system in FIG. 25 .
DETAILED DESCRIPTION
[0090] In the drawings, a first embodiment of a portable infusion pump unit or apparatus is disclosed designated the reference numeral 10 in its entirety. The apparatus 10 comprises a housing composed of two shell-like housing parts 12 and 14 constituting a front and rear housing part, respectively. The front an rear housing parts 12 and 14 , respectively, are easily disassembled allowing the user to obtain access to the interior of the apparatus for substituting an interior fluid passage component to be described in greater detail below with reference to FIG. 3 constituting a disposable pre-sterilized component which is easily demounted after use and readily replaced prior to use. From the rear side of the housing part 14 , a clip 16 allowing the apparatus 10 to be fixed to a strap or a belt extends. It is to be realised that terms such as upper, lower, front, rear, etc., unless otherwise stated, in the present context define positions or orientations determined by the intentional application of the apparatus 10 as the apparatus is positioned in an upright and substantially vertical position, e.g. received in the belt of a user by means of the clip 16 or otherwise positioned exteriorly or non-implantatedly relative to the user.
[0091] In the front housing part 12 , a display 20 is provided, comprising two sets of two digits designated the reference numerals 22 and 24 , respectively, for displaying digits representing the time lapsed or the time remaining for infusion operation expressed in minutes and hours, respectively, or seconds and minutes, respectively, or alternatively for displaying digits representing the supply of infusion liquid as expressed in volume per time unit, e.g. ml per hour. The display 20 further includes a display area 26 for informing the user and/or a person operating the infusion pump apparatus 10 or nursing the user regarding the operational mode of the apparatus, such as standby or running information. Furthermore, the display 20 includes a number of individual displays positioned above one another and above the standby/running display 26 , one of which is designated the reference numeral 28 . These individual displays 28 are adapted to display information such as the operational mode, e.g. the information that the apparatus is in a program mode, information regarding whatever information is presented on the two-digit displays 22 , 24 , such as the time remaining for infusion operation, the total time of the infusion operation, whether or not the apparatus is running or is to be started, or any other relevant information to be presented to the user or operator. The display 20 further includes three individual alarm displays 30 , 32 and 34 for informing the user of the presence of air in the infusion pump circuitry, pressure fault or failure or low battery, respectively. A further display 36 informs the user or operator of the program sequence presently used or programmed, which program sequence is represented by a digit displaced by a 1-digit display 38 . A 3-digit display 40 of the display 20 represents information to the user or operator regarding the infusion supply measured in ml per hour or similar relevant measure or ratio.
[0092] Below the display 20 , a keyboard 42 is provided including a set of keys, one of which is designated the reference numeral 44 for allowing the user/operator to control the portable infusion pump unit 10 to perform a specific operation or to program the apparatus by shifting between specific program sequences by increasing a specific digit displayed in a 1-, 2- or 3-digit display, such as the displays 22 , 24 , 38 and 40 , by increasing or reducing the digit in question and by shifting a cursor route relative to the various individual displays of the display 20 for allowing the user/operator to modify the operational mode or shift between various preset programs of the apparatus.
[0093] At the one side wall of the housing, composed by the housing parts 12 and 14 of the unit or apparatus 10 , two terminals 46 and 48 are provided for allowing the apparatus 10 to be connected to an electronic charger for supplying electric power to an internal rechargeable battery pack or cell of the apparatus. The terminals 46 and 48 may alternatively or additionally serve as input/output terminals for establishing communication between the apparatus 10 and an external apparatus or equipment such as an external data logging apparatus or surveillance apparatus or further alternatively for communicating with an external processing unit such as a personal computer or data logging apparatus. Still further, the apparatus 10 may be provided with a conventional input/output terminal such as a conventional RS 232 terminal for establishing communication between the apparatus 10 and an external computer such as the above-mentioned personal computer for processing data produced by the apparatus concerning the operational mode of the apparatus and also supplementary data produced by the apparatus or auxiliary equipment, e.g. data representing the temperature of the infusion liquid supplied by the apparatus 10 or data supplied by additional external measuring or surveillance equipment. In the top wall of the housing of the apparatus 10 two recesses are provided for receiving two tube connectors 50 and 52 constituting a fluid inlet and a fluid outlet, respectively, of the above-mentioned fluid passage component to be described in further detail below with reference to FIG. 3 . As is evident from FIG. 2 , a further fluid outlet 54 is provided in the bottom wall of the housing of the apparatus 10 opposite to the fluid outlet 52 .
[0094] In FIG. 2 , the interior structure of the portable infusion pump unit or apparatus 10 is disclosed, illustrating the fluid inlet 50 and the fluid outlets 52 and 54 . In FIG. 2 , the reference numerals 56 and 58 designate two printed circuit boards including the electronic circuitry of the apparatus and including the display, the rechargeable power pack or cell circuitry and the CPU-circuitry of the apparatus controlling the overall operation of the apparatus including the infusion operation. Alternatively, the electronic circuitry of the apparatus may be included in a single printed circuit board or, alternatively, three or more printed circuit boards. The internal re-chargeable battery pack or cell is designated the reference numeral 60 .
[0095] In FIG. 2 , the internal flow system of the portable infusion pump apparatus 10 is disclosed, constituting a disposable and replaceable fluid passage component as mentioned above and including an inlet tube 62 connected to the fluid inlet 50 . Two capacitive detectors 64 and 66 are mounted on the inlet tube 62 and communicate with the electronic circuitry of the apparatus housed on the printed circuit board 56 and 58 for detecting presence of air bubbles, if any, in the infusion liquid input to the fluid inlet 50 . At its output end, the inlet tube 62 communicates with a first check valve 68 which constitutes an inlet to a pump housing component 70 , in which an internal fluid passage is provided, as will be described in greater details below with reference to FIG. 3 , which fluid passage terminates in an output or second check valve 72 from which two branched-off outlet tubes 74 and 76 communicate with the fluid outlets 54 and 52 , respectively. For transferring the infusion liquid or any other liquid input to the portable infusion pump unit 10 through the fluid inlet 50 to an application site through one of the fluid outlets 52 and 54 , a piston type pump actuator 78 is provided. The internal flow system of the portable infusion pump comprising the fluid inlet 50 , the inlet tube 52 , the capacitive detectors 64 and 66 belonging to the inlet tube 62 , the first check valve 68 , the pump housing component 70 , the output check valve 72 , the outlet tubes 74 and 76 , and the outlets 52 and 54 constitute an integral disposable and replaceable fluid passage component to be described in greater detail below with reference to FIG. 3 .
[0096] In FIG. 3 , the interior of the check valves and also the pump housing component 70 is disclosed in greater detail. The first check valve 58 basically comprises a central circular cylindrical housing component 80 from which a frusto-conical top part 81 extends upwardly communicating with the inlet tube 62 and arresting an inlet filter element 82 at the transition between the frusto-conical top part 81 and the cylindrical housing component 80 . The cylindrical housing component 80 comprises a central annular oral component 84 which is sealed off in the initial or non-active position by a downwardly deflectable sealing membrane 86 . Provided the pressure below the sealing membrane 86 is lower than the pressure above the membrane 86 , the membrane 86 is forced downwardly allowing liquid to pass through the central aperture of the central annular component 84 and further through apertures 87 provided offset relatively to the centre of the sealing membrane 86 .
[0097] The first check valve 68 communicates with an inlet passage 88 of the pumping house component 70 terminating in an inner chamber defined within an upwardly protruding annular top housing component 90 in which a reciprocating plunger 94 of the piston pump actuator 78 is movable in the direction to and from an abutting pin 96 which separates the inlet passage 88 from an outlet passage 98 . The interspace between the reciprocating plunger of the piston pump 78 and the inner surface of the annular top housing component 90 is sealed by means of a highly flexible sealing gasket 92 .
[0098] The outlet passage 98 communicates with the above described second check valve 72 which is basically of a configuration similar to and functioning as a check valve similar to the above described first check valve 58 , however differing from the above described first check valve in that the second check valve 72 does not include any filter element similar to the filter element 82 . The second check valve 72 includes a downwardly protruding annular housing part 100 , which is cast integral with the pumping house component 70 , fulfilling, however, the same purpose as the above described annular housing part 80 of the first check valve. From the annular housing part 100 , a downwardly protruding frusto-conical housing part 101 similar to the above described frusto-conical housing part 81 extends communicating with the outlet tube 74 and similarly the outlet tube 76 described above with reference to FIG. 2 . Within the annular housing part 100 , a sealing membrane 102 similar to the above described sealing member 86 is received, which includes apertures 103 similar to the apertures 87 described above. The sealing membrane 102 communicates with a conical bore 99 communicating with the outlet passage 98 for sealing off communication from the outlet passage 98 , through the conical bore 99 to the outlet tube 74 provided the sealing membrane 102 rests against an abutting lower surface defining the lower boundary of the conical bore 99 .
[0099] The pumping operation of the portable infusion pump unit 10 is established as follows. Initially, the first check valve 68 and the second check valve 72 are in their initial and sealing positions. It is also assumed that liquid is present within the inlet tube 62 within the inlet passage 88 and the outlet passage 98 and also within the outlet tube 74 . The piston pump actuator 78 is activated through the supply of an electric signal such as an alternating electric signal or a pulsed signal causing the reciprocating plunger 94 to move upwardly or downwardly. The piston pump actuator 78 will be described in greater detail below with reference to FIGS. 6-12 . The plunger 94 is pressed downwardly in relation to the orientation of the piston pump actuator 78 shown in FIG. 3 .
[0100] Assuming that the first movement of the reciprocating plunger 94 is in movement upwardly, a relative vacuum is created within the inlet passage 88 and the outlet passage 98 by the increase of the volume defined below the sealing gasket 92 . Through the creation of the relative vacuum within the inlet passage 88 , the first check valve 68 is operated as the downwardly deflectable sealing membrane 86 is caused to move downwardly allowing liquid to flow into the inlet channel 88 through the central aperture of the central annular component 84 as described above. At the same time, the relative vacuum within the outlet passage 98 creates a relative vacuum above the sealing membrane 102 which is biased so as to prevent free flow through the second check valve 72 urging or forcing the sealing membrane into sealing off and abutting engagement with a wall part circumferentially encircling and defining the conical bore 99 , and consequently preventing liquid from being transferred from the outlet passage 98 to the outlet tube 74 . In summary, during the raising of the reciprocating plunger 94 , the first check valve 68 is activated and caused to open whereas the second check valve 72 is blocked.
[0101] As the reciprocating plunger is moved downwardly, a relative increased pressure is created within the inlet passage 88 and the outlet passage 98 and the operations of the first and second check valves are shifted as the relative increased pressure within the inlet passage 88 causes the first check valve 68 to block and seal off whereas the increased pressure within the outlet passage 98 causes the second check valve 72 to open allowing the fluid present within the outlet passage 98 to be forced out through the conical passage 99 , through the apertures 103 of the sealing membrane 102 and further into the outlet tube 74 . The rate of transfer and consequence the flow of liquid from the outlet tube 74 is controlled by the rate of operation of the piston pump actuator 78 as an increased frequency of reciprocating the reciprocating plunger 94 increases the velocity of flow of fluid or liquid from the inlet tube 62 to the outlet tube 74 .
[0102] Above the second check valve 72 , a bypass valve is provided, comprising a sealing membrane 104 which is acted upon by a central stem element 106 of a turnable knob 108 so as to force the sealing membrane 104 into sealing off and abutting engagement with a conical bore 105 provided above and in registration with the above described conical bore 99 . Provided the conical bore 105 is sealed off by means of the sealing membrane 104 , the bypass valve is not in operation. Provided the sealing membrane 104 is raised from its sealing off and abutting engagement with the conical bore 105 as the knob 108 is rotated for causing elevation of the actuator stem 106 , communication from the outlet passage 98 is established through a bypass passage 110 , bypassing the communication from the outlet passage 98 through the conical passage 99 for allowing fluid to flow from the outlet passage 98 through the bypass passage 110 and further through the apertures 103 of the sealing membrane 102 which is consequently not functioning as the bypass valve is in operation.
[0103] The piston pump actuator 78 , which may constitute a replaceable component of the portable infusion pump unit or apparatus 10 , may provide a specific stroke and, consequently, a specific flow volume per stroke. Therefore, the actuator 78 is preferably provided with a switch cooperating with a switch of the electronic circuitry of the apparatus for informing the microprocessor of the electronic circuitry of the apparatus of the type of piston pump actuator included within the apparatus at present. The technique of providing information to the microprocessor concerning the type of piston pump included within the apparatus at present may be established by means of numerous techniques well-known in the art per se such as by means of code switches, optic capacitive or inductive readers, or simply by means of a feedback circuit monitoring the work rate of the piston pump actuator.
[0104] In FIG. 3 , an inlet tube 112 is shown establishing communication from the inlet tube 62 through the fluid inlet 50 not shown in FIG. 3 , however, shown in FIG. 2 from an infusion bag 114 which may constitute an infusion bag including an infusion liquid simply constituting physiological liquid or additionally or alternatively a drug suspended in any appropriate liquid, or alternatively blood plasma. The outlet from the outlet tube 74 of the portable infusion pump unit 10 shown in FIG. 4 is connected to an outlet tube 116 through the fluid outlet 54 , not shown in FIG. 3 , however, shown in FIG. 2 , which external outlet tube 116 communicates with a cannular assembly 118 of a basically conventional structure.
[0105] The inlet tube 112 and the outlet tube 116 may constitute separate inlet and outlet tubes to be connected to the infusion pump unit 10 through the inlet and outlet 50 and 52 or, alternatively, 54 , respectively. Alternatively, and preferably, the inlet tube 112 and the outlet tube 116 constitute integral components of the disposable and replaceable fluid passage component illustrated in FIG. 3 , which fluid passage component is cooperating with and activated by means of the piston pump actuator 78 . Further alternatively, the infusion bag 114 may be configurated and housed within a container component which is configurated so as to allow the infusion bag 114 to be received and supported on top of the infusion pump unit or apparatus 10 as the above-mentioned receiver is simply connected to and supported by the housing of the portable infusion unit or apparatus 10 .
[0106] The infusion of liquid from the infusion bag 104 is further illustrated in FIG. 4 , in which the portable infusion pump 10 is received and fixed relative to an individual 120 by means of a belt or strap 122 on which the infusion bag 114 is further fixated. In FIG. 4 , the external inlet tube 112 , the external outlet tube 116 and the cannular assembly 118 are also illustrated.
[0107] In FIG. 5 , the above described first embodiment of the portable infusion pump unit or apparatus 10 is shown in duplicate received within a stationary receptor 140 in which a plurality of receptor compartments 142 are defined. Each of the receptor compartments 142 is provided with a set of charger terminals for establishing electrical conductive communication with the charger terminal 46 and 48 of the apparatus or unit 10 received within the receptor compartment 140 in question for charging the internal rechargeable battery pack or cell of the apparatus or unit through the supply of electric energy from a mains power supply unit of the receptor assembly 140 which mains supply power supply unit receives electric power through a coiled mains supply wire 148 terminating in a mains plug 150 which is received in a mains AC outlet socket 152 .
[0108] The receptor assembly 140 further includes a set of indicator lamps 144 and 146 . Provided none of the indicator lamps 144 and 146 corresponding to a specific receptor compartment 142 are turned off, the indication informs the user or operator that no charging is taking place in the receptor compartment in question. Provided a portable infusion pump unit is received within a specific receptor compartment 142 , one of the lamps 144 and 146 corresponding to the receptor compartment is turned off, one of which informs the user or operator that the potable infusion pump unit in question is to be recharged, or alternatively the other lamp is turned on informing the user or operator that the portable infusion pump unit in question is fully charged and ready for use. Alternative information display modes, such as flashing of lamps for informing malfunction in the rechargeable battery pack or cell of the portable infusion pump is of course also readily deduceable.
[0109] In connection with infusion pumps, particularly portable medicinal infusion pumps, it is important that the pumping action be carried out by a very compact actuator functioning as quietly as possible, with as low energy consumption as possible and with as small a waste heat production as possible.
[0110] The pump actuator 78 in FIGS. 2 and 3 is, according to the invention, a shape memory alloy actuator which embodies all the above desirable characteristics. Several shape memory alloy actuators for use as a pump actuator in medicinal infusion pumps will be described in following, it being understood that these actuators are particularly useful as the pump actuator 78 in FIGS. 2 and 3 .
[0111] Referring now to FIGS. 6 and 7 , a pivotable body in the form of a circular disc 1 ′ is arranged for pivoting around a central pivot 2 ′ fixedly attached to a not shown frame of the actuator, and the disc 1 ′ is provided with a peripheral extension 3 ′ and a yoke-like peripheral extension 5 ′. A tension coil spring 6 ′ is at one end thereof pivotably attached to a fastening pin 7 ′ fixedly attached to said frame and is at the other end thereof pivotably attached to a fastening pin 8 ′ fixedly attached to the peripheral extension 3 ′.
[0112] Two wires or filaments 9 ′ and 10 ′ of a shape memory alloy such as nickel titanium alloy or nitinol, for instance supplied by the company DYNALLOY, INC, of Costa Mesa, Calif., USA, under the trade name FLEXINOL, are attached at one end thereof to electrically conductive terminals 11 ′ and 12 ′, respectively, fixedly attached to said frame.
[0113] The other end of each of the wires 9 ′ and 10 is attached to an electrically conductive terminal 13 ′ fixedly attached to the periphery of the disc 1 ′. The wires 9 ′ and 10 ′ extend along the periphery of the disc 1 ′ such that the wires 9 ′ and 10 ′ when tensioned extend along and are supported by said periphery. In the drawings the wires 9 ′ and 10 ′ are shown spaced from said periphery for the sake of clarity.
[0114] A sliding body 14 ′ having two arms 15 ′ and 16 ′ is arranged for sliding movement between two stop pins 17 ′ and 18 ′ attached to the frame. A pin 19 ′ attached to the sliding body 14 ′ is received in the fork 5 a ′ of the yoke-like extension 5 ′ such that the pin 19 ′ may slide and rotate freely in the fork when the disc 1 ′ pivots from the position shown in FIG. 6 to the position shown in FIG. 7 thereby slidingly displacing the body 14 ′ from abutment against stop pin 18 ′ to abutment against stop pin 17 ′ with the arm 15 ′, constituting the activating pin of the actuator, fully extended.
[0115] A proximity sensor 20 ′ is attached to the frame and connected to not shown electrical conductors for transmitting a signal from the sensor to a not shown receiver. The terminals 11 ′ and 12 ′ are likewise each connected to an electrical conductor, not shown, connected to a not shown power source for supplying electrical power to the wires 9 ′ and 10 ′ for resistance heating thereof, the terminal 13 ′ being likewise connected to the not shown power source through a not shown electrical conductor for closing the resistance heating circuit.
[0116] In use, the wires 9 ′ and 10 ′ are intermittently heated to the transformation or transition temperature (from martensitic to austenitic state) of the shape memory alloy which temperature for nitinol is approximately 90° C. Thereby the length of the wire is shortened. When the wire cools to below 90° C. the length thereof reverts to normal, i.e. the wire lengthens. The speed at which the shortening takes place, i.e. the contraction time, is directly related to the current input. i.e. the voltage applied over the terminals 11 ′ or 12 ′ and 13 ′.
[0117] In the position depicted in FIG. 6 , the intermediate disc 1 ′ is in its outermost counter clock-wise position with the arm 15 ′ fully retracted and with the wire 9 ′ cooled to below 90° C. and the wire 10 ′ heated to above 90° C. by applying an electrical voltage between the terminal 12 ′ and 13 ′ whereby an electrical current will flow through the wire 10 ′. The disc 1 ′ has therefore been rotated counter clock-wise to the position shown by the contraction force exerted by the wire 10 ′.
[0118] In the next step, the wire 10 ′ is cooled to below 90° C. and thereby lengthens to the shape indicated by the dotted line 10 a ′ in FIG. 6 . The actuator is now ready to perform an activating extension of the arm 15 ′ towards the left, the end of the arm 15 ′ being intended to come into contact with a not shown plunger 94 and depress or activate same during the movement of the arm 15 ′ to the extended leftwards position thereof as depicted in FIG. 7 .
[0119] Thereafter or simultaneously, the wire 9 ′ is heated to above 90° C. whereby it contracts and exerts a clock-wise force on the disc 1 ′ pivoting it clock-wise around the pivot 2 ′ past the balance position of the disc 1 ′ and spring 6 ′ in which the attachment pins 7 ′ and 8 ′ of the spring 6 ′ are aligned with the pivot 2 ′.
[0120] When the disc 1 ′ has rotated clock-wise past said balance point, the tension force exerted by the spring 7 ′ will continue the clock-wise rotation of the disc 1 ′ to the position shown in FIG. 7 with the arm 15 ′ fully extended and the wire 9 ′ slack though still above 90° C. This is the actual activating movement of the actuator where the force applied to the sliding body 14 ′ by the extension 5 ′ increases because of the increasing lever of force or moment arm of the tension force exerted by the spring 6 ′ on the intermediate disc 1 ′ with respect to the pivot 2 ′ or axis of rotation of the disc 1 ′.
[0121] For applications where the force necessary to perform the function of the actuator, such as depressing the pump plunger 94 in FIG. 3 , increases during the activating stroke, said increase of the spring force moment arm as the disc 1 ′ rotates is a very advantageous feature as will be explained more in detail in connection with FIGS. 13 and 14 in the following.
[0122] An increase of the activating force of the actuator during the activating stroke is also achieved or enhanced by decreasing the distance of the pin 19 ′ from the pivot 2 ′ or axis of rotation of the disc 1 ′ during the activating stroke whereby the moment arm or lever of force of the displacement force exerted on the pin 19 ′ by the yoke-like extension 5 ′ with respect to the pivot 2 ′ is decreased and thereby the displacement force is increased during the activating stroke. This shortening of said distance can be seen from the situation in FIG. 6 at the beginning of the activation stroke to the situation in FIG. 7 at the end of the activation stroke.
[0123] Finally, the wire 10 ′ is heated above 90° C. so that it contracts and pivots the disc 1 ′ back to the position shown in FIG. 6 whereby the activating cycle is ready to be repeated.
[0124] The length of the wire 10 ′ is larger than the length of the wire 9 ′ because the contraction or shortening of the wire 10 ′ must be large enough to pivot the disc 1 ′ from the position shown in FIG. 7 past the balance point mentioned above while the shortening of the wire 9 ′ only has to be enough the pivot the disc 1 ′ from the position shown in FIG. 6 past said balance point.
[0125] Nitinol wires will typically contract about 3%-6% when heated past the transition temperature. The uncontracted length of the wire 10 ′ should be enough to ensure that the uncontracted wire is fully extended in the position shown in FIG. 7 and that the contracted wire 10 ′ is fully extended when the disc 1 ′ is at least slightly past said balance point in the counter-clockwise direction, i.e. the uncontracted length of wire 10 ′ should be about 22-25 times the distance of travel of terminal 13 ′ between the FIG. 7 position thereof and the balance point position thereof.
[0126] The necessary contraction force to be exerted by wires 9 ′ and 10 ′ are rather different because the contraction force of wire 9 ′ only has to counteract the torque or moment of the spring force of spring 6 ′ with the relatively small torque arm in FIG. 6 while the contraction force of wire 10 ′ has to counteract the considerably larger torque of said spring force in FIG. 7 . The contraction force of a nitinol wire is larger the larger the diameter or cross sectional area of the wire. The cross sectional area of wire 10 ′ is thus considerably larger than the cross sectional area of wire 9 ′ or there may be a number of wires 10 ′ with the same cross sectional area.
[0127] The latter possibility is chosen if it is necessary that the cooling-off time for the wires 10 ′ is as short of possible so that the interval between the activating cycles may be as short as possible. Several small diameter wires with a certain total cross sectional area will cool more rapidly than a single larger diameter wire with the same cross sectional area.
[0128] The signal emitted by the proximity sensor 20 ′ each time the extension 3 ′ is in the position shown in FIG. 7 may be utilised for many different purposes such as for instance a mere monitoring of the correct function of the actuator or for controlling the timing of the heating of the wires 9 ′ and 10 ′ and thereby the timing of the activating stroke of the sliding body 14 ′. Naturally, the location of the proximity sensor or of any other type of sensor for sensing the position of the disc 1 ′ may be varied according to the purpose thereof, and several such sensors may be provided in different locations for instance for achieving a more complex control of the timing of the activating effect of the actuator.
[0129] Referring now to FIG. 8 , this embodiment differs from the embodiment of FIGS. 6-7 in that a double activating effect may be achieved for each cycle of heating and cooling the shape memory wires 21 ′ and 22 ′ that in this case are of equal length and cross sectional area. The rotation of the disc 1 ′ counter-clockwise and clockwise is limited by stop pins 23 ′ and 24 ′, respectively.
[0130] The activating member may be a sliding body similar to body 14 ′ in FIG. 6-7 where both the arm 15 ′ and the arm 16 ′ perform an activating function, or the activating function may be a pull/push activation by for instance arm 15 ′.
[0131] The disc 1 ′ may alternatively be provided with a central torsion shaft projecting at right angles to the plane of the disc 1 ′ as a prolongation of the pivot 2 ′ such that the torsion shaft functions as the activating member by for instance rotating a lever to and fro. Many different types of activating members connected to the disc 1 ′ will be obvious to those skilled in the art.
[0132] In the position shown in FIG. 8 , the disc 1 ′ has just performed an activating rotation counter-clockwise under the influence of the counter-clockwise torque of the force of the spring 6 ′ and is ready for the initiation of a rotation clockwise by heating the wire 21 ′ so that the disc 1 ′ is rotated against the counter-clockwise torque of the spring force until the balance point is passed. Then the activating rotation clock-wise is performed by the clock-wise torque of the spring force. Also in this embodiment the moment arm of the activating force of the spring 6 ′ increases during the activating stroke in both directions.
[0133] Referring now to FIG. 9 , the terminal 13 ′ of the embodiments of FIGS. 6-8 has been substituted by a combined terminal and abutment member 28 ′ for abutting the stop pins 24 ′ and 25 ′. Furthermore, another type of biasing means is utilized, namely a piston and cylinder mechanism comprising a pressurized cylinder 24 ′ pivotably attached to pin 7 ′, a piston 26 ′ and a piston rod 27 ′ pivotably attached to the disc 1 ′ by means of a pin 27 ′.
[0134] The piston and cylinder mechanism 24 ′- 25 ′ functions like a compression spring and could in fact be substituted by a compression spring. In FIG. 9 the disc 1 ′ is in the balance point position where the pin 7 ′, the pin 27 ′ and the pivot 2 ′ are aligned such that the pressure exerted on the disc 1 ′ by the piston rod 25 ′ does not produce any torque on the disc 1 ′. In the situation shown in FIG. 9 , the wire 22 ′ is contracting and rotating the disc counter clock-wise past the balance point. As soon as the balance point has been passed, the torque from the piston rod 25 ′ will cause the activating counter clock-wise rotation of the disc 1 ′ until the member 28 ′ abuts the stop pin 23 ′ whereupon a clockwise rotation may be initiated in a manner very similar to that described above in relation to FIG. 8 .
[0135] The tension spring 6 ′ in FIGS. 6-7 could also be substituted by a piston and cylinder mechanism or a compression spring in an arrangement similar to FIG. 9 .
[0136] Referring now to FIGS. 10-12 an activating body 30 ′ is arranged linearly displaceable in the directions of arrows R 1 and R 2 under the influence of a shape memory alloy wire 31 ′ and a two-armed lever 32 ′.
[0137] One end of the wire 31 ′ is attached to the body 30 ′ at 33 ′ and the other end is attached to a fixed portion 37 a ′ of a not shown frame of the actuator, the wire 31 ′ extending around a pulley 34 ′ pivotably arranged on a slide 35 ′ displaceable in the directions of the arrows R 1 and R 2 . A compression spring 36 ′ is arranged between the body 30 ′ and the slide 35 ′ and extends through a passage through a fixed portion 37 ′ of said frame.
[0138] The two-armed lever 32 ′ is arranged pivotable around a pivot 38 ′, one arm 39 ′ of the lever abutting a pin 40 ′ on the body 30 ′ and the other arm 41 ′ of the lever being attached at 42 ′ to one end of a tension spring 43 ′, the other end being attached to a fixed portion 44 ′ of said frame such that displacement of the body 30 ′ in the direction of arrow R 1 tensions the spring 43 ′ via rotation of the intermediate lever 32 ′.
[0139] A pawl or hook element 45 ′ is arranged pivotable around a pivot 46 ′ such that a hook or projection 47 ′ of the hook element 45 ′ may be received in a matching recess 48 ′ in the body 30 ′. A shape memory alloy wire 49 ′ is at one end attached to the hook element 45 ′ and at the other end attached to a fixed portion 50 ′ of said frame. A compression spring 51 ′ is arranged between the fixed portion 50 ′ and the hook element 45 ′
[0140] In use, the body 30 ′ is moved to and fro in the direction of the arrows R 1 and R 2 to activate the plunger 94 during the activating stroke of the body in the direction R 1 .
[0141] In FIG. 10 the wire 31 ′ is cooled to below the transformation temperature of the alloy (for instance by sandwiching the wire between two aluminum rails coated with PTFE) and is at its maximum length and is maintained taut by the biasing action of the compression spring 36 ′. The hook 47 ′ is received in the recess 48 ′ and holds the body 30 ′ against the biasing force of the spring 43 ′ transmitted to the pin 40 ′ by means of the lever 32 ′. The wire 49 ′ is also in its cool state and at its maximum length.
[0142] When the activating stroke is to be initiated, the wire 49 ′ is heated to the transformation temperature and shortens or contracts, thereby pivoting the hook element 45 ′ against the biasing force of the spring 51 ′ such that the hook 47 ′ is pulled out of the recess 48 ′ to the release position shown in FIG. 11 . The body 30 ′ is thus released for displacement in direction R 1 under the influence of the lever 32 ′ pivoted by the spring 43 ′.
[0143] During the activating stroke of body 30 ′ in direction R 1 the lever or moment arm of the force exerted by the spring 43 ′ relative to the pivot 38 ′ or the axis of rotation of the lever 32 ′ increases such that the displacement force exerted on the pin 40 ′ by the arm 39 ′ increases as the body 30 ′ is displaced in the direction R 1 .
[0144] Likewise, during the activating stroke by the body 30 ′ in direction R 1 , the lever or moment arm of the displacement force exerted by the arm 39 ′ on the pin 40 ′ relative to the pivot 38 ′ decreases whereby said displacement force increases as the body 30 ′ is displaced in the direction R 1 .
[0145] When the slide 35 ′ abuts the fixed frame portion 37 ′, the activating stroke in direction R 1 will be stopped as shown in FIG. 11 . In practice the activating stroke preferably is stopped by the resistance to the activating stroke of the body 30 ′ by the plunger 94 being activated such that the stroke is stopped before the slide 35 ′ abuts the fixed frame portion 37 ′.
[0146] So as to cock the actuator again, the wire 49 ′ is cooled to allow the spring 51 ′ to pivot the hook element 45 ′ towards the holding position thereof while the wire 31 ′ is heated until it shortens and thereby causes the slide 35 ′ to abut the fixed frame portion 37 ′ and the pulley 34 ′ to rotate clock-wise while the body 30 ′ is displaced in the direction R 2 against the force of the spring 43 ′ that thereby is lengthened while the lever 32 ′ pivots counter clock-wise. When the body 30 ′ has reached the position shown in FIG. 12 , the hook 47 ′ is pressed into the recess 48 ′ and the wire 31 ′ may then be cooled so that the situation in FIG. 10 is re-established ready to initiate a new activation cycle of the actuator.
[0147] During the tensioning of the spring 43 ′, the force exerted by the wire 31 ′ necessary for this tensioning is largest at the beginning of the displacement of the body 30 ′ in the direction R 2 because of the large moment arm of the force of the spring 43 ′ and the small moment arm of the rotation force of the pin 40 ′ on the arm 39 ′, and the force exerted by the wire 31 ′ decreases as the body 30 ′ is displaced in the direction R 2 . This is an advantageous development of the force in the wire 31 ′ during the cocking of the actuator as will be explained more in detail in the following in connection with FIGS. 13 and 14 .
[0148] By adapting the actuator according to the invention such that the activating stroke is performed by a force exerted by a biasing means, a further advantage is obtained in that any blocking of the activating stroke of the activating body, for instance because the pump plunger 94 is blocked, will only entail that the activation stroke is stopped with no damage to the SMA wire. If the activating stroke were carried out under the influence of a shortening of a shape memory alloy wire, said wire would probably be damaged or snapped if the activating stroke were blocked.
[0149] The extra length of the wire 31 ′ obtained by means of the pulley 34 ′ is advantageous for giving a longer activating stroke with a compact construction of the actuator.
[0150] The heating of the wires 31 ′ and 49 ′ is carried out in a manner similar to the heating of the wires 9 ′ and 10 ′ in FIGS. 6-7 by means of not shown electrically conductive connections of the ends thereof to the battery pack 60 of the infusion pump unit according to the invention.
[0151] Referring now to FIG. 13 , the curve or line 80 ′ indicates the relationship between the force exerted by an SMA wire on a body in one direction while the body id biased by a tension spring in the opposite direction as a function of the contraction or shortening thereof. The force increases proportionally with the contraction because of the proportional increase of the spring force of the spring when it is stretched by contraction of the wire.
[0152] The line or curve 81 is symbolic of the curves corresponding to the relationship between contraction and force exerted for the embodiments of FIGS. 6-9 where the force in the wires 10 ′, 22 ′, 24 ′ and 31 ′, respectively is largest at the beginning of the contraction or shortening, and the contraction length of the wire is much larger because of the variation in the length of the moment arm or arms during the activating stroke as described above.
[0153] In this manner, a high coefficient of mechanical efficiency is obtained because the longer contraction distance for a given input of energy to heat the SMA wires gives an increased input of energy into the activating system.
[0154] The actual curves 81 will not be linear but will reflect the varying rate of change of the moment arm or moment arms during the activating stroke.
[0155] Referring now to FIG. 14 and FIGS. 10-12 , an actuator as shown in FIGS. 10-12 is applied to depress the plunger 94 of the infusion pump in FIG. 3 thereof with the body 30 ′.
[0156] The plunger 94 and body 30 ′ travel from 0.2 mm to 3.4 mm during the activating stroke of the body 30 ′. The force required to displace the plunger increases substantially proportionally from approx. 0.5 N to approx. 2N where the force increases steeply because the plunger has reached the end of its path.
[0157] The force exerted by the spring 43 ′ on the body 30 ′ and thus the plunger 94 develops as an increasing parable-like curve corresponding to the curve for the tension or force in the SMA wire 31 ′ necessary to retract the body 30 ′ against the leveraged force of the spring 43 ′.
[0158] It is clear that the curves show that the actuator according to the invention can produce an increasing force as the displacement increases which is very advantageous in applications such as pumping with piston pumps where the force required increases with the distance traveled by the plunger.
[0159] Referring now to FIGS. 15 and 16 , the infusion pump unit 10 is very similar to the infusion pump unit 10 of FIG. 2 , the sole difference being the location of the print cards 56 and 58 . The actuators of FIGS. 6-7 and 10 - 12 are utilized as the pump actuator 78 in FIG. 15 and FIG. 16 , respectively. The SMA wires are supplied with electrical current for heating by the battery pack 60
[0160] The SMA actuators of FIGS. 6-7 and 10 - 12 are particularly well-suited for depressing the pump membrane 92 (see FIG. 3 ) as the force needed for this operation increases as the membrane is depressed and the fluid is pressed out into the conduit 98 . Furthermore, the operation of the SMA actuators is very quiet and the energy consumption is low while the space requirements are limited and the weight low.
[0161] As an example the SMA wire 31 ′ of the SMA pump actuator of FIG. 16 is supplied with 4 amperes during 4 milliseconds for each pump depression cycle, and the maximum number of depression cycles for the infusion pump is normally of the order of magnitude of 10,000 cycles/hour.
[0162] Referring now to FIGS. 17 and 18 , a fluid pumping system 60 ′ comprises a flexible tube 61 ′ extending through or between at least three clamping devices 62 ′- 64 ′ arranged adjacent one another. As illustrated in FIG. 18 the clamping devices each comprise a pivotable jaw 65 ′ that is arranged to pivot towards a fixed jaw 66 ′ to flatten the tube 61 ′ extending between the jaws 65 ′ and 66 ′ and to pivot away from the fixed jaw 66 ′ to allow the tube 61 to return to its natural open shape.
[0163] Each of the pivotable jaws 65 ′ is attached to one end of a biasing means such as a tension spring 67 ′ the other end of which is attached to a fixed portion 68 ′ of a not shown frame. Each of the pivotable jaws 65 ′ is furthermore attached to one end of a shape memory alloy wire 69 ′ the other end of which is attached to a fixed portion 70 ′ of said frame. The jaws 65 ′ are held in the closed position against jaw 66 ′ by the springs 67 ′ with the tube 61 ′ flattened while shortening or contraction of the SMA wires 69 ′ opens the clamping devices by pivoting the jaws 65 ′ away from the fixed jaw 66 ′.
[0164] The pumping action is achieved by the sequence indicated from left to right in FIG. 17 , all three clamping devices 62 ′- 64 ′ being clamped shut in the first stage from the left with all three wires 69 ′ cooled to below the transition temperature and therefore slack.
[0165] In the second stage from the left devices 63 ′ and 64 ′ are opened by heating the corresponding wires 69 ′ to above the transition temperature whereby fluid enters the thus opened portion of the tube 61 ′ as indicated by arrow R 5 .
[0166] In the third stage from the left device 64 ′ is clamped shut by cooling the corresponding wire 69 ′ such that the corresponding spring 67 ′ can pull the corresponding jaw 65 ′ against the tube 61 ′ flattening it. Hereby a portion of fluid is trapped a space 71 ′ in the tube 61 ′.
[0167] In the fourth stage from the left, the device 61 ′ opens while the device 62 ′ closes whereby the portion of fluid trapped in the space 71 ′ is forced to flow in the direction of arrow R 6 whereafter device 61 ′ is closed and the first stage from the left has been re-established to begin a new pumping cycle.
[0168] If more than three clamping devices are utilized, the pumping effect will be enhanced.
[0169] This “finger” pump may substitute the pumping system in FIGS. 3, 15 and 16 as well as the check valves 68 and 72 , and the pumping system (tube 61 ′) may still be replaced without replacing the pump actuator by threading the tube 61 ′ from between the jaws 65 ′ and 66 ′. Thereby an extremely cheap replaceable pump is provided.
[0170] The pivoting of each of the jaws 65 ′ of the clamping devices 62 ′- 64 ′ towards the fixed jaw 66 ′ may be achieved by means of a body 15 ′ of the actuator in FIG. 6 or a body 30 ′ of the actuator in FIG. 5 .
[0171] The tube 61 ′ may alternatively be flattened directly by said bodies 15 ′ or 30 ′ without the use of a clamping device. Hereby, a particularly simple pumping system is achieved where the replacement of the tube 61 ′ is particularly simple.
[0172] Referring now to FIG. 19 , a toothed wheel or gear 55 ″ is rotatably arranged on a power output shaft 56 ″ journalled in a not shown frame of the actuator motor. A body 57 ″ having an edge portion 58 ″ fitting between two neighbouring teeth 59 ″ of the gear 55 ″ is arranged in said frame displaceable between the position shown in full lines and the position shown in dotted lines.
[0173] A shape memory alloy wire 60 ″ is at one end attached to the body 57 ″ and at the other end to a fixed portion 61 ″ of said frame. A coiled flat or wire spring 62 ″ integral with or connected to an arm 63 ″ is attached to said frame such that said arm 63 ″ may pivot around one end thereof opposite the free end thereof. The arm 63 ″ abuts a pin 64 ″ on the body 57 ″.
[0174] A pawl 65 ″ is pivotably arranged on a pivot 66 ″ and is biased by a tension spring 67 ″ so as to constantly abut the rim of the gear 55 ″.
[0175] In use, the gear 55 ″ is turned clock-wise by the body 57 ″ being displaced from the full line position to the dotted line position thereof by the force of the spring 62 ″ acting through the intermediate arm 63 ″ on the pin 64 ″, whereby the gear advances the width of one tooth 59 ″ and the pawl 65 ″ moves from locking engagement between one pair of teeth 59 ″ to a locking position between the next pair of teeth in the counter clock-wise direction.
[0176] When the gear is locked against rotating counter clock-wise by the pawl 65 ″, the SMA wire 60 ″ is heated and shortens whereby the body is displaced from the dotted line position to the full line position against the force of the intermediate arm 63 ″ on the pin 64 ″ thereby cocking the spring 62 ″.
[0177] The lever or moment arm of the displacement force exerted by the intermediate arm in the clock-wise direction with respect to the pivoting point of the arm decreases as the body is displaced in the activating direction from the full line position to the dotted line position whereby the displacement force exerted by the intermediate arm 63 ″ on the pin 64 ″ increases.
[0178] Referring now to FIG. 20 , a SMA actuator motor similar to the motor of FIG. 19 is shown, the spring 62 ″ and intermediate arm 63 ″ being substituted by a tension spring 68 ″ fastened to the body 57 ″ and to a fixed portion 69 ″ of a not shown frame.
[0179] The operation of the motor of FIG. 20 is very similar to the one in FIG. 19 except that the displacement force exerted on the body 57 ″ by the spring 68 ″ is exerted directly and declines substantially proportionally with the distance of displacement.
[0180] Referring now to FIG. 21 , an infusion pump 70 ″ particularly well suited for infusing insulin to a diabetes patient comprises a housing 71 ″ containing a display 72 ″, on/off buttons 73 ″, print cards 74 ″ and a not shown battery pack. These elements will not be described further as they are well known to those skilled in the art and may vary greatly within the scope of the invention as defined by the appended patent claims.
[0181] A dispensing cartridge, ampoule or syringe 75 ″ is replaceably arranged in the housing 71 ″ and has an outlet nozzle 76 ″ for communication with a not shown conduit means connected to the patient for delivering the fluid, preferably insulin, in the syringe 75 ″ to said patient in a controlled manner either continuously or according to a predetermined sequence.
[0182] A piston 77 ″ is slidably arranged in the syringe 75 ″. A threaded rod or spindle 78 ″ abuts the piston 77 ″ for displacing it towards the outlet nozzle 76 ″ and meshes with a gear 79 ″ meshing with a pinion 80 ″ rotated by a shape memory alloy motor for displacing the spindle 78 ″ towards the outlet nozzle 76 ″.
[0183] Referring now to FIG. 22 , the SMA motor of FIG. 20 is shown arranged and adapted for rotating the pinion 80 ″ such that rotation of the gear 55 ″ is geared down to a much slower rotation of the spindle 78 ″ so as to dispense the liquid or paste in the syringe 75 ″ in very small amounts.
[0184] The SMA motor of FIG. 19 may very advantageously replace the motor of FIG. 19 in the configuration of FIG. 22 because of the reverse characteristic of the spring 62 ″ compared to the characteristic of spring 68 ″ as discussed in connection with FIGS. 13 and 14 .
[0185] Referring now to FIG. 23 , a different embodiment of the piston operation is illustrated, a double headed piston 81 ″ being displaced by an arm 82 ″ mounted on a carrier block 83 ″ rotatably mounted on a spindle 84 ″ such that rotation of the spindle 83 ″ displaces the block 83 ″, arm 82 ″ and piston 81 ″ towards the nozzle 76 ″ for expelling liquid or paste in the syringe 75 ″.
[0186] The spindle meshes with a gear 85 ″ meshing with a pinion 86 ″ attached to the shaft 56 ″ of the SMA motor of FIG. 19 , the spring 67 ″ not being shown for the sake of clarity.
[0187] Referring now to FIG. 24 , a rack 70 ′″ is arranged displaceable in a not shown frame in the direction R 4 and a body 71 ′″ is arranged displaceable in the directions R 3 and R 4 as well as transversely thereto. A SMA wire 72 ′″ is attached to the body 71 ′″ and to a fixed portion 73 ′″ of said frame. A coil spring 74 ′″ attached to said frame and integral with or connected to an intermediate arm 75 ′″ exerts a displacement force on a pin 76 ′″ of the body 71 ′″ through the intermediate arm 75 ′″ in a manner very similar to spring 62 ″ in FIG. 19 .
[0188] The rack 70 ′″ advances the distance of the width of one tooth 78 ′″ thereof in the direction R 4 for every cycle of heating and cooling of the SMA wire 72 ′″ in the same way as gear 55 ″ in FIG. 19 is rotated by wire 60 ″, spring 62 ″, intermediate arm 63 ″ and body 57 ″ in FIG. 19 .
[0189] The rack 70 ″ may be used to push the piston 77 ″ in FIG. 22 or piston 81 ″ in FIG. 23 by means of front end 77 ′″, to empty said cylinder of liquid or paste through an aperture in said cylinder.
[0190] Referring now to FIGS. 25 and 26 , an optional number of infusion pump units 10 with corresponding inlet tube 112 and infusion bag 114 may be aggregated in a system of individual docking stations 100 ′ arranged on a not shown standard hospital rack allowing horizontally adjustable location of the docking stations 100 ′ that such two or more stations may be aligned abutting one another as shown in FIG. 25 .
[0191] A power distribution and computer connection box 101 ′ having connections 102 ′ to a power source and a computer is also adapted for abutting a docking station 100 ′ in aligned configuration therewith.
[0192] The distribution box 101 ′ has a number of female contact plugs 103 ′ for mating with corresponding, not shown, male contact plugs in a lateral wall of a docking station 100 ′. A diode 101 a ′ indicates whether the distribution box is functioning or not. Each docking station has a number of female contact plugs 104 ′ in the opposite lateral wall identical to contact plugs 103 ′ for mating with said not shown male contact plugs of an adjacent docking station 100 ′.
[0193] The female and male contact plugs distribute electrical energy to the individual docking station and to the individual infusion pumps 10 docked in the docking stations 100 ′ via female contact plugs 105 ′ mating with not shown corresponding male contact plugs in the bottom of each infusion pump 10 .
[0194] Each infusion pump 10 is carried by a carrying frame 106 ′ between arms 107 ′ thereof and supported on a bottom platform 108 ′ thereof. A hook 109 ′ is provided on the carrying frame 106 ′ for hooking into an aperture 110 ′ of the infusion bag 114 . The frame 106 furthermore has a top aperture 111 ′ for receiving a hook on a bed or wheel chair when the pump 10 and bag 114 are to be removed from the docking station 100 ′ for following a patient away from the fixed docking station array.
[0195] Each docking station 100 ′ is provided with three diodes 112 ′ for indicating status of the docking station and the pump as regards power supply, pumping status and fluid supply or other parameters desired monitored. Each docking station furthermore has two opposed grooves for slidingly receiving the lateral edges of a frame 106 ′
[0196] The system of FIG. 25 affords great flexibility as to number of infusion pumps per patient and as regards mode of transport together with the patient either on the frame 106 ′ or removed therefrom. | An infusion pump unit includes a housing sized to allow the pump unit to be carried as a portable unit. The housing contains a controllable pumping system for pumping fluid. The pump actuator is lighter, smaller, quieter and less power consuming. | 0 |
RELATED APPLICATIONS
This application claims the benefit of provisional patent application Ser. No. 61/412,584, filed Nov. 11, 2010, and provisional patent application Ser. No. 61/419,369, filed Dec. 3, 2010, the disclosures of which are hereby incorporated herein by reference in their entireties.
FIELD OF THE DISCLOSURE
The present disclosure relates to, in a first aspect, automatically sharing the location of a user based on a social context of the user. In another aspect, the present disclosure relates to automatically generating and sending a status update for a user based on a social context of the user.
BACKGROUND
People are becoming increasingly comfortable with revealing or reporting some aspects of their current location and activities to their social network via check-in services such as FourSquare™ and social networking services such as Facebook®. However, in both instances, the current generation of services is predominantly manual. There is a desire for a system and method for performing automatic check-ins and/or generating and sending status updates.
SUMMARY
The present disclosure relates to automatically sharing a location of a user and/or automatically generating and sending a status update for a user based on a social context of the user. As used herein, a social context of a user is generally any data that describes a location at which the user is currently located or users that are spatially proximate to the user. Notably, data that describes a location is to be distinguished from the location itself. In one embodiment, a social context of a user is determined. Then, a determination is made as to whether to automatically share a current location of the user based on the social context of the user and one or more predefined automatic location sharing rules. The current location of the user is then automatically shared if the determination is made to automatically share the current location of the user. In one preferred embodiment, the current location of the user is shared by performing an automatic check-in for the user at a Point of Interest (POI) that corresponds to the current location of the user.
In another embodiment, a social context of a user is determined. Then, a determination is made as to whether to send an automatic status update for the user based on the social context of the user and one or more predefined automatic status update rules. If the determination is made to send the automatic status update, a status update is automatically generated and sent on behalf of the user. In one embodiment, the status update is personalized based on the social context of the user.
Those skilled in the art will appreciate the scope of the present disclosure and realize additional aspects thereof after reading the following detailed description of the preferred embodiments in association with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The accompanying drawing figures incorporated in and forming a part of this specification illustrate several aspects of the disclosure, and together with the description serve to explain the principles of the disclosure.
FIG. 1 illustrates a system for performing automatic check-ins and/or automatically generating and sending status updates for users based on social contexts of the users according to one embodiment of the present disclosure;
FIG. 2 is a flow chart illustrating the operation of the Automatic Check-in and Status Update (ACSU) server of FIG. 1 according to one embodiment of the present disclosure;
FIGS. 3A through 3C illustrate an exemplary Graphical User Interface (GUI) that enables a user to configure settings and rules for automatic check-ins and automatic status updates according to one embodiment of the present disclosure;
FIG. 4 illustrates an exemplary rule builder dialog that enables a user to create an automatic check-in or automatic status update rule according to one embodiment of the present disclosure;
FIG. 5 illustrates a syntax of the rule builder dialog of FIG. 4 according to one embodiment of the present disclosure;
FIG. 6 illustrates a number of exemplary rules defined via the rule builder dialog of FIG. 4 according to one embodiment of the present disclosure;
FIG. 7 illustrates an exemplary status update generated according to a personalized style defined by a user for which the status update is generated according to one embodiment of the present disclosure;
FIG. 8 is a block diagram of the server computer hosting the ACSU server of FIG. 1 according to one embodiment of the present disclosure;
FIG. 9 is a block diagram of one of the mobile devices of FIG. 1 according to one embodiment of the present disclosure;
FIG. 10 is a block diagram of an exemplary computer server hosting the check-in service of FIG. 1 according to one embodiment of the present disclosure; and
FIG. 11 is a block diagram of an exemplary computer server hosting the social networking service of FIG. 1 according to one embodiment of the present disclosure.
DETAILED DESCRIPTION
The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the embodiments and illustrate the best mode of practicing the embodiments. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the disclosure and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.
The present disclosure relates to automatically sharing a location of a user and/or automatically generating and sending a status update for a user based on a social context of the user. As used herein, a social context of a user is generally any data that describes a location at which the user is currently located or users that are spatially proximate to the user. Notably, data that describes a location is to be distinguished from the location itself. For example, the location may be a street address, whereas the data that describes the location may be a name of a corresponding Point of Interest (POI) (e.g., a business name) located at that street address. Specifically, as used herein, a social context of a user includes one or more of the following: a POI corresponding to the current location of the user, information describing a POI corresponding to the current location of the user, information describing an event currently being held at a POI corresponding to the current location of the user, historical aggregate profile data for the current location of the user, an aggregate profile for a crowd of users in which the user is currently located, an aggregate profile for each of one or more crowds currently located near the user, a list of nearby devices, a list of nearby users, a list of nearby friends, a list of nearby friends and friends-of-friends, mode of transportation, activity being performed by the user (e.g., listening to song X by artist Y), and websites that the user is logged into at that time. As used herein, a “check-in” is an electronic means by which a user indicates that he or she is currently located at a particular place (e.g., a POI). The indication may be sent to other users, retrieved by other users, sent to or retrieved by businesses, displayed on social networking sites or other websites, or the like. As used herein, a status update is a text, audio, or video message posted or otherwise sent by a user. Preferably, the status update is sent to and published by a social networking service (e.g., a Facebook® post or Twitter® tweet). Further, the status update may be published to other users or entities (e.g., businesses).
FIG. 1 illustrates a system 10 for performing automatic check-ins and/or generating and sending automatic status updates for users according to one embodiment of the present disclosure. Notably, while check-ins are discussed herein as being the preferred manner in which to share the current locations of the users, the present disclosure is not limited thereto. Other location sharing technologies may be used. As illustrated, the system 10 includes a server computer 12 , a number of mobile devices 14 - 1 through 14 -N (generally referred to herein collectively as mobile devices 14 or individually as mobile device 14 ) having associated users 16 - 1 through 16 -N (generally referred to herein collectively as users 16 and individually as user 16 ), a check-in service 18 , a social networking service 20 , and one or more social context data sources 22 connected via a network 24 . The network 24 may be any type of network or any combination of networks. Specifically, the network 24 may include wired components, wireless components, or both wired and wireless components. In one exemplary embodiment, the network 24 is a distributed public network such as the Internet, where the mobile devices 14 are enabled to connect to the network 24 via local wireless connections (e.g., Wi-Fi® or IEEE 802.11 connections) or wireless telecommunications connections (e.g., 3G or 4G telecommunications connections such as GSM, LTE, W-CDMA, or WiMAX® connections).
The server computer 12 is a physical computing device (i.e., a hardware device). Note that while only a single server computer 12 is illustrated, it should be appreciated that the functions of the server computer 12 described herein may be performed by a number of server computers 12 operating in a collaborative manner for purposes of redundancy and/or load sharing. As illustrated, the server computer 12 hosts an Automatic Check-in and Status Update (ACSU) server 26 and a user records repository 28 . The ACSU server 26 is preferably implemented in software and is executed by the server computer 12 . As discussed below, the user records repository 28 is maintained by the ACSU server 26 and stored in one or more secondary storage devices of the server computer 12 . The user records repository 28 includes a user record for each of the users 16 . For each user 16 , the user record of the user 16 includes one or more automatic check-in rules defined by the user 16 , one or more automatic status update rules defined by the user 16 , and credentials of the user 16 (e.g., username(s) and password(s) for accessing the check-in service 18 and/or the social networking service 20 ). In addition, the user record of the user 16 may include one or more social context records that store social context data that defines the social context of the user 16 over time.
The ACSU server 26 includes a rules manager 30 , a social context function 32 , an automatic check-in function 34 , and an automatic status update function 36 , which may be implemented by one or more corresponding software components. As described below in detail, the rules manager 30 generally operates to obtain automatic check-in rules and automatic status update rules from the users 16 and store the automatic check-in rules and automatic status update rules in the corresponding user records of the users 16 maintained in the user records repository 28 . The social context function 32 operates to determine the social contexts of the users 16 . The automatic check-in function 34 operates to perform automatic check-ins for the users 16 based on the social contexts of the users 16 and the corresponding automatic check-in rules of the users 16 . In general, for each of the users 16 , rather than performing automatic check-ins for all POIs visited by the user 16 , automatic check-ins are performed only when appropriate as determined by the social context of the user 16 and the automatic check-in rules of the user 16 . Similarly, the automatic status update function 36 operates to generate and send automatic status updates for the users 16 based on the social contexts of the users 16 and the corresponding automatic status update rules of the users 16 . In general, for each of the users 16 , automatic status updates are generated and sent only when appropriate as determined by the social context of the user 16 and the automatic status update rules of the user 16 .
Each of the mobile devices 14 is generally any type of mobile personal computing device such as, but not limited to, a mobile smart phone, a portable media player device, a mobile gaming device, an e-book device, a notebook or laptop computer, a tablet computer, or the like. Some exemplary mobile devices that may be programmed or otherwise configured to operate as the mobile devices 14 are the Apple® iPhone®, the Palm Pre®, the Samsung Rogue™, the Blackberry Storm™, the Motorola DROID or similar phone running Google's Android™ Operating System, an Apple® iPad®, and the Apple® iPod Touch® device. However, this list of exemplary mobile devices is not exhaustive and is not intended to limit the scope of the present disclosure.
The mobile devices 14 - 1 through 14 -N include ACSU clients 38 - 1 through 38 -N (generally referred to herein collectively as ACSU clients 38 and individually as ACSU client 38 ) and location functions 40 - 1 through 40 -N (generally referred to herein collectively as location functions 40 and individually as location function 40 ), respectively. For each of the mobile devices 14 , the ACSU client 38 of the mobile device 14 is preferably implemented in software and executed by the mobile device 14 . In general, the ACSU client 38 enables the user 16 to interact with the ACSU server 26 to define automatic check-in rules and/or automatic status update rules and provide credentials for accessing the check-in service 18 and/or the social networking service 20 for the user 16 . In addition, in some embodiments, the ACSU client 38 obtains a current location of the mobile devices 14 from the corresponding location functions 40 and provides the current location of the mobile devices 14 , and thus the users 16 , to the ACSU server 26 automatically or upon request.
Still further, in some embodiments, the ACSU client 38 gathers and reports at least some social context data to the ACSU server 26 . The ACSU client 38 may collect social context data such as, for example, device identifiers of nearby devices, calendar information from a calendar application or calendar feature of an application on the mobile device 14 , mode of transportation, activity performed by the user 16 , and websites the user 16 is logged in to. Additionally, information such as aggregate profile information may be available at the ACSU client 38 , or the like. The device identifiers of nearby devices may be, for example, Bluetooth® identifiers (IDs) of devices detected by a Bluetooth® interface (not shown) of the mobile device 14 , Media Access Control (MAC) addresses of devices detected by a local wireless interface (not shown) of the mobile device 14 such as, for example, a Bluetooth® interface or IEEE 802.11x interface of the mobile device 14 . The calendar information may be a calendar entry, or data from a calendar entry, that contains data describing the current location of the user 16 , data identifying friends currently located near the user 16 (e.g., other attendees of a meeting being attended by the user 16 ), or the like.
The location function 40 of the mobile device 14 may be implemented in hardware, software, or a combination thereof. In one embodiment, the location function 40 operates to determine or otherwise obtain the location of the mobile device 14 . As used herein, the location of the mobile device 14 includes any information that defines the location of the mobile device 14 in two-dimensional or three-dimensional space such as, for example, a latitude and longitude coordinate pair and optionally an altitude, a street address, or the like. For example, the location function 40 may be or include a Global Positioning System (GPS) receiver. In addition or alternatively, the location function 40 may include hardware and/or software that enables improved location tracking in indoor environments such as, for example, shopping malls. For example, the location function 40 may be part of or compatible with the InvisiTrack Location System provided by InvisiTrack and described in U.S. Pat. No. 7,423,580 entitled “Method and System of Three-Dimensional Positional Finding” which issued on Sep. 9, 2008, U.S. Pat. No. 7,787,886 entitled “System and Method for Locating a Target using RFID” which issued on Aug. 31, 2010, and U.S. Patent Application Publication No. 2007/0075898 entitled “Method and System for Positional Finding Using RF, Continuous and/or Combined Movement” which published on Apr. 5, 2007, all of which are hereby incorporated herein by reference for their teachings regarding location tracking.
In this embodiment, the check-in service 18 is a third-party service hosted by one or more server computers. The check-in service 18 is a service by which users, such as but not limited to the users 16 , are enabled to manually check-in to POIs via their mobile devices while the users 16 are at those POIs. For example, if the user 16 - 1 were to visit Sullivan's Steakhouse at 414 Glenwood Avenue in Raleigh, N.C., the user 16 - 1 may manually check-in to Sullivan's Steakhouse via the check-in service 18 . One exemplary check-in service is the FourSquare™ check-in service. However, whereas the check-in service 18 enables users to manually check-in, the ACSU server 26 interacts with the check-in service 18 to enable automatic check-ins for the users 16 .
In this embodiment, the social networking service 20 is a third-party service hosted by one or more server computers. The social networking service 20 is generally any type of social networking service that enables users, such as the users 16 , to manually create and send status updates to individuals or groups of users (e.g., send status updates by posts to Facebook® friends or groups, send tweets to Twitter® followers, or the like). Exemplary social networking services are the Twitter® social networking service, the Facebook® social networking service, the MySpace® social networking service, and the like. However, whereas the social networking service 20 enables users to manually send status updates, the ACSU server 26 interacts with the social networking service 20 to enable automatic status updates from the users 16 .
It should be noted that while the check-in service 18 and the social network service 20 are third-party services in this embodiment, the present disclosure is not limited thereto. In an alternative embodiment, some or all of the functionality of the ACSU server 26 may be incorporated into the check-in service 18 and/or the social networking service 20 . For example, the functionality of the ACSU server 26 with respect to automatic check-ins may be incorporated into the check-in service 18 , and the functionality of the ACSU server 26 with respect to automatic status updates may be incorporated into the social networking service 20 . Alternatively, the ACSU server 26 may include the check-in service 18 , the social networking service 20 , and/or one or more social context data source(s) 22 .
The one or more social context data sources 22 are generally any type of source(s) that may be utilized to obtain data that defines the social context of the users 16 based on, for example, the current locations of the users 16 . In one embodiment, the one or more social context data sources 22 include a Mobile Aggregate Profile (MAP) server that operates to provide historical aggregate profile data and/or aggregate profiles for crowds of users as described in U.S. Patent Application Publication No. 2010/0198828, entitled “Forming Crowds And Providing Access To Crowd Data In A Mobile Environment,” which was filed Dec. 23, 2009 and published Aug. 5, 2010; U.S. Patent Application Publication No. 2010/0197318, entitled “Anonymous Crowd Tracking,” which was filed Dec. 23, 2009 and published Aug. 5, 2010; U.S. Patent Application Publication No. 2010/0198826, entitled “Maintaining A Historical Record Of Anonymized User Profile Data By Location For Users In A Mobile Environment,” which was filed Dec. 23, 2009 and published Aug. 5, 2010; U.S. Patent Application Publication No. 2010/0198917, entitled “Crowd Formation For Mobile Device Users,” which was filed Dec. 23, 2009 and published Aug. 5, 2010; U.S. Patent Application Publication No. 2010/0198870, entitled “Serving A Request For Data From A Historical Record Of Anonymized User Profile Data In A Mobile Environment,” which was filed Dec. 23, 2009 and published Aug. 5, 2010; U.S. Patent Application Publication No. 2010/0198862, entitled “Handling Crowd Requests For Large Geographic Areas,” which was filed Dec. 23, 2009 and published Aug. 5, 2010; and U.S. Patent Application Publication No. 2010/0197319, entitled “Modifying A User's Contribution To An Aggregate Profile Based On Time Between Location Updates And External Events,” which was filed Dec. 23, 2009 and published Aug. 5, 2010; all of which are hereby incorporated herein by reference for their teachings related to historical aggregate profile data and aggregate profiles for crowds of users.
The one or more social context data sources 22 may also include one or more web-based sources of content that describe the current locations of the users 16 . For example, if the user 16 - 1 is located at a POI that is a venue where various types of sporting events, concerts, and the like are held, the social context data sources 22 may include a web-based source that may be queried or searched by the ACSU server 26 to obtain data that describes the event being held at the venue at a desired point in time. For instance, for a particular point in time, the ACSU server 26 may query the web-based source to obtain data that indicates that the user 16 - 1 is attending a concert for a particular music group, which is data that describes the social context of the user 16 - 1 at that time.
The one or more social context data sources 22 may also include one or more databases or sources for mapping the current locations of the users 16 to POIs or POI types of the POIs at which the users 16 are currently located. Alternatively, the server computer 12 may host or otherwise have access to a POI database that can be utilized to map the current locations of the users 16 to POIs at which the users 16 are located and/or POI types of the POIs at which the users 16 are located.
FIG. 2 is a flow chart illustrating the operation of the ACSU server 26 of FIG. 1 according to one embodiment of the present disclosure. As illustrated, the rules manager 30 of the ACSU server 26 first receives automatic check-in and automatic status update rules from one of the users 16 and stores the automatic check-in and automatic status update rules in the user record of the user 16 (step 1000 ). Note that while FIG. 2 illustrates receiving and storing the automatic check-in and automatic status update rules as a single step 1000 , it should be appreciated that the user 16 is preferably enabled to update the automatic check-in and automatic status update rules as desired.
More specifically, in one embodiment, the ACSU client 38 of the mobile device 14 of the user 16 provides an interface by which the user 16 is enabled to define and update the automatic check-in rules and automatic status update rules of the user 16 . In general, the automatic check-in rules define social contexts for which automatic check-ins are permitted by the user 16 . More specifically, the automatic check-in rules may positively define social contexts for which automatic check-ins are permitted (e.g., a rule stating that automatic check-ins are permitted for restaurants) or negatively define social contexts for which automatic check-ins are not permitted (e.g., a rule stating that automatic check-ins are not permitted for doctor's offices). The automatic check-in rules may be prioritized in order to, for example, resolve conflicting rules. The automatic check-in rules may be based on criteria including one or more of the following:
POI type (e.g., restaurant, house of worship, grocery store, hardware store, clothing store, sports arena, bar, park, city, or the like); event data that describes the event being held at the POI at which the user 16 is located; historical aggregate profile data for the current location of the user 16 ; aggregate profile for a crowd of users in which the user 16 is located; aggregate profiles of one or more crowds of users 16 near the current location of the user 16 ; device IDs of devices located near the current location of the user 16 ; friends in a social network of the user 16 (i.e., other users directly related to the user 16 in a social network such as that maintained by the social networking service 20 ) that are located at or near the current location of the user 16 (e.g., within a predefined distance from the user 16 or at the same POI); number of friends in a social network of the user 16 that are located at or near the current location of the user 16 ; friends-of-friends of the user 16 (i.e., other users that are indirectly related to the user 16 in a social network such as that maintained by the social networking service 20 ) that are located at or near the current location of the user 16 ; and number of friends and friends-of-friends of the user 16 that are located at or near the current location of the user 16 .
Notably, a friend-of-friend of the user 16 may be a predefined maximum number of degrees of separation (e.g., limited to 2 degrees of separation such that the friends-of-friends only include friends of direct friends of the user 16 or limited to 3 degrees of separation such that the friends-of-friends include both friends of direct friends of the user 16 and friends-of-friends of direct friends of the user 16 ).
As an example, the user 16 may define automatic check-in rules such as:
do not perform automatic check-ins when located at a doctor's office because the user 16 deems being at a doctor's office as being too private to share with others; do not perform automatic check-ins when located at a grocery store because the user 16 deems being at a grocery store as too boring to share with others; perform automatic check-ins when located at any restaurant; perform automatic check-ins when located at any POI where a concert or sporting event is being held; perform automatic check-ins when located at any POI having a historical profile having defined characteristics; do not perform automatic check-ins when located in or near a crowd having an aggregate profile having defined characteristics; do not perform automatic check-ins when a device having a defined Bluetooth® ID is detected by a Bluetooth® interface of the mobile device 14 of the user 16 ; perform automatic check-ins when one or more defined friends are near the current location of the user 16 (e.g., within a defined distance from the current location of the user 16 or at the same POI); or perform automatic check-ins when at least a threshold number of friends or friends-of-friends of the user 16 are near the current location of the user 16 (e.g., within a defined distance from the current location of the user 16 or at the same POI).
In a similar manner, the automatic status update rules define social contexts for which automatic status updates are permitted. The automatic status update rules may be prioritized in order to, for example, resolve conflicting rules. More specifically, the automatic status update rules may positively define social contexts for which automatic status updates are permitted (e.g., a rule stating that automatic status updates are permitted for restaurants) or negatively define social contexts for which automatic status updates are not permitted (e.g., a rule stating that automatic status updates are not permitted for doctor's offices). Like the automatic check-in rules, the automatic status update rules may also be based on criteria including one or more of the following:
POI type (e.g., restaurant, house of worship, grocery store, hardware store, clothing store, sports arena, bar, or the like); event data that describes the event being held at the POI at which the user 16 is located; historical aggregate profile data for the current location of the user 16 ; aggregate profile for a crowd of users in which the user 16 is located; aggregate profiles of one or more crowds of users 16 near the current location of the user 16 ; device IDs of devices located near the current location of the user 16 ; friends in a social network of the user 16 (i.e., other users directly related to the user 16 in a social network such as that maintained by the social networking service 20 ) that are located at or near the current location of the user 16 ; number of friends in a social network of the user 16 that are located at or near the current location of the user 16 ; friends-of-friends of the user 16 (i.e., other users that are indirectly related to the user 16 in a social network such as that maintained by the social networking service 20 ) that are located at or near the current location of the user 16 ; and number of friends and friends-of-friends of the user 16 that are located at or near the current location of the user 16 .
As an example, the user 16 may define automatic status update rules such as:
do not generate and send automatic status updates when located at a doctor's office because the user 16 deems being at a doctor's office as being too private to share with others; do not generate and send automatic status updates when located at a grocery store because the user 16 deems being at a grocery store as too boring to share with others; generate and send automatic status updates when located at any restaurant; generate and send automatic status updates when located at any POI where a concert or sporting event is being held; generate and send automatic status updates when located at any POI having a historical profile having defined characteristics; do not generate and send automatic status updates when located in or near a crowd having an aggregate profile having defined characteristics; do not generate and send automatic status updates when a device having a defined Bluetooth® ID is detected by a Bluetooth® interface of the mobile device 14 of the user 16 ; generate and send automatic status updates when one or more defined friends are near the current location of the user 16 (e.g., within a defined distance from the current location of the user 16 or at the same POI); or generate and send automatic status updates when at least a threshold number of friends or friends-of-friends of the user 16 are near the current location of the user 16 (e.g., within a defined distance from the current location of the user 16 or at the same POI).
The automatic status update rules may be global rules that apply to all automatic status updates from the corresponding user 16 . For example, the automatic status update rules may be a single set of rules that define when automatic status updates are to be tweeted from the user 16 via Twitter® to all of the Twitter® followers of the user 16 , when automatic status updates are to be posted to the Facebook® wall of the user 16 where the status updates are visible to all Facebook® friends of the user 16 , or the like. In addition or alternatively, the user 16 may define separate sets of automatic status update rules for different groups of users (e.g., different Facebook® groups; friends versus friends-of-friends; family versus friends; or the like) or different individuals (e.g., different friends). Note that the ACSU server 26 may interact with the social networking service 20 to obtain a listing of the different groups of users and friends of the user 16 if separate sets of automatic status update rules are to be provided for different groups of users or different friends of the user 16 .
Once the automatic check-in and automatic status update rules are received and stored, the social context function 32 determines whether it is time to update the social context of the user 16 (step 1002 ). For example, the social context function 32 may determine that it is time to update the social context of the user 16 in response to a triggering event. As discussed below, in one embodiment, the triggering event is the receipt of a location update and, optionally, social context data from the mobile device 14 of the user 16 . If it is not time to update the social context of the user 16 , the process returns to step 1002 .
If it is time to update the social context of the user 16 , the social context function 32 of the ACSU server 26 determines the social context of the user 16 (step 1004 ). In general, the social context function 32 determines the social context of the user 16 by obtaining social context data that defines the social context of the user 16 from the mobile device 14 of the user 16 and/or the one or more social context data sources 22 . More specifically, in one embodiment, the social context function 32 obtains the current location of the user 16 and maps the current location to a POI at which the user 16 is located. The current location of the user 16 may be mapped to the POI at which the user 16 is located using a local POI database stored by the server computer 12 or a remote POI database. The POI database stores, for each of a number of known POIs, information defining locations that map to the POI, a name of the POI (e.g., Sullivan's Steakhouse), and optionally information describing the POI (e.g., POI type). In one exemplary embodiment, the information that defines locations that map to a POI is a location (e.g., a latitude and longitude) and a geographic area that is centered at or otherwise encompasses the location such that the current location of the user 16 is mapped to the POI if the current location of the user 16 is within the geographic area for the POI. As a specific example, the information that defines locations that map to a POI may be a location and a radius (e.g., 50 meters) such that the current location of the user 16 is mapped to the POI if the current location of the user 16 is within the defined radius from the defined location for the POI. If no POI is found for the current location of the user 16 , the social context function 32 may assign the closest POI. Alternatively, the social context function 32 may create a new POI based on the current location of the user 16 . For example, the social context function 32 may determine the closest known street address to the current location and create a POI for that street address. In another example, the social context function 32 may also default to the closest zip code, city, etc. POIs may be nested. For example, there may be a POI for a city and several POIs within the city. In addition, if the POI to which the current location of the user 16 is mapped or assigned is a venue at which events are held, the social context function 32 may query or search one or more of the social context data sources 22 to obtain data describing the event that is being held at the venue at the current time, if any. The POI, information describing the POI, and data describing any event being held at the venue form social context data that may define, at least in part, the social context of the user 16 .
In addition or alternatively, the one or more social context data sources 22 may include a source of historical aggregate profile data by location, and the social context function 32 may obtain the current location of the user 16 and query the source of historical aggregate profile data for historical aggregate profile data for the current location of the user 16 . The historical aggregate profile data is generally an aggregation of user profiles for users previously located at or near the current location of the user 16 . For example, if the current location of the user 16 maps to a POI, the historical aggregate profile data may be an aggregation of interests defined in user profiles of users that were located at the POI during one or more historical time periods (e.g., the last week, weekday evenings from 7 pm to 11 pm, or the like). The historical aggregate profile data may be expressed as a list of user interests found in the user profiles of the users previously located at or near the current location of the user 16 and, for each interest, a value reflecting a degree to which the user interest is found in the user profiles of the users previously located at or near the current location of the user 16 . The historical aggregate profile data may define, at least in part, the social context of the user 16 .
In addition or alternatively, the one or more social context data sources 22 may include a source of crowd data, and the social context function 32 may query the source of crowd data for an aggregate profile of a crowd in which the user 16 is currently located and/or aggregate profiles of one or more crowds at or near the current location of the user 16 . The aggregate profile for a crowd is generally an aggregation of user profiles of a number of users in the crowd. For example, the aggregate profile of a crowd may be expressed as a list of user interests found in the user profiles of the users in the crowd and, for each user interest, a number of user matches for the interest among the users in the crowd and/or a ratio of the number of user matches for the interest among the users in the crowd over a total number of users in the crowd. The aggregate profile(s) of the crowd(s) may define, at least in part, the social context of the user 16 .
Still further, the social context function 32 may query the social networking service 20 for a list of friends that are currently located near the user 16 (e.g., friends within a defined distance from the user 16 , friends at the same POI as the user 16 , or the like). The friends located near the user 16 or the number of friends near the user 16 may define, at least in part, the social context of the user 16 . In a similar manner, the social context of the user 16 may include the friends and friends-of-friends or the number of friends and friends-of-friends located near the user 16 .
Lastly, the social context data that defines the social context of the user 16 may include social context data received from the ACSU client 38 of the mobile device 14 of the user 16 . The social context data received from the ACSU client 38 may include a list of devices detected by a wireless Local Area Network (LAN) or wireless Personal Area Network (PAN) interface (e.g., an IEEE 802.11x or Bluetooth® interface) of the mobile device 14 of the user 16 , calendar information from a calendar entry from a calendar application or feature of the mobile device 14 where the calendar entry includes information such as information that describes the location of the user 16 at the current time (e.g., calendar entry for Bill's birthday party) and/or identifies a number of users scheduled to be near the user 16 (e.g., the other participants in a scheduled meeting).
The data defining the social context may then be stored in the user record of the user 16 . In one embodiment, the user record includes a number of social context records that store the data defining the social context of the user 16 at corresponding points in time. In one embodiment, each social context record may include a unique record ID, an identifier of the user 16 (e.g., a username), a status (e.g., checked-in, checked-out, or status update) that indicates whether a check-in, check-out, and/or status update resulted from the social context defined by the social context record, a timestamp identifying a date and time at which the social context record was created, the POI at which the user 16 was located at that time, an activity being performed by the user 16 at that time (e.g., listening to song X by artist Y, purchased item Z, chatting with person A, or the like), a mode of transportation (e.g., walking, driving, bicycling, or flying), any calendar event data, and information identifying any website that the user 16 is logged into at that time.
Once the social context of the user 16 is determined, the automatic check-in function 34 determines whether to perform an automatic check-in for the user 16 based on the social context of the user 16 and the automatic check-in rules of the user 16 (step 1006 ). In addition, the automatic check-in function 34 may consider system-defined rules such as rules defining POI types from which automatic check-ins are always permitted (assuming that the user 16 has also permitted automatic check-ins from those POI types), POI types from which automatic check-ins are never permitted even if the user 16 has given permission to provide automatic check-ins from those POI types, or the like. Still further, if the current location of the user 16 does not map to a POI, then the automatic check-in function 34 determines that an automatic check-in is not to be performed. In some embodiments, if the current location of the user 16 does not map to a POI, a new POI may automatically be created at the current location of the user 16 . However, certain criteria may be required to be satisfied before a new POI is automatically created (e.g., the user 16 must have been at the POI for more than a threshold amount of time such as, for example, 30 minutes).
If an automatic check-in is not to be performed, the process proceeds to step 1010 . If an automatic check-in is to be performed, the automatic check-in function 34 performs an automatic check-in for the user 16 at the POI corresponding to the current location of the user 16 (step 1008 ). More specifically, in this embodiment, the automatic check-in function 34 communicates with the check-in service 18 to automatically perform a check-in (i.e., an automatic check-in) for the user 16 at the POI corresponding to the current location of the user 16 . Notably, any credentials of the user 16 needed to perform the automatic check-in on behalf of the user 16 such as, for example, a username and password of the user 16 for the check-in service 18 may be provided to the ACSU server 26 by the user 16 in advance and stored in the user record of the user 16 . For instance, the credentials of the user 16 may be provided by the user 16 during a registration or initial configuration process. Preferably, the automatic check-in is performed without any interaction with the user 16 . However, in an alternative embodiment, a confirmation message may be provided to the user 16 to request confirmation from the user 16 that the user 16 desires to check-in to the POI before performing the check-in on behalf of the user 16 .
Before proceeding, it should be noted that at some point after the automatic check-in is performed, the user 16 will check-out of the POI or will be automatically checked-out of the POI such that the user 16 is no longer indicated as being at the POI. The check-out may be performed manually by the user 16 . Alternatively, the check-out may be performed automatically by the automatic check-in function 34 . The user 16 may be automatically checked-out of the POI, for example, when the user 16 is no longer at the POI, when the user 16 has been gone from the POI for at least a predefined threshold amount of time, when the user 16 is located more than a predefined threshold distance from the POI, or the like.
Next, in this embodiment, the automatic status update function 36 of the ACSU server 26 determines whether to send an automatic status update for the user 16 based on the social context of the user 16 and the automatic social update rules of the user 16 (step 1010 ). In addition, the automatic status update function 36 may consider system-defined rules such as rules defining POI types from which automatic status updates are always permitted (assuming that the user 16 has also permitted automatic status updates from those POI types), POI types from which automatic status updates are never permitted even if the user 16 has given permission to provide automatic status updates from those POI types, or the like.
If an automatic status update is not to be sent, the process returns to step 1002 . If an automatic status update is to be sent, the automatic status update function 36 generates and sends an automatic status update for the user 16 (step 1012 ) and then the process returns to step 1002 . More specifically, in this embodiment, the automatic status update function 36 automatically generates a status update for the user 16 based on the social context of the user 16 . For example, if the user 16 is located at a POI, the automatic status update function 36 may generate a status update stating that the user 16 is currently at the POI. Still further, if the user 16 is located at the POI with a number (M) of his friends, the status update may be generated to state that the user 16 is located at the POI with M of his friends. As another example, if the user 16 is located at a POI with his friends Bill, Tammy, and Susie, the status update may be generated to state that user 16 is at the POI with his friends Bill, Tammy, and Susie. As a final example, if the user 16 is listening to rock music and is near his friends Ken, Vicky, and Brad, the status update may be generated to state that the user 16 is “rocking out with Ken, Vicky, and Brad.” Note that the exemplary status updates generated above are exemplary and are not intended to limit the scope of the present disclosure. Numerous other types of automatically generated status updates that are personalized based on the social context of the user 16 will be appreciated by one of ordinary skill in the art upon reading this disclosure and are considered within the scope of the present disclosure.
The status update automatically generated by the automatic status update function 36 may automatically be sent to the social networking service 20 for distribution without interaction from the user 16 . Additionally, the status update automatically generated by the automatic status update function 36 may automatically update the user's profile. Alternatively, the generated status update may be sent to the ACSU client 38 of the mobile device 14 of the user 16 for confirmation and, optionally, editing by the user 16 before any automated actions are performed. Once confirmation and any edits are received from the user 16 , the automatic status update function 36 sends the status update to the social networking service 20 for distribution. Notably, any credentials of the user 16 needed to send the automatic status update on behalf of the user 16 such as, for example, a username and password of the user 16 for the social networking service 20 may be provided to the ACSU server 26 by the user 16 in advance and stored in the user record of the user 16 . For instance, the credentials of the user 16 may be provided by the user 16 during a registration or initial configuration process.
Once the status update is received by the social networking service 20 , the social networking service 20 delivers the status update according to the normal operation of the social networking service 20 (e.g., post the status update to the Facebook® wall of the user 16 , send the status update to the Twitter® followers of the user 16 , or the like depending on the particular implementation of the social networking service 20 ). Alternatively, the social networking service 20 may provide global or individualized filtering in order to reduce the number of or types of automatic status updates received by users of the social networking service 20 . For example, the social networking service 20 may filter automatic status updates such that automatic status updates are not delivered to recipients at a rate greater than a predefined maximum rate (e.g., no more than 1 automatic status update per 30 minutes). As another example, the social networking service 20 may enable the users of the social networking service 20 to define individual filtering criteria to control the number and types of automatic status updates received from other users (e.g., maximum rate of automatic status update receipt, no status updates from users located at bars, or the like). Any conflicts between filtering criteria may be resolved by assigning priorities to the filtering criteria.
It should be noted that while FIGS. 1 and 2 illustrate an embodiment where the ACSU server 26 provides both automatic check-ins and automatic status updates for the users 16 , the present disclosure is not limited thereto. More specifically, in one embodiment, the ACSU server 26 includes the automatic check-in function 34 and not the automatic status update function 36 such that the ACSU server 26 performs automatic check-ins for the users 16 but does not send automatic status updates for the users 16 . In another embodiment, the ACSU server 26 includes the automatic status update function 36 but not the automatic check-in function 34 such that the ACSU server 26 sends automatic status updates for the users 16 but does not perform automatic check-ins for the users 16 . In yet another embodiment, the ACSU server 26 includes both the automatic check-in function 34 and the automatic status update function 36 , but each of the users 16 may choose to have the ACSU server 26 only perform automatic check-ins for the user 16 or only send automatic status updates for the user 16 by, for example, defining automatic check-in rules but not automatic status update rules or vice versa or by activating/deactivating automatic check-ins and/or automatic status updates via a corresponding feature of the ACSU server 26 .
In addition, the ACSU server 26 may enable the users 16 to review and edit automatic check-ins previously performed for the users 16 and automatic status updates previously sent for the user 16 . For example, the ACSU server 26 may enable the user 16 to view a log of automatic check-ins performed for the user 16 and enable the user 16 to delete previous check-ins performed by the user 16 such that those check-ins are no longer available via the check-in service 18 . In response to such deletions, the ACSU server 26 may automatically update the automatic check-in rules to prevent automatic check-ins in the future for the user 16 when in the same or similar social contexts as the social contexts of the user 16 at the time of performing the deleted automatic check-ins. In a similar manner, the ACSU server 26 may enable the user 16 to view a log of automatic status updates sent for the user 16 and enable the user 16 to edit and/or delete those status updates. If status updates are deleted, the ACSU server 26 may automatically update the automatic status update rules of the user 16 to prevent automatic status updates in the future for the user 16 when in the same or similar social contexts as the social contexts of the user 16 at the time of performing the deleted automatic social updates.
FIGS. 3A through 5 illustrate exemplary Graphical User Interfaces (GUIs) that enable the users 16 to define automatic check-in and automatic status update rules according to one exemplary embodiment of the present disclosure. These GUIs may be provided by the ACSU clients 38 of the mobile devices 14 of the users 18 or provided by the ACSU server 26 for presentation to the users 16 via the ACSU clients 38 of the mobile devices 14 of the users 16 . More specifically, FIGS. 3A through 3C illustrate a first exemplary GUI 42 presented to the user 16 according to one embodiment of the present disclosure. The GUI 42 includes an Accounts tab 44 , a Settings tab 46 , and a Rules tab 48 . In FIG. 3A , the Accounts tab 44 is selected such that the GUI 42 presents a corresponding Accounts screen 50 to the user 16 . The Accounts screen 50 includes buttons 52 through 58 for corresponding check-in and/or social network services with which the user 16 is or may be registered. The user 16 can select the buttons 52 through 58 to enter his login information for the corresponding check-in and/or social networking services. For example, the user 16 can select the Facebook Connect button 52 to enter his login information for the Facebook® social networking service in order to enable the ACSU server 26 to perform automatic check-ins and/or automatic status updates for the user 16 via the Facebook® social networking service. In addition, the Accounts screen 50 includes check boxes 60 through 66 that enable the user 16 to select whether automatic check-ins are to be performed for the corresponding services. In this example, the user 16 has chosen to permit automatic check-ins for Facebook® and FourSquare™ by selecting the corresponding check boxes 60 and 64 . In a similar manner, the Accounts screen 50 includes check boxes 68 through 74 that enable the user 16 to select whether automatic status updates are to be performed for the corresponding services. In this example, the user 16 has chosen to permit automatic status updates for Twitter® and Black Planet by selecting the corresponding check boxes 70 and 74 . The user 16 can select an OK button 76 to accept the configurations set via the GUI 42 or a Cancel button 78 to cancel without accepting any changes to the configurations set via the GUI 42 .
As shown in FIG. 3B , when the user 16 selects the Settings tab 46 , a Settings screen 80 is presented to the user 16 . The Settings screen 80 generally enables the user 16 to configure a number of settings to be used by the ACSU server 26 when performing automatic check-ins and/or sending automatic status updates on behalf of the user 16 . In this example, the Settings screen 80 includes a minimum check-in interval slider bar 82 having a corresponding slider 84 for configuring a minimum check-in interval. The minimum check-in interval is a minimum amount of time between automatic check-ins for the user 16 . Here, the minimum check-in interval can be configured to be anywhere from 1 hour to 1 week. The Settings screen 80 also includes a maximum interval activity slider bar 86 having a corresponding slider 88 for configuring a maximum interval activity. The maximum interval activity limits the number of automatic check-ins and/or automatic status updates per day when radio button 90 is selected, per week when radio button 92 is selected, and per month when radio button 94 is selected. Still further, the Settings screen 80 includes a proximate distance slider bar 96 having a corresponding slider 98 for configuring a proximate distance definition. The proximate distance definition defines a threshold distance to be used when determining whether the user 16 is spatially proximate to a location, a POI, a friend, or the like, depending on the particular implementation. For example, POIs may be defined as a location rather than a geographic area. The user 16 may then be determined to be at the POI when the user 16 is within the defined proximate distance from the location of the POI. Lastly, the Settings screen 80 includes an OK button 100 that can be selected to accept the configurations set via the GUI 42 and a Cancel button 102 that can be selected to cancel without accepting any changes to the configurations set via the GUI 42 .
As illustrated in FIG. 3C , when the Rules tab 48 is selected, a Rules screen 104 is presented to the user 16 . In general, the Rules screen 104 enables the user 16 to define automatic check-in rules and/or automatic status update rules. Specifically, in this example, the user 16 has already created rules 106 through 112 . Notably, the order of the rules 106 through 112 from top to bottom corresponds to priorities of the rules from 106 through 112 from highest to lowest. The Rules screen 104 includes buttons 114 through 120 , buttons 122 through 128 , and buttons 130 through 136 . The buttons 114 through 120 enable the user 16 to delete the corresponding rules 106 through 112 (e.g., the user 16 can select the button 114 to delete the rule 106 ). The buttons 122 through 128 enable the user 16 to create new rules using a rule builder dialog. More specifically, the buttons 122 through 128 enable the user 16 to create a new rule immediately below the corresponding rules 106 through 112 (e.g., the user 16 can select the button 122 to create a new rule between the rules 106 and 108 ). Lastly, the buttons 130 through 136 enable the user 16 to open a rule builder dialog to modify the corresponding rules 106 through 112 . Lastly, the Rules screen 104 includes an OK button 138 that can be selected to accept the configurations set via the GUI 42 and a Cancel button 140 that can be selected to cancel without accepting any changes to the configurations set via the GUI 42 .
FIG. 4 illustrates an exemplary rule builder dialog 142 presented to the user 16 in response to selecting one of the buttons 122 through 128 to create a new rule or in response to selecting one of the buttons 130 through 136 to modify one of the corresponding rules 106 through 112 . The rule builder dialog 142 enables the user 16 to select an action via an action pull-down menu 144 , select a condition via a condition pull-down menu 146 that defines when the action is to be performed, and select a qualifier via a qualifier pull-down menu 148 . The rule builder dialog 142 includes check box 150 that enables the user 16 to define whether confirmation is to be obtained from the user 16 before performing the action and a check box 152 that enables the user 16 to enable sharing of the rule with other users 16 . Text box 154 enables the user 16 to enter a description for the rule. Lastly, the rule builder dialog 142 includes an OK button 156 that enables the user 16 to complete the creation or modification of the rule and a Cancel button 158 that enables the user 16 to cancel creation or modification of the rule.
FIG. 5 illustrates an exemplary syntax for the rule builder dialog 142 . More specifically, FIG. 5 illustrates exemplary actions (e.g., check-in, status update, block check-in, and block status update) and conditions (e.g., person, proximate friends, POI, location, event, crowd, timer interval, and date/time) that may be available to the user 16 via the rule builder dialog 142 . Notably, the qualifiers available in the qualifier pull-down menu 148 depend on the selected condition. FIG. 6 illustrates the rules 106 through 112 of FIG. 3C having been defined by the rule builder dialog 142 .
FIG. 7 illustrates an exemplary status update automatically generated by the automatic status update function 36 of the ACSU server 26 according to another embodiment of the present disclosure. In this embodiment, each of the users 16 may choose or select a predefined personal style (also referred to herein as “persona”) for his status updates. The personal style chosen or selected by the user 16 or information defining the personal style chosen or selected by the user 16 may be stored in the user record of the user 16 . The user 16 chooses or selects his personal style in advance before the ACSU server 26 operates to generate and send status updates based on the social context of the user 16 . Some exemplary personal styles are a Police Report style, a Hollywood Reporter or Paparazzi style, a Tattle Tale style, a Private Investigator style, a Young Child style, a Religious Zealot style, a Valley Girl style, an Obituary style, a Tabloid style, a Network Nightly News style, a Commercial style, or the like. The user 16 may select his desired personal style from a number of predefined styles provided by the ACSU server 26 or define his own personal style using, for example, an authoring tool provided by the ACSU server 26 or the ACSU client 38 . A personal style generally includes a template that may be personalized by the user 16 by inserting, for example, a picture and text. Thereafter, when the social context of the user 16 is such that the automatic status update function 36 generates an automatic status update to be sent on behalf of the user 16 , the automatic status update is generated according to the personal style of the user 16 . For instance, a natural language generation engine may be utilized to generate text to be entered into the template for the personal style of the user 16 based on the social context of the user 16 .
Turning to the specific example of FIG. 7 , an exemplary status update 160 is illustrated, where the status update 160 has been generated according to a personal style of the user 16 for which the status update is to be sent. In this example, the personal style is a Tabloid style that has been personalized with a picture of the user 16 and the text “THE SHAME OF AARON ROGERS” and “CAUGHT AT —————— AGAIN!”, where the space “ —————— ” represents the name of the current location or POI of the user 16 to be inserted into the status update by the automatic status update function 36 . In this example, the current location of the user 16 corresponds to the home of a person named “Bianca,” which may be a friend of the user 16 . The current location of the user 16 is matched to Bianca's home address using, for example, an address book maintained by the mobile device 14 of the user 16 . This may be reported to the ACSU server 26 by the ACSU client 38 as social context data for the user 16 . The automatic status update function 36 then inserts “BIANCA'S” into the space in the template for the Tabloid style to thereby generate the status update 160 for the user 16 . In this example, the status update 160 is returned to the mobile device 14 for presentation to the user 16 before sending the status update 160 . The user 16 may choose to cancel the status update 160 by selecting a “Delete” button 162 , edit the status update 160 by selecting an “Edit” button 164 , or send the status update 160 by selecting a “Send” button 166 .
Notably, in the example above, the user 16 has selected the desired personal style. However, in another embodiment, the personal style for a status update may be automatically selected by the ACSU server 26 based on the context of the user 16 (e.g., location, nearby friends, time of day, day of the week, POI type, or the like) or a target audience for the status update (e.g., friends, family, co-workers, or the like). For example, the user 16 may pre-define a number of personal styles and corresponding contexts for which the personal styles are to be used. For instance, the user 16 may define one personal style to be used when at work or during work hours, another personal style to be used when the user 16 is at church, another personal style to be used when the target audience of a status update includes the friends of the user 16 , or the like.
FIG. 8 is a block diagram of the server computer 12 according to one embodiment of the present disclosure. As illustrated, the server computer 12 includes a controller 168 connected to memory 170 , one or more secondary storage devices 172 , and a communication interface 174 by a bus 176 or similar mechanism. The controller 168 is a microprocessor, digital Application Specific Integrated Circuit (ASIC), Field Programmable Gate Array (FPGA), or similar hardware component. In this embodiment, the controller 168 is a microprocessor, and the ACSU server 26 ( FIG. 1 ) is implemented in software and stored in the memory 170 for execution by the controller 168 . Further, the user records repository 28 ( FIG. 1 ) may be stored in the one or more secondary storage devices 172 . The secondary storage devices 172 are digital data storage devices such as, for example, one or more hard disk drives. The communication interface 174 is a wired or wireless communication interface that communicatively couples the server computer 12 to the network 24 ( FIG. 1 ). For example, the communication interface 174 may be an Ethernet interface, local wireless interface such as a wireless interface operating according to one of the suite of IEEE 802.11 standards, or the like.
FIG. 9 is a block diagram of one of the mobile devices 14 according to one embodiment of the present disclosure. As illustrated, the mobile device 14 includes a controller 178 connected to memory 180 , one or more communication interfaces 182 , one or more user interface components 184 , and the location function 40 by a bus 186 or similar mechanism. The controller 178 is a microprocessor, digital ASIC, FPGA, or similar hardware component. In this embodiment, the controller 178 is a microprocessor, and the ACSU client 38 is implemented in software and stored in the memory 180 for execution by the controller 178 . In this embodiment, the location function 40 is a hardware component such as, for example, a GPS receiver. The one or more communication interfaces 182 include a wireless communication interface that communicatively couples the mobile device 14 to the network 24 ( FIG. 1 ). For example, the one or more communication interfaces 182 may include a local wireless interface such as a wireless interface operating according to one of the suite of IEEE 802.11 standards, a mobile communications interface such as a cellular telecommunications interface, or the like. The one or more communication interfaces 182 may also include a Bluetooth® interface or other local wireless interface to, for example, detect nearby devices. Note that the same local wireless interface may be utilized to both connect the mobile device 14 to the network 24 and detect nearby devices. The one or more user interface components 184 include, for example, a touchscreen, a display, one or more user input components (e.g., a keypad), a speaker, or the like, or any combination thereof.
FIG. 10 is a block diagram of a server computer 188 hosting the check-in service 18 according to one embodiment of the present disclosure. As illustrated, the server computer 188 includes a controller 190 connected to memory 192 , one or more secondary storage devices 194 , and a communication interface 196 by a bus 198 or similar mechanism. The controller 190 is a microprocessor, digital ASIC, FPGA, or similar hardware component. In this embodiment, the controller 190 is a microprocessor, and the check-in service 18 is implemented in software and stored in the memory 192 for execution by the controller 190 . The one or more secondary storage devices 194 are digital storage devices such as, for example, one or more hard disk drives. The communication interface 196 is a wired or wireless communication interface that communicatively couples the server computer 188 to the network 24 ( FIG. 1 ). For example, the communication interface 196 may be an Ethernet interface, local wireless interface such as a wireless interface operating according to one of the suite of IEEE 802.11 standards, a mobile communications interface such as a cellular telecommunications interface, or the like.
FIG. 11 is a block diagram of a server computer 200 operating to host the social networking service 20 according to one embodiment of the present disclosure. As illustrated, the server computer 200 includes a controller 202 connected to memory 204 , one or more secondary storage devices 206 , and a communication interface 208 by a bus 210 or similar mechanism. The controller 202 is a microprocessor, digital ASIC, FPGA, or similar hardware component. In this embodiment, the controller 202 is a microprocessor, and the social networking service 20 is implemented in software and stored in the memory 204 for execution by the controller 202 . The one or more secondary storage devices 206 are digital storage devices such as, for example, one or more hard disk drives. The communication interface 208 is a wired or wireless communication interface that communicatively couples the server computer 200 to the network 24 ( FIG. 1 ). For example, the communication interface 208 may be an Ethernet interface, local wireless interface such as a wireless interface operating according to one of the suite of IEEE 802.11 standards, a mobile communications interface such as a cellular telecommunications interface, or the like.
Those skilled in the art will recognize improvements and modifications to the preferred embodiments of the present disclosure. All such improvements and modifications are considered within the scope of the concepts disclosed herein and the claims that follow. | Methods and Devices are disclosed for performing automatic check-ins for a user associated with a mobile device. In some embodiments, the process is completely automated with no user intervention once the process has started. In some embodiments, the user is prompted for confirmation before the check-in is generated. The automatic check-in is performed based on detecting a social context which includes a current location of the user of the mobile device and applying rules. The rules may include an action part, a condition part, and qualifier part. The rules and the individual parts of the rules may be independently editable by the user. | 6 |
This application is a continuation of application Ser. No. 07/909,045 filed Jul. 6, 1992, now abandoned.
BACKGROUND
1. The Field of the Invention
The present invention relates to mandrels used for fabricating hollow continuous filament wound vessels and tanks and methods of constructing such mandrels.
2. The Prior Art
Methods of constructing filament wound vessels, tanks, and containers are well known in the prior art. Typically, a rigid mandrel made of aluminum, fiberglass, or other high strength and relatively lightweight material, or the like is prepared and mounted on a filament winding machine so that the mandrel may be selectively rotated. The surface of the mandrel is coated with an appropriate mold release preparation and then wound with resin impregnated or coated filaments, such as glass, KEVLAR®, graphite, nylon or boron fibers. Commonly, the winding progresses from end to end for an elongated shape or from side to side for a more spherical shape. When the desired thickness of the winding layers is achieved, the winding is stopped and the resin is cured.
In many cases, the resulting filament wound vessel is removed from the mandrel by cutting the vessel about its circumference, generally at a location near the center thereof. The two halves of the vessel are then removed from the mandrel and the halves joined and bonded together to form the desired vessel or tank. A short helical wind of a resin coated filament strand or roving may be made over the joint of the vessel in an attempt to further secure the two halves together.
Examples of prior art winding techniques and methods are disclosed in U.S. Pat. Nos. 3,386,872, 3,412,891, 3,697,352, 3,692,601, 3,533,869, 3,502,529 and 3,414,449.
Because of the joint in the completed vessel, an inherent weakness exists which may be the first to fail or fracture when the completed vessel is subjected to pressure or stress. Because of the weakness in the resulting vessel and the added labor costs associated with cutting the vessel and rejoining the two halves of the vessel, techniques have been developed which allow the fabrication of hollow vessels without the need to cut the vessel to remove it from the mandrel.
In some cases, for example, a hollow mandrel is designed to become an integral part of the completed fiber wound vessel. Disadvantageously, the intended use of the completed fiber wound vessel is often not compatible with retaining the mandrel as the interior of the vessel. Another technique involves using a mandrel which is destroyed once the vessel is formed. It will be appreciated that if a large number of a particular configuration of fiber wound vessel are to be fabricated, destroying the mandrel with each use is an exorbitantly expensive technique. Thus, reusable mandrels have been developed.
In some cases, segmented metal mandrels, which can be disassembled into small sections and then removed through an opening in the completed vessel, have been used. Disadvantageously, building a reusable metal mandrel is costly and time consuming. The difficulty of building a reusable segmented metal mandrel makes it too expensive for all but the most demanding applications of high volume vessel fabrication.
Another type of mandrel which has been used to produce seamless completed fiber wound vessels is a collapsible mandrel. Collapsible mandrels are hollow mandrels made of flexible, air tight materials such as a rubber which can be inflated while the vessel is being formed thereon and then deflated and removed through an opening in the completed vessel.
One collapsible mandrel which can be removed through an opening in a completed vessel is disclosed in U.S. Pat. No. 4,684,423 to Brooks. While the method of forming the mandrel and, the resulting mandrel structure, which are disclosed in the Brooks reference represented a great advance in the art, several disadvantages still remain. The Brooks reference requires that the resulting mandrel be cut in half to remove it from a rigid mandrel. Cutting and splicing the mandrel structure results in an inherently weaker and less desirable mandrel. Since the area at the resulting joint is weaker than the remaining structure, the joint often fails sooner than the other portions of the structure. Thus, the usable life of the mandrel is often unduly limited because of the presence of the joint.
Further drawbacks and disadvantages inherent in the structure and method disclosed in the Brooks reference include the additional labor which is required to cut and rejoin the mandrel. Moreover, since the outside surface of the mandrel determines the shape and uniformity of the interior surface of the completed fiber wound structure, a poorly formed seam in the collapsible mandrel can result in an inconsistent surface in the completed fiber wound hollow structure. Even though the use of collapsible mandrels to form seamless completed structures is known, for example as in the Brooks reference, the problems inherent in a mandrel which has been cut and spliced together has not been addressed in the art.
In view of the forgoing, it would be an advance in the art to provide a seamless, collapsible, and reusable mandrel structure and an accompanying method of forming the same.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
In view of the above described state of the art, the present invention seeks to realize the following objects and advantages.
It is a primary object of the present invention to provide a collapsible mandrel which is suitable for use in the fabrication of filament wound vessels and which is seamless, as well as, an accompanying method of making the same.
It is also an object of the present invention to produce an improved collapsible mandrel which is suitable for use in the fabrication of filament wound vessels which maintains its proper shape as the vessel is fabricated upon it, as well as, an accompanying method of making the same.
It is also an object of the present invention to provide an improved collapsible and reusable mandrel upon which high quality filament wound vessels can be consistently produced.
It is another object of the present invention to provide a collapsible and reusable mandrel which has a long useful life and which can be fabricated at a relatively low cost.
These and other objects and advantages of the invention will become more fully apparent from the description and claims which follow, or may be learned by the practice of the invention.
The present invention provides a method for fabricating, and a resulting structure for, a seamless, reusable and collapsible mandrel suitable for forming a plurality of seamless and hollow fiber wound vessels upon. The method of fabricating the seamless reusable mandrel includes readying a destructible mandrel upon which the seamless reusable mandrel is formed. The destructible mandrel is the general shape of the seamless mandrel and is preferably formed from a material which can be destroyed by dissolving the material, for example, materials such as foam or plaster.
The structure of the seamless, collapsible, and reusable mandrel of the present invention includes a plurality of different layers, each layer having a particular function. Different embodiments of the present invention require different numbers of layers in the seamless, collapsible, and reusable mandrel. Exemplary of the layers which are laid upon the destructible mandrel to fabricate the seamless, collapsible, and reusable mandrel of the present invention include: a first layer of generally fluid impermeable material; a second layer of continuous fibers wound about the destructible mandrel; and a layer which functions as a release surface forming the outermost layer of the seamless, collapsible, and reusable mandrel of the present invention. The release surface is formed in the shape of the interior of the completed seamless and hollow fiber wound vessel which will be formed on the seamless, collapsible, and reusable mandrel. The outer surface of the seamless, collapsible, and reusable mandrel is preferably machined so that it exactly matches the desired shape of the interior of a completed fiber wound hollow vessel to be formed thereon.
The destructible mandrel is removed from the interior of the seamless, reusable and collapsible mandrel preferably by dissolving the material from which the destructible mandrel is formed. Thus, the integrity of the seamless, collapsible, and reusable mandrel is not disturbed by a seam. Previously available mandrels, which needed to be cut in half and spliced back together to remove them from the rigid mandrel upon which they were formed, are inherently weaker and less desirable than the seamless mandrels produced by the present invention.
The seamless, reusable and collapsible mandrel of the present invention includes at least means for conducting a gas under pressure to the interior of the mandrel and a fluid impermeable layer capable of retaining a gas within the interior of the mandrel. Also included is a fiber reinforcement layer capable of limiting the expansion of the mandrel when pressurized gas is introduced therein such that as the pressure inside the mandrel is increased and the material forming the vessel is added to the outer surface of the reusable and collapsible mandrel, the mandrel maintains its desired shape. The fiber reinforcement layer is formed using continuous fiber winding techniques. Also included is an outer release surface. The outer release surface receives the materials of the seamless and fiber wound hollow vessel formed thereon. The seamless, reusable and collapsible mandrel of the present invention can be reused many times and consistently produces high quality fiber wound vessels at a relatively low cost.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better appreciate how the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to a specific embodiment thereof which is illustrated in the appended drawings. Understanding that these drawings depict only a typical embodiment of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is a partially cut away perspective view of the presently preferred embodiment of the completed seamless, collapsible, and reusable mandrel of the present invention.
FIG. 2 is a cross sectional view of the mandrel of the present invention as it appears when mounted on a winding machine shaft ready to receive the filament windings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made to the drawings wherein like structures will be provided with like reference designations.
It will be appreciated that as the number and kinds of applications for filament wound hollow vessels increases, the demand for easily fabricated, precision mandrels has also increased. The present invention provides the benefits of low cost which accompany the use of seamed inflatable mandrels as well as the added benefits of precision and long life which, prior to the present invention, only accompanied the use of segmented metal mandrels.
Reference will now be made to the presently preferred seamless, collapsible, and reusable mandrel generally represented at 100 shown in a partially cut away perspective view in FIG. 1. The seamless, collapsible, and reusable mandrel 100 represented in FIG. 1 is fabricated using known materials and techniques in conjunction with inventive teachings set forth herein. Those skilled in the pertinent arts will readily recognize the materials and techniques described herein are also of the general type and class referred to in U.S. Pat. No. 4,684,423 to Brooks which is now incorporated herein by reference.
FIG. 1 represents the various structural layers of the seamless, collapsible, and reusable mandrel 100 of the present invention. While the mandrel 100 illustrated in FIG. 1 is of a cylindrical shape, the mandrels of the present invention can be fabricated into any number of shapes needed to form hollow vessels.
The steps set forth below are presently preferred for fabricating the seamless, collapsible, and reusable mandrel 100 illustrated in FIG. 1.
A non-reusable mandrel 90 is first fabricated, on a shaft 92, upon which the seamless, collapsible, and reusable mandrel 100 will be fabricated. The non-reusable mandrel 90 is only partially represented in phantom image in FIG. 1 to show its relationship to the seamless, collapsible, and reusable mandrel 100. The shape of the non-reusable mandrel will determine the shape of the seamless, collapsible, and reusable mandrel 100. Utilization of a non-reusable mandrel is essential to the present invention in order to fabricate the resulting reusable collapsible mandrel 100 as a seamless mandrel. Such a non-reusable mandrel must be destroyed during use in order to remove the resulting seamless mandrel. Thus, such a mandrel is also referred to herein as a destructible mandrel.
The non-reusable mandrel 90 can be formed from many different materials and procedures; those skilled in the art will realize that the herein described materials and procedures are merely preferred and that other materials and procedures can also be used. The important criteria is that the resulting mandrel 90 must be readily destructible in order to remove it from the small polar opening, 112 in FIG. 1, which remains in the seamless, collapsible, and reusable mandrel 100.
To form the mandrel 90, it is preferred that a foam block be set up on a shaft 92 and formed using a turning mechanism. The foam block should be formed to slightly smaller than a shape which conforms to the finished shape of the non-reusable mandrel 90.
A screeding template is formed which conforms exactly to the finished shape and size of the non-reusable master mandrel 90. The screeding template is set to the proper orientation on the turning mechanism. A mixture consisting of 80% plaster and 20% milled glass fibers (1/32 inch to 1/4 inch) is prepared. The plaster is preferably one which is readily dissolved or destroyed such as that available under the trademark EASY OUT.
While the foam block is rotated on the shaft turning mechanism, glass cloth strips (7500 style or equivalent) and plaster is laid on the foam block. After a first layer of glass cloth strips and plaster has dried, a further layer(s) of glass cloth strips and plaster is added until the surface is about 1/4 inch from the surface of the screed. After the previous layers of cloth and plaster have hardened a final layer of only plaster is added using the screeding template to form the surface to the exact shape and size desired. The non-reusable mandrel 90 is then allowed to dry for 24 hours.
After the non-reusable mandrel 90 is dried, it is preferably cured at 300° F. to 600° F. for two hours for each inch thickness of plaster mixture added to the surface of the foam block. Upon completion of the cure time, the non-reusable mandrel 90 should be cooled at a rate not exceeding 5° F. per minute. The non-reusable mandrel 90 should then be inspected and any rough areas smoothed with a fine grit sand paper as required. The surface of the non-reusable mandrel 90 is then sealing with any appropriate resin, tape, or soluble liquid sealant which will provide a suitable release surface for the non-reusable mandrel 90.
The completed non-reusable mandrel 90 is mounted on a 3-axis winding machine having a fiber delivery system as is known in the art. With the surface of the non-reusable master mandrel prepared with a release material, an inner rubber layer 102 of uncured rubber is applied using methyl-ethylketone (MEK) sparingly as a tackifier. The sheet of rubber should be trimmed so that the sheets overlap by at least 1/8 inch. The rubber sheets will need to be trimmed so that the rubber lies evenly on the contours of the non-reusable master mandrel.
A dispersion solution is prepared and used next. The dispersion solution preferably comprises small bits of nitrile sheet which have been soaked in MEK for at least 1 hour with mixing until the bits are well dissolved and the solution is the consistency of paint. This dispersion solution will be used for encapsulating the Kevlar fiber during winding. The dispersion solution should be agitated and thinned with MEK as needed to avoid clumping.
The winding machine should be programmed to the required specifications as is known in the art. As is known in the art, the lowest angle helical is normally wound first to create helical fiber plies as represented at fiber wound layer 104 in FIG. 1. The resulting fiber band should be in a "space wind" configuration with a minimum of 1/8" spacing between tows.
After the first helical winding is completed, the nitrile/MEK solution should be allowed to outgas at room temperature for at least 20 minutes. The winding machine can be used to apply winding angles in addition to the first helical winding to further complete the helical fiber plies comprising the fiber reinforced layer 104. Care should be exercised to avoid bridging the rubber layers between the fibers in order to achieve a strong rubber-to-rubber bond. In the case of small, seamless, collapsible, and reusable mandrels, both a hoop and helical ply may be needed together at this point for the helical fiber plies 104 to have the desired characteristics. Next, if desired, the winding machine can be programmed to wind another helical layer.
After the helical plies have been completed to form the fiber reinforced layer 104, a first middle rubber layer 106 of uncured rubber is applied in a manner the same as or similar to that described for the inner rubber layer 102. As indicated earlier, the rubber sheets should be trimmed so that the sheets overlap so that the rubber lies evenly on the contours of the non-reusable mandrel 90.
The winding machine should next be programmed to the hoop winding program to form another fiber reinforced layer 108, this time using a hoop fiber ply as represented in FIG. 1 and as indicated earlier. The hoop fiber ply, forming another fiber reinforced layer 108 is wound from tangent to tangent and, upon completion, the nitrile/MEK solution should again be allowed to outgas at room temperature for at least 20 minutes.
Next, a second middle layer of rubber 114 is laid on as described earlier followed by the winding machine being programmed and executing a high angle helical wind forming a second fiber reinforced layer 116. Following the completion of the winding, the structure is outgassing at room temperature for at least 20 minutes. If desired, additional fiber reinforced layers (e.g., hoop or tangent windings) and rubber layers can be added to the mandrel 100 of the present invention followed by the outgassing steps.
Next, the outer rubber layer 110 is applied as indicated in the earlier described steps. If desired, extra sheets of rubber can be applied to the outer rubber layer 110 to serve as a sacrificial machining layer. The surface of the outer rubber layer 110 will function as a release surface in the shape of the interior of the completed fiber wound hollow vessel. If needed, material such as glass cloth strips (7500 style or equivalent) can be used to reinforce the outer rubber layer 110 as required to achieve added strength and/or rigidity.
The entire seamless, collapsible, and reusable mandrel is next wrapped in perforated TEDLAR® release film. The seamless, collapsible, and reusable mandrel is then preferably enveloped in a nylon vacuum bag equipped with an N-10 breather as is known in the art. Importantly, it should be assured that the interior of the seamless, collapsible, and reusable mandrel is evacuated. The greatest vacuum available should be applied to the seamless, collapsible, and reusable mandrel at room temperature for best results. Checks should be made to detect any leaks.
Next, the bagged seamless, collapsible, and reusable mandrel is cured at 350° F. for 2 hours (minimum) or cured in accordance with the rubber manufacturer's recommendations. A lower temperature hold is permissible, if desired. Preferably, an autoclave (capable of pressures of at least 30 p.s.i.g.) should be used but internal pressure or thermal compaction techniques, as known in the art, may also be employed.
After the cure time is complete, the seamless, collapsible, and reusable mandrel is allowed to cool down slowly and the bagging material is removed. After the bagging material is removed, the seamless, collapsible, and reusable mandrel should be trimmed in the appropriate areas. The non-reusable mandrel 90 should then be removed. Preferably, the non-reusable mandrel 90 is removed by destroying it and removing the resulting slurry and/or pieces through the small polar opening 112. An ultrasonic knife or very sharp trimming tools should be used to cut Kevlar.
After the seamless, collapsible, and reusable mandrel 100 is free from the non-reusable mandrel 90 and finished, it should be mounted onto a winding shaft with all of its associated hardware (see FIG. 2) to verify that the seamless, collapsible, and reusable mandrel 100 is concentric to the shaft with very little runout (preferably less than 0.020 inch). A leak check at 2 p.s.i. minimum should also be performed.
The outside of the seamless, collapsible, and reusable mandrel should be machined as necessary to contour the outer rubber surface. In preparation for fabricating a fiber wound filament vessel on the seamless, collapsible, and reusable mandrel, a 1-2 mil thick FEP release layer (as known in the art) can be sprayed onto the outer rubber layer 110, if required. Further inspection of the mandrel 100 using templates, tape, and dial indicators should be performed to ensure consistent quality.
FIG. 2 is a diagrammatic cross sectional view of the seamless, collapsible, and reusable mandrel 100 mounted on a hollow winding shaft S commonly found in a winding machine (not shown) as known in the art. The winding shaft includes a passageway A which conducts a gas under pressure to the interior of the seamless, collapsible, and reusable mandrel 100.
The seamless, collapsible, and reusable mandrel 100 is held in place on the winding shaft S by a polar boss 118, which will become part of the completed fiber wound hollow vessel (not shown), and various pieces of hardware 120 which retain the polar boss 118 and grasp the winding shaft S. Such structures can be those which are known in the art.
With the seamless, collapsible, and reusable mandrel 100 mounted on the winding shaft S, the fiber wound hollow vessel is formed thereon. As more material is added to the mandrel 100, the pressure within the seamless, collapsible, and reusable mandrel 100 is adjusted to maintain the proper shape of the mandrel 100. When the fiber wound hollow vessel (not represented) is completed, the mandrel 100 is deflated and the hardware 120 removed, and the mandrel 100 removed through the end opening of the completed fiber wound hollow vessel (not shown).
Since the mandrel 100 is seamless, it is inherently stronger than a corresponding mandrel which was cut and spliced while being formed. Thus, the mandrel 100 is reusable many times more than similar mandrels having a seam. Moreover, the represented seamless mandrel 100 is capable of producing more uniform completed fiber wound hollow vessels.
It will be appreciated that the present invention provides a collapsible mandrel which is suitable for use in the fabrication of various filament wound hollow vessels and which is seamless. The present invention also produces an inflatable mandrel which maintains its proper shape as a hollow vessel is fabricated upon it as well as being reusable to consistently fabricate high quality filament wound hollow vessels and which is relatively low cost.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A method for fabricating, and a resulting structure for, a seamless, reusable and collapsible mandrel suitable for forming a plurality of seamless and hollow fiber wound vessels upon is disclosed. A destructible mandrel is used to form the seamless reusable mandrel. The destructible mandrel is preferably formed from a material which can be destroyed by dissolving, for example, materials such as foam or plaster. The seamless, collapsible, and reusable mandrel includes a plurality of different layers including a gas impermeable layer, a continuous fiber wound layer, and a release surface forming the outermost layer of the seamless, collapsible, and reusable mandrel. The resulting seamless, reusable and collapsible mandrel has advantages over mandrels which include a seam. Such advantages include a longer useful life and consistently high quality fiber wound vessels at a relatively low cost. | 1 |
The present application is a divisional application of application Ser. No. 10/215,158, filed on Aug. 8, 2002, now issued as U.S. Pat. No. 6,958,211, which claims priority from provisional application No. 60/310,480, filed on Aug. 8, 2001.
The present invention relates to methods and products for evaluating treatment of human immunodeficiency virus (HIV). In particular, molecular events at HIV integrase and their effect on therapeutic efficacy of drugs are determined. Suitably, the events are analysed by genotyping or phenotyping of HIV integrase. The methods and products described herein find use in multiple fields including diagnostics, drug screening, pharmacogenetics and drug development.
Several different treatment regimens have been developed to combat HIV infection. However, since the HIV virus is mutating quickly, because reverse transcriptase (RT) duplicating the genetic material has no proofreading capacity, it can counter the effects of drugs or drug combinations used against it. Current HIV chemotherapy involves inhibitors of the reverse transcriptase (RT) and protease enzymes. Despite the development of novel classes of inhibitors and complex drug regimens, drug resistance is increasing. Thus, new types of anti-HIV drugs are continually necessary. Development of compounds that inhibit other HIV gene products in vivo such as the envelope, tat, and integrase (IN) is a key area of investigation.
The integrase protein represents a target for HIV inhibitor research. HIV integrase is required for integration of the viral genome into the genome of the host cell, a step in the replicative cycle of the virus. It is a protein of about 32 KDa encoded by the pol gene, and is produced in vivo by protease cleavage of the gag-pol precursor protein during the production of viral particles. The integration process takes place following reverse transcription of the viral RNA. First, the viral integrase binds to the viral DNA and removes two nucleotides from the 3′ end of the viral long-terminal repeat (LTR) sequences on each strand. This step is called 3′ end processing and occurs in the cytoplasm within a nucleoprotein complex termed the pre-integration complex (PIC). Second, in a process called strand transfer, the two strands of the cellular DNA into which the viral DNA will be inserted, i.e. the target DNA, are cleaved in a staggered fashion. The 3′ ends of the viral DNA are ligated to the 5′ ends of the cleaved target DNA. Finally, remaining gaps are repaired, probably by host enzymes.
With the increasing number of available anti-HIV compounds, the number of potential treatment protocols for HIV infected patients will continue to increase. Many of the currently available compounds are administered as part of a combination therapy. The high complexity of treatment options coupled with the ability of the virus to develop resistance to HIV inhibitors requires the frequent assessment of treatment strategies. The ability to accurately monitor the replicative capacity of viruses in patients subjected to a drug regimen and to use that data to modify the doses or combinations of inhibitors allows physicians to effectively reduce the formation of drug resistant virus and provide an optimal, tailored treatment for each patient.
Sophisticated patient monitoring techniques have been developed for analysis of current therapies, e.g. such as Antivirogram®, (described in WO 97/27480 and U.S. Pat. No. 6,221,578 B1; incorporated herein by reference) and Phenosense™ (WO 97/27319). These cellular based assays determine the resistance of the patient borne virus towards a defined drug regimen by providing information about the susceptibility of the patient's virus strain to the treatment based on protease and reverse transcriptase inhibitors treatment. Other monitoring strategies include immunological means or sequencing techniques.
The Antivirogram® and Genseq™ assays determine the phenotype and genotype respectively of a patient's reverse transcriptase and protease genes. The relevant coding regions are obtained from patient samples, reverse transcribed and amplified by the polymerase chain reaction (PCR). Within lymphocyte cells the relevant coding regions are combined with viral deletion constructs to create chimeric viruses. The ability of these chimeric viruses to invade and kill cells in culture is assessed in the presence of HIV reverse transcriptase and protease inhibitors. A database combining phenotypic and genotypic information can be developed, as described in WO 00/73511 (incorporated herein by reference).
While phenotyping and genotyping assays such as Antivirogram® and Genseq™ have been developed for reverse transcriptase and protease genes, protocols for evaluation of drug resistance at the integrase gene have not been successfully developed.
DETAILED DESCRIPTION OF THE INVENTION
The instant invention provides techniques for evaluating human immunodeficiency (HIV) drug effectiveness. Assays for wild type or mutant HIV integrase are provided, using a set of primers designed for the amplification and analysis of HIV genetic material. The assessment of patient borne viral integrase leads to a better prediction of the drugs suitable for treatment of the strains present in the infected individual. The protocols and products may be used for diverse diagnostic, clinical, toxicological, research and forensic purposes including, drug discovery, designing patient therapy, drug efficacy testing and patient management. The assays described herein may be used in combination with other assays. The results may be implemented in computer models and databases. The products described herein may be incorporated into kits.
The instant invention relates to a method for determining the susceptibility of at least one HIV virus to at least one treatment, comprising: i) obtaining at least one sample of HIV RNA, wherein the sample comprises at least one IN gene or a portion thereof; ii) reverse-transcribing and amplifying the HIV RNA with primers specific for IN region of the HIV genome to obtain at least one DNA construct comprising the at least one IN gene or a portion thereof; iii) preparing at least one recombinant virus by homologous recombination or ligation between the amplified at least one DNA construct and a plasmid comprising the wild-type HIV sequence with a deletion in the IN region of the HIV genome, and iv) determining the phenotypic susceptibility of at least one HIV virus to at least one treatment by monitoring the at least one recombinant virus in the presence of the at least one treatment.
In particular, the present invention relates to a method for determining the susceptibility of at least one HIV virus to at least one drug, comprising: i) obtaining at least one sample comprising HIV RNA, wherein the sample comprises at least one IN gene or a portion thereof; ii) reverse transcribing and amplifying the HIV RNA with primers specific for IN region of the HIV genome to obtain at least one amplicon comprising the at least one IN gene or a portion thereof; iii) using nucleic acid amplification to generate a plasmid comprising the wild-type HIV sequence with a deletion in the IN region of the HIV genome; iv) preparing at least one recombinant virus by homologous recombination or ligation between the amplified at least one amplicon and a plasmid comprising the wild-type HIV sequence with a deletion in the IN region, and v) monitoring the at least one recombinant virus in the presence of the at least one treatment to determine the phenotypic susceptibility of at least one HIV virus to said at least one drug.
Reverse transcription and amplification may be performed with a single set of primers. Alternatively, more than one set of primers may be used in a hemi-nested approach to reverse transcribe and amplify the genetic material. Particularly, more than one set of primer is used in a nested approach. Following the generation of the recombinant construct, the chimeric virus may be grown and the viral titer determined (expressed as multiplicity of infection, MOI) before proceeding to the determination of the phenotypic susceptibility. The indicator gene, encoding a signal indicative of replication of the virus in the presence of a drug or indicative of the susceptibility of the virus in the presence of a drug may be present in the culturing cells such as MT-4 cells. In addition, said indicator gene may be incorporated in the chimeric construct introduced into the culturing cells or may be introduced separately. Suitable indicator genes encode fluorescent proteins, particularly green fluorescent protein or mutants thereof. In order to allow homologous recombination, genetic material may be introduced into the cells using a variety of techniques known in the art including, calcium phosphate precipitation, liposomes, viral infection, and electroporation. The monitoring may be performed in high throughput.
A human immunodeficiency virus (HIV), as used herein refers to any HIV including laboratory HIV strains, wild type HIV strains, mutant HIV strains and any biological sample comprising at least one HIV virus, such as, for example, an HIV clinical isolate. HIV strans compatible with the present invention are any such strains that are capable of infecting mammals, particularly humans. Examples are HIV-1 and HIV-2. For reduction to practice of the present invention, an HIV virus refers to any sample comprising at least one HIV virus. As for instance a patient may have HIV viruses in his body with different mutations in the integrase (IN) gene. It is to be understood that a sample may contain a variety of different HIV viruses containing different mutational profiles in the IN gene. A sample may be obtained for example from an individual, from cell cultures, or generated using recombinant technology, or cloning. HIV strains compatible with the present invention are any such strains that are capable of infecting mammals, particularly humans. Viral strains used for obtaining a plasmid are preferably HIV wild-type sequences, such as LAI or HXB2D. LAI, also known as IIIB, is a wild type HIV strain. One particular clone thereof, this means one sequence, is HXB2D. This sequence may be incorporated into a plasmid.
Instead of viral RNA, HIV DNA, e.g. proviral DNA, may be used for the methods described herein. In case RNA is used, reverse transcription into DNA by a suitable reverse transcriptase is needed. The protocols describing the analysis of RNA are also amenable for DNA analysis. However, if a protocol starts from DNA, the person skilled in the art will know that no reverse transcription is needed. The primers designed to amplify the RNA strand, also anneal to, and amplify DNA. Reverse transcription and amplification may be performed with a single set of primers. Suitably a hemi-nested and more suitably a nested approach may be used to reverse transcribe and amplify the genetic material.
Thus, the phenotyping method of the present invention may also comprise: i) obtaining at least one sample comprising HIV DNA, wherein the sample comprises at least one IN gene or a portion thereof; ii) amplifying the HIV DNA with primers specific for IN region of the HIV genome to obtain at least one amplicon comprising the at least one IN gene or a portion thereof; iii) generating a plasmid comprising the wild-type HIV sequence with a deletion in the IN region of the HIV genome characterized in that said deletion is generated using nucleic acid amplification; iv) preparing at least one recombinant virus by homologous recombination or ligation between the amplified at least one amplicon and a plasmid comprising the wild-type HIV sequence with a deletion in the IN region, and v) monitoring the at least one recombinant virus in the presence of the at least one drug to determine the phenotypic susceptibility of at least one HIV virus to at least one drug.
Nucleic acid may be amplified by techniques such as polymerase chain reaction (PCR), nucleic acid sequence based amplification (NASBA), self-sustained sequence replication (3SR), transcription based amplification (TAS), ligation chain reaction (LCR). Often PCR is used.
Any type of patient sample may be used to obtain the integrase gene, such as, for example, serum and tissue. Viral RNA may be isolated using known methods such as described in Boom, R. et al. (J. Clin. Microbiol. 28(3): 495–503 (1990)). Alternatively, a number of commercial methods such as the QIAAMP® viral RNA kit (Qiagen, Inc.) may be used to obtain viral RNA from bodily fluids such as plasma, serum, or cell-free fluids. DNA may be obtained by procedures known in the art (e.g. Maniatis, 1989) and commercial procedures (e.g. Qiagen).
The complete integrase (IN) or a portion of the IN gene may be used. The complete IN gene comprises 864 nucleotides (nt), coding for a 288 amino acid long integrase. A portion of the IN gene is defined as a fragment of IN gene recovered from patient borne virus, lab viruses including IIIB and NL4-3, or mutant viruses. This fragment does not encompass the complete 864 nt. Said fragment may be obtained directly from its source, including a patient sample, or may be obtained using molecular biology tools following the recovery of the complete IN sequence. Amplicon refers to the amplified, and where necessary, reverse transcribed integrase gene or portion thereof. It should be understood that this IN may be of diverse origin including plasmids and patient material. Suitably, the amplicon is obtained from patient material. For the purpose of the present invention the amplicon is sometimes referred to as “DNA construct”. A viral sequence may contain one or multiple mutations versus the consensus reference sequence given by K03455. Said sequence, K03455, is present in Genbank and available through the internet. A single mutation or a combination of IN mutations may correlate to a change in drug efficacy. This correlation may be indicative of an altered i.e. decreased or increased susceptibility of the virus for a drug. Said mutations may also influence the viral fitness.
“Chimeric” means a construct comprising nucleic acid material from different origin such as for example a combination of wild type HIV with a laboratory HIV virus, a combination of wild type HIV sequence and patient derived HIV sequence.
A “drug” means any agent such as a chemotherapeutic, peptide, antibody, antisense, ribozyme and any combination thereof. Examples of drugs include protease inhibitors including ritonavir, amprenavir, nelfinavir; reverse transcriptase inhibitors such as nevirapine, delavirdine, AZT, zidovudine, didanosine; integrase inhibitors; agents interfering with envelope (such as for example T-20, T-1249). Treatment or treatment regimen refers to the therapeutic management of an individual by the administration of drugs. Different drug dosages, administration schemes, administration routes and combinations may be used to treat an individual.
An alteration in viral drug sensitivity is defined as a change in susceptibility of a viral strain to said drug. Susceptibilities are generally expressed as ratios of EC 50 or EC 90 values (the EC 50 or EC 90 value being the drug concentration at which 50% or 90% respectively of the viral population is inhibited from replicating) of a viral strain under investigation compared to the wild type strain. Hence, the susceptibility of a viral strain towards a certain drug can be expressed as a fold change in susceptibility, wherein the fold change is derived from the ratio of for instance the EC 50 values of a mutant viral strain compared to the wild type EC 50 values. In particular, the susceptibility of a viral strain or population may also be expressed as resistance of a viral strain, wherein the result is indicated as a fold increase in EC 50 as compared to wild type EC 50 . The IC 50 is the drug concentration at which 50% of the enzyme activity is inhibited.
The susceptibility of at least one HIV virus to a drug may be tested by determining the cytopathogenicity of the recombinant virus to cells. In the context of this invention, the cytopathogenic effect means the viability of the cells in culture in the presence of chimeric viruses. The cells may be chosen from T cells, monocytes, macrophages, dendritic cells, Langerhans cells, hematopoetic stem cells or precursor cells, MT4 cells and PM-1 cells. Suitable host cells for homologous recombination of HIV sequences include MT4 and PM-1. MT4 is a CD4 + T-cell line containing the CXCR4 co-receptor. The PM-1 cell line expresses both the CXCR4 and CCR5 co-receptors. All of the cells mentioned above are capable of producing new infectious virus particles upon recombination of the IN deletion vectors with IN sequences such as those derived from patient samples. Thus, they can also be used for testing the cytopathogenic effects of recombinant viruses. The cytopathogenicity may, for example, be monitored by the presence of any reporter molecule including reporter genes. A reporter gene is defined as a gene whose product has reporting capabilities. Suitable reporter molecules include tetrazolium salts, green fluorescent proteins, beta-galactosidase, chloramfenicol transferase, alkaline phophatase, and luciferase. Several methods of cytopathogenic testing including phenotypic testing are described in the literature comprising the recombinant virus assay (Kellam and Larder, Antimicrob. Agents Chemotherap. 1994, 38, 23–30, Hertogs et al. Antimicrob. Agents Chemotherap. 1998, 42, 269–276; Pauwels et al. J. Virol Methods 1988, 20, 309–321)
The susceptibility of at least one HIV virus to at least one drug may be determined by the replicative capacity of the recombinant virus in the presence of at least one drug, relative to the replicative capacity of an HIV virus with a wild-type IN gene sequence. Replicative capacity means the ability of the virus or chimeric construct to grow under culturing conditions. This is sometimes referred to as viral fitness. The culturing conditions may contain triggers that influence the growth of the virus, examples of which are drugs. The methods for determining the susceptibility may be useful for designing a treatment regimen for an HIV-infected patient. For example, a method may comprise determining the replicative capacity of a clinical isolate of a patient and using said replicative capacity to determine an appropriate drug regime for the patient. One approach is the Antivirogram® assay.
The IN phenotyping assays of the present invention can be performed at high throughput using, for example, a microtiter plate containing a variety of anti-HIV drugs. The present assays may be used to analyse the influence of changes at the HIV IN gene to any type of drug useful to treat HIV. Examples of anti-HIV drugs that can be tested in this assay include, nucleoside and non-nucleoside reverse transcriptase inhibitors, nucleotide reverse transcriptase inhibitors, protease inhibitors, membrane fusion inhibitors, and integrase inhibitors, but those of skill in the art will appreciate that other types of antiviral compounds may also be tested. The results may be monitored by several approaches including but not limited to morphology screening, microscopy, and optical methods, such as, for example, absorbance and fluorescence. An IC 50 value for each drug may be obtained in these assays and used to determine viral replicative capacity in the presence of the drug. Apart from IC 50 also e.g. IC 90 or EC 50 (effective concentrations) can be used. The replicative capacity of the viruses may be compared to that of a wild-type HIV virus to determine a relative replicative capacity value. Data from phenotypic assays may further be used to predict the behaviour of a particular HIV isolate to a given drug based on its genotype.
The assays of the present invention may be used for therapeutic drug monitoring. Said approach includes a combination of susceptibility testing, determination of drug level and assessment of a threshold. Said threshold may be derived from population based pharmacokinetic modelling (WO 02/23186). The threshold is a drug concentration needed to obtain a beneficial therapeutic effect in vivo. The in vivo drug level may be determined using techniques such as high performance liquid chromatography, liquid chromatography, mass spectroscopy or combinations thereof. The susceptibility of the virus may be derived from phenotyping or interpretation of genotyping results i.e. virtual phenotyping (WO 01/79540).
The assays of the present invention may be useful to discriminate an effective drug from an ineffective drug by establishing cut-offs i.e. biological cut-offs (see e.g. WO 02/33402). A biological cut-off is drug specific. These cut-offs are determined following phenotyping a large population of individuals containing wild type viruses. The cut-off is derived from the distribution of the fold increase in resistance of the virus for a particular drug.
The instant invention also relates to a kit for phenotyping HIV integrase. Such kit, useful for determining the susceptibility of at least one HIV virus to at least one drug, may comprise: i) at least one of the primers selected from SEQ ID NO: 1–16, and ii) a plasmid as described in the present invention. For the purpose of performing the phenotyping assay, such kit may be further completed with at least one inhibitor. Optionally, a reference plasmid bearing a wild type HIV sequence may be added. Optionally, cells susceptible of HIV transfection may be added to the kit. In addition, at least one reagent for monitoring the indicator genes, or reporter molecules such as enzyme substrates, may be added.
The present invention also describes a method for determining the susceptibility of at least one HIV virus to at least one drug, comprising: i) obtaining at least one sample comprising HIV RNA, wherein the sample comprises at least one IN gene or a portion thereof; ii) reverse-transcribing and amplifying said HIV RNA with primers specific for the IN region of the HIV genome to obtain an amplicon comprising the IN gene or a portion thereof; iii) determining the nucleotide sequence of the amplicon or a portion thereof, and iv) comparing the nucleotide sequence of the amplicon to the sequence of known sequences to determine the susceptibility of at least one HIV virus to at least one drug. This assay protocol is commonly referred to as genotyping.
The genotype of the patient-derived IN coding region may be determined directly from the amplified DNA, i.e. the DNA construct, by performing DNA sequencing during the amplification step. Alternatively, the sequence may be obtained after sub-cloning into a suitable vector. A variety of commercial sequencing enzymes and equipment may be used in this process. The efficiency may be increased by determining the sequence of the IN coding region in several parallel reactions, each with a different set of primers. Such a process could be performed at high throughput on a multiple-well plate, for example. Commercially available detection and analysis systems may be used to determine and store the sequence information for later analysis. The nucleotide sequence may be obtained using several approaches including sequencing nucleic acids. This sequencing may be performed using techniques including gel based approaches, mass spectroscopy and hybridisation. However, as more resistance related mutations are identified, the sequence at particular nucleic acids, codons or short sequences may be obtained. If a particular resistance associated mutation is known, the nucleotide sequence may be determined using hybridisation assays (including Biochips, LipA-assay), mass spectroscopy, allele specific PCR, or using probes or primers discriminating between mutant and wild-type sequence. For these purposes the probes or primers may be suitably labelled for detection (e.g. Molecular beacons, TaqMan®, SunRise primers). Suitably, fluorescent or quenched fluorescent primers are used. The primer is present in a concentration ranging from 0.01 pmol to 100 pmol, suitably between 0.10 and 10 pmol. The cycling conditions include a denaturation step during 0.5 to 10 minutes, suitably, 1 to 5 minutes at a temperature ranging from 85 to 99° C. Interestingly, the temperature is between 90 and 98° C. Subsequently, the material is cycled during 14 to 45 cycles, suitably between 20 to 40 cycles, more suitably during 25 to 35 cycles. Nucleic acid is denatured at 90 to 98° C. during 5 seconds to 2 minutes. Suitably, denaturation periods range from 15 seconds to 1 minute. Annealing is performed at 40 to 60° C., specifically, between 45° C. and 57° C. The annealing period is 5 seconds to 1 minute, especially between 10 seconds and 35 seconds. Elongation is performed at 60° C. to 75° C. during 10 seconds to 10 minutes. Preferably, the elongation period is 15 seconds to 5 minutes. A selected set of sequencing primers includes SEQ ID NO: 17–22. This particular selection has the advantage that it enables the sequencing of the complete HIV integrase gene. Consequently, using this set of primers all possible mutations that may occur in the HIV integrase gene may be resolved.
The patient IN genotype provides an additional means to determine drug susceptibility of a virus strain. Phenotyping is a lengthy process often requiring 2 or more weeks to accomplish. Therefore, systems have been developed which enable the prediction of the phenotype based on the genotypic results. The results of genotyping may be interpreted in conjunction with phenotyping and eventually be subjected to database interrogation. A suitable system is virtual phenotyping (WO 01/79540). In the virtual phenotyping process the complete IN genes may be used. Alternatively, portions of the genes may be used. Also combinations of mutations, preferentially mutations indicative of a change in drug susceptibility, may be used. A combination of mutations is sometimes referred to as a hot-spot (see e.g. WO 01/79540). Briefly, in the process of virtual phenotyping, the genotype of a patient derived IN sequence may be correlated to the phenotypic response of said patient derived IN sequence. If no phenotyping is performed, the sequence may be screened towards a collection of sequences present in a database. Identical sequences are retrieved and the database is further interrogated to identify if a corresponding phenotype is known for any of the retrieved sequences. In this latter case a virtual phenotype may be determined. A report may be prepared including the EC 50 of the viral strain for one or more therapies, the sequence of the strain under investigation, biological cut-offs.
The present invention also relates to a kit for genotyping HIV integrase. Such kit useful for determining the susceptibility of at least one HIV virus to at least one drug may comprise at least one primer selected from SEQ ID NO: 1–12 and 17–22. Optionally, additional reagents for performing the nucleic amplification and subsequent sequence analysis may be added. Reagents for cycle sequencing may be included. The primers may be fluorescently labelled.
The instant invention provides a method of identifying a drug effective against HIV integrase comprising: i) obtaining at least one HIV integrase sequence, ii) determining the phenotypic response of the integrase towards said drug, iii) using said phenotypic response to determine the effectiveness of said drug. The phenotypic response is determined according to the methods of the instant invention.
The methods described in the instant invention may be used in a method of identifying a drug effective against HIV integrase comprising: i) obtaining at least one HIV integrase sequence, determining the sequence of said HIV integrase, ii) comparing said sequence with sequences present in a database of which the susceptibility has been determined of the HIV integrase, iii) using said sequence comparison to determine the effectiveness of said drug. The susceptibility and the sequence of the HIV integrase gene are determined according to the methods disclosed in the instant invention.
The genotyping and phenotyping methods as described herein can be used to create a genotypic and phenotypic database of IN sequences, comprising: i) obtaining samples comprising HIV RNA comprising the IN gene or a portion thereof; ii) reverse-transcribing and amplifying said HIV RNA with primers specific for the IN region of the HIV genome to obtain an amplicon comprising the IN gene or a portion thereof; iii) determining the nucleotide sequence of the amplicon or portions thereof; iv) generating a plasmid comprising the wild-type HIV sequence with a deletion in the IN region of the HIV genome characterized in that said deletion is generated using nucleic acid amplification; v) preparing recombinant virus by homologous recombination or ligation between the amplicon and a plasmid comprising the wild-type HIV sequence with a deletion in the IN region of the HIV genome, characterised in that said deletion is introduced using PCR; vi) determining the relative replicative capacity of the recombinant virus in the presence of anti-HIV drugs compared to an HIV virus with a wild-type IN gene sequence; vii) correlating the nucleotide sequence and relative replicative capacity in a data table.
According to the methods described herein a database may be constructed comprising genotypic and phenotypic data of the HIV integrase, wherein the database further provides a correlation between genotypes and between genotypes and phenotypes, wherein the correlation is indicative of efficacy of a given drug regimen. A database of IN sequences may be created and used as described in WO 01/79540. For example, such a database may be analysed in combination with pol and pro sequence information and the results used in the determination of appropriate treatment strategies. Said database containing a collection of genotypes, phenotypes and samples for which the combined genotype/phenotype are available may be used to determine the virtual phenotype (see supra). In addition, instead of interrogating the complete IN sequences, particular codons correlating to a change in drug susceptibility of the virus may be interrogated in such database.
A primer may be chosen from SEQ ID NO: 1–23. A particular set of primers is SEQ ID NO: 1–10, 13, 15, and 23. Primers specific for the IN region of the HIV genome such as the primers described herein and their homologs are claimed. The primer sequences listed herein may be labelled. Suitably, this label may be detected using fluorescence, luminescence or absorbance. The primer for creating a deletion construct may contain a portion that does not anneal to the HIV sequence. That portion may be used to introduce a unique restriction site. Interestingly, primers may be designed in which the unique restriction site is partially present in the HIV sequence. The primers are chosen from those listed herein or have at least 80% homology as determined by methods known by the person skilled in the art such BLAST or FASTA. Specifically, the homology is at least 90%, more specifically, at least 95%. In addition, primers located in a region of 50 nucleotides (nt) upstream or downstream from the sequences given herein constitute part of the invention. Especially, said region is 20 nucleotides up or downstream from the position in the HIV genome of the primer sequences given herein. Alternatively, primers comprising at least 8 consecutive bases present in either of the primers described here constitute one embodiment of the invention. Interestingly, the primers comprise at least 12 consecutive bases present in either of the primers described herein.
The present invention comprises the plasmids described in the experimental part and the use of the plasmids in the methods described herein. The HIV sequence incorporated in the plasmid may be based on the K03455 sequence. The complete HIV sequence may be incorporated or only part thereof. A suitable plasmid backbone may be selected from the group including pUC, pSV or pGEM.
A plasmid comprising a deleted integrase, wherein the deletion comprises at least 100 bp of the HIV integrase gene is provided herein. Suitably, more that 500 bp of the integrase gene are deleted, more suitably the complete IN gene is deleted. The deletion may also comprise parts of flanking genes, or eventually more than one gene, e.g. deletion of integrase and protease.
To prepare vectors containing recombinant IN coding sequences, the patient derived IN RNA can be reverse transcribed and amplified by the polymerase chain reaction (PCR), then inserted into a vector containing the wild type HIV genome sequence but lacking a complete IN coding region. Initially 36 different primer combinations were used to obtain amplified DNA sequences from 16 patient samples. The 5′ to 3′ sequences and the primers identified by SEQ ID NO: 1–10 of primers that can be successfully used to reverse transcribe and PCR amplify IN coding regions are listed below in Table 1.
A number of reverse transcription and PCR protocols known in the art may be used in the context of the present invention. A nested PCR approach to amplify the patient derived cDNA after reverse transcription may be used as described in Kellam, P. and Larder, B. A., (Antimicrobial Agents and Chemotherapy 38: 23–30 (1994)), which is incorporated herein by reference. The nested approach of the instant invention utilizes two sets of primers, the outer primers are 5′EGINT1 (SEQ ID NO 1) and 3′EGINT10 (SEQ ID NO 11), while the inner primers are 5′EGINT107 (SEQ ID NO 2) and 3′EGINT11 (SEQ ID NO 12). An additional inner 5′ primer, 5′EGINT2 (SEQ ID NO 3), may also be used as a “rescue primer” to improve the yield of amplified DNA. Amplification using these primers yields a PCR product encompassing the complete IN coding sequence. Alternatively, 5′EGINT3 (SEQ ID NO 4) and 3′EGINT10 (SEQ ID NO 11) are used as outer PCR primers, while 5′EGINT4 (SEQ ID NO 5) or 5′EGINT5 (SEQ ID NO 6) and 3′EGINT6 (SEQ ID NO 7) are used as inner primers, yielding a PCR product encompassing a portion of the IN coding sequence.
TABLE 1
Primers for IN reverse transcription and PCR
amplification. The underlined portions do not
anneal to the sequence to be amplified.
Primer
Name
SEQ ID NO
5′ to 3′ sequence
R-IN-vif and IN outer and inner primers
5′EGINT1
SEQ ID NO: 1
GGTACCAGTTAGAGAAAGAACCCA
5′EGINT107
SEQ ID NO: 2
GGAGCAGAAACCTTCTATGTAGATG
5′EGINT2
SEQ ID NO: 3
GGCAGCTAACAGGGAGACTAA
5′EGINT3
SEQ ID NO: 4
GGAATCATTCAAGCACAACCAGA
5′EGINT4
SEQ ID NO: 5
TCTGGCATGGGTACCAGCACA
5′EGINT5
SEQ ID NO: 6
AGGAATTGGAGGAAATGAACAAGTA
3′EGINT6
SEQ ID NO: 7
GTTCTAATCCTCATCCTGTCT
3′EGINT7
SEQ ID NO: 8
CCTCCATTCTATGGAGTGTCTATA
3′EGINT8
SEQ ID NO: 9
GGGTCTACTTGTGTGCTATATCTC
3′EGINT9
SEQ ID NO: 10
CAGATGAATTAGTTGGTCTGCTA
3′EGINT10
SEQ ID NO: 11
CCT CCA TTC TAT GGA GAC TCC
CTG
3′EGINT11
SEQ ID NO: 12
GCA TCC CCT AGT GGG ATG TG
R-IN-vif deletion-mutagenesis primers
MUT-IN1
SEQ ID NO: 13
GGG TGA CAA CTT TTT GTC TTC
CTC TAT
MUT-IN2
SEQ ID NO: 14
GGA TCC TGC AGC CC G GGA AAG
CTA GGG GAT GGT TTT ATA
IN deletion-mutagenesis primers:
MUT-IN3
SEQ ID NO: 15
GGG CCT TAT CTA TTC CAT CTA
AAA ATA GT
MUT-IN4
SEQ ID NO: 16
GGA TCC TGC AGC CC G GGA TTA
TGG AAA ACA GAT GGC A
Sequencing primers
IN_SEQ1F
SEQ ID NO: 17
AGT CAG TGC TGG AAT CAG G
IN_SEQ2F
SEQ ID NO: 18
TTC CAG CAG AAA CAG GGC AG
IN_SEQ3F
SEQ ID NO: 19
GTA GAC ATA ATA GCA ACA GAC
IN_SEQ1R
SEQ ID NO: 20
CCC TGA AAC ATA CAT ATG GTG
IN_SEQ2R
SEQ ID NO: 21
CTG CCA TTT GTA CTG CTG TC
IN_SEQ1R
SEQ ID NO: 22
TGA ACT GCT ACC AGG ATA AC
To prepare recombinant vectors comprising the amplified patient-derived IN sequences, these sequences can be inserted into vectors comprising the wild-type HIV sequence and a deletion of all or part of the IN coding region. The wild type HIV sequence can be obtained from a plasmid such as pSV40HXB2D that is capable of transfecting lymphocyte cells to produce viable virus particles. A deletion of the entire IN coding region on the pSV40HXB2D vector may effectively be created by PCR amplifying the plasmid using primers annealing to sequences at or near the ends of the IN coding region in the vector. The amplified product can be cleaved with a restriction enzyme introduced into the primers, then re-ligated to create a pSV40HXB2D-based IN deletion vector with a unique restriction site at the location of the deletion. The IN deletion vector can have a deletion of the complete IN coding sequence, optionally with part of the preceding RNase and/or subsequent Vif coding sequences also deleted. Alternatively, a partial deletion of the IN coding sequence is created. This restriction site is unique for the complete plasmid including the HIV gene. An example of such restriction site is the SmaI restriction site. Interestingly, the primers for creating a deletion construct are selected from SEQ ID NO: 13–16.
Those of skill in the art will appreciate that several types of HIV vectors and cloning procedures known in the art may be used to create IN deletion plasmids for recombination or ligation with patient derived sequences and creation of infectious viruses. Generally, such vectors must be created to allow re-insertion of the deleted sequences without disrupting the reading frame of the gag-pol gene.
The amplified IN sequences may be inserted into the appropriate vector by homologous recombination between overlapping DNA segments in the vector and amplified sequence. Alternatively, the amplified IN sequence can be incorporated into the vector at a unique restriction site according to cloning procedures standard in the art. This latter is a direct cloning strategy.
EXPERIMENTAL PART
Example 1
Phenotyping HIV Integrase
1. PCR Amplification of Integrase Encoding Sequence
The integrase encoding sequence was amplified from either wildtype HIV-1 (IIIB) or NL4.3 virus, or HXB2D site-directed mutant viruses containing mutations in integrase (such as T66I, S153Y, M154I, or combinations thereof) (Hazuda et al., Science 2000, 287, 646–650), or patient samples. Starting from RNA, extracted from virus supernatant or plasma using the QIAamp® viral RNA extraction kit (Qiagen), cDNA was synthesized by reverse transcription (Expand™ reverse transcriptase, 30 min at 42° C.) with the primer 3′EGINT10 (SEQ ID NO 11), followed by a nested PCR. The outer PCR was performed with the primers 5′EGINT1 (SEQ ID NO 1) and 3′EGINT10 (SEQ ID NO 11) (R-IN-vif construct) or 5′EGINT3 (SEQ ID NO 4) and 3′EGINT10 (SEQ ID NO 11) (IN construct) (Expand™ High Fidelity PCR system), and 5 μl of the outer product was used for an inner PCR with primers 5′EGINT2 (SEQ ID NO 3) and 3′EGINT11 (SEQ ID NO 12) (R-IN-vif construct) or 5′EGINT4 (SEQ ID NO 5) and 3 ′EGINT6 (SEQ ID NO 7) (IN construct). In a second protocol the outer primers were identical as described above, the inner primers are 5′EGINT5 (SEQ ID NO 6) and 3′EGINT6 (SEQ ID NO 7). The amplicons can be used for genotyping and phenotyping. Cycling conditions for both PCRs are denaturation for 3 min at 95° C., followed by 30 cycles of 1 min 90° C., 30 sec 55° C., and 2 min 72° C. A final extension was performed at 72° C. for 10 min. For recombination, PCR products are purified using the QiaQuick® 96 PCR BioRobot kit (Qiagen), according to the manufacturer's protocol. If the protocol starts from DNA containing the HIV material such as proviral DNA, the reverse transcriptase step is not needed. The nested approach is also not needed when starting from proviral DNA. The obtained amplicons were sequenced using the primers: In_seq1F (SEQ ID NO 17), In_seq2F (SEQ ID NO 18), In_seq3F (SEQ ID NO 19), IN_seq1R (SEQ ID NO 20), IN_seq2R (SEQ ID NO 21), and IN_seq3R (SEQ ID NO 22). The sequence of the IIIB and patient amplicon, and the NL4.3 amplicon were identical to the reference IIIB and NL4.3 sequences respectively (data not shown).
2. Preparation of a IN Deletion Construct
A R-IN-vif or IN deletion construct was generated by site-directed mutagenesis on the template pSV40HXB2D with the primers MUT-IN1 (SEQ ID NO 13) and MUT-IN2 (R-IN-vif construct) (SEQ ID NO 14) or MUT-IN3 (SEQ ID NO 15) and MUT-IN4 (SEQ ID NO 16) (IN construct) (protocol Site-directed mutagenesis kit, Stratagene). After DpnI digestion for removal of the methylated template DNA, the construct was digested with SmaI and ligated to circulize the plasmid. The plasmid was transformed into competent cells such as Top10 cells, and colonies were screened for the presence of the deletion construct. The IN-deletion construct was checked by sequence analysis with primers 5′EGINT1 (SEQ ID NO 1) or 5′EGINT10 (SEQ ID NO 11) and 3′EGINT10 (SEQ ID NO 11) or 3′EGINT11 (SEQ ID NO 12). For use in recombination experiments, large-scale plasmid DNA preparations were linearized by SmaI digestion and recombined with PCR amplified integrase genes from wild type, mutant, or patient viruses. The plasmid containing the integrase deletion (IN) has been deposited pSV40HXB2D- IN. The sequence of said plasmid is 14377 nucleotides long. The R-IN-vif deletion construct is 13975 nucleotides long. The pSV40HXB2D- IN was deposited at the Belgian Coordinated Collections of Micro-Organisms located at the Universiteit Gent—Laboratorium voor Moleculaire Biologie on Aug. 5, 2002 and the accession number is LMBP 4574.
3. Recombination of Integrase-Amplified Sequences With the Corresponding Deletion Construct
Recombinant virus was produced by co-transfection by electroporation of the SmaI-linearized IN-deletion construct and the integrase amplicon into MT4 cells or MT4 cells equipped with an LTR driven reporter gene construct. Production of recombinant virus was evaluated by scoring the cytopathogenic effect (CPE) that is induced by HIV-infection of MT4 cells or by the LTR-driven reporter signal induced by HIV infection in MT4 reporter cells. Green fluorescent protein was used as the reporter signal. Viruses are harvested and titrated at maximum CPE. For recombination the deletion construct pSV40HXB2D-IN was used. Recombination experiments were performed with amplicon from wildtype HIV IIIB and NL4.3, and patient sample 146514 generated by both primer sets. For each recombination 2 μg amplicon was co-transfected with 10 μg SmaI-digested pSV40HXB2D- IN by electroporation into MT4-LTR-EGFP cells. Virus stocks were titrated and tested in an antiviral experiment on a reference panel including nucleoside reverse transcriptase inhibitors (NRTI), non-nucleoside reverse transcriptase inhibitors (NNRTI), protein inhibitor (PR), entry and integrase (IN) inhibitors (Table 2).
Recombination was checked by nucleic acid sequence analysis using protocols known to the person skilled in the art. Sequencing primers which can be used are In_seq1F (SEQ ID NO 17), In_seq2F (SEQ ID NO 18), In_seq3F (SEQ ID NO 19), IN_seq1R (SEQ ID NO 20), IN —seq 2R (SEQ ID NO 21), and IN_seq3R (SEQ ID NO 22). The recombinant virus was evaluated in an anti-viral assay with a panel of reference compounds including nucleoside RT inhibitors (NRTI) Zidovudine (AZT) Lamivudine (3TC), Didanosine (DDI), non-nucleoside RT inhibitors (NNRTI) Nevirapine (NVP), 4-[[6-amino-5-bromo-2-[(4-cyanophenyl)amino]4-pyrimidinyl]oxy]-3,5-dimethyl-benzonitrile also referred to as compound 1,4-[[6-amino-5-bromo-2-[(4-cyanophenyl)amino]-4-pyrimidinyl]oxy]-3,5-dimethyl-Benzonitrile, also referred to as compound 2 protease inhibitors (PR) Saquinavir (SQV), Amprenavir (APV), Indinavir (DV), [(1S,2R)-3-[[(4-aminophenyl)sulfonyl](2-methylpropyl)amino]-2-hydroxy-1-(phenylmethyl)-propyl-, (3R,3aS,6aR)-hexahydrofuro[2,3-b]furan-3-yl ester carbamic acid also referred to as compound 3, entry-inhibitors (Entry) (AMD3100, DS5000, ATA), and integrase inhibitor (IN) 2-(1-methylethyloxy)-, -dioxo-5-(phenylmethyl)-benzenebutanoic acid also referred to as compound 4. The results are compiled in Table 2. AVE means antiviral experiment. Type means the type of inhibitor investigated. The fold change is the fold change in EC 50 . WT IIIB means that a portion of the wild type IIIB strain has been amplified and used in the antiviral experiment, including transfection and generation of recombinant virus. NL 4-3 means the integrase gene of this laboratory strain has been amplified and subsequently used for the antiviral experiment. Patient 146514 means that the integrase gene of an HIV sample retrieved from said patient has been amplified and used in the antiviral experiment. pHXB2D has been used as a control. No recombination has been effected using this HIV clone. pHXB2D has been used directly for transfection and antiviral experiment. Primer set 3 consist of outer primers 5′EGINT3 (SEQ ID NO 4) and 3′EGINT10 (SEQ ID NO 11), and inner primers 5′EGINT4 (SEQ ID NO 5) and 3′EGINT6 (SEQ ID NO 7). Primer set 4 consist of outer primers 5′EGINT3 (SEQ ID NO 4) and 3′EGINT10 (SEQ ID NO 11), and inner primers 5′EGINT5 (SEQ ID NO 5) and 3′EGINT6 (SEQ ID NO 7). Other suitable integrase inhibitors include L-731,988, diketo-acids and S-1360.
The antiviral activity of these compounds against recombinant virus from wildtype HIV-1 IIIB or NL4.3 was identical to the activity against the HIV-1 IIIB and pHXB2D control strain, where no recombination has been performed. Recombinant virus generated from site-directed mutant virus gave a fold increase in EC 50 against compound 4 of respectively 2-fold (T66I mutation), 5-fold (S153Y), 3-fold (M154I mutation), 10-fold (T66I/S153Y mutations or T66I/M154I mutations). Recombinant virus generated from patient samples without mutations in the integrase coding sequence, displyed analogous results as the wildtype strains in the antiviral assay. The panel of protease and reverse transcriptase inhibitors were included in the list to prove that no background resistance, expressed as a fold increase in EC 50 , was detected. The reverse transcriptase and protease genes present in the antiviral experiments were derived from wild type HIV sequence, which does not confer resistance to the drugs included. The instant results (Table 2) indicate that no change in susceptibility for any of these compounds is found.
TABLE 2
Antiviral experiment
Example 2 Genotyping of integrase
The methods and conditions used for sequence analysis of HIV integrase
gene are outlined below. The sequencing primers (cfr. Table 1) cover
the region of 864 nucleotides, from nucleotide 4230 until 5093
according to the sequence present in the HIV clone HXB2D. The
sequencing primers were diluted until 1 pmol/μl and used
in the mix and conditions as described below.
Reaction Mix
Component
Reaction Mix
Big Dye Terminator Mix
4
μl
2.5 Dilution Buffer
4
μl
Water
4.8
μl
Primer (1 pmol/μl)
3.2
μl
Sample (200–500 ng/μl)
4
μl
TOTAL
20
μl
Thermal Cycle Conditions
Initial Denaturation
3′ on 96° C.
Denaturation
30″ on 96° C.
|
Annealing
15″ on 50° C.
|
30 cycles
Elongation
4′ on 60° C.
|
Hold on 4° C.
After cycle sequencing the reaction products were purified and run on the 3700 DNA analyzer.
Example 3
Construction of a Recombinant IN Vector
A) construction of pSV40HXB2D R-IN-vif
The pSV40HXB2D R-IN-vif vector has a deletion of the complete IN coding sequence as well as part of the preceding RNase and subsequent Vif coding sequences. It was constructed by PCR amplification of pSV40HXB2D and religation of the amplified fragment. The primers used for amplification were MUT IN1 (5′ GGG TGA CAA CTT TTT GTC TTC CTC TAT 3′; SEQ ID NO:13) and IN2 (5′ GGA TCC TGC AGC CCG GGA AAG CTA GGG GAT GGT TTT ATA GA 3′; SEQ ID NO:23), which contain a SmaI site. Primer MUT IN1 (SEQ ID NO 13) anneals to nucleotides 3954 to 3928, and primer IN2 (SEQ ID NO 23) anneals to nucleotides 5137 to 5163. The first 14 nucleotides of N2 (SEQ ID NO 23) comprise the Sma I tail, which does not anneal to the vector. The amplified product was cleaved with Sma I and re-ligated to create pSV40HXB2D R-IN-vif, with a Sma I recognition site at the location of the deletion.
B) Amplification of Patient Derived IN Sequences for Insertion into pSV40HXB2D R-IN-vif
To amplify the complete IN coding region and the flanking segments of the RNase and Vif coding regions for insertion into the pSV40HXB2D R-IN-vif vector, a nested PCR method was used. The outer primers were 5′EGINT1 (SEQ ID NO 1) and 3′EGINT10 (SEQ ID NO 11), while the inner set was 5′EGINT107 (SEQ ID NO 2) and 3′EGINT11 (SEQ ID NO 12). An additional inner 5′ primer, 5′EGINT2 (SEQ ID NO 3), was used to improve the yield of amplified DNA. (The sequences of these primers are given in Table 1, above.)
C) Construction of the pSV40HXB2D In Vector
To create pSV40HXB2D IN, the pSV40HXB2D vector was PCR amplified and re-ligated to effectively delete most of the IN coding region, leaving the nucleotides coding for the N-terminal 8 amino acids and the C-terminal 20 amino acids in place. The amplification was performed using the primers MUT IN3 (5′ GGG CCT TAT CTA TTC CAT CTA AAA ATA GT 3′; SEQ ID NO:15) and MUT IN4 (5′ GGA TCC TGC AGC CCG GGA TTA TGG AAA ACA GAT GGC A 3′; SEQ ID NO:16), containing a SmaI site. Primer MUT IN3 (SEQ ID NO 15) anneals to nucleotides 4254 to 4226, and primer MUT IN4 (SEQ ID NO 16) anneals to nucleotides 5 create 036 to 5057. The resulting amplified fragment can be cleaved with SmaI and religated to pSV40HXB2D IN.
D) Amplification of Patient Derived IN Sequences for Insertion into pSV40HXB2D IN
Patient derived IN sequences was prepared for insertion into the HIV deletion vector using a nested PCR approach as in part B above. 5′EGINT3 (SEQ ID NO 4) and 3′EGINT10 (SEQ ID NO 11) were used as outer PCR primers, while 5′EGINT4 (SEQ ID NO 5) or 5′3GINT5 (SEQ ID NO 6) and 3′EGINT6 (SEQ ID NO 7) were used as inner primers. The sequences and SEQ ID NO 4–8 of these primers are given in Table 1. The underlined portion of MUT IN4 (SEQ ID NO 16) represents the SmaI tail that does not anneal to the vector.
E) Homologous Recombination and Ligation to Insert the PCR Products Into the Vectors.
The pSV40HXB2D IN or pSV40HXB2DAR-IN-vif vectors was linearized with SmaI. The vectors and the amplified IN DNA fragments were transfected by electroporation into MT4 cells, MT4 cells equipped with a LTR reporter gene construct (MT4rep) or PM-1 cells. By homologous recombination between overlapping portions of the vector and IN amplicons, the HIV genome was reconstituted with a patient derived IN coding region. The recombinant vectors were capable of producing virus particles in infected cells. Virus production was evaluated by scoring the cytopathogenic effect (CPE) that was normally induced by HIV infection of MT4, MT4-rep, or PM-1 cells, or was evaluated by the induced LIR-driven reporter signal in MT4-rep or PM-1 cells. Homologous recombination with wild type IN sequences was used as a control.
The presence of recombinant IN DNA and RNA sequences in the transfected cells was monitored by reverse transcription and PCR analysis. The presence of PCR products corresponding to correctly inserted IN sequences showed that recombination successfully occurred and that viral RNA was produced in the cells.
Patient derived IN sequences and wild type controls were alternatively inserted into SmaI-linearized pSV40HXB2D N or pSV40HXB2D R-IN-vif vectors by a standard restriction digestion and ligation procedure. The IN amplicons were modified to create SmaI cleaved ends and were then inserted by ligation into the SmaI site on the vectors.
Example 4
Genotyping of Patient Derived IN Coding Sequences
A) Obtaining and Amplifying Patient Derived IN Sequences
RNA was isolated from 100 μl of plasma according to the method described by Boom et al. (1990), and reverse transcribed with the GENEAMP® reverse transcriptase kit (Perkin Elmer) as described by the manufacturer using an HIV-1 specific downstream primer. Two subsequent nested PCRs were set up using specific outer primers and inner primers, respectively. The outer primer reaction were performed as described in WO97/27480 and U.S. Pat. No. 6,221,578 (which are incorporated herein by reference). The inner amplification was performed in a 96 well plate as follows: 4 μl of the outer amplification product was diluted to a final volume of 50 μl using a 10× amplification mix consisting of 5 μl 10× PCR buffer containing 15 mM MgCl 2 , 1 μl dNTP's (10 mM) 0.5 μl each primer (0.25 μg/ml), 0.4 μl EXPAND® High Fidelity polymerase (3.5 U/μl; Roche) and deionized water. Amplification was initiated after a short denaturation of the amplification product made using the outer primers (2 min at 94° C.). Ten amplification cycles were run, each consisting of a 15 sec denaturation step at 94° C., a 30 sec annealing step at 60° C. and a 2 min polymerization step at 72° C. This amplification was immediately followed by 25 cycles consisting of a 15 sec denaturation step at 94° C., a 30 sec annealing step at 60° C. and a variable time polymerization step at 72° C. The polymerization step was initially run for 2 min and 5 sec, then was increased by 5 seconds in each cycle. Amplification was completed by an additional polymerization step of 7 min at 72° C. The reactions were held at 4° C. until further analysis or stored at −20° C. (for short periods) or −70° C. (for longer periods). The products can be analysed on DNA agarose gels and visualised by UV-detection. The products can be purified using the QIAQUICK® 96-well plate system as described by the manufacturer (Qiagen).
B. Sequencing of IN Coding Region
The IN coding region present on the amplified fragments were sequenced using techniques known in the art. The sequencing was started by first distributing 4 μl of the primer stocks (4.0 μM) over a 96 well plate where each stock was pipetted down the column. In a second step, master mixes were made consisting of 14 μl deionized water, 17.5 μl dilution buffer, 7 μl sample (PCR fragment) and 14 μl Big Dye™ Terminator Mix (Perkin Elmer). A fraction (7.5 μl) of each master mix, containing a specific PCR fragment, was transferred to a specific place into the 96 well plate so that each sample fraction was mixed with a different PCR primer set. Samples were pipetted across the rows. Samples were placed in a thermal cycler and sequencing cycles started. The sequencing reaction consisted of 25 repetitive cycles of 10 sec at 96° C., 5 sec at 50° C. and 4 min at 60° C., respectively. Finally, sequence reactions were be held at 4° C. or frozen until further analysis. The sequencing reactions were precipitated using a standard ethanol precipitation procedure, resuspended in 2 μl formamide and heated for 2 minutes at 92° C. in the thermal cycler. Samples were cooled on ice until ready to load. 1 μl of each reaction was loaded on a 4.25% vertical acrylamide gel in a 377 sequencer system and gel was run until separation of the fragments is complete.
C. Sequence Analysis of IN Coding Region
Sample sequences were imported as a specific project into the sequence manager of Sequencher™ (Genecodes) and compared to the wild type reference sequence. Sequences were assembled automatically and set at 85% minimum match. Secondary peaks were searched and the minimum was set at 60%. Any sequence that extended beyond the 5′ end or the 3′ end of the reference were deleted. When a region of overlap between sequences from the same strand was reached, the poorest quality of sequence was deleted leaving an overlap of 5–10 bases. Ambiguous base calls were considered poor matches to exact base calls. The sequence assembly was saved within an editable contig.
Obtained sequences were edited to facilitate interpretation of the base calls. Ambiguous sequences were retrieved and checked for possible errors or points of heterogeneity. When the point of ambiguity appeared correct (both strands of sequence agreed but were different from the reference sequence) it was interpreted to be a variant. The reference sequence was used as an aid for building a contig and as a guide to overall size and for trimming. The reference sequence was not used for deciding base calls. A change was only made when both strands agreed. All gaps were deleted or filled, unless they occurred in contiguous groups of multiples of three (i.e., insertion or deletion of complete codons) based on data form both sequence strands. Once the editing was complete, the new contig sequence was saved as a consensus sequence and used for further analysis.
Detailed sequence editing was performed following certain rules: A) Applied Biosystems, Inc. primer blobs were trimmed at 5′ ends where 1 consecutive base remained off the scale, the sequence was trimmed not more than 25% until the first 25 bases contained less than 1 ambiguity, at least the first 10 bases from the 5′ end were removed, and B) 3′ ends were trimmed starting 300 bases after the 5′ trim, the first 25 bases containing more than 2 ambiguities were removed, the 3′ end was trimmed until the last 25 bases contained less than 1 ambiguity. The maximum length of the obtained sequence fragment after trimming was 550 bases.
Sequences that failed to align were removed from the assembly and replaced by data retrieved from new sequence analyses. When further failures occur, PCR reactions were repeated. Chromatograms were visualised using an IBM software system.
Legends to the Figures
FIG. 1 : Overview of the HIV genome indicating the primer positions | The present invention relates to methods and products for the evaluation of HIV treatment. The methods are based on evaluating molecular events at the HIV integrase resulting in altered therapeutic efficacy of the investigated compounds. The methods rely on providing an integrase gene and evaluating either through genotyping or phenotyping the integrase gene. The present invention relates to the fields of diagnostics, drug screening, pharmacogenetics and drug development. | 2 |
[0001] The applicant claims the benefit of provisional patent application No. 61/54,302 filed on Feb. 20, 2009 for a “Light gauge metal Zee clip”.
DESCRIPTION
[0002] The present invention relates to a light to heavy gauge metal Zee clip. The clip consists of the following components:
Light to heavy gauge sheet metal bent into a Z shape. The clip has two horizontal legs which can vary in length from one half inch to four inches; the vertical/diagonal leg will vary from one half inch to four and one half inches. The depth of the vertical/diagonal leg will depend on the thickness of fireproofing required for that particular bar joist, I-beam or H-column. The horizontal legs are not necessarily equal lengths or widths. The overall length of the ZEE clip and depth of the U shaped clips will vary and will coincide with the width and thickness of the flange of the steel I-beams, bar joist and columns to which the ZEE clip is attached.
This invention is a piece of sheet metal bent into a Z shape. Looking at the clip from the end (so you see the shape of a Z), the bottom horizontal section will be longer than the vertical/diagonal and top sections of the Z. The additional length on the bottom horizontal section, starting as a straight flat piece, will be double or multiple bent or radius bent to create the U shaped clips under the Z and will not necessarily be equal lengths on each end of the Z. The overall length of the vertical/diagonal and top sections will vary from 2 to 24 inches depending on the width of the bar joist, I-beam or column it will be attached to. Each end of the bottom section will have two successive bends, multiple bends or a radius bend with the first bend or radius being in the direction away from the vertical/diagonal section. The first bend or radius on each end of the Z clip will start at a 40 to 50 degree angle to the length of the ZEE clip, and parallel with each other. By starting the bend for the tabs at an angle it sets up so that the radius bend or second bend creates U shaped tabs/ears on each end of the clip that face opposite directions. The two bends, multiple bends or radius bend will in turn make a U shaped tab at each end, on the bottom of the ZEE clip. The distance between the two parallel surfaces of the U will vary from ⅛ of an inch to 2 and ½ inches or greater, and will coincide with the thickness of the steel bar joist, beam or column flanges. The two surfaces of the U are not necessarily parallel to each other and could be made so the U is actually in a slightly closed U shape. The direction of the tabs will be in such a manner that the Z clip will be turned in a clockwise motion to lock the tabs onto a bar joist, I-beam or column. This tab/ear at each end will make up the attachment which will hold the clip onto the beam or column flanges with a friction fit. The tabs/ears will have a slight upward bend diagonally on the corner of the leading edge to ease the installation of the clip onto a bar joist, I-beam or column.
[0006] One of the key benefits of using this new invention is to improve employee safety. Installing the clip with a specifically designed tool reduces fall hazards by working from the floor level versus having to climb a ladder or scaffolding. Another key benefit of the Z clip is that the only items needed are the Z clip and the installation tool. This saves time and money by allowing simple mobilization during the early phases of construction in buildings which contain structural steel. The Z clip can be used on buildings with or without fireproofing requirements. Installing extra Z clips where you “might” need them can be done at minimal cost and would reduce fireproofing patchwork costs by reducing the number of missed clips.
[0007] The ZEE clip could be mechanically fastened to the bar joist, I-beam or column using a power driven fastener such as a steel pin driven through the ZEE clip leg (which is flat against the steel bar joist, I-beam or column) and into the structural steel bar joist, I-beam or column. It could also be tack welded using an electrode welding rod or wire fed welding unit to permanently connect the ZEE clip to the bar joist, I-beam or column. Either one of these options of connecting the ZEE clip to the structure could be used to prevent the clip from being removed or accidentally knocked off of the bar joist, I-beam or column.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawings are an illustration of one of the many uses for the light gauge metal Zee clip. The drawings include the Zee clip, a structural steel I beam and metal stud partition components attached to the Zee clip.
[0009] FIG. 1 is a view of the Zee clip ( 10 ) that clearly shows the position of the tabs ( 15 ), which wrap around the I beam flange ( 20 ), and the angle at which the tabs are bent. The angle and direction of the bends to create the tabs allows for the installation of the Zee clip onto the flange of an I beam ( 20 ).
[0010] FIG. 2 is a view of two Zee clips ( 10 ) attached to the flanges of an I beam ( 20 ).
[0011] FIG. 3 is a close up view of how the Zee clip ( 10 ) attaches and specifically how the tab ( 15 ) wraps around the I beam flange ( 20 ) for a tight friction fit. FIG. 3 also shows the flared corner ( 25 ) on the leading edge of the tab ( 15 ) which allows the tab ( 15 ) to easily slip over the flange of the I beam ( 20 ).
[0012] FIG. 4 is a view of two Zee clips ( 10 ) attached to the underside of an I beam ( 20 ) and steel stud partition track attached to the Zee clips ( 10 ).
[0013] FIG. 5 is a close up view of the steel stud partition track ( 30 ) attached to the Zee clip with sheet metal screws ( 40 ).
[0014] The clip could be constructed to resemble a (square) C shape rather than a Z shape with all or some of the attributes of the Z shaped clip. The ZEE clip could be constructed in such a manner that only one tab is used to clip onto one flange of a steel bar joist, I-beam or column instead of being clipped to both flanges. This can be achieved by cutting the length down by 50% or more and eliminating the tab/ear on one end. It could also be manufactured where the tabs are bent in the direction that would require turning the ZEE clip counterclockwise to install the ZEE clip onto the bar joist, I-beam or column. The ZEE clip could also be constructed with the tabs bent in a manner in which the ends of the tabs are facing each other and in line with the length of the clip. Another way the ZEE clip could be constructed is to make the top part of the clip, which the wall track attaches to, extend beyond the beam or column flanges so walls could be built offset from the beam or column. This will allow the wall framing and/or finishes to by-pass the beams or columns. The ZEE clip could be constructed in a manner in which the vertical/diagonal leg would be closer to horizontal and would allow some minor vertical movement of the structure and help reduce sound transmission from the structure to the wall. The clip could also be constructed in two pieces (resembling two 90 degree L angles) with slotted holes on one vertical leg and tabs or screws loosely attached through the slotted holes to the other vertical leg. This would allow greater vertical movement than a one piece Z clip. The ZEE clip could have small punched slots near the ends of the first horizontal section. These slots would only be punched through on three sides pushing the small piece of sheet metal down slightly. This would create a small friction tab (about ¼ inch wide and about ¾ inch long) to help hold the ZEE clip on the beam or column. The ZEE clip could be made by cutting or stamping a T shape out of a flat sheet of metal in such a way that the angle of the tabs is built into the ZEE clip as the sheet metal is in a flat state. The stamped shape would resemble a T shape with the body of the T being considerably wider than the top of the T. The top of the T would be fairly long and narrow and the last 30 to 40% on each end of the T would be angled at approximately 40 to 50 degrees. The angled ends of the top of the T will be facing opposite directions, one up and one down. The body of the T shape would then be bent into a ZEE or Cee shape at the locations and distances required to fit its intended use. The angled ends at the top of the T would be bent to create the U tabs for connection to steel I beams. Looking from a top view, the first bend or radius will be made on the angled ends of the T. The bends will be made on each end of the Z clip and the initial bends or radius will be parallel to each other to produce tabs facing opposite directions. The ZEE clip could be used for attachment of overhead plumbing or mechanical piping, ductwork or electrical piping by using multiple ZEE clips and installing straps or hanger rods with support material, such as angle iron or steel channel, spanning between the straps or rods. The straps or rods can be of any length to fit the need. This will create a cradle or rack at a desired elevation above the finished floor and the clearance from the structure above to carry ductwork, single or multiple electrical, mechanical or plumbing pipes. The ZEE clip could also be used on columns to connect electrical, plumbing or mechanical piping, electrical boxes, mechanical or plumbing valves or other materials that need to be supported at certain elevations or intervals.
[0015] While the present invention has been described in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. This invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and will fully convey the full scope of the invention to those skilled in the art. Indeed, many modifications and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure, the drawings and the claims. | This invention is a piece of sheet metal bent into a Z shape. It has integral U shaped tabs at each end of the Z shaped clip. The tabs are created by having the bottom portion of the Z extend 6 to 8 inches longer than the middle and top portions. This longer flat portion is then double bent away from the middle portion to form U shaped tabs. The tabs wrap around the two opposing flanges of a steel bar joist, I-beam or H-column and hold the Z shaped clip onto the bar joist, I-beam or column. The Z clip can be installed prior to spray applied fireproofing used in structural steel buildings. It subsequently provides a connection point for metal stud walls and other materials or equipment that need to be supported by the steel structure at a specific distance away from the bar joist, I-beam or column. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates generally to textile fabric finishing apparatus and, more particularly, to apparatus for the surface treatment of pile and plush fabrics, e.g., fabric shearing and tigering machines.
In the manufacture of pile and other plush-type textile fabrics, it is common to perform various finishing operations to enhance the appearance or hand of the pile or plush surface. For example, shearing machines are often employed to sever the tips of pile loops on a pile fabric to produce a velour-type plush surface effect. Napping and tigering machines may be employed as a subsequent processing step to brush the plush fabric surface to liberate and remove excess loose fibers and thereby improve the surface appearance and feel.
One of the difficulties in performing such finishing operations on pile and plush fabrics in a commercial production setting is that the resultant surface effect on the fabric and the affected fabric characteristics, e.g., surface appearance, hand, drapeability, fabric weight, etc., cannot necessarily be predicted accurately in advance simply by selection of the variable operating parameters and settings of the fabric treating machine. Accordingly, the control and regulation of fabric shearing, tigering and other surface treatment operations on pile and plush fabrics is to at least some extent an art based in part on experience and experimentation. Disadvantageously, in the commercial production of fabric, trial and error experimentation in the set-up of such finishing machines leads to fabric waste and decreased production efficiency and, in turn, once a commercial operation is underway, militates against frequent changes in machine production settings which might otherwise be desirable to accomplish a variety of fabric effects.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a novel apparatus for the surface treatment of pile and plush fabrics, which is particularly suitable for preliminary testing and experimentation on sample pieces of fabric, e.g., in a laboratory or research and development setting, as a means of facilitating more efficient and predictable set-up of commercial production machinery, e.g., shearing, napping and tigering machines, so that fabric waste can be minimized and production efficiency can be optimized.
Briefly summarized, the apparatus of the present invention is particularly adapted for the surface treatment of a finite length of pile and plush fabrics and, for such purpose, basically comprises a rotatably driven treating roller having a pile-engaging periphery (e.g., a shear roller, napping roller or tigering roller), and means for supporting the length of fabric for presentation to the roller for surface treatment. The fabric supporting means is movable between a fabric loading position spaced from the treating roller and a treatment position in close adjacency to the roller, and comprises a pair of fabric clamps, means for moving the clamps selectively toward one another for engagement of opposite ends of the length of fabric respectively by the clamps and away from one another for tensioning the length of fabric, and means for moving the clamps in synchronism with one another to cause the length of fabric to travel in tensioned condition for presentation to the roller for surface treatment.
In the preferred embodiment, the fabric supporting means comprises an arm which is pivotably movable between the fabric loading and treatment positions, with a pair of elongate endless chain mechanisms mounted generally coextensively with one another to the arm for selective movement in opposite directions, each of the fabric clamps being affixed to a respective one of the chain mechanisms. A clutch is provided for operatively connecting and disconnecting the chain mechanisms with respect to one another. Preferably, each chain mechanism comprises a pair of essentially identical endless chains connected with one another in spaced parallel facing relation for integral movement.
It is also preferred that a system of rollers or other fabric guides are provided to enable either an endless loop of fabric or an extended indeterminate length of fabric to be selectively trained and conveyed to travel to and from the fabric supporting means, so that the apparatus is enabled to perform experimental tests on fabrics of varying lengths and even to test differing fabrics in a single shearing operation by sewing lengths of differing fabrics together. A seam detector may be provided to recognize the approach to the treating roller of each fabric seam.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially schematic perspective view of a textile shearing machine in accordance with one preferred embodiment of the present invention;
FIG. 2 is a front elevational view of the fabric supporting arm assembly of FIG. 1;
FIG. 3 is a side elevational view of the shearing machine of FIG. 1, with the fabric supporting arm thereof disposed in fabric-loading position;
FIG. 4 is another side elevational view of the shearing machine of FIG. 1, with the fabric supporting arm thereof in treatment position at the start of a shearing operation on a relatively short length of fabric;
FIG. 5 is another side elevational view of the shearing machine of FIG. 1, showing the machine threaded with, and in shearing operation on, a continuous loop of fabric; and
FIG. 6 is another side elevational view of the shearing machine of FIG. 1, showing the machine threaded with, and in shearing operation on, an indeterminate extended length of fabric.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings and initially to FIG. 1, a textile fabric shearing machine is shown generally at 10 in accordance with one preferred embodiment of the present invention specifically designed and intended for use in a laboratory or research and development facility for performing experimental shearing operations on sample pieces of textile fabrics.
The shearing machine 10 comprises a rectangular floor-standing frame 12, normally enclosed by top, side and end panels which have been omitted to expose the internal operating components of the machine. A shearing cylinder 14 equipped with a plurality of helically extending shear blades 16 is rotatably supported laterally across the upper rearward side of the frame 12 by a mounting assembly 18 affixed to the frame 12. The shearing cylinder 14 is rotatably driven by a drive motor, shown only representatively at 20, connected to one end of the cylinder shaft 15. The mounting assembly 18 includes a ledger blade 22 (FIGS. 3 and 4) extending forwardly in close adjacency to the periphery of the shearing cylinder 14 and terminating in a cutting edge 24 extending in axially parallel relation to the cylinder 14 and shear-cutting relation with its blades 16. The mounting assembly 18 includes various mechanisms by which the relative disposition of the cylinder 14 and the ledger blade 22 to one another and to the machine frame 12 can be selectively adjusted, comparable to the adjustment mechanisms provided on conventional commercial production shearing machines.
An arm assembly 26 for supporting and conveying a length of textile fabric (not shown in FIG. 1) is pivotably mounted at its lower end to the frame 12 for movement between a fabric loading position (FIG. 3) wherein the arm assembly 26 is in an upstanding disposition spaced forwardly from the shearing cylinder 14 and a shearing disposition (FIG. 4) wherein the arm assembly 26 is inclined rearwardly with its upward end in close adjacency to the shearing cylinder 14. As best seen in FIG. 2, the arm assembly 26 has a supporting pivot shaft 28 mounted to the frame 12 by rotational bearings and a pair of upright arm members 30 affixed to opposite ends of the pivot shaft 28 in spaced parallel facing relation. A pair of toothed sprockets 32,34 are mounted for independent rotation to the lower end of each arm member 30 coaxially with each other and with the pivot shaft 28. Similarly, a pair of sprockets 36,38 are coaxially mounted to the upper end of each arm member 30 for independent rotation. At each opposite side of the arm assembly 26, the respective sprockets 32,36 are aligned in a common vertical plane with an endless timing chain 40 trained in meshing engagement about the respective sprockets 32,36 and, likewise, the respective sprockets 34,38 are aligned in another common vertical plane spaced closely parallel to the first plane with another endless timing chain 42 trained in meshing engagement about the respective sprockets 34,38.
A clamping bar 44 extends transversely between, and is fixed at its opposite ends to, the two chains 40 at the opposite sides of the arm assembly 26. Similarly, another clamping bar 46 extends transversely between, and is rigidly fixed at its opposite ends to, the two chains 42 at the opposite sides of the arm assembly 26. In this manner, the chains 40 together with the connecting clamping bar 44 move integrally with one another about the sprockets 32,36, while the chains 40 with their connecting clamping bar 46 travel integrally about the sprockets 34,38. Each clamping bar 44 includes a pair of clamping members 48 which are pivotably connected to one another for opening and closing movement to receive and then clamp an edge of fabric. A pair of retaining clips 50 are provided at opposite ends of each clamping bar 44 to selectively hold the clamping members 48 in clamping engagement.
At one side of the machine frame 12, the sprockets 32,34 are connected to a clutch, preferably a magnetic particle clutch, shown only representatively at 52, by which the sprockets 32,34 may be selectively coupled or uncoupled so that, in turn, the respectively associated chains 40,42 and clamping bars 44,46 can be selectively coupled for independent or unitary movement with the sprockets. At the same side of the machine, the sprocket 32 is connected through the clutch 52 with a drive motor 54, by which the sprocket 32 and, in turn, its associated chain 40 and sprocket 36, together with the corresponding sprockets 32,36 and chain 40 at the opposite side of the machine, can be driven independently of the sprockets 34,38 and chains 42 when the clutch is disengaged. At the opposite side of the machine, the sprocket 34 is connected to a variable speed drive motor 56 by which the sprocket 34 and its associated chain 42 and sprocket 38, together with the corresponding sprockets 34,38 and chain 42 at the opposite side of the machine, can be selectively driven either independently of or unitarily with the sprockets 32,36 and chains 40 depending upon the condition of the clutch 52.
A tapered fabric nose bar 58 is affixed to and extends laterally between the upper ends of the arm members 30 in parallel relation to the axis of the shear cylinder 14 for deflection over the nose bar 58 of a piece of fabric for shear cutting operation, as more fully explained below.
A linear actuator 60, e.g., a fluid-operated piston-and-cylinder assembly, is mounted at one end to the frame 12 and at the other end to the arm assembly 26 to control pivoting movement of the arm assembly 26 between the fabric-loading position of FIG. 3 and the shear-cutting position of FIG. 4.
A central microprocessor 62 is connected to the drive motors 54,56, the clutch 52, and the linear actuator 60 and is selectively programmed to control their respective operation in the manner hereinafter described.
The normal operation of the machine 10 for shearing a sample piece of textile fabric F may best be understood with reference to FIGS. 3 and 4. The arm assembly 26, particularly the spacing of the sprockets 32,34,36,38 and the length of the chains 40,42, is adapted to accommodate relatively small sample pieces of fabric, e.g., between 12 inches and 32 inches in length and up to 24 inches in width. A suitable piece of fabric F within these dimensional parameters is loaded into the machine 10 by entering an appropriate command into the microprocessor 62 to initiate a programmed fabric-loading sequence wherein, first, the linear actuator 60 is withdrawn to pivot the arm assembly 26 into the upright fabric-loading position of FIG. 3 and, then, the drive motors 54,56 and the clutch 52 are operated to drive the sprockets 32,34,36,38 and the chains 40,42 oppositely to position the respective clamping bars 44,46 at the opposite forward and rearward sides at the upper end of the arm assembly 26, as also shown in FIG. 3.
In this disposition of the arm assembly 26, each clamping bar 44,46 can be opened by a machine operator and the opposite end edges of the fabric piece F inserted and secured into the respective clamping bars 44,46, with the intermediate length of the fabric F extending upwardly over the nose bar 58 with the pile or plush surface of the fabric F facing upwardly. Next, with the clutch 52 deactuated, the drive motor 54 is energized to drive the sprockets 32,36, their respective chains 40, and the associated clamping bar 44 downwardly to tension the fabric F lengthwise over the nose bar 58. Once the fabric F is satisfactorily tensioned in this manner (which can be monitored and signaled to the microprocessor 62 in any appropriate manner), the drive motor 54 is deactuated and the clutch 52 is energized to effectively couple the sprockets 32,34,36,38, the associated chains 40,42, and the associated clamping bars 44,46 for unitary driven operation and the linear actuator 60 is extended to pivot the arm assembly 26 into the fabric shearing disposition of FIG. 4.
Any necessary positional adjusting of the shearing cylinder 14 is carried out and, then, the shearing cylinder motor 20 is energized to drive rotation of the shearing cylinder 14 and the drive motor 56 is also energized to unitarily drive the chains 40,42 in the direction indicated by the arrows in FIG. 4 to cause the fabric F to travel lengthwise over the nose bar 58 for presentation of the pile or plush fabric surface to the nip area between the shearing cylinder blades 16 and the ledger blade 22 for shear-cutting of the fabric surface. Based on the fabric tension sensing arrangement, the microprocessor 62 initially computes and stores the length of the fabric piece during the initial fabric loading sequence and utilizes this stored data to terminate the fabric travel before the clamping bar 44 advances into engagement with the nose bar 58. If desirable, the microprocessor 62 can be commanded to reverse the traveling movement of the fabric to carry out a second shearing pass of the fabric.
Advantageously, by selectively adjusting variable operating parameters of the machine 10, such as the relative spacing and dispositions of the shearing cylinder 14 and the ledger blade 22 and the traveling speed of the fabric, experimentation with differing shearing effects on differing pieces of the same or differing types of fabrics can be easily carried out in a controlled laboratory or research and development setting as a means of determining appropriate settings of commercial production shearing machinery.
As best seen in FIGS. 5 and 6, the shearing machine 10 is equipped with a number of guide rolls 66 rotatably mounted to the machine frame 12 to extend transversely thereacross, whereby a continuous loop of fabric F' may be selectively loaded into the machine 10 for shear-cutting experiments, as depicted in FIG. 5, or alternatively an extended indeterminate length of fabric F" may be threaded through the machine for shear-cutting experiments, as depicted in FIG. 6. In either case, the fabric loop F' or the length of fabric F" may be comprised of two or more shorter lengths of fabric sewn together at abutting fabric end edges. As will be understood, it may be important in many circumstances that the seam between differing pieces of fabric not be subjected to shear-cutting by the shearing cylinder 14 and, accordingly, the arm assembly 26 is equipped with an electronic seam detector 64 shortly in advance of the nose bar 58 to signal the microprocessor 62 upon the approach of each fabric seam to the nose bar 58, whereby the microprocessor 62 can actuate a momentary adjusting movement of the shearing cylinder mounting assembly 18 away from the nose bar 58 to protect the integrity of the fabric seam. In this manner, more extensive experimentations can be carried out with larger pieces of fabric to better simulate and assess shearing effect in a production setting.
As those persons skilled in the art will readily recognize, the machine 10 of the present invention is not limited to shearing operations. For example, it is contemplated that the machine 10 may be equipped with other forms of fabric surface-treating rolls than the shearing cylinder 14, such as a tigering roll (not shown), and thus it is to be understood that the present invention is not limited to the particular shearing embodiment illustrated and described herein.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | An apparatus for shearing, tigering, napping or other surface treatment of a finite length of a textile fabric, particularly pile and plush fabrics, is disclosed which is especially adapted for experimental research and development usage in a laboratory setting. The apparatus includes a rotatably driven roller having a fabric surface-engaging periphery and an arm assembly for supporting the fabric piece for presentation to the roller, the arm assembly being movable between a fabric-loading position spaced from the roller and a treatment position in close adjacency to the roller. The arm assembly has a pair of fabric clamps mounted to respective chain assemblies which can be moved in opposite or the same directions independently or in tandem to facilitate attachment of the opposite ends of the fabric to the respective clamps by movement of the clamps toward one another, fabric tensioning by movement of the clamps away from one another, and fabric travel past the roller by coordinated unitary movement of the clamps in tandem. Guide rollers within the apparatus alternatively enable either a continuous loop of fabric or an indeterminate traveling length of fabric to be processed. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/522,058, filed Aug. 10, 2011, which is incorporated herein by reference.
BACKGROUND
[0002] The present embodiments are directed to an ice hockey skate system that is useful in providing optional blade stiffness and ease of swapping out ice hockey skate blades.
[0003] For nearly 150 years, hockey has been an important winter pastime for outdoor enthusiasts. In that time, hockey has evolved in rules and equipment. For example, in 1879, teams had nine players on each side, yet today teams have only six players. Also, old fashioned hockey skates were once steel blades tied to the bottom of stiff pair of shoes, but today their construction can include over-molded stainless steel blades attached to high technology skate boots.
[0004] Today the sport of ice hockey has spread to street hockey, which does not require any skate whatsoever to rollerblading and roller skating. However, the hockey skate is distinguishable over other forms of roller related skates, such as roller skates or roller blades because of the high rigidity required by the ice hockey skate. Accordingly, the only thing similar between a roller skate or roller blade and a hockey skate is the boot. All other aspects have diverged (though they may look similar) because of the very different requirements between ice hockey skates and roller blades, roller skates, etc.
[0005] FIG. 1 is a prior art illustration depicting the present state of the art hockey skate 100 . As depicted, today's hockey skate 100 provides a standard leather or plastic boot 104 with a tendon guard 102 and a high stiffness arrangement comprising a skate blade 108 embedded in a one-piece blade holder 106 that is riveted or screwed onto the boot sole 112 .
[0006] It is to innovative improvements related to ice hockey skates systems that the claimed invention is generally directed.
SUMMARY
[0007] The present embodiments generally relate to an ice hockey skate system that is useful in providing optional blade stiffness and ease of swapping out ice hockey skate blades. Some embodiments of the present invention contemplate a hockey skate apparatus comprising: a first runner-blade assembly that possesses: a steel ice-hockey skate blade that extends in length between a front end and a back end and has an ice surface and a top surface; a runner that is integrated with the skate blade, the runner essentially covers the top surface and extends part way towards the ice surface; a front cup removably attached to the first runner-blade assembly towards the front end; a back cup removably attached to the first runner-blade assembly towards the back end, the back cup and the front cup are adapted to be independent from one another, the front cup and the back cup are of a different material than the runner; the front cup and the back cup are removably attached to an ice-skate boot sole such that when fully assembled, the cups and the first runner-blade assembly essentially form a rigid structure connected to the ice-skate boot sole; the first runner-blade assembly adapted to be replaced with a second runner-blade assembly that possesses a different stiffness than the first runner-blade assembly.
[0008] Other embodiments contemplate the hockey skate wherein the front cup and the back cup have different vibration damping properties than the runner, wherein the front cup is removably attached to the first runner-blade assembly via a front bolt and the back cup is removably attached to the first runner-blade assembly via a back bolt, wherein the first runner-blade assembly is adapted to be replaced with the second runner-blade assembly by removing the front cup and the back cup from the ice-skate boot sole, wherein at least one of the cups is adapted to be removably attached to the ice-skate boot sole in various lateral positions, wherein the runner is composed of a polymer based material, wherein the cups are composed of magnesium, wherein further comprising either a front mounting plate between the front cup and the ice-skate boot sole or a back mounting plate between the back cup and the ice-skate boot sole, the runner essentially covers the top surface of the skate blade means the runner covers at least 90% of the top surface, the first runner-blade assembly is attached to the front cup by way of a bolt that is accommodated by a hole that penetrates both the skate blade and the runner.
[0009] Yet other embodiments envision the hockey skate apparatus wherein the runner possesses a slot that accommodates the skate blade, and further, the skate blade is received by a plurality of different runners wherein each of the runners provides different stiffness.
[0010] Other embodiments contemplate the hockey skate apparatus further comprising both a front mounting plate between the front cup and the ice-skate boot sole and a back mounting plate between the back cup and the ice-skate boot sole, wherein the mounting plate is metal, wherein the mounting plates are adapted to create a vibration damping interface, wherein the mounting plates further include at least one layer of dissimilar material adapted to create a vibration damping interface, wherein the at least one layer of dissimilar material is from the group consisting of: a metal plate, a polymer, a compliant metal (lead), compliant glue.
[0011] Other embodiments contemplate a hockey skate apparatus comprising: a hockey boot possessing a boot sole that defines a toe end and a heal end; attached to the boot sole near the toe end is a first cup and attached to the boot sole near the heal end is a second cup, wherein the first cup is capable of being swapped out with a like first cup from the boot sole while the second cup remains attached; a first runner-blade assembly attached to the first and the second cups, the runner-blade assembly possessing a steel ice-hockey skate blade that extends in length between a front end and a back end and has an ice surface and a top surface; the runner-blade assembly further possessing a runner that is integrated with the skate blade, the runner covers a significant portion of the length of the top surface and extends part way towards the ice surface on both sides of the skate blade; the cups and the first runner-blade assembly when fully attached to the boot sole are essentially positionally fixed.
[0012] Yet other embodiments envision the hockey skate apparatus wherein the first cup is a different material than the second cup, or wherein the cups are attached to the boot sole via at least one intermediary structure, wherein the at least one intermediary structure is an interface plate or wherein the at least one intermediary structure is made of a different material than the cups.
[0013] Yet other embodiments contemplate a method comprising: providing a first runner-blade assembly that is fixedly connected to a first front cup and a first back cup wherein the first cups are attached to a hockey skate sole, the first cups are positionally static relative the first runner-blade assembly and the hockey skate sole; detaching the first cups from the hockey skate sole without detaching the first runner-blade assembly; attaching a second front cup and a second rear cup, that are fixedly connected to a second runner-blade assembly, to the hockey skate sole wherein the second runner-blade assembly has a different stiffness than the first runner-blade assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an illustration of a prior art ice hockey skate.
[0015] FIGS. 2A and 2B are illustrations of an ice hockey skate constructed in accordance with certain embodiments of the present invention.
[0016] FIGS. 3A-3D are illustrations of an ice hockey blade and runner and runner-blade assembly constructed in accordance with certain embodiments of the present invention.
[0017] FIGS. 4A-4F are illustrations of ice hockey cups including their construction with a ice hockey blade and runner-blade assembly constructed in accordance with certain embodiments of the present invention.
[0018] FIGS. 5A-5C are illustrations of a mounting plate and the mounting plate's relationship with the runner-blade assembly constructed in accordance with certain embodiments of the present invention.
[0019] FIG. 6 is a block diagram of a method to swap out runner-blade assemblies in accordance with certain embodiments of the present invention.
DETAILED DESCRIPTION
[0020] Before proceeding with the detailed description, it is to be appreciated that the present teaching is by way of example only, not by limitation. The concepts herein are not limited to use or application with a specific ice hockey skate system or method. Thus, although the instrumentalities described herein are for the convenience of explanation shown and described with respect to exemplary embodiments, it will be understood and appreciated that the principles herein may be applied equally in various types of ice hockey skates.
[0021] It should further be appreciated that the forgoing description is strictly intended for only ice hockey skates because the demands on the structures that comprise the inventive embodiments provide the essential rigidity absent in non-ice hockey skates, such as roller-blades, for example. Non-ice hockey skates, such as roller-blades require the kind of vibration related structures to compensate for rough asphalt and bumpy surfaces, which do not exist on a sheet of ice.
[0022] Referring to the drawings in general, and more specifically to FIG. 2A , shown therein is an illustration of a ice hockey skate arrangement 200 constructed in accordance with various embodiments of the present invention. In what follows, similar or identical structures may be identified using identical callouts.
[0023] More specifically, FIG. 2A illustratively shows the hockey skate arrangement 200 possessing a hockey skate boot 218 , which is adapted to accommodate a hockey player's foot (not shown). The hockey skate boot 218 has a toe end (front end) 106 and a heal end (back end) 104 . Fixedly attached to the ice hockey skate boot sole 216 at the toe end 106 is a front mounting plate 208 . Fixedly attached to the ice hockey skate boot sole 216 at the heal end 106 is a rear mounting plate 206 . The front mounting plate 208 removably connects a front cup 202 to the toe end 106 of the boot sole 216 and the back mounting plate 206 removably connects a back cup 204 of the heal end 104 of the boot sole 216 . The term removably attached is used herein to indicate that an object is essentially rigidly attached to another object but removable such as by bolts, screws, etc. Objects which are glued or welded together are considered not removably attached because there is no intention to separate the objects. The front cup 202 and the back cup 204 are removably connected to a runner-blade assembly 220 via a front bolt 212 and a rear bolt 214 respectively. The term cup is used herein to mean any structure or mechanism suitable for directly or indirectly attaching the runner-blade assembly 220 to the skate boot. The runner-blade assembly 220 is comprised of an ice-hockey blade 211 , preferably made from stainless steel, that is integrated with a runner 210 , preferably made from a polymeric material, such as nylon to withstand impacts of a hockey puck, hockey stick, or other hockey skate, for example.
[0024] FIG. 2B illustrates a preferred embodiment consistent with embodiments of the present invention wherein the front mounting plate 208 is recessed in the front cup 202 and the rear mounting plate 206 is recessed in the back cup 204 such that the cups 202 and 204 are essentially flush with the bottom/externally exposed part of the boot sole 216 . As shown by the illustrative embodiment, the constructed components essentially comprise the runner-blade assembly 220 , the cups 202 and 204 , the mounting plates 208 and 206 and the boot sole 216 to form, more or less, a rigid structure. That is, the constructed components when attached are immobile and static with the exception of the natural deflection properties associated with the structures that are dictated by modulus of elasticity and moment(s) of inertia. Hence, to a layman, the constructed components essentially feel like a solid rigid structure when attempted to be manipulated by a pair of hands. Certain embodiments contemplate the opening 280 can optionally be small enough to prevent a hockey puck from going through the opening 280 . Optional embodiments contemplate a shield (not shown) that can block a substantial portion, or all of, the opening 280 .
[0025] With reference to FIGS. 3A-3D , shown therein is an embodiment of the runner-blade assembly 220 consistent with embodiments of the present invention. As illustratively shown in FIG. 3A , in conjunction with FIG. 3B and FIG. 3C , the runner-blade assembly 220 is generally comprised of runner 210 that is integrated with an ice skate blade 211 . The ice skate blade 211 extends in length between a front end 308 and a back end 306 , whereby the front end 308 corresponds to approximately where the toe end 106 of the hockey skate boot 218 resides and the back end 306 corresponds to approximately where the heal end 104 of the hockey skate boot 218 resides (see FIGS. 2A and 2B ). Certain embodiments of the present invention contemplate the front end 308 of the runner-blade assembly 220 extending beyond the toe end 106 of the hockey skate boot 218 (shown in FIG. 2A ), and, optionally, the back end 306 of the runner-blade assembly 220 extending beyond the heal end 104 of the hockey skate boot 218 (shown in FIG. 2A ). With further reference to the ice skate blade 211 embodiment, shown in FIG. 3B , the ice skate blade 211 is defined by a top surface 312 and an ice surface 310 , whereby the ice surface 310 is adapted to be in contact with a sheet of ice (not shown). The runner 210 is integrated with the ice skate blade 211 such that the runner 210 essentially covers the top surface 312 of the ice skate blade 211 . As shown in the present illustrative embodiment, the front end 318 of the ice skate blade 211 extends beyond the runner 210 , however the back end 320 of the ice skate blade 211 does not extend beyond the runner 210 , hence, the runner 210 essentially covers the top surface 312 of the ice skate blade 211 . In this embodiment, essentially covers is contemplated to mean that at least 90% of the top surface 312 of the ice skate blade 211 is covered by the runner 210 . In optional embodiments, the back end 220 of the ice skate blade 211 extends beyond the runner 210 . As further shown, the ice skate blade 211 includes a front protrusion 316 that accommodates a front hole 304 and a rear protrusion 314 that accommodates a rear hole 304 . The front hole 304 and the rear hole 302 provide a suitable location for the front bolt 212 and the rear bolt 214 to respectively connect the runner-blade assembly 220 to the front cup 202 and the back cup 204 . Optional embodiments contemplate other means for removably connecting the runner-blade assembly 220 to the front cup 202 and the back cup 204 , such as pins, for example.
[0026] FIG. 3C provides an axial views of the front 308 of the runner-blade assembly 220 integrated with the runner 210 and the ice skate blade 211 and FIG. 3D provides an axial view of the front 308 of the runner-blade assembly 220 not integrated with the runner 210 and the ice skate blade 211 , consistent with certain embodiments of the present invention. As shown in FIG. 3C , the runner 210 is adapted to accommodates the ice skate blade 211 via a slot 325 . The top of the runner 210 is also illustratively shown possessing a runner-blade tongue 336 that engages a cup 202 , discussed in more detail in conjunction with FIGS. 5A and 5B . FIG. 3D illustratively shows the runner 210 extending over the top surface 312 of the ice skate blade 211 about 50% part way towards the ice surface 310 . In a preferred embodiment, the runner 210 extends between 25%-75% from the top surface 312 of the ice skate blade 211 towards the ice surface 310 of the ice skate blade 211 . Other embodiments contemplate the runner 210 extending from the top surface 312 of the ice skate blade 211 towards the ice surface 310 of the ice skate blade 211 in different percentages. Certain embodiments contemplate the runner 210 being made from a polymeric material such as nylon 6/6 to withstand being struck by a hockey puck. Yet other embodiments contemplate the runner 210 being constructed from a carbon fiber, such as a carbon mesh in a resin that is directionally positioned to provide various engineered stiffness.
[0027] In an optional embodiment, the ice skate blade 211 and the runner 210 are irremovably connected. One embodiment contemplates the runner 210 formed over the ice skate blade 211 and a polymeric runner material molded over the ice skate blade 211 and cured with contiguous polymeric material in the holes 302 and 304 , thus locking the ice skate blade 211 to the runner 210 . Other embodiments contemplate a different means for irremovably connecting the runner 210 and the ice skate blade such as rivets, pins that are expanded in the holes 302 and 304 , over-molded bolts and pins, etc.
[0028] FIGS. 4A-4E illustratively show an embodiment of cups 202 and 204 in more detail. With reference to FIGS. 4A and 4B , shown therein are perspective views of one half of the front cup 202 and one half of the back cup 204 , respectively. Both the front cup 202 and the back cup 204 show a hollowed out portion 408 and stiffening webs 406 . The hollowed out portion 408 provides weight reduction while the stiffening webs 406 increase the stiffness of the cups 202 and 204 . The front cup 202 illustratively shows a front runner-blade assembly cup space 402 that accommodates the front end 308 of the runner-blade assembly 220 . The front cup 202 further provides a front hole 304 adapted to align with the front hole 304 in the runner-blade assembly 220 to accommodate the front bolt 212 . Likewise, the back cup 204 illustratively shows a back runner-blade assembly cup space 404 that accommodates the back end 306 of the runner-blade assembly 220 . The back cup 204 further provides a back hole 302 adapted to align with the back hole 302 in the runner-blade assembly 220 to accommodate the back bolt 214 . The front runner-blade assembly cup space 402 and rear runner-blade assembly cup space 404 are recessed to accommodate the width of the runner-blade assembly 220 . The front and back cups 202 and 204 also provide top surfaces 410 and 412 and holes 414 , respectively, that can accommodate the mating surfaces of the front mounting plate 208 and the rear mounting plate 206 , which are removably attached via cup-plate bolts 413 .
[0029] FIG. 4C illustratively shows an embodiment of a cut-away assembly of one half of the front cup 202 and one half of the back cup 204 with the ice skate blade 211 in a removably attached position. The ice skate blade 211 is shown without the runner 210 to illustrate the position of the ice skate blade 211 relative to the cups 202 and 204 . The front bolt 212 and the back bolt 214 are disposed in the respective holes 304 and 302 to help illustrate the placement of the ice skate blade 211 .
[0030] FIG. 4D illustratively shows an embodiment of a cut-away assembly of one half of the front cup 202 and one half of the back cup 204 with the runner-blade assembly 220 in an attached position. The runner-blade assembly 220 is illustratively shown in a mounted position with the front bolt 212 and the back bolt 214 in the respective holes 304 and 302 .
[0031] FIG. 4E illustratively shows an embodiment of a full assembly of the front cup 202 and the back cup 204 with the runner-blade assembly 220 removably connected thereto. The runner-blade assembly 220 is in a mounted position with the front bolt 212 and the back bolt 214 disposed in the respective holes 304 and 302 . Hence, the back cup 204 is removably attached to the runner-blade assembly 220 towards the back end 306 and the front cup 202 is removably attached to the runner-blade assembly 220 towards the front end 308 . Because the front cup 202 is separate and independent from the back cup 204 , the front cup 202 can be replaced (swapped out) with a different front cup while the back cup 204 remains attached to the runner-blade assembly 220 , and vice-versa. The runner-blade assembly 220 fits, via a runner-blade tongue 336 (shown in FIG. 3 ), into an accommodating runner-blade assembly slot 430 in the cups 202 and 204 . In the present embodiment, the front cup halves 202 A and 202 B and the back cup halves 204 A and 204 B are fixedly assembled together with epoxy, however other means for fixedly attaching the halves of the cups together contemplate bolts, welds, and other means known to those skilled in the art. In an optional embodiment, the front cup 202 and back cup 204 do not have halves but are rather formed as a single cup 202 and 204 . In another optional embodiment, the front cup halves 202 A and 202 B and the back cup halves 204 A and 204 B are removably assembled together with bolts, however other means for attaching the cup halves such pins, latches or quick releases are contemplated. Certain embodiments contemplate the cups 202 and 204 being made from metal, such as a titanium alloy or an aluminum alloy to withstand the shock impact of a hockey puck or stick, for example. Other embodiments contemplate the cups 202 and 204 being made out of composite carbon such as a woven carbon mesh in a resin. Yet other embodiments envision stiff composite polymer cups 202 and 204 .
[0032] FIG. 4F illustratively shows a front view of the runner-blade assembly 220 removably attached to the front cup 202 . The runner-blade tongue 336 fits into the accommodating runner-blade assembly slot 430 , as shown. Certain embodiments contemplate the runner-blade assembly slot 430 comprising an angle that tapers from the opening of the slot 432 to the back of the slot 434 in order to improve the seating of the runner-blade assembly 220 , or more specifically the runner-blade tongue 336 , in the slot to a “snug fit”. Certain embodiments further contemplate the runner-blade tongue 336 possessing a similar angle to the angle of the tapered runner-blade assembly slot 430 in order to optimally mate. In a preferred embodiment, the tapered runner-blade assembly slot 430 is between 1 degree and 8 degrees whereby the opening of the slot 432 is wider than the back of the slot 434 . Other embodiments contemplate a taper as much as 25 degrees or more. Optional embodiments contemplate a compliant surface, such as a rubber coating, on the surface of slot 432 and/or the runner-blade tongue 336 to improve friction between the slot 432 and the runner-blade tongue 336 when assembled together with the bolts 212 and 214 .
[0033] FIGS. 5A and 5B illustratively show a mounting plate consistent with certain embodiments of the present invention. In certain embodiments, the front mounting plate 208 and the rear mounting plate 206 are essentially identical, herein generically designated as element 500 . Other embodiments contemplate the front and rear mounting plates 208 and 206 as having different shapes, but fundamentally both function to attach the cups 202 and 204 to the boot sole 216 . With continued reference to the mounting plate 500 , shown therein are three bolts 413 that are used to removably attach the cup 202 or 204 to the mounting plate 500 . Other means for removably attaching the cups 202 and 204 to the mounting plates 500 include quick releases, mating structures that removably interlock, just to name a few examples. Certain embodiments contemplate the mounting plates 500 integrated in (built in) the boot sole 216 . For example, the mounting plates 500 are formed in the rigid boot sole 216 such that the mounting plate top 502 is essentially flush with the top portion of the boot sole 216 that is in contact with a hockey player's foot or a sole insert (not shown) that is used as a cushion between the hard top portion and the hockey player's foot. Certain embodiments contemplate the mounting plate thickness 506 to be essentially the thickness of the boot sole 216 . In one embodiment, the boot sole 216 is constructed out of a hard plastic that is molded around by the boot sole 216 to fixedly retain the mounting plate 500 in the boot sole 216 exposing only the mounting plate top 502 and the mounting plate bottom 504 , wherein the mounting plate bottom 504 provides a surface that is adapted to be in contact with the top 410 or 412 of a cup 202 or 204 , respectively. Another optional embodiment contemplates the boot sole 216 being constructed from carbon fiber that is molded around to fixedly retain the mounting plate 500 exposing only the mounting plate top 502 and the mounting plate bottom 504 . In yet another optional embodiment, the mounting plate top 502 is slightly buried under the inside surface of the boot sole 216 , such that slotted shapes are machined out from the inside surface of the boot sole 216 to expose the slotted openings 510 . One embodiment contemplates the mounting plate 500 being textured to be better secured to the boot sole 216 when molded therein. The mounting plates 500 can be made of metal, such as aluminum, steel, titanium, etc., or can be a composite carbon material or polymer, for example, or ceramic. Yet other embodiments contemplate the mounting plates 500 constructed from a laminate of different materials sandwiched together that run parallel to the surface that mates with the ice hockey skate boot sole 216 .
[0034] In an optional embodiment, shown in FIGS. 5 B 1 and 5 B 2 , the mounting plate 500 provides slotted openings 510 that accommodate the bolts 413 and allow for offset adjustment of the cups 202 and 204 and runner-blade assembly 220 . More specifically, as illustratively shown in FIG. 5 B 1 , the bolts 413 fixedly screw into accommodating holes 414 in the back cup 204 essentially retaining the cup 204 in an offset position to the far left to create an offset of the runner-blade assembly 220 . The back cup 204 is used herein to simplify the explanation; however the same optional adjustments can be done with the front cup 202 . FIG. 5 B 2 shows the inverse of FIG. 5 B 1 whereby the bolts 413 are positioned in the far right of the slots 510 , thus creating an offset with the runner-blade assembly 220 in the other direction. Optionally, the bolts 413 are positioned in the slots 510 of the front mounting plate 500 to the far left and the bolts 413 are positioned in the slots 510 of the rear mounting plate 500 to the far left, thus positioning the runner-blade assembly 220 offset to one side of the boot sole 216 , but without an angular offset. Optionally, the bolts 413 are positioned in the center of the slots 510 in the front and back mounting plates 500 for a neutral positioning of the runner-blade assembly 220 . Optionally, the bolts 413 are positioned in the slots 510 such that the positioning of the runner-blade assembly 220 offset has an angular offset (e.g., the bolts 413 are to the left side of the slots 510 in the rear mounting plate 500 and to the right side of the slots 510 in the front mounting plate 500 ). Other embodiments contemplate the tops 410 and 412 of the cups 202 and 204 , respectively, and/or the mounting plates 500 providing detents to position the offset in a standard manner, for example −3 (corresponding to the far left), −2, −1, 0 (corresponding to neutral), +1, +2, +3 (corresponding to the far right). In this way, a hockey player that knows their personal setting is a +1 (a little in offset to the right), for example, can simply move the mounting plate to +1 and tighten the bolts 413 .
[0035] Certain embodiments contemplate the front mounting plate 208 and the back mounting plate 206 being joined together to form a one piece unit 520 , as illustratively shown in FIG. 5C . A one piece unit 520 can improve the stiffness of the boot sole 216 and the manufacturability of integrating the mounting plates within or on the sole. Another embodiment contemplates a boot sole and the mounting plates being one and the same unit. For example, the one sole unit being a size-9, yet another being a size-12 unit that is integrated (sown in, glued in) the boot 218 .
[0036] The slots 510 can accommodate a method for customizing the position of the runner-blade assembly 220 relative to the boot sole 216 . One embodiment contemplates loosening the bolts 413 , such as with an allen-key if it is an allen-head bolt, in the rear mounting plate 206 and in the front mounting plate 208 . This is accomplished by accessing the inside surface of the boot sole 216 by reaching inside the hockey skate boot 218 ; sliding the front cup 202 to a non-neutral position, such that the bolts 413 slide to one side of the slots 510 in the front mounting plate 208 ; sliding the back cup 204 to a non-neutral position, such that the bolts 413 slide to one side of the slots 510 in the rear mounting plate 206 , wherein the neutral position is when the bolts 413 are in the center of the slots 510 ; tightening the bolts 413 to essentially lock the cups 202 and 204 to the mounting plates 206 and 208 in an immobile arrangement to secure the offset positioning. The offset positioning can be optimized for a specific hockey skater.
[0037] Certain embodiments contemplate a compliant gasket between the bottom surface 504 of the mounting plates 208 and 206 and the mating surface 410 and 412 of the cups 202 and 204 , respectively, such as a rubber gasket, a low elastic modulus metal gasket, a fabric gasket, etc. Such a surface adds friction to reduce the chance of any movement between the cups 202 and 204 and the mounting plates 208 and 206 . Yet other embodiments contemplate a compliant overcoat on the surfaces of the mounting plates 206 and 208 that mate with (are in contact with) the ice hockey skate boot sole 216 , such as a thin rubber or polymer paint, for example. Yet other embodiments contemplate an interlocking structure on the bottom surface 504 of the mounting plates 208 and 206 and the mating surface 410 and 412 of the cups 202 and 204 , respectively. Such interlocking structures can be grooves, waffle shapes, pins and accommodating holes, etc.
[0038] FIG. 6 illustrates an embodiment of a method for exchanging (swapping out) a first runner-blade assembly that has a first stiffness with a second runner-blade assembly with a second stiffness that is different from the first stiffness. FIG. 6 is described in conjunction with FIGS. 2B and 4F . It should be recognized that the steps presented in the described embodiments of the present invention do not necessarily require any particular sequence unless otherwise stated. When the runner-blade assembly 220 needs to be replaced with a different runner-blade assembly because of damage, wear to the blade surface 310 , or to change the stiffness of the runner-blade assembly the following steps are carried out. With reference to step 602 , the front bolt 212 is loosened and removed from the front cup 202 and the rear bolt 214 is loosened and removed from the back cup 204 . As illustratively shown in step 604 , once the bolts 212 and 214 are removed, the first runner-blade assembly 220 is pulled-out from the corresponding runner-blade assembly slots 430 in the bottom of the cups 202 and 204 . A second runner-blade assembly is then inserted, via the second runner-blade assembly tongues 336 , in the corresponding runner-blade assembly slots 430 in the bottom of the cups 202 and 204 , step 606 . Once the holes 302 and 304 are aligned, the front bolt 212 is inserted and tightened in place and the rear bolt 214 is inserted and tightened in place. Certain embodiments contemplate a mating structure in the tongue 336 and corresponding runner-blade assembly slot 430 to align the holes 304 between the cups 202 and 204 and the runner-blade assembly 220 , such as a key and key-hole, or another tongue and groove system that extends from the opening of the slot 432 to the back of the slot 434 . A stiffer runner-blade assembly may be used for a heavier, more aggressive, or less tired hockey player, for example.
[0039] It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with the details of the structure and function of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, the shape of the runner 210 and ice skate blade 211 may differ from the depicted embodiments to alter certain directional stiffness, for example, while still maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Another example can include alternate assemblies to construct the cups 202 and 204 , such as a molded or machined cup without a top 410 or 412 whereby the top 410 or 412 are attached later to form the complete cup 202 and 204 , or optionally no top exists, just receiving holes 414 for the bolts 413 , to name a few examples while still maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Further, for purposes of illustration, a first and second runner-blade assembly is used herein to simplify the description for a plurality of optional runner-blade assemblies. Additionally, as touched upon in conjunction with FIGS. 2A and 2B , multiple styles of hockey skate boots, such as a goalie's boot or a defense player's boot, can operatively be employed while maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Another example can include alternate runner-blade assemblies that are shorter, longer, higher, etc., with the ability to interchangeably couple to the cups 102 and 104 to name a few examples while still maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Finally, although the preferred embodiments described herein are directed to standard ice hockey skate and related technology, it will be appreciated by those skilled in the art that the teachings of the present invention can be applied to alternate types of ice hockey skates, without departing from the spirit and scope of the present invention.
[0040] It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes may be made which readily suggest themselves to those skilled in the art and which are encompassed in the spirit of the invention disclosed and as ultimately defined in the claims. | A customizable hockey skate includes a removable runner-blade assembly such that a runner-blade assembly having a first stiffness may be readily replaced with a runner-blade assembly having a second stiffness. The runner-blade assembly may be removably attached to first and second cups that are optionally removably attached to the sole of a skate boot. The first and second cups optionally are removably attachable at multiple lateral locations on the sole. Mounting plates to which the first and second cups are mounted may be included to provide damping interfaces between the first and second cups and the boot sole. The first and second cups may be separately removable from the sole such that the first cup may be replaced with a third cup (for example, a cup having a different stiffness than the first cup) without removal of the second cup. | 0 |
BACKGROUND OF THE INVENTION:
[0001] 1. Field of the Invention
[0002] This invention relates to drill strings employed in well drilling, and more particularity to a method and apparatus for drilling straight wells by preventing unwanted spiraling progressions and slotting effects generally associated with drilling through relatively irregular formations, specifically through extra hard earthen formations.
[0003] 2. Background of the Invention
[0004] Drill string collars generally used in drilling operations consist of long columns of thick walled tubes directly above the drill bit. These collars add additional weight to the drill string pipe to push the rotating drill bit through earthen formations. These drill string collars are generally connected to the thousands of feet of drill string pipe connected thereabove. A rotary drilling rig turns the drill string pipe, which turns the drill collars, which turn the drill bits used in creating a well.
[0005] It is well known in the drilling industry that when a drill bit comes into contact with an extra hard earthen formation, especially those formations positioned at an acute angle, the drill bits tend to drift, thus making an elongated hole or slot through the extra hard earthen formation. This drift is caused by the drill bit's attempt to take the path of least resistance as it creates a borehole. Since the drill string pipe which spins to drive the drill bit is not as large in diameter as the drill bit, the slot tends to be larger down-slope than at the first contacted up-slope area of the formation. Thus, when the bit contacts an extra hard earthen formation at an acute angel and drifts, an elongated hole or slot is created which has a much smaller diameter on the up-slope of the formation. This elongated hole or slot causes problems when attempting to withdraw the bit or when running other tools into the well. This dilemma is known in the industry as “key slotting” or “key holing.” Once the drill bit has completely penetrated this extra hard formation, the drill bit tends to follow a course consistent with the exiting course of the drill bit as it exits the formation.
[0006] In any angled or deviated borehole, there exists a force generated by the pendulum effect of the lower end of the drill string. The earth's own gravitational force exerts a downward pull upon the drill string whereby the drill string reacts to this pull by trying to swing through the lower side of the hole toward a true vertical orientation. The use of heavy drill collars did not have enough force generated by the pendulum effect to overcome the physical and structural forces of the earth's strata which causes the drill bit to deviate. In other words, the force tending to deviate the drill bit is greater than the counter-force tending to return the drill bit to vertical.
[0007] Another problem encountered while drilling through extra hard earthen formations is based upon the application of applying weight to a rotating drill string having torque applied thereto. The application of weight forces the drill bit against the formation as it is rotated by the long drive shaft action of the drill string pipe. The drill string pipe is rotatably driven to provide the rotary drilling action of the drill bit. The rotation of the drill string itself, coupled with the biting effect of the rotary drill bit as it contacts a formation as well as the applied weight and torque to the drill bit, tends to bow the drill string pipe and causes the drill bit to take a spiral-like path often referred to as the “corkscrew effect.” This corkscrewing of the drill pipe may be quite pronounced in some cases having a spiral several feet in diameter and up to three complete spirals per 100 feet of well depth. Obviously, such spiraling uses more pipe footage and requires more time to drill than would be required with drilling straighter bored wells.
[0008] Various types of stabilizers and friction-reducing technologies have been employed to reduce this corkscrew effect, eliminate vibrations and the key slotting problem. Some drilling operators use an adjustable, rotatable sleeve surrounding the main body of the tool which allows the joint to be adjusted to compensate for out of balance conditions. Other stabilizing tools have blades which may be mechanically or hydraulically positioned outwardly relative to the tool body to provide counter balance to the rotating string. In any case, the prior methods' objects are the same, to reduce the amount of wobble, imbalance or vibration in the drill string in an attempt to straighten the drill paths through earthen formations.
[0009] A wholly opposite approach has also been applied in the present invention to solve both the key slotting and corkscrewing complications described above. In the 1960's, Cyril Hinds, the inventor of the present invention, modified standard 30 foot to 40 foot long tubulars by boring into one half of the outside surface of the tubular's walls. Essentially, bores were made along one side of the tubulars which created cavities within one half of the surface area of the drill collar. In operation, these tubulars were thought to create an unbalanced condition in the drill string which would compensate for the natural tendency of the drill bit to walk or drift away from the intended drill path. However, these modified tubulars tended to fracture due to the moment created as a result of the unbalanced rotation of the drill string coupled with the weakened tubular wall due to the borings. Thus, the modified tubulars would break off within the well and had to be fished out of the wells creating severe delays and additional expenses.
[0010] U.S. Pat. No. 3,391,749 issued to Arnold shows a drill collar which is eccentrically weighted with respect to its longitudinal axis of rotation to prevent deviation from its vertical path by drilling blind holes along a side of the collar. These drill collars tended to break under the stress generated by the high torque pendulum effect.
[0011] U.S. Pat. No. 4,068,730 issued to Arnold shows an improved drill collar which is eccentrically weighted to its longitudinal axis of rotation to prevent deviation from its vertical path by drilling blind holes along the side of the collar that vary in size in a cyclical pattern along the length of the collar. These drill collars sought to overcome the weakened conditions associated with U.S. Pat. No. 3,391,749.
[0012] U.S. Pat. No. 4,190,122 issued to Arnold shows numerous drill collars which are eccentrically weighted to their respective longitudinal axis of rotation to prevent deviation from its vertical path by drilling blind holes along the side of each collar to prevent the drill collar string's rubbing contact with the sides of the borehole.
[0013] U.S. Pat. Nos. 3,391,749; 4,068,730; and 4,190,122 have a common design flaw in common. The blind holes, grooves, slots, etc. disposed on the outer surface of the drill collar as disclosed in each of these patents tend to fill-up with drilling fluids, mud and debris during drilling operations. The material filling-up the various cavities formed on the surface of the drill collar will reduce and/or eliminate the eccentric weight these patents seek to achieve. Therefore, these devices must be continually washed and unclogged to keep their desired eccentric weight to be effective.
[0014] U.S. Pat. No. 4,776,436 issued to Nenkov et al. shows a drill collar with an internal 360 degree cavity formed withing the walls of the drill collar filled with articles to dampen and/or absorb shock. Nenkov et al. shows a uniform dispersion of the articles filling the 360 degree cavity with absolutely no off-balance.
[0015] U.S. Pat. No. 4 , 522 , 271 issued to Bodine et al. shows a similar drill collar with a 360 degree cavity filled with balls, pellets and mud to dampen sonic waves and absorb shock. Bodine et al. also shows a uniform dispersion of the articles filling the 360 degree cavity with absolutely no off-balance.
[0016] U.S. patent application Ser. No. 08/999,620, filed by Dewey E. Owens on Mar. 24, 1997, ABANDONED, disclosed a drill collar including a 180 degree cavity within the cross sectional area of the drill collar's walls including a magnetic strip therein and a plurality of steel balls contained within the cavity to provide a counter balancing effect of the drill string pipe while driving a bore hole, whereby the magnetic strip attracts the steel balls to stabilize the drill string and reduce wobble created by any imbalance created by the 180 degree cavity. This invention described in U.S. patent application Ser. No. 08/999,620 was additionally offered for sale on Apr. 16, 1998. The purpose of the invention described in U.S. patent application Ser. No. 08/999,620 was to eliminate the wobble and/or oscillations experienced by drill collars by a counter balancing effect.
[0017] The objects, features and advantages of the present invention will become apparent from the drawings and descriptions given herein, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a diagram of a typical drilling rig demonstrating problems associated with key holing and corkscrewing;
[0019] [0019]FIG. 2 is a side exploded view of the drill sub assembly;
[0020] [0020]FIG. 3 is an alternate side prospective exploded view of the drill sub assembly;
[0021] [0021]FIG. 4 is a cross section view of the drill sub assembly taken along sight line “30” seen in FIG. 2;
[0022] [0022]FIG. 5 is a vertical section showing a bit surmounted the sub assembly of the present invention at work in a well, the deviation of which form the vertical has been exagerated to make it more clearly apparent.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The complications described above are detailed in FIG. 1. As shown in FIG. 1, a typical drilling rig 50 attempting to drill a substantially vertical well 51 . When the drill bit contacts a extra hard earthen formation 52 at an acute angel 53 , the bit tends to drift across the surface of the extra hard earthen formation 52 creating an elongated hole 54 often described as the “key slotting” or “key holing” effect. Additionally, as additional weight is applied to the rotating drill string having torque applied thereto to penetrate the extra hard earthen formation 52 , the drill bit tends to have a biting effect when it contacts such extra hard earthen formations 52 . The rotation of the drill string pipe itself, coupled with the applied weight and torque, tends to bow the drill string pipe and causes the drill bit to take a spiral-like path 55 often referred to as the “corkscrew effect.” This spiral-like path 55 of the drill bit results in wasted drill string pipe, time, and extensive costs. The complications such as elongated holes 54 in earthen formations, or key slotting effect, coupled with a spiral-like path 55 , or corkscrewing, are overcome by the present invention. As shown in FIG. 1, the intended path 56 of the well has been substantially deviated from due to both key slotting and the corkscrewing effect of the drill bit.
[0024] [0024]FIG. 2 is a side view of an exploded drill sub assembly 1 of the present invention for a drill for drilling a well, such as an oil well, comprising a top adapter 2 of cylindrical shape, had having an internal thread for interconnecting the sub assembly 1 and a drill collar string (not shown in the drawing). Subs are well known in the art as tubular members that are usually less than the average length of a standard 30 to 40 foot drill string members. The sub assembly 1 also comprises a bottom adapter 3 of cylindrical shape, having an external thread for interconnecting the sub assembly 1 and a drill bit (not shown in the drawing). A drill string pipe (not shown in the drawing) is rotatably driven to provide the rotary drilling action for the drill bit (not shown in the drawings). Interposed between the drill collar string (not shown in the drawing) and the drill bit (not shown in the drawing) is the sub assembly 1 of the present invention. The sub assembly 1 includes a heavy wall body 5 portion having a cavity 6 therein. As seen in FIG. 4, the sub assembly 1 being a typical sub tool joint similar to a heavy wall drill collar which has a internally threaded box end top adapter 2 and an external thread pin end bottom adapter 3 . The cavity 6 is separated from the internal core 10 by a wall 7 . The internal core 10 is in fluid communication with the drill bit and through which drilling fluids are pumped fro working up the cuttings and for cooling the drills. The cavity 6 extends approximately the length of the sub assembly 1 between the top adaptor 2 and bottom adaptor 3 , formed by exposing a portion of the heavy wall main body 5 , leaving only a wall partition 7 surrounding the core 10 . A partial encasement 8 having a radius consistent with that of the main body 5 is welded in place as shown in FIG. 4, thereby forming an outer wall for the cavity 6 . The cavity 6 thus formed within the heavy wall of the tubular member 5 occupies approximately 180 degrees of the tubular member's wall section.
[0025] The 180 degree cavity 6 creates an eccentrically weighted sub assembly which magnifies the pendulum effect to such an extent that the forces tending to cause the drill bit to return to its vertical position are greater than those of the formation tending to cause it to deviate. Thus the eccentrically weighted sub assembly is provided with a heavy side and a light side (the side containing the 180 degree cavity therein). When the drill string rotates about its center during drilling, centrifugal forces are generated. As the drilling sub's heavy side revolves around the center line of the drilling string, the gravitational pendulum effect and the resultant centrifugal force of the heavy side of the collar tend to coincide and are additive. As a result, the drilling sub tends to push the drilling bit with increased force toward the low side of the hole. This action occurs once during each revolution of the drill string and the cumulative affect is to cause the well-bore to return to its original intended vertical position.
[0026] It will of course be understood that the cavity 6 may be of any shape, and could be filled with a material heavier than the materials of the sub assembly, such as lead, instead of being left hollow, and the sub assembly may be used with any conventional bits.
[0027] In operation, the drill sub assembly 1 is threadably located between the drill collar string and the drill bit. Computer simulations and preliminary testing demonstrate that the drill sub assembly's 1 unbalanced rotation drastically reduces spiraling or corkscrewing by as much as 92% and eliminates key slotting 54 . These simulations and preliminary tests indicate that when the drill sub assembly is attached to a drill bit, the drill bit tends to process about the intended drill path 56 while continually oscillating across the intended drill path 56 instead of forming a spiraling revolution around the intended drill path 56 . The cavity 6 within the sub assembly 1 creates an unbalanced condition in the drilling string which tends to compensate for the natural tendancy of the drill bit to walk around the intended drill path 56 . The sub assembly 1 further provides additional friction in the formation, absorbs shock and vibrations while creating a straight hole due to the sub assembly's imbalance.
[0028] In accordance with the present invention, any deviation from the drill bit's intended vertical path is inhibited by imposition on the drill bit a weight which is eccentrically positioned with respect to the axis about which the drill bit is designed to turn. As the top of the drill string is constrained against any horizontal displacement at the rig floor, the effect of the centrifugal force resulting from the eccentrically weighted sub when the string is rotated with the drill string vertical is to urge the drill bit to swing in a circular path, instead of rotating about a fixed point, so that the sides of the bit on which the eccentric weight is positioned is urged against the side of the borehole. This affects all sides of the borehole equally, so long as the borehole is vertical, since the heavy side of the eccentrically weighted sub assembly spends an equal portion of the cycle directed toward each side of the borehole.
[0029] However, if and when the drill bit deviates from its intended vertical path so as to be positioned at an angle to the vertical, the weight of the drill bit and sub assembly tend to cause them to gravitate toward the low side of the hole exerting thereagainst a force dependent on the angle between the borehole and the vertical. This is true regardless of whether the sub assembly is eccentrically weighted or not as is a well known phenomenon. Now, when an eccentrically weighted sub assembly of the present invention is utilized, each time the heavy side of the sub assembly is rotated away from the low side of the borehole, the created centrifugal force urges the drill bit and sub assembly towards the heavy side of the eccentrically weighted sub assembly, away from the low side of the borehole, thus subtracting from the force exerted by the weight of the bit. Oppositely, when the heavy side of the eccentrically weighted sub assembly approaches the low side of the borehole, the centrifugal force resulting from the eccentric weight is added to that resulting from the weight of the bit. The result is an intermittent pounding force which acts preferentially against the low side of the hole only, since the weight of the eccentrically weighted sub assembly and drill bit always adds to the pressure against the low side of the borehole but is subtracted from that against the high side of the borehole. It is believed that this pounding tends to abrade away the low side of, and thus straighten, the borehole.
[0030] A threaded aperture 12 is provided in the cavity's 6 encasement 8 for allowing insertion or removal of an optional steel ball 20 approximately 1 to 2 inches in diameter and plugged with a bung plug 13 , the plug having a square socket therein. The internal core 10 is in fluid communication with the drill bit and through which drilling fluids are pumped fro working up the cuttings and for cooling the drills. The drilling fluids are often very abrasive and tend to degrade the wall partition 7 between the internal core 10 and the cavity 6 . When the wall partition 7 has been compromised, drilling fluid will fill the cavity and will diminish the off-balanced object of the present invention. Thus, an optional steel ball 20 may be inserted into the cavity 6 via the threaded aperture 12 to alarm rig operators when the wall partition 7 has been compromised. The rig operators must periodically pull the drilling tools out of the well for routine maintenance and cleaning. The operators can easily determine if the wall partition 7 has been compromised by moving the utility sub 1 of the present invention and listening for the steel ball 20 to rattle around. If the wall partition 7 has been compromised and the cavity 6 contains any drilling fluids, the steel ball 20 will be restricted in its movement within the cavity 6 .
[0031] Now referring to FIG. 5, it will be seen that a conventional drill bit 20 , e.g., a three-cone rock bit, is mounted at the bottom of a string of pipe. Immediately above the bit 20 is the sub assembly 1 of the present invention. The outer surface of the sub assembly 1 is preferably, but not necessarily, concentric with or symmetrical with respect to its longitudinal axis. One side of the sub assembly 1 is, however, heavier than the other so that as the drill string rotates the sub assembly 1 will tend to revolve or gyrate about the longitudinal axis of the string. It is, however, neither necessary nor desirable for the sub assembly 1 itself to swing far enough out of line to brush against the wall of the well.
[0032] As the sub assembly 1 revolves about its longitudinal axis the bit 20 swings from its solid line position 35 against the low side of the hole to its dotted line position 40 toward the high side once every rotation. (This distance has likewise been exaggerated in the figure so that it may be clearly seen.) As hereinbefore pointed out, every time the heavy side of the collar approaches the low side of the hole, a force representing a component of the total weight of the sub assembly 1 and bit is added to the centrifugal force due to the extra weight on the heavy side of the sub assembly 1 to produce an abrasive pounding of the low side of the hole, but the effect of this component of the total weight is subtracted from that of centrifugal force as the heavy side of the sub assembly 1 approaches its dotted line position 40 , so that there is much less force exerted against the high side of the hole.
[0033] To further reduce the complications associated with key slotting and the corkscrew effect, the drilling rig operator should recognize when the drill bit strikes an extra hard earthen formation. After the drill bit strikes an extra hard earthen formation, the operator should lift the drill bit away from the surface of the earthen formation and increase the rotations-per-minute (rpm) of the bit. Once the rpms have increased, the operator then lowers the drill bit against the extra hard earthen formation until the oscillating bit cuts away the uphill slope of the formation. This process is repeated until the drill bit has formed a shoulder on the surface of the extra hardened formation. This shoulder will ensure the drill will continue along its original course and reduce the possibility of key slotting or the corkscrew effect. The drilling rig operators repeated raising and lowering of the drill bit is often referred to as yo-yo'ing the drill bit. This technique quickly creates an intended path for the drill bit through the extra hard earthen formation.
[0034] The foregoing disclosure and description of the invention is illustrative and explanatory thereof, and it will be appreciated by those skilled in the art, that various changes in the size, shape and materials as well as in the details of the illustrated construction or combinations of features of the various coring elements may be made without departing from the spirit of the invention. | A well borehole is prevented from deviating from its intended vertical path as it is being drilled by use of a sub assembly which is eccentrically weighted with respect to its axis of rotation. Such a sub assembly can comprise a straight tubular member weight relieved along one side by, for example, forming a cavity within the heavy walls of the tubular member along the side of the collar. Thus, the eccentric weight is imposed upon the drill bit without providing any protrusions or elbows which are designed to bear on the wall of the borehole. Additionally, as the cavity is contained within the heavy walls of the tubular member, drilling fluids containing various debris cannot inhabit the cavity, thus maintaining a constant eccentric weight upon the drill bit. | 4 |
BACKGROUND
[0001] Cables, particularly fiber optic cables, are used ubiquitously in the downhole drilling and completions industry. These cables are used for enabling a variety of downhole conditions and parameters, such as temperature, vibration, sound, pressure, strain, etc. to be monitored. Due chiefly to their pervasive use, there is an ever-present desire in the industry for alternate styles of sensing cables, particularly for enhancing the ability to more accurately sense a specific parameter such as strain.
SUMMARY
[0002] A sensing cable, including an outer cladding; and at least one sensing bundle contained within the cladding, each sensing bundle having a sensing fiber wrapped strain-transmissively by at least one strand.
[0003] A method of sensing strain including deploying a cable having at least one at least one sensing bundle contained within a cladding, each sensing bundle having a sensing fiber wrapped strain-transmissively by at least one strand; and transmitting strain to the fiber via the at least one strand.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0005] FIG. 1 is a prospective view of a strain-sensing cable according to an embodiment disclosed herein with a cladding partially stripped off,
[0006] FIG. 2 is a cross-sectional view of the cable of FIG. 1 ; and
[0007] FIG. 3 is a prospective view of a strain-sensing cable according to another embodiment disclosed herein.
DETAILED DESCRIPTION
[0008] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0009] Referring now to FIG. 1 , a cable assembly 10 is illustrated. The assembly 10 includes at least one braid or bundle 12 for improving a strain-sensing capability of the cable 10 . Specifically, each of the bundles 12 includes a fiber 14 that is wrapped with or surrounded by a plurality of strands 16 . The fibers 14 are arranged for sensing one or more downhole conditions or parameters such as temperature, pressure, strain, acoustics, etc. In one embodiment, the fibers 14 are optical fibers. In a further embodiment, the fibers 14 , in the form of optical fibers, include fiber Bragg gratings for enabling the aforementioned sensing capabilities.
[0010] The strands 16 are included to facilitate the transfer of strain directly to the fibers 14 so that the cable 10 can be used, e.g., to measure strain in a tubular string or downhole component. To this end, the strands 16 are wrapped, wound, or secured, e.g., helically, spirally, circumferentially, etc., about each of the fibers 14 . The number of the strands 16 and the number of turns of the strands 16 per unit length of the fibers 14 may vary in different embodiments. In one embodiment, the strands 16 are stainless steel, although it is to be appreciated that other materials can alternatively be used that exhibit good strain transfer capabilities (e.g., resiliency, ductility, etc.) and resistance to downhole conditions (e.g., maintain good strain transmission to the fibers 14 in high temperature or high pressure environments, etc.).
[0011] Similar to the strands 16 being wrapped or wound about the fibers 14 in each of the bundles 12 , the bundles 12 in the embodiment of FIG. 1 are wrapped or wound, e.g., helically, spirally, circumferentially, etc., about a core or central wire 18 . The gauge, material, properties, etc. of the central wire 18 can be selected for setting the properties of the cable 10 , such as ductility, flexibility, conformability, radial compression strength, tensile strength, etc. In the illustrated embodiment, the bundles 12 are interspaced about the central wire 18 with a plurality of tubes 20 . It should of course be appreciated that the tubes 20 could be optional in some embodiments and that any number of the tubes 20 and the bundles 12 could be included in any desired arrangement or pattern (e.g., a sequence that is alternating/non-alternating, repeating/non-repeating, randomized, etc.). An internal passageway through ach of the tubes 20 enables, e.g., one or more sensing fibers 22 (e.g., resembling the fibers 14 but without the strands 16 ) to be located within the tubes 20 for sensing a variety of non-strain related properties (e.g., temperature, pressure, acoustics, etc.). In one embodiment, the tubes 20 and the sensing fibers forming assemblies according to known fiber in metal tube (FIMT) techniques by sealing one or more fibers resembling the fibers 22 within the tubes 20 . According to known FIMT techniques, the tubes 20 may be filled with a gel or fluid to aid in the operation of the tubes 20 and/or the cable 10 . It is additionally noted that the tubes 20 also play a role in setting the properties and performance of the cable 10 , for example, by increasing the compressive strength of the cable 10 in order to avoid the cable 10 collapsing in high pressure downhole applications. It is to be appreciated that ones of the tubes 20 could be replaced with solid wires resembling the central wire 18 , that the central wire 18 could be hollow and resemble one of the tubes 20 , or other modifications could be made to the cable 10 .
[0012] The cable 10 includes a cladding or sheath 24 to further protect and set the properties of the cable 10 as well as to maintain the assembled arrangement of the components (e.g., to maintain the strands 16 , bundles 12 , and tubes 20 being wrapped around their corresponding components). Additionally, a cavity 26 formed by the empty space within the cladding 24 located between the bundles 12 , the central wire 18 , and/or the tubes 20 , can be filled with a polymer or other filler material, e.g., for achieving the aforementioned objectives of the cladding 24 . In one embodiment the filler material in the cavity 26 is a plastic elastomer, such as that marketed under the trade name Hytrel® and made commercially available from E. I. du Pont de Nemours and Company (DuPont).
[0013] An alternate embodiment is illustrated in FIG. 3 , namely, a cable 10 ′. The components of the cable 10 ′ generally resemble those in the cable 10 and have thus been numbered in accordance with the above-discussed embodiment where appropriate. While the bundles 12 are spirally wrapped in the cable 10 , a plurality of bundles 12 ′ in the cable 10 ′ extends axially within the cladding 24 in a non-spiraling manner (but otherwise resemble the bundles 12 ). A plurality of tubes 20 ′ are also shown extending axially in a non-spiraling manner, but otherwise resemble the tubes 20 discussed above. For example, the bundles 12 ′ and/or the tubes 20 ′ in the cable 10 ′ may extend straight along the central member 18 , in parallel with the central member 18 , concentrically with the cladding 24 in lieu of the central member 18 , etc. It is noted that a cross-section of the cable 10 ′ would generally resemble the illustration of FIG. 2 . The cable 10 ′ may have particular benefits, for example, in a shape-sensing application in which strain measurements by the fibers 14 are utilized in calculating or determining the shape of a component about or with which the cable 10 is installed.
[0014] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. | A sensing cable, including an outer cladding; and at least one sensing bundle contained within the cladding, each sensing bundle having a sensing fiber wrapped strain-transmissively by at least one strand. A method of sensing strain is also included. | 3 |
FIELD OF THE INVENTION
This invention relates to AC voltage regulators and is more particularly directed to highly efficient regulators having a continuously variable and precise voltage control.
The regulator that is the subject of this application first was first designed to save electric power and reduce electric utility bills. Power supplied by utility companies is usually provided at a nominal voltage, plus or minus five percent on a long term average. Short term deviations may be as great as plus or minus ten percent of the nominal voltage.
Most electrical equipment is designed to operate over a range of ten percent over the nominal voltage to twelve to fifteen percent under the nominal voltage. The additional tolerance for low voltage is required to accommodate voltage drops that occur in building wiring between the utility entrance and the equipment.
If the electrical power supplied by the utility company is closely regulated to a constant voltage at the utility entrance or at major distribution points within the user's facility, the voltage can be controlled at the minus ten percent level to reduce the power consumed. A voltage level of minus seven or eight percent could be used to provide some safety margin if needed. This adjustment may be made by the individual user to suit the specific need.
Many additional benefits are realized by operating electrical equipment at seven to ten percent below its nominally rated voltage. Virtually everything runs cooler and lasts longer.
To obtain the maximum benefit in energy savings, the regulating equipment itself must be highly efficient. Given the present efficiency of commercial transformers and semiconductor switches, an efficiency rate greater than 99% can be achieved with the present invention, making it a cost effective method of reducing utility bills.
In addition to the above described use, the present invention may also be used to condition the input power to computer systems or other critical equipment by reducing transverse mode noise as well as providing accurately regulated voltage. Additionally, with appropriate control connections, the input and output terminals of the regulator may be interchanged. Thus the configuration of the regulator may be modified to produce an output voltage higher than its input voltage.
Prior methods of regulating AC voltage are not suitable for the energy conservation application discussed above. Ferroresonant and other saturated magnetics types of regulators are too inefficient. Electro-mechanical tap switching regulators and variable transformer regulators respond too slowly. Phase controlled SCR regulators introduce too much distortion for general use. Electronic tap switching regulators respond quickly but their regulation is not very accurate (plus or minus five percent to plus or minus seven percent).
There is a need for an accurate, efficient AC voltage regulator with low distortion. The present invention meets these requirements.
SUMMARY OF THE INVENTION
The preferred embodiment of the subject invention described herein includes an autotransformer 14 electrically connected to a load and to two switches 16 and 17. Each switch has positions 1 and 2, as symbolically shown in FIG. 2. With the switches in position 1, an input voltage across input leads 12 and 13 will yield an output reduced in voltage across output leads 18 and 20. For example, with the switches in position 1, an input of 126 volts across input leads 12 and 13 would yield an output of 110 volts across output leads 18 and 20. With the switches in position 2, an input of 110 volts yields an output of 110 volts. For any input voltage between 126 volts and 110 volts, the output is maintained at 110 volts by varying the length of time the switches are in each position. The switches alternate between positions 1 at 2 at a high frequency, such as 20 Khz. The operation of the switches is regulated by a control circuit 22 that compares the output of the voltage regulator to the desired voltage and produces a pulse width modulated (PWM) control signal to alternate the position of the switches.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of the AC switching voltage regulator that is the preferred embodiment of the present invention.
FIG. 2 is a symbolic schematic diagram of the preferred embodiment.
FIG. 3 is a schematic diagram of a voltage regulator comprised of the voltage regulator of FIG. 2 with the addition of an input transformer to pre-increase the input voltage.
FIG. 4 is a symbolic schematic diagram of the preferred embodiment, with the input and output terminals interchanged to provide a voltage step up regulator.
FIG. 5 is a schematic diagram of a voltage regulator comprised of the voltage regulator of FIG. 4 with the addition of an input transformer to pre-reduce the input voltage.
FIG. 6 is a timing diagram showing the time relation of some of the important signals.
FIG. 7 is a block diagram of the voltage regulator.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2, the voltage regulator that is the subject of this invention is shown in symbolic form. The input voltage is applied to the regulator via input leads 12 and 13. The path of current through the autotransformer 14 is determined by the position of two switches, indicated as numerals 16 and 17. When the switches are in position 1 as shown in FIG. 2, the output voltage across leads 18 and 20 will be less than the input voltage by a percentage that depends on the turns ratio of the autotransformer 14.
The voltage regulator can be adjusted in a manner that will be described later, to produce any desired output voltage within a given range. By way of example, again referring to FIG. 2, we will assume that 110 volts has been selected as the desired output voltage and that the transformer ratio is such that when the switches 16 and 17 are in position 1, the output will be 110 volts for an input of 126 volts. With the switches 16 and 17 in position 2, an input voltage of 110 volts produces an output voltage of 110 volts. For an input voltage between 126 volts and 110 volts, switches 16 and 17 will alternate between position 1 and position 2 as is necessary to provide an output of 110 volts.
To produce the desired output voltage in the regulators shown in FIGS. 2-5, control circuit 22 regulates the length of time the switches 16 and 17 are in each position. The switches of the preferred embodiment operate at a high frequency, typically 20 khz.
DESCRIPTION OF THE CONTROL CIRCUIT
The autotransformer 14, switches 16 and 17, and the control circuit 22 of FIG. 2 are components of the regulator as shown in the electrical schematic of FIG. 1.
The regulator has an input lead 12 and neutral input lead 13. The voltage applied across leads 12 and 13 is filtered by capacitor C1. The two switches 16 and 17, each comprising a bridge rectifier and two parallel connected field effect transistors (FETs), are operated to change the primary connection of the transformer 14. The control circuit is designed so that the switches 16 and 17 may only be energized alternately. In the preferred embodiment these switches are turned on and off at 20 Khz, with the switches remaining in the OFF state and the ON state for the length of time necessary to produce the desired output voltage. With an input voltage of 110 volts and a desired output of 110 volts, switch 16 of FIG. 2 will be activated constantly. The switches would be in position 2 as shown in the schematic of FIG. 2. With an input voltage of 126 volts and a desired output of 110 volts, switch 17 will be activated constantly. In the schematic shown in FIG. 2 the switches would be in position 1. For the purposes of discussion, we will assume here that the desired output is 110 volts and that the regulator is as shown in FIG. 2, unless otherwise specified. The output voltage can be varied, as will be described later.
For an input voltage of 118 volts and a desired output voltage of 110 volts, each switch will remain in the OFF state approximately one-half of the time and in the ON state approximately one-half of the time. The capacitor C2 connected between output leads 18 and 20 in conjunction with the leakage inductance between the two sections of the transformer winding (shown symbolically as L in FIG. 2) smooth the output voltage to produce an average voltage of 110 volts as a undistorted sine wave.
The output lead 18 is also concurrently connected to a voltage follower circuit 50, comprising resistors R1, R2, R3, R4, capacitor C3 and amplifier A1. The output lead 18 is connected to resistor R1. Resistors R2 and R3 are connected in parallel between a 12 volt power supply and the second side of resistor R1. Resistor R4 and capacitor C3 are connected in parallel between the second side of resistor R1 and ground. Resistors R1, R2, R3 and R4 form a voltage divider that reduces the 110 volt output across leads 18 and 20 to a 2.4 volt AC signal with a 6 volt DC bias which is supplied to the noninverting input of amplifier A1.
The inverting input of amplifier A1 is fed by the amplifier A1 output. The output voltage of amplifier A1 is equal to the voltage applied to its noninverting input, but at a lower impedance. The output of amplifier A1 (at point A) supplies a 2.4 AC signal with a 6 volt DC bias to a biased absolute value circuit which produces an output equal to the sum of the DC bias and the absolute value of the instantaneous value of the AC signal.
The absolute value circuit 52 comprises amplifiers A2 and A3 and the associated resistors, diodes and capacitor, as discussed below.
The output of comparator A1 is supplied both to the inverting input of comparator A3 via resistor R5 and to the noninverting input of comparator A2. The inverting input of comparator A2 is fed through resistor R7 by the output of comparator A3 via forward biased diode D4. Diode D1 is connected between the output and inverting input of comparator A2 to clamp comparator A2 to avoid saturation when the signal at point A is negative. When the signal at point A is positive, the output of comparator A2 is positive and is connected to the output of the absolute value circuit 52.
A similar group of components, diodes D3 and D4, and resistor R6, controls the voltage output of comparator A3. Gating diode D3 is connected between the output and inverting input of comparator A3 to limit the error introduced to comparator A3. Forward biasing diode D4 connects the positive output of comparator A3, occurring when the signal at point A is negative, to the output of the absolute value circuit 52. Resistor R6 is connected between the inverting input of comparator A3 and the output of the circuit 52. Resistor R26 and capacitor C14 are serially connected between point A, the input to the absolute value circuit, and ground. The noninverting input of comparator A3 is connected to the juncture between resistor R26 and capacitor C14.
By way of example, we will assume the DC bias at the output of buffer amplifier A1 is 6 volts and that the instantaneous value of the AC signal is +2 volts. The voltage at the input to the absolute value circuit is 6+2=8 volts. The voltage at the noninverting input to amplifier A3 will equal the 6 volt bias. Under these conditions diodes D2 and D3 will conduct, diodes D1 and D4 will not conduct and amplifier A2 will drive the output to 8 volts. Assume now that the instantaneous value of the AC wave is -2 volts. The voltage at the input to the absolute value circuit is 6-2=4 volts. The voltage at the noninverting input to amplifier A3 will equal the 6 volt bias. Under these conditions diodes D1 and D4 will conduct, diodes D2 and D3 will not conduct and amplifier A3 will drive the output to 8 volts.
The absolute value circuit 52 rectifies the sign wave input without producing the voltage drop usually experienced across diodes. The output of the absolute value circuit 52 is fed to the error amplifier 54, consisting of amplifier A4, resistors R8, R9, R10 and R11, and capacitors C4 and C5.
The output of the absolute value circuit 52 is supplied through resistor R8 to the inverting input of amplifier A4. Capacitor C4 and resistor R9 are connected in series in the feedback loop between the output and inverting input of amplifier A4. These two components provide stability in the operation of the overall high gain closed loop regulator system. The noninverting input of amplifier A4 is supplied a DC reference voltage by potentiometer R33. Potentiometer R33 is connected in series between resistors R30 and R31, with the entire assembly being connected between a 12 volt power supply and ground. The setting of potentiometer R33 determines the output voltage of the regulator established across output leads 18 and 20. Although in the preferred embodiment this voltage is assumed to be set for 110 volts, the desired output voltage may be varied over a wide range by varying the potentiometer setting.
The output of amplifier A4 is connected through a resistor R10 to a connection between a grounded capacitor C5 and a resistor R11. The negative feedback loop of capacitor C4 and resistor R9 combined with resistor R10 and capacitor C5 low pass filter the output of amplifier A4 to a steady DC voltage with a slight ripple. The output of amplifier A4 varies inversely as the difference between the regulator output voltage between leads 18 and 20, and the desired output voltage, as determined by the setting of potentiometer R33. As the regulator's output voltage increases, amplifier A4's output decreases.
The other side of resistor R11 is connected to the noninverting input of comparator A7. Capacitor C6 is in the feedback loop between the output and noninverting input of comparator A7. The inverting input of comparator A7 is supplied by a triangle wave generator 26.
The triangle wave generator 26 includes two comparators A5 and A6, the output of each being connected to an input of a NOR gate, G1 or G2, respectively. The NOR gates, G1 and G2, are interconnected forming a type R-S flip-flop. A voltage divider, consisting of resistors R12, R13, and R14 is connected between a 12 volt power supply and ground to provide a constant DC reference voltage of 9 volts to the inverting input of comparator A5 and a reference voltage of 3 volts to the noninverting input of comparator A6. The noninverting input of comparator A5 and the inverting input of comparator A6 are connected concurrently to receive the triangle wave generated on grounded capacitor C7.
The inverting input to comparator A5 and the noninverting input to comparator A6 are held constant by grounded capacitors C10 and C9, respectively. The outputs of comparators A5 and A6 appear on respective leads 42 and 44 which are each connected to the 12 volt power supply via pull up resistors R18 and R19, respectively, to provide sufficient drive for NOR gates G1 and G2.
When the triangle wave voltage on capacitor C7 exceeds the 9 volts established at the inverting input of comparator A5, the output of comparator A5 goes high. The output of gate G1 then goes low and capacitor C7 begins discharging via resistor R15 connected from the output of gate G1 to capacitor C7. When the voltage across capacitor C7 discharges to 3 volts, the output of comparator A6 goes high, causing the flip flop to return to its original state and again charge capacitor C7 via resistor R15, completing a cycle of the triangle wave.
The output of gate G2 is connected serially through resistor R16 and capacitor C8 to the inverting input of comparator A7. Resistor R17 connects the triangle wave generated at capacitor C7 to the inverting input of comparator A7, the pulse width modulator.
Comparator A7, the pulse width modulator, compares the output of the error amplifier 54 to the triangle wave generated on capacitor C7. The output of the pulse width modulator is a square wave. Its duty cycle is determined by the output of the error amplifier 54. If the regulator output voltage is too low, a wider duty cycle will be generated. If the regulator output voltage is too high, a narrower duty cycle will be generated. This signal controls, via starting circuit 60, pulse generators P1 and P2, buffers A8 and A9, and driver transformer 28, the conduction of main power switches 16 and 17. When the output of the pulse width modulator is high, switch 17 will be turned on. When its output is low, switch 16 will be turned on.
Resistors R16 and R17 and capacitor C8 put a spike at each peak and valley of the triangle wave to insure that the output of comparator A7 changes states twice each cycle of the triangle wave generator even if the error amplifier is saturated. This is necessary to recharge the gate input capacitance of the capacitors of the transistors Q1 through Q4 every 50 microseconds, as will be discussed later, so that these transistors do not drift into a semiconducting state. The preferred embodiment of the present invention utilizes components that produce a triangle wave form with an oscillating frequency of 20 Khz.
The output of comparator A7 is a square wave having a varied duty cycle depending on the feed back error voltage at its noninverting input. When the output voltage of the triangle generator 26 is less than the output voltage of the error amplifier 24, the output of comparator A7 is high. The square wave output alternates between approximately 0 volts and approximately 12 volts. The output of comparator A7 is connected through pull up resistor R20 to a 12 volt power supply and is supplied to a starting circuit 60.
Starting circuit or starter 60 comprising comparator A8, transistor Q5, relay K1, NOR gates G3 and G4, flip flop F1, transformer T2, diodes D5, D6, D7, D8, D9, D10, Z5, and resistors R36, R37, R38, R39, R41, R42, R43, R44, R45, R46, monitors the 12 volt power supply and provides appropriate control signals for switches 16 and 17. When the power supply voltage is too low, K1 will be off, turning switch 16 on and switch 17 off. When the supply voltage is normal K1 will be on and the pulse width modulator will control the switches.
When the output of the 12 volt power supply is less than 10 volts, the output of comparator A8 will be a logical high. When the output of the 12 volt power supply is greater than 11 volts, the output of comparator A8 will be a logical low.
When the output of comparator A8 is a logical low, the power supply voltage is adequate for proper operation and relay K1 is energized by transistor Q5. The series connection of diode D5 and resistor R44 connected in parallel with the coil terminals of relay K1 provide a means for safely dissipating the stored energy in the coil of relay K1 when transistor Q5 turns off there by protecting transistor Q5.
Three sets of contacts of relay K1 are used in the present invention. The normally closed contact of the first set of contacts is connected to the gate terminal of transistors Q1 and Q2 via resistors R21 and R22, respectively. The armature contact of the first set of Q1 and Q2 via diode D10. Additionally the armature contact of the first set of contacts is connected to the positive terminal of the bridge rectifier BR3 comprising diodes D6, D7, D8 and D9 via current limiting resistor R46. The negative terminal of the bridge rectifier BR3 is connected to the source terminal of transistors Q1 and Q2. The AC terminals of the bridge rectifier BR3 are connected to and driven by the secondary coil of transformer T2. The primary coil of transformer T2 is connected between the input terminal 40 of transformer 14 and circuit common lead 13. These connections provide a means to turn transistors Q1 and Q2 on when the 12 volt power supply is low and K1 is de-energized.
The armature contact of the second set of contacts of relay K1 is connected to the gate terminal of transistors Q3 and Q4 via resistors R23 and R24, respectively. The normally closed contact of the second set of contacts of relay K1 is connected to the source terminal of transistors Q3 and Q4. These connections provide a means of inhibiting transistors Q3 and Q4 from conducting when the 12 volt power supply is low and K1 is de-energized.
The armature contact of the third set of contacts of relay K1 is grounded. The normally open contact of the third set of contacts is connected to the first input terminal of NOR gate G3. The first input terminal of NOR gate G3 is additionally connected to the 12 volt power supply via pull up resistor R45. The second input terminal of NOR gate G3 and additionally the J input terminal of flip flop F1 are connected to and driven by the output terminal of comparator A8. The K input terminal of flip flop F1 is connected to and driven by the output terminal of NOR gate G3. The R and S input terminals of flip flop F1 are grounded. The clock input terminal of flip flop F1 and additionally the first input terminal of NOR gate G4 are connected to and driven by the pulse width modulator signal at the output terminal of comparator A7. The Q output terminal of flip flop F1 is connected to and drives the second input terminal of NOR gate G4. The output of NOR gate G4 is connected to and drives monostable pulse generators P1 and P2. These connections provide a means for orderly transition of control of switches 16 and 17 between that provided by the first two sets of contacts of relay K1 and that provided by the pulse width modulator. Relay K1 controls the drive to switches 16 and 17 during system start up and periods of low power supply voltage. The pulse width modulator controls the drive to switches 16 and 17 during normal operation.
The period of pulse generators P1 and P2 is set to 2 microseconds by C12, R34 and C11, R35, respectively.
The outputs of pulse generators P1 and P2 are each connected through respective inverters A8 and A9 to opposite sides of primary winding 30 of the pulse transformer 28. Upon either of pulse generators P1 or P2 being activated, that pulse generator produces a 2 microsecond positive voltage pulse. At all other times the outputs of the pulse generators P1 and P2 are at ground potential. When both outputs of the pulse generators P1 and P2 are at zero, the outputs of both inverters A8 and A9 are at 12 volts, creating a zero potential differential across the primary winding 30. At this time, no current flows through the pulse transformer 28. When one of the pulse generators, for example P2, emits a positive voltage 2 microsecond pulse, the output of the associated inverter, here A9, goes low to induce a negative voltage pulse across the primary winding 30.
The pulse transformer 28 has two secondary windings 32 and 34. Each of the two secondary windings 32 and 34 are connected to similar circuits to control the energization of switches 16 and 17, respectively. A positive voltage pulse at the start terminal of secondary winding 32 charges the input capacitance of transistors Q1 and Q2 turning the transistors on. Zener diode Z2 limits the gate voltage. The transistors remain on until a negative voltage pulse at the start terminal of secondary winding 32 of sufficient amplitude to cause zener diode Z1 to conduct discharges the input capacitance of the transistors turning the transistors off.
Secondary winding 34 drives transistors Q3 and Q4 in a similar manner except that the winding polarity is reversed with respect to secondary winding 32. Thus a primary pulse of either polarity will always turn one switch on and the other off.
The start terminal of secondary winding 32 is connected through zener diode Z1 and transistors R21 and R22 to the respective gates of field effect transistors Q1 and Q2. Zener diode Z2 is connected from the cathode of zener diode Z1 to the source terminals of transistors Q1 and Q2. The finish terminal of secondary winding 32 is connected to the source terminals of transistors Q1 and Q2. The source terminals of transistors Q1 and Q2 are also connected to the negative terminal of bridge rectifier BR1 while the drain terminals of transistors Q1 and Q2 are connected to the positive terminal of bridge rectifier BR1. One AC terminal of rectifier BR1 is connected to lead 40 of transformer 14. The other AC terminal is connected to lead 38 which is connected via inductor 40 to transformer 14.
Secondary coil 34 of transformer 28 is connected to switch 17 in a manner very similar to the connection of secondary coil 32 to switch 16, except with opposite polarity. The finish terminal of secondary coil 34 is connected through zener diode Z3 and resistors R23 and R24 to the respective gate terminals of field effect transistors Q3 and Q4. Zener diode Z4 is connected from the cathode of zener diode Z3 to the source terminals of transistors Q3 and Q4, and to the start terminal of secondary winding 34. The source terminals of transistors Q3 and Q4 are connected to the negative terminal of bridge rectifier BR2 while the drain terminals of transistors Q3 and Q4 are connected to the positive terminal of bridge rectifier BR2.
The polarities of the secondary windings 32 and 34 are such that a given pulse through the primary winding 30 will turn on only one set of switches, either transistors Q1 and Q2 or transistors Q3 and Q4. When transistors Q1 and Q2 are on the output voltage across leads 18 and 20 equals the input voltage across leads 12 and 13. When transistors Q3 and Q4 are on, transformer action in transformer 14 causes the output voltage to be less than the input voltage. The energization of transistors Q1 and Q2 is the equivalent of the switch 16 being in position 2 as shown in FIG. 2, while the energization of transistors Q3 and Q4 produces the effect of switch 17 in position 1 as shown in FIG. 2.
FIG. 6 shows the time relation of some of the important signals of the regulator. Trace 1 is the error signal at A7-5 superimposed on the triangle wave with spikes at A7-4. Trace 2 is the pulse width modulator's output at A7-2. It is high when the error signal is more positive than the triangle wave. Traces 3 and 4 are the outputs of pulse generators P1 and P2, P1 produces a pulse when the pulse width modulator output rises. P2 produces a pulse when the pulse width modulator output falls. Traces 5 and 6 are the drive signals for the main power switches. A high signal turns a switch on and a low signal turns it off. A pulse at P1 charges the gates of Q1 and Q2 turning them on and discharges the gate of Q3 and Q4 turning them off. A pulse at P2 charges the gates of Q3 and Q4 turning them on and discharges the gate of Q1 and Q2 turning them off.
Time interval t1 represents a time of nominal input voltage. The duty cycle is approximately 50%. During t2 the AC voltage rises causing the error signal to fall. This results in more duty cycle for Q3 and Q4 and less for Q1 and Q2. The error amplifier is saturated during t3, but the spikes on the triangle wave cause the PWM to continue to operate, and keep the FET gates charged. The AC voltage falls during interval t4. The AC voltage is low during t5, resulting more duty cycle for Q1 and Q2 and less for Q3 and Q4.
The components used in the preferred embodiment of the invention described herein are indicated in the following list. It will be understood by those skilled in the art that the specific design herein described is limited to output power levels of less than 2kVA. It will also be understood by those skilled in the art that the maximum output power level may be increased to any practical level through the use of appropriate semiconductor switches and drive means.
______________________________________R1, R2 430 kohmR3, R4, R5, R6 20 kohmR7 10 kohmR8 100 kohmR9, R10, R11, R12 10 kohmR13 20 kohmR14, R15, R16 10 kohmR17 7.5 kohmR18, R19 10 kohmR20 2 kohmR21, R22, R23, R24 100 ohmR26 100 kohmR30 5.1 kohmR31 15 kohmR33 10 kohmR34, R35 15 kohmR36 750 ohmR37 30 kohmR38 43 kohmR39 10 kohmR41 180 kohmR42, R43 10 kohmR44 100 ohmR45 10 kohmR46 1 kohmR47 10 kohmC1, C2 7 uFC3, C4 50 nFC5 470 nFC6 68 pfC7 2.2 nFC8 33 pfC9, C1O 10 nFC11, C12 100 pFC14 1.0 uFQ1, Q2, Q3, Q4 IRF730Q5 2N2907BR1, BR2 PB40D1, D2, D3, D4 1N914D5, D6, D7, D8, D9 1N4005Z1, Z2, Z3, Z4 IN5240Z5 1N821A1, A2, A3, A4 LM324A5, A6, A7, A8 LM339G1, G2, G3, G4 CD4001P1, P2 CD4098A8, A9 CD40106______________________________________
The voltage regulator described above is capable of producing a controlled output voltage that is always equal to or less than the input voltage. By modifying the regulator as shown in FIG. 4, the output voltage will always be greater than or equal to the input voltage. Further modification as shown in FIGS. 3 or 5 allows the output voltage to vary both above and below the input voltage.
To regulate an input voltage that varies both above and below the desired output voltage, the voltage regulator of FIG. 2 is combined with step-up transformer 24 of FIG. 3. The step-up transformer 24 increases the input voltage to an intermediate level that is always above or equal to the desired output voltage. The voltage regulator of FIG. 2 then reduces the intermediate voltage to the desired output voltage in the manner described above.
The voltage regulator shown in FIG. 4 is identical to the regulator of FIG. 2 with the exception that the input and output terminals have been interchanged. The control system is connected to the output as in the regulator of FIG. 2. It operates in a manner similar to the voltage regulator of FIG. 2 except that the FIG. 4 regulator produces an output voltage that is higher than or equal to its input voltage.
The voltage regulator of FIG. 5 is similar to the voltage regulator of FIG. 3. The step-up transformer of FIG. 3 is replaced with a step-down transformer 48. The step-down voltage regulator unit is replaced with the step-up voltage regulator unit of FIG. 4. Like the voltage regulator of FIG. 3, this regulator is also intended for applications having an input voltage that varies both above and below the desired output voltage. Whether the configuration of FIG. 3 is preferred over that of FIG. 5, or vice versa, depends on the relationship between desired output voltage to the input voltage range. Either configuration may be adapted to cover any desired range, but the factors above will determine which configuration is more economical.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the broader aspects of the invention. Also, it is intended that broad claims not specifying details of a particular embodiment disclosed herein as the best mode contemplated for carrying out the invention should not be limited to such details. Furthermore, while generally specific claimed details of the invention constitute important specific aspects of the invention, in appropriate instances even the specific claims involved should be construed in light of the doctrine of equivalents. | A switching AC voltage regulator including a transformer, two solid state AC switches, and sensing means controlling the switches to produce the desired output voltage. The two switches conduct alternately and are switched at a rate much higher than the frequency of the regulated AC voltage. When the first switch is activated, the transformer is shorted out, causing the output of the transformer to equal the input. When the second switch is activated, normal transformer action occurs, creating an output voltage either higher or lower than the input, depending on the transformer arrangement. The duty cycle of the switches is varied to provide precise control of the output voltage. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of plastic foams. More specifically, it relates to a process and apparatus for introducing a gas into at least one of the reaction components so as to obtain a foam with a uniformly sized and distributed cell structure.
2. Description of the Prior Art
When producing molded parts of polyurethane foam, the charge of gas in the initial components has a significant effect on the foam structure and quality of the molded part. Dissolved gases and trapped gas bubbles change the viscosity and density of the component mixture. Gas charging not only affects mixing quality and machine adjustment, it also significantly alters foam structure and foam density distribution. It serves as a nucleating aid.
Even visual examination of the foam parts permits conclusions to be drawn relative to gas charging. With low gas charging, a dark molded part with a few large cells is obtained. As gas charging increases, the foam becomes lighter and the number of cells per unit volume increases, their radius becomes smaller. A qualitatively good foam must contain at least a given amount of gas. This is true both for flexible foams and for rigid and integral-skin foams.
In order to achieve this end, it has already been proposed that gas be introduced directly into the mixing chamber of a mixing head. Here, however, the component mixture leaves the mixing chamber in an uneven or atomized manner, which has a disadvantageous effect on even and accurate pouring. Moreover, adding gas to the supply tank in order to mix it with the corresponding component has also proven to be extremely unreliable. When the gas is introduced into the component in the supply tank by means of an agitator, the gas again separates very quickly from the component, so that introducing the gas is largely ineffective.
In addition, DE-OS No. 25 44 559 also describes charging one or both components with gas before actual reaction mixing takes place. To do this, the stream of reaction component which is to be charged with gas is constricted and, by maintaining the respective component flow rate, a vacuum is produced in the axis of said constriction. The gas is added in the area of this vacuum and thereby mixed into the component. However, the size of the gas bubbles which can be achieved in the components using this method is not generally sufficient to prevent a large degree of bubble coalescence from taking place or to assure that the gas content will be highly dispersed in the components, in particular when such components must be kept on hand in tanks for a relatively long time.
Thus, the objective of the invention was to develop a process and device with which gas used in preparing a reaction mixture of at least two reaction components could be dispersed in one of the components in a simple manner in the most uniform and finely divided possible manner.
SUMMARY OF THE INVENTION
This invention is a process for the preparation of a reaction mixture from at least two reaction components for the production of plastic foams in which the liquid components are delivered separately from individual feed tanks under pressure to a mixing zone and are mixed for reaction, at least one of the components is charged with a chemically inert gas in a recycle circuit having a compression zone wherein the pressure is maintained higher than that of the feed tank, said gas being admixed with the reaction component at the point of initiation of the compression zone and said higher pressure being relieved immediately following downstream of the compression zone prior to return to the feed tank. Auxiliary equipment to measure gas content, regulate input and reduce concentration of gas in the component are present in the recycle circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing showing a recycle line added to the normal feed line-return line connecting a supply tank and a mixing zone.
FIG. 2 is a schematic drawing showing a by-pass line from the feed line to the return line of a prior art system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the invention gas can be mixed into one reaction component with comparative ease and in a very effective manner provided that said component is recirculated from the supply tank by means of a delivery unit in a separate recycle circuit or if the component flows through a bypass between the component feed and component return. The gas is preferably introduced in the suction area of the circulation pump. Gas can also be supplied on the discharge side of the circulation pump or directly into the pump, but this requires a comparatively higher gas pressure and is, therefore, only used when the performance of the pump would be adversely affected by higher gas content in the component. In particular, air, nitrogen, and, in some cases, carbon dioxide are used as the gas.
The two-phase gas-reaction component mixture present after the gas has been introduced is brought to a higher level of pressure in a compression zone located directly downstream from the circulating pump. The pressure in this compression zone can vary across a wide range and it is increased relative to the 1 to 5 bar pressure in the supply tank, preferably by from 0.5 to 200 bar, more preferably by from 3 to 20 bar. When this takes place, the gas is at least partially dissolved in the component. The compression zone is generally sized such that the residence time of the gas-reaction component mixture is approximately 1.5 to 200 sec., preferably from 1 to 20 sec. The residence time of the gas-reaction component mixture depends on the solubility of the gas in the component, in other words on the type of gas selected as well as on the composition of the component and the component temperature, and it can be easily determined by simple preliminary tests.
Downstream from the compression zone the gas-reaction component mixture is again released with the aid of a throttle element to the pressure of the supply tank and is returned to the supply tank. Suitable throttle elements are, for example, precision control valves as well as adjustable components such as nozzles, diaphragms, etc. The action of the throttle element causes the gas to be at least partially liberated once again and the result is gas bubbles which are small and uniformly distributed in the component. Intensive mixing of the component in the supply tank is not necessary to maintain or re-establish the dispersed condition. In addition, further measures to finely disperse the gas in the component are not necessary, even during charging into the mixing zone.
The device of the invention for performing this process is characterized by the fact that the gas feed line merges into a recycle line provided with a delivery pump or into a bypass between the feed and return line and by the fact that a throttle element is provided at a distance from the point where the gas feed line merges. The delivery pump and the throttle element, moreover, produce an increase in pressure between these locations. This pressure is necessary to dissolve and disperse the gas which has been metered in. In a further characteristic of the invention, an analyzer is provided in the recycle line or in the bypass ahead of the metering pump to determine the gas content in the component, so that the gas charged into the component can be analyzed in a rapid and reproducible manner. Among those measurement methods which can be used here are processes which utilize the following physical phenomenon: the partial pressure, the absorption of a beam of light, the density as well as the compressibility and solubility of a gas. These measuring methods are known and are described in Kunststoffe 67 (1977), 284- 287.
In a particular embodiment, the analyzer is coupled to a control device so that the charging of gas into the component no longer needs to be controlled manually, but rather can be performed automatically. The control unit can be used both to control the addition of gas and to control the pressure of the component in the recycle line or in the by-pass.
The following section gives a closer description of the device of the invention with reference made to the drawings.
FIGS. 1 and 2 provide a schematic representation of a high-pressure mixing device with a supply tank (1) for one component and a mixing head (2). The supply tank and mixing head are connected to one another through a feed line (4) containing a metering pump and a return line (5). An agitator (6) is indicated in the supply tank. A gas feed line (7) is provided to maintain a given tank pressure. To keep the drawing simple, the supply tank and piping system for the other component are not shown.
A recycle line (8) routed in a separate circuit is connected to the supply tank (1). This recycle line returns to the supply tank at (9) (FIG. 1). A delivery pump (10) and a throttle element (11) are provided in the recycle line. Section (12) of the recycle line between the delivery pump and the throttle element is designed to be a compression zone.
The component charged with gas is recirculated prior to being mixed with the other component by means of the delivery pump (3). Here the supply of gas through the gas feed line (13) runs directly into the suction area and/or pressure area of the delivery pump, or, if necessary, also directly into the delivery pump. The pressure required for effective adsorption of the gas in the compression zone (12) is adjusted by means of the delivery pump and the throttle element (11). This pressure is measured by means of a sensor (14). The observed value can be indicated directly and can be used for adjusting the throttle element by hand. It is also possible to use this observed value for automatically controlling the throttle element by means of an adjusting device.
Continuous conditioning of the components in the supply tank (1) to a specified gas content independent of the operating condition of the remaining mixing device is possible through use of the component circuit which is independent of the metering pump (3). In particular, in production plants with high outputs and short pause times, in which mixing with the other component does not take place, additional advantages are achieved, for example, by eliminating the interruptions in the charging of gas to one or both components which would otherwise be necessary.
In order to determine the gas content in the component, a corresponding analyzer (15) is located in the recycle line (8) ahead of the delivery pump (10). The analyzer is connected to a regulating device (16) which acts on a valve (17) in the gas feed line (13). Depending on the deviation of the observed value from a specified value, the gas feed or also the output of the delivery pump (10) can be changed.
In order to increase the accuracy of gas charging measurements, a throttle valve (18) is provided ahead of the analyzer (15). This valve can be used to lower the component pressure to a value lower than the tank pressure. In this way, the portion of gas dissolved in the component can be partially or completely determined in addition to the portion of gas dispersed in the component.
Finally, the recycle line contains a degassing device for removing excess amounts of gas in the component. It is controlled by a three-way valve (20). When this valve is open, the gas-reaction component mixture flows through the degassing device, whereby a portion of the gas is released, and then the mixture flows through piping section (21) back into the delivery pump (10) suction area.
As FIG. 2 shows, the charging of gas to one or both components can also take place in a bypass (22) between the feed line (4) and the return line (5). Such a design may be used when the delivery output of the metering pump (3) is not affected by the component flow in the bypass.
ln special cases, for example with very high gas charging of the reaction components in the supply tank (1), it is advantageous to tap off part of the flow of the gas-reaction component mixture ahead of the throttle element (11) and direct this partial flow to the metering pump (3).
For the production of foams it is possible, according to the invention, to adjust by simple means the gas content in the starting components of each foam system. The component throughput, the pressure level in the circuits, and also the amount of gas added can be controlled relative to amount and time, so that gas contents up to 35 vol. percent can be achieved in the components. In order to achieve a high degree of production reliability and greater variability, all the relevant observed values for a process sequence can also be fed into a computer, processed there, and the set signals can be further transmitted to the various control elements. The computer can also be used to determine the equilibrium values between the gas and the respective liquid component relative to pressure, temperature and component composition in order to convert the observed gas content to standard conditions. | When producing molded foam parts from liquid reaction components, the charge of gas in the initial components has a significant effect on the foam structure and quality of the molded part. This invention provides a process and apparatus for introducing a gas into at least one of the liquid reaction components prior to mixing said components for reaction. The component which is to be charged with gas is circulated from a feed tank through a recycle circuit to a compression zone which is maintained at a higher pressure than that of the feed tank. Said gas is admixed with said component at the point of initiation of the compression zone and the higher pressure is relieved through a throttle element prior to returning the gas-charged component to the feed tank. A finely divided stable gas dispersion which can be mixed with other components for reaction is obtained. | 8 |
SPECIFICATION
Field of the Invention
This is a continuation application of United Kingdom application 9913567.5 filed in the U.K., Jun. 11, 1999, now pending. Priority is claimed to PCT application No. GB 99/04097 filed Dec. 10, 1999.
This invention relates generally to handling of waste materials especially particulate solids. A method of transferring such materials from one location to another, and an apparatus suitable for performing the method, is described hereinafter. The invention finds particular utility in the oil and gas industry for disposal of well or drill cuttings (“hereinafter cuttings”) discharged from the solids control system on a well drilling site.
BACKGROUND OF THE INVENTION
Cuttings are typically pieces of rock, which have been chipped, ground or scraped out of a formation by a drill bit. Various types of drill cutting tools_are in use for this purpose and the invention hereinafter described is not limited to use of any particular type.
The drilling operation is conducted several hundred meters below the operation control point, which means that performance of the drill bit is critical to the operation. The effectiveness of the drill bit during a drilling operation relies upon the continual removal of cuttings; otherwise the drill would rapidly foul up due to accumulation of cuttings. Therefore, the cuttings are normally removed by delivery of a drilling fluid (often referred to as “drilling mud”) down to and around the drill bit in a recirculated manner by use of the drill string and annulus casing well established in the industry.
Accordingly the cuttings are commonly separated from the drilling fluid by devices such as a shale shaker, which captures cuttings and large solids from the drilling fluid during the circulation thereof. Basically, such a device has a sloping, close mesh, screen over which fluid returning from the hole being drilled passes. The screen may be typically of from 200×200 down to 30×30 mesh and is vibrated to facilitate separation of the majority of fluids from the solids. The solids captured on the screen travel down the sloping surface to be collected in the shaker ditch or cuttings trough. It is also desirable to recover as much of the expensive drilling fluids as possible. Therefore, other devices, which play a role in the separation of solids from drilling fluids, include cyclone separators, and centrifuges. The cuttings discharged from the shakers, cyclone's and centrifuges that are collected in the shaker ditch or cuttings trough are still highly contaminated with the drilling fluids and therefore form a slurry or heavy sludge. The slurry or sludge is very difficult to move or otherwise transfer in any conventional manner.
In some cases the cuttings slurry may be discharged directly into a cuttings box where space permits or vacuum collected, which under current practice means that the cuttings are sucked from the cuttings ditch or trough, by an applied vacuum, directly into a cuttings box for transport to an approved disposal site for re-claimation suggested in GB-A-2 286 615. However, in some cases in order to facilitate removal of the cuttings, a collection hopper may be used which allows a particular ground clearance typically of about 4 meters whereby the cuttings are discharged from the hopper by free-fall into open cuttings containers.
It is also proposed there to include another trough for intermediate collection of cuttings. A screw conveyor for lateral displacement of cuttings from beneath the intermediate trough is described. The screw conveyor pushes the cuttings, which fall into it from the trough towards a discharge trap door that opens under the weight of the cuttings to periodically allow the cuttings to fall into the holding tank.
The intermediate trough described remains under the influence of the suction pump to continue delivery of recovered fluid to a recycle system, whilst the screw conveyor below the trough shifts cuttings towards the trap door.
In a more recent operational system a vacuum cuttings hopper is provided including, a helical screw therein on a vertically arranged shaft driven by an overhead motor assists the delivery of the solids to the free-fall outlet for collection below the hopper, The cuttings are further subjected to compression by the helical screw prior to discharge thus extracting and recovering a substantial amount of the remaining fluids in the slurry. The extracted fluid is then withdrawn through a perforated casing around the screw under the action of a pump.
The problems associated with cuttings handling for disposal are familiar to all workers on a drilling installation and include the need for the presence of several storage containers to handle the volumes of cuttings produced and the time demands upon the installation's crane devoted to the shifting of a filled container to substitute an empty container close to the shaker station. This container “shuttling” routine is not only absorbing useful operational time for the crane but also presents additional physical hazards to workers involved in other tasks in close proximity to the cuttings containers. Furthermore, the cuttings recovery equipment and the containers themselves are usually accessed by workers scaling ladders, or scaffolding or the like staging up to heights often approaching 5 or 6 meters or thereabouts in order to open container lids or service the cuttings handling equipment. Of necessity the containers themselves must be sited close to the cuttings shaker station and be accessible by the crane. These factors have an impact on use of deck space, personnel mobility, and other task completion operations around the deck.
Further the filling and relocation of cuttings containers is dictated by the volume of cuttings being produced by the drilling operation in any given period of time. Therefore, it is essential that the cuttings handling apparatus and its methods of operation be capable of handling the volumes required to maintain production.
An object of the present invention is to provide improvements in cuttings handling for disposal and recovery of reusable drilling fluids and muds from the drill cuttings slurry thereby reducing cost of disposal and recycling. A
object fulfilled by aspects of the invention to be described hereinafter is to provide a drill cuttings recovery system of more compact or efficient design.
A still further object is to provide a more flexible disposal method allowing the operator greater degree of freedom in the options for handling the cuttings prior to disposal.
Generally the invention seeks to provide a system and method for handling of cuttings, which offers an improved alternative to current handling systems.
The invention, according to a first aspect, provides a method for handling cuttings that includes providing a system utilizing a screw pump to remove the cuttings from the cuttings trough and disperse them through a piping system to various disposal points.
The invention according to another aspect, provides a method for handling of cuttings, which method comprises providing a vessel adapted to sustain a reduced internal pressure with respect to external ambient atmospheric pressure, and external pumping means, said vessel and pumping means being operationally connected by means including a conduit, collecting cuttings from a drilling fluid/cuttings separation device in said vessel, removing cuttings from said vessel by means of said pumping means through said conduit whilst maintaining a reduced pressure, and selectively delivering removed cuttings by means of pumping to at least one of a variety of disposal points including a cuttings re-injection apparatus, removable transportable cuttings containers including a barge or the like for shipping to a remote disposal site.
According to another aspect of the invention there is provided an apparatus for handling of cuttings, comprising a vessel adapted to sustain a reduced internal pressure with respect to external ambient atmospheric pressure, and further provide a means for extracting fluids, the apparatus also having operationally connected thereto, external pumping means capable of maintaining the reduced internal pressure and removing the separated fluids while discharging the cuttings to a variety of storage containers or to a cuttings re-injection apparatus.
In accordance with still another aspect of the invention a centrifugal dryer is provided for drying the drill cuttings prior to distribution, by way of a blowers and or vacuum systems, to various holding containers located on or near the rig. This drying process removes the fluids and thereby allows all of the cuttings being produced by the drilling operation to be contained on the rig for longer periods of time prior to removal or re-injection.
Significantly, according to the invention, the proposed use of the pumping means for not only initially collecting the cuttings under vacuum, but also removing cuttings under reduced pressure or “vacuum” conditions, and utilizing the pumping means to selectively convey the cuttings onwards via dedicated conduits to a cuttings storage container, or directly into a cuttings re-injection facility, offers several significant advantages.
Firstly, the demands on the crane are reduced because the cuttings containers do not need to be continually cycled around for filling and emptying operations. The containers can be stowed or sited in convenient locations without taking account of the shaker station position other than to ensure that suitable vacuum conduit lines are available or provided to feed the cuttings directly into the containers. The crane then becomes essentially free to fulfill other essential tasks such as handling drill pipe etc. The freedom to locate containers anywhere that a cuttings vacuum transport line can be installed and accessed immediately also provides greater freedom on the deck for operator movement, and greater flexibility in utilization of deck space around the shaker station and elsewhere.
Secondly it offers the possibility of directly off-loading cuttings to a barge or bulk transport ship standing on station close to the drilling facility.
Thirdly, health and safety aspects are enhanced due to reduced contact between workers and the cuttings, who need longer clamber over the cuttings containers to access them thereby reducing contamination hazards and risks of personal injury by falls.
The conduit network may be a fixed installation or arranged so as to permit re-deployment of a selected or each conduit at will. The conduits are designed sufficiently to permit transfer of the particulate solids constituting the cuttings and avoid blockages, and pump overloading but are also sized to avoid loss of vacuum transfer velocity.
It will be understood that the pumping means referred to herein in relation to the various aspects of the invention may consist of one or more pumps having the necessary functions of generating a pressure differential to move cuttings in the desired way and combinations of pumps can be adopted.
Preferably, the pumping means comprises, at least, (i) gas pumping means e.g. a vacuum generating unit capable of creating the desired pressure reduction in the vessel and (ii) a solids displacement means, which may be one of several types suitable to the purpose, including positive displacement pumps, e.g. a piston pump, or paddle devices e.g. using rubber paddles, or a progressive cavity pump capable of continuous displacement of solids, preferably at about 25 tons per hour or more. Advantageously, location of the pumping means external to the vessel is such that solids displacement is so primarily lateral rather than vertical as required for the known solids free-fall under gravity system, which reduces height requirements The vessel can then be installed at ground (deck) level with no height elevation requirements which improves safety for operatives.
In this way equipment provided in accordance with the invention can exhibit a relatively low profile compared with prior art systems and is more easily installed and maintained by operatives with less risk of injury due to falls. Furthermore in contrast with the prior art operational system described above where the vertically arranged helical screw is within the cuttings hopper itself, the pressure vessel arrangement described herein is less complicated in structure and provides for easier care and maintenance operations.
Overall, the system proposed herein results in more efficient use of space in the installation, and reduces hazards associated with earlier systems.
The vessel and pumping means described herein are operationally connected so as to maintain a reduced pressure or vacuum within the system, which may be achievable by fastening arrangements satisfying usual industry pressure vessel standards, including flanged connections and dedicated hard conduits of adequate strength. The reduced pressure can be maintained by a suitable type pump known in the industry or custom built for this system.
It will be understood that primarily the invention addresses solids handling, and the precise nature of the vacuum unit or gas pump is not critical. The arrangement of the invention is such that the pumped cuttings can either be directed from the reduced pressure vessel into appropriate storage facilities such as containers or directly into a cuttings re-injection device enabling the cuttings to be returned to the drilled formation. Furthermore the cuttings can be “piped” off the installation into a barge or similar bulk cargo transporter.
Cuttings re-injection under high pressure back into an earth formation is described in principle in the following U.S. Pat. Nos. 4,942,929, 5,129,409, and 5,109,933, and treatment of drill cuttings is discussed in the following U.S. Pat. Nos. 4,595,422, 5,129,468, 5,361,998 and 5,303,786. However, these early proposals have not been easy to implement in the field for those lacking the appropriate skill and understanding, and this has resulted in cuttings re-injection not gaining wide acceptance amongst operators, especially in offshore drilling installations in the North Sea.
The present invention arises from developments following on from proven re-injection techniques successfully employed by APOLLO Inc. in offshore drilling operations.
DESCRIPTION OF THE DRAWINGS
The invention will now be further described with reference to the accompanying drawings in which:
FIG. 1 is a plumbing illustration arrangement for the preferred embodiment of the materials handling system;
FIG. 2 is a plumbing illustration arrangement for an alternate embodiment of the preferred system;
FIG. 3 is a plumbing illustration arrangement for an alternate vacuum system;
FIG. 4 is a plumbing arrangement and an optional discharge receptacle for the system shown in FIG. 3 system;
FIG. 5 is a plumbing arrangement and an optional discharge receptacle for the system shown in FIG. 3 system;
FIG. 6 is a cutaway side elevation of a low profile reduced pressure vessel and associated pumping means in accordance with the invention;
FIG. 7 is side elevation of a low profile reduced pressure vessel and associated pumping means in accordance with the invention:
FIG. 8 is a plumbing arrangement for the system shown in FIG. 2 adding an optional surge tank.
FIG. 9 is a plumbing arrangement for the system shown in FIG. 1 with addition of an optional surge tank and pump combination;
FIG. 10 is a plumbing arrangement for the system shown in FIG. 5 with separator discharging into a surge tank.
FIG. 11 is a top view of the surge tank;
FIG. 12 is a cross section view of the surge tank;
FIG. 13 is a plumbing arrangement for the system first shown in shown in FIG. 8 substituting a centrifugal dryer for the surge tank;
FIG. 14 is a second embodiment of the plumbing arrangement for the system shown in FIG. 13;
FIG. 15 is a third embodiment of the plumbing arrangement for the system shown in FIG. 13; and
FIG. 16 is a fourth embodiment of the plumbing arrangement for the system shown in FIG. 13 .
DETAILED DESCRIPTION
As shown in FIG. 1, the preferred embodiment of the invention is a system by which cuttings leaving the shaker 10 may be collected from the cuttings trough 12 by gravity feed into a progressive cavity or fixed displacement piston type solids pump 14 and then pumped through a system, of conduits selectively to one or more of the possible discharge ports or disposal points located around the drilling site or platform. Such disposal points or discharge ports may be selected by opening valves 16 as needed to dispense the cuttings to a cuttings/fluid separator 18 , a barge 20 a cuttings box 22 or other transport means such as a truck 24 for further disposition.
Defluidized cuttings discharged from the separator 18 may be collected in various containers such as a cuttings box 22 seen in FIG. 3, a truck 24 as seen in FIG. 5 or into a slurry processing unit 26 for injection into the earth formation around the well as also seen in FIG. 1 .
By adding a vacuum pump unit 28 and vacuum chamber 30 as seen in FIG. 2 to the solids pump 14 and its associated system shown in FIG. 1 the system is then capable of extracting the cuttings from the cuttings trough by vacuuming them directly into the chamber 30 which serves as a hopper for feeding the cuttings to the solids pump 14 . As discussed herein this arrangement is useful when space under the cutting trough is insufficient to accommodate the solids pump 14 . Since the cuttings are still in slurry they can be pumped to the various discharge points. However, once the fluids have been extracted by the separator 18 it is much more difficult to move the materials without adding more fluid. Therefore, the defluidized cuttings are discharged from the separator 18 directly to the containers 22 , 24 or to the injection processing unit 26 as disclosed in FIGS. 3-5.
Turning now to FIG. 3 we see that the previously known fluid separator 18 may also be used as the vacuum chamber for extracting the cuttings directly from the cuttings trough 12 . However, the separator has the distinct advantage of being capable of efficiently removing and reclaiming most of the remaining fluids from the cuttings thereby reducing the weight and volume of the cuttings to be transported.
As shown in FIG. 6, the previously known operational fluid separator system 18 collects cuttings 15 from the cuttings trough 12 that collects solids falling via gravity from inlet suction line 32 as a result of the separator having a reduced internal pressure created by the gas suction pump system 28 seen in FIG. 2 attached to the separator by line 34 . The separator 18 is generally diametrical in shape having cylindrical side walls 35 and a top 40 with a sloping mid portion 110 and a smaller cylindrical lower portion 52 culminating at an open discharge port 85 . The interior is divided into an upper chamber 38 bound by side wall 35 , top 40 and inclined partition 45 , a mid chamber 105 bound by the inclined partition 45 sloping side wall 110 and partition 56 and a lower chamber 58 within the smaller cylindrical lower portion 52 serving as the housing for an adjustable valve assembly 75 .
The upper chamber communicates with the mid and lower chambers 105 , 58 with screen assembly 50 . Positioned substantially central along the vertical axis of the screen member 55 is a shaft 60 , which supports a screw conveyor driven by a motor drive 90 . The screw flight portion 65 extending from the upper chamber through the screen assembly 50 and culminating at the screen discharge end portion 70 which is substantially blocked by valve assembly 75 .
Cutting being conveyed from the upper chamber 38 to the discharge port 70 must force the valve open to allow the cuttings to 15 to communicates with lower chamber 58 and be discharged through the discharge chute 80 . Chute 80 empties into opening 85 which disposes cuttings into a container as seen in FIGS. 3-5.
The side walls 35 , inclined walls 45 , and screen assembly 50 communicate and form a seal with the screw flighting 65 and the mid chamber 105 so that when a vacuum is applied using suction line 34 , cuttings can be suctioned from trough 12 to the upper chamber 38 of the separator and then conveyed through the screen assembly 50 to wards the closed valve assembly 75 thereby compressing the cuttings 15 and forcing fluids and solids less than 20 micron through the screen 55 and apertures in screen sleeve member 100 . Fluids accumulated in the mid chamber 105 are then drawn off by pump 115 to be a fluids recovery container 120 via discharge line 95 . The remaining solids are disposed of via discharge valve assembly 75 and travel down the discharge chute 80 under gravity and are emptied into containers via the opening 85 where they await disposal or re-injection.
The reduced pressure vessel 30 first illustrated in FIG. 2 and further detailed in FIG. 7, illustrating this aspect of the invention, there is shown a relatively low profile reduced pressure vessel 205 and associated pumping means 210 in accordance with the present invention. The apparatus 200 for handling of cuttings comprises a vessel 205 adapted to sustain a reduced internal pressure with respect to external ambient atmospheric pressure, and operationally connected thereto, external pumping means 210 capable of both operations of maintaining the reduced internal pressure and removing cuttings from the vessel 205 , and means including a conduit 215 for selectively delivering cuttings to either a storage facility or to a cuttings re-injection apparatus. (not shown)
The illustrated vessel 205 has four generally rectangular sides 225 , which communicate with an opening 230 via inclined walls 255 and a delivery chute 240 . The vessel 205 also has a rectangular top cover 245 . The vessel 205 is supported by a framework 250 to which it is attached, e.g. by welds. However, it will be appreciated that other shapes of sealed pressure vessel can be adapted in the invention. The system described here is designed to fully satisfy current industry pressure vessel standards.
The pumping means 210 illustrated comprises a progressive cavity pump 220 capable of continuous displacement of solids, here at about 25 tons per hour or more. Other positive displacement pumps may also be used, Location of the pumping means 210 external to the vessel 205 is such that solids displacement is primarily lateral rather than vertical as required for the known solids free-fall under gravity system which provides for low height requirements. The vessel 205 is installed at ground level with no height elevation requirements. In this way the equipment has a low profile and is more easily installed and maintained with less risk to maintenance technicians or other operatives of falling.
Furthermore in contrast with the prior art operational system described above where the vertically arranged helical screw is within the vessel itself, the arrangement described herein is less complicated in structure and provides for easier care and maintenance operations.
The vessel 205 and pumping means 210 described herein are operationally connected so as to maintain a reduced pressure be low atmosphere or vacuum within the system, which may be achievable by fastening arrangements satisfying usual pressure vessel standards, including flanged connections 240 and dedicated hard conduits of adequate strength. The reduced pressure can be maintained by a vacuum pump of any suitable type, and although illustrated here as having both gas and solids pumping means together, the gas (vacuum) pump could be remote from the solids pump. The arrangement of the invention is such that the pumped cuttings can either be directed from the reduced pressure vessel 205 into appropriate storage containers or directly back into a cuttings re-injection device as a matter of operator's choice, as is apparent from the flow illustration seen in FIGS. 1 and 2.
As seen in FIG. 8 the cuttings handling system may also be configured to include a surge or holding tank 300 whereby the cuttings slurry being discharged from the pump 14 is received and held for selective redistribution and pumping to the various containers and systems around the drill site. This surge tank 300 may be necessary to insure that the system does not become constipated and back up as result an inability to discharge the cuttings freely to a container.
As seen in FIG. 9 the surge tank 300 which includes an integral progressive cavity pump 310 may also be used as the prime pump system whereby the cuttings are received directly from the shaker screens 10 or from the shaker trough 12 by gravity feed. The cuttings are then agitated and maintained in solution until pumped down stream to the site containers or other systems.
As seen in FIG. 10 it is also possible to locate the surge tank 300 in position to receive cuttings directly from the cuttings fluid separator 18 . In this case the cuttings have been striped of their valuable drilling fluids and recovered. Therefore, the cutting may be discharged into the surge tank where water or other environmentally adaptable fluids are added through conduit 312 , which help prepare the cuttings for earth reclamation prior to discharge to the cuttings container and systems.
As seen in FIGS. 11 and 12 the surge tank 300 includes a rectangular vessel having a bottom 314 and side and end walls 318 , 316 . A progressive cavity or other such large volume positive displacement type pump is integrated into one end wall as best seen in FIG. 12. A partition 320 having a central gate portion 322 with removable portions 324 to allow for control of fluid/sediment levels within the vessel. An agitation system 326 is also provided which is trackable on wheels along rails attached to the upper sides of the tank walls 318 . The agitator includes a bridge 328 supported by wheel assemblies. A drive 332 is also provided for moving the bridge 328 from one end of the tank to the other. A pair of telescopic cylinders 334 is provided for extending and retracting a centralizing screw conveyor auger 336 . The auger serves to move the cuttings toward the center of the tank and help maintain them in solution so that they will flow over the partition gate 322 .
In off-shore drilling, it is essential that digestion and disposal of the drill cuttings flowing from the well at inconsistent flow rates be processed and disposed of in a manner that prevents constipation of the drilling operation. Therefore, the more alternatives available for cuttings disposal and fluid recovery on a drilling rig the better. In keeping with this principle alternatively, a centrifugal dryer 400 may be adapted to the systems as previously illustrated in FIGS. 1 and 2 in the manner illustrated in FIGS. 13 and 14. As seen in FIG. 13 cuttings are transferred to the vacumn receiving tank and pump assembly 30 through suction line 32 from the cuttings trough 12 in the same manne as in FIG. 12 . The cuttings are then transferred from the vacuum chamber 30 with the pump 14 and deposited into the inlet 402 of the centrifugal dryer 400 where the cuttings are spun at high speed forcing the fluids from the slurry out though the fluid ejection tube 404 . The relatively dry cuttings, typically below 3% fluid by weight, are then deposited into a receiving bin 403 capable of storing large quantities of the dried cuttings before being discharged by way of the transfer conveyor 406 . The transfer conveyer may also contain a metering feeder 408 with internal seals to prevent back flow of the dried cuttings, prior to feeding the cuttings into the transfer line 500 . The transfer line 500 may be charged with an additional blower 28 a such as that used in assembly 28 previously disclosed herein. A venturi located within jet pump 502 may be used to help draw the dry cuttings into the charged discharge line 500 . Dry cuttings are then directed to any of several optional outlets leading to receiving units 20 - 26 by opening and closing valves 16 . Cyclone separators 504 are located at each of the receiving units for separating and exhausting the pressurized air prior to discharge into the receiving units. Exhausted air may be discharged to atmosphere through exhaust/filter units to remove fine cuttings particles.
As seen in FIG. 13 dried cuttings may be transferred directly from the transfer conveyor 406 to transfer lines leading to the optional outlets 20 - 26 . In this case a second vacuum pump 28 is collectively connected to the discharge of each cyclone separator 504 located at each of the optional distribution outlets 20 - 26 thereby drawing the cuttings through the distribution lines. In this case any airborne fines are collect in the filter receiver 510 located inline ahead of the vacuum pump 512 .
As seen in FIG. 14 a primary and secondary means of fluid separation and recover may be used whereby the fluid separator unit 18 is utilized as the vacuum chamber for vacuuming the cuttings from the cuttings trough regardless of whether or not the cuttings compression feature of the separator is utilized or not. However, if the cuttings compression and fluidseperation feature is utilized the cuttings will enter the inlet of the centrifical dryer unit 400 with less moisture content, thereby insuring a more through recover of drilling fluids and muds and dryer cuttings being fed to the cuttings transfer system.
It is also anticipated that cuttings may be collected from any number of cuttings troughs 12 and conveyed by a screw conveyer 405 to the inlet of the centrifugal dryer unit 400 as seen in FIG. 16 .
In either case the systems shown in FIGS. 15 and 16 reduce cuttings bulk and transport weight and further recover expensive drilling fluids.
The cuttings handling systems proposed herein offers remarkably higher levels of safety due to the reduced number of handling operations such as interventions by operatives to hook up containers to the crane, transfers of containers around the shaker station, etc. Furthermore, the sealed vacuum pressure vessel and associated network of vacuum conduits provides for delivery of cuttings to a container, re-injection equipment or transport for shipping to a remote disposal site, thereby preventing the possibility of constipation due to high production of drill cuttings at any given time.
The full significance of the capabilities of the system proposed here, and variants thereof will be apparent to those appropriately skilled in this art and who will recognize that the scope of the invention is not limited to the illustrative embodiment specifically described above. | An apparatus and method for removing and recovering up to 98 percent of the residual drilling mud and fluids from drill cuttings for reuse and storing the drill cuttings in a relatively dry state thereby reducing cuttings volume requirements for storage and transport thereby reducing constipation of the drilling process due to disposal congestion. The present invention further provides methods for collecting and transferring drill cuttings in either dry or wet states to various locations on or adjacent the rig for processing, containerization, transport and disposal, thereby reducing handling and contamination thus simplifying recycling while reducing cost. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus for cleaning sewer lines, pipe lines, and closed chambers and/or conduits in which water is jetted into the conduits at high pressures and in which a partial vacuum is applied for removal of liquids and solids from the conduits.
2. Description of the Prior Art
It is well-known to provide a mobile sewer cleaning unit having a reservoir for a large supply of water, and water-handling components including a hose reel, a hose normally coiled thereon, and a high pressure pump suitably connected between the reservoir and the hose to deliver water to the hose at high pressure. A nozzle which is typically attached to the free end of the hose reverses the direction of the high-pressure water in such a way as to develop a reaction force which pulls the hose into the sewer line from the hose reel. It is also conventional practice to provide a drive means for the pump including an internal combustion engine, the water handling components and drive means usually being mounted upon a rear platform of a truck or on the bed of a trailer.
It is also well-known to provide such sewer cleaning units with means for collecting the debris flushed from the sewer line by the high-pressure water system. Such debris collecting means typically include a receptacle for storing debris, a boom-mounted conduit extending from the receptacle, an intake tube at the end of the conduit to be lowered into the sewer or other chamber from which the debris is removed, and means for creating a suction force at the intake tube to suck the debris through the conduit and into the receptacle.
The suction creating means used in sewer cleaning units are generally either air conveyance systems or vacuum systems. Air conveyance systems for pickking up debris from sewer pipes and similar chambers are well-known, such as that shown in U.S. Pat. No. 3,568,589, issued to R. E. Shaddock. Such units use a large fan or compressor to create an air flow in the conduit which carries debris to a receiving tank. In contrast to these air conveyance systems, vacuum systems utilize a vacuum pump to create a partial vacuum in a collecting tank. With this vacuum, solid and liquid material in the sewer pipe or chamber is sucked through the conduit into the tank.
In general, sewer cleaning units using vacuum systems have advantages over those using air conveyance systems. Air conveyance units use an open exhaust system for their fan or compressor. When the debris tank is over-filled, contaminated water is picked up into the air stream and discharged into the atmosphere, polluting the air and damaging any objects which are sprayed. In contrast, vacuum units use a completely sealed system. When the tank becomes completely full, an automatic check valve system may be used to shut off the vacuum pump to prevent discharge of the contaminanted material.
Furthermore, vacuum units by reason of the high suction created in the tank are capable of collecting both liquid and solid material. The air movement created by an air conveyance system is capable of drawing with it solid particulate debris, but it is limited in drawing up large amounts of liquid. If water in the sewer covers the intake tube on an air conveyance unit, it will cut down the suction capability of the unit. On the other hand, vacuum systems are especially adapted to pick up liquids, since the end of the intake should be sealed in order to maintain a vacuum in the system, and this seal is usually accomplished by submerging the end of the intake tube below the water line in the sewer chamber.
In prior sewer cleaning units, the water storage reservoir tank and the debris receiving tank were either constructed in two separate tanks or in a single tank having a vertical separation. The construction of two separate tanks is costly, and the use of a single vertically divided tank creates numerous problems. The vertically separated tanks permit connection of the suction conduit only at the rear of the tank. If the debris were to be stored in the front of the tank, it would be necessary to reposition the vertical divider so that the debris could be dumped out through the rear compartment. This design is unacceptable because all of the water in the rear of the tank is then lost or dumped out with the debris.
The connection of the conduit at the rear of the tank presents various problems such as axle overloads on the vehicle. When the conduit and its supporting boom is mounted at the rear of the vehicle, there are increased loads on the rear of the vehicle, requiring an increased number of rear axles. The connection of the conduit at the rear of the vehicle also requires the operator to stand at rear of vehicle while operating the unit, thus exposing the operator to the hazards of oncoming traffic when operating the unit on busy city streets. While it would be desirable for the operator to stand in front of the vehicle and to be protected by the vehicle while operating the unit, this would require extending the rear-mounted conduit to the front of the vehicle, resulting in an extremely long conduit which would decrease the vacuum and suction capability at the intake end of the conduit.
SUMMARY OF THE INVENTION
The shortcomings and disadvantages of the prior art are overcome by the sewer cleaning apparatus of the present invention.
It is an object of the present invention to provide an improved apparatus for cleaning sewer lines, pipes and other conduits and chambers in which a high pressure water system is used to flush the chamber and a vacuum system is used to remove liquids and solids flushed from the chamber by the high pressure water system.
Another object of this invention is to provide a sewer cleaning apparatus having a single tank assembly mounted on a wheeled vehicle, which single tank assembly is substantially horizontally divided into two tank portions, one tank portion adapted to store a supply of water for the high-pressure water system and the other tank portion adapted to receive and hold debris, removed by the vacuum system.
Another object is to provide a sewer cleaning apparatus in which the conduit for carrying debris to the tank assembly may be mounted on the front of the tank assembly, thereby decreasing the load on the rear axle of the vehicle and allowing the operator to stand at the front of the vehicle while operating the apparatus, thus protecting the operator from oncoming traffic without using an excessively long conduit which may result in loss of vacuum pressure.
Another object is to provide a sewer cleaning apparatus in which the solid debris stored in one of the tank portions may be discharged from the tank portion through the conduit, thus eliminating the necessity of moving the apparatus to a dump site, while water may be returned from the debris holding tank portion to the water storage tank portion, thus increasing the effective tank capacity of the apparatus.
Another object is to provide an apparatus having a suction system and a water jetting hose reel assembly capable of being operated simultaneously by a single operator, in which hand-operated controls are positioned on the intake end of the conduit, and foot-operated controls may be connected to the hose reel, so that the operator need not remove his hands from the conduit to operate the hose reel.
Another object is to provide an apparatus also capable of being used as a sludge application for sewage treatment plants by spreading sludge pumped from the debris holding tank portion, thus permitting the transfer of sludge to lagoons or drying beds.
Another object is to provide an apparatus also capable of being used as a street flusher by pumping water from the water storage tank portion through nozzles beneath the apparatus.
These and other objects are accomplished by the apparatus of the present invention which comprises a sewer cleaning unit having a single tank assembly mounted on a wheeled vehicle. The tank assembly has a substantially horizontal fixed divider forming first and second tank portions. The first tank portion is adapted to carry a supply of water, and the second tank portion is adapted to receive and hold debris. The tank assembly has a rear door adapted to be opened to discharge debris from the second tank portion. A conduit which is adapted to be lowered into the chamber to be cleaned, is mounted on top of the tank assembly and connected to the second tank portion. Means are provided for creating a suction in the second tank portion, such as a pump, to suck debris through the conduit and into the second tank portion. A hose reel is mounted on the vehicle, the reel having a hose connected to the first tank portion. The hose is adapted to be inserted into the chamber to discharge water.
In accordance with another aspect of this invention the forward end of the conduit has a hand-operated control means adapted to be handled by an operator. Preferably, foot-operated control means are connected to the hose reel, so that the foot-operated control means and the hand-operated control means are capable of being operated simultaneously by a single operator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the sewer cleaning unit of the present invention mounted on a truck body.
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is an end elevational view taken along line 3--3 of FIG. 1.
FIG. 4 is a side elevational view similar to FIG. 1 showing the opposite side of the truck-mounted unit of the present invention.
FIG. 5 is a side elevational view similar to FIG. 4 showing the unit with the tank assembly raised for the discharge of debris from the tank assembly.
FIG. 6 is a detailed view of the valve mechanism at the connection of the conduit on top of the tank assembly.
FIG. 7 is a top sectional view of the reverse valving mechanism of the vacuum pump taken along line 7--7 of FIG. 9.
FIG. 8 is a top sectional view similar to FIG. 7 showing the mechanism in its reversed position.
FIG. 9 is a side elevational view in section of the vacuum pump of the unit showing the reverse valving mechanism.
FIG. 10 is a front perspective view of the apparatus showing the simultaneously operable hand and foot controls.
FIG. 11 is a front elevational view of the hose reel to a larger scale than FIGS. 1 and 10, and taken along line 11--11 of FIG. 1.
FIG. 12 is a side elevational detailed view of the hose reel partially sectioned taken along line 12--12 of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings and initially to FIGS. 1-5, there is shown the sewer cleaning unit of the present invention. The unit includes a wheeled vehicle, such as a truck 20, or a trailer, railroad car, or the like. The truck 20 (FIG. 1) is of conventional design with a forward driver's cab 21 having a hood 22 containing the engine and a chassis 23 extending rearwardly from the cab. The truck engine powers a hydraulic pump which supplies hydraulic fluid to drive the other components of the unit. A generally cylindrical tank assembly 25 is mounted on the truck chassis 23 over the rear wheels of the truck. The tank assembly 25 has a curved divider 26 (FIG. 2) extending substantially horizontally along the length of the tank assembly and separating the tank assembly 25 into two permanently separated tank portions. An upper tank portion 27 forms a reservoir for the storage of water for jetting into the sewer or other chamber to be cleaned, and a lower tank portion 28 provides a receptacle for the storage of sludge, solid, and liquid debris removed from the sewer or other chamber in the cleaning operation. While the divider 26 is preferably fixed permanently in the tank assembly 25, the divider can be movable, if desired.
For the removal of debris from the lower tank portion 28, a rear door 30 (FIGS. 1, 4, 5) is pivotally mounted on a hinge 31 to the top of the rearward end of the tank assembly 25. The rear door 30 is opened and closed manually or hydraulically and is sealingly clamped to the tank assembly 25 in its closed position by latches 32 so that a vacuum may be maintained in the lower tank portion 28. The rearward end of the upper tank portion 27 is closed by a fixed rear wall 33 (FIGS. 1, 3) so that the upper tank portion 27 is not exposed when the rear door 30 is opened, but only the debris-containing lower tank portion 28 is accessible. The rear door 30 includes sight glasses 34 for indicating the level of material in the tank portions and a drain valve 35.
The entire tank assembly 25 is pivotally mounted on the rearward end of the truck chassis 23 by a hinge means 37 so that the entire tank assembly may be raised to a dumping position (FIG. 5) by a conventional hydraulic hoisting jack 38. When the tank assembly 25 is raised to its dumping position, the rear door 30 may be hydraulically opened to permit debris to be dumped from the lower tank portion 28. Water in the upper tank portion 27 is retained by the horizontal divider 26 and the rear wall 33.
Debris enters the lower tank portion 28 through a sealed vertical tube 40 (FIGS. 1, 2) which connects the lower tank portion with an outwardly projecting boom 41 carrying a flexible conduit 42. The boom 41 extends from a mast 43 which is pivotally mounted on the top of the tank assembly 25. Hydraulically powered control means are provided to raise and lower the outwardly projecting end of the boom 41 and to rotate the boom through 300°. Due to the horizontal division of the tank assembly 25, the boom mast 43 may be mounted anywhere along the entire axis of the tank assembly. Preferably, the boom mast 43 is mounted near the forward end of the tank assembly 25. The forward mounting position permits an even distribution of weight across the vehicle and permits the boom 41 to easily extend in almost any direction for operation on all sides of the vehicle including in front of the cab 21 without requiring an excessively long conduit 42. Whenn not in use, the boom 41 extends rearwardly over the tank assembly 25 and is lowered to its bottommost position and fastened to a bracket 44 mounted on top of the tank assembly (FIG. 4). By mounting boom 41 rearwardly when not in use, the operator driving the vehicle is given an unobstructed view in the cab 21.
A hydraulically or pneumatically operated valve 46 (FIG. 6) is provided between the top of the vertical tube 40 and the end of the conduit 42. The valve 46 includes a valve head 47 operable on a piston rod 48 extending from a cylinder 49, the head 47 being capable of resting on a valve seat 50 at the end of the conduit 42. Upon actuation of the valve 46, the conduit 42 is closed from the lower tank portion 28.
The construction of boom 41 includes a telescopic support 52 (FIG. 1) which may be extended by a hydraulic cylinder 53 having a piston rod 54. The flexible conduit 42 is maintained within the support 52. At the projecting end of the boom 41, the support 52 curves downwardly, and the flexible conduit 42 is support on a plurality of rollers 55. An intake tube 56 (FIGS 4, 10), for insertion downwardly into the sewer or other chamber to be cleaned, is connected to the end of the flexible conduit 42. A pair of operator-controlled handles 57 (FIG. 10) are mounted on each side of the intake tube 56 to assist the operator in guiding the tube 56 into the manhole H or chamber entrance. Push button controls 58, which are included on the handles 57, are connected to the unit by cables and include controls for the operation of the boom 41 and of the apparatus which produces a vacuum in the lower tank portion 28 to produce suction in the conduit 42. Separate boom controls are also located at the rear of the tank assembly 25.
A vacuum is produced in the lower tank assembly 28 by means of a rotary-vane vacuum pressure pump 60 mounted on one side of the truck chassis 23 beneath the tank assembly 25 (FIG. 4). The pump 60 is connected by a hose 61 which extends along the front of the tank assembly 25 and which includes a quick-disconnect fitting 62 which separates when the tank assembly 25 is lifted to its dumping position (FIG. 5). The other end of the hose 61 is connected to a moisture trap 63 which removes moisture in the air from the lower tank assembly 28 to protect the pump 60 by preventing contaminantion from entering the pump. A drain hose 64 extends from the moisture trap 63 down along the side of the tank assembly 25 for the release of moisture removed by the trap. The other end of the moisture trap 63 is connected by a hose 65 to a port 66 on the top of the tank assembly 25 which is connected to the lower tank portion 28 by a vertical tube 67. If desired, the moisture trap 63 may be provided with a conventional sight glass 68.
Vacuum pump 60 is shown in greater detail in FIGS. 7-9. The pump 60 includes a known rotary pumping assembly 69 powered by a hydraulic drive unit 70 or by any conventional mechanical drive, such as a belt drive. An inlet port 71 and an outlet port 72 are connected to a reverse valving mechanism 73 which is rotatably mounted on the top of the pump 60. The mechanism connects the ports 71 and 72 with the hose 61 which leads to the lower tank portion 28 and with an exhaust port 74. Under normal operation as shown in FIG. 8, the mechanism 73 is positioned such that the hose 61 is connected to the inlet port 71 and the outlet port 72 is connected to the exhaust port 74, and the pump 60 operates to pump out air from the lower tank assembly 28, and thus produce a vacuum in the lower tank portion to permit debris to be sucked thereinto. Upon rotation of the mechanism 73 (FIG. 7), the hose 61 is connected to the outlet port 72 while the inlet port 71 is connected to the exhaust port 74, and the action of the pump 60 is reversed so that a positive pressure is applied to the lower tank portion 28. With the positive pressure established in the lower tank portion 28 by the pump 60, it is possible to force liquid debris from the lower tank portion up through the vertical tube 40. By using compression from the vacuum pump 60, liquids in the lower tank portion 28 may be discharged back through the intake tube 56 to remove liquids from the lower tank portion without moving the unit. This liquid discharging capability increases the usable capacity of the tanks by allowing the tanks to be filled primarly with solid debris and sludge.
To provide a visual indication that the lower tank portion 28 is filled with debris or that the upper tank portion 27 has reached a certain level, conventional sight glasses 76 and 77 (FIG. 1) are connected to the tank portions 27 and 28, respectively. The sight glasses 76 are connected at various levels to the upper tank portion 27 and are vertically spaced on the exterior side of the tank assembly 25, while the slight glass 77 is connected to the top of the lower tank portion 28 and extends laterally from the front of the tank assembly 25 so that it can be seen from the front of the unit. The drive unit 70 of the vacuum pump 60 includes an automatic check valve shutoff mechanism which stops the pump when the lower tank portion 28 is full or when the upper tank portion 27 is empty. A warning light 78, which may be mounted on the front hose reel assembly (FIGS. 1, 12), provides a visual indication to the operator that the automatic shut-off mechanism has been actuated.
Water is discharged from the upper tank portion 27 through a high-pressure jetting pump 80 (FIG. 1) which is mounted on the truck chassis 23 beneath the tank assembly 25 opposite the vacuum pump 60. The pump 80 is connected to the upper tank portion 27 by a hose 81. The exhaust from the truck engine is fed back through an exhaust pipe 82 into the compartment containing the high pressure pump 80, thus keeping the pump and the water piping system above freezing temperatures regardless of the outside ambient temperature.
A hose reel assembly 84 (FIG. 11, 12) is mounted on the front of the cab 21. The assembly 84 includes a high-pressure flexible hose 85 wound on a reel 86. The hose reel 84 may be similar to that disclosed in U.S. Pat. No. 3,476,139. The hose 85 is connected to the high-pressure jetting pump 80 by a tube 87, hollow shaft 88 and tube 89. The reel 86 is mounted for rotation on the shaft 88. In accordance with known design, the hose 85 may be provided with a self-propelling spray nozzle on its leading end which has rearwardly directed outlets, so that the force of the water issuing from the outlets propels the leading end of the hose through a sewer pipe or other conduit. If desired, a conventional rotary root cutting head may also be installed on the leading end of the hose 85. Preferably, the hose reel assembly 84 is pivotally mounted to the front of the cab 21 on a hinge 90 permitting the assembly 84 to be lowered upon the release of a locking pin 91, as desired. This pivoting of the reel assembly 84 permits the assembly to be moved out of the way when the truck hood 22 is raised (FIG. 1). Adjacent to the reel 86 are the warning light 78 and a plurality of gauges 92 for monitoring the various pressures on the unit. The reel 86 may be driven by a hydraulic motor 94 which is supplied with hydraulic fluid by the hydraulic system powered by the truck chassis motor. The motor 94 is connected to the shaft 88 by means of a sprocket and chain drive 95. The rotation of the hose reel 86 is controlled by a foot control 96 (FIGS. 1, 10) which is attached to the reel assembly 84 by a line 97 such as a cable or hose. The control 96 is preferably an electrical switch connected by a cable to control the flow direction of a hydraulic valve in the line which supplies fluid to the hydraulic motor 94, so that actuation of the switch 96 by the operator drives the hydraulic motor forward or reverse for rotation of the reel 86. Alternatively, the control 96 may be a hydraulic valve connected by a hose to the motor 94 so that actuation of the switch 96 by the operator directly starts or reverses the flow of fluid to the motor. The operator thus controls the pay-out and retrieval of the hose 85 from the hose reel 86 by means of the foot control switch 96 which may be operated simultaneously with the hand-operated controls 58 on the intake tube 56.
The electrical switch incorporated in the foot control 96 may also be located with the hand controls 58 on the handles 57 so that the operator may simultaneously control the operations of the unit by operating the controls on the handles.
A smaller hose reel 99 (FIGS. 4, 10) is also mounted on the front cab 21 and is connected to the supply of water in the upper tank portion 27. A smaller flexible hose 100 is wound on the smaller hose reel 99 and is equipped with a hand-operated spray nozzle gun. The smaller hose 100 may be used for operations such as manually cleaning residual debris from the lower tank portion 28.
If desired, the truck may also be provided with street flushing nozzles beneath the truck body, with appropriate piping connecting the flushing nozzles with the jetting pump 80, or with an additional flushing pump.
To permit water mixed with the sludge and sold debris in the lower tank portion 28 to be transferred to the upper tank 27 and be reused, the unit may be provided with a centrifugal separator 102 in the upper tank assembly 27 (FIGS. 1, 2), which may be similar to the separator shown in U.S. Pat. No. 3,947,364. Water mixed with debris which is fed to the separator 102 is collected in the lower tank portion 28 through a floating collector 103 having a float which maintains the collector at the top level of the liquid in the lower tank portion, so that the collector receives the liquid in the tank portion without being clogged with solid debris. The floating collector 103 is connected by a hollow lever arm 104 to a hose 105 which extends from the lower tank portion 28, and which leads to a valve 106. A hose 107 is connected to the other end of the valve 106 and extends along the exterior of the tank assembly 25 and is connected to the inlet end of the separator 102. The lower discharge end of the separator 102 from which solid debris is discharged is connected to the lower tank portion 28 by a fitting 108 which extends out of the upper tank portion 27, a valve 109 on the exterior of the tank assembly 25 at the end of the fitting 108, and a hose 110 which is connected to the valve 109 and extends into the lower tank portion. Water removed by the separator 102 is returned to the upper tank portion 27 through upper outlet 111.
In the operation of the sewer cleaning unit of the present invention, the truck 20 may be driven over streets or roads and is positioned with the module H or other opening to a chamber in front of and preferably to the right of the vehicle as shown in FIGS. 1 and 10. The hydraulically powered boom controls are actuated to position the boom 41 toward the front of the vehicle so that the intake tube 56 connected to the conduit 42 can extend downwardly into the hole. The operator then positions himself adjacent to the hole (FIG. 10) and moves the foot control 96 so that it can be easily operated. The motor 94 driving hose reel 86 is actuated to unwind the jetting hose 85 from the reel downwardly into the hole. The operator then grasps the handles 57 on the intake tube 56 and using the controls 58 on the handle, extends and positions the boom 41 so that the tube extends downwardly into the hole. Using the controls 58 and 96, the operator can simultaneously control the operations of the unit.
The jetting pump 80 is actuated so that water is supplied from the upper tank portion 27 to the hose 85. The self-propelling nozzle on the leading end of the hose 85 feeds the hose through the sewer pipe or other conduit to be cleaned as the hose unwinds from the reel 86. The operator then actuates the hydraulic drive unit 70 on the vacuum pump 60 to create a partial vacuum in the lower tank portion 28. With the hydraulically controlled valve 46 open, suction is created at the mouth of the intake tube 56 so that debris is carried from the chamber through the conduit 42 and into the lower tank portion 28.
When the supply of jetting water decreases, as indicated by the sight glass 76, water can be recovered from the contents of the lower tank portion 28. With the valve 46 at the top of the vertical tube 40 closed, the valves 106 and 109 on the exterior of the tank assembly 25 are opened, and the reversible valving mechanism 73 on the vacuum pump 60 is rotated to revese the connections on the inlet and outlet ports 71 and 72 of the vacuum pump. The drive unit 70 to the pump 60 is actuated to create a positive pressure in the lower tank portion 28, forcing liquid entering the floating collector 103 up through the hose 107 and into the centrifugal separator 102. Clean water is thus forced out of the separator 102 into the upper tank portion 27 to replenish the supply of water therein, and the suspended solids in the debris are returned from the separator 102 to the lower tank portion 28 through the fitting 108 and the hose 110. After sufficient liquid has been removed from the lower tank portion 28, the valve 106 leading to the inlet of the separator 102 is closed, and the reversible valving mechanism 73 on the vacuum pump 60 is returned to its normal operating position. With the valve 109 open, suction is created in the lower tank portion 28 by the vacuum pump 60, pulling all of the remaining solid debris out of the separator 102 through the fitting 108 and hose 110. After the separator 102 is cleaned of debris, the valve 109 is closed, and the unit may be again used for other operations.
If desired, liquid contents in the lower tank portion 28 can also be removed through the conduit 42. With the valve 46 open, the reversible valving mechanism 73 on the vacuum pump 60 is positioned so that the pump 60 creates a positive pressure in the lower tank portion 28. This pressure separates the solid and liquid debris in the lower tank portion 28 and forces the liquids up the vertical tube 40 and out the conduit 42 to a convenient disposal site at the end of the intake tube 56 without moving the truck.
Since the sight glass 77 extends from the side of the tank assembly 25, the operator can easily see the sight glass 77 from his normal operating position at the side of the hose reel assembly 84, and can immediately tell when the lower tank portion 28 is full. When the lower tank portion 28 is full of sludge and solid debris, the truck 20 can be driven to a disposal site, whereupon the latches 32 are loosened, the hydraulically powered rear door 30 is opened, and the hydraulic hoisting jack 38 is actuated to raise the tank assembly 25 and dump debris from the lower tank portion 28 (FIG. 5). Water in the upper tank portion 27 is not released because of the design of the tank assembly having the substantially horizontal divider 26 and the rear wall 33 at the end of the upper tank portion 27 which prevents water from escaping from the tank portion 27 when the rear door 30 is opened.
The unit can also be used for the application of sludge to lagoons and drying beds in sewer treatment plants. Sludge may be forced out of the lower tank portion 28 by positive pressure produced by the vacuum pump 60 with the mechanism 73 in its reversed position. The sludge can then be spread by known means attached to the rear of the truck chassis 23, such as, for example, an applicator attached to the rear drain 35. An additional high volume progressive cavity pump may also be used to permit rapid transfer of sludge from the lower tank portion.
If desired, the entire tank assembly 25 can be used as a water storage, such as, for instance, when the vehicle is used as a street flusher. In this mode of operation, the lower tank portion 28 as well as the upper tank portion 27 are filled with water, and the water is pumped using the vacuum pump 60 in its reversed position and the jetting pump 80 or using the additional high volume progressive cavity pump to appropriate flushing nozzles located beneath the vehicle.
While the preferred form of this invention has been specifically illustrated and described herein, it will be apparent to those skilled in the art that modification and improvements may be made to the form herein specifically disclosed. Accordingly, the present invention is not to be limited to the form herein specifically disclosed nor in any other way inconsistent with the progress in the art promoted by this invention. | A sewer cleaning unit is disclosed which comprises a single tank assembly mounted on a wheeled vehicle. The single tank assembly has a substantially horizontal fixed divider forming a first tank portion adapted to carry and discharge a supply of water, and a second tank portion adapted to receive and hold debris, thus obviating the disadvantages of tank designs of the prior art. The unit may also be provided with hand-operated control means near the intake end of the conduit connected to the second tank portion and a control means connected to the reel for the hose from which water is discharged from the first tank portion, the reel control means and the hand-operated control means capable of being operated simultaneously by a single operator. | 4 |
This application is a continuation of application Ser. No. 07/928,383, filed Aug. 12, 1992, now abandoned which application is a division of application Ser. No. 07/770,826, filed Oct. 4, 1991, now U.S. Pat. No. 5,169,241.
BACKGROUND OF THE INVENTION
This invention relates to a squeeze film shaft damper oil system and more particularly to a circular array of radial oil inlets at unequally spaced and non-symmetrical positions circumferentially about the squeeze film space in a damper with a frequency independent, flexibility responsive, check valve in each inlet.
In a typical squeeze film shaft damper, a bearing support member such as the outer race of a rolling element bearing supported shaft is fitted in an annular chamber in its bearing housing to have limited radial motion therein. The outer planar surface of the outer race fits closely adjacent the opposed annular chamber wall to define a thin annular squeeze film space into which damper oil is introduced. Vibratory or radial motion of the shaft and its bearing generate hydrodynamic forces in the damper oil in the squeeze film space for damping purposes.
One problem associated with dampers as described involves orbital motion of a shaft. For example, in a camper bearing application for hot gas turbine engines, such as aircraft gas turbine engines, a turbine rotor/shaft imbalance may cause the shaft to undergo some limited orbital motion. This orbital motion causes alternate squeezing of the squeeze film space for very high oil pressure at one peripheral region and a lower pressure at an opposite region. The alternating action causes oil in the squeeze film space to flow circumferentially with an unequal pressure distribution such that, at the lower pressure region there may be a lack of a sufficient quantity of oil for damping effectiveness, referred to as cavitation or oil starvation. For this reason it has been a practice to utilize oil systems which supply oil to the low pressure region of the operating damper to prevent cavitation and modulate peripheral pressures in the squeeze film space. Such systems usually require complex and rigorous oil flow check valves to prevent backflow of high pressure oil from the rotating hydrodynamic peak pressure regions of the squeeze film space into the oil supply system. In addition, peripheral location of oil inlets are not always in an arrangement which accommodates both variable and static conditions of the damper.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an improved oil supply system for squeeze film dampers.
It is another object of this invention to provide an improved peripheral arrangement of oil inlets into a squeeze film damper.
It is a further object of this invention to provide an improved oil flow check valve for squeeze film damper oil supply systems.
It is a still further object of this invention to provide a frequency independent, flexibility responsive, check valve controlled peripheral and radial oil supply system for squeeze film shaft dampers.
SUMMARY OF THE INVENTION
In a squeeze film shaft damper defining an annular squeeze film space, a dual section, dual pressure, circumferential oil manifold concentrically surrounds the squeeze film space. A non-symmetrical row of radially inwardly directed oil inlets open into the squeeze film space at predeterminedly advantageous locations with some of said inlets providing higher pressure oil than others. Each inlet is provided with a non-frequency dependent synthetic resin check valve to prevent backflow of oil through the inlet.
This invention will be better understood when taken in connection with the following drawings and description.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial and schematic view of a squeeze film damper to which this invention is applicable.
FIG. 2 is a cross-sectional and plan view of an oil supply system for the damper of FIG. 1.
FIG. 3 is a cross-sectional and plan view of the improved oil supply system of this invention as applied to the FIG. 1 damper.
FIG. 4 is a schematic and cross-sectional view of the improved automatic check valve of this invention in a radial oil inlet.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, damper assembly 10 comprises a rolling element bearing housing 11 in which an outer annular race 12 of a rolling element bearing is fitted for limited radial motion. Outer race 12 fits closely adjacent an opposed housing wall to define a thin annular oil filled squeeze film space 13 which is closed or sealed by means of spaced piston rings 14 positioned in annular grooves in race 12 and bearing against the opposite wall of housing 11. An oil supply system for damper 10 may comprise a circumferential oil channel or manifold 15 concentrically surrounding squeeze film space 13, and damper oil is supplied to space 13 from a plurality of circumferentially spaced and radially inwardly oriented oil inlets 16 leading from manifold 15 into squeeze film space 13 or interconnecting manifold 15 and squeeze film space 13 in fluid flow relationship as illustrated in FIG. 2.
Referring now to FIG. 2, oil supply system 17 comprises circumferential channel or manifold 15 concentrically surrounding damper assembly 10 and squeeze film space 13. Manifold 15 is usually located at the axial midpoint of a damper such as damper 10 of FIG. 1. Radial oil inlets 16 are usually positioned peripherally equidistantly in manifold 15 such as, in FIG. 2 at about 60° circumferentially spaced locations.
The oil supply system as illustrated in FIG. 2 has not been found to be optimally effective over a full range of damper operation. For example, a critical period for damper operation with respect to hot gas turbine engines is initial start up rotation of the turbine wheel and its shaft. After a long rest or non-operating period of time, the shaft supporting the relatively massive turbine wheel becomes very slightly bowed or set. Rapid start up under these conditions includes an initial high degree of orbiting motion of the shaft which imposes severe requirements on the damper and its oil supply system which may not provide an immediate lift off of the shaft and full support of the shaft by oil in squeeze film space 13. Under normal operating or running conditions, an oil supply system should immediately supply oil to the low pressure or cavitation side of the damper while preventing exit of high pressure oil from the squeeze film space when at its minimum thickness. An improved oil system which accommodates the noted problems is shown in FIG. 3.
Referring now to FIG. 3, an improved oil system 18 comprises a modified circumferential manifold or channel 19 with modified oil inlets 20. Modified radial oil inlets 20 are not arranged in equidistant circumferential relationship. Oil inlets 20 are arranged non-symmetrically circumferentially, in that, of the 6 inlets illustrated, four are arranged at 90° intervals, but at the 180° position, the remaining two inlets are positioned closely adjacent the oil inlet at the 180° region which is described as the rest position of the gas turbine engine. This cluster or concentration of three or more inlets at the 180° region will supply the necessary oil at the shaft rest position on start up of the engine to lift race 12 from contact with housing 11 for better start up operation and cavitation control. Higher pressure oil to the cluster of inlets is advantageous for lift off and start up operation. In order to provide higher pressure oil to the cluster of oil inlets 20 a dual pressure manifold 19 is utilized. Dual pressure manifold 19 comprises a pair of separate and independent manifold segments 21 and 22 defined by inner partitions 23 and 24 which effectively separate manifold 19 into the pair of arc segments 21 and 22. One segment 21 is connected to its separate oil supply by conduit 25 and serves the cluster of inlets 20 in the 180° region. The other segment 22 serves the remaining oil inlets and is connected, by means of conduit 26, to a supply of oil at a pressure different from, and lower than, the supply of oil for segment 21. Oil system 18 is a dual pressure system with a non-symmetrical circumferential array of oil inlets 20 operative to supply higher pressure oil to select or cluster inlets.
The higher pressure oil flowing to the cluster of inlets is prevented from backflowing through the inlets in the cluster or through other inlets by means of an improved combined oil inlet and check valve structure 27. This check valve structure 27 is used in each oil inlet to prevent any backflow of oil due to high oil pressures generated in the damper during its operation. A cross-sectional illustration of such a combination oil inlet and check valve structure 27 is illustrated in FIG. 4.
Referring now to FIG. 4, the dual manifold assembly 28 similar to manifold 19 of FIG. 3, includes therein a combined oil inlet and check valve structure 27 for each oil inlet 20 of FIG. 3. Structure unit 27 comprises a hollow step bushing member 29 having an externally threaded shaft or shank part 30 with an expanded head part 31. Bushing 29 also includes a stepped coaxial passage 32 therethrough with a narrow part of a passage 32 in the shank part of the bushing and an enlarged part or counterbore in the head part 31. A shoulder 33 separates the passage sections. Bushing 29 is threaded into an appropriately threaded opening 34 in housing 11 opening into squeeze film space 13. The expanded head part 31 of bushing 29 is enclosed by manifold 19 (FIG. 3) which encircles squeeze film space 13 and defines a shoulder 35 for inlet openings 34. The expanded hollow head 31 of bushing 29 also defines a threaded counterbore opening into bushing 29 and rests on a gasket 36 on shoulder 35. As described, hollow bushing 29 defines a stepped cylindrical passage interconnecting manifold 19 and squeeze film space 13 in fluid flow relationship. Manifold 19 is larger than expanded head 31 so that, when manifold 19 is filled with oil, expanded head 31 is submerged and oil may flow through bushing 29 into squeeze film space 13. However, a synthetic rubber uniflow or single direction flow check valve 37 is inserted into bushing 29 to prevent backflow of oil from squeeze film space 13 into manifold 19.
Check valve 37 comprises a hollow conical section 38 with its cone base radially flared to form a gasket flange section 39 which rests on shoulder 33 of bushing 29. A threaded cover plate 40 with a concentric aperture 41 therethrough is threaded into the expanded and internally threaded head of bushing 29 to engage the flange extension 39 of cone 38 between the cover plate and shoulder 33. The described clamping arrangement prevents cone check valve 37 from being forced, by high pressure oil flow, into squeeze film space 13. Conical section 38 of valve 37 has a small opening at its apex 42 to define an open oil flow channel from manifold 19 into squeeze film space 13 which remains open under the flow of oil in or through the cone section 38 into squeeze film space 13. In the event of a very high build up of oil pressure in space 13 tending to force oil into bushing 29 in a direction toward manifold 19, oil is forced into the intervening passage space between cone section 38 and bushing 29. Due to the readily flexible nature of the material of cone section 38, cone section 38 is caused to collapse inwardly along its axis to seal off the opening at its apex 42 as well as a significant extent of its interior conical space 43 and preventing backflow of oil from squeeze film space 13 into manifold 19. Check valve 37 is expeditiously produced from a strong durable but easily flexible material such as a synthetic rubber material. It is this flexibility which expands cone section 38 for full flow of oil into squeeze film space 13, and provides a rapid collapse, as described, for backflow conditions. Check valve 37 is described as a flexibility responsive check valve operationally independent of vibration frequency.
Concentric aperture 41 of cover plate 40 is a metering feed aperture of a predetermined size to control the flow rate of oil passing through check valve 37.
The number of oil inlets for the dual pressure system of this invention may vary according to the needs of specific engine designs. One example of such a system, as illustrated in FIG. 3, may comprise six inlets arranged at the clock hour positions of 12, 3, 5, 6, 7 and 9 o'clock, an arrangement which provides a cluster of three inlets adjacent the 180° or rest position.
The dual pressure oil system of this invention with non-symmetrical peripheral distribution of oil inlets, provides higher pressure oil to a group or cluster of oil inlets to the squeeze film space at the rest position of a shaft and its damper bearing race, and lower pressure oil to the remaining inlets. Backflow of oil from all inlets is effectively controlled by means of self-acting flexibility responsive and vibration frequency independent check valves.
This invention particularly provides an improved oil system for an annular squeeze film damper which comprises a hollow manifold encircling the damper squeeze film space and a plurality of oil inlet means circumferentially distributed in a non-symmetrical manner along the manifold and opening from the manifold into the squeeze film space. The non-symmetrical arrangement provides a cluster of oil inlet means located near the rest position of the damper. The described system is broadly applicable to various damper applications involving other than rolling element bearings such as, for example, anti-friction and hydrodynamic journal bearings.
While this invention has been disclosed and described with respect to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention of the following claims. | A non-symmetrical circular row of oil inlets are located in a circular manifold surrounding a squeeze film space in a squeeze film damper. The oil inlets are directed radially inwardly from said manifold to open into the squeeze film space. Certain cluster of inlets provide higher oil pressure to the squeeze film space than other inlets. All inlets are equipped with automatically closing synthetic rubber check valves. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. patent application Ser. Nos. 60/832,338 and 60/879,180, filed Jul. 21, 2006 and Jan. 8, 2007, respectively, both of which are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] The present disclosure relates generally to an apparatus for applying lipstick, lip gloss, lip balm, or any such beauty aid to one's lips. There are many cosmetic and other lip products on the market, including, for example, lip gloss, lip sticks, and lip balm. While some lip products may be applied by a finger or a brush, many are dispensed using an applicator. For example, lip sticks are usually applied through the use of an applicator that incorporates a lip product disposed within a receptacle. The receptacle is generally a recessed member designed to hold a portion of one end of the product, the remainder of the product extending therefrom. As is common, the receptacle may incorporate a mechanism that allows the user to extend and retract the product as desired.
[0003] One of the problems with applicators is the ease, speed, and consistency with which a lip product may be applied. This problem is especially evident in the context of a performance setting, such as the set of a theatre or a motion picture. In such circumstances, it is often necessary to repeatedly apply a lip product to the lips of a single performer, or to the lips of a great multitude of performers. In this setting, it would be desirable to be able to do so very quickly in preparation for the next scene or segment of a performance. Accordingly, applying such products using an individual lip stick, for example, may be cumbersome or impractical given the need for accuracy and caution during application to ensure that the lip product is applied evenly and correctly to the performer's lips.
[0004] Therefore, a need exists for a product that facilitates facile, rapid, and reliable application a lip product.
SUMMARY
[0005] In one embodiment, a lip applicator is disclosed which includes a base portion having at least one surface configured and dimensioned to stabilize the lip applicator in a free-standing orientation, a stem portion, and a generally lip-shaped applying portion. The stem portion has a proximal end connected to the applying portion and a distal end connected to the base portion. In one embodiment, the proximal end of the stem portion is releasably connected to the applying portion, and in another embodiment, the applying portion is configured and dimensioned to rotate relative to the stem portion.
[0006] In one aspect of the present disclosure, the lip applicator further includes one or more applicator sponges that are selectively engagable with the applying portion.
[0007] The present disclosure contemplates that the stem portion may include first and second stem portions that are configured and dimensioned to be selectively movable with respect to one another. In one embodiment, the first and second stem portions are configured and dimensioned such that the first stem portion may be telescopically received within the second stem portion.
[0008] In still another embodiment, the base portion is at least partially composed of a semi-resilient material. In another embodiment, the base portion includes a cavity defined therein that is dimensioned to house or retain a beauty aid. It is contemplated that the base portion may be configured and dimensioned to selectively extend or releasably engage the beauty aid, or that the base portion may be integrally associated with therewith.
[0009] In one embodiment of the present disclosure, the lip applicator includes an applying portion that is configured and dimensioned to transition from a first position, in which the applying portion is configured for the application of a beauty aid, to a second position, in which the applying portion is configured for storage. In one embodiment, the applying portion includes a hinge portion that permits the selective folding of the applying portion thereabout prior to transitioning from the first position to the second position.
[0010] According to another aspect of the present disclosure, a lip applicator is disclosed which includes an applying portion, a stem portion that supports the applying portion, and a base portion that is operatively connected to the applying portion through the stem portion. In this embodiment, the base portion is at least partially semi-resilient such that the base portion may be selectively deformed from a first position, in which a beauty aid is retained therein, to at least one subsequent position, in which the base portion is at least partially deformed such that the beauty aid is at least partially expelled therefrom, subsequently traversing the stem portion, and exiting onto the applying portion.
[0011] In one embodiment, the lip applicator further includes a bladder disposed within the base portion that is configured and dimensioned to retain a beauty aid therein. In this embodiment, the bladder is in communication with the stem portion and is at least partially semi-resilient such that the bladder is selectively deformable from a first position to at least one subsequent position. In the first position, the bladder remains undefomed and the beauty aid remains therein. In the at least one subsequent position, however, the bladder is at least partially deformed such that the beauty aid is at least partially expelled therefrom, subsequently traversing the stem portion, and exiting onto the applying portion.
[0012] In another embodiment, the base portion is selectively engagable with the stem portion, and in an additional embodiment, the base portion defines a recess therein that is configured and dimensioned to selectively receive at least one cleaning sheet. In yet another embodiment, the base portion includes at least one surface that is at least partially reflective.
[0013] The present disclosure also contemplates a kit which includes a base portion, a stem portion having a proximal end connected to an applying portion and a distal end connected to the base portion, and a plurality of applicator sponges configured and dimensioned to selectively engage the applying portion. The present disclosure contemplates that the applicator sponges may have a beauty aid disposed thereupon.
[0014] These and other features of the microwave tissue treatment device and method of use disclosed herein will become more readily apparent to those skilled in the art from the following detailed description of various embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Various embodiments of the present disclosure are described hereinbelow with references to the drawings, wherein:
[0016] FIG. 1 is a front, perspective view of a lip applicator in accordance with the principles of the present disclosure;
[0017] FIG. 2 is a front, perspective view of a lip applicator, in accordance with one embodiment of the present disclosure, including a selectively extendible stem portion;
[0018] FIG. 3 is a front, perspective view of a lip applicator, in accordance with another embodiment of the present disclosure, including a base portion with a cavity dimensioned and configured to retain a beauty aid therein;
[0019] FIG. 4A is a front, perspective view of a lip applicator, in accordance with the embodiment of FIG. 3 , shown in a first position;
[0020] FIG. 4B is a front, perspective view of a lip applicator, in accordance with the embodiment of FIG. 3 , shown in a second position;
[0021] FIG. 5A is a front, perspective view of a lip applicator, in accordance with one embodiment of the present disclosure, shown in a first position, including a release mechanism and a cavity dimensioned and configured to receive a stem portion and an applying portion;
[0022] FIG. 5B is a front, perspective view of the lip applicator of FIG. 5A , shown in a second position;
[0023] FIG. 6A is a front, perspective view of a lip applicator, in accordance with another embodiment of the present disclosure, shown in a first position, that includes a release mechanism, a selectively foldable applying portion, a stem portion, and a base portion with a cavity dimensioned and configured to receive the stem portion and the applying portion;
[0024] FIG. 6B is a front, perspective view of the lip applicator of FIG. 6A shown in a second position;
[0025] FIG. 7A is a front, perspective view of a lip applicator, according to one embodiment of the present disclosure, that includes a conduit disposed within a stem portion, and an applying portion having an aperture;
[0026] FIG. 7B is a front, perspective view of a lip applicator, in accordance with another embodiment of the present disclosure, including a conduit disposed within a stem portion, an applying portion having an aperture, a base portion, and a bladder;
[0027] FIG. 8 is a front, perspective view of a lip applicator, in accordance with one embodiment of the present disclosure, including a base portion that defines a recess;
[0028] FIG. 9 is a front, perspective view of a lip applicator, according to another embodiment of the present disclosure, including a base portion with a reflective surface;
[0029] FIG. 10 is a side, plan view illustrating the use of a lip applicator in accordance with the principles of present disclosure;
[0030] FIG. 11 is a front, perspective view of a lip applicator, according to yet another embodiment of the present disclosure, that includes an applicator surface configured to retain an applicator sponge;
[0031] FIG. 12A is a front, perspective view of a sheet that includes a multitude of applicator sponges varying in size; and
[0032] FIG. 12B is a front, perspective view of a sheet that includes a multitude of applicator sponges of one particular size.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0033] Specific embodiments of the lip applicator disclosed herein will now be described in detail with reference to the foregoing figures, wherein like reference numerals identify similar or identical elements. In the drawings, and in the description which follows, the term “beauty aid” may refer to a lipstick, a lip gloss, or any such product that may be topically applied to one's lips. In addition, the term “user” may refer either to the person to whom the beauty aid is applied, or to the person handling the lip applicator and applying a beauty aid to the lips of another. Finally, the terms “proximal” and “distal” will be understood as referring to those portions of the lip applicator that are closest to, and furthest from, respectively, the applying portion, as defined below.
[0034] Referring now to the drawings, FIG. 1 generally illustrates a lip applicator 10 for applying a beauty aid 12 to one's lips (see also FIG. 10 ). Lip applicator 10 includes a generally lip-shaped applying portion 14 , which is configured to retain beauty aid 12 thereon, a stem portion 16 that extends distally from and supports the applying portion 14 , and a base portion 18 that is configured to support the lip applicator 10 in an upward, or free-standing orientation, as seen in FIG. 1 , if so desired.
[0035] In each embodiment of the present disclosure described herein, a variety of configurations and sizes are contemplated for applying portion 14 , such that lip applicator 10 may be compatible with a greater multitude of user's.
[0036] Base portion 18 may be configured to facilitate handling and may include various contours, scallops, protuberances and/or gripping surfaces to enhance a user's grip thereof. The base portion 18 includes a bottom surface 20 which is configured and dimensioned to stabilize the lip applicator 10 atop a table or other surface 22 when not in use. Bottom surface 20 may be configured and dimensioned in any suitable manner that facilitates the stabilization of lip applicator 10 . Configurations for bottom surface 20 may include, but are not limited to, a flat surface, a concave surface, a surface including independent support legs, or a surface that includes an adhesive mechanism, e.g., a suction-cup, as would be appreciated by one of ordinary skill in the art. As depicted in FIG. 1 , bottom surface 20 is flat and rectilinear in shape, but a base portion 18 having another geometric configuration, or an ornamental shape, is not beyond the scope of the present disclosure. Bottom surface 20 may also be textured, or may include a plastic, rubberized, or any other suitable surface that may enhance the stability and/or handling of lip applicator 10 .
[0037] Referring still to FIG. 1 , applying portion 14 is generally “lip-shaped”. This configuration allows for the even and facile application of a beauty aid 12 to one's lips. The present disclosure contemplates that applying portion 14 may be integrally formed with stem portion 16 through any suitable method or mechanism including, but not being limited to, screws, adhesives, or monolithic formation therewith. It is further contemplated that applying portion 14 may be releasably connected to stem portion 16 , again through any suitable method, including, but not limited to, a snap-fit arrangement or interference fitting, such that applying portion 14 may be selectively engagable therewith, or replaceable.
[0038] In one embodiment, as seen in FIG. 2 , lip applicator 100 includes an applying portion 114 , a stem portion 116 , and a base portion 118 . It is contemplated that applying portion 114 and base portion 118 may each be releasably or integrally connected to stem portion 116 . Stem portion 116 includes a first portion 116 a configured and dimensioned to be selectively movable with respect to a second portion 116 b . First and second stem portions 116 a , 116 b may allow for continuous or incremental movement with respect to one another such that applying portion 114 may be adjusted relative to base portion 118 during or prior to use.
[0039] First and second stem portions 116 a , 116 b may be configured and dimensioned in any manner such that one of the first and second stem portions 116 a , 116 b is movable in relation to, and may be received by, the other, e.g. telescopically. In the embodiment depicted in FIG. 2 , first stem portion 116 a is telescopically moveable in the direction indicated by arrow “A” within lower stem portion 116 b , such that lip applicator 100 is selectively extendable. In an alternate embodiment, it is contemplated that second stem portion 116 b may be received by, and may be movable within, first stem portion 116 a , again enabling the selective extension of the lip applicator 100 .
[0040] In another embodiment, as seen in FIG. 3 , lip applicator 200 includes an applying portion 214 , a stem portion 216 and a base portion 218 that defines a cavity 224 therein which is dimensioned to releasably retain a beauty aid 212 . Beauty aid 212 may be releasably engageable with base portion 218 through any suitable mechanism or structure including, but not limited to, snap-fit or interference fit arrangements, to allow for the selective removal, replacement, and/or substitution of various beauty aids, or beauty aid 212 may be integrally associated with, or formed within, base portion 218 such that beauty aid 212 may not be replaced, substituted, or removed therefrom.
[0041] Referring now to FIGS. 4A-4B , a lip applicator 300 is disclosed that includes an applying portion 314 , a stem portion 316 , and a base portion 318 rotatably connected to the stem portion 316 through any suitable mechanism or structural adaptation, such that lip applicator 300 may be selectively transitioned or moved from a first position to a second position.
[0042] In the first position, seen in FIG. 4A , beauty aid 312 is disposed within cavity 324 , whereas in the second position, seen in FIG. 4B , beauty aid 312 at least partially extends therefrom. To move lip applicator 300 from the first position to the second position, and thereby selectively extend beauty aid 312 from cavity 324 , either base portion 318 , or stem portion 316 , may be rotated. To move lip applicator 300 from the second position to the first position, and thereby selectively retract beauty aid 312 , again, either base portion 318 , or stem portion 316 , may be rotated. In transitioning from the first position to the second position, or from the second position to the first position, base portion 318 , or stem portion 316 , may be rotated either clockwise, in the direction of arrow “B”, or counterclockwise, in the direction of arrow “C”.
[0043] In the embodiments shown in FIGS. 3 and 4 A- 4 B, it is contemplated that the configuration and dimensions of the cavity may be varied such that base portion may accommodate a variety of beauty aids. In addition, with respect to each embodiment discussed heretofore, it is contemplated that the lip applicator may employ a plurality of cavities, each of which may vary in size and/or configuration, thereby allowing for the incorporation of a multitude of beauty aids. It is further contemplated, in each embodiment described thus far, that the stem portion may include two or more sections configured and dimensioned to be respectively movable with respect to each other, e.g., telescopically, as disclosed in the embodiment depicted in FIG. 2 .
[0044] In FIGS. 5A-5B , a lip applicator 400 is disclosed that includes an applying portion 414 , a stem portion 416 , and a base portion 418 . Lip applicator 400 further includes a release mechanism 426 and a cavity 424 defined in base portion 418 that is configured and dimensioned to removably receive stem portion 416 and applying portion 414 , as will be discussed in further detail below. Applying portion 414 is movably secured to stem portion 416 , e.g. rotatably or pivotably secured, such that applying portion 414 and stem portion 416 are selectively movable in relation to one another, either in the direction of arrow “D” or arrow “E”, from a first position, seen in FIG. 5A , to a second position, seen in FIG. 5B .
[0045] In the first or applying position, seen in FIG. 5A , lip applicator 400 defines a first height H 1 , and applying portion 414 is substantially horizontal in orientation, thereby facilitating the application of beauty aid 412 by a user. If desired, applying portion 414 may be rotated and moved into the second position, in which applying portion 414 is substantially vertical in orientation and at least a portion thereof is removably disposed within cavity 424 , together with at least a portion of stem portion 416 , as seen in FIG. 5B . In the second position, lip applying portion 414 may be substantially protected from the ambient, thereby remaining free of dust, particulates, or the like during non-use. In the second position, the overall height H 2 of lip applicator 400 is substantially reduced when compared to that of lip applicator 400 in the first position. This reduction in height may facilitate the convenient storage or transport of the lip applicator 400 , if so desired. It is contemplated that stem portion 416 may include two or more sections that may be configured and dimensioned to move with respect to one another in any suitable manner such that one of the portions may be movable in relation to, and may be received by, the other portion, e.g. telescopically, as depicted in the embodiment of FIG. 2 .
[0046] Referring still to FIGS. 5A-5B , as discussed above, lip applicator 400 includes release 426 . Release 426 maintains lip applicator 400 in either the first position, or the second position, until it is desired by the user to move therebetween. At such time, the user may actuate release 426 and configure the lip applicator 400 either for storage, or for use. Release 426 may be any mechanical mechanism suitable for the intended purpose of preventing the unintentional transitioning between the first and second positions, illustrative examples of which include, but are not limited to, a depressible button, a rotatable knob, or a slidable button set within a track 428 , as seen in FIGS. 5A-5B .
[0047] FIGS. 6A-6B illustrate a lip applicator 500 having an applying portion 514 with two individual portions 514 a , 514 b and a hinge portion 530 , a stem portion 416 , and a base portion 418 . Lip applicator 500 functions in a manner identical to that disclosed with respect to the previous embodiments depicted in FIGS. 5A-5B , in that lip applicator 500 is adapted to transition from a first, applying position, to a second storage position in which lip applying portion 514 and stem portion 516 are at least partially disposed within and removable from a cavity 524 in base portion 518 .
[0048] Portions 514 a and 514 b are selectively foldable in the direction of arrow “G” relative to one another about hinge portion 530 , such that the dimensions of applying portion 514 may be substantially reduced, thereby facilitating the storage thereof in base portion 518 while in the second position. In one aspect of the present disclosure, applying portion 514 may be manually folded about hinge portion 530 at the will of the user, whereas in another aspect, applying portion 514 may only be folded upon the actuation of release 526 . Release 526 , therefore, may serve dual purposes. First, release 526 may facilitate the folding of applying portion 514 about hinge portion 530 . And second, release 526 may facilitate the movement or transition of lip applicator 500 from the first position, seen in FIG. 6A , to the second position, seen in FIG. 6B , or from the second position to the first position, as discussed above. In a further aspect of the present disclosure, lip applicator 500 may employ multiple, independent release mechanisms (not shown), one to permit the folding and/or the unfolding of the applying portion 514 about a hinge portion 530 , and a second to permit the transition of the lip applicator from the first position to the second position. With respect to the folding and unfolding of the applying portion, the release, or releases, employed may be any mechanism or structural adaptation suitable for preventing against the inadvertent folding or unfolding of the applying portion.
[0049] With respect to the embodiments of FIGS. 5A-6B , the base portion may be configured and dimensioned to retain a beauty aid therein, either integrally or selectively, as disclosed in the embodiments of FIGS. 2-4B . It is also contemplated that the dimensions of the cavity may be varied such that base portion may accommodate a variety of beauty aids. In addition, the lip applicator may employ a plurality of cavities, each of which may vary in size and/or configuration, thereby allowing for the incorporation of additional beauty aids. It is also contemplated that the stem portion may include two or more sections that may be configured and dimensioned to move with respect to one another in any suitable manner such that one section may be movable in relation to, and may be received by, the other section, e.g. telescopically, as disclosed in the embodiment of FIG. 2 .
[0050] Referring now to FIG. 7A , lip applicator 600 includes an applying portion 614 with an aperture 638 , a stem portion 616 having a conduit 632 defining proximal and distal ends 634 , 636 disposed therein, and a base portion 618 .
[0051] Base portion 618 is configured and dimensioned to retain a beauty aid 612 therein, and is formed, either in whole or in part, of any resilient or semi-resilient material capable of transitioning from a first, initial position (not shown) to a second, deformed position (not shown), upon the application of a force “F” thereto, as may be appreciated by one of ordinary skill in the art. Force “F” may be generated by squeezing base portion 618 , or in any other suitable manner, including, but not being limited to, twisting.
[0052] In the first position, base portion 618 is not subject to any external force. Accordingly, in this position, beauty aid 612 remains within the base portion 618 . However, upon the application of force “F” thereto, the walls 640 of base portion 618 may begin to deform inwardly, thereby decreasing the volume of base portion 618 , as would be appreciated by one of ordinary skill in the art, such that the beauty aid 612 may be forced outwardly therefrom. Conduit 632 is in fluid communication with base portion 618 such that beauty aid 612 may enter conduit 632 through the distal end 636 thereof upon expulsion from base portion 618 , subsequently being communicated therethrough, and exiting onto applying portion 614 through proximal end 634 and aperture 638 .
[0053] It is contemplated herein that base portion 618 may be rotatably secured to stem portion 616 such that the force “F” required to deform the base portion 618 , and expel beauty aid 612 therefrom, may be generated through the rotation, or twisting, of base portion 618 .
[0054] Base portion 618 may be selectively engageable with stem portion 616 through any suitable mechanism or arrangement, including, but not limited to, screw-type or snap-fit arrangements, such that base portion 618 and the beauty aid 612 retained therein, may be replaced when necessary or desired. Alternatively, base portion 618 may be integrally formed with stem portion 616 such that the lip applicator 600 may be considered disposable.
[0055] Referring now to FIG. 7B , lip applicator 700 includes an applying portion 714 , a stem portion 716 , and a base portion 718 having a bladder 742 disposed therein and secured thereto through any suitable means, including, but not being limited to, adhesives. Base portion 718 and bladder 742 may be formed, either in whole or in part, of any resilient or semi-resilient material capable of transitioning from a first, initial position (not shown) to a second, deformed position (not shown) upon the application of a force “F” thereto, again generated in any suitable manner. Conduit 732 is in fluid communication with bladder 742 such that a beauty aid 712 , retained therein, may enter conduit 732 through a distal end 736 thereof upon being expelled from bladder 742 , as discussed above with respect to the disclosure in FIG. 7A . Subsequently, beauty aid 712 may be communicated through conduit 732 , and the proximal end 734 thereof, onto applying portion 714 through an aperture 738 .
[0056] In one embodiment, base portion 718 may be rotatably secured to stem portion 716 such that the force “F” required to deform bladder 742 and expel beauty aid 712 therefrom may be generated through the rotation of base portion 718 . In this embodiment, the force “F” created through the rotation of base portion 718 is transmitted to bladder 742 through the connection therebetween.
[0057] Base portion 718 , and therefore bladder 742 , may be selectively engagable with stem portion 716 through any suitable mechanism or arrangement, including, but not limited to, screw-type or snap-fit arrangements, such that base portion 718 , bladder 742 , and the beauty aid 712 retained therein, may be replaced when necessary or desired. It is further contemplated that base portion 718 may be integrally formed with stem portion 716 such that lip applicator 700 may be considered disposable.
[0058] In one embodiment, as seen in FIG. 8 , lip applicator 800 is disclosed which includes an applying portion 814 , a stem portion 816 , and a base portion 818 that defines a recess 844 therein configured and dimensioned to releasably retain at least one cleaning sheet 846 , e.g., a tissue or an anti-bacterial wipe, for selective distribution. Base portion 818 may be selectively engagable with stem portion 816 such that base portion 818 , and the cleaning sheets 846 retained therein, may be replaced when necessary. It is further contemplated that base portion 818 may be integrally formed with stem portion 816 such that lip applicator 800 may be considered disposable.
[0059] In another embodiment, as seen in FIG. 9 , a lip applicator 900 is disclosed that includes an applying portion 914 , a stem portion 916 , and a base portion 918 including at least one reflective surface 948 . Reflective surface 948 may be disposed on any suitable surface of base portion 918 , including, but not limited to, any face 950 , or the bottom surface 952 . Reflective surface 948 may also be disposed in any other suitable location, including, but not being limited to applying portion 914 . It is further envisioned that base portion 918 itself be formed, in whole or in part, of a reflective material, thereby obviating the need for an additional reflective element.
[0060] Referring now to FIG. 10 , a lip applicator 1000 is illustrated. As illustrated, base portion 1018 and/or stem portion 1016 may be grasped by the user. Applying portion 1014 may then be raised and pressed to the user's lips, either by the user, or by another party, as shown. Applying portion 1014 is then pressed against the user's lips until such time that the desired beauty aid (not shown) is sufficiently applied thereto.
[0061] FIG. 11 discloses yet another embodiment of the present disclosure. Lip applicator 1100 is generally similar to lip applicator 10 shown in FIG. 1 and includes applying portion 1114 , stem portion 1116 , and base portion 1118 . Applicator 1100 further includes an applicator surface 1154 configured to releasably retain an applicator sponge 1156 . Applicator sponge 1156 has a general configuration mimicking that of applicator surface 1154 . Applicator sponges of various shapes and sizes, in particular, but not limited to, small, medium, and large sponges 1156 a , 1156 b , 1156 c may be used in conjunction with lip applicator 1100 dependent upon the labial characteristics of the person to whom a beauty aid (not shown) need be applied.
[0062] In preparation for use, the user orients applicator sponge 1156 with respect to applicator surface 1154 and applies a force thereto in the direction of arrow “H”. Applicator sponge 1156 may include an adhesive substrate (not shown) disposed on any suitable surface thereof, including, but not being limited to, underside 1158 , which may releasably adhere to applicator surface 1154 . Applicator sponge 1156 may also include a peel-away liner (not shown) to protect the adhesive substrate (not shown) prior to use. Any adhesive substrate may be employed, including water or liquid-activated adhesives. Alternatively, applicator surface 1154 may include an adhesive-like substance (not shown) which adheres to applicator sponge 1156 when placed upon applicator surface 1154 . A reusable or tacky substance may be utilized to accomplish this purpose.
[0063] As best shown in FIGS. 12A and 12B , a plurality of applicator sponges 1156 a - 1156 c , that may vary in size, may be arranged on sheet 1160 and sold as a package. Sheet 1160 may be made from a releasable film (e.g., wax-like paper) that allows a user to simply peel-away one or more sponges 1156 a - 1156 c for use. Sheet 1160 may also simply be a support structure, e.g., cardboard, for selling a large number of sponges in a single package. After use, the user simply peels applicator sponge 1156 from surface 1154 and discards the sponge 1156 .
[0064] The present disclosure contemplates that a beauty aid (not shown) may be pre-applied to applicator sponges 1156 . To preserve the integrity of the beauty aid (not shown) prior to application, the beauty aid may by disposed beneath and protected by a peel-away film (not shown), or the like, as would be appreciated by one of ordinary skill in the art. Following the orientation of sponge 1156 atop applicator surface 1154 , as describe above, the user may simply remove the protective film (not shown), and thereby expose the beauty aid (not shown).
[0065] From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the same. While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims to be appended hereto. | A lip applicator generally relating to the application of a variety of products, including lipstick, lip gloss, lip balm, or any such beauty aid, to one's lips. The lip applicator disclosed herein may be held during use, but is adapted for upright placement on a table-top or other flat surface during non-use. The lip applicator disclosed herein facilitates the facile, rapid, and reliable application a lip product, and may be of particular import in those settings requiring the repeated or frequent application of a beauty aid to one or more people's lips, such as the set of a motion picture or theatrical performance. | 0 |
[0001] The present invention relates to a rolling bearing and a camshaft assembly.
BACKGROUND INFORMATION
[0002] Camshafts are used in valve train assemblies of internal combustion engines for the purpose of controlling the opening and/or closing of inlet valves and/or outlet valves in a targeted manner. The camshaft is driven by a crankshaft.
[0003] Adjustment of the phase angle of the camshaft with respect to the crankshaft may take place with the aid of a hydraulic phase adjusting device which is placed, for example, in or on the camshaft and which is supplied with a hydraulic pressure medium such as motor oil, for example via the oil pump of the internal combustion engine. Pressure medium-conducting channels may be formed in the camshaft for the purpose of supplying the hydraulic phase adjusting device with the hydraulic pressure medium.
[0004] Publication EP 2 326 804 B1 describes a camshaft assembly, in which a hydraulic phase adjusting device is supplied with pressure medium via a radial channel in the camshaft.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide a preferably installation space-saving option for transferring a hydraulic medium, for example for a camshaft whose phase angle with respect to a crankshaft is adjustable with the aid of a hydraulic pressure medium, using a hydraulic phase adjusting device.
[0006] The present invention provides a rolling bearing which has a rolling bearing inner ring, a rolling bearing outer ring and a rolling bearing ball cage ring and which includes at least one channel for conducting a hydraulic pressure medium. Due to the at least one channel, a hydraulic pressure medium may be advantageously conducted in an installation space-saving manner.
[0007] For example, the rolling bearing inner ring may be designed to be rotatable and the rolling bearing outer ring to be stationary, or the rolling bearing inner ring may be designed to be stationary and the rolling bearing outer ring to be rotatable. The rolling bearing ball cage ring may be designed to be both stationary and rotatable or to be loosely or floatingly supported.
[0008] The rolling bearing may be used, for example, for the purpose of, in particular rotatable, support of a camshaft. The camshaft may be, in particular, a camshaft whose phase angle with respect to a crankshaft is adjustable with the aid of a hydraulic pressure medium, for example using a hydraulic phase adjusting device. The hydraulic phase adjusting device may be designed, for example, as a vane-type adjuster. For example, the hydraulic phase adjusting device may be situated at least partially within the camshaft or its interior and/or be supplied with the hydraulic pressure medium via the interior of the camshaft. For this purpose, the camshaft may include, for example, at least one radial channel.
[0009] In particular, the rolling bearing may be designed to transfer a hydraulic pressure medium from a stationary component to a rotatable component. For example, a pressure medium channel formed in a stationary component, for example in a cylinder head-affixed component, may communicate with the phase adjusting device via the at least one channel of the rolling bearing. For example, the pressure medium channel may communicate with the phase adjusting device via the at least one channel of the rolling bearing and at least one radial channel of the camshaft and/or the interior of the camshaft. The pressure medium channel may also be, for example, a radial channel.
[0010] A cylinder head-affixed component may be understood, in particular, to be a component which is immovably situated on the cylinder head. This component may be, for example, the cylinder head, a cylinder head cover, a crankcase, a chain case or an ancillary component connected to these components.
[0011] Communicating may be understood to be a direct pressure medium transfer as well as an indirect pressure medium transfer, for example via one or multiple additional, for example interposed, openings, channels and/or components.
[0012] Within the scope of one specific embodiment, the rolling bearing includes at least one pressure medium transfer element. The pressure medium transfer element may be, in particular, an independent component or an independent component arrangement. The pressure medium transfer element may be situated loosely or floatingly supported in the rolling bearing or fastened to a rolling bearing component, for example to the rolling bearing inner ring or to the rolling bearing outer ring or to the rolling bearing ball cage ring. The pressure medium transfer element may be, in particular, an annular component or an annular component arrangement.
[0013] Within the scope of another specific embodiment, on the other hand, at least one rolling bearing component, in particular the rolling bearing inner ring and/or the rolling bearing outer ring and/or the rolling bearing ball cage ring, itself is used to transfer the hydraulic pressure medium.
[0014] Within the scope of one preferred specific embodiment, at least one pressure medium transfer element and/or rolling bearing component, in particular the rolling bearing inner ring and/or the rolling bearing outer ring and/or the rolling bearing ball cage ring, includes at least one annular channel for the purpose of transferring the hydraulic pressure medium, in particular, between a stationary component and a rotatable component.
[0015] In particular, the at least one annular channel of the pressure medium transfer element or the rolling bearing component may have an annular channel opening extending in the circumferential direction of the annular channel and at least one radial channel opening opposite the annular channel opening and emptying into a radial channel.
[0016] A pressure medium transfer between a stationary component and a rotatable component may advantageously take place in a simple, reliable and installation space-saving manner via the annular channel opening and the at least one radial channel opening of the at least one annular channel of the pressure medium transfer element or the rolling bearing component. In particular, at least one pressure medium channel in a stationary component, for example a cylinder head-affixed component, may communicate with at least one channel in the rotatable component, for example the camshaft, via the annular channel opening and radial channel opening(s) of the annular channel of the pressure medium transfer element.
[0017] Within the scope of another preferred specific embodiment, at least one pressure medium transfer element and/or rolling bearing component, in particular the rolling bearing inner ring and/or the rolling bearing outer ring and/or the rolling bearing ball cage ring, includes at least one radial channel which empties into a radial channel opening of the at least one annular channel of the pressure medium transfer element or the rolling bearing component.
[0018] The at least one pressure medium transfer element and/or rolling bearing component may include both one annular channel and two or more annular channels. It is also possible for two or possibly more radial channels to be provided.
[0019] In particular, the rolling bearing may include two or more components, which each include at least one annular channel, in particular having an annular channel opening extending in the circumferential direction of the annular channel, and at least one radial channel opening opposite the annular channel opening and emptying into a radial channel, and, if necessary, at least one radial channel emptying into a radial channel opening of the annular channel. For example, the rolling bearing may include two pressure medium transfer elements of this type or one pressure medium transfer element of this type and one rolling bearing component of this type or two rolling bearing components of this type. For example, the rolling bearing inner ring and the rolling bearing outer ring or the rolling bearing ball cage ring and the rolling bearing inner ring and/or the rolling bearing outer ring may each be designed in this way. The pressure medium transfer among the components may take place via the annular channel openings and radial channel openings of the annular channels. In particular, annular channels of different components may empty into each other and have, for example, annular channel openings which are situated opposite each other, in particular directly adjacent to each other.
[0020] In principle, it is possible to fasten the pressure medium transfer element or the rolling bearing component in an angle-oriented manner. To dispense with an angle-oriented mounting, it may, however, be advantageous to provide one or multiple additional (mounting) annular channels and/or one or multiple additional (mounting) radial channels, for example having radial channel openings which are enlarged axially and/or in the circumferential direction. Due to the additional (mounting) annular channels and/or (mounting) radial channels, mounting tolerances may be advantageously compensated for and the mounting simplified thereby.
[0021] For example, the at least one radial channel of the pressure medium transfer element or the rolling bearing component may empty into another (mounting) annular channel and/or another (mounting) radial channel having enlarged radial channel openings, for example which has an opening provided in an outer surface of the component. The additional (mounting) annular channel or (mounting) radial channel may be formed in the pressure medium transfer element or rolling bearing component or in a component adjacent thereto and having a channel, for example the camshaft or a cylinder head-affixed component.
[0022] At least one pressure medium transfer element and/or rolling bearing component, in particular the rolling bearing inner ring and/or the rolling bearing outer ring and/or the rolling bearing ball cage, preferably includes at least one annular channel having a radially outer annular channel opening and, in particular, at least one radially inner radial channel opening and/or at least one annular channel having a radially inner annular channel opening and, in particular, at least one radially outer radial channel opening.
[0023] The terms outer and inner refer to the particular annular channel, the term radial also referring to the rotationally symmetrical axis of the particular annular channel or also to the rotation axis of the camshaft or the rolling bearing or possibly of the camshaft.
[0024] Within the scope of another preferred specific embodiment, at least one pressure medium transfer element and/or rolling bearing component, in particular the rolling bearing inner ring and/or the rolling bearing outer ring and/or the rolling bearing ball cage ring, includes at least one annular channel having a radially outer annular channel opening. In particular, the annular channel may have at least one radially inner radial channel opening.
[0025] Within the scope of one special embodiment, at least one pressure medium transfer element and/or rolling bearing component, in particular the rolling bearing inner ring and/or the rolling bearing outer ring and/or the rolling bearing ball cage, includes at least one annular channel having a radially outer annular channel opening and, in particular, at least one radially inner radial channel opening, an annular channel having a radially inner annular channel opening and, in particular at least one radially outer radial channel opening as well as at least one radial channel which connects the annular channel having the radially outer annular channel opening to the annular channel having the radially inner annular channel opening. The at least one radial channel may empty, in particular, into the at least one radial inner radial channel opening of the annular channel having the radially outer annular channel opening and into the at least one radially outer radial channel opening of the annular channel having the radially inner annular channel opening. The annular channel having the radially outer annular channel opening and, in particular, the at least one radially inner radial channel opening may be, for example, an annular channel which is formed with the radially inner annular channel opening and the at least one radially outer radial channel opening radially outward from the annular channel, it being possible to refer to the annular channel having the radially outer annular channel opening as the outer annular channel and the annular channel having the radially inner annular channel opening as the inner annular channel.
[0026] This embodiment has the advantage, on the one hand, that it may be situated, loosely or floatingly supported, for example between the stationary component and the rotatable component, for example between the rolling bearing inner ring and the rolling bearing outer ring or between a rolling bearing component and the cylinder head-affixed component or the camshaft or between the cylinder head-affixed component and the camshaft, it being possible to both facilitate a pressure medium transfer between a stationary component and a rotating component and to dispense with an angle-oriented alignment, due to the two annular channels.
[0027] On the other hand, if this embodiment is fixedly connected to a component or integrated therein, this has proven to be advantageous, since it facilitates a pressure medium transfer between a stationary component and a rotating component via the one annular channel and may be fastened via the surface having the other annular channel, without taking into account an angle-oriented alignment, whereby the mounting may be advantageously simplified.
[0028] The rolling bearing may include a component of this type, for example a pressure medium transfer element of this type or a rolling bearing component of this type, for example a rolling bearing inner ring or rolling bearing outer ring or rolling bearing ball cage ring of this type. A pressure medium transfer element of this type may be situatable or situated, for example, between the rolling bearing inner ring and the rolling bearing outer ring, or between the rolling bearing inner ring or the rolling bearing outer ring and the cylinder head-affixed component, or between the rolling bearing outer ring or the rolling bearing inner ring and the camshaft. A rolling bearing inner ring of this type may be situatable or situated, for example, between the camshaft and the rolling bearing ball cage ring or the rolling bearing outer ring or the cylinder head-affixed component. A rolling bearing outer ring of this type may be situatable or situated, for example, between the cylinder head-affixed component and the rolling bearing ball cage ring or the rolling bearing inner ring or the camshaft. A rolling bearing ball cage ring of this type may be situatable or situated, for example, between the rolling bearing inner ring or the camshaft and the rolling bearing outer ring or the cylinder head-affixed component. The pressure medium transfer element or rolling bearing component may be loosely or floatingly supported or fastenable or fastened to a rotatable or stationary component. For example, one of the annular channels of the pressure medium transfer element or rolling bearing component may communicate with a channel of a stationary or rotatable, in particular stationary, component, for example a pressure medium channel of a cylinder head-affixed component, or empty therein, in particular radially, for example directly or indirectly, via an annular channel opening, for example, the annular channel opening being situated opposite, in particular directly adjacent to, an opening of the channel of the component. The other annular channel of the pressure medium transfer element or rolling bearing component may communicate with a channel of a rotatable or stationary, in particular rotatable, component, for example one or multiple radial channels of the camshaft, or empty therein, in particular radially, for example directly or indirectly, via an annular channel opening, for example, the annular channel opening being situated opposite, in particular directly adjacent to, an opening of the channel of the component.
[0029] It is furthermore possible that the rolling bearing has two or more components of this type. For example, the rolling bearing may include two pressure medium transfer elements of this type or one pressure medium transfer element of this type and one rolling bearing component of this type or two rolling bearing components of this type. For example, the rolling bearing inner ring and the rolling bearing outer ring or the rolling bearing ball cage ring and the rolling bearing inner ring and/or the rolling bearing outer ring may each be designed in this way. Or the rolling bearing includes a pressure medium transfer element of this type and a rolling bearing inner ring or rolling bearing outer ring or rolling bearing ball cage ring of this type. For example, one of the components may be rotatable, for example fastenable to the camshaft, or fastened to the rotatable rolling bearing ring, or it may be the rotatable rolling bearing ring itself, or it may be loosely or floatingly supported, for example fastened to the rolling bearing ball cage ring, in particular to an axial surface of the rolling bearing ball cage ring, or it may be the rolling bearing ball cage ring itself or it may be situated adjacent to the rolling bearing ball cage ring. The other component may be stationary, for example, fastenable to the cylinder head-affixed component, or fastened to the stationary rolling bearing ring, or it may be the stationary rolling bearing ring itself, or it may be loosely or floatingly supported, for example fastened to the rolling bearing ball cage ring, in particular to an axial surface of the rolling bearing ball cage ring, or it may be the rolling bearing ball cage ring itself or it may be situated adjacent to the rolling bearing ball cage ring. An annular channel of the rotatably/floatingly supported component facilitates a pressure medium transfer to an annular channel of the stationary/floatingly supported component. For example, the radially inner annular channel opening of the annular channel of the one, for example stationary/floatingly supported, component may be situated opposite, in particular directly adjacent to, the radially outer annular channel opening of the annular channel of the other, for example rotatably/floatingly supported component. An angle-oriented mounting may be advantageously dispensed with, due to the surfaces in which the annular channel openings of the two other annular channels of the components are formed (see FIG. 4 ).
[0030] Within the scope of one particularly special embodiment, the rolling bearing inner ring includes an annular channel having a radially outer annular channel opening and, in particular, at least one radially inner radial channel opening, an annular channel having a radially inner annular channel opening and, in particular, at least one radially outer radial channel opening as well as at least one radial channel which connects the annular channel having the radially outer annular channel opening of the rolling bearing inner ring to the annular channel having the radially inner annular channel opening of the rolling bearing inner ring, in particular the least one radial channel of the rolling bearing inner ring emptying into the at least one radially inner radial channel opening of the annular channel having the radially outer annular channel opening of the rolling bearing inner ring and into the at least one radially outer radial channel opening of the annular channel having the radially inner annular channel opening of the rolling bearing inner ring.
[0031] The rolling bearing outer ring also includes an annular channel having a radially outer annular channel opening and, in particular, at least one radially inner radial channel opening, an annular channel having a radially inner annular channel opening and, in particular, at least one radially outer radial channel opening as well as at least one radial channel which connects the annular channel having the radially outer annular channel opening of the rolling bearing outer ring to the annular channel having the radially inner annular channel opening of the rolling bearing outer ring, in particular the least one radial channel of the rolling bearing outer ring emptying into the at least one radially inner radial channel opening of the annular channel having the radially outer annular channel opening of the rolling bearing outer ring and into the at least one radially outer radial channel opening of the annular channel having the radially inner annular channel opening of the rolling bearing outer ring.
[0032] The radially outer annular channel opening of the annular channel of the rolling bearing inner ring is situated opposite, in particular directly adjacent to, the radially inner annular channel opening of the annular channel of the rolling bearing outer ring.
[0033] The annular channel having the radially inner annular channel opening of the rolling bearing inner ring may communicate with a channel of a rotatable or stationary, in particular rotatable, component, for example with at least one radial channel of the camshaft, or the annular channel having the radially outer annular channel opening of the rolling bearing outer ring may communicate with a channel of a stationary or rotatable, in particular stationary, component, for example with a pressure medium channel of a cylinder head-affixed component. In particular, the annular channel having the radially inner annular channel opening of the rolling bearing inner ring may empty, in particular radially, into a channel of a rotatable or stationary, in particular rotatable, component, for example into one or multiple radial channels of the camshaft, for example, the radially inner annular channel opening of the rolling bearing inner ring being situated opposite, in particular directly adjacent to, a radially outer opening of the channel of the component, for example one or multiple radially outer radial channel openings of the camshaft. The annular channel having the radially outer annular channel opening of the rolling bearing outer ring may empty, in particular radially, into a channel of a stationary or rotatable, in particular stationary, component, for example into the pressure medium channel of the cylinder head-affixed component, for example, the radially outer annular channel opening of the rolling bearing outer ring being situated opposite, in particular adjacent to, a radially inner opening of the channel of the component, for example a radially inner opening of the pressure medium channel of the cylinder head-affixed component.
[0034] Within the scope of another special embodiment, a pressure medium transfer element or a rolling bearing ball cage ring is situated between the rolling bearing inner ring and the rolling bearing outer ring, which includes at least one annular channel, in particular having an annular channel opening extending in the circumferential direction of the annular channel, and at least one radial channel opening opposite the annular channel opening and emptying into a radial channel and at least one radial channel which empties into a radial channel opening of at least one annular channel of the pressure medium transfer element or the rolling bearing ball cage ring. The pressure medium transfer element may be situated, for example, loosely or floatingly supported, for example adjacent to the rolling bearing ball cage ring or fastened to the rolling bearing ball cage ring, in particular to an axial surface of the rolling bearing ball cage ring. If the pressure medium transfer element is fastened to the rolling bearing call cage ring, the pressure medium transfer element may be situated in a stationary or rotatably or loosely/floatingly supported manner as a function of the rolling bearing ball cage.
[0035] In particular within the scope of this embodiment, the rolling bearing inner ring and the rolling bearing outer ring may (each) include a radial channel. The radial channel of the rolling bearing outer ring may communicate with the radial channel of the rolling bearing inner ring via the pressure medium transfer element or the rolling bearing ball cage ring, in particular via the at least one annular channel and radial channel of the pressure medium transfer element or the rolling bearing ball cage ring.
[0036] On the other hand, the radial channel of the rolling bearing inner ring may communicate with a channel of a rotatable or stationary, in particular rotatable, component, for example with one or multiple radial channels of the camshaft, or the radial channel of the rolling bearing outer ring may communicate with a channel of a stationary or rotatable, in particular stationary, component, for example with a pressure medium channel of a cylinder head-affixed component.
[0037] In particular, the radial channel of the rolling bearing inner ring may empty into a channel of a rotatable or stationary, in particular rotatable, component, for example into one or multiple radial channels of the camshaft, in particular radially, for example directly or indirectly, for example via another (mounting) annular channel and/or (mounting) radial channel having radial channel opening(s) which are enlarged, for example, in the circumferential direction and/or axially, for example, a channel opening of the rolling bearing inner ring being situated opposite, in particular directly adjacent to, an opening of the channel of the component, for example one or multiple radial channel openings of the camshaft. The radial channel of the rolling bearing outer ring may empty into a channel of a stationary or rotatable, in particular stationary, component, for example into the pressure medium channel of the cylinder head-affixed component, in particular radially, for example directly or indirectly, for example via another (mounting) annular channel and/or (mounting) radial channel having radial channel opening(s) which are enlarged, for example, axially and/or in the circumferential direction, for example, a channel opening of the rolling bearing outer ring being situated opposite, in particular directly adjacent to, an opening of the channel of the component, for example an opening of the pressure medium channel of the cylinder head-affixed component. The additional (mounting) annular channel and/or (mounting) radial channel may have, for example, an opening formed in an inner lateral surface of the rolling bearing inner ring or in an outer lateral surface of the rolling bearing outer ring. For example, the additional (mounting) annular channel and/or (mounting) radial channel may be formed in the rolling bearing inner ring radially inwardly of the radial channel of the rolling bearing inner ring or in the rolling bearing outer ring radially outwardly of the radial channel of the rolling bearing outer ring.
[0038] The pressure medium transfer element or the pressure medium transfer elements may include an annular base body in the form of an annular U profile or H profile having an essentially axially oriented profile middle section, at least one radial channel extending through the profile middle section. The at least one radial channel may be designed, for example, in the form of a continuous material recess, for example a bore. Due to the profile middle section and two profile side sections connected thereto, one annular channel may be provided in the case of a U profile or two annular channels may be provided in the case of an H profile. This embodiment has the advantage, on the one hand, that the pressure medium transfer element may be easily manufactured. On the other hand, an annular base body designed in this way may simultaneously function as a compression seal, as explained in greater detail below.
[0039] A U profile may be understood to be, in particular, a profile having an essentially U-shaped cross-sectional surface. An H profile may be understood to be, in particular, a profile having an essentially H-shaped cross-sectional surface. Essentially may be understood to mean, in particular, that, to the extent that the lateral sections of the cross-sectional surface have a similar, in particular radial, extension to each other, the intermediate profile middle section may have shape deviations and may be provided, for example, with a wavy design. A wavy design of the profile middle section has the advantage that a compression seal and/or another annular groove and/or seal receptacles may be provided thereby (see FIGS. 5 through 7 ).
[0040] However, the pressure medium transfer element or the pressure medium transfer elements may also include an annular base body, in which the at least one annular channel is provided in the form of an annular groove, at least one radial channel, which empties into the at least one annular groove-shaped annular channel, extending through the annular base body. The at least one radial channel may be designed, for example, in the form of a continuous material recess, for example a bore, which empties into the at least one annular groove-shaped annular channel. In particular, two annular channels in the form of annular grooves may be provided in the annular base body, at least one radial channel, which empties into the two annular groove-shaped annular channels, extending through the annular base body.
[0041] The annular base body may be made of metal or plastic, in the case of a design as a profile as well as in the case of a design as a component having an annular groove. For example, the annular base body may be a formed part, a cast part or a turned part. For example, the annular base body may be a metal sheet, for example a sheet metal ring, or a metal or plastic cast part.
[0042] For the purpose of sealing the pressure medium transfer system, the pressure medium transfer element or the rolling bearing component designed for pressure medium transfer may be equipped, for example, with sealing rings and/or be designed as compression seals and/or be provided with one or multiple clearance fits.
[0043] A sealing of the pressure medium transfer system may take place within the rolling bearing, in particular with the aid of one or multiple clearance fits, in particular with the aid of at least one clearance fit between the rolling bearing inner ring and the rolling bearing outer ring.
[0044] The pressure medium transfer element or the rolling bearing component designed for pressure medium transfer may be sealed against one or multiple adjacent components to be sealed with respect thereto, with the aid of one or multiple clearance fits.
[0045] Alternatively or additionally, however, it is also possible that the pressure medium transfer element or the rolling bearing component designed for pressure medium transfer (each) includes at least two sealing rings, which extend, in particular essentially in parallel, to both sides of an annular channel. In particular, two sealing ring receptacles formed on both sides of an annular channel, for example in the form of annular indentations, may be provided for accommodating the sealing rings.
[0046] If the pressure medium transfer element or the rolling bearing component designed for pressure medium transfer includes two annular channels and is fixedly connected to another component via a surface having an annular channel, or if it is integrated therein, it is possible to provide sealing rings or sealing ring receptacles only on the two sides of one of the annular channels, namely the annular channel formed in an unconnected surface.
[0047] If the pressure medium transfer element or the rolling bearing body designed for pressure medium transfer has two annular channels and is a loosely or floatingly supported component or a loosely or floatingly supported component arrangement, it is possible to provide two sealing rings or sealing ring receptacles on both sides of both annular channels, i.e., a total of at least four sealing rings or sealing ring receptacles.
[0048] Alternatively or additionally, however, it is also possible that the pressure medium transfer element or the rolling bearing component designed for pressure medium transfer itself functions as a compression seal, a section of the pressure medium transfer element or the rolling bearing component designed for pressure medium transfer being pressable against an adjacent component to be sealed with respect thereto for the purpose of achieving a sealing effect upon application of pressure medium and, if necessary, upon deformation. The component to be sealed, for example the cylinder head-affixed component, or the camshaft or the rotatable or stationary rolling bearing ring, may have a compression sealing contact and/or accommodating section, which, if necessary, is also used for the purpose of, in particular, radial and/or axial stabilization of the position of or blocking of the compression seal section of the pressure medium transfer element or of the rolling bearing component designed for pressure medium transfer.
[0049] The present invention also provides a camshaft assembly which includes a camshaft, a hydraulic phase adjusting device for adjusting the phase angle of the camshaft with respect to a crankshaft with the aid of a hydraulic pressure medium, a pressure medium channel formed in a stationary component, in particular in a cylinder head-affixed component, as well as a rolling bearing according to the present invention. In particular, the pressure medium channel may communicate with the phase adjusting device via the at least one channel of the rolling bearing.
[0050] The camshaft may be rotatably supported, in particular, by the rolling bearing.
[0051] For example, the camshaft may include, for example, at least one radial channel. The pressure medium channel may communicate with the phase adjusting device, in particular, via the at least one channel of the rolling bearing as well as the at least one radial channel of the camshaft.
[0052] A pressure medium transfer element of the rolling bearing or a rolling bearing component designed for pressure medium transfer may be connected, in particular rotatably fixedly, to the camshaft. With respect to the cylinder head-affixed component, the pressure medium transfer element of the rolling bearing or the rolling bearing component designed for pressure medium transfer may be rotatably supported. The pressure medium channel may empty into an annular channel of the pressure medium transfer element of the rolling bearing or of the rolling bearing component designed for pressure medium transfer via an annular channel opening, in particular radially, for example directly, or for example indirectly via another (mounting) radial channel and/or (mounting) annular channel. The at least one radial channel of the pressure medium transfer element of the rolling bearing or of the rolling bearing component designed for pressure medium transfer may empty into at least one radial channel of the camshaft, in particular radially, for example directly, or for example via another radial channel and/or annular channel.
[0053] Additionally or alternatively, a pressure medium transfer element of the rolling bearing or a rolling bearing component designed for pressure medium transfer may be connected, in particular fixedly, to the stationary, in particular cylinder head-affixed, component. The pressure medium transfer element of the rolling bearing or the rolling bearing component designed for pressure medium transfer may be situated, in particular, in a stationary manner, with respect to the camshaft. The at least one radial channel of the camshaft may empty into an annular channel of the pressure medium transfer element of the rolling bearing or of the rolling bearing component designed for pressure medium transfer via an annular channel opening, in particular radially, for example directly, or for example indirectly via another (mounting) radial channel and/or (mounting) annular channel. The at least one radial channel of the pressure medium transfer element of the rolling bearing or of the rolling bearing component designed for pressure medium transfer may empty into a pressure medium channel of the stationary, in particular cylinder head-affixed, component, in particular radially, for example directly or, for example indirectly via another radial channel and/or annular channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] The present invention is explained by way of example below on the basis of preferred exemplary embodiments with reference to the appended drawings, the features illustrated below being able to represent one aspect of the present invention both individually and in combination.
[0055] FIG. 1 shows a schematic cross section of a first specific embodiment, which includes a pressure medium transfer element situated between the rolling bearing inner ring and the rolling bearing outer ring;
[0056] FIG. 2 shows a schematic cross section of a second specific embodiment, which includes a rolling bearing cage ring designed for pressure medium transfer;
[0057] FIG. 3 shows a schematic cross section of a third specific embodiment, which includes a rolling bearing inner ring designed for pressure medium transfer;
[0058] FIG. 4 shows a schematic cross section of a fourth specific embodiment, in which both the rolling bearing inner ring and the rolling bearing outer ring are designed for pressure medium transfer;
[0059] FIG. 5 shows a schematic cross section detail of a fifth specific embodiment, which includes a pressure medium transfer element having an annular base body fastened to the rolling bearing inner ring in the form of an annular U profile as well as having sealing rings;
[0060] FIG. 6 shows a schematic cross section detail of a sixth specific embodiment, which includes a pressure medium transfer element having an annular base body fastened to the rolling bearing inner ring in the form of an annular U profile, which also functions as a compression seal; and
[0061] FIG. 7 shows a schematic cross section detail of a seventh specific embodiment, which includes a pressure medium transfer element having an annular base body, loosely or floatingly supported, in the form of an annular U profile, which also functions as a compression seal.
DETAILED DESCRIPTION
[0062] FIGS. 1 through 4 show camshaft assemblies which include a camshaft 10 and a hydraulic phase adjusting device 20 for adjusting the phase angle of camshaft 10 with respect to a crankshaft with the aid of a hydraulic pressure medium P. Camshaft 10 includes multiple radial channels 11 , which communicate with phase adjusting device 20 via interior 12 of camshaft 10 . At least one part of phase adjusting device 20 is situated inside camshaft 10 . Camshaft 10 has an essentially tube-shaped design. Interior 12 is delimited by phase adjusting device 20 , on the one hand, and by a closing element 13 , on the other hand.
[0063] Camshaft 10 is rotatably supported around a rotation axis R with respect to a cylinder head-affixed component 30 via a rolling bearing 50 . At least one part of camshaft 10 projects into cylinder head-affixed component 30 .
[0064] Cylinder head-affixed component 30 includes a pressure medium channel 31 in the form of a radial channel, which extends radially outward from radial channels 11 of camshaft 10 .
[0065] Rolling bearing 50 includes a rolling bearing inner ring 51 , a rolling bearing outer ring 52 and a rolling bearing ball cage ring 53 situated therebetween, with rolling bearing balls 54 accommodated therein. Rolling bearing inner ring 51 is, in particular, rotatably fixedly fastened to an outer lateral surface of camshaft 10 via an inner lateral surface of rolling bearing inner ring 51 . Rolling bearing outer ring 52 is fastened to an inner lateral surface of cylinder head-affixed component 30 via an outer lateral surface of rolling bearing outer ring 52 . Camshaft 10 and rolling bearing inner ring 51 are rotatable components, and rolling bearing outer ring 52 and cylinder head-affixed component 30 are stationary components. Rolling bearing ball cage ring 53 may be loosely or floatingly supported and situated, for example, between rolling bearing inner ring 51 and rolling bearing outer ring 52 , secured only against an axial movement, and it may, if necessary, be rotatable together with a rotary motion of rolling bearing inner ring 51 . Alternatively, rolling bearing ball cage ring 53 may be fastened either to rolling bearing inner ring 51 or to rolling bearing outer ring 52 or integrated therein.
[0066] FIGS. 1 through 7 show that rolling bearing 50 includes at least one channel 41 , 42 , 45 , 41 *, 42 *, 45 *, 51 a , 51 b , 51 a ′, 52 a , 52 b , 52 a ′, 53 a , 53 b , 53 a ′ for conducting hydraulic pressure medium P.
[0067] For the purpose of transferring hydraulic pressure medium P from a stationary component 31 , 30 to a rotatable component 11 , 10 , rolling bearing 50 , within the scope of FIGS. 1 , 5 , 6 and 7 , includes a pressure medium transfer element 40 in the form of an independent component or an independent component arrangement.
[0068] Within the scope of the specific embodiments illustrated in FIGS. 2 , 3 and 4 , at least one rolling bearing component 53 , 51 , 52 is designed to transfer hydraulic pressure medium P from a stationary component 31 , 30 to a rotatable component 11 , 10 and is itself used as pressure medium transfer element 40 , 40 *.
[0069] Pressure medium transfer element or rolling bearing components 40 , 40 *, 53 , 51 , 52 designed for pressure medium transfer each include one or multiple annular channels 41 , 45 , 41 *, 45 *, each of which has an annular channel opening 411 , 452 , 412 *, 451 * extending in the circumferential direction of the annular channel 41 , 45 , 41 *, 45 *, and at least one radial channel opening 412 , 451 , 411 *, 452 * opposite annular channel opening 411 , 452 , 412 *, 451 * and emptying into a radial channel 42 , 42 *, 11 . It is facilitated that a channel of the stationary component, in particular pressure medium channel 31 of cylinder head-affixed component 30 , communicates with a channel of the rotatable component, in particular radial channels 11 of camshaft 10 , via annular channel opening 411 , 452 , 412 *, 451 * and the at least one radial channel opening 412 , 451 , 411 *, 452 * of annular channel(s) 41 , 45 , 41 *, 45 * of pressure medium transfer elements 40 , 40 *.
[0070] To conduct pressure medium P past the ball cage of rolling bearing 50 and not through it, rolling bearing inner ring 51 or rolling bearing inner ring 51 and rolling bearing outer ring 52 and possibly also rolling bearing ball cage ring 53 have an axially elongated design.
[0071] Within the scope of the specific embodiment illustrated in FIG. 1 , rolling bearing 50 includes not only rolling bearing inner ring 51 , rolling bearing outer ring 52 and rolling bearing ball cage ring 53 , with rolling bearing balls 54 situated therein, but also a pressure medium transfer element 40 , which includes an annular channel 41 having a radially outer annular channel opening 411 extending in the circumferential direction of annular channel 41 and multiple radially inner radial channel openings 412 opposite annular channel opening 411 as well as multiple radial channels 42 which each empty into one of radial channel openings 412 of annular channel 41 .
[0072] Pressure medium transfer element 40 is an independent annular component or component arrangement. Pressure medium transfer element 40 may include, for example, an annular base body 43 , in which annular channel 41 is provided in the form of an annular grove, multiple radial channels 42 extending through annular base body 43 and emptying into annular groove-shaped annular channel 41 . Alternatively—as explained in greater detail in FIGS. 5 through 7 —pressure medium transfer element 40 includes an annular base body 43 in the form of an annular U profile having an essentially axially oriented profile middle section and two profile side sections extending radially outwardly, radial channels 42 extending through the profile middle section.
[0073] FIG. 1 shows that pressure medium transfer element 40 is situated between rolling bearing inner ring 51 and rolling bearing outer ring 52 . In the specific embodiment illustrated in FIG. 1 , pressure medium transfer element 40 is fastened to rolling bearing inner ring 51 , in particular the lateral surface thereof 51 , in particular via its inner lateral surface. However, it is also possible to fasten pressure medium transfer element 40 to a different component of rolling bearing 50 , for example rolling bearing outer ring 52 or rolling bearing ball cage ring 53 , or to situate pressure medium transfer element 40 , loosely or floatingly supported, between rolling bearing inner ring 51 and rolling bearing outer ring 52 (not illustrated), whereby pressure medium transfer element 40 should then have a different design.
[0074] For the purpose of fastening to the rolling bearing outer ring, the pressure medium transfer element may have, for example, a reversed design and include an annular channel having a radially inner annular channel opening extending in the circumferential direction of the annular channel and multiple radially outer radial channel openings opposite the annular channel opening as well as multiple radial channels which each empty into one of the radial channel openings of the annular channel (not illustrated).
[0075] For the purpose of fastening to the rolling bearing ball cage ring or for a loosely or floatingly supported arrangement, the pressure medium transfer element may include, for example, an annular channel having a radially inner annular channel opening extending in the circumferential direction of the annular channel and multiple radially outer radial channel openings, an annular channel having a radially outer annular channel opening extending in the circumferential direction of the annular channel as well as multiple radial channels, which each connect the annular channel having the radially outer annular channel opening to the annular channel having the radially inner annular channel opening (not illustrated). In a loosely or floatingly supported arrangement, the position of the pressure medium transfer element may be secured or blocked radially by the rolling bearing inner ring and the rolling bearing outer ring. The position of the pressure medium transfer element may be secured or blocked axially by the rolling bearing ball cage ring and/or the rolling bearing inner ring and/or the rolling bearing outer ring and/or, if necessary, one or multiple additional components (not illustrated).
[0076] Within the scope of the specific embodiment illustrated in FIG. 1 , rolling bearing outer ring 52 includes a radial channel 52 a ′, and rolling bearing inner ring 51 includes multiple radial channels 51 a ′ which empty radially into an annular channel 51 a of rolling bearing inner ring 51 .
[0077] Radial channel 52 a ′ of rolling bearing outer ring 52 empties radially into annular channel 41 of pressure medium transfer element 40 , a radially inner opening of radial channel 52 a ′ of rolling bearing outer ring 52 being situated opposite, in particular directly adjacent to, radially outer annular channel opening 411 of pressure medium transfer element 40 . Annular channel 41 of pressure medium transfer element 40 , in turn, empties into radial channels 42 of pressure medium transfer element 40 . Radial channels 42 of pressure medium transfer element 40 , in turn, empty radially into radial channels 51 a ′ of rolling bearing inner ring 51 , radially inner openings of radial channels 42 of pressure medium transfer element 40 being situated opposite, in particular directly adjacent to, radially outer openings of radial channels 51 a ′ of rolling bearing inner ring 51 . In this way, radial channel 52 a ′ of rolling bearing outer ring 52 communicates with radial channels 51 a ′ of rolling bearing inner ring 51 via pressure medium transfer element 40 , in particular via annular channel 41 and radial channels 42 of pressure medium transfer element 40 .
[0078] FIG. 1 furthermore shows that pressure medium channel 31 of cylinder head-affixed component 30 empties radially into radial channel 52 a ′ of rolling bearing outer ring 52 , a radially inner opening 312 of pressure medium channel 31 being situated opposite, in particular directly adjacent to, a radially outer opening of radial channel 52 a ′ of rolling bearing outer ring 52 . Radial channels 51 a ′ of rolling bearing inner ring 51 empty into annular channel 51 a of rolling bearing inner ring 51 . Annular channel 51 a of rolling bearing inner ring 51 , in turn, empties radially into radial channels 11 of camshaft 10 , a radially inner annular channel opening of annular channel 51 a of rolling bearing inner ring 51 being situated opposite, in particular directly adjacent to, radially outer openings of radial channels 11 of camshaft 10 . In this way, pressure medium channel 31 communicates with radial channels 11 of camshaft 10 via radial channel 52 a ′ of rolling bearing outer ring 52 and via pressure medium transfer element 40 , in particular via annular channel 41 and radial channels 42 of pressure medium transfer element 40 and via radial channels 51 a ′ and annular channel 51 a of rolling bearing inner ring 51 and, in turn, with hydraulic phase adjusting device 20 via radial channels 11 as well as interior 12 of camshaft 10 . A pressure medium transfer from stationary pressure medium channel 31 of cylinder head-affixed component 30 to rotatable radial channels 11 of camshaft 10 and, in particular to rotatably situated phase adjusting device 20 , may thus be advantageously implemented.
[0079] Within the scope of the embodiment illustrated in FIG. 1 , annular channel 51 a of rolling bearing inner ring 51 is used, in particular, to avoid an angle-oriented alignment of rolling bearing inner ring 51 with respect to radial channels 11 of camshaft 10 during mounting and makes it possible to advantageous simplify the mounting of rolling bearing inner ring 51 onto camshaft 10 .
[0080] In the specific embodiment illustrated in FIG. 1 , however, pressure medium transfer element 40 should be mounted in an angle-oriented manner with respect to radial channels 51 a ′ of rolling bearing inner ring 51 on rolling bearing inner ring 51 , and rolling bearing outer ring 52 should be mounted in an angle-oriented manner with respect to pressure medium channel 31 of cylinder head-affixed component 30 .
[0081] To avoid these angle orientations as well or to increase their tolerance range (not illustrated), a (mounting) annular channel and/or a (mounting) radial channel having a radial channel opening enlarged axially and/or in the circumferential direction may be provided between the radial channel of the pressure medium transfer element and the radial channel of the rolling bearing inner ring and/or between the radial channel of the rolling bearing outer ring and the pressure medium channel, which may be provided, for example in the pressure medium transfer element or the rolling bearing inner ring or in the rolling bearing outer ring or the cylinder head-affixed component. An angle-oriented mounting may be avoided with the aid of a (mounting) annular channel. With the aid of a (mounting) radial channel having a radial channel opening which is enlarged axially and/or in the circumferential direction, in particular compared to the adjacent openings, at least the tolerance range of the angle orientation may be advantageously increased and the mounting simplified thereby.
[0082] Within the scope of the specific embodiment illustrated in FIG. 1 , a sealing of the pressure medium transfer system may be implemented with the aid of a clearance fit between pressure medium transfer element 40 and rolling bearing outer ring 52 . However, it is also conceivable to implement a seal with the aid of sealing rings or a compression seal (see FIGS. 5 through 7 ).
[0083] The specific embodiment illustrated within the scope of FIG. 2 essentially differs from the specific embodiment illustrated in FIG. 1 in that pressure medium transfer element 40 is fastened to rolling bearing ball cage ring 53 , or it is integrated therein, which means that rolling bearing ball cage ring 53 itself includes channels 53 b , 41 ; 53 a ′, 42 ; 53 a , 45 for transferring hydraulic pressure medium P from a stationary component 31 , 30 to a rotatable component 11 , 10 .
[0084] Rolling bearing ball cage ring 53 may be fastened to rolling bearing inner ring 51 or to rolling bearing outer ring 52 as well as loosely or floatingly supported or rotatably situated with respect to rolling bearing inner ring 51 and rolling bearing outer ring 52 .
[0085] For this reason or—as explained in greater detail in connection with FIG. 1 —to avoid an angle-oriented mounting, the specific embodiment illustrated in FIG. 2 also differs from the specific embodiment illustrated in FIG. 1 in that pressure medium transfer element 40 or rolling bearing ball cage ring 53 includes not only one, in particular outer, annular channel 53 b , 41 but also two annular channels 53 b , 41 ; 53 a , 45 connected to each other via radial channels 53 a ′, 42 , the one annular channel 53 b , 41 being formed radially outwardly from the other annular channel 53 a , 45 , and radial channels 53 a ′, 42 extending radially between the two annular channels 53 b , 41 ; 53 a , 45 .
[0086] Outer annular channel 53 b , 41 of pressure medium transfer element 40 or of rolling bearing call cage ring 53 has a radially outer annular channel opening 411 and multiple radially inner radial channel openings 412 , inner annular channel 53 a , 45 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 having a radially inner annular channel opening 452 and multiple radially outer radial channel openings 451 . Radial channels 53 a ′, 42 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 connect outer annular channel 53 b , 41 having radially outer annular channel opening 411 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 to inner annular channel 53 a , 45 having radially inner annular channel opening 452 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 and each empty into outer annular channel 53 b , 41 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 via a radially inner outer radial channel opening 412 , on the one hand, and into inner annular channel 53 a , 45 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 via a radially outer inner radial channel opening 451 , on the other hand.
[0087] Radial channel 52 a ′ of rolling bearing outer ring 52 empties radially into outer annular channel 53 b , 41 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 , a radially inner opening of radial channel 52 a ′ of rolling bearing outer ring 52 being situated opposite, in particular, directly adjacent to, radially outer annular channel opening 411 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 . Outer annular channel 53 b , 41 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 , in turn, empties into inner annular channel 53 a , 45 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 via radial channels 53 a ′, 42 of pressure medium transfer element 40 or rolling bearing ball cage ring 53 . Inner annular channel 53 a , 45 of pressure medium transfer element 40 or rolling bearing ball cage ring 53 , in turn, empties radially into radial channels 51 a ′ of rolling bearing inner ring 51 , radially inner annular channel opening 452 of inner annular channel 53 a , 45 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 being situated opposite, in particular, directly adjacent to, radially outer openings of radial channels 51 a ′ of rolling bearing inner ring 51 . In this way, radial channel 52 a ′ of rolling bearing outer ring 52 communicates with radial channels 51 a ′ of rolling bearing inner ring 51 via pressure medium transfer element 40 , in particular rolling bearing ball cage ring 53 , in particular via annular channels 53 b , 41 ; 53 a , 45 and radial channels 53 a ′, 42 of pressure medium transfer element 40 or rolling bearing ball cage ring 53 .
[0088] Radial channels 51 a ′ of rolling bearing inner ring 51 empty into annular channel 51 a of rolling bearing inner ring 51 . Annular channel 51 a of rolling bearing inner ring 51 , in turn, empties radially into radial channels 11 of camshaft 10 , a radially inner annular channel opening of annular channel 51 a of rolling bearing inner ring 51 being situated opposite, in particular, directly adjacent to, radially outer openings of radial channels 11 of camshaft 10 .
[0089] Pressure medium channel 31 of cylinder head-affixed component 30 empties radially into radial channel 52 a ′ of rolling bearing outer ring 52 , a radially inner opening 312 of pressure medium channel 31 being situated opposite, in particular, directly adjacent to, a radially outer opening of radial channel 52 a ′ of rolling bearing outer ring 52 .
[0090] In this way, pressure medium channel 31 communicates with radial channels 11 of camshaft 10 via radial channel 52 a ′ of rolling bearing outer ring 52 and via pressure medium transfer element 40 or rolling bearing ball cage ring 53 , in particular via annular channels 53 b , 41 ; 53 a , 45 and radial channels 53 a ′, 42 of pressure medium transfer element 40 or of rolling bearing ball cage ring 53 and via radial channels 51 a ′ and annular channel 51 a of rolling bearing inner ring 51 and, in turn, with hydraulic phase adjusting device 20 via radial channels 11 as well as interior 12 of camshaft 10 . A pressure medium transfer from stationary pressure medium channel 31 of cylinder head-affixed component 30 to rotatable radial channels 11 of camshaft 10 and, in particular, to rotatably situated phase adjusting device 20 may thus be advantageously implemented.
[0091] Within the scope of the specific embodiment illustrated in FIG. 3 , rolling bearing 50 , in particular rolling bearing inner ring 51 , is designed to transfer hydraulic pressure medium P from a stationary component 30 to a rotatable component 10 . Rolling bearing inner ring 51 , 43 is designed to be elongated axially with respect to rolling bearing outer ring 52 and rolling bearing ball cage ring 53 and includes an outer annular channel 51 b , 41 having a radially outer annular channel opening 411 extending in the circumferential direction of outer annular channel 51 b , 41 and multiple radially inner radial channel openings 412 opposite annular channel opening 411 , and an inner annular channel 51 a , 45 having a radially inner annular channel opening 452 extending in the circumferential direction of inner annular channel 51 a , 45 and multiple radially outer radial channel openings 451 opposite annular channel opening 452 , as well as radial channels 51 a ′, 42 which connect outer annular channel 51 b , 41 having radially outer annular channel opening 411 to inner annular channel 51 a , 45 having radially inner annular channel opening 452 and each emptying, in particular, into one of radial channel openings 412 , 451 of the two annular channels 51 b , 41 ; 51 a , 45 .
[0092] Within the scope of the specific embodiment illustrated in FIG. 3 , pressure medium channel 31 empties, in particular, directly into outer annular channel 51 b , 41 of rolling bearing inner ring 51 , in particular, a radially inner opening 312 of pressure medium channel 31 being situated opposite, in particular, directly adjacent to, radially outer annular channel opening 411 of rolling bearing inner ring 51 . Inner annular channel 51 a , 45 of rolling bearing inner ring 51 empties, in particular radially, into radial channels 11 of camshaft 10 , radially inner annular channel opening 452 of inner annular channel 51 a , 45 of rolling bearing inner ring 51 being situated opposite, in particular directly adjacent to, radially outer openings 111 of radial channels 11 of camshaft 10 .
[0093] Since outer annular channel 51 b , 41 of rolling bearing inner ring 51 is connected to inner annular channel 51 a , 45 of rolling bearing inner ring 51 by radial channels 51 a ′, 42 of rolling bearing inner ring 51 , it is thus made possible that, in particular, stationary pressure medium channel 31 communicates with, in particular, rotatable radial channels 11 of camshaft 10 via the two annular channels 51 b , 41 ; 51 a , 45 and radial channels 51 a ′, 42 of rolling bearing inner ring 51 and with hydraulic phase adjusting device 20 via these radial channels 11 as well as interior 12 of camshaft 10 .
[0094] FIG. 3 furthermore shows that sealing rings 51 c , 44 may also be used instead of one or multiple clearance fits to seal the pressure medium transfer system. FIG. 3 shows that pressure rolling bearing inner ring 51 includes two sealing rings 51 c , 44 , which extend essentially in parallel to the two axially outer sides of outer annular channels 51 b , 41 . Sealing rings 51 c , 44 are situated in sealing ring receptacles 51 d , 46 , which are provided in the form of annular indentations in the outer lateral surface of rolling body inner ring 51 and which extend essentially in parallel to the two axially outer sides of outer annular channels 51 b , 41 . Within the scope of the specific embodiment illustrated in FIG. 3 , rolling bearing inner ring 51 is fastened to the outer lateral surface of camshaft 10 via its inner lateral surface. Due to the fixed connection, within the scope of this specific embodiment, additional sealing ring receptacles and sealing rings in the inner lateral surface of annular base body may be dispensed with.
[0095] FIG. 4 shows another specific embodiment, in which both rolling bearing inner ring 51 and rolling bearing outer ring 52 are designed to transfer hydraulic pressure medium P from a stationary component 31 , 30 to a rotatable component 11 , 10 and are themselves used as pressure medium transfer elements 40 , 40 *.
[0096] Rolling bearing inner ring 51 includes an annular channel 51 b , 41 having a radially outer annular channel opening 411 and multiple radially inner radial channel openings 412 , an annular channel 51 a , 45 having a radially inner annular channel opening 452 and multiple radially outer radial channel openings 451 as well as multiple radial channels 51 a ′, 42 , which connect annular channel 51 b , 41 having radially outer annular channel opening 411 of rolling bearing inner ring 51 to annular channel 51 b , 45 having radial inner annular channel opening 451 of rolling bearing inner ring 51 . Radial channels 51 a ′, 42 of rolling bearing inner ring 51 each empty into a radially inner radial channel opening 412 of annular channel 51 b , 41 having radially outer annular channel opening 411 of rolling bearing inner ring 51 and into a radially outer radial channel opening 451 of annular channel 51 a , 45 having radially inner annular channel opening 411 of rolling bearing inner ring 51 .
[0097] Rolling bearing outer ring 52 also includes an annular channel 52 a , 45 * having a radially outer annular channel opening 451 * and multiple radially inner radial channel openings 452 *, an annular channel 52 b , 41 * having a radially inner annular channel opening 412 * and multiple radially outer radial channel openings 411 * as well as multiple radial channels 52 a ′, 42 *, which connect annular channel 52 a , 45 * having radially outer annular channel opening 451 * of rolling bearing outer ring 52 to annular channel 52 b , 41 * having radially inner annular channel opening 412 * of rolling bearing outer ring 52 . Radial channels 52 a ′, 42 * of rolling bearing outer ring 52 each empty into a radial inner radial channel opening 452 * of annular channel 52 a , 45 * having radially outer annular channel opening 451 * of rolling bearing outer ring 52 and into a radially outer radial channel opening 411 * of annular channel 52 b , 41 * having radially inner annular channel opening 412 * of rolling bearing outer ring 52 .
[0098] Rolling bearing inner ring 51 and rolling bearing outer ring 52 have an axially elongated design with respect to rolling bearing ball cage ring 53 , rolling bearing inner ring 51 and rolling bearing outer ring 52 being directly adjacent to and opposite each other in the sections designed for pressure medium transfer and, in particular, rolling bearing ball cage ring 53 not extending between the sections of rolling bearing inner ring 51 and rolling bearing outer ring 52 designed for pressure medium transfer.
[0099] Within the scope of the specific embodiment illustrated in FIG. 4 , a sealing of the pressure medium transfer system may be implemented, in particular, with the aid of a clearance fit between surfaces facing one another of rolling bearing inner ring 51 and rolling bearing outer ring 52 .
[0100] Radially inner annular channel opening 412 * of annular channel 52 b , 41 * of rolling bearing outer ring 52 is directly adjacent to and opposite radially outer annular channel opening 411 of annular channel 51 b , 41 of rolling bearing inner ring 51 .
[0101] As a result, inner annular channel 52 b , 41 * of rolling bearing outer ring 52 empties radially into outer annular channel 51 b , 41 of rolling bearing inner ring 51 .
[0102] Since outer annular channel 52 a , 45 * of rolling bearing outer ring 52 empties into inner annular channel 52 b , 41 * of rolling bearing outer ring 52 via radial channels 52 a ′, 42 * of rolling bearing outer ring 52 , and outer annular channel 51 b , 41 of rolling bearing inner ring 51 empties into inner annular channel 51 a , 45 of rolling bearing inner ring 51 via radial channels 51 a ′, 42 of rolling bearing inner ring 51 , outer annular channel 52 a , 45 * of rolling bearing outer ring 52 may communicate with inner annular channel 51 a , 45 of rolling bearing inner ring 51 in this way.
[0103] FIG. 4 furthermore shows that pressure medium channel 31 of cylinder head-affixed component 30 empties radially into outer annular channel 52 a , 45 * of rolling bearing outer ring 52 , a radially inner opening 312 of pressure medium channel 31 being situated opposite, in particular, directly adjacent to, radially outer annular channel opening 411 of outer annular channel 52 a , 45 * of rolling bearing outer ring 52 . Inner annular channel 51 a , 45 of rolling bearing inner ring 51 empties into radial channels 11 of camshaft 10 , radially inner annular channel opening 452 of inner annular channel 51 a , 45 of rolling bearing inner ring 51 being situated opposite, in particular, directly adjacent to, radially outer openings 111 of radial channels 11 of camshaft 10 . In this way, pressure medium channel 31 communicates with radial channels 11 of camshaft 10 via annular channels 52 a , 45 *; 52 b , 41 * and radial channels 52 a ′, 42 * of rolling bearing outer ring 52 and annular channels 51 b , 41 ; 51 a , 45 and radial channels 51 a ′, 42 of rolling bearing inner ring 51 . A pressure medium transfer from stationary pressure medium channel 31 of cylinder head-affixed component 30 to rotatable radial channels 11 of camshaft 10 and, in particular, to rotatably situated phase adjusting device 20 may thus be advantageously implemented.
[0104] Within the scope of the embodiment illustrated in FIG. 4 , outer annular channel 52 a , 45 * of rolling bearing outer ring 52 and inner annular channel 51 a , 45 of the rolling bearing inner ring are used, in particular, to avoid an angle-oriented alignment of rolling bearing outer ring 52 with respect to pressure medium channel 31 or of rolling bearing inner ring 51 with respect to radial channels 11 of camshaft 10 during mounting and make it possible to advantageous simplify the mounting of rolling bearing outer ring 52 on cylinder head-affixed component 30 and of rolling bearing inner ring 51 on camshaft 10 .
[0105] FIGS. 5 through 7 show enlarged schematic cross sectional views to illustrate different embodiments of pressure medium transfer elements 40 or sealing concepts.
[0106] In particular, FIGS. 5 through 7 show pressure medium transfer elements 40 , which include an annular base body 43 in the form of an annular U profile, which includes an essentially axially oriented profile middle section and two profile side sections extending radially outwardly, radial channels 42 extending through the profile middle section.
[0107] FIGS. 5 and 7 show that essentially may be understood to mean, in particular, that—to the extent that the profile side sections of the cross-sectional surface have a similar, in particular radial, extension to one another—the intermediate profile middle section may have shape deviations and may be provided, for example, with a wavy or bent design, as illustrated in FIG. 5 or 7 .
[0108] Pressure medium transfer elements 40 , which are designed as explained within the scope of FIGS. 5 through 7 , may be used, for example, in the specific embodiments illustrated within the scope of FIG. 1 or 2 and be situated, in particular, between rolling bearing inner ring 51 and rolling bearing outer ring 52 .
[0109] Within the scope of the specific embodiment illustrated in FIG. 5 , the profile middle section has, in particular, two lateral subsections, which are bent radially inwardly, and one subsection, which extends therebetween and is bent radially outwardly. Radial channels 42 extend through the subsection bent radially outwardly, the two lateral subsections bent radially inwardly being used as sealing ring receptacles 46 for sealing rings 44 . A profile having a cross section of this type may generally also be referred to as a W profile or an M profile, it being possible to view this as a special type of U profile.
[0110] An outer annular channel 41 is provided by the profile middle section and the two profile side sections connected thereto and extending radially outwardly, an inner annular channel 45 being provided by the two lateral subsections bent radially inwardly and the subsection of the profile middle section extending therebetween and bent radially outwardly.
[0111] The specific embodiment illustrated within the scope of FIG. 6 has in common with the specific embodiment illustrated in FIG. 5 the fact that pressure medium transfer element 40 includes an annular base body 43 in the form of an annular U profile having an axially oriented profile middle section and two profile side sections extending radially outwardly, radial channels 42 extending through the profile middle section. In contrast to the specific embodiment illustrated in FIG. 5 , the profile middle section here is, however, provided with an axially linear or planar and not a wavy design, for which reason annular base body 43 has only one outer annular channel 41 within the scope of the specific embodiment illustrated in FIG. 6 .
[0112] Moreover, in contrast to the specific embodiment illustrated in FIG. 5 —instead of sealing rings—a compression seal is used for sealing the pressure medium transfer system, annular base body 43 of pressure medium transfer element 40 itself functioning as a compression seal. The sealing effect is achieved by the fact that the profile side sections are pressed against the adjacent component to be sealed, in this case rolling body outer ring 52 , upon the application of pressure medium. Rolling bearing outer ring 52 includes a compression sealing contact and accommodating section 52 c , against which the profile side sections of annular base body 43 are pressed upon the application of pressure medium. Annular base body 43 is fastened to the outer lateral surface of rolling bearing inner ring 51 via the inner lateral surface of the profile middle section.
[0113] In contrast to the specific embodiment illustrated in FIG. 6 , within the scope of the specific embodiment illustrated in FIG. 7 , annular base body 43 is supported loosely or floatingly between rolling bearing inner ring 51 and rolling bearing outer ring 52 . Within the scope of the specific embodiment illustrated in FIG. 7 , the profile middle section is furthermore not axially linear or planar, as in the specific embodiment illustrated in FIG. 6 , but rather only essentially axial, namely wavy, and designed similarly to the specific embodiment illustrated in FIG. 5 , for which reason annular base body 43 within the scope of the specific embodiment illustrated in FIG. 7 has an outer annular channel 41 and an inner annular channel 45 .
[0114] Since annular base body 43 is situated in a loosely or floatingly supported manner, its radial and axial positions are stabilized by compression sealing contact and accommodating section 52 c of rolling bearing outer ring 52 . Upon the application of pressure medium, not only the profile side sections are pressed against compression sealing contact and accommodating section 52 c , but the lateral subsections of the profile middle section, bent radially to the inside, are also pressed against the outer lateral surface of rolling bearing inner ring 51 . Inner radial channel 45 of annular base body 43 makes it possible that a transfer of pressure medium is ensured even with a rotation of annular base body 43 with respect to rolling bearing inner ring 51 and its radial channels 51 a ′ or with respect to rolling bearing outer ring 52 and its radial channel 52 a ′ and, in particular, no angle orientation is required.
LIST OF REFERENCE NUMERALS
[0000]
10 Camshaft
11 Radial channel
111 Radially outer radial channel opening
12 Camshaft interior
13 Closing element
14 Annular channel
15 Sealing ring
16 Sealing ring receptacle
20 Hydraulic phase adjusting device
30 Cylinder head-affixed component, in particular cylinder head
31 Pressure medium channel
312 Radially inner pressure medium channel opening
40 , 40 * Pressure medium transfer element
41 , 41 * Annular channel
411 Radially outer annular channel opening
411 * Radially outer radial channel opening
412 Radially inner radial channel opening
412 * Radially inner annular channel opening
42 , 42 * Radial channel
43 Annular base body
44 Sealing ring
45 , 45 * Annular channel
451 Radially outer radial channel opening
451 * Radially outer annular channel opening
452 Radially inner annular channel opening
452 * Radially inner radial channel opening
46 Sealing ring receptacle
50 Rolling bearing
51 Rolling bearing inner ring
52 Rolling bearing outer ring
53 Rolling bearing ball cage ring
54 Rolling bearing ball
51 a , 52 a , 53 a Annular channel
51 a ′, 52 a ′, 53 a ′ Radial channel
51 b , 52 b , 53 b Annular channel
51 c Sealing ring
51 d Sealing ring receptacle
52 c Compression sealing contact and accommodating section
P Pressure medium
R Rotation axis of the camshaft | A rolling bearing ( 50 ) which includes a rolling bearing inner ring ( 51 ), a rolling bearing outer ring ( 52 ) and a rolling bearing ball cage ring ( 53 ). The aim of the invention is to enable a hydraulic pressure medium (P) to be transferred, economizing as much mounting space as possible, for example for a camshaft ( 10 ), the phase position thereof being adjustable in relation to a crankshaft via a hydraulic pressure medium (P) through a hydraulic phase adjusting device ( 20 ). The rolling bearing ( 50 ) includes at least one channel ( 51 a, 51 a′, 52 a′, 41, 42 ) for guiding hydraulic pressure medium (P). A camshaft assembly equipped with such a rolling bearing ( 50 ). | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/859,677, filed on Apr. 9, 2013, issued as U.S. Pat. No. 9,225,126 B2, which claims the benefit of U.S. Provisional Application No. 61/640,002 electronically filed on Apr. 30, 2012 and given EFS ID 12656459 and Confirmation Number 1024.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a power connector and, in particular, a power connector without probes for electrical connection.
Description of Related Art
Conventional power connectors comprise of a male plug component having contact prongs extending outwards for inserting into a corresponding receiving member in a female plug component or a socket, where the receiving member holds the prongs in place and the male and female plug components are electrically connected using frictional force. In some situations, for example in very low temperatures, the insertion and removal of the prongs becomes difficult and may cause damage to the cord and devices connect to the cord.
U.S. Pat. No. 7,311,526 disclosed a magnetic connector that connects a direct current (DC) power supply to a device. Such connector has safety issues if used for transmitting high voltage alternative current (AC) signal, as electric shock may occur when the user touches electrically live high voltage exposed contacts. Therefore an improved power connector design is desired to accommodate high voltage AC electric power supplies. Other power connector systems that may share common design features with the current system are shown in the following patents:
U.S. Pat. No. 7,621,753 Pai U.S. Pat. No. 7,874,844 Fitts U.S. Pat. No. 7,442,042 Lewis U.S. Pat. No. 6,739,915 Hyland U.S. Pat. No. 7,339,205 McNeely U.S. Pat. No. 6,770,986 Nagao U.S. Pat. No. 5,584,715 Ehrenfels U.S. Pat. No. 4,748,343 Engel U.S. Pat. No. 7,351,066 DiFonzo U.S. Pat. No. 7,517,222 Rohrbach U.S. Pat. No. 7,645,143 Rohrbach
BRIEF SUMMARY OF THE INVENTION
In the light of the foregoing background, it is an object of the present invention to provide an alternate power connector.
Accordingly, the present invention, in one aspect, is an apparatus for electrically connecting a power source to an electrical device. The apparatus comprises a first component and a second component. The first component has a substantially planar contoured first face, and the first face comprises, in part, a set of 3 electrical pad contacts, one for each: hot, neutral, and ground connected to the power source. The second component has a substantially planar contoured second face complementary to the first face, and the second face comprises, in part, a set of 3 electrical pad contacts, one for each: hot, neutral, and ground connected to the electrical device. The first set of contacts becomes electrically coupled to the second set of contacts upon connecting the first face with the second face, thereby establishing a first (primary) electrical path between the power source and the electronic device.
In an exemplary embodiment of the present invention, the power source may be any standard household AC supply outlet and the primary electrical path is an AC supply path between the outlet and the electronic device. The first plug component further comprises power rectifier circuitry which branches off from the primary path and supplies DC power via a secondary electrical path to internal power switching circuitry.
In a another exemplary embodiment, the power connector further comprises at least one electrically operated switch and one actuating sensor. The switch is initially in the off position and is disposed in the primary electrical path. The actuating member is disposed in the secondary electrical path. When the first and second faces are attached, the actuating sensor is triggered by the presence of the magnet and closes the switch located in the first electrical path resulting in power conduction to the electronic device.
In another exemplary embodiment of the present invention, the male plug face comprises a ferromagnetic element and the female plug face comprises a magnetic element. The primary electrical path is established upon connecting the male plug face comprising of a ferromagnetic element, to the female plug face comprising a magnetic element, whereby the presence of the magnet on the female plug face triggers the actuating sensor inside the male plug component and closes the switch disposed in the primary electrical path and results in power conduction. In addition to actuating power conduction, the attractive force between the ferromagnetic and magnetic plates, on the male and female faces respectively, binds the plug components together allowing the electrical coupling between the pad contacts to be maintained during plug operation.
There are many advantages to the present invention. First of all, the male plug component and the female plug component (i.e. the first component and the second component) are held together by non-frictional forces such as magnetic forces, and the contact face between the components is substantially planar and contoured. Attaching the components is simply completed by contacting the male plug face with the female plug face. Separating the components requires minimal pulling force and as a result will not cause any damage to the components in low temperatures due to excessive friction force caused by variable temperature induced contraction of components. The performance of the substantially planar contoured contact face is not affected by contraction and expansion due to changes in ambient temperature. As a result, the force required to separate the plug components is also independent of ambient temperature.
The strength of the magnetic force is chosen to be removable with deliberate force but is considerably less than the maximum connective force of other connections, such that in situations where the device is pulled from the power supply with excessive force, the magnetic coupling between the male plug component and the female plug component of the power cord is always first to break, preventing damage to the device and the power supply. An example of such situation is in engine block heaters in vehicles where the user may drive a vehicle away from its parked position without noticing that the block heater cord is connected to a wall socket via an extension cord, a common practice used to keep the engine warm enough to be started in cold climates.
Another advantage of the present invention is that the circuit is designed to prevent the electrical contacts from being live with AC power when the male plug component is connected to the power source but not to the female plug. In the absence of the safety shut off mechanism, a user would suffer electric shock upon touching an electrically live contact. Using an electrically operated switching mechanism as a part of the circuit ensures that the power transmission components are only actuated when the male plug face is in contact with the female plug face, which in the case of the present invention means that the contacts are accurately connected between the corresponding male and female plug components.
Another advantage of the present invention is that the power connector has no moving parts and the surface of contact is substantially planar and contoured, therefore debris such as dust, dirt or ice will not easily collect on the components and potentially affect the operation of the connector such as shorting the circuit, especially so if the power connector is to be usable in outdoor environments. Where debris does collect on the contact surfaces, the surfaces can be readily wiped clean due to their substantially planer nature.
An additional advantage of the present invention is that the electrical contacts located on the male plug face will be slightly recessed below the contact surface of the ferromagnetic plate located on the contact face. This is primarily a safety feature which further reduces the chance of electric shock if a metal object is accidentally lodged between the male and female plug face when they are connected and the system is actuated to the on-position by the presence of the magnet.
BRIEF DESCRIPTION OF THE SEVERAL VIES OF THE DRAWINGS
FIG. 1 is a block diagram of the power connector male and female faces according to an embodiment of the present invention.
FIG. 2 is a front view of a male plug face according to an embodiment of the present invention.
FIG. 3 is a front view of a female plug face according to an embodiment of the present invention.
FIG. 4 a is a cutaway cross-section (X-Y) of the contoured male plug face according to an embodiment of the present invention.
FIG. 4 b is a front view of the male plug face showing the location of cross-section (X-Y) according to an embodiment of the present invention.
FIG. 5 a is a cutaway cross-section (X′-Y′) of the contoured female plug face according to an embodiment of the present invention.
FIG. 5 b is a front view of the female plug face showing the location of cross-section (X′-Y′) according to an embodiment of the present invention.
FIG. 6 is a complete circuit diagram of the power connector circuitry of the male plug component according to an embodiment of the present invention.
FIG. 7 is a complete circuit diagram of the power connector circuitry of the female plug component according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As used herein and in the claims, “comprising” means including the following elements but not excluding others.
As used herein and in the claims, “couple” or “connect” refers to electrical coupling or connection either directly or indirectly via one or more electrical means unless otherwise stated.
Referring now to FIGS. 1, 2 and 3 , the first embodiment of the present invention is a power connector 1 comprising a male plug component 2 and a female plug component 3 . The male plug component 2 has a standard male power supply connector at the rear (not shown) adapted to connect to a power supply such as a wall socket. The female plug component 3 has a standard female connector at the rear (not shown) adapted to connect to an external electrical device to be powered. The male plug component 2 further comprises a male plug face 4 which is substantially planar and contoured, and the female plug component 3 further comprises a female plug face 5 which is also substantially planar and contoured. There is at least one set of contacts on the male plug face 4 . In the specific example as shown in FIG. 2 , there are three (3) electrical pad contacts, one for each: hot, neutral, and ground denoted by 6 a , 6 b and 7 respectively. There is also at least one set of contacts on the female plug face 3 . In the specific example as shown in FIG. 3 , there are three (3) electrical pad contacts, one for each: hot, neutral, and ground, denoted by 8 a , 8 b and 9 respectively. The contour of the male plug face 2 and the female plug face 3 are complementary to each other such that the entire male plug face 2 can be contacted to the female plug face 3 .
In operation of the power connector 1 , the male plug component 2 is brought into contact with the female plug component 3 . The entire male plug face 4 is in contact with the female plug face 5 due to their substantially planer and complementary construction. When the two faces are in contact, the first set of three contacts 6 a , 6 b and 7 are electrically coupled to the corresponding second set of three contacts, 8 a , 8 b and 9 . This completes the electrical path between the power supply and the electrical device. As a result, electric power can flow from the power supply to the electrical device.
In an exemplary embodiment, referring to FIG. 2 and FIG. 3 , one ferromagnetic element 10 is disposed on the male plug face 4 , and at least one magnetic element 11 is disposed on the female plug face 5 . The ferromagnetic element 10 and the magnetic element 11 become connected through magnetic attractive force when the male plug face 4 is brought into contact with the female plug face 5 , thus attaching the male plug component 2 to the female plug component 3 and vice versa. In a further embodiment, the ferromagnetic element 10 and the magnetic element 11 are installed at predetermined locations in the male plug component 2 and the female plug component 3 respectively, such that the male plug component 2 can only be attached to the female plug component 3 in a predetermined orientation, where the predetermined orientation ensures the electrical path to be established in a safe manner and isolates the individual electrical pad contacts located on each of the plug faces.
Magnetic elements generate magnetic fields. When one magnetic element 10 is brought into proximity of a ferromagnetic element 11 , a magnetic attractive force is generated between the two elements. The magnetic force acts substantially along the axis of the magnetic element. As such, in the present invention, when the male plug face 4 is brought into proximity of the female plug face 5 , a magnetic attractive force is generated perpendicular to the male plug face 4 and the female plug face 5 causing them to attach. The magnetic force prevents the components from detaching once connected unless sufficient external force is applied to detach the components.
In another exemplary embodiment, FIG. 4 a and FIG. 4 b show cross-section cutaways of the male plug face 4 , and FIG. 5 a and FIG. 5 b show cross-section cutaways for the female plug face 5 . The cross-sections show the substantially planer and complementary contoured design of the plug faces. The electrical contacts on the male plug face 4 are 6 a , 6 b and 7 and are recessed within the contoured folds of the male and plug. Since the electrical pad contacts ( 6 a , 6 b and 7 ), on the male plug face 4 have to potential to be live when the system is actuated, this recessed design ensures additional safety and creates asymmetrical contours on the substantially planer face which ensure that the male plug face 4 and female plug face 5 only connect in one specific orientation.
In an exemplary embodiment, the magnetic element 11 is a permanent magnet, made of neodymium-iron-boron or samarium cobalt type disc or ring magnet. The magnetic force generated will be calibrated to be strong enough to prevent unintentional detachment but not too strong for possible damage to other parts, such as the power supply cable or the electrical device, before the connector components can be detached either accidentally or intentionally. Preferably, a force between approximately 3 lbs to 5 lbs should be produced between the magnetic and ferromagnetic elements.
In another exemplary embodiment, a disc-type magnet has a diameter of 0.375 inch or 0.5 inch and a thickness ranging from 0.1 inch to 0.125 inch. In yet another exemplary embodiment, a ring-type magnet has an outer diameter of 0.375 inch to 0.5 inch, an inner diameter of 0.125 inch and a thickness ranging from 0.1 inch to 0.125 inch.
In an exemplary embodiment, an electric circuit is provided to control the establishment of the electrical path. Referring to FIG. 6 , three circuit component-groups are disposed in the male plug component 2 each of which perform a separate function while working together to activate the plug system. The AC/DC power supply component-group 12 converts conventional household power (120 volt AC) into a low-voltage direct current (DC) supply. The AC/DC power supply component-group 12 is connected to the 120 volt AC power source (house power plug) on one end and on the other end is connected to the sensor and switching component-group 13 . The sensor and switching component-group 13 performs the function of detecting the presence of a magnetic field. As shown in FIG. 6 , this component-group is connected to the AC/DC power source component-group 12 at one end, and on the other is connected to the power transmission component-group 14 . The power transmission is attached to a standard residential power supply at one end, and to the hot and neutral contacts ( 6 a , 6 b ) on the male plug face 4 on the other. A final component group is place between the power transmission component-group and the contacts 6 a and 6 b on the male plug face 4 . This is the indicator light component group 15 which consists of two light-emitting-diodes (LED) in parallel, and a capacitor in series with the LEDs. The indicator light component group informs the plug system operator that the relays are engaged and that power is being transmitted by the system.
Referring to FIGS. 2, 3 and 6 , at least one electronic sensor and one electrically operated switch is disposed in the male plug component 2 . In a specific embodiment as shown in FIG. 6 , one hall-effect switch 16 is disposed inside the male plug component 2 , and two power relay type switches 17 are disposed inside the male plug component 2 . The system is powered on when the hall-effect sensor 16 in the male plug component 2 senses the presence of a magnetic field from the magnet disposed on the female plug face 5 . When the male plug component 2 and female plug component 3 are connected, they attach by magnetic attraction force between the magnet 11 disposed on the female plug face 5 and the ferromagnetic plate 10 disposed on the male plug face 4 . Simultaneous with the connection of the plug components, the hall-effect sensor 16 detects the presence of the magnetic field and begins to provide current to the coil of the power relay switches 17 . This triggers the relays into the “on” position where they begin to conduct AC power to the attached electric device. The relay power output terminals are electrically connected to contacts 6 a and 6 b disposed on the male plug face 4 .
In a further exemplary embodiment, with reference to FIG. 1 , FIG. 6 and FIG. 7 , when the male plug component 2 and female plug component 3 are attached, contacts 6 a , 6 b and 7 disposed on the male plug face 4 are in direct contact with contacts 8 a , 8 b and 9 disposed on the female face. In turn, the electric device is connected via the female plug component 3 to contacts 8 a and 8 b internally ( FIG. 7 ). As a result, power is transferred to the electronic device. When the user detaches the male plug component 2 from the female plug component 3 , the magnet 13 and associated magnetic field is also removed from the vicinity of the Hall-Effect sensor 16 causing the Hall-Effect sensor to terminate current transfer to the coils of the relays. This causes the relays to return to the “off” position and stop the transition of power to contacts 6 a and 6 b making the system electronically inactive.
In an exemplary embodiment, the AC/DC conversion circuit is a transformer-based conversion circuit that outputs a 6V DC voltage.
In one embodiment, with reference to FIG. 7 , an indicator circuit 19 is provided within the female plug component 3 electrically parallel to the device connecting wires of the female component 3 to alert the user when electric power is supplied to the electrical device. In an exemplary embodiment, the indicator 19 is a visual indicator light emitting diode (LED) circuit.
The exemplary embodiments of the present invention are thus fully described. Although the description referred to particular embodiments, it will be clear to one skilled in the art that the present invention may be practiced with variation of these specific details. Hence this invention should not be construed as limited to the embodiments set forth herein.
For example, the casing or external housing of the male 2 and female 3 plug components can be constructed of any rigid synthetic, semi-synthetic or organic composite polymeric material such as polyvinyl chloride, and can be constructed in any shape conductive to the adapted use, so long as the design parameters and functional constrains previously described are maintained.
In another example, a gasket can be provided surrounding the male plug face 6 and the female plug face 7 . The gaskets then push against each other when the male plug face 2 is in contact with the female plug face 3 , preventing external particles such as dust or ice to enter, causing damage to the power connector system.
In yet another example, the actuating element may be spring loaded piston within the male plug component upon which live electrical contacts are mounted. Once the male and female plug components are connected, the piston is drawn forward and electrically coupled with contacts on the female component thus transmitting power to a connected electronic device.
An AC/DC conversion circuit with transformer-less or capacitative elements can be used in place of a transformer conversion circuit with the same function. A transformer-less conversion circuit generally occupies less space.
It is obvious to one skilled in the art that the plug faces can be contoured in a way to improve alignment of the components, as long as an axial frictional force is not created during attachment. The construction and assembly of the embodiments previously described is accomplished through conventional means and uses conventional components and therefore should be consistent with the common general knowledge of a person skilled in the art. | An apparatus for electrically connecting a power source to an electrical device is disclosed. The apparatus has a first component and a second component. The first component has a first face having a ferromagnetic plate, a first set of contacts electrically connectable to a power source, two power switches and a magnetically actuated sensor controlling the switches. The second component has a second face complementary to the first face having a magnet and a second set of electrically conductive contacts electrically connectable to the electrical device. Connecting the first and second faces, results in the first and second pair of contacts electrically coupling and establishes an electrical path between the power source and the device, and connects the components by magnetic attractive force which actuates the power switches and initiates power to the device. The apparatus further has a safety circuit for preventing electric shock. | 7 |
This is a continuation of application Ser. No. 08/142,886, filed on Oct. 25, 1993, now abandoned which is a continuation U.S. Ser. No. 07/949,970 filed Sep. 24, 1992, now abandoned.
FIELD OF THE INVENTION
This invention relates to antigenic conjugate molecules comprising the capsular polysaccharide of Group B streptococcus type II which are covalently linked to protein. This invention also relates to vaccines and methods of immunizing mammals, including humans against infection by Group B streptococcus type II (GBS II). Multivalent vaccines comprising the conjugate molecules of this invention and antigens to other pathogenic bacterial are also claimed.
BACKGROUND OF THE INVENTION
Infections due to group B streptococci (GBS) are the most common single cause of sepsis and meningitis in newborns in developed countries (3, 31). Recent reports from some centers in the United States reflect a lower mortality (9 to 13%) than in series from the 1970s, perhaps as a result of earlier diagnosis and intensive care (1, 10). Nonetheless, fatal infections still occur, and equally important, up to 50% of survivors of GBS meningitis have chronic neurologic injury ranging from deafness and mild learning disabilities to profound motor, sensory, and cognitive impairment (3). Prevention rather than improved diagnosis or therapy is likely to have the most significant impact in further reducing GBS-related morbidity and mortality.
Because GBS capsular polysaccharide-specific antibodies appear to protect both experimental animals (23, 24) and human infants (4, 5) from GBS infection, some of the polysaccharides have been purified and tested in healthy adults as experimental vaccines (6). Were a safe and efficacious GBS vaccine available, it could be administered to women before or during pregnancy to elicit antibodies that would transfer to the fetus in utero and provide protection against neonatal infection. Of the three GBS polysaccharides (types Ia, II, and III) tested in volunteers, type II had the highest rate of immunogenicity, eliciting a type II-specific antibody response in 88% of previously nonimmune recipients (6). In neonates, the level of specific antibody required for protection against type II GBS infection is not precisely defined but has been estimated at 2 or 3 μg/ml (6). In a vaccine recipient who achieves an antibody response only slightly above the minimum required for protection, the amount of maternal antibody transferred across the placenta may be inadequate to protect a premature infant, because of the incomplete transfer to the fetus of material immunoglobulin G (IgG), or an infant with late-onset infection, since the half-life of maternal IgG antibodies in the newborn is about 25 days (13). Many of the infants in these two groups of patients might be protected if the magnitude of the specific antibody response to vaccination were higher. The transfer of maternal IgG to the fetus increases throughout the third trimester, so a higher maternal antibody level would provide protection earlier, i.e., to a more premature infant (16). Similarly, higher maternal levels would result in longer persistence of maternal antibodies in the infant, thereby providing protection against late-onset disease, as well.
The immunogenicity of several bacterial polysaccharide antigens has been increased by the attachment of suitable carrier proteins to polysaccharides or to derivative oligosaccharides (2, 14, 17-19, 22, 27, 29, 30, 34). Desirable properties of polysaccharide-protein conjugate vaccines include enhanced immunogenicity of the polysaccharide, augmented hapten-specific antibody response to booster doses, and a predominance of IgG class antibodies. Recently, we have been successful in developing a GBS III-Tetanus Toxoid (TT) vaccine by using the side chain sialic acid moieties as sites of directed protein coupling (33). The III-TT vaccine elicited GBS type III-specific, opsonically active antibodies, while the unconjugated type III polysaccharide was nonimmunogenic in rabbits (33).
SUMMARY OF THE INVENTION
This invention claims antigenic conjugate molecules comprising the capsular polysaccharide derived from Group B streptococcus type II and a protein component wherein two or more side chains terminating in sialic acid residues of the polysaccharide component are each linked through a secondary amine bond to protein.
Also claimed is a method of preparing a conjugate molecule of a capsular polysaccharide of Group B streptococcus type II and a protein comprising:
(a) subjecting the Group B streptococcus type II capsular polysaccharide to periodate oxidation sufficient to introduce an aldehyde group into one or more terminal sialic acid residues linked to the backbone of the polysaccharide;
(b) coupling the oxidized Group B streptococcus type II capsular polysaccharide to a protein through reductive amination to generate a secondary amine bond between the capsular polysaccharide and the protein.
Conjugate molecules prepared according to the method described above are also claimed.
This invention further claims a vaccine comprising the conjugate molecule described above. In addition, this invention claims multivalent vaccines comprising the conjugate molecule of the invention and at least one other immunogenic molecule capable of eliciting the production of antibodies to a pathogenic substance other than Group B streptococcus type II. In particular in addition to comprising the GBS type II conjugate molecules,the multivalent vaccine, according to the invention, further comprises other immunogenic molecules capable of eliciting the production of antibodies to pathogens selected from the group consisting of Group B streptococcus types Ia, Ib, III, IV and V, Haemophilus influenzae type b and E. coli type K1.
In another embodiment of this invention, a method of immunizing neonates is claimed wherein the vaccine comprising the conjugate molecules of the invention are administered in an immunogenic amount to a female human so as to produce antibodies capable of passing into a fetus conceived prior to or after administration of the vaccine in an amount sufficient to produce protection against infection in the neonate at birth.
A method of immunizing adults wherein a vaccine comprising the conjugate molecules of the invention are administered in an immunogenic amount to a human adult is also claimed. In addition, a method of immunizing adults wherein a vaccine comprising the conjugate molecules of the invention are administered in an immunogenic amount to a person at risk for being infected by Group B streptococcus type II is claimed.
Another embodiment of this invention is a method of immunizing dairy herds against bovine mastitis consisting of administering a vaccine comprising the conjugate molecules of the invention in an immunogenic amount to dairy cows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. Structure of the heptasaccharide repeating unit of type II GBS capsular polysaccharide 920).
FIG. 2. GBS type II polysaccharide competitive ELISA. GBS type Ia (◯), type II (), and type III (▴) polysaccharides were used as inhibitors of II-TT vaccine antibody binding to plates coated with type II polysaccharide. Results are expressed as percentages of inhibition relative to that of control wells that lacked inhibitor.
FIG. 3. GBS type II polysaccharide competitive ELISA. Native () and desialylated or core (□) type II polysaccharides were used as inhibitors of antibodies elicited by II-TT vaccine. Datum points are means (with standard deviations) of triplicate determinations. Results are expressed as percentage of inhibition relative to that of control wells that lacked inhibitor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Bacterial strains. GBS type II strain 18RS21 and type Ia strain 090 were originally obtained from the late Rebecca Lancefield of Rockefeller University and were maintained as frozen cultures at -80° C. Strain 18RS21 was used in in vitro and in vivo assays and was the source of type II capsular polysaccharide used in the conjugate vaccine. Two GBS type II clinical isolates (strains S16 and S20) and type III strain M781 were obtained from the Channing Laboratory's culture collection.
Conjugation of GBS type II polysaccharide to TT. Type II capsular polysaccharide was purified from strain 18RS21 cells by methods described previously for purification of type III polysaccharide (33). The conjugation of type II polysaccharide to monomeric TT was performed by using techniques detailed previously for the conjugation of TT to GBS type III polysaccharide (33). In brief, native type II polysaccharide was size fractionated on a Sepharose CL-6B column (1.6 by 85 cm; Pharmacia Fine Chemicals). The material eluting at the center of the of the major peak was pooled, dialyzed against water, and lyophilized to yield material with a relative molecular weight of 200,000. Analysis of this material by 1 H-nuclear magnetic resonance spectroscopy at 500 MHz confirmed the native type II polysaccharide structure (20) and the absence of group B antigen (26). The size-fractionated type II polysaccharide was subjected to mild oxidation with sodium meta-periodate (18). This procedure resulted in the conversion of a portion of the sialic acid residues on the polysaccharide to the eight-carbon analog of sialic acid, 5-acetamido-3,5-dideoxy-D-galactosylocrulosonic acid (33). The percentage of sialic acid residues oxidized was estimated by gas chromatography-mass spectrometry of the sialic acid residues and their oxidized derivatives as described previously (33).
The oxidized type II polysaccharide was linked to monomeric TT (Institute Armand Frappier, Montreal, Canada) by reductive amination as described previously (33). The TT was purified to its monomer from by gel filtration chromatography also as described previously (33). In brief, 10 mg of the periodate-treated type II polysaccharide and 10 mg of purified TT were dissolved in 0.6 ml of 0.1M sodium bicarbonate (pH 8.1). Sodium cyanoborohydride (20 mg) was added to the mixture and incubated at 37° C. for 5 days. The progress of the conjugation was monitored by fast protein liquid chromatography (FPLC) of small aliquots of the reaction mixture analyzed on a Superose 6 (Pharmacia) gel filtration column. The reaction was terminated when the height of the peak eluting at the void volume of the column (representing the high-molecular-weight conjugate) remained constant. The conjugate was purified by chromatography on a column of Biogel A, 0.5M (Bio-Rad Laboratories, Richmond, Calif.) as described previously (33). The protein content of the vaccine was estimated by the method of Lowry et al. (25), with bovine serum albumin as a standard. The carbohydrate content was assessed by the method of Dubois et al. (11), with purified type II polysaccharide as a standard. Examples of other proteins suitable for conjugating to the polysaccharide include diphtheria toxoid and the cross reactive material ("CRM") CRM 197 .
Vaccination of rabbits with II-TT vaccine. Groups of three New Zealand White female rabbits (Millbrook Farms, Amherst, Mass.), each rabbit weighing approximately 3 kg, were vaccinated subcutaneously at four sites on the back with 50 μg of either uncoupled native type II polysaccharide or II-TT vaccine, each emulsified with complete Freund's adjuvant in a total volume of 2 ml. These animals received booster injections (50 μg) of vaccine prepared with incomplete Freund's adjuvant on days 20 and 41. Serum was obtained from each animal on days 0, 20, 34, 41, 55, and 70; filtered sterile; and stored at -80° C.
ELISA. GBS type II-specific rabbit antibodies were quantified by enzyme-linked immunosorbent assay (ELISA) with goat anti-rabbit IgG conjugated to alkaline phosphatase (Tago Inc. Burlingham, Calif.) at 1/3,000 dilution. Microtiter plates (Immulon 2; Dynatech Laboratories, Inc., Chantility, Va.) were coated with 100 ng of purified type II polysaccharide linked to poly-L-lysine per well as described before (15, 33). Antibody titers were recorded as the reciprocal dilution that resulted in an A 405 of 20.3 when wells containing the reference serum (rabbit antiserum raised to whole BGS 18RS21 cells) at a dilution of 1/800 reached an A 405 of 0.5. The amount of antibody specific for the protein portion of the conjugate vaccine was estimated by ELISA by using plates coated with monomeric TT (100 ng per well). TT-specific IgG titers were recorded as the reciprocal dilution that resulted in an A 405 of ≧.3 35 min after addition of the substrate, p-nitrophenyl phosphate (Sigma 104 phosphatase substrate tablets; Sigma Chemical Co.).
Separation of IgG and IgM from Immune rabbit serum. Protein A-agarose affinity column chromatography (Pierce Chemical Co., Rockford, Ill.) was used to separate immunoglobulins (IgG and IgM) from 0.5 ml of pooled immune rabbit serum, obtained on day 70, raised to II-TT vaccine as described elsewhere (28). Separation of antibody classes was confirmed with type II polysaccharide-coated ELISA plates with goat anti-rabbit IgG (γ and light chain specific; Tago) used at 1/500 dilution and goat anti-rabbit IgM (μ chain specific; Sera-Lab, Westbury, N.Y.) used at a 1/200 dilution.
Competitive ELISA. The specificity of rabbit serum raised to the II-TT vaccine was determined by competitive ELISA with homologous (type II) and heterologous (types Ia and III) polysaccharides as inhibitors. Epitope specificity of vaccine-induced pooled rabbit serum (obtained on day 70) was examined with native and desialylated type II polysaccharide and β-O-methylgalactopyranose as inhibitors of antibody binding. Native type II polysaccharide was desialylated by treatment with 6% acetic acid at 80° C. for 2 h. Polysaccharide inhibitors were serially diluted 4-fold and mixed with an equal volume (75 μl) of pooled rabbit serum (diluted 10,000-fold) obtained on day 70 after vaccination with II-TT vaccine. This mixture (100 μl) was then added to type II polysaccharide-coated ELISA wells. Alkaline phosphatase-conjugated anti-rabbit IgG was used as the secondary antibody at a dilution of 1/3,000. Results are expressed as follows: % inhibition- A 405 with no inhibitor -A 405 with inhibitor)/A 405 with no inhibitor!×100.
In vitro antibody-mediated killing of GBS. The ability of vaccine-induced rabbit antibodies to opsonize GBS cells for subsequent killing by human peripheral blood leukocytes was assessed by an in vitro opsonophagocytosis assay (7,8).
Passive protection of mice by vaccine-induced rabbit antibodies. Groups of 10 Swiss-Webster outbred female mice (Taconic Farms, Germantown, N.Y.), each mouse weighing 18 to 20 g, were injected intraperitoneally with 0.2 ml of pooled serum (day 70) from rabbits vaccinated with either type II polysaccharide or II-TT vaccine. The titer, as measured by ELISA, of the pooled serum obtained on day 70 from rabbits immunized with type II polysaccharide was 100, and that of II-TT vaccine was 12,800. Control groups of five mice received pooled preimmunization rabbit serum or pooled antiserum raised to uncoupled TT (27). Twenty-four hours later, mice were challenged with type II strain 18RS21 (1.5×10 5 CFU per mouse) in a total volume of 1.0 ml of Todd-Hewitt broth. The challenge dose for each strain was previously determined to be lethal for >90% of mice of similar weights and ages. Surviving mice were counted daily for three subsequent days.
Statistical Analysis. Fisher's exact test was used to compare the abilities of different rabbit sera to passively protect mice against lethal GBS infection.
RESULTS
Preparation and composition of II-TT vaccine. GBS II-TT vaccine was prepared by methods detailed previously for the construction of the GBS type III conjugate vaccine (33). Controlled periodate oxidation of type II GBS polysaccharide resulted in the modification of 7% of the polysaccharide's sialic acid residues as determined by gas chromatography-mass spectrometry analysis. Monomeric TT was covalently linked to modified sialic acid sites on the type II polysaccharide by reductive amination. The purified II-TT vaccine contained 32% (wt/wt) protein and 68% (wt/wt) carbohydrate. The final yield of II-TT vaccine was 7.8 mg, or 39%.
Immunogenicity of II-TT vaccine in rabbits. The immunogenicities of the II-TT vaccine and native type II polysaccharide were compared in rabbits. An increase in type II-specific antibody was seen following the primary dose of II-TT vaccine (Table 1). A booster dose of vaccine further increased the antibody response. Antibody levels remained unchanged or rose slightly following a second booster, dose on day 41 and were sustained throughout the remainder of the study (Table 1). In contrast to the II-TT vaccine, uncoupled native GBS type II polysaccharide failed to elicit a specific antibody response (Table 1). Animals vaccinated with the II-TT vaccine also developed antibodies to TT, achieving approximately a 3-log 10 increase over preimmunization levels.
TABLE 1______________________________________GBS type II polysaccharide-specific antibodytiters of rabbits vaccinated with native type IIpolysaccharide or II-TT vaccine Antibody titer in ELISA as day:.sup.aVaccine and rabbit 0 20.sup.b 34 41.sup.b 55 70______________________________________Native type IIpolysaccharide1 100 100 100 200 100 1002 100 100 100 100 100 1003 200 100 100 100 100 100II-TT1 100 400 3,200 3,200 6,400 12,8002 100 1,600 3,200 6,400 6,400 25,6003 100 6,400 12,800 25,600 12,800 12,800______________________________________ .sup.a A value of 100 indicates an antibody titer of ≦100. Values are the means of duplicate determinations. Rabbits were vaccinated subcutaneously with 50 μg of vaccine emulsified with complete Freund's adjuvant on day 0. .sup.b Booster doses with incomplete Freund's adjuvant were administered.
Antigenic properties of vaccine-induced rabbit sera. The conjugation of polysaccharide to a protein carrier should not alter important antigenic epitopes found on the polysaccharide in its native form. We tested the specificity of II-TT vaccine-induced antibodies by competitive ELISA using homologous and heterologous GBS polysaccharides as inhibitors. Native type II polysaccharide at a concentration of 450 ng/ml inhibited 50% of the binding of rabbit antibodies raised to II-TT vaccine (FIG. 2). GBS type Ia and type III polysaccharides did not inhibit binding of serum raised to II-TT vaccine even at concentrations as high as 500 μg/ml. (FIG. 2). These result verify the serotype specificity of II-TT vaccine-induced antibodies for the target antigen and indicate preservation of antigenic epitopes of the polysaccharide portion of the conjugate vaccine.
To determine whether the epitope influenced by sialic acid was maintained during the preparation of II-TT vaccine, native and desialylated type II polysaccharides were used in a competitive ELISA as inhibitors of binding of rabbit antibodies raised to II-TT vaccine. Desialylation of the polysaccharide was accomplished by treatment with 6% acetic acid at 80° C. for 2h. Quantitative removal of sialic acid residues was confirmed by the thiobarbituric acid assay (32) with N-acetylneuraminic acid (Sigma) as the standard. The K av of native type II polysaccharide before acid treatment was 0.49, whereas the K av of acid-treated polysaccharide was 0.52 on a Superose 6 FPLC column (LKB-Pharmacia, Sweden), indicating a slight reduction in molecular size of the polysaccharide due to the loss of the side chain sialic acid residues that make up 20% of the native polysaccharide by weight. Even 200 μg of desialylated GBS type II polysaccharide per ml inhibited by 33% of the binding of II-TT vaccine antibodies to native type II polysaccharide (FIG. 3). The relatively poor recognition of the desialylated or core type II polysaccharide by II-TT vaccine antiserum was confirmed by immunoelectro-phoresis gels, which showed a precipitin band formed with the native but not the core type II polysaccharide (not shown). Binding of II-TT vaccine antisera to native type II polysaccharide could not be inhibited with β-O-methylgalactopyranose used at a concentration range of 0.01 to 10 mg/ml (not shown).
In vitro activity of GBS vaccine-induced antibodies. The ability of immune serum to opsonize GBS for killing by human peripheral blood leukocytes in vitro has correlated with protective efficacy against GBS in animal protection experiments (27,33). Antibodies raised in the three rabbits vaccinated with II-TT vaccine enhanced the killing of GBS type II strain 18RS21 by ≧1.8 log 10 (Table 2). Preimmunization rabbit serum or serum from rabbits vaccinated with native GBS type II polysaccharide or uncoupled TT failed to enhance the in vitro killing of GBS (Table 2). Vaccine-induced rabbit antibodies promoted the killing by human blood leukocytes of two GBS type II clinical isolates (strains S16 and S20) by ≧1.8 log 10 compared with preimmunization rabbit serum (Table 3). Rabbit serum to II-TT vaccine was determined to be serotype specific, as it failed to promote the in vitro killing of heterologous (types Ia and III) GBS strains (Table 3).
TABLE 2______________________________________In vitro opsonophagocytic killing of GBS type IIstrain 18RS21 by rabbit antiserum raised to native type IIpolysaccharide, II-TT vaccine, or TT GBSSerum source CFU killed(day of collection) 0 min 60 min (log.sub.10)______________________________________Type II polysaccharide (70).sup.b 4.3 × 10.sup.6 6.6 × 10.sup.6 -0.19II-TT vaccine (0) 6.0 × 10.sup.6 6.4 × 10.sup.6 -0.03II-TT vaccine (70)Rabbit 1 4.0 × 10.sup.6 5.7 × 10.sup.4 1.85Rabbit 2 4.3 × 10.sup.6 2.7 × 10.sup.4 2.20Rabbit 3 3.9 × 10.sup.6 4.3 × 10.sup.4 1.96TT (70) 4.2 × 10.sup.6 6.9 × 10.sup.6 -0.21None 3.9 × 10.sup.6 7.1 × 10.sup.6 -0.26______________________________________ .sup.a Reaction mixture contained serum (at a final assay concentration o 1%) to be tested, type II GBSabsorbed human serum as a source of complement, human peripheral blood leukocytes, and type II GBS 18RS21. Values are means of duplicate determination. .sup.b Rabbit serum collected following the primary dose of native type I polysaccharide in complete Freund's adjuvant.
TABLE 3______________________________________In vitro opsonophagocytic killing of GBS strainsby preimmunization and immune rabbit serumraised to II-TT vaccine GBS killed (log.sub.10).sup.a Preimmunization Immune II-TT vaccineGBS type and strain (day 0) (day 70)______________________________________II18RS21 -0.36 1.98S16 0.96 2.78S20 -0.01 1.84I 090 ND -0.51III M781 ND -0.54______________________________________ .sup.a CFU (log.sub.10) at 60 min CFU (log.sub.10) at 0 min. Reaction mixture contained serum to be tested, type II GBSabsorbed human serum as source of complement, human peripheral blood leukocytes, and type II GBS I8SR21. Values are means of duplicate determinations. ND, not done.
Protein A-affinity-purified IgG and IgM were obtained from pooled serum raised to II-TT vaccine (28). The specificity of each Ig fraction was confirmed by ELISA with class-specific secondary antibody. The A 405 S of the IgM and IgG fractions (diluted 1/100) were 0.384 and 0.009, respectively, with μ-chain-specific conjugate and 0.086 and 2.367, respectively, with goat anti-rabbit IgG (γ and light chain specific). Isolated IgM and IgG were tested for their abilities to enhance opsonic killing of type II GBS by human blood leukocytes. Unfractionated sera raised to II-TT vaccine diluted 1:100 and an equivalent 1:100 dilution of the IgG fraction from the same sera promoted killing of type II GBS by 1.65±0.22 and 0.95±0.09 log 10 , respectively. In contrast, type II GBS were not killed but grew in the presence of preimmunization serum (-0.39±0.13 log 10 ) and IgM-enriched fraction from serum raised to II-TT vaccine (-0.28±0.09 log 10 ) in the opsonophagocytic assay.
Mouse protection assay. To test the in vivo protective abilities of vaccine-induced antibodies, mice were passively immunized with pooled II-TT vaccine sera (day 70) 24 h prior to challenge with type II GBS 18RS21. Previously, the challenge does was determined to be lethal for 90 to 100% of mice tested. Complete (100%) protection was afforded to groups of mice that received serum raised to GBS II-TT vaccine, whereas only one of five mice receiving prevaccination serum survived (Table 4). There were no survivors among mice that received serum from rabbits vaccinated with either uncoupled type II polysaccharide or uncoupled TT (Table 4).
TABLE 4______________________________________Passive protection of Swiss-Webster outbred miceagainst GBS type II strain 18RS21 with sera from rabbitsvaccinated with native type II polysaccharideII-TT vaccine, or TT.sup.aRabbit serum.sup.b No. of survivors/(day of collection) total no. of mice.sup.c % Survival______________________________________II-TT vaccine (70) 10/10 100.sup.dII-TT vaccine (0) 1/5 20Type II polysaccharide (70) 0/10 0TT (70) 0/5 0______________________________________ .sup.a Mice were given a 90% lethal dose (1.5 × 10.sup.5 CFU per mouse) of GBS. .sup.b Serum samples from three rabbits were pooled. .sup.c Survival was determined 72 h after challenge. .sup.d P = 0.0037 compared with preimmunization (day 0) values.
The coupling strategy used with GBS type III polysaccharide, first developed for meningococcal polysaccharide (18), may be applicable to all GBS capsular polysaccharide antigens, since they all contain sialic acid. However, unlike the other GBS polysaccharides that have sialic acid as the terminal saccharide of di- or trisaccharide side chains, the GBS type II polysaccharide has a repeating unit that bears sialic acid as the sole sugar on one of the two monosaccharide side chains (9, 20). In constructing the GBS type II conjugate vaccine, we oxidized 7% of sialic acid residues on the type II polysaccharide and used these as sites for coupling the polysaccharide to TT. Purified II-TT vaccine eluted in the void volume of a Superose 6 column (compatible with a molecular weight of >10 6 ) and was composed of 68% (wt/wt) carbohydrate and 32% (wt/wt) protein.
II-TT vaccine emulsified with adjuvant was immunogenic in rabbits in contrast to uncoupled native type II polysaccharide, which failed to elicit type II polysaccharide-specific antibody. Two of three rabbits immunized responded strongly 3 weeks after a single dose of II-TT vaccine. Optimal type-specific antibody was achieved in all three rabbits 3 weeks after a booster dose of II-TT vaccine. Further increases in type II-specific antibody titer were not seen after the third dose of II-TT vaccine. Results from in vitro and in vivo experiments indicated that antibodies raised to II-TT vaccine were functionally active against type II GBS. Serum from each of three rabbits vaccinated with II-TT vaccine promoted the in vitro killing of type II GBS by human peripheral leukocytes and provided outbred mice with complete (100%) protection against a lethal dose of type II GBS. II-TT vaccine antiserum was opsonically active against homologous GBS strains (18RS21, S16, and S20) but not heterologous GBS serotypes (types Ia and III) tested.
Whereas native type II polysaccharide inhibited binding of II-TT vaccine antisera to type II polysaccharide-coated ELISA wells, <40% inhibition was obtained with desialylated type II polysaccharide, even when it was used at a concentration of 200 μg/ml. This result suggests that an important antigenic determinant of type II polysaccharide is dependent on the presence of sialic acid residues. This result corroborated those obtained with rabbit antisera raised to whole type II organisms (21). However, ELISA inhibition experiments using β-O-methylgalactopyranose as an inhibitor indicated that rabbit antisera raised to II-TT vaccine did not contain galactose-specific antibodies. No inhibition of binding of II-TT vaccine antiserum to type II native polysaccharide was obtained even with β-O-methylgalactopyranose at a concentration of 10 mg/ml. Therefore, the side chain galactose does not appear to be an immunodominant epitope of type II polysaccharide when the polysaccharide is coupled to TT. These results are in contrast to immunochemical studies performed with rabbit sera raised to whole type II GBS organisms (12,21) in which the galactose side chain appeared to be one of two immunodominant sites, along with a sialic acid-dependent epitope, of type II polysaccharide. Whole type II GBS cells used in previous studies (12,21) and not cultured in pH-controlled conditions may possess polysaccharides that, to some degree, lack sialic acid. Under these circumstances, the side chain galactose might be major antigenic epitope. The source of type II polysaccharide used to synthesize the II-TT vaccine was a culture of type II GBS maintained at a pH of 7.0; a final analysis confirmed that sialic acid constituted ˜20% (wt/wt) of the polysaccharide. We cannot exclude the possibility that coupling type II polysaccharide to TT altered the conformation of the polysaccharide, thereby rendering the galactose epitope unavailable for recognition by the host immune system. Although II-TT vaccine-induced rabbit antiserum lacked galactose-specific antibodies, it was fully functional in vitro and in vivo against type II GBS organisms. Neither chemical modification of some of the sialic acid residues nor the subsequent binding of TT to these sites altered critical antigenic epitopes necessary to elicit functional type II-specific antibody. That purified IgG from rabbit sera raised to II-TT vaccine promoted killing in vitro of type II GBS by human leukocytes suggests that not only was the immunogenicity of type II polysaccharide increased by conjugating it to TT but also that functional IgG antibodies were elicited.
Like III-TT vaccine, II-TT vaccine demonstrated improved immunogenicity in rabbits compared with active polysaccharide and elicited opsonically active IgG in rabbits despite difference in polysaccharide structure, position of the sialic acid on the polysaccharide to which TT was linked, and vaccine composition. We anticipate that GBS polysaccharide-protein conjugates of this design will ultimately constitute components of a multivalent GBS vaccine capable of providing protection against the GBS serotypes most often associated with disease in humans.
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15. Gray, B. M. 1979. ELISA methodology for polysaccharide antigens: protein coupling of polysaccharides for adsorption to plastic tubes. J. Immunol. Methods 28:187-192.
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27. Paoletti, L. C., D. L. Kasper, F. Michon, J. DiFabio, K. Holme, H. J. Jennings, and M. R. Wessels. 1990. An oligosaccharide-tetanus toxoid conjugate vaccine against type III group B Streptococcus. J. Biol. Chem. 265:18278-18283.
28. Paoletti, L. C., D. L. Kasper, F. Michon, H. J. Jennings, T. D. Tosteson, and M. R. Wessels. 1992. Effects of chain length on the immunogenicity in rabbits of group B Streptococcus type III oligosaccharide-tetanus toxoid conjugates. J. Clin. Invest. 89:203-209.
29. Schneerson, R. O. Barrera, A. Sutton, and J. B. Robbins. 1980. Preparation, characterization and immunogenicity of Haemophilus influenzae type b polysaccharide-protein conjugates. J. Exp. Med. 152:361-376.
30. Svenson, S. B. and A. A. Lindberg. 1979. Coupling of acid-labile Salmonella specific oligosaccharides to macromolecular carriers. J. Immunol. Methods 25:323-335.
31. Walsh, J. A., and S. Hutchins. 1989. Group B streptococcal disease: its importance in the developing world and prospect for prevention with vaccines. Pediatr. Infect. Dis. J. 8:271-276.
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33. Wessels, M. R., L. C. Psoletti, D. L. Kasper, J. L. DiFabio, F. Michon, K. Holme, and H. J. Jennings. 1990. Immunogenicity in animals of a polysaccharide-protein conjugate vaccine against type III group B Streptococcus, J. Clin. Invest. 86:1428-1433.
34. Zigterman, J. W. J. , J. E. G. van Dam, H. Snippe, F. T. M. Rottsveel, M. Janszs, J. M. N. Willers, J. P. Kamerling, and J. F. G. Vlegenthart. 1985. Immunogenic properties of octasaccharide-protein conjugates derived from Klebsiella serotype II capsular polysaccharide. Infect. Immun. 47:421-428.
While we have hereinbefore described a number of embodiments of this invention, it is apparent that the basic constructions can be altered to provide other embodiments which utilize the methods of this invention. therefore, it will be appreciated that the scope of this invention is defined by the claims appended hereto rather than by the specific embodiments which have been presented hereinbefore by way of example. | This invention relates to antigenic conjugate molecules comprising the capsular polysaccharide of Group B streptococcus type II which are covalently linked to protein. This invention also relates to vaccines and methods of immunizing mammals, including humans against infection by Group B streptococcus type II (GBS II). Multivalent vaccines comprising the conjugate molecules of this invention and antigens to other pathogenic bacteria are also claimed. | 0 |
BACKGROUND OF THE INVENTION
The invention concerns electromagnetic lenses.
There are known electromagnetic lenses which comprise two conductive sides between which there is arranged a cavity provided in its lateral portion with electromagnetic coupling transitions to authorize a set of propagation laws between pairs of such inputs/outputs.
However, the practical manufacture of such lenses poses problems, in particular for obtaining the set of propagation laws.
The present invention provides an advantageous solution for this problem.
SUMMARY OF THE INVENTION
According to one aspect of the invention the device comprises, substantially centered in the cavity, a substrate comprising a printed conductive patch of predetermined dimensions, the two conductive sides and the patch thus creating a three-plate structure with a suspended strip line, wherein the content of the cavity and the geometries of the cavity and of the conductive patch, are chosen to comply with the propagation laws.
According to another aspect of the invention, the coupling transitions are formed by horns printed on the suspended strip line, starting from its conductive patch and leading to respective transmission lines.
Very advantageously, the device comprises decoupling resistors between the printed horns constituting the inputs/outputs.
The device thus obtained comes, in a quasi-optimal way, close to the theoretical characteristics which form the advantage of electromagnetic lenses, that is to say the device has a wide operating band and a constant beam aperture.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention will become apparent on examining the detailed description given below, as well as the drawings wherein:
FIGS. 1A and 1B are geometrical diagrams explaining the operation of a Luneberg lens;
FIG. 2 illustrates an embodiment of a spherical-type Luneberg lens;
FIGS. 3A and 3B respectively illustrate in a schematic view and in cross-section, another embodiment of a Luneberg lens, in a flat, cylindrical version;
FIGS. 4A and 4B respectively illustrate two known embodiments of electromagnetic transmission lines of the three-plate type, and with a suspended strip line;
FIGS. 5A and 5B schematically illustrate the principle of the lens improved in accordance with the present invention;
FIG. 5C illustrates a dielectric wafer of FIG. 5A in a top view;
FIG. 6 is a view before mounting of the main elements of a lens in a preferred embodiment of the present invention; and
FIG. 7 is a part view of a lens in another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The attached drawings are, at least in part, of a definitive nature, and it is clear that the present invention involves shapes. Consequently, and to this extent, the drawings should be considered as an integral part of the description and may not only contribute to a better understanding of the latter but also participate in the definition of the invention, if required.
In optical lenses, the function of electromagnetic lenses is to focus a plane incident wave, of a given direction, at a specific point (called the focus) of the considered direction.
First of all, we will consider the Luneberg lens ("Mathematical Theory of Optics", R. K. LUNEBERG, Brown University Press, 1944). This concerns a region of spherical symmetry (FIG. 1A), wherein the index n varies according to the law
n.sup.2 (r)=2-r.sup.2 /R.sup.2
where R is the radius of the region, and r the radius of the current point. A plane wave, of any direction, entering into the region will be considered. This wave (FIG. 1B) is focused at a focus F situated at the intersection of the circumference of the region with the direction of propagation of the plane wave. Such a "Luneberg lens" has, in particular, the following two properties:
it has an infinite number of focal points situated on its circumference;
if a source of electromagnetic radiation is placed at any point F on the circumference of the lens, at the output a radiating width of a dimension 2 R will be obtained.
The Luneberg lens is thus suitable for the creation of beams over 360 angular degrees. It may be the object of a spherical embodiment and above all, of a flat cylindrical embodiment. The latter makes it possible to devise in particular :
antennas with circular beam scanning by switching over 360°, with the retention of the beam width at a given frequency, or
multibeam antenna systems capable of operating simultaneously along several directions, for example, for satellite transmission between mobile units.
There exist other types of electromagnetic lenses with a constrained propagation, based on different geometries and/or laws of index variations, in particular the lenses termed R2R or, more generally, RkR.
One of the theoretical advantages of these lenses is that they are capable of operating in a wideband. All the same, it is necessary that the practical embodiment of these lenses should retain these theoretical advantages.
Indeed, obtaining a continuous variation of the index industrially has been difficult.
Proposals have been made, in particular in "Les Antennes" [Antennas] of L. THOUREL, CEPADUES EDITIONS, 1988.
In the case of a spherical lens, the procedure generally adopted lies in creating a medium, wherein the variation of the index from the value 1 (external surface 29) towards the value 2 (center) is effected in stages, starting with a sphere 20 with the index 2 at the center, and concentric shells 21, each with a constant index (FIG. 2).
Although these performances are diminished because of the formulation of an index variation law that is not really continuous, this procedure is considered as quite distinctly preferable to attempts at creating a continuous variation of the index, which would then stipulate the intervention, for example, of a density weighting of a polystyrene, or a weighting with a polyethylene that is, for example, charged to a greater or lesser extent with particles. Indeed this often leads, as compared with the nominal law, to index deviations which are just as much of a nuisance as the deterioration of the performances due to the variation of the index by stages (better controlled), illustrated in FIG. 2.
In the case of a flat lens, it is possible to proceed as with a spherical lens by providing concentric rings of different indices, which poses the same problems, as before, of the limitation of the performances. To this there is added the fact that the collection of the energy by horns is not optimal.
Another procedure lies in varying the guided wavelength of a wave that is propagated between two metal plates, which is reflected in a variation of the equivalent index of the guide. In the example of FIGS. 3A and 3B, this is obtained by causing the distance d between two plates to vary, at the point where an electromagnetic wave is propagated in the TE mode.
The advantage of this method lies in the possibility of creating a closed metal wafer provided with wave guide elements at its inputs and outputs (a horn). On the other hand, a considerable drawback lies in the difficulty of machining the hollow metal plates. Another drawback is due to the limitation of the operating band, which is due to the propagation in the TE mode.
The present invention aims to propose a more satisfactory design.
Before starting the description of the invention, reference will be made to the known three-plate type propagation medium (a strip line) which basically consists of a strip-type conductor held between two conductive plates.
A conventional version, where small dielectric plates are provided between the central strip 40 and the end plates 41 and 42, is illustrated in FIG. 4A. For a conventional line operating in the TEM propagation mode, the guided wavelength is
λ.sub.g =λ.sub.o /√ε
where λ o is the wavelength in air and ε is the relative permittivity of the dielectric between the dielectric plates 43 and 44.
A propagation line of the suspended substrate (or suspended strip line type) as illustrated in FIG. 4B, is a particular type of the three-plate line, where the metal strip constituting the central conductor 40 is obtained by printing on a thin dielectric film 45, using technology of the printed circuit type. It has been observed that this type of structure combines the qualities of reduced losses and a high power level.
It will also be noted that in FIG. 4B the lateral extensions of the end plates 41 and 42 serve to hold the substrate film 45.
According to the present invention, an electromagnetic lens (in the example chosen for this detailed description, a Luneberg lens) is obtained from a propagation medium of the three-plate type with a strip line suspended between two metal plates which are here planar, by causing the propagation speed of the wave to vary on the basis of the variation of the relative permittivity of the dielectric between the two metal plates.
The variation of the permittivity is, in this example, obtained on the basis of the variation of the relative dosage (sizes) of two dielectric materials with a different permittivity by following the Luneberg law. Since the propagation of the electromagnetic waves will, in principle, be effected in the TEM mode (which permits a wideband operation), the proposed device retains the particularly advantageous wideband properties.
More precisely (FIG. 5A), the proposed Luneberg lens comprises in its central portion a printed metal disk 50 placed at the center of a cavity of cylindrical symmetry, on a substrate 55 of a small thickness.
Two plane metal plates 51 and 52 create the rest of the three-plate structure, one on each side of metal disk 50, preferably forming a casing.
In the gap between the substrate 55 and the plates 51 and 52, the cavity comprises:
on the one hand a dielectric, such as air, whose relative permittivity is close to 1,
on the other hand, on either side of the central circular patch 50, and preferably symmetrically relative to the patch, two dielectric wafers 56, 57 whose permittivity is higher than 2. These wafers can be made, for example, of Teflon or Stycast (Trade Marks). These wafers are preferably bonded on either side of the substrate.
The law for the wafer thickness is calculated in such a way that the relative permittivity of the propagation medium follows the Luneberg law.
In a simple embodiment, the two dielectric wafers are identical and have a permittivity ε 2 .
For a given radius r (FIG. 5B), the relative permittivity ε r may be defined by the following approximate relation: ##EQU1##
In the chosen example where the other dielectric is air, ε1 is equal to 1.
Of course, this simplified embodiment is only given by way of example, and it is possible to devise the same system in which the characteristics of the geometry and of the nature of wafers differ, amongst themselves and in relation to the size of the conductive patch 50.
Other indications regarding the calculation of the properties of wave guides partly filled with dielectrics will be found in the work of N. MARCUVITZ, "Waveguide Handbook", McGraw-Hill, 1951, pages 392 et sec.
FIG. 5C illustrates the wafer 56 (or 57) of FIG. 5A in a top view.
A more complete embodiment is illustrated in FIG. 6.
The dielectric film 55 which has a circular shape and coaxially supports a central conductive disk 50 will again be found at the center. The electric wafers 56 and 57 are bonded on either side of this disk. The casing is closed by the two half-casings 51 and 52. In the casing 52, it will be seen that this is internally hollow, and has a side wall 520 coming to bear on the vicinity of the film 55, just like the corresponding wall 510 of the disk 51.
The input/output transitions of the lens are obtained by horns, such as 501, with a decreasing size starting from the central disk 50, and ending at a transmission line 502 whose impedance is, for example, 50 Ohms.
In this way, it is possible, according to requirements, to obtain a large number of transitions around the central disk 50 in a regular or irregular manner.
Instead of the transmission lines with an impedance of 50 ohms, it is of course possible to provide coaxial connectors, fixed to the metal plates 51 and 52 serving to hold the substrate 55.
Preferably resistors may be added between the different access points, such as 502 and 508, by providing printed resistors on the substrate 55. Such a resistor is illustrated in FIG. 6 and bears the reference numeral 509. This makes it possible to increase the decoupling between these access transitions, which then become much better than that which can be obtained with the existing technologies.
Moreover, subject to being suitably positioned, and having sufficiently high values (of the order of 200 ohms), these resistors make it possible to increase the operating frequency band of the lens by the expedient of an improvement of the stationary wave rate (or more generally of the adaptation) of each feeding horn, as well as by the elimination of distortions produced by the undesirable couplings between adjacent horns at the transmission level between input and output channels.
Thus the present invention makes it possible to obtain a planar wideband Luneberg lens made on the basis of printed technology of the type comprising a strip line suspended between two parallel metal plates, where the variation of the index of the medium, in which the electromagnetic wave is propagated, is obtained by the positioning of dielectric wafers of variable thicknesses.
The fact that this makes it possible to use a propagation in the TEM mode thus obtains a proper functioning in terms of the width of the frequency band, both from the point of view of the adaptation--stationary wave rate--and from that of the transmission rate.
This aspect is further improved in the variation using decoupling resistors between the input-output transitions of the lens.
Moreover, the present invention provides a technology whose operation is remarkably simple since it uses base materials with a constant electrical permittivity, capable of manufacture by moulding or injection, in particular as regards the wafers, while ensuring that a continuous variation of the index is obtained.
Moreover, the fact that the lens is based on printed circuit-type technology facilitates the connection to the user circuits which will also be in a printed technology, or towards coaxial connectors that are conventionally used for ultrahigh frequency circuit casings.
The printed technology also permits the use of mixed technologies in relation to fields which are, on the one hand, that of ultrahigh frequency printed circuits (decoupling resistor) and, on the other hand, that of antennas (an evolutive printed horn feeding the lens).
Of course, the present invention is not limited to the embodiment described.
For example, the plates 51 and 52 may be metallised rather than metal.
On the other hand, the invention is not limited to structures with a spherical or cylindrical symmetry. It extends to parts of such structures, as well as to combinations of these structures or of their parts. Even more generally, it extends to any relatively thin lens structure using an index variation.
Thus there exists a great variety of lens types whose principle lies in causing the dielectric constant to vary from 1 at the edges to a value ε c at the center, with the following variants:
if ε c <2, the focal radius is situated outside the lens,
if ε c =2 (the case of the Luneberg lens), the focal radius is situated on the circumference of the lens,
if ε c >2, the focal radius is situated inside the lens.
All these lenses can be made by using the improvement in accordance with the present invention.
The invention is capable of even wider applications than hitherto described.
Thus it may, in particular, extend to the case of R2R or RkR types of lenses made in a printed circuit technology. These are here, in fact, other types of lenses with a constrained propagation which, without being identical with Luneberg lenses, proceed from a geometry and considerations regarding the law of propagation, which are of the same order. More detailed indications regarding the general structure of these types of lenses may be obtained from the articles "A survey of symmetric arrays", J. H. PROVENCHER, Phased Array Antennas, Artech House, 1972, and "Extending the R2R lens to 360°", R. CLAPP, IEEE Transactions on Antennas and Propagation, vol. AP-32, No.7, July 1984.
For example, it has been possible to make R2R or RkR printed lenses having printed horns as input-output transitions, and wherein printed resistors have been added in the manner described above. Here too, improvement has been observed in the operating properties in a wide frequency band of this type of electromagnetic lens.
An example of the embodiment of an R2R-type lens is given in FIG. 7.
This lens comprises, substantially centered in a cavity (not shown), a substrate 55 of a small thickness on which is printed a metal disk 50 of the type described for the Luneberg lens, and having a radius R. The horns, such as 501, are connected by means of matched connecting cables 532 having identical lengths, to radiating elements 531 placed on the circumference of a wall 530, with cylindrical symmetry, of radius 2R.
The invention, of course, also makes it possible to obtain a considerable reduction of the size of the lenses as compared with the conventional solution, and also a reduction in their cost. | An electromagnetic lens comprises two conductive sides between which there is arranged a cavity provided in its lateral portion with electromagnetic input/output coupling transitions to authorize a set of propagation laws between pairs of such inputs/outputs. Moreover, it comprises, substantially centered in the cavity, a substrate comprising a printed conductive patch of predetermined dimensions, so that the two conductive sides and the patch thus create a suspended three-plate strip line structure. The content of the cavity and the respective geometries of the cavity and of the conductive patch are chosen to comply with the propagation laws. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a blood leak detector and more particularly to a detector which passes light through a sample solution and indicates the ratio of light passing through the sample at frequencies of high blood absorption to light passing through the sample at frequencies of low blood absorption.
2. Description of the Prior Art
In a number of known clinical systems, such as hemodialysis systems, it is desirable and sometimes necessary to detect the presence of small amounts of blood in a clinical solution. In the hemodialysis system, for example, the presence of blood in the salt solution utilized for dialysis indicates leakage through the dialyzer membrane or some other point in the system. Leakage in a very small proportionality (e.g. concentrations from 0.25 to 7.0 mg % of hemoglobin (hb)) must be detected in order to sound an alarm to indicate a system malfunction.
Known blood leak detection systems typically operate in response to the difference between a sample reading that is responsive to turbidity of the solution, and a reference reading which represents the average broadband light output of the lamp source. Using the broadband or some other average characteristic of the light source as a reference, the different reading provided by the turbidity-responsive sampling provides a signal indicating the presence of hemoglobin in the blood. However, contamination of the windows in the optical path or any source of turbidity which usually collects during the course of dialysis tends to diminish the reading channel intensity, substantially affecting the accuracy of the measurement that is provided. Similarly, the presence of other turbidity than hemoglobin can effect the reference level, as can the light output of the illuminating source, which tends to diminish with aging of the lamp. It is possible to compensate, at extra expense, for lamp aging effects and for other reference signal variations by servo techniques which, for example, increase lamp energization current in order to tend to maintain a constant illumination output. However, it is still not feasible to provide a highly sensitive output that is relatively unaffected by contamination and turbidity effects.
Other problems in known systems relate to automatic response to alarm conditions. On a typical blood dialysis system the dialyzer must be bypassed and the detector flushed upon the detection of blood. However, flushing of the detector eliminates the alarm condition to cause the system to oscillate between normal and alarm operation modes. In at least one system that is protected against oscillation, it is extremely difficult to restart normal operation once an alarm condition is detected.
SUMMARY OF THE INVENTION
Blood responsive detectors in accordance with the present invention optically sample, from a common light source, the light transmitted at two wavelength regions, one of which is highly responsive to the absorption effect of hemoglobin. The ratio of the signals derived at these two wavelength regions is determined, and this ratio represents with accuracy and freedom from noise effects the presence of small amounts of hemoglobin in the sample solution.
In a more particular example of a system in accordance with the invention, the light transmissivity of a sample solution at approximately 4200 A and a broader band encompassing 5000 A is derived by suitable optical filtering at separate photoresistive elements. To determine the ratio between these readings, one photoresistive photosensor element is coupled in the input circuit of an operational amplifier, with the other photoresistive photosensor element being coupled in the feedback circuit of the operational amplifier, with the amplifier output then representing a high gain counterpart of the hemoglobin concentration. In accordance with more specific aspects of the invention, the output signal current is linearized and then converted to a voltage which may both drive an indicator and be compared to a selectable voltage level in alarm circuits which provide a lamp and signal indication when selectable limits are exceeded.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention may be had by reference to the following description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a combined sectional and block diagram representation of a blood leak detector system in accordance with the invention;
FIG. 2 is an enlarged fragmentary view of a light sensing channel in accordance with the invention;
FIG. 3 is a graphical representation of light absorption characteristics of hemoglobin and oxyhemoglobin; and
FIG. 4 is a schematic diagram of circuits employed in the arrangement of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 an exemplification of a blood leak detector system 10 in accordance with the invention disposes a photosensing system within a generally cylindrical housing 12, in association with electronics which provide desired measurement, display and alarm functions. In the system, an effluent sample is passed through an input port 14 into an observation channel that is cylindrical in form and not quite horizontally disposed, the solution inlet 14 being on the underside of the observation channel 16 proximate a lower end 18 thereof and a solution outlet 20 being spaced apart along the length of the channel 16 and on the upper end 22 relative to a horizontal axis 24. This slightly upward tilted disposition permits the relatively slow moving fluid to be retained within the channel 16 while bubbles in the effluent sample move rapidly from the inlet 14 to a bubble outlet 26 proximate an upper chamber surface 28 and the upper end 22 and therefore have minimum effect on the readings taken.
A lamp 30 is energized from a suitable power source and is disposed at one end of the housing 12 along the axis 24 of the observation channel 16, and light is directed through a concentrator lens 32 along the length of the observation channel 16 through transmissive windows 36, 37 which form the ends 18, 22 in conventional fashion. Adjacent the exterior side of the downstream window 36 at end 18 relative to the observation channel is disposed a ground glass which scatters the incident light on the air side of the observation channel 16.
An angularly disposed first photodetection system 38 on the side of the housing 12 opposite the light source 30 detects the average light intensity of the emissions from the diffuse light source represented by the light scattering window 36 which pass through chamber 16. System 38 forms an optical channel 40 having a relatively long, small cross-sectional pinhole light path 42. An adjustable screw 44 intercepts the pinhole light path 42 to an extent determined by the position of screw 44. Thus, screw 44 permits control of aperture size and adjustment of the normal light intensity incident on a reference photocell 46 which responds to the average light level at the ground glass, including light at frequencies not readily absorbed by blood. The adjustment of screw 44 is preferably made with clear fluid within chamber 16.
Along the main axis 24 of the observation channel, at the opposite end of the housing 12 from the lamp 30 there is disposed a sample photocell 50, which may be referred to as the blue photocell. Cell 50 receives light from the ground glass 36 that is passed through chamber 16 past optical channel 40 and through a pair of focusing lenses 52, 54 which are separated by a blue filter 56 which has a narrow bandpass characteristic at light frequencies having a wavelength of approximately 4200 A. This bandpass characteristic corresponds to the light absorption characteristic of the hemoglobin constituent of blood as depicted in FIG. 3, which is representative of a graph shown in an article, "Hemoglobin-Oxygen Equilibrium," Journal of Biological Chemistry, Vol. 123, p. 335 at 342 (1938), A. E. Sidwell Jr., R. H. Munch, E. S. G. Barron, and T. R. Hogness.
The light detected by the reference photocell may be referred to as white light, inasmuch as it is responsive to color constituents both below and above the 4200 A wavelength at which hemoglobin and oxyhemoglobin provide greatest light attenuation. In actuality, however, as shown by the published data shown in FIG. 3, the least attenuation of the spectro band occurs in the region of 4700 A to 5000 A, so that the reference photocell should be responsive to frequencies of light passing through chamber 16 in this band. This low attenuation factor provides a significant benefit because the relatively close spacing between the reference and the blue photocell channels, in terms of wavelength response, means that as the lamp characteristics change both channels are affected substantially equally. Also, non-spectral changes in characteristics, i.e. the gray level, affect both channels substantially equally.
Referring to the block diagram portion of FIG. 1, lamp 30 illuminates blood leak detector 60 which includes the two photocells 46, 50. Both of the photocells are photosensors of the photoresistive type, and each is coupled in a ratio detector circuit 62 which provides a varying voltage level signal representing the ratio of the blue light with respect to the white light samples to a linearizer circuit 64 which improves the accuracy of the reading across the entire range. The output signal 66 from the linearizer is coupled to drive an adjustable meter 68 and may provide a direct reading of blood concentration in standard terms such as milligram percent, or milligrams of hemoglobin per 100 cc of solution. The output signal 66 is also coupled to alarm circuits which include a failure limit detector 70 which actuates an indicator lamp 72 to provide an output alarm signal in the event that either a preset level determined by threshold selector 74 or a fixed maximum level is exceeded.
In the operation of the system of FIG. 1, the effluent sample passing from the inlet 14 to the outlet 20 through the observation channel 16 is illuminated by the light from the lamp 30 which falls on the ground glass screen on the air side of the observation channel as concentrated by the lens system and attenuated by the turbidity factors in the observation channel 16, including the hemoglobin and oxyhemoglobin constituents of the blood that may be present. The variable size aperture is adjusted to a selected zero setting at which the resistances of cells 46 and 50 are equal while a clear liquid is within chamber 16. The values of the variable resistances represented by the reference photocell 46 and the blue photocell 50 are determined by the broadband illumination of the reference photocell 46 and the blue filtered illumination of the blue photocell 50. In the ratio detector 62, an output voltage V O is determined by the ratios of the states of the two photocells in accordance with the equation:
V.sub.O = - R.sub.b /R.sub.ref × V.sub.I,
where V I is the input voltage to the reference photocell, R b is the resistance of the blue photocell, and R ref is the resistance of the reference photocell.
Significant benefits are derived by the use of the ratio relationship and the 4200 A bandpass filter in the manner described. The presence of a minute amount of blood sharply diminishes the signal at the blue photocell, while having only a minor effect at the reference photocell. A concentration of 7 mg. % Hb affects the blue channel approximately 100 times greater than the reference channel. The net result is a 100:1 ratio between the input and output voltages, as opposed to a mere difference between the readings, which could be several orders of magnitude less depending upon initial input voltages and light levels. Changes in the spectral characteristics or in the gray level of the system affect both channels equally and have little effect on the ratio. Thus the system is actually sensing blood property, and is substantially unaffected by contamination and turbidity, whether caused by dirt on the windows or turbidity of other kinds than blood matter in the sample effluent.
The output signal from the ratio detector is amplified over the input signal with considerable gain, and is linearized in the linearizer circuits, which provide a varying current level output.
As shown in FIG. 4, the detection circuitry 80 for the blood leak detection system 10 includes the ratio detector 62, linearizer 64, meter 68, failure limit detector 70, and lamp indicator 72. The illumination source lamp 30 is coupled through a 7.5 ohm resistor 82 to -15 volts.
The ratio detector 62 includes an operational amplifier 88 having a negative input coupled through the resistance of the reference photo cell 46 and then through a three-way parallel combination of a 15K resistor 90 to -15 volts, a 100 ohm resistor 92 to ground and a 2.74 K resistor 94 to an output 96 of the ratio detector circuit 62. The resistors 90 and 92 operate through voltage divider action to drive resistance R ref with a small negative voltage, V I , equal to approximately -0.1 volt. The output of amplifier 88 is coupled through a 2.74K resistor 98 to the output 96 of ratio detector circuit 62. The positive input to amplifier 88 is coupled to ground. This creates a virtual ground at the negative input. Resistances R b and R ref are normally on the order of 10K during blood leak detector operation. Resistance R b is coupled as a feedback resistance between the output of amplifier 88 and the negative input so that the output of amplifier 88, is V O = R b /R ref × V I . Under normal conditions, R b = R ref so that V 0 = -V I and the voltage divider action of equal resistances 94 and 98 maintain the ratio detector output 96 at approximately ground potential. In the event that blood enters the blood leak detector 60, the resulting decrease in incident light upon photocell 50 causes resistance R b to be substantially increased with a corresponding increase in the output 96 of ratio detector 62.
The output 96 of ratio detector 62 is coupled through a linearizing circuit 64 which includes a summing junction coupled to the negative input of an operational amplifier 100. The output of amplifier 100 is the system output signal 66 which is fed back through a 470K resistor 102 to the negative input of amplifier 100. The positive input of amplifier 100 is coupled to ground.
As one summing input, the voltage at the output 96 of ratio detector 62 is coupled through a 25K resistor 104 to the negative input of amplifier 100. Output signal 96 is also coupled through a unity gain threshold amplifier circuit 106. Threshold amplifier circuit 106 provides a negative output voltage equal to the extent that signal 96 exceeds approximately 0.41 volts. This negative output voltage is coupled through a 3.9K resistor 108 to the negative input of amplifier 100 and substracts from the signal coupled through resistor 104. Similarly, a second unity gain threshold circuit 110 is coupled to provide a negative output voltage equal to the difference between the voltage of output signal 96 and approximately 4.1 volts. This negative output voltage of threshold amplifier 110 is coupled through a 15.6K resistor 112 to the input of amplifier 100 to further subtract from the ratio detector output signal 96 which is coupled through resistor 104. The unity gain threshold amplifier circuits 106 and 110 of linearizer circuit 64 compensate for the increase in resistance R b which tends to be greater than linear as the incident light on photocell 50 decreases. The output signal 66 from amplifier 100 is coupled through and approximately 5K resistance 120A, 120B to a meter 68 which may be a milliameter having a scale calibrated in appropriate units such as milligram percent. Meter 68 provides a linear indication of blood leakage.
The output 66 is also coupled to a pair of threshold detectors 122, 124. Threshold detector 122 causes generation of an alarm signal at an output 126 when signal 66 exceeds a fixed, factory selected threshold. The output of threshold circuit 124 is ORed with the output of circuit 122 to generate alarm signal 126 whenever the magnitude of signal 66 exceeds an operator determined threshold which is selected by potentiometer 128. This double detector alarm circuit arrangement permits the threshold detection level to be operator selected by threshold detector 124 while eliminating the dangerous possibility that the alarm circuit might be unwittingly disabled by the accidental setting of the threshold at too high a magnitude. The threshold detectors 122 and 124 thus provide both adjustable and absolute maximum threshold sensing levels. Threshold circuits 122 and 124 are implemented with inverters 130, 132 which may be implemented as suitable logic elements such as C-mos inverters which are compatible with the +15 volt source used to energize the operational amplifiers in the circuit 80.
Normally the output 66 of amplifier 100 is at an approximately zero potential. However, in the event that blood enters the chamber 16, signal 96 becomes positive and signal 66 becomes negative. If signal 66 become sufficiently negative one of the inverters 130, 132 becomes activated and its normally low output switches to a high voltage to drive alarm signal 126 high. The output alarm signal 126 is coupled to drive a latching circuit 136. When signal 126 goes high the input to an inverter 138 goes high to drive the output low and in turn drive the input to an inverter 140 low. A 806K positive feedback resistor 142 is coupled between the output of inverter 140 and the input of inverter 138 to provide hysteresis and help hold the alarm indication in latched condition to provide stability. An alarm output signal 144 at the output of inverter 140 is coupled through a diode 146 to drive a set input of a latch circuit 148. When latch circuit 148 becomes set, it drives the base of a transistor 150 having the collector and emitter thereof coupled between output 144 and the input to inverter 138 to latch thealarm condition until the latch 148 is reset by manual activation of a switch 154. The latched alarm output signal 144 is also coupled through a resistance 156 to drive the base of a transistor 160 which operates as a lamp driver switch for alarm indicator lamp 72. A second alarm latching circuit 180 is responsive to a bubble trap signal indicating that the bubble trap is not working properly to cause the normally low input to an inverter 182 to go high, to drive the input of an inverter 184 coupled thereto low and drive the bubble latch circuit output 186 at the output of inverter 184 high. A 806K positive feedback resistor 188 is coupled between output 186 and the input to inverter 182 and a transistor 190 having its base input coupled to the output of latch 148 also has its collector coupled to output 186 and its emitter coupled to the input to inverter 182. The output 186 of bubble trap latch circuit 180 is coupled through a diode OR gate 192 to the set input of latch 148. Thus, once a positive output signal is generated at output 186, the latch 148 is set to turn on transistor 190 and maintain the alarm signal in a latched condition until latch 148 is reset by activation of switch 154. The output 186 is also coupled to the base of a lamp driver transistor 194 which causes illumination of a bubble trap alarm indicator 196 whenever the output signal 186 goes high.
A rinse switch 198 selectively couples a 15 volt source to the inputs of inverters 140 and 184 to artifically hold the inputs high and thus the outputs low to prevent an alarm indication signal during maintenance operation such as rinsing when it is desired to maintain the system in a normal operating mode even though an alarm condition may be detected.
While there has been shown and described above a particular arrangement of a blood leak detector system in accordance with the invention for the purpose of enabling a person of ordinary skill in the art to make and use the invention, it will be appreciated that the invention is not limited thereto. Accordingly, any modifications, variations, or equivalent arrangements within the scope of the attached claims should be considered to be within the scope of the invention. | A system for detecting small amounts of hemoglobin in a solution detects the ratio between the light transmissivities at separated wavelengths of a sample solution, one of which wavelengths is in a range at which hemoglobin is highly light absorptive. Through the use of the ratios of the signals, a reading of high sensitivity and linearity is provided in the presence of substantial contamination and turbidity in the sample or the system. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 61/165,941, filed Apr. 2, 2009.
FIELD OF INVENTION
[0002] The present application relates to particles, compositions comprising such particles, and processes for making and using such particles and compositions.
BACKGROUND OF THE INVENTION
[0003] Benefit agents, such as perfume delivery compositions, bleaching agents and fabric softening agents, are expensive and generally less effective when employed at high levels in personal care compositions, cleaning compositions, and fabric care compositions. As a result, there is a desire to maximize the effectiveness of such benefit agents. One method of achieving this objective is to improve the delivery efficiencies of such benefit agents. Unfortunately, it is difficult to improve the delivery efficiencies of benefit agents as such agents may be lost due to the agents' physical or chemical characteristics or such agents may be incompatible with other compositional components or the situs that is treated.
[0004] In an effort to improve the delivery efficiencies of benefit agents, the industry, in many cases, encapsulated such benefit agents. Unfortunately, in certain applications, a large portion of the resulting capsules rupture prematurely. Thus, there is a need for a particle and/or agglomerate that minimizes or eliminates the aforementioned drawbacks.
SUMMARY OF THE INVENTION
[0005] The present application relates to particles and/or agglomerates, compositions comprising such particles and/or agglomerates, and processes for making and using such particles and/or agglomerates and compositions. Such particles and/or agglomerates minimize or eliminate certain drawbacks of encapsulated benefit agents.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0006] As used herein “consumer product” means baby care, beauty care, fabric & home care, family care, feminine care, health care, snack and/or beverage products or devices intended to be used or consumed in the form in which it is sold, and not intended for subsequent commercial manufacture or modification. Such products include but are not limited to diapers, bibs, wipes; products for and/or methods relating to treating hair (human, dog, and/or cat), including, bleaching, coloring, dyeing, conditioning, shampooing, styling; deodorants and antiperspirants; personal cleansing; cosmetics; skin care including application of creams, lotions, and other topically applied products for consumer use; and shaving products, products for and/or methods relating to treating fabrics, hard surfaces and any other surfaces in the area of fabric and home care, including: air care, car care, dishwashing, fabric conditioning (including softening), laundry detergency, laundry and rinse additive and/or care, hard surface cleaning and/or treatment, and other cleaning for consumer or institutional use; products and/or methods relating to bath tissue, facial tissue, paper handkerchiefs, and/or paper towels; tampons, feminine napkins; products and/or methods relating to oral care including toothpastes, tooth gels, tooth rinses, denture adhesives, tooth whitening; over-the-counter health care including cough and cold remedies, pain relievers, RX pharmaceuticals, pet health and nutrition, and water purification; processed food products intended primarily for consumption between customary meals or as a meal accompaniment (non-limiting examples include potato chips, tortilla chips, popcorn, pretzels, corn chips, cereal bars, vegetable chips or crisps, snack mixes, party mixes, multigrain chips, snack crackers, cheese snacks, pork rinds, corn snacks, pellet snacks, extruded snacks and bagel chips); and coffee.
[0007] As used herein, the term “cleaning composition” includes, unless otherwise indicated, granular or powder-form all-purpose or “heavy-duty” washing agents, especially cleaning detergents; liquid, gel or paste-form all-purpose washing agents, especially the so-called heavy-duty liquid types; liquid fine-fabric detergents; hand dishwashing agents or light duty dishwashing agents, especially those of the high-foaming type; machine dishwashing agents, including the various tablet, granular, liquid and rinse-aid types for household and institutional use; liquid cleaning and disinfecting agents, including antibacterial hand-wash types, cleaning bars, mouthwashes, denture cleaners, dentifrice, car or carpet shampoos, bathroom cleaners; hair shampoos and hair-rinses; shower gels and foam baths and metal cleaners; as well as cleaning auxiliaries such as bleach additives and “stain-stick” or pre-treat types, substrate-laden products such as dryer added sheets, dry and wetted wipes and pads, nonwoven substrates, and sponges; as well as sprays and mists.
[0008] As used herein, the term “fabric care composition” includes, unless otherwise indicated, fabric softening compositions, fabric enhancing compositions, fabric freshening compositions and combinations there of.
[0009] As used herein, the phrase “benefit agent delivery particle” encompasses microcapsules including perfume microcapsules.
[0010] As used herein, the articles including “a” and “an” when used in a claim, are understood to mean one or more of what is claimed or described.
[0011] As used herein, the terms “include”, “includes” and “including” are meant to be non-limiting.
[0012] Asked herein, waxes include natural waxes, chemically modified waxes and the synthetic waxes. The natural waxes include, for example, plant waxes such as candelilla wax, carnauba wax, Japan wax, esparto grass wax, cork wax, guaruma wax, rice germ oil wax, sugarcane wax, ouricury wax or montan wax, animal waxes such as beeswax, shellac wax, zein wax, spermaceti, lanolin (wool wax), or uropygial grease, mineral waxes such as ceresin or ozokerite (earth wax), or petrochemical waxes such as petrolatum, paraffin waxes or microwaxes. The chemically modified waxes include, for example, hard waxes such as montan ester waxes, sassol waxes or hydrogenated jojoba waxes. Synthetic waxes include polyalkylene waxes or polyalkylene glycol waxes. Suitable synthetic waxes include higher esters of phthalic acid, in particular dicyclohexyl phthalate, which is obtainable commercially under the name Unimoll® 66 (Bayer AG). Also suitable are synthetic waxes made from lower carboxylic acids and fatty alcohols, for example dimyristyl tartrate which is obtainable under the name Cosmacol® ETLP (Condea). Synthetic or semisynthetic esters of lower alcohols with fatty acids include, for example, Tegin® 90 (Goldschmidt), a glycerol monostearate palmitate.
[0013] The test methods disclosed in the Test Methods Section of the present application should be used to determine the respective values of the parameters of Applicants' inventions.
[0014] Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.
[0015] All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.
[0016] It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
Wax Coated Particles
[0017] Applicants discovered that the problem of achieving effective and efficient benefit agent delivery can be solved in an economical manner when the benefit agent and/or melamine formaldehyde encapsulated benefit agent is delivered coated with a wax including but not limited to, shellac and/or zein.
[0018] In one aspect, a composition comprising:
1.) a benefit agent selected from the group consisting of:
a.) an encapsulated benefit agent wherein said encapsulated benefit agent comprises a material selected from the group consisting of a perfume; a perfume delivery composition; a bleaching agent comprising a material selected from the group consisting of a diacyl, a clathrated diacyl, sodium nonanoyloxybenzene sulfonate, a bleach booster, a metal catalyst and mixtures thereof; a fabric softening agent; and mixtures thereof; and a melamine formaldehyde polymer, said melamine formaldehyde polymer encapsulating said material; b.) a perfume delivery composition; c.) a bleaching agent comprising a material selected from the group consisting of a diacyl, a clathrated diacyl, sodium nonanoyloxybenzene sulfonate, a bleach booster, a metal catalyst and mixtures thereof; and d.) a fabric softening agent; and e.) mixtures thereof; and
2.) a wax selected from the group consisting of shellac, zein, paraffins and mixtures thereof, said wax covering said benefit agent to form a particle, an agglomerate, or a bead; and 3.) an adjunct material.
[0027] In one aspect of the aforementioned composition, whether encapsulated by a melamine formaldehyde polymer or unencapsulated, the diacyl may comprise a material selected from the group consisting of dinonoyl peroxide, didecanoyl peroxide, diundecanoyl peroxide, dilauroyl peroxide, dibenzoyl peroxide, di-(3,5,5-trimethyl hexanoyl) peroxide and mixtures thereof and the aforementioned diacyl component of the clathrated diacyl may be selected from the group consisting of dinonoyl peroxide, didecanoyl peroxide, diundecanoyl peroxide, dilauroyl peroxide, dibenzoyl peroxide, di-(3,5,5-trimethyl hexanoyl) peroxide and mixtures thereof.
[0028] In one aspect of the aforementioned composition, whether encapsulated by a melamine formaldehyde polymer or unencapsulated, the perfume delivery composition may comprise a material selected from the group consisting of amine reaction product, a polymer assisted delivery system, starch encapsulated accord, zeolite or inorganic comprising an accord and mixtures thereof. Examples of suitable perfume delivery compositions and processes of making same are found in USPA publications: 2007/0275866 A1; 2008/0200359 A1 and 2008/0200363 A1.
[0029] In one aspect of the aforementioned composition, whether encapsulated by a melamine formaldehyde polymer or unencapsulated, the bleach booster may comprise a material selected from the group consisting of:
[0030] 2-[3-[(2-hexyldodecyl)oxy]-2-(sulfooxy)propyl]-3,4-dihydroisoquinolinium, inner salt;
[0031] 3,4-dihydro-2-[3-[(2-pentylundecyl)oxy]-2-(sulfooxy)propyl]isoquinolinium, inner salt;
[0032] 2-[3-[(2-butyldecyl)oxy]-2-(sulfooxy)propyl]-3,4-dihydroisoquinolinium, inner salt;
[0033] 3,4-dihydro-2-[3-(octadecyloxy)-2-(sulfooxy)propyl]isoquinolinium, inner salt;
[0034] 2-[3-(hexadecyloxy)-2-(sulfooxy)propyl]-3,4-dihydroisoquinolinium, inner salt;
[0035] 3,4-dihydro-2-[2-(sulfooxy)-3-(tetradecyloxy)propyl]isoquinolinium, inner salt;
[0036] 2-[3-(dodecyloxy)-2-(sulfooxy)propyl]-3,4-dihydroisoquinolinium, inner salt;
[0037] 2-[3-[(3-hexyldecyl)oxy]-2-(sulfooxy)propyl]-3,4-dihydroisoquinolinium, inner salt;
[0038] 3,4-dihydro-2-[3-[(2-pentylnonyl)oxy]-2-(sulfooxy)propyl]isoquinolinium, inner salt;
[0039] 3,4-dihydro-2-[3-[(2-propylheptyl)oxy]-2-(sulfooxy)propyl]isoquinolinium, inner salt;
[0040] 2-[3-[(2-butyloctyl)oxy]-2-(sulfooxy)propyl]-3,4-dihydroisoquinolinium, inner salt;
[0041] 2-[3-(decyloxy)-2-(sulfooxy)propyl]-3,4-dihydroisoquinolinium, inner salt;
[0042] 3,4-dihydro-2-[3-(octyloxy)-2-(sulfooxy)propyl]isoquinolinium, inner salt;
[0043] 2-[3-[(2-ethylhexyl)oxy]-2-(sulfooxy)propyl]-3,4-dihydroisoquinolinium, inner salt; and
[0000] mixtures thereof;
[0044] In one aspect of the aforementioned composition, whether encapsulated by a melamine formaldehyde polymer or unencapsulated, the metal catalyst may comprise a material selected from the group consisting of dichloro-1,4-diethyl-1,4,8,11-tetraaazabicyclo[6.6.2]hexadecane manganese(II); dichloro-1,4-dimethyl-1,4,8,11-tetraaazabicyclo[6.6.2]hexadecane manganese(II) and mixtures thereof; and mixtures thereof; a fabric softening agent; and mixtures thereof.
[0045] In one aspect of the aforementioned composition, such composition may have a weight ratio of benefit agent to wax of from about 95:5 to about 1:99, from about 95:5 to about 15:85, or even from about 90:10 to about 50:50 and a mean particle size of from about 1 micron to about 5 mm, from about 2 microns to about 2 mm or even from about 5 microns to about 100 microns.
[0046] In one aspect, of the aforementioned composition, such composition's wax may comprise shellac.
[0047] In one aspect, of the aforementioned composition, such composition's wax may encapsulate such composition's benefit agent.
[0048] In one aspect, of the aforementioned composition, such composition's wax may encapsulate such composition's benefit agent to form a particle.
[0049] In one aspect, of the aforementioned composition, such composition's wax may comprises shellac and such composition's benefit agent may comprise an encapsulated benefit agent that may comprise perfume microcapsules that may comprise perfume and a melamine formaldehyde polymer that may encapsulate said perfume, such particle may have a mean particle size of from about 5 microns to about 100 microns.
[0050] In one aspect, of the aforementioned composition, such composition's shellac may comprise borax and/or ammonia.
[0051] In one aspect, of the aforementioned composition, such composition's wax may comprise a plasticizer selected from the group consisting of dibutyl sebacate, polyethylene glycol and polypropylene glycol, dibutyl phthalate, diethyl phthalate, triethyl citrate, tributyl citrate, acetylated monoglyceride, acetyl tributyl citrate, triacetin, dimethyl phthalate, hydroxypropyl methylcellulose, benzyl benzoate, butyl and/or glycol esters of fatty acids, refined mineral oils, oleic acid, castor oil, corn oil, camphor, glycerol, sorbic acid, sorbitol and mixtures thereof.
[0052] In one aspect, of the aforementioned composition such composition's wax and benefit agent may form an agglomerate particle.
[0053] In one aspect, of the aforementioned composition, such composition's benefit agent may comprise a bleaching agent.
[0054] In one aspect, of the aforementioned composition, such composition's benefit agent may comprise a material selected from the group consisting of dilauroyl peroxide; dinonoyl peroxide; sodium nonanoyloxybenzene sulfonate; isoquinolinium, 2-[3-[(2-butyloctyl)oxy]-2-(sulfooxy)propyl]-3,4-dihydro-, inner salt; isoquinolinium, 2-[3-[(2-ethylhexyl)oxy]-2-(sulfooxy)propyl]-3,4-dihydro-, inner salt; dichloro-1,4-dimethyl-1,4,8,11-tetraaazabicyclo[6.6.2]hexadecane manganese(II); dichloro-1,4-diethyl-1,4,8,11-tetraaazabicyclo[6.6.2]hexadecane manganese(II); and mixtures thereof.
[0055] In one aspect, of the aforementioned composition, such composition's benefit agent may comprise a fabric softening agent.
[0056] In one aspect, of the aforementioned composition, such composition's benefit agent may comprise a fabric softening agent selected from the group consisting of a paraffin, an oil, a silicone, a clay and mixtures there of.
[0057] In one aspect, a composition that may comprise any combination of the aforementioned parameters as listed in the aforementioned aspects is disclosed.
[0058] The suitable materials and equipment for practicing the present invention may be obtained from: United Initiators, GmbH & Co. KG, Dr.-Gustav-Adolph-Str. 3, 82049 Pullach, Germany SSB, Stroever GmbH & Co. KG, Muggenburg 11, 28217 Bremen, Germany; Emerson Resources INC, Suite 1, 600 Markley Street, Norristown, Pa. 19401; Appleton, 825 E Wisconsin Avenue, P.O. Box 359, WI 54912-0359, US; Sigma Aldrich NV/SA, Kardinaal Cardijnplein 8, 2880 Bornem, Belgium; ProCepT nv, Rosteyne 4, 9060 Zelzate, Belgium; Ingeniatrics, Avd. Américo Vespucio 5-4, 1 a p., mód. 12, Sevilla, Spain; GEA Process Engineering Inc.•9165 Rumsey Road•Columbia, Md. 21045, US; Mettler-Toledo, Inc., 1900 Polaris Parkway, Columbus, Ohio, 43240, US; IKA-Werke GmbH & Co. KG, Janke & Kunkel Str. 10, 79219 Staufen, Germany; Alfa Aesar GmbH & Co KG, Zeppelinstrasse 7, 76185 Karlsruhe, Germany; Eastman Chemical Company, PO Box 431, Kingsport, Tenn. 37662, US.
Process of Making
[0059] In one aspect, the process of making the aforementioned compositions, including wax coated particles and/or agglomerates may comprise two (2) parts: a) combining and/or contacting a solution comprising a wax, including but not limited to, shellac and/or zein, and a solvent, including but not limited to water and/or ethanol, with melamine-formaldehyde microcapsules comprising a benefit agent and/or a slurry comprising such melamine-formaldehyde microcapsules to form a shellac/microcapsule slurry and b) collecting wax coated melamine formaldehyde microcapsules from such slurry. In one aspect, a wax solution is prepared and a slurry comprising melamine-formaldehyde microcapsules comprising a benefit agent, is added to such solution to form a slurry comprising wax and such melamine-formaldehyde microcapsules. In one aspect, when flow focusing is employed to collect the wax coated melamine formaldehyde microcapsules, the aforementioned slurry is contacted with a second wax solution that may comprise a wax including but not limited to, shellac and/or zein. In one aspect, a plasticizer may be added to the wax/melamine-formaldehyde microcapsule slurry to modify the properties of the resulting wax coated melamine formaldehyde microcapsules—for example to soften the wax coated microcapsules and/or improve the wax coated microcapsules' benefit agent's release during use. Suitable plasticizers include plasticizers selected from the group consisting of dibutyl sebacate, polyethylene glycol and polypropylene glycol, dibutyl phthalate, diethyl phthalate, triethyl citrate, tributyl citrate, acetylated monoglyceride, acetyl tributyl citrate, triacetin, dimethyl phthalate, hydroxypropyl methylcellulose, benzyl benzoate, butyl and/or glycol esters of fatty acids, refined mineral oils, oleic acid, castor oil, corn oil, camphor, glycerol, sorbic acid, sorbitol and mixtures thereof. In one aspect, said plasticizer comprises glycerol. In one aspect, the wax and melamine-formaldehyde microcapsule slurry is combined with an organic material, for example an oil including but not limited to a vegetable oil such as soybean oil, to form a slurry comprising wax, melamine formaldehyde microcapsules and the organic material. Optionally, when the wax and melamine-formaldehyde microcapsule slurry is combined with an organic material, a material that can provide cations may then be combined with the wax, melamine formaldehyde and organic material slurry to assist in hardening the wax coated melamine formaldehyde microcapsules that may be collected from such slurry. In one aspect, the wax and melamine-formaldehyde microcapsule slurry may be contacted with a material that can provide cations—typically such material comprises water and a cation that may be supplied by a salt, such as calcium chloride and/or magnesium and such contact is achieved by passing drops of such slurry through such material that can provide cations. Optionally, when such slurry is contacted with a material that can provide cations, such material may comprise a density modifier such as organic solvent like an alcohol such as ethanol. In one aspect, a second solvent is added to the wax/melamine formaldehyde microcapsule slurry and the first solvent is evaporated which results in wax coated melamine formaldehyde microcapsules in the second solvent. In any of the aforementioned aspects of the invention, the aforementioned slurry may, as needed, be kept homogenous by continual mixing and/or the addition of a surfactant prior to drying. Suitable collecting techniques, include, but are not limited to, spray drying, filtration, flow focusing, and combinations thereof.
[0060] In one aspect, a process of making wax coated particles and/or agglomerates may comprise contacting a benefit agent with a fluid wax such as shellac and/or zein, to form wax coated particles. In one aspect said process comprises contacting a benefit agent and/or a melamine formaldehyde benefit agent with a liquid wax such as paraffin, to form wax coated particles. In one aspect, a plasticizer may be combined with the wax to modify the properties of the resulting wax coated particles—for example to soften the wax coated particles and/or improve the wax coated particles' benefit agent's release during use. In one aspect, when flow focusing is employed to collect the wax coated particles, a material selected from the group consisting of a benefit agent, a melamine formaldehyde encapsulated benefit agent, a liquid wax comprising a benefit agent and/or a melamine formaldehyde encapsulated benefit agent and mixtures there of may be contacted with a second wax that may comprise a wax including but not limited to, shellac, paraffin and/or zein. Additional collection techniques include, but are not limited to spray drying, filtration, cooling and combinations thereof.
[0061] In one aspect a process of making wax coated particles and/agglomerates may comprise the use of a fluidized bed, wherein a material selected from the group consisting of a benefit agent, a melamine formaldehyde encapsulated benefit agent, a wax coated a benefit agent and/or a wax coated melamine formaldehyde encapsulated benefit agent and mixtures thereof may be contacted with a second wax, that may comprise a wax including but not limited to, shellac, paraffin and/or zein.
Compositions Comprising Applicants' Compositions
[0062] Compositions comprising the aforementioned variants of Applicants' compositions may comprise any embodiment of such variants including the particle variant disclosed in the present application and mixtures of such variants. In one aspect, said composition comprising a variant of Applicants' compositions may be a consumer product. While the precise level of Applicants' composition that is employed depends on the type and end use of the composition, consumer products may comprise, in one aspect, based on total composition weight, from about 0.001% to about 20%, from about 0.001% to about 5%, from about 0.001% to about 1%, from about 0.001% to about any variant or mixture there of Applicants' compositions.
[0063] In one aspect, a cleaning composition may comprise, based on total cleaning composition weight, from about 0.1 to about 1 weight % of the Applicants' composition. In one aspect, a fabric treatment composition may comprise, based on total fabric treatment composition weight, from about 0.01 to about 10% of the particles of any variant or mixture there of Applicants' compositions.
[0064] Aspects of the invention include the use of the particles of the present invention in laundry detergent compositions (e.g., TIDE™), hard surface cleaners (e.g., MR CLEAN™) automatic dishwashing liquids (e.g., CASCADE™), dishwashing liquids (e.g., DAWN™) Bleach Additives (e.g. Ace) and floor cleaners (e.g., SWIFFER™). The cleaning compositions disclosed herein are typically formulated such that, during use in aqueous cleaning operations, the wash water will have a pH of between about 6.5 and about 12, or between about 7.5 and 10.5. Liquid dishwashing product formulations typically have a pH between about 6.8 and about 9.0. Cleaning products are typically formulated to have a pH of from about 7 to about 12. Techniques for controlling pH at recommended usage levels include the use of buffers, alkalis, acids, etc., and are well known to those skilled in the art.
[0065] Fabric treatment compositions disclosed herein typically comprise a fabric softening active (“FSA”). Suitable fabric softening actives, include, but are not limited to, materials selected from the group consisting of quats, amines, fatty esters, sucrose esters, silicones, dispersible polyolefins, clays, polysaccharides, fatty oils, polymer latexes and mixtures thereof.
Adjunct Materials
[0066] While not essential for the purposes of the present invention, the non-limiting list of adjuncts illustrated hereinafter are suitable for use in the instant compositions and may be desirably incorporated in certain embodiments of the invention, for example to assist or enhance performance, for treatment of the substrate to be cleaned, or to modify the aesthetics of the composition as is the case with perfumes, colorants, dyes or the like. It is understood that such adjuncts are in addition to the components that are supplied via Applicants' compositions and other components of products previously disclosed herein. The precise nature of these additional components, and levels of incorporation thereof, will depend on the physical form of the composition and the nature of the operation for which it is to be used. Suitable adjunct materials include, but are not limited to, polymers, for example cationic polymers, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfume and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. In addition to the disclosure below, suitable examples of such other adjuncts and levels of use are found in U.S. Pat. Nos. 5,576,282, 6,306,812 B1 and 6,326,348 B1 that are incorporated by reference.
[0067] As stated, the adjunct ingredients are not essential to Applicants' cleaning and fabric care compositions. Thus, certain embodiments of Applicants' compositions do not contain one or more of the following adjuncts materials: bleach activators, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic metal complexes, polymeric dispersing agents, clay and soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfumes and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. However, when one or more adjuncts are present, such one or more adjuncts may be present as detailed below:
[0068] Surfactants—The compositions according to the present invention can comprise a surfactant or surfactant system wherein the surfactant can be selected from nonionic and/or anionic and/or cationic surfactants and/or ampholytic and/or zwitterionic and/or semi-polar nonionic surfactants. The surfactant is typically present at a level of from about 0.1%, from about 1%, or even from about 5% by weight of the cleaning compositions to about 99.9%, to about 80%, to about 35%, or even to about 30% by weight of the cleaning compositions.
[0069] Builders—The compositions of the present invention can comprise one or more detergent builders or builder systems. When present, the compositions will typically comprise at least about 1% builder, or from about 5% or 10% to about 80%, 50%, or even 30% by weight, of said builder. Builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphosphates, alkali metal silicates, alkaline earth and alkali metal carbonates, aluminosilicate builders polycarboxylate compounds. ether hydroxypolycarboxylates, copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1,3,5-trihydroxybenzene-2,4,6-trisulphonic acid, and carboxymethyl-oxysuccinic acid, the various alkali metal, ammonium and substituted ammonium salts of polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic acid, as well as polycarboxylates such as mellitic acid, succinic acid, oxydisuccinic acid, polymaleic acid, benzene 1,3,5-tricarboxylic acid, carboxymethyloxysuccinic acid, and soluble salts thereof.
[0070] Chelating Agents—The compositions herein may also optionally contain one or more copper, iron and/or manganese chelating agents. If utilized, chelating agents will generally comprise from about 0.1% by weight of the compositions herein to about 15%, or even from about 3.0% to about 15% by weight of the compositions herein.
[0071] Dye Transfer Inhibiting Agents—The compositions of the present invention may also include one or more dye transfer inhibiting agents. Suitable polymeric dye transfer inhibiting agents include, but are not limited to, polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof. When present in the compositions herein, the dye transfer inhibiting agents are present at levels from about 0.0001%, from about 0.01%, from about 0.05% by weight of the cleaning compositions to about 10%, about 2%, or even about 1% by weight of the cleaning compositions.
[0072] Dispersants—The compositions of the present invention can also contain dispersants. Suitable water-soluble organic materials are the homo- or co-polymeric acids or their salts, in which the polycarboxylic acid may comprise at least two carboxyl radicals separated from each other by not more than two carbon atoms.
[0073] Enzymes—The compositions can comprise one or more detergent enzymes which provide cleaning performance and/or fabric care benefits. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A typical combination is a cocktail of conventional applicable enzymes like protease, lipase, cutinase and/or cellulase in conjunction with amylase.
[0074] Enzyme Stabilizers—Enzymes for use in compositions, for example, detergents can be stabilized by various techniques. The enzymes employed herein can be stabilized by the presence of water-soluble sources of calcium and/or magnesium ions in the finished compositions that provide such ions to the enzymes.
[0075] Catalytic Metal Complexes—Applicants' compositions may include catalytic metal complexes. One type of metal-containing bleach catalyst is a catalyst system comprising a transition metal cation of defined bleach catalytic activity, such as copper, iron, titanium, ruthenium, tungsten, molybdenum, or manganese cations, an auxiliary metal cation having little or no bleach catalytic activity, such as zinc or aluminum cations, and a sequestrate having defined stability constants for the catalytic and auxiliary metal cations, particularly ethylenediaminetetraacetic acid, ethylenediaminetetra (methyl-enephosphonic acid) and water-soluble salts thereof. Such catalysts are disclosed in U.S. Pat. No. 4,430,243.
[0076] If desired, the compositions herein can be catalyzed by means of a manganese compound. Such compounds and levels of use are well known in the art and include, for example, the manganese-based catalysts disclosed in U.S. Pat. No. 5,576,282.
[0077] Cobalt bleach catalysts useful herein are known, and are described, for example, in U.S. Pat. Nos. 5,597,936 and 5,595,967. Such cobalt catalysts are readily prepared by known procedures, such as taught for example in U.S. Pat. Nos. 5,597,936, and 5,595,967.
[0078] Compositions herein may also suitably include a transition metal complex of a macropolycyclic rigid ligand—abbreviated as “MRL”. As a practical matter, and not by way of limitation, the compositions and cleaning processes herein can be adjusted to provide on the order of at least one part per hundred million of the benefit agent MRL species in the aqueous washing medium, and may provide from about 0.005 ppm to about 25 ppm, from about 0.05 ppm to about 10 ppm, or even from about 0.1 ppm to about 5 ppm, of the MRL in the wash liquor.
[0079] Preferred transition-metals in the instant transition-metal bleach catalyst include manganese, iron and chromium. Preferred MRL's herein are a special type of ultra-rigid ligand that is cross-bridged such as 5,12-diethyl-1,5,8,12-tetraazabicyclo[6.6.2]hexa-decane.
[0080] Suitable transition metal MRLs are readily prepared by known procedures, such as taught for example in WO 00/32601, and U.S. Pat. No. 6,225,464.
Processes of Making and Using Compositions
[0081] The compositions of the present invention can be formulated into any suitable form and prepared by any process chosen by the formulator, non-limiting examples of which are described in U.S. Pat. No. 5,879,584; U.S. Pat. No. 5,691,297; U.S. Pat. No. 5,574,005; U.S. Pat. No. 5,569,645; U.S. Pat. No. 5,565,422; U.S. Pat. No. 5,516,448; U.S. Pat. No. 5,489,392; U.S. Pat. No. 5,486,303 all of which are incorporated herein by reference.
Method of Use and Treated Situs
[0082] Any of the compositions and/or products/compositions comprising any aspect of Applicants' compositions disclosed herein may be used to clean or treat a situs inter alia a surface or fabric. Typically at least a portion of the situs is contacted with an embodiment of Applicants' composition and/or /compositions comprising any aspect of Applicants' compositions, in neat form or diluted in a liquor, for example, a wash liquor and then the situs may be optionally washed and/or rinsed. In one aspect, a situs is optionally washed and/or rinsed, contacted with any of the compositions and/or products/compositions comprising any aspect of Applicants' compositions disclosed herein then optionally washed and/or rinsed. For purposes of the present invention, washing includes but is not limited to, scrubbing, and mechanical agitation. The fabric may comprise most any fabric capable of being laundered or treated in normal consumer use conditions. Liquors that may comprise the disclosed compositions may have a pH of from about 3 to about 11.5. Such compositions are typically employed at concentrations of from about 500 ppm to about 15,000 ppm in solution. When the wash solvent is water, the water temperature may range from about 5° C. to about 90° C. and, when the situs comprises a fabric, the water to fabric ratio may be from about 1:1 to about 30:1. In one aspect, a situs that has been treated in accordance with any of the aforementioned methods is disclosed.
Test Methods
[0083] It is understood that the test methods that are disclosed in the Test Methods Section of the present application should be used to determine the respective values of the parameters of Applicants' invention as such invention is described and claimed herein.
[0084] (1) Mean Particle Size
The mean particle size of the wax coated particles is determined using a Lasentec M500L-316-K supplied by Mettler-Toledo, Inc., 1900 Polaris Parkway, Columbus, Ohio, 43240, US. The equipment is setup (Lasentec, FBRM Control Interface, version 6.0) as described in the Lasentec manuel, issued February 2000. Software setup and sample analysis is performed using Windox software (Windox XP, version 2002) in the WINDOX manual.
EXAMPLES
[0086] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
Example 1
60 wt % Core/40 wt % Wall Shellac Microcapsules in Dry Laundry Composition
[0087] A 25% solution of shellac SSB-63-HE-N (SSB, Bremen, Germany) in demi-water is prepared at 60 C and filtered with a 1.2 microns filter (Albet, Dassel, Germany). This solution is cooled to room temperature and 2% Glycerol (Sigma Aldrich) is added as plasticizer. 1200 g of microcapsules (Appleton, Wis., US) containing a perfume composition as benefit agent, are suspended in 1680 g of the previous shellac solution and 500 g demi-water are added, to have a 30% of solids in the suspension. This suspension is stirred for 1 hour at 700 rpm and then introduced in the spray-drier (Niro GmbH, Gemany) using a peristaltic pump (Watson-Marlow, Massachusetts, US). Solid particles are collected and then analyzed by microscopy techniques: SEM (TM-1000, Hitachi), Axio Microscope (Zeiss, Germany) and STEREO microscope (Zeiss, Germany). These particles containing perfume as benefit agent, are mixed in a dry laundry composition as follows,
[0000] % w/w granular laundry detergent composition Component A B C D E F G Brightener 0.1 0.1 0.1 0.2 0.1 0.2 0.1 Soap 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Ethylenediamine disuccinic acid 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Acrylate/maleate copolymer 1.5 1.5 1.5 1.5 1.5 1.5 1.5 Hydroxyethane di(methylene 0.4 0.4 0.4 0.4 0.4 0.4 0.4 phosphonic acid) Mono-C 12-14 alkyl, di-methyl, 0.5 0.5 0.5 0.5 0.5 0.5 0.5 mono-hydroyethyl quaternary ammonium chloride Linear alkyl benzene 0.1 0.1 0.2 0.1 0.1 0.2 0.1 Linear alkyl benzene sulphonate 10.3 10.1 19.9 14.7 10.3 17 10.5 Magnesium sulphate 0.4 0.4 0.4 0.4 0.4 0.4 0.4 Sodium carbonate 19.5 19.2 10.1 18.5 29.9 10.1 16.8 Sodium sulphate 29.6 29.8 38.8 15.1 24.4 19.7 19.1 Sodium Chloride 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Zeolite 9.6 9.4 8.1 18 10 13.2 17.3 Photobleach particle 0.1 0.1 0.2 0.1 0.2 0.1 0.2 Blue and red carbonate speckles 1.8 1.8 1.8 1.8 1.8 1.8 1.8 Ethoxylated Alcohol AE7 1 1 1 1 1 1 1 Tetraacetyl ethylene diamine 0.9 0.9 0.9 0.9 0.9 0.9 0.9 agglomerate (92 wt % active) Citric acid 1.4 1.4 1.4 1.4 1.4 1.4 1.4 PDMS/clay agglomerates (9.5% wt % 10.5 10.3 5 15 5.1 7.3 10.2 active PDMS) Polyethylene oxide 0.2 0.2 0.2 0.2 0.2 0.2 0.2 Enzymes e.g. Protease (84 mg/g 0.2 0.3 0.2 0.1 0.2 0.1 0.2 active), Amylase (22 mg/g active) Suds suppressor agglomerate 0.2 0.2 0.2 0.2 0.2 0.2 0.2 (12.4 wt % active) Sodium percarbonate (having 7.2 7.1 4.9 5.4 6.9 19.3 13.1 from 12% to 15% active AvOx) Perfume oil 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Solid perfume particles 0.4 0 0.4 0.4 0.4 0.4 0.6 Shellac particles* 1.3 2.4 1 1.3 1.3 1.3 0.7 Misc 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Balance Water *Shellac particles added as fine powder
and tested in a full washing test using non-coated microcapsules with perfume as benefit agent as reference.
Example 2
Beads Generation Entrapping Microcapsules in Shellac Cross-Linked with Calcium by Extrusion
[0088] 30 g microcapsules slurry with perfume as benefit agent (Appleton, Wis., US) are suspended in 100 g Marcoat 125 solution (Emerson Resources INC, Pennsylvania, US). Using a Nisco encapsulator with a vibration unit nozzle, above suspension is dropped into a 7.5% calcium chloride (Sigma Aldrich) aqueous bath. Particles are kept there for one hour, then aqueous phase is removed and particles are dried 48 hours at room temperature. Particles are suspended in a liquid laundry composition containing hydrogen peroxide for 72 hours at 35 C and then used in a wash with a powder and/or liquid co-detergent to determine microcapsule release. Fabrics are checked with microcopy techniques assessing deposition of microcapsules in dry fabrics and positive odor benefit after rubbing.
Example 3
20 wt % Core/80 wt % Wall Shellac Microcapsules in Liquid Laundry Composition
[0089] A 25% solution of shellac SSB-NPU-N (SSB, Bremen, Germany) in demi-water is prepared at 60 C and filtered with a 1.2 microns filter (Albet, Dassel, Germany). This solution is cooled to room temperature and 4% Glycerol (Sigma Aldrich) is added as plasticizer. 400 g of microcapsules (Appleton, Wis., US) containing a perfume composition as benefit agent and containing a 50% of solids, are suspended in 3216 g of the previous shellac solution. This suspension is stirred for 1 hour at 700 rpm and then introduced in the spray-drier (Niro GmbH, Gemany) using a peristaltic pump (Watson-Marlow, Massachusetts, US). Solid particles are collected and then analyzed by microscopy techniques: SEM (TM-1000, Hitachi), Axio Microscope (Zeiss, Germany) and STEREO microscope (Zeiss, Germany). These particles contain perfume as the benefit agent, and they are used in a liquid laundry composition as follows:
[0000]
% w/w liquid laundry detergent
composition
Component
A
B
C
D
C11.8 linear alkylbenzene
17.2
17.2
13.5
14.0
sulfonic acid
Neodol 23-5
5.2
Neodol 23-9
10.4
10.4
5.2
8.4
Citric acid
5.0
5.0
4.5
4.1
DTPA 1
0.3
0.3
0.2
0.2
Ethanolamine
3.3
3.3
2.6
2.6
Sodium hydroxide
0.6
to adjust
to adjust
to adjust
pH
pH
pH
ethoxylated amine polymer
2.0
2.0
1.6
1.6
ethanol
2.0
2.0
2.0
2.0
silicone suds suppressor
0.04
0.04
0.03
0.03
Tinopal CBS-X
0.2
0.2
0.2
0.2
Perfume
0.3
0.3
0.2
0.2
Blue EM 2
0.005
Basic Violet 3 (CI 42555) 3
0.005
Basic Violet 4 (CI 42600) 4
0.001
Acid Blue 7 (CI 42080) 5
0.0003
Thickener
0.1-0.5
0.1-0.5
0.1-0.5
0.1-0.5
water
balance
balance
balance
balance
neat pH (of composition)
3.2
3.2
2.5
2.7
reserve acidity 6
2.5
2.5
2.9
2.5
Shellac particles 7
1.3
2.4
1
1.3
Misc
0.1
0.1
0.1
0.1
Balance Water
1 diethyleneetriaminepentaacetic acid sodium salt
2 polymeric colorant from Milliken
3,4 fabric hueing dyes
5 non-fabric substantive dye
6 gNaOH/100 g of product
7 Shellac particles added as fine powder
[0090] The liquid laundry detergents of Example 3 are used and tested in a full washing test using free perfume as reference.
Example 4
[0091] 20 wt % Core/80 wt % Shellac Coated Dichloro-1,4-diethyl-1,4,8,11-tetraaazabicyclo[6.6.2]hexadecane manganese(II) in liquid laundry composition. A 10% solution of shellac SSB-63-HE-N (SSB, Bremen, Germany) in demi-water is prepared at 60 C and filtered with a 1.2 microns filter (Albet, Dassel, Germany). This solution is cooled to room temperature. 2 g of Dichloro-1,4-diethyl-1,4,8,11-tetraaazabicyclo[6.6.2]hexadecane manganese(II) are added to 98 g of the shellac solution previously prepared and mixed (IKA RW-16-Basic, supplied by IKA-Werke GmbH & Co. KG, Janke & Kunkel Str. 10, 79219 Staufen, Germany) till Dichloro-1,4-diethyl-1,4,8,11-tetraaazabicyclo[6.6.2]hexadecane manganese(II) is completely dissolved. Then a spray-dryer is used to collect the particles (4M8 Spray-Dryer from ProCepT, Belgium). Parameters used in the spray-drying process: nozzle 0.4 mm; schuin 60 cyclone; temperature inlet air 140 C; air flow 0.4 m 3 /min; feeding speed 2 mL/min with syringe. A Yield of 58.14% is obtained. Particles are collected and then analyzed by SEM (TM-1000, Hitachi) and performance is assessed in a standard laundry washing test.
Example 5
[0092] 70 wt % Core/30 wt % Shellac coated sodium nonanoyloxybenzene sulfonate in liquid laundry composition. 400 g of sodium nonanoyloxybenzene sulfonate (Eastman, Tenn., US) are weighed and introduced in a fluid bed coater with wurster (4M8-Fluidbed, ProCepT, Belgium). Hot air is set up at 60 C and shellac Splendid C2 (SSB, Bremen, Germany) is sprayed from the bottom at a rate of 3 mL/min. Material is collected and analyzed by SEM (TM-1000, Hitachi) assessing that coating is not uniform, but standard performance test, after aging the particles in a laundry composition, provides cleaning benefits in laundry.
Example 6
[0093] 13 wt % Core/87 wt % Shellac coated sodium nonanoyloxybenzene sulfonate in liquid laundry composition. A 25% solution of shellac SSB-63-HE-N (SSB, Bremen, Germany) in demi-water is prepared at 60 C and filtered with a 1.2 microns filter (Albet, Dassel, Germany). This solution is cooled to room temperature. 13 g of sodium nonanoyloxybenzene sulfonate are added to 348 g of the shellac solution, previously prepared, and mixed (IKA RW-16-Basic, supplied by IKA-Werke GmbH & Co. KG, Janke & Kunkel Str. 10, 79219 Staufen, Germany) till sodium nonanoyloxybenzene sulfonate is completely dissolved. Then a spray-dryer is used to collect the particles (4M8 Spray-Dryer from ProCepT, Belgium). Parameters used in the spray-drying process: nozzle 0.2 mm; temperature inlet air 120 C; air flow 0.4 m 3 /min; feeding speed 3 mL/min with peristaltic pump. Collected particles have a particle size distribution with a mean of 20.8 microns, analyzed with Lasentec (Mettler-Toledo, Ohio, US) as described above.
[0094] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.
[0095] All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0096] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | The present application relates to particles, compositions comprising such particles, and processes for making and using such particles and compositions. Such particles minimize or eliminate certain drawbacks of benefit agents including encapsulated benefit agents. When employed in compositions, for example, cleaning or fabric care compositions, such particles increase the efficiency of benefit agent delivery, there by allowing reduced amounts of benefit agents to be employed. In addition to allowing the amount of benefit agent to be reduced, such particles allow a broad range of benefit agents to be employed. | 3 |
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