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REFERENCE TO RELATED APPLICATION
This application claims priority to and the benefit of U.S. Provisional Application Ser. No. 61/275,074 which was filed Aug. 25, 2009, entitled RECONFIGURABLE GOLF BALL STRUCTURAL TEE SYSTEM AND METHOD TO SUPPORT A STATIONARY GOLF BALL, the entirety of which is hereby incorporated by reference as if fully set forth herein.
FIELD OF INVENTION
The present invention relates generally to a golf ball structural support system and method and more particularly to a reconfigurable golf ball structural tee system and method wherein the reconfigurable golf ball structural tee is formed in a flat card stock and is reconfigured to support a stationary golf ball.
BACKGROUND OF THE INVENTION
Golf tees are generally well known. They are made from wood, rubber and metal. Normally, they are formed from a single material and have an upper concave surface for supporting the golf ball and a tapered shank with a pointed surface at the base of the golf tee for penetrating the ground, for example. Numerous wooden golf tees are broken and/or lost while playing golf. In addition, golf tees are often stored in a golf bag pocket and the golf tees can take up substantial room due to their haphazard position in the golf bag pocket. Also, tees can be used for advertising except that to have one line of lettering imprinted on a tee is very limited, for example. In addition, if a player runs out of tees in their golf bag it can be a large inconvenience.
Therefore, a need exists for golf tees that are easier to store, that can be used for wider advertising than conventional tees, that can be stored in a wallet, pocket or golf bag and tees that are more durable than conventional wooden tees.
SUMMARY OF THE INVENTION
The following presents a simplified summary in order to provide a basic understanding of one or more aspects of the invention. This summary is not an extensive overview of the invention, and is neither intended to identify key or critical elements of the invention, nor to delineate the scope thereof. Rather, the primary purpose of the summary is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
The invention is directed to a reconfigurable golf tee that is formed within a flat card stock, wherein the flat card stock is configured to accept advertising such as lettering, logos, and the like. Various forms of the reconfigurable tees are also provided, along with releasable means for detaching the tee from the card stock.
It is additional embodiment of the present to provide a tee element that provides less resistance and a lower mass that a typical tee and therefore allows a golf ball to be driven further of the tee element than a typical tee.
It is therefore an object of this invention to provide at least one tee element on a flat card stock which can be reconfigured to hold a stationary golf ball off of a ground surface.
It is another object of this invention to provide a flat card stock which is easily manufactured and easily attached, for example to golf equipment comprising a golf bag, a golf cart and stored in a wallet.
It is yet another embodiment of the present invention to provide a flat card stock with at least one tee element which displays an advertisement comprising a business card, a magnetic strip gift card, a display card, and the like.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a golf tee system 100 formed on card stock in accordance with a preferred embodiment of the present invention;
FIG. 2 is a front view of an exemplary tee element 200 removed from the card stock used in accordance with one or more aspects of the present invention for holding a stationary golf ball above the ground in accordance with a preferred embodiment;
FIG. 3 is a front view of the exemplary tee element illustrated in FIG. 2 wherein the tee element is folded in half, in accordance with a preferred embodiment of the present invention;
FIG. 4 is a perspective view illustrating an exemplary tee element 400 , similar to the tee element 300 shown in FIG. 3 used in accordance with one or more aspects of the present invention wherein the tee element 400 is folded in half and inserted into the ground to hold a stationary golf ball in an elevated position according to one or more aspects of the present invention;
FIG. 5 is a perspective view illustrating an exemplary tee element 500 used in accordance with one or more aspects of the present invention for supporting a stationary golf ball above the ground;
FIG. 6 is a figure illustrating an exemplary tee element 600 supporting a stationary golf ball in accordance with one or more aspects of the present invention;
FIG. 7 is a front view of yet other embodiment of a golf tee system 700 illustrating at least one tee element formed in a card stock such as may be used in accordance with one or more aspects of the present invention;
FIG. 8 is a perspective view illustrating yet another embodiment of an exemplary tee element 800 illustrated in accordance with an aspect of the present invention;
FIGS. 9A , 9 B and 10 are figures of a dovetail tee assembly as may be assembled and used in accordance with one or more aspects of the present invention;
FIGS. 11-12 illustrate figures of an assembled dovetail tee assembly inserted into a flexible material to simulate the tee inserted into the ground in accordance with an aspect of the present invention;
FIGS. 13-16 illustrate figures of a three prong tee assembly in various configurations in accordance with one or more aspects of the present invention;
FIG. 17 illustrates yet another embodiment of a three prong tee holding a stationary golf ball according to the present invention;
FIGS. 18-21 illustrates figures of a four prong tee assembly in various configurations in accordance with one or more aspects of the present invention;
FIGS. 22 , 23 A and 23 B illustrate figures of yet another four prong tee assembly in various configurations in accordance with one or more aspects of the present invention;
FIG. 24 illustrates a strip of tees in accordance with yet another aspect of the present invention; and
FIG. 25 illustrates a method of forming a structural tee element in accordance with one or more aspects of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described with reference to the attached drawings, wherein like reference numerals are used to refer to like elements throughout.
FIG. 1 illustrates an embodiment of an exemplary golf tee system 100 used in accordance with at least one aspect of the present invention. FIG. 1 illustrates several advantages of the present invention, the golf tee system 100 over the prior art discussed supra. The preferred embodiment of the golf tee system 100 comprises a card stock or material 102 with at least one tee element 104 non-fixedly attached to, formed within a part of the card stock 102 and configured to be removable from the card stock 102 by bending the at least one tee element 104 along a defined break line 106 until the break line 106 holding the at least one tee element 104 to the card stock 102 is detached. The bend lines are formed so that the card stock will not break when bent over the maximum distance possible. The at least one tee element 104 can be bent and/or folded into a structural shape by bending the at least one tee element 104 along a defined bend line 118 . The defined break line 106 and/or the defined bend line 118 can be formed using techniques comprising laser, laser cutting, die cutting, cutting perforations in the card stock 102 and creasing the card stock 102 , for example. The techniques of forming the defined bend line 118 and/or the defined break line 106 in the card stock 102 are well known by those of ordinary skill in the art. In one embodiment, the card stock 102 can take the shape of a credit card where a thickness of the card stock 102 can be approximately about 10 to 70 mils, a width 110 of approximately about 2 inches and a length 112 of approximately about 3 inches. In this embodiment the at least one tee element 104 has through slots 120 configured to form a crown area 122 of the at least one tee element 104 . In addition the least one tee element 104 can have a minimum thickness as long as it will structurally hold the golf ball. The crown area 122 is approximately the area of the at least one tee element 104 between the crown area top edge 124 and the top of the through slot 120 , for example. In this embodiment the slots 120 are, for example, using techniques comprising laser cutting and die cutting, for example, all the way through the card stock 102 . However, the through slots 120 can be perforated cuts or not a complete through cut, for example.
The at least one tee element 104 comprises at least one tee element first side 114 and at least one tee element second side 116 configured on opposite sides of the defined bend line 118 from the top of the crown area 122 to the end of a bottom portion 128 . The at least one tee element 104 is folded in half so that the at least one tee element first side 114 and the at least one tee element second side 116 come in close proximity to each other, at a location perpendicular to and away from the defined bend line 118 . A body portion 130 of the least one tee element 104 is approximately located in the center of the at least one tee element 104 . A bottom portion 128 is located approximately in the bottom area of the at least one tee element 104 . The bottom portion 128 can be shaped as a point, a tip, and the like for insertion into the ground.
The card stock 102 shown in FIG. 1 is blank; however the card stock 102 can be printed with artwork comprising logos and/or lettering on one side of the card stock 102 . In addition, the cardstock 102 can be printed with artwork and/or lettering on both sides of the card stock 102 . The artwork and/or lettering can be black and white, grayscale or colored. A through hole 126 can optionally be made in the card stock 102 for a key chain, a strap and the like. The through hole 126 allows the card stock 102 to be attached equipment comprising golf bag or golf cart, for example.
Although the card stock 102 is illustrated in the form of a credit card however, the card stock can take any shape comprising an animal, a club head, a company name, etc. In addition, although the tee elements are shown as symmetrical and the tees are similar in shape, the tees can be non-symmetrical and tees of dissimilar shape can be formed on the same card stock.
Illustrated in FIG. 2 is a tee element 204 removed from a card stock (not shown). In embodiment 200 of the invention, the tee element 204 comprises a tee element first side 214 , a tee element second side 216 and slots 220 that pass through the tee element 204 . The tee element 204 is configured so that the element first and second halves, 214 and 216 respectively, can be folded along a defined bend line 218 so that the tee element 204 is folded in half as illustrated in FIG. 3 . A crown area 222 is approximately the upper portion of the tee element 204 between the slots 220 and a crown area top edge 224 . A body portion 230 of the least one tee element 104 is approximately located in the center of the at least one tee element 104 . A bottom portion 228 is located approximately in the bottom area of the at least one tee element 204 . In FIG. 3 , for example, the first side wall 214 (not shown) and the second side wall 216 are folded toward each other.
In another embodiment 400 illustrated in FIG. 4 , a bend line 418 comprises a crease or perforations, for example, that allows the tee element 404 to be folded in half along the bend line 418 and inserted into a ground surface 438 . Initially, when the tee element 404 is removed from a card stock, both a tee element first side 414 and a tee element second side 416 are lying on a single plane. FIG. 4 illustrates the tee element 404 wherein the first side 414 and the second side 416 are folded toward and in contact with each other prior to insertion into the ground surface 438 .
A crown area 422 of the tee element 404 is approximately the area of the first side 414 and the second side 416 between the crown area top edge 424 and the top of slots 420 , for example. In this embodiment the slots 420 are, for example, laser cut or die cut, for example, all the way through the card stock. However, the slots 120 could be perforated cuts or not a complete through cut. A slot end 434 prevents the crown area 422 of the tee element first side 414 and a tee element second side 416 from being spread apart further without tearing the slot end 434 . As the first side 414 and second side 416 are spread apart a tee element first side slot beginning 432 and a tee element second side slot beginning 533 ( FIG. 5 ), are moved further apart.
Now referring to FIG. 5 , the crown area 422 of the first side 414 and the second side 416 of the tee element 404 of FIG. 4 is spread apart starting from spreading the crown area 422 by separating the tee element first side slot beginning 432 ( FIG. 4 ) away from the tee element second side slot beginning (not shown in FIG. 4 ). The tee element 404 , for example is opened at an angle θ wherein the tee element first side slot end 434 and the tee element second side slot end 435 prevents the crown area first side 422 and the crown area second side 423 from being spread further apart without tearing the slot ends 434 and 435 . The angle θ between a tee element first side 414 and a tee element second side 416 is approximately 10 to 40 degrees. The angle θ allows the tee element 404 to support a golf ball on the crown area first side top edge 424 the crown area second side top edge 425 . Of course, those skilled in the art will recognize many modifications that may be made to this configuration, without departing from the scope or spirit of what is described herein.
FIG. 6 is a photograph of the tee element 404 illustrated in FIG. 4 wherein the tee element 404 inserted into the ground surface 438 is configured to support a stationary golf ball 640 . The inventors appreciate as do those of ordinary skill in the art that many configurations of the tee element are possible comprising various shapes, sizes, thickness, lengths, widths, numbers of slots, etc. and reconfigurations of the tee element (e.g., rounded, triangular, square, etc.), are possible both symmetrical and non-symmetrical to result in a structure that will support a stationary golf ball. All such structures and configurations are contemplated herein. The inventors recognized that by providing a lighter mass tee element and the tee element was struck with a club head the tee element would bend over would result in greater distance than a typical plastic or wood golf tee.
FIGS. 7 and 8 illustrate yet another embodiment of the present invention wherein a card stock 700 ( FIG. 7 ) is configured with tee elements 704 . FIG. 7 is an illustration of each of the tee elements 704 is configured with a tee element first side 714 and a tee element second side 716 and is configured to fold along a defined folding line 718 . Each of the tee elements 704 is configured with a first side slot 720 and a second side slot 721 , wherein the slots, 720 and 721 can be cut entirely through the card stock 702 or perforated in the card stock, for example.
The tee elements 704 are configured with a first side crown area 722 and a second side crown area 723 that can be reconfigured to hold a stationary golf ball on a crown area first side top edge 724 and crown area second side top edge 725 . The stationary golf ball is held on a first point 742 , a second point 744 and a third point 746 , for example.
A tee element 802 is illustrated in the photo 800 shown as FIG. 8 , wherein a tee element 802 is configured to hold a golf ball (not shown) in a stationary position. The tee element 802 is configured with a tee element first side 814 and a tee element second side 816 and is shown folded along a defined folding line 818 . The tee element 802 is configured with a first side slot 820 and a second side slot 821 , wherein the slots, 820 and 821 can be cut entirely through a card stock or perforated in the card stock, for example.
The tee element 802 is configured with a first side crown area 822 and a second side crown area 823 that can be reconfigured to hold a stationary golf ball on a crown area first side top edge 824 and a crown area second side top edge 825 . The stationary golf ball can be held on three points, for example on a first point 842 , a second point 844 and a third point 846 , with the points, 842 , 844 and 846 , as illustrated. The tee element 802 is shown with a tee element tip 748 ( FIG. 7 ) inserted into a ground surface 850 . The tip 748 can take various shapes, pointed, rounded, triangular, and the like.
FIG. 9A illustrates a small dovetail component 900 and a large dovetail component 950 of a simplified two prong dovetail component 902 of an exemplary four point dovetail tee assembly 1000 ( FIG. 10 ), such as may be used as an improved structural tee assembly, in accordance with the present invention. The small dovetail component 902 comprises a first prong 962 , a second prong 964 and a first interconnecting slot 966 . FIG. 9B illustrates a photo 950 of a two prong elongated dovetail component 952 that comprises an elongated dovetail component tip 958 , a second interconnecting slot 960 . The two prong elongated dovetail component 952 is configured with a third prong 968 , a forth prong 970 and an elongated dovetail component body 972 .
FIG. 10 illustrates the four prong assembled tee 1000 that is configured with a simplified two prong dovetail component 902 interlocked with a two prong elongated dovetail component 952 . A two prong dovetail component first interconnecting slot 966 ( FIG. 9A ) is configured to engage and non-fixedly attach with an elongated dovetail component second interconnecting slot 960 ( FIG. 9B ), as illustrated in FIG. 10 .
FIG. 11 illustrates a top view photograph 1100 of a four point dovetail tee assembly 1102 inserted into a ground surface 1168 . A stationary golf ball 1220 is illustrated in FIG. 12 mounted on a four point dovetail tee assembly 1202 inserted in the ground 1204 .
FIGS. 13-16 illustrate yet another embodiment of the present invention 1300 , 1400 , 1500 and 1600 . FIG. 13 illustrates a three prong tee 1302 that can, for example be molded from one piece of plastic or a third prong 1304 can be added as illustrated in FIG. 13 of this embodiment as a secondary operation. The third prong 1304 can comprise bendable metal, plastic, biodegradable plastic, and the like. A first prong 1306 and second prong 1308 as illustrated in FIG. 14 are formed as an integrated two prong tee component 1310 .
FIG. 15 illustrates the three prong tee 1302 configured to allow the third prong 1304 to be adjusted away from the first prong 1306 and the second prong 1308 so that the three prong tee 1302 can support a stationary golf ball 620 , as illustrated in FIG. 16 . The golf ball 1620 is supported on the three prongs shown in FIGS. 15 , 1304 , 1306 and 1308 , respectively.
In another embodiment as illustrated in FIG. 17 , the card stock can be manufactured comprising stamped, molded, or the like, into a contiguous three prong tee 1702 , as illustrated in FIG. 17 with a third prong 1704 integrated into and a contiguous part of the three prong tee 1702 and the third prong 1704 is not affixed utilizing a secondary operation comprising, e.g., gluing, molding, etc. FIG. 17 illustrates the three prong tee 1702 , with the third prong 1704 bent outward when the tee 1702 is removed from the retaining card, for example. The center or third prong 1704 , as illustrated in FIG. 17 is longer than the first and second prongs, 1706 and 1708 , respectively. The tee 1702 is shown as it would be inserted into a ground surface 1738 .
FIGS. 18 and 19 illustrate yet another embodiment of the present invention 1800 and 1900 involving a four prong tee 1804 such as may be inserted into a ground surface for holding a stationary golf ball in accordance with one or more aspects of the present invention. FIGS. 18 and 19 are perspective views of the four prong tee 1804 , in accordance with one or more aspects of the present invention.
The four prong tee 1804 in the present embodiment 1800 comprises two pre-stamped cards, for example, glued or adhered to each other up to a tee head base. This allows a tee head comprising a first two prong section 1946 and a second two prong section 1948 to be opened like a butterfly, as illustrated in FIG. 20 . In FIG. 21 a stationary golf ball 2120 can be placed on the four prongs 1806 ( FIG. 18 ) with the center of gravity of the golf ball 2120 positioned over a four prong tee assembly 2104 .
FIGS. 22 , 23 A and 23 B illustrate an embodiment of an exemplary golf tee system 2200 used in accordance with at least one aspect of the present invention. FIGS. 22 and 23A illustrate several advantages of the present invention, the golf tee system 2200 . The golf tee system 2200 comprises a card stock 2202 with at least one tee element 2204 non-fixedly attached to the card stock 2202 and configured to be removable from the card stock 2202 by bending the at least one tee element 2204 along a defined break line 2206 until the break line 2206 holding the at least one tee element 2204 to the card stock 2202 is broken. The at least one tee element 2204 can be bent and/or folded into a structural shape by bending the at least one tee element 2204 along a defined bend line 2218 . The defined break line 2206 and/or the defined bend line 2220 can be formed by a laser, laser cutting or die cutting perforations in the card stock 2202 or creasing the card stock 2202 , for example. The techniques of forming the defined bend line 2220 and/or the defined break line 2206 in the card stock 2202 are well known by those of ordinary skill in the art. In one embodiment, the card stock 2202 can take the shape of a credit card, however various other shapes can be used such as pinwheels, long strips of tees, and tees on a key ring. In this embodiment the at least one tee element 2204 is configured to form a crown area 2222 of the at least one tee element 2204 . The crown area 2222 is approximately the area in close proximity to the top of the at least one tee element 2204 , for example.
The card stock 2202 shown in FIG. 22 is shown with a colored graphic on the front face. The cardstock 2202 can be printed with artwork and/or lettering on one or both sides of the card stock 2202 . The artwork and/or lettering can be black and white, grayscale or colored. A ball marker 2266 can optionally be made in the card stock 2202 for marking a golf ball, and the like.
Illustrated in FIG. 23A and FIG. 23B is a tee element 2304 comprises a tee element first side 2314 and a tee element second side 2316 configured on opposite sides of a defined bend line 2318 from the top of a crown area 2322 to an end of the first side 2328 . The tee element first side 2214 is smaller than the second side 2316 . The tee element 2304 in FIG. 23B is shown folded along a defined bend line 2318 so that the tee element first side 2314 and the tee element second side 2316 come in close proximity to each other, at a location away from the defined bend line 2318 . A body portion 2330 of the tee element 2304 is approximately located in the center of the tee element 2304 . A ground penetration point 2328 is located approximately at a bottom of the tee element 2304 .
A card stock strip 2402 shown in FIG. 24 is illustrated with a logo and lettering printed on one side the card stock strip 2402 , however the strip 2402 can be printed without artwork and/or lettering. In addition, the card stock strip 2402 can be printed with artwork and/or letter on both sides of the card stock 2402 . The artwork and/or lettering can be black and white, grayscale or colored. A through hole 2426 can optionally be made in the card stock strip 1102 for a key chain, a strap and the like, that can be attached to a golf bag, for example. The strip 1102 comprises tees 2420 similar to those shown in FIG. 1 , for example. Even though the tees 2420 are shown in a symmetric manner where the tees have identical shapes, however the tees on a card stock can be dissimilar in shape, in the way in which they are assembled and the like. In addition the card stock can be formed in various shapes, for example animal shapes, non-symmetric shapes, etc.
FIG. 25 is a flow diagram of a method 2500 of forming a golf ball tee in accordance with an aspect of the present invention. The method 2500 can be performed as part of a placing a tee to hold a stationary golf ball. In addition, the method makes reference to FIGS. 1-6 , for example.
The method 2500 begins at block 2502 , wherein at least one tee element 104 ( FIG. 1 ) is removed from a card stock 102 ( FIG. 1 ) by snapping the at least one tee element 104 off of and out of the card stock 102 . The desired materials for the card stock 102 can include, for example, polyvinyl chloride acetate, polyvinyl chloride, celluloid, corn based material, acrylonitrile butadiene styrene, polyethylene terephthalate, polycarbonate, corn-based polylactic acid, petroleum-based plastics, bioplastics, teslin, and the like. In addition, the tee can be made from any plastic, metal, biodegradable material and wood, for example capable of holding a golf ball.
At 2504 , the at least one tee element 104 is folded completely in half as illustrated in FIG. 3 by folding the at least one tee element 104 along a defined bend line 118 ( FIG. 2 ). The defined bend line 118 can be formed by a laser, laser cutting, die cutting perforations in the card stock 102 or scoring the card stock 102 , for example.
At 2506 , the folded tee 300 can be grasped at a body portion 130 of the at least one tee element 104 by tightly squeezing the body portion 130 between a thumb and index finger, for example. The body portion 130 can be grasped with a golfer's left or right hand.
The at least one tee element 104 can be inserted into a ground surface 438 ( FIG. 4 ) and can be adjusted to a desired height of the at least one tee element 104 above the ground surface 438 . When the desired height has been obtained the golfer can open or spread apart a crown area first side 422 and a crown area second side with the thumb and index finger at 2510 . The golf ball 640 ( FIG. 6 ) can then be placed at 2512 on and supported by a crown area first side top edge 424 and a crown area second side top edge 425 .
Although the invention has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, circuits, systems, etc.), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary implementations of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” | A golf tee system comprising a card stock having a thickness, a width, a length with bend lines and break lines formed on the card stock, a tee element formed within the card stock, wherein the card stock is approximately flat and configured to allow at least one tee element to be removed from the card stock and assembled into a structural tee device for holding a golf ball, a top portion, a bottom portion, a body portion connected to and extending upward from the bottom portion, having a first side wall and a second side wall, wherein the first side wall and a second side wall when folded toward each other at least partially bound and define an inner cavity within the body portion, wherein a folded upper crown of the top portion defines a ball receipt surface configured to receive and hold the golf ball off of a ground surface and wherein the reconfigurable golf tee is detached from scored card stock. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of U.S. Provisional Application for Patent Ser. No. 61/238,206, filed on Aug. 30, 2009, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hinge assembly for rotationally attaching a first member to a second member to allow rotational movement of the first member relative to the second member between a closed position and an open position.
2. Description of the Prior Art
Hinge assemblies for rotationally attaching a first member to a second member to allow rotational movement of the first member relative to the second member between a closed position and an open position are known in the prior art. In particular spring loaded hinge assemblies that assist the opening of the first member relative to the second member by storing energy in a spring during the closing operation are shown in U.S. Pat. No. 7,055,215 B1 to Ligtenberg at al., issued on Jun. 6, 2006. However, these hinges require special machined springs that are extremely costly and complex to manufacture. The multi-layer torsion bar of the present invention, which functions to assist the opening of the first member relative to the second member by storing energy during the closing operation, drastically reduces the cost and complexity of spring manufacture while maintaining the same performance. These and other advantages of the present invention will become apparent from the description and drawings that follow. None of the prior art hinge assemblies are seen to teach or suggest the unique features of the present invention or to achieve the advantages of the present invention.
SUMMARY OF THE INVENTION
The present invention is directed to a hinge assembly for rotationally attaching a first member to a second member to allow rotational movement of the first member relative to the second member between a closed position and an open position. The hinge assembly of the present invention includes a spring that assists the opening of the first member relative to the second member by storing energy in the spring during the closing operation. The spring is of a unique multilayered torsion bar design. The hinge assembly also includes a friction mechanism that exerts a sufficient frictional force on the hinge shaft such that the first member can be held in a range of desired angular positions on either side of the angular position corresponding to the relaxed state of the hinge spring and including the angular position corresponding to the relaxed state of the hinge spring. In addition, the multilayered torsion bar spring with its unique design and features is a significant invention in and of itself. Applying a torsion bar spring to a friction hinge is also another aspect of the invention.
Accordingly, it is an object of the invention to provide a multi-layer torsion bar spring.
It is another object of the invention to provide a spring assisted friction hinge that employs a multi-layer torsion bar spring.
It is yet another object of the invention to provide a spring assisted friction hinge that employs a torsion bar spring.
These and other objects of the present invention will become apparent from the attached description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental view of the hinge assembly of the present invention showing the hinge assembly applied to a laptop computer with the lid of the laptop computer in the closed position.
FIG. 2 is an environmental view of the hinge assembly of the present invention showing the hinge assembly applied to a laptop computer with the lid of the laptop computer in an angular position relative to the base of the laptop computer that corresponds to the relaxed state of the hinge spring.
FIG. 3 is an environmental view of the hinge assembly of the present invention showing the hinge assembly applied to a laptop computer with the lid of the laptop computer in an angular position relative to the base of the laptop computer that corresponds to the fully open state of the laptop computer lid.
FIG. 4 is a fragmentary environmental view showing the installation of the hinge assembly of the present invention to a laptop computer.
FIG. 5 is a fragmentary environmental view with a section taken through the laptop computer to show the installation of the hinge assembly of the present invention to the laptop computer.
FIGS. 6-13 are views of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring.
FIG. 14 is an exploded view of the hinge assembly of the present invention.
FIG. 15 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring.
FIG. 16 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring with the spring cover removed to show the multilayered torsion bar spring in its relaxed state.
FIG. 17 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring.
FIG. 18 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring with the hinge assembly sectioned to reveal its internal details.
FIG. 19 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully twisted state of the hinge spring with the spring cover and cap removed and with the end piece of the hinge assembly sectioned to show the multilayered torsion bar spring in its fully twisted state.
FIG. 20 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid.
FIG. 21 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid with the spring cover removed to show the multilayered torsion bar spring in a twisted state corresponding to the fully open position of the laptop computer lid.
FIG. 22 is a cross-sectional view of the hinge assembly of the present invention taken along the line A-A in FIG. 26 to reveal its internal details.
FIG. 23 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully twisted state of the hinge spring.
FIG. 24 is an isometric view of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully twisted state of the hinge spring with the spring cover removed to show the multilayered torsion bar spring in its fully twisted state.
FIG. 25 is a fragmentary enlarged view showing the multilayered torsion bar spring in its fully twisted state.
FIGS. 26-27 are top and side views of the hinge assembly of the present invention to provide a guide to show the cut lines along which the cross-sectional views in FIGS. 22 and 28 - 35 are taken.
FIG. 28 is a cross-sectional view of the hinge assembly of the present invention taken along the line D-D in FIG. 27 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid.
FIG. 29 is a cross-sectional view of the hinge assembly of the present invention taken along the line D-D in FIG. 27 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring.
FIG. 30 is a cross-sectional view of the hinge assembly of the present invention taken along the line D-D in FIG. 27 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully-twisted state of the hinge spring.
FIG. 31 is a cross-sectional view of the hinge assembly of the present invention taken along the line C-C in FIG. 27 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid.
FIG. 32 is a cross-sectional view of the hinge assembly of the present invention taken along the line C-C in FIG. 27 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring.
FIG. 33 is a cross-sectional view of the hinge assembly of the present invention taken along the line C-C in FIG. 27 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully-twisted state of the hinge spring.
FIG. 34 is a cross-sectional view of the hinge assembly of the present invention taken along the line B-B in FIG. 27 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring.
FIG. 35 is a cross-sectional view of the hinge assembly of the present invention taken along the line B-B in FIG. 27 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully-twisted state of the hinge spring.
FIGS. 36-41 are views of the adaptor of the hinge assembly of the present invention for attaching the hinge assembly to a first member such as, for example, a laptop computer lid.
FIGS. 42-49 are views of the spring end cap of the hinge assembly of the present invention for axially constraining one end of the multi-layer torsion bar spring relative to the hinge shaft.
FIGS. 50-57 are views of the end piece of the hinge assembly of the present invention for rotationally constraining one end of the multi-layer torsion bar spring relative to a second member such as, for example, a laptop computer base.
FIGS. 58-62 are views of one leaf of the multi-layer torsion bar spring of the hinge assembly of the present invention.
FIGS. 63-70 are views of the hinge base of the hinge assembly of the present invention.
FIGS. 71-76 are views of the hinge shaft of the hinge assembly of the present invention.
FIGS. 77-82 are views of the friction element of the friction mechanism of the hinge assembly of the present invention.
FIGS. 83-89 are views of the friction mechanism cover of the hinge assembly of the present invention.
FIGS. 90-95 are views of the channel insert of the friction mechanism of the hinge assembly of the present invention.
FIGS. 96-102 are views of the torsion bar spring cover of the hinge assembly of the present invention.
FIG. 103 is an environmental view of a second embodiment of the hinge assembly of the present invention showing the hinge assembly applied to a laptop computer with the lid of the laptop computer in the closed position.
FIG. 104 is an environmental view of the second embodiment of the hinge assembly of the present invention showing the hinge assembly applied to a laptop computer with the lid of the laptop computer in an angular position relative to the base of the laptop computer that corresponds to the relaxed state of the hinge spring.
FIG. 105 is an environmental view of the second embodiment of the hinge assembly of the present invention showing the hinge assembly applied to a laptop computer with the lid of the laptop computer in an angular position relative to the base of the laptop computer that corresponds to the fully open state of the laptop computer lid.
FIGS. 106-107 are fragmentary environmental views showing the installation of the second embodiment of the hinge assembly of the present invention to a laptop computer.
FIG. 108 is a fragmentary environmental view with a section taken through the laptop computer to show the installation of the second embodiment of the hinge assembly of the present invention to the laptop computer.
FIGS. 109-112 are views of the second embodiment of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring.
FIG. 113 is a view of the second embodiment of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring and with the outer shell and inner sleeves removed to show the torsion bar spring.
FIGS. 114-115 are cross sectional views of the second embodiment of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge spring.
FIGS. 116-117 are exploded views of the second embodiment of the hinge assembly of the present invention.
FIG. 118 is an isometric view of the second embodiment of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the closed state of the hinge assembly and the fully twisted state of the hinge spring.
FIGS. 119-121 are views of the second embodiment of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the closed state of the hinge assembly and the fully twisted state of the hinge spring and that are partially broken away to reveal internal details.
FIG. 122 is an isometric view of the second embodiment of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the open position of the laptop computer lid.
FIG. 123 is a view of the second embodiment of the hinge assembly of the present invention showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid and that is partially broken away to reveal internal details.
FIG. 124 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line B-B in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully closed position of the laptop computer lid.
FIG. 125 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line B-B in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge assembly.
FIG. 126 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line B-B in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid.
FIG. 127 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line C-C in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully closed position of the laptop computer lid.
FIG. 128 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line C-C in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge assembly.
FIG. 129 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line C-C in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid.
FIG. 130 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line D-D in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully closed position of the laptop computer lid.
FIG. 131 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line D-D in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge assembly.
FIG. 132 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line D-D in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid.
FIG. 133 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line E-E in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully closed position of the laptop computer lid.
FIG. 134 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line E-E in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the relaxed state of the hinge assembly.
FIG. 135 is a cross-sectional view of the second embodiment of the hinge assembly of the present invention taken along the line E-E in FIG. 109 showing the hinge adaptor in an angular position relative to the base of the hinge assembly that corresponds to the fully open position of the laptop computer lid.
FIGS. 136-142 are views of the adaptor of the second embodiment of the hinge assembly of the present invention for attaching the hinge assembly to a first member such as, for example, a laptop computer lid.
FIGS. 143-150 are views of the first spring end cap or holder of the second embodiment of the hinge assembly of the present invention for axially constraining one end of the multi-layer torsion bar spring relative to the hinge base.
FIGS. 151-158 are views of the second spring end cap or holder of the second embodiment of the hinge assembly of the present invention for axially constraining one end of the multi-layer torsion bar spring relative to the hinge shaft.
FIGS. 159-162 are views of one leaf of the multi-layer torsion bar spring of the second embodiment of the hinge assembly of the present invention.
FIGS. 163-170 are views of the hinge base of the second embodiment of the hinge assembly of the present invention, which also constitutes the friction mechanism of the second embodiment of the hinge assembly of the present invention.
FIGS. 171-178 are views of the hinge shaft of the second embodiment of the hinge assembly of the present invention.
FIGS. 179-186 are views of the outer shell covering the torsion bar spring of the second embodiment of the hinge assembly of the present invention.
FIGS. 187-194 are views of the inner torsion bar spring covers or sleeves of the second embodiment of the hinge assembly of the present invention that fit between the outer shell and the torsion bar spring.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-102 , the present invention is directed to a hinge assembly 300 , 500 for rotationally attaching a first member to a second member to allow rotational movement of the first member relative to the second member between a closed position and an open position. Referring to FIGS. 1-5 , two hinge assemblies 300 and 500 made in accordance with the present invention are shown being used to rotationally attach the lid 204 of a laptop computer 200 to the base 202 of the laptop computer 200 . The laptop lid 204 typically houses the laptop screen 206 and its angular position relative to the laptop base 202 should be adjustable within a range of angular positions suitable for people of a variety of sizes to properly view the laptop screen 206 .
The hinge assembly 300 is a left hinge assembly and the hinge assembly 500 is a right hinge assembly. The right hinge assembly 500 is a mirror image of the hinge assembly 300 about a plane perpendicular to longitudinal axes of the shafts of each of the hinge assemblies and positioned halfway between the two hinge assemblies. Accordingly, only the hinge assembly 300 is described in detail. The laptop lid 204 typically is releasably secured in the closed position relative to the laptop base 202 by a latch (not shown) of some sort. The latch can be operated by a user to release or free the laptop lid 204 for rotational movement to the open position relative to the laptop base 202 .
The hinge assembly 300 can be used to rotationally attach a first member to a second member to allow rotational movement of the first member relative to the second member between a closed position and an open position. In the illustrated example, the first member is the laptop lid 204 and the second member is the laptop base 202 . The hinge assembly 300 includes an elongated shaft 320 , an adaptor 340 , a hinge base 302 , a friction mechanism 430 , an end piece 360 , a torsion bar spring 380 , a cap 400 , and a torsion bar cover 420 .
Referring to FIGS. 1-35 and 71 - 76 , the elongated shaft 320 has at least a first end portion 326 , a second portion 324 and a head portion 322 . The first end portion 326 of the shaft 320 is provided with a plurality of elongated teeth 328 of triangular cross section evenly distributed about the circumference of the first end portion 326 of the shaft 320 . Each of the plurality of elongated teeth 328 extends for at least the majority of the length of the first end portion 326 of the shaft 320 . In the illustrated example, the second portion 324 of the shaft 320 is of larger diameter compared to the first end portion 326 . The head portion 322 of the shaft 320 is in the form of a cylindrical disk of a larger diameter as compared to the second portion 324 . The head portion 322 of the shaft 320 has a slot 330 that extends transversely, i.e. perpendicularly, to the longitudinal axis of the shaft 320 . The head portion 322 of the shaft 320 has a pair of prongs 332 projecting from the head portion 322 on either side of the slot 330 . The prongs 332 extend from the head portion 322 of the shaft 320 in a direction parallel to the longitudinal axis of the shaft 320 and away from the first end portion 326 and the second portion 324 . The prongs 332 have a plurality of ribs 334 provided on their outer surfaces. In the illustrated example, the ribs 334 are curved and have a saw tooth profile in cross section.
The adaptor 340 is attached to the shaft 320 at the first end portion 326 of the shaft 320 . The adaptor 340 is attached to the first end portion 326 of the shaft 320 such that the adaptor 340 is constrained to rotate with the shaft 320 as a unit. The adaptor 340 is adapted for fixed attachment to the first member, the laptop lid 204 in the illustrated example, so as to move with the first member as a unit. Referring to FIGS. 1-35 and 36 - 41 , the adaptor 340 has a body portion 342 that is rectangular with two rounded corners in plan view. The body portion 342 of the adaptor 340 is provided with a plurality of holes 344 to allow the adapter 340 to be securely fastened to the first member, for example the laptop lid 204 , by screws 346 .
The adaptor 340 has a bore 348 provided on one side of the rectangular body portion 342 . The bore 348 of the adapter 340 is designed to receive the first end portion 326 of the shaft 320 in a press fit or interference fit such that the shaft 320 is securely fastened to the adaptor 340 and the shaft 320 and the adaptor 340 are rotationally coupled to rotate together as a unit. The teeth 328 on the shaft's end portion 326 assist in rotationally coupling the shaft 320 to the adaptor 340 by providing a stronger grip between the internal surface of the bore 348 of the adapter 340 and the exterior surface of the first end portion 326 of the shaft 320 . Thus, the bore 348 of the adapter 340 and the toothed exterior surface of the first end portion 326 of the shaft 320 form the means for securely fastening the shaft 320 to the adaptor 340 and rotationally coupling the shaft 320 and the adaptor 340 together in the illustrated embodiment.
Many other suitable means may also be employed for securely fastening the shaft 320 to the adaptor 340 and rotationally coupling the shaft 320 and the adaptor 340 together. The exterior surface of the first end portion 326 of the shaft 320 may be smooth and inserted into the bore 348 in an interference fit to secure and couple the shaft 320 and the adaptor 340 together. A key cooperating with slots in the shaft 320 and the bore 348 may be used to secure and couple the shaft 320 and the adaptor 340 together. Fasteners extending through the wall of the bore 348 either extending into corresponding holes in the shaft 320 or frictionally engaging the shaft 320 may be used to secure and couple the shaft 320 and the adaptor 340 together. Also, the adaptor 340 may be clamped to the shaft 320 using a clamping arrangement such as by providing a longitudinal slot that extends completely through the wall of the bore 348 and providing one or two flanges adjacent the longitudinal slot with screws that can be tightened to draw the edges of the longitudinal slot together to clamp the adaptor 340 to the shaft 320 .
The hinge base 302 is adapted for fixed attachment to the second member, the laptop base 202 in this example, so as to move with the second member as a unit. The hinge base 302 has at least one bearing surface 304 , 306 that rotationally supports the shaft 320 such that, when the adaptor 340 is attached to the first member and the hinge base 302 is attached to the second member, the first member is rotationally attached to the second member such that the first member can rotationally move relative to the second member between a closed position and an open position. In the illustrated example, the first and second members are the laptop lid 204 and the laptop base 202 , respectively. The bearing surface of the hinge base 302 supports a portion of the second portion 324 of the shaft 320 to provide for rotational support of the shaft 320 by the hinge base 302 .
Referring to FIGS. 1-35 and 63 - 70 , in the illustrated example, the hinge base 302 has two bearing surfaces 304 and 306 . The hinge base 302 has one side 308 that is closest to the adaptor 340 and one side 310 that is farthest from the adaptor 340 . The side 308 has an opening 312 that allows the shaft 320 to extend outward from the hinge base 302 to the adapter 340 . The side 310 has an opening 314 that allows the head portion 322 of the shaft 320 to be at least partially exposed and accessible from the side of the hinge base 302 farthest from the adapter 340 . A curved recess 316 is provided along a portion of the rim of the opening 314 . The recess 316 has end walls 318 and 319 . The hinge base 302 has a flange 301 that has a plurality of holes 303 to allow the hinge base 302 to be securely fastened to the second member, for example the laptop base 202 , by screws 305 .
Referring to FIGS. 1-35 , 63 - 70 , and 77 - 95 , the hinge assembly 300 is provided with a friction mechanism 430 for frictionally resisting rotational motion of the shaft 320 relative to the hinge base 302 . The friction mechanism 430 is supported by the hinge base 302 . The friction mechanism 430 is located between the bearing surfaces 304 and 306 . The friction mechanism 430 includes a plurality of friction elements 440 , a channel insert, and friction mechanism cover 460 . The hinge base 302 has a channel 307 that extends between the bearing surfaces 304 and 306 in a direction parallel to the longitudinal axis of the shaft 320 . The friction elements 440 are of the symmetrical friction clip type and have a C-shaped portion 442 and a stem 444 . The stem 444 projects outward from the outer surface of the C-shaped portion 442 at a location opposite the gap between the tips 446 and 448 of the C-shaped portion 442 . The friction elements 440 engage the portion of the second portion 324 of the shaft 320 that extends between the bearing surfaces 304 and 306 . The inner radius of the C-shaped portion 442 is smaller than the radius of the outer surface of the second portion 324 of the shaft 320 so that the C-shaped portion 442 expands when placed around the second portion 324 of the shaft 320 . The resilience of the C-shaped portion 442 of the friction elements 440 causes the C-shaped portions 442 of the friction elements 440 to exert a gripping force on the second portion 324 of the shaft 320 .
The channel insert 450 fits into the channel 307 . The channel insert 450 is U-shaped in cross section and extends for the length of the channel 307 . The stems 444 of the friction elements 440 are received in the channel insert 450 and consequently in the channel 307 to prevent the friction elements 440 from rotating with the shaft 320 . Thus, the friction elements 440 are prevented from rotating relative to the hinge base 302 . The gripping force exerted by the C-shaped portions 442 of the friction elements 440 on the shaft 320 generates a friction torque that resists rotational motion of the shaft 320 relative to the hinge base 302 . The friction torque generated by the friction elements 440 can be matched to any specified value for a particular application by adjusting the geometry, number and material of the friction elements 440 . The friction mechanism cover 460 is C-shaped in cross section and extends for the length of the gap between the bearing surfaces 304 and 306 . The edges of the friction mechanism cover 460 seal against the outer surfaces of the C-shaped portions 442 of the friction elements 440 and the portions of the hinge base 302 that form the bearing surfaces 304 and 306 . The friction mechanism cover 460 keeps dirt and abrasive particles out of the friction mechanism 430 and keeps lubricant, needed to ensure smooth hinge operation and prevent premature friction element failure, confined to the friction mechanism 430 . The channel insert 450 is made of a relatively harder material compared to the hinge base 302 and acts to distribute forces exerted by the stems of the friction elements 440 evenly on the walls of the channel 307 so that the stems of the friction elements 440 do not dig into and warp the channel 307 .
The end piece 360 is adapted for fixed attachment to the second member, in this example the laptop base 202 , so as to move with the second member as a unit. The end piece 360 has a flange 362 and a socket 364 . The socket 364 has a front opening 366 , a back wall 368 , side edges 370 and 372 , top edge 374 and bottom edge 376 . The front opening 366 is rectangular. The flange 362 of the end piece 360 has a plurality of holes 378 to allow the end piece 360 to be securely fastened to the second member, for example the laptop base 202 , by screws 379 . FIGS. 1-5 show the end piece 360 fastened to the laptop base 202 .
Referring to FIGS. 1-35 and 42 - 62 , the torsion bar spring 380 extends from the end piece 360 to the head portion 322 of the shaft 320 . The torsion bar spring 380 has a first end 382 and a second end 384 . The torsion bar spring 380 is resilient and has a longitudinal axis. The first end 382 of the torsion bar spring 380 is constrained to rotate with the shaft 320 as a unit. The second end 384 of the torsion bar spring 380 is constrained by the end piece 360 so there can be essentially no relative rotation between the end piece 360 and the second end 384 of the torsion bar spring 380 about the longitudinal axis of the torsion bar spring 380 such that rotation of the shaft 320 relative to the end piece 360 causes the torsion bar spring 380 to be twisted about its longitudinal axis when the shaft 320 is initially in a neutral position. The neutral position refers to the position of any part of the hinge assembly 300 that corresponds to the relaxed state of the torsion bar spring 380 . The torsion bar spring 380 stores energy as it is twisted and tends to exert a force to restore the shaft 320 and the adaptor 340 to their neutral positions due to the resilience of the torsion bar spring 380 .
The torsion bar spring 380 is made of a plurality of leaves 390 that are stacked together in superimposed fashion. Each spring leaf 390 is in the form of an elongated rectangular strip having lateral tabs 391 extending from either side at one end of the elongated rectangular strip to form a T-shaped head 392 . As the spring leaves 390 are stacked together they give the first end 382 of the torsion bar spring 380 a “T” shape. The first end 382 of the torsion bar spring 380 is constrained against rotation relative to the head portion 322 of the shaft 320 and the second end 384 of the torsion bar spring 380 is constrained against rotation relative to the end piece 360 such that rotation of the shaft 320 relative to the end piece 360 causes the torsion bar spring 380 to be twisted about its longitudinal axis when the shaft 320 is initially in a neutral position.
The first end 382 of the torsion bar spring 380 is constrained against rotation relative to the head portion 322 of the shaft 320 by a cap 400 . The cap 400 has a rectangular opening 401 with rounded lateral edges 402 and top and bottom edges 403 and 404 , respectively. The cap 400 has two cavities 405 that receive the prongs 332 of the head portion 322 of the shaft 320 to securely fasten the cap 400 to the head portion 322 of the shaft 320 . Each cavity 405 receives a respective one of the prongs 332 . The prongs 332 will be in an interference fit with the cavities 405 . The ribs 334 on the prongs' outer surfaces assist in securely fastening the cap 400 to the head portion 322 of the shaft 320 by providing a stronger grip between the internal surface of the cavities 405 and the exterior surface of the prongs 332 . Thus, the cavities 405 and the prongs 332 form the means for securely fastening the cap 400 to the head portion 322 of the shaft 320 in the illustrated embodiment.
The cap 400 has a rib 406 and two axial lateral projections 407 and 408 . The axial lateral projections 407 and 408 extend in a direction parallel to the longitudinal axis of the shaft 320 from either side of the cap 400 . When the cap 400 is securely fastened to the head portion 322 of the shaft 320 , the axial lateral projections 407 and 408 fit at least in part into the slot 330 of the shaft head portion 322 and close off the ends of the slot 330 . When the cap 400 is securely fastened to the head portion 322 of the shaft 320 , the rib 406 extends at least in part into the recess 316 of the hinge base 302 to limit the rotation of the hinge shaft 320 relative to the hinge base 302 . The rib 406 engages the end wall 319 of the recess 316 to stop the rotation of the hinge shaft 320 and adaptor 340 at a position corresponding to the fully open position of the laptop lid 204 . The rib 406 engages the end wall 318 of the recess 316 to stop the rotation of the hinge shaft 320 and adaptor 340 at a position slightly passed the closed position of the laptop lid 204 . The rib 406 and the recess 316 constitute a safety means for preventing the over stressing of the torsion bar spring 380 that can lead to breakage of the torsion bar spring 380 .
The torsion bar spring 380 extends through the opening 401 of the cap 400 . The rounded lateral edges 402 of the cap 400 are in direct contact with the surfaces 393 of the outermost leaves 390 of the torsion bar spring 380 . The distance between the rounded lateral edges 402 of the opening 401 of the cap 400 is such that the fit of the torsion bar spring 380 between the rounded lateral edges 402 of the opening 401 is very tight or with minimal clearance. Thus, the rounded lateral edges 402 of the opening 401 are responsible for transferring torque between the shaft 320 and the torsion bar spring 380 . Using the rounded lateral edges 402 of the opening 401 for torque transfer between the shaft 320 and the torsion bar spring 380 , places the torque transfer edges 402 at a slight displacement from the T-shaped heads 392 of the spring leaves 390 . This avoids the problem of stress concentration at the joint between the T-shaped heads 392 and the remainder of the rectangular strip body portions of the spring leaves 390 , which can lead to the premature failure of the torsion bar spring 380 . Also, the rounding of the edges 402 of the opening 401 of the cap 400 prevents stress concentration at the edges of the outermost spring leaves 390 , which can also lead to failure of the spring leaves 390 and consequently of the torsion bar spring 380 . The distance between the top edge 407 and the bottom edge 408 of the opening 401 of the cap 400 is such that the T-shaped heads 392 of the leaves 390 cannot pass through the opening 401 , and the T-shaped heads 392 of the leaves 390 are captured between the cap 400 and the shaft head portion 322 . This arrangement constrains the axial movement, i.e. movement in a direction parallel to the longitudinal axis of the shaft 320 , of the T-shaped heads 392 of the leaves 390 .
The ends 394 of the leaves 390 that are farthest from the T-shaped heads 392 are stacked together in superimposed fashion when the torsion bar spring 380 is in a relaxed state, and the ends 394 form the second end 384 of the torsion bar spring 380 . The torsion bar spring 380 extends through the opening 366 of the socket 364 . The lateral edges 370 and 372 of the socket opening 366 are rounded. The rounded lateral edges 370 and 372 of the socket opening 366 are in direct contact with the surfaces 393 of the outermost leaves 390 of the torsion bar spring 380 . The distance between the rounded lateral edges 370 and 372 of the opening 366 of the socket 364 is such that the fit of the torsion bar spring 380 between the rounded lateral edges 370 and 372 of the opening 366 is very tight or with minimal clearance. Thus, the rounded lateral edges 370 and 372 of the opening 366 are responsible for transferring torque between the end piece 360 and the torsion bar spring 380 . Using the rounded lateral edges 370 and 372 of the opening 366 for torque transfer between the end piece 360 and the torsion bar spring 380 , provides for uniform stress distribution over the width of the spring leaves 390 and prevents stress concentration at the edges of the outermost spring leaves 390 . Both of these results enhance the life span of the spring leaves 390 and reduce the chance of the failure of the spring leaves 390 and consequently of the torsion bar spring 380 . The distance between the top edge 374 and the bottom edge 376 of the opening 366 of the socket 364 is such that the top edge 374 and the bottom edge 376 of the opening 366 will not interfere with the movements of the ends 394 of the leaves 390 within the socket 364 .
As the torsion bar spring 380 is twisted about its longitudinal axis to any given amount, the length per degree of twist of the helical path followed by the spring leaves 390 is longer for each leaf 390 the farther away it is from the center of the stack of leaves 390 . Accordingly, the ends 394 of the hinge leaves 390 begin to pull away from the back wall 368 of the socket 364 such that the farther a hinge leaf 390 is from the middle of the stack of leaves the more its end 394 will be pulled away from the back wall 368 . This result is illustrated in FIGS. 19 and 25 . Constraining this axial movement of the ends 394 of the hinge leaves 390 would result in spring leaf breakage. Accordingly, at least one end of each of the plurality of leaves 390 must be free to move axially as the torsion bar spring 380 is twisted. The end 394 of each of the spring leaves 390 must be far enough into the socket opening 366 such that there is no possibility of it being pulled completely out of the socket opening 366 over the entire range of rotation of the shaft 320 .
It is possible to provide a mirror image of the socket 364 in the shaft head portion 322 in place of the cap 400 . In such an arrangement there would be no need for the spring leaves to have T-shaped heads; the spring leaves would simply be in the form of rectangular strips. No axial constraint would be applied to either end of the torsion bar spring, except that in the relaxed state all the spring leaves would be captive between the back walls of the socket in the end piece 360 and the socket in the shaft head portion 322 .
As the torsion bar spring 380 is twisted, the leaf ends 394 on one side of the middle of the stack tend to move up or down toward either the top edge 374 or the bottom edge 376 depending upon and in the direction of rotation of the shaft 320 , and the leaf ends 394 on the other side of the middle of the stack tend to move in the opposite direction but still in the same direction as the direction of rotation of the shaft 320 . These movements must also be accommodated to avoid overstressing the spring leaves 390 , which again could lead to spring leaf failure. Therefore, as was previously mentioned, the distance between the top edge 374 and the bottom edge 376 of the opening 366 of the socket 364 is such that the top edge 374 and the bottom edge 376 of the opening 366 will not interfere with the movements of the ends 394 of the leaves 390 within the socket 364 .
The torsion bar cover 420 fits over the exposed portion of the torsion bar spring 380 between the end piece 360 and the hinge base 302 . The torsion bar cover 420 is tubular with openings at both ends. The torsion bar cover 420 acts as a grease or lubricant container and does not restrict any of the movements and deflections of the spring leaves 390 , but provides for lubrication of the individual spring leaves. The openings 422 and 424 at the ends of the torsion bar cover 420 seal against the hinge base 302 and the end piece 360 , respectively. The torsion bar cover 420 provides continuous lubrication between the spring leaves 390 to ensure that the spring leaves can slide against one another as necessary to prevent overstressing and damage to the spring leaves. The torsion bar cover 420 has alignment feature on one side in the form of a rectangular or square opening 424 to assist in the assembly process of the torsion bar spring 380 . It is possible for both openings 422 and 424 to be circular or any other shape large enough not to interfere with the twisting of the torsion bar spring 380 .
With the hinge assembly 300 and its mirror image hinge assembly 500 installed in a laptop as shown, the neutral position of the adaptor 340 and of the laptop lid 204 , which correspond to the relaxed state of the torsion bar spring 380 , is between the fully open position of the laptop lid and the fully closed position of the laptop lid. In the illustrated example, the neutral position of the laptop lid is 32° from the fully open position and 85° from the closed position. The operation of the hinge assembly 300 will be described with the laptop lid initially in the neutral position. To close the laptop lid 204 , enough force must initially be applied to overcome the friction torque due to the friction mechanism 430 . As the laptop lid 204 rotates toward the closed position, the hinge shaft 320 is rotated causing the torsion bar spring 380 to be twisted. As the torsion bar spring 380 is twisted the force needed to continue the closing of the laptop lid 204 increases due to the resilience of the torsion bar spring 380 , however, because it is mechanically advantageous for a user to push down than to pull up, due to the action of gravity on the lid and by bringing his or her body weight into play if necessary, this is not a disadvantage. Also, as the torsion bar spring 380 is twisted energy is stored in the deformation of the torsion bar spring 380 . When the laptop lid 204 is in the closed position, a latch (not shown) releasably secures the laptop lid 204 in the closed position. To open the laptop lid a user operates the latch to release the laptop lid 204 for rotation to the open position. The laptop lid 204 automatically moves away from the closed position, without any effort from the user, as the torque exerted by the torsion bar spring 380 overcomes the frictional resistance or torque of the friction mechanism 430 until a point is reached, which is intermediate the neutral position and the closed position, where the torque exerted by the torsion bar spring 380 has dropped to equal the friction torque of the friction mechanism 430 . At that point the laptop lid 204 stops moving, and the user can comfortably move the laptop lid 204 manually to any desired position between that point and the fully open position of the laptop lid 204 to suit his or her needs. Even though there will be some deformation of the torsion bar spring 380 at any position away from the neutral position, within the range of positions corresponding to the normal usage range of the laptop screen 206 the friction torque of the friction mechanism 430 will hold the laptop screen in the desired position.
The material used for the spring leaves 390 is steel such as stainless steel or spring steel or any steel with a spring steel temper. The shaft 320 is also made of steel. The end piece 360 , the adapter 340 , and the hinge base 302 can be made of a die cast metal such as aluminum or zinc or of a high impact plastic. For lower torque applications the spring leaves 390 can be made of a composite or a polymer material as long as it has the requisite elasticity.
Referring to FIGS. 103-194 , a second illustrative embodiment of the hinge assembly 600 , 800 in accordance with the present invention can be seen. Each of the hinge assemblies 600 , 800 provides for rotationally attaching a first member to a second member to allow rotational movement of the first member relative to the second member between a closed position and an open position. Referring to FIGS. 103-105 , two hinge assemblies 600 and 800 made in accordance with the present invention are shown being used to rotationally attach the lid 204 a of a laptop computer 200 a to the base 202 a of the laptop computer 200 a . The laptop lid 204 a typically houses the laptop screen 206 a and its angular position relative to the laptop base 202 a should be adjustable within a range of angular positions suitable for people of a variety of sizes to properly view the laptop screen 206 a.
The hinge assembly 600 is a left hinge assembly and the hinge assembly 800 is a right hinge assembly. The right hinge assembly 800 is a mirror image of the hinge assembly 600 about a plane perpendicular to longitudinal axes of the shafts of each of the hinge assemblies and positioned halfway between the two hinge assemblies. Accordingly, only the hinge assembly 600 is described in detail. The laptop lid 204 a typically is releasably secured in the closed position relative to the laptop base 202 a by a latch (not shown) of some sort. The latch can be operated by a user to release or free the laptop lid 204 a for rotational movement to the open position relative to the laptop base 202 a.
The hinge assembly 600 can be used to rotationally attach a first member to a second member to allow rotational movement of the first member relative to the second member between a closed position and an open position. In the illustrated example, the first member is the laptop base 202 a and the second member is the laptop lid 204 a . The hinge assembly 600 includes an elongated shaft 620 , an adaptor 640 , a hinge base 602 , a friction mechanism 730 , an end piece 660 , a torsion bar spring 680 , a first cap 700 , and a shell 677 .
Referring to FIGS. 103-132 and 171 - 178 , the elongated shaft 620 has at least a first end portion 626 , a second or intermediate portion 624 and a second end portion 622 . The first end portion 626 of the shaft 620 is provided with a plurality of elongated teeth 628 of triangular cross section evenly distributed about the circumference of the first end portion 626 of the shaft 620 . Each of the plurality of elongated teeth 628 extends for at least the majority of the length of the first end portion 626 of the shaft 620 . The teeth 628 are also known in the art as splines. In the illustrated example, the second or intermediate portion 624 of the shaft 620 is of larger diameter compared to the first end portion 626 . The second end portion 622 of the shaft 620 is also provided with a plurality of teeth or splines 623 that are similar in configuration to the teeth 628 . The intermediate portion 624 of the shaft 620 is of a larger diameter as compared to the second end portion 622 . The second end portion 622 of the shaft 620 is inserted into a bore 625 of the first cap 700 to fix the first cap 700 to the second end portion 622 of the shaft 620 such that there can be no relative movement between the second end portion 622 of the shaft 620 and the first cap 700 . The teeth 623 on the shaft's second end portion 622 assist in rotationally coupling the shaft 620 to the first cap 700 by providing a stronger grip between the internal surface of the bore 625 of the first cap 700 and the exterior surface of the second end portion 622 of the shaft 620 . This is due to the teeth 623 providing a more positive grip between the internal surface of the bore 625 of the first cap 700 and the exterior surface of the second end portion 622 of the shaft 620 when the second end portion 622 of the shaft 620 is press fitted to the bore 625 of the first cap 700 . Thus, the bore 625 of the first cap 700 and the toothed exterior surface of the second end portion 622 of the shaft 620 form the means for securely fastening the shaft 620 to the first cap 700 and rotationally coupling the shaft 620 and the first cap 700 together in the illustrated embodiment. (See also FIGS. 143-150 )
The first cap 700 also has a front opening 630 that has side edges 632 and 634 , top edge 633 and bottom edge 635 . The front opening 630 is rectangular.
The adaptor 640 is attached to the shaft 620 at the first end portion 626 of the shaft 620 . The adaptor 640 is attached to the first end portion 626 of the shaft 620 such that the adaptor 640 is constrained to rotate with the shaft 620 as a unit. The adaptor 640 is adapted for fixed attachment to the first member, the laptop base 202 a in the illustrated example, so as to move with the first member as a unit. Referring to FIGS. 103-135 and 136 - 142 , the adaptor 640 has a body portion 642 that is provided with a plurality of holes 644 to allow the adapter 640 to be securely fastened to the first member, for example the laptop base 202 a , by screws 646 .
The adaptor 640 has a bore 648 provided on one side of the body portion 642 . The bore 648 of the adapter 640 is designed to receive the first end portion 626 of the shaft 620 in a press fit or interference fit such that the shaft 620 is securely fastened to the adaptor 640 and the shaft 620 and the adaptor 640 are rotationally coupled to rotate together as a unit. The teeth 628 on the shaft's first end portion 626 assist in rotationally coupling the shaft 620 to the adaptor 640 by providing a stronger grip between the internal surface of the bore 648 of the adapter 640 and the exterior surface of the first end portion 626 of the shaft 620 . Thus, the bore 648 of the adapter 640 and the toothed exterior surface of the first end portion 626 of the shaft 620 form the means for securely fastening the shaft 620 to the adaptor 640 and rotationally coupling the shaft 620 and the adaptor 640 together in the illustrated embodiment.
Many other suitable means may also be employed for securely fastening the shaft 620 to the adaptor 640 and the first cap 700 and rotationally coupling the shaft 620 to the adaptor 640 and to the first cap 700 . These include the same means enumerated for the attachment of the shaft 320 to the adaptor 340 . Of course, means where the bores 648 , 625 , and 348 have teeth that mate with the teeth 628 , 623 , and 328 , respectively, is part of this list.
The hinge base 602 is adapted for fixed attachment to the second member, the laptop lid 204 a in this example, so as to move with the second member as a unit. The hinge base 602 has at least one bearing surface 604 , 606 that rotationally supports the shaft 620 such that, when the adaptor 640 is attached to the first member and the hinge base 602 is attached to the second member, the first member is rotationally attached to the second member such that the first member can rotationally move relative to the second member between a closed position and an open position. In the illustrated example, the first and second members are the laptop base 202 a and the laptop lid 204 a , respectively. The bearing surface of the hinge base 602 supports a portion of the second or intermediate portion 624 of the shaft 620 to provide for rotational support of the shaft 620 by the hinge base 602 .
Referring to FIGS. 103-135 and 163 - 170 , in the illustrated example, the hinge base 602 has two bearing surfaces 604 and 606 . The hinge base 602 has one side 608 that is closest to the adaptor 640 and one side 610 that is farthest from the adaptor 640 . The side 608 has an opening 612 that allows the shaft 620 to extend outward from the hinge base 602 to the adapter 640 . The side 610 has an opening 614 that allows the shaft 620 to extend outward from the hinge base 602 toward the torsion bar spring 680 where it can engage the first cap 700 . A stop projection 616 is provided along a portion of the rim of the opening 612 . The stop projection 616 has end walls 618 and 619 . The hinge base 602 has a flange 601 that has a plurality of holes 603 to allow the hinge base 602 to be securely fastened to the second member, for example the laptop lid 204 a , by screws 605 .
Referring to FIGS. 103-135 and 163 - 170 , the hinge assembly 600 is provided with a friction mechanism 730 for frictionally resisting rotational motion of the shaft 620 relative to the hinge base 602 . In this example, the friction mechanism 730 is integrated into the material of the hinge base 602 . The friction mechanism 730 is formed by at least one band 740 , 742 that is attached at one end to the flange 601 . The band 740 , 742 wraps around at least part of the intermediate portion 624 of the shaft 620 and the band 740 , 742 terminates in a free end that is spaced apart from the band's attachment to the flange 601 to define a C-shaped profile for the band 740 , 742 . In the illustrated example, two bands 740 and 742 are provided that wrap around the intermediate portion 624 of the shaft 620 in opposite directions. The bands 740 and 742 define the bearing surfaces 604 and 606 , respectively. The bands 740 and 742 also define the friction elements of the friction mechanism 730 by frictionally gripping the intermediate portion 624 of the shaft 620 to provide a friction torque that acts as a resistance to relative rotation between the shaft 620 and the hinge base 602 . The inner radius of the C-shaped bands 740 and 742 is originally smaller than the radius of the outer surface of the second portion 624 of the shaft 620 so that each of the C-shaped bands 740 and 742 expands when placed around the second portion 624 of the shaft 620 . The resilience of the C-shaped bands 740 and 742 causes the C-shaped bands 740 and 742 to exert a gripping force on the second portion 624 of the shaft 620 .
Because the friction elements 740 , 742 are attached at one end to the flange 601 , the friction elements 740 , 742 are prevented from rotating relative to the hinge base 602 . The gripping force exerted by the C-shaped bands or friction elements 740 , 742 on the shaft 620 generates a friction torque that resists rotational motion of the shaft 620 relative to the hinge base 602 . The friction torque generated by the friction elements 740 , 742 can be matched to any specified value for a particular application by changing the geometry, number and material of the friction elements 740 , 742 .
The end piece 660 , also referred to as the second cap, must be held in a fixed relationship relative to the second member, in this example the laptop lid 204 a , in order for the torsion bar spring 680 to generate the spring torque for the proper operation of the hinge assembly 600 . In hinge assembly 600 the end piece 660 is fixed relative to the second member by being fixed to the hinge base 602 , which is then mounted to the second member, rather than being directly mounted to the second member as in the case of the end piece 360 of the hinge assembly 300 . Accordingly, once the hinge base 602 is mounted to the second member, the end piece 660 becomes fixed relative to the second member such that the end piece 660 moves with the second member as a unit. The end piece 660 has two lateral projections 662 and a socket 664 . The socket 664 has a front opening 667 , a back wall 668 , side edges 670 and 672 , top edge 674 and bottom edge 676 . The front opening 667 is rectangular. The projections 662 of the end piece 660 engage and fit into respective notches 675 provided in one end of the outer shell 677 in order to prevent relative rotation between the end piece 660 and the shell 677 . The shell 677 is in turn fixed to the hinge base 602 in order to rotationally fix the end piece 660 to the hinge base 602 . The shell 677 is cylindrical and encases the torsion bar spring 680 . The end piece 660 is axially held in place at the end of the shell 677 distal from the hinge base 602 by friction fit to the bore of the shell 677 , by adhesives, by pins or other fasteners, or by any other suitable means. The shell 677 has one or more flanges 673 that register with a portion of the hinge base flange 601 . Two flanges 673 are provided in the illustrated example that straddle a portion of the hinge base flange 601 . Each flange 673 is provided with one or more holes 678 that register with one or more corresponding holes 681 in the hinge base flange 601 to allow the shell 677 , and in turn the end piece 660 , to be securely fastened to the hinge base 602 by, for example, the rivets 679 .
Referring to FIGS. 103-135 and 159 - 162 , the torsion bar spring 680 extends from the end piece 660 to the first end cap 700 on the shaft 620 . The torsion bar spring 680 has a first end 682 and a second end 684 . The torsion bar spring 680 is resilient and has a longitudinal axis. The first end 682 of the torsion bar spring 680 is constrained to rotate with the shaft 620 so there can be essentially no relative rotation between the shaft 620 and the first end 682 of the torsion bar spring 680 about the longitudinal axis of the torsion bar spring 680 . The second end 684 of the torsion bar spring 680 is constrained by the end piece 660 so there can be essentially no relative rotation between the end piece 660 and the second end 684 of the torsion bar spring 680 about the longitudinal axis of the torsion bar spring 680 such that rotation of the shaft 620 relative to the end piece 660 causes the torsion bar spring 680 to be twisted about its longitudinal axis when the shaft 620 is initially in a neutral position. The neutral position refers to the position of any part of the hinge assembly 600 that corresponds to the relaxed state of the torsion bar spring 680 . The torsion bar spring 680 stores energy as it is twisted and tends to exert a force to restore the shaft 620 and the adaptor 640 to their neutral positions due to the resilience of the torsion bar spring 680 .
The torsion bar spring 680 is made of a plurality of leaves 690 that are stacked together in superimposed fashion. Each spring leaf 690 is in the form of an elongated rectangular strip. The first end 682 of the torsion bar spring 680 is constrained against rotation relative to the second end portion 622 of the shaft 620 and the second end 684 of the torsion bar spring 680 is constrained against rotation relative to the end piece 660 such that rotation of the shaft 620 relative to the end piece 660 causes the torsion bar spring 680 to be twisted about its longitudinal axis when the shaft 620 is initially in a neutral position.
A lug 706 is provided on the shaft 620 . When the hinge assembly 600 is fully assembled, the lug 706 is positioned to contact the stop projection 616 of the hinge base 602 to limit the rotation of the hinge shaft 620 relative to the hinge base 602 . The lug 706 engages the end wall 619 of the stop projection 616 to stop the rotation of the hinge shaft 620 and adaptor 640 at a position corresponding to the fully open position of the laptop lid 204 a . The lug 706 engages the end wall 618 of the stop projection 616 to stop the rotation of the hinge shaft 620 and adaptor 640 at a position slightly passed the closed position of the laptop lid 204 a . The lug 706 and the stop projection 616 constitute a safety means for preventing the over stressing of the torsion bar spring 680 that can lead to breakage of the torsion bar spring 680 .
The first ends 692 of the leaves 690 that are farthest from the end piece 660 are stacked together in superimposed fashion when the torsion bar spring 680 is in a relaxed state. The first ends 692 of the leaves 690 form the first end 682 of the torsion bar spring 680 . The ends 694 of the leaves 690 that are farthest from the first cap 700 are stacked together in superimposed fashion when the torsion bar spring 680 is in a relaxed state, and the second ends 694 form the second end 684 of the torsion bar spring 680 . The torsion bar spring 680 extends through the opening 667 of the socket 664 of the end piece 660 . The lateral edges 670 and 672 of the socket opening 667 are rounded. The rounded lateral edges 370 and 372 of the socket opening 667 are in direct contact with the surfaces 693 of the outermost leaves 690 of the torsion bar spring 680 . The distance between the rounded lateral edges 670 and 672 of the opening 667 of the socket of the end piece 660 is such that the fit of the torsion bar spring 680 between the rounded lateral edges 670 and 672 of the opening 667 is very tight or with minimal clearance. Thus, the rounded lateral edges 670 and 672 of the opening 667 are responsible for transferring torque between the end piece 660 and the torsion bar spring 680 . Using the rounded lateral edges 670 and 672 of the opening 667 for torque transfer between the end piece 660 and the torsion bar spring 680 , provides for uniform stress distribution over the width of the spring leaves 690 and prevents stress concentration at the edges of the outermost spring leaves 690 . Both of these results enhance the life span of the spring leaves 690 and reduce the chance of failure of the spring leaves 690 and consequently of the torsion bar spring 680 . The distance between the top edge 674 and the bottom edge 676 of the opening 667 of the socket of the end piece 660 is such that the top edge 674 and the bottom edge 676 of the opening 667 will not interfere with the movements of the ends 694 of the leaves 690 within the socket 664 .
As the torsion bar spring 680 is twisted about its longitudinal axis to any given amount, the length per degree of twist of the helical path followed by the spring leaves 690 is longer for each leaf 690 the farther away it is from the center of the stack of leaves 690 . Accordingly, the ends 694 of the hinge leaves 690 begin to pull away from the back wall 668 of the socket 664 such that the farther a hinge leaf 690 is from the middle of the stack of leaves the more its end 694 will be pulled away from the back wall 668 . This result is illustrated in FIGS. 119-121 . Constraining this axial movement of the ends 694 of the hinge leaves 690 would result in spring leaf breakage. Accordingly, at least one end of each of the plurality of leaves 690 must be free to move axially as the torsion bar spring 680 is twisted. The end 694 of each of the spring leaves 690 must be far enough into the socket opening 667 such that there is no possibility of it being pulled completely out of the socket opening 667 over the entire range of rotation of the shaft 620 .
The opening 630 in the end cap 700 is a mirror image of the socket opening 667 . The torsion bar spring 680 extends through the opening 630 of the first cap 700 . The lateral edges 632 and 634 of the opening 630 are rounded. The rounded lateral edges 632 and 634 of the opening 630 are in direct contact with the surfaces 693 of the outermost leaves 690 of the torsion bar spring 680 . The distance between the rounded lateral edges 632 and 634 of the opening 630 of the end cap 700 is such that the fit of the torsion bar spring 680 between the rounded lateral edges 632 and 634 of the opening 630 is very tight or with minimal clearance. Thus, the rounded lateral edges 632 and 634 of the opening 630 are responsible for transferring torque between the end cap 700 and the torsion bar spring 680 . Using the rounded lateral edges 632 and 634 of the opening 630 for torque transfer between the end cap 700 and the torsion bar spring 680 , provides for uniform stress distribution over the width of the spring leaves 690 and prevents stress concentration at the edges of the outermost spring leaves 690 . Both of these results enhance the life span of the spring leaves 690 and reduce the chance of failure of the spring leaves 690 and consequently of the torsion bar spring 680 . The distance between the top edge 633 and the bottom edge 635 of the opening 630 of the end cap 700 is such that the top edge 633 and the bottom edge 635 of the opening 630 will not interfere with the movements of the ends 692 of the leaves 690 within the socket formed by the first cap 700 and the shaft's second end portion 622 .
As the torsion bar spring 680 is twisted about its longitudinal axis to any given amount, the length per degree of twist of the helical path followed by the spring leaves 690 is longer for each leaf 690 the farther away it is from the center of the stack of leaves 690 . Accordingly, the ends 692 of the hinge leaves 690 begin to pull away from the shaft's second end portion 622 such that the farther a hinge leaf 690 is from the middle of the stack of leaves the more its end 692 will be pulled away from the shaft's second end portion 622 . This result is illustrated in FIGS. 119-121 . Thus, in the embodiment 600 , both ends of each of the plurality of leaves 690 are free to move axially as the torsion bar spring 680 is twisted. The end 692 of each of the spring leaves 690 must be far enough into the opening 630 such that there is no possibility of it being pulled completely out of the opening 630 over the entire range of rotation of the shaft 620 . All the spring leaves 690 are captivated between the back wall of the socket in the end piece 660 and the socket formed by the first cap 700 and the shaft's second end portion 622 .
As the torsion bar spring 680 is twisted, the leaf ends 694 on one side of the middle of the stack tend to move up or down toward either the top edge 674 or the bottom edge 676 depending upon and in the direction of rotation of the shaft 620 , and the leaf ends 694 on the other side of the middle of the stack tend to move in the opposite direction but still in the same direction as the direction of rotation of the shaft 620 . These movements must also be accommodated to avoid overstressing the spring leaves 690 , which again could lead to premature spring leaf failure. Therefore, as was previously mentioned, the distance between the top edge 674 and the bottom edge 676 of the opening 667 of the socket 664 is such that the top edge 674 and the bottom edge 676 of the opening 667 will not interfere with the movements of the ends 694 of the leaves 690 within the socket 664 . The situation is the same for the ends 692 of the spring leaves 690 .
The two inner sleeves 720 , 721 fit over the portion of the torsion bar spring 680 between the end piece 660 and the first cap 700 inside the shell 677 . The two inner sleeves 720 , 721 are tubular with openings at both ends. The two inner sleeves 720 , 721 act as grease or lubricant containers and do not restrict any of the movements and deflections of the spring leaves 690 , but provide for lubrication of the individual spring leaves. The openings 722 at one end of each of the inner sleeves 720 , 721 seal against the first cap 700 and the end piece 660 , respectively. The openings 724 of the inner sleeves 720 , 721 seal against one another. The inner sleeves 720 , 721 provide continuous lubrication between the spring leaves 690 to ensure that the spring leaves can slide against one another as necessary to prevent overstressing and damage to the spring leaves. The openings 722 at one end of each of the inner sleeves 720 , 721 are in the form of rectangular openings to serve as alignment feature on one side to assist in the assembly process of the torsion bar spring 680 . The two inner sleeves 720 and 721 also provide bearing support to the outer shell 677 .
With the hinge assembly 600 and its mirror image hinge assembly 800 installed in a laptop as shown, the neutral position of the hinge base 602 and of the laptop lid 204 a , which correspond to the relaxed state of the torsion bar spring 680 , is between the fully open position of the laptop lid and the fully closed position of the laptop lid. In the illustrated example, the neutral position of the laptop lid is 32° from the fully open position and 85° from the closed position. The operation of the hinge assembly 600 will be described with the laptop lid initially in the neutral position. To close the laptop lid 204 a , enough force must initially be applied to overcome the friction torque due to the friction mechanism 730 . As the laptop lid 204 a rotates toward the closed position, the end piece 660 is rotated causing the torsion bar spring 680 to be twisted. As the torsion bar spring 680 is twisted the force needed to continue the closing of the laptop lid 204 a increases due to the resilience of the torsion bar spring 680 , however, because it is mechanically advantageous for a user to push down than to pull up, due to the action of gravity on the lid and by bringing his or her body weight into play if necessary, this is not a disadvantage. Also, as the torsion bar spring 680 is twisted energy is stored in the deformation of the torsion bar spring 680 . When the laptop lid 204 a is in the closed position, a latch (not shown) releasably secures the laptop lid 204 a in the closed position. To open the laptop lid a user operates the latch to release the laptop lid 204 a for rotation to the open position. The laptop lid 204 a automatically moves away from the closed position, without any effort from the user, as the torque exerted by the torsion bar spring 680 overcomes the frictional resistance or torque of the friction mechanism 730 until a point is reached, which is intermediate the neutral position and the closed position, where the torque exerted by the torsion bar spring 680 has dropped to equal the friction torque of the friction mechanism 730 . At that point the laptop lid 204 a stops moving, and the user can comfortably move the laptop lid 204 a manually to any desired position between that point and the fully open position of the laptop lid 204 a to suit his or her needs. Even though there will be some deformation of the torsion bar spring 380 at any position away from the neutral position, within the range of positions corresponding to the normal usage range of the laptop screen 206 a the friction torque of the friction mechanism 730 will hold the laptop screen in the desired position.
It is possible to interchange the friction mechanisms 730 and 430 and to interchange the structures for rotationally coupling the torsion bar springs 680 , 380 to the hinge shafts 620 , 320 between the two disclosed embodiments 300 and 600 . Such permutations of the disclosed embodiments are within the scope of the invention.
The preferred material used for the spring leaves 690 is steel such as stainless steel or spring steel or any steel with a spring steel temper. The hinge base 602 is preferably also made of a resilient steel. The shaft 620 is also made of steel. The end piece or second cap 660 and the adapter 640 can be made of a die cast metal such as aluminum or zinc or of a high impact plastic. For lower torque applications the spring leaves 690 can be made of a composite or a polymer material as long as it has the requisite elasticity.
Although the hinge assemblies 300 and 600 have been illustrated in the context of a laptop computer, the counterbalancing function provided by the torsion bar springs 380 , 680 can be used to allow friction hinges to be used in heavier applications, where friction torque alone would cause the operating efforts to be objectionably high, or beyond the limits of normal human factors. The laminated design of the torsion bar spring allows the counterbalancing function to be achieved in a compact space, and with relatively low cost. The hinge assemblies 300 , 600 or a similar hinge assembly employing the laminated torsion bar design could be used in other applications where gas springs are typically used, such as toolbox lids, storage bins, baggage doors, deck hatches, and vehicle lift gates.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | A friction hinge assembly includes a spring that assists the opening of a first member relative to a second member by storing energy in the spring during the closing operation. The spring is of a unique multilayered torsion bar design. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improvement in chlorination stage bleaching in the process of chemical delignification of wood chips. More particularly, this invention relates to washing unbleached softwood pulp with alcohol which results in diminished production of chlorinated dioxins and furans during subsequent chlorination and alkaline extraction stages. The alcohol of choice is a mono-hydric alcohol such as methanol, ethanol, propanol, isopropanol, or octanol. The preferred alcohol is ethanol.
2. Description of the Prior Art
Four ingredients are necessary to make paper: (1) raw materials--such as wood from the forest; (2) energy--from coal, oil, gas, or wood by-products, e.g., bark or wastes from the paper making process itself; (3) water, much of which is used as a conveyer belt to transport material along the process and is recirculated, but some of which is discharged to the atmosphere as vapor from driers or as liquid after purification in a waste treatment plant; and (4) skilled operators and management.
Not all pulps are produced chemically. "Groundwood" or "mechanical pulp," as the names imply, is produced by grinding a log of wood against abrasive stone surfaces or between rotating steel discs with cutting bars against their faces to yield fibers and fragmented fiber bundles. Such pulp is used in newsprint and similar paper where high opacity and good printability are desirable properties but where mechanical strength is not a prime requirement.
Chemical pulping begins with cutting the wood into chips. The chips are screened, rejects being both oversize slivers or undersize fines, and are taken to the top of a "digester" or a high pressure cooking vessel. Chemicals are added and the reaction is allowed some time under a prescribed program of temperatures, for the lignin of the wood and some hemicelluloses to be dissolved and extracted from the chips. Then the cooked material is discharged discontinuously in a batch process or continuously into a blow-tank where steam and other volatiles are flashed off. The cooking liquor--which is now a "black liquor" because of the dissolved lignin--is passed on to a chemical recovery cycle.
The pulp is washed with water to remove black liquor on, for example, a series of wire covered rotating drums. The washed brown stock is screened, diluted, and may be passed on to arrays of centrifugal cyclonic cleaners to separate large and heavy "dirt"--e.g., silica or metal particles--before bleaching. Since the screening operation and cyclone cleaners are only efficient with dilute suspensions, while bleaching requires higher consistencies for economical reasons, the stock is "thickened" by extracting some of its water, using wire covered, perforated drums on which the stock is made to form a mat.
The thick brown stock is next subjected to a series of bleaching operations. These can vary widely both in the types of chemicals used and their sequences.
In a favored system called CEDED, (Chlorine-Extraction-chlorine Dioxide-Extraction-chlorine Dioxide) the pulp is first delignified with chlorine gas, then extracted with sodium hydroxide and finally bleached with chlorine dioxide. As is well known in the art, this first chlorination stage of bleaching often involves various combinations of chlorine and chlorine dioxide. Chlorine dioxide attacks lignin specifically to a far greater extent than it attacks cellulose--unlike chlorine which is a more indiscriminate oxidant--but it is more expensive. Thus, it is preferably used for the final steps. After the final bleaching, the bright stock is washed to leave the pulp mill and enter the paper mill.
Much concern has been expressed about the environmental effects of chlorinated compounds formed by bleaching chemical pulp. Although investigations are incomplete and debate continues as to whether these compounds represent any true risk to the environment, special attention has been given chlorinated dibenzo-p-dioxins and dibenzofurans. Results, previously obtained by analyzing sediments sampled outside a pulp mill, suggest that there exists a very close correlation between these groups of compounds as reported at the 7th International Symposium on Chlorinated Dioxins and Related Compounds (Dioxin '87) in Las Vegas, Nev. Studies have indicated that 2,3,7,8-tetrachlorodibenzofuran (2378-TCDF) can be used as an indicator of the presence of 2,3,7,8-tetrachlorodibenzodioxin (2378-TCDD), the corresponding chlorinated dioxin isomer, at lower levels.
Practical means for preventing or reducing formation of these and related compounds are being sought in laboratory and mill studies. Certain approaches, such as oxygen delignification or high substitution of chlorine dioxide for chlorine in the chlorination stage, involve great expense, both in terms of capital equipment and processing costs. In addition to cost, significant time is required to implement these options. Some inexpensive, shorter term solution is desired.
The prior art approaches to the reduction of TCDD/F levels have focused primarily on modification of the chlorination stage of bleaching. Swedish researchers, for example, have claimed that TCDD/F levels are exponentially related to the "chlorine multiple" or "Kappa factor"--actually saying that the critical factor is the amount of chlorine applied to a certain amount of lignin ("The Influence of Lignin Content and Bleaching Chemicals on the Formation of Chlorinated Dioxins, Dibenzofurans and Phenolics" by Axegard et al. and "Influence of Oxygen Pretreatment and Chlorine Ratio on the Formation of PCDDs and PCDFs in Pulp Bleaching" by Swanson et al., presented at the Dioxin '88 Conference in Umea, Sweden.). On the other hand, co-pending U.S. patent application Ser. No. 262,534 reports the discovery that the amount of chlorine actually may remain at conventional levels as long as the concentration of chlorine does not exceed a definite level at any time during the chlorination bleaching stage, as a method for controlling formation of these undesirable compounds.
Washing the pulp after chlorination with excess water lowered the levels of 2378-TCDD and 2378-TCDF in the subsequent E-stage by only 5-10%. This suggests that the potential is low for removing chlorinated dioxins and furans from bleached pulp by improved bleach plant washing.
SUMMARY OF THE INVENTION
It has been discovered that washing unbleached softwood pulp with aqueous alcohol decreases the amount of chlorinated dioxins and furans formed during subsequent chlorination and alkaline extraction stages by 80%, or higher, as compared to a control representing the prior art method which omits such pre-chlorination washing step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bar graph depiction of the relative quantities of 2378-TCDD formation in parts per trillion during the chlorination and extraction bleaching stages of pulping unbleached, screened, softwood pulp washed with ethanol as compared to bleaching the pulp "as is" from the paper mill.
FIG. 2 is a bar graph depiction of the relative quantities of 2378-TCDF formation in parts per trillion during the chlorination and extraction bleaching stages of pulping unbleached, screened, softwood pulp washed with ethanol as compared to bleaching the pulp "as is" from the paper mill.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Unbleached, screened softwood pulp was collected from a mill. The Kappa number was determined using TAPPI Useful Method T236 os-76. An aliquot of the pulp was bleached through the chlorination and extraction stages with no additional prewashing or processing. Another aliquot was extensively washed with water, and aqueous and absolute ethanol before bleaching. A Kappa factor (defined as KF=[% Cl 2 +(% ClO 2 ×2.63)]/Kappa number) of 0.30 was used in all chlorinations with 10% substitution of ClO 2 , added 15 seconds after Cl 2 -water. The unbleached pulp Kappa number did not change significantly after ethanol washing as compared to the original pulp. After chlorination the pulp slurry was simply thickened with no additional washing to maximize TCDD/F concentrations in the pulp. High chlorine charges were used to ensure formation of measurable levels of TCDD/Fs.
Example
Replicate experiments were conducted according to the following procedures:
Alcohol Washing. The desired quantity (200 grams) of unbleached softwood pulp was slurried in water at 1% consistency and stirred mechanically for ten minutes. The slurry was filtered using a 300 mesh screen in a large Buchner funnel. (Contact with plastics and paper were avoided--all glassware was rinsed before use with absolute ethanol). The "first pass" filtrate was poured back through the formed pad of pulp to retain fines and fibers. As much filtrate was removed as possible using aspirator vacuum.
The pulp was then washed (without disrupting the pad) with a volume of 50% aqueous ethanol equivalent to three times the estimated water content of the pad. The ethanol was added without vacuum on the Buchner funnel, allowed to sit one minute, and then pulled through the pad by suction. No fines loss was noted by visual inspection of the lightly colored filtrate. This washing was repeated with warm (45° C.) absolute (200 proof) ethanol, then again with 50% aqueous ethanol, and finally with portions of hot deionized water until the ethanol odor in the pulp was not detectable.
The pad was mixed in a Hobart mixer. Pulp Kappa number was found to be unchanged as compared to the unwashed sample. Yield was near 96% after ethanol washing.
The effect of ethanol washing on removal of DBD and DBF from the first experiment is shown in Table I, which indicates that ethanol washing is more effective in removing DBD from unbleached pulp (180 to 7.2 ppt) as compared to removal of DBF (5600 to 1540 ppt).
TABLE I______________________________________Effect of Ethanol Washing onRemoval of Dibenzo-p-Dioxin (DBD)and Dibenzofuran (DBF) fromSoftwood Brownstock PulpSample DBD DBFDescription (ppt) (ppt)______________________________________Control (as is)Unbleached pulp 189 5600C-Stage pulp 60 4590E-Stage pulp 22 2700EtOH WashedUnbleached pulp 7.2 1540C-Stage pulp 4.5 3940E-Stage pulp 8.9 2320______________________________________
Chlorination Stage. Seventy-gram batches (oven dried basis) of pulp at 3% consistency were chlorinated in a two-liter continuously stirred reactor. Chlorination temperature was 50° C., retention time one hour in each case. All were conducted at 10% substitution of ClO 2 , added 15 seconds after injection of chlorine water. Residual active chlorine in the filtrate was determined following the reaction. Chlorinated K-numbers (25 ml) were determined as well. See Table II for additional experimental details.
TABLE II______________________________________Experimental Conditions Experiment 1 Experiment 2 Un- EtOH Un- EtOH washed Washed washed Washed______________________________________Before ChlorinationKappa Number 26.4 26.4 26.4 26.4Viscosity (cp) 27.1 27.3 27.1 27.3Chlorination% Solids 10.4 14.4 10.4 14.4OD Pulp Used, g 70 70 300 290ClO.sub.2 Used, ml 29.5 29.5 124.0 109.3Cl.sub.2 --H.sub.2 O, ml 581.7 586.5 2647 2648Final pH 1.4 1.4 1.6 1.6Consumption of Cl.sub.2, % 99.4 99.9 99.8 100.0Actual Cl.sub.2 Consumption,% on OD Pulp 7.9 7.9 7.9 7.925 ml K number 6.7 7.9 6.4 6.3Extraction% Solids 14.4 15.6 14.0 15.2OD Pulp Used, g 40.0 40.0 60.0 60.0Alkali, % 3.0 3.0 3.0 3.0Initial pH 11.7 11.9 12.5 12.9Final pH 8.1 8.5 9.8 9.525 ml K number 3.6 3.9 3.4 3.4______________________________________
Extraction Stage. Forty-gram batches were extracted at 70° C. in a stainless steel Parr reactor for one hour. Testing on this pulp included viscosity and CE K number. Initially, there was a significant difference in both chlorinated pulp K number and CE K number, comparing EtOH washed and unwashed samples. When the experiment was repeated, both the ethanol washed and unwashed pulps had the same lignin content after the CE stages. This apparent difference in applied Cl 2 did not have a major effect on the formation of TCDD/F during bleaching, as shown in Table III.
Analytical.
Aliquots of unbleached, chlorinated and extracted pulps were analyzed for TCDD/F and the resulting data is set forth in Table III.
TABLE III______________________________________Effect of Ethanol Washing on Formation of ChlorinatedDibenzo-p-Dioxins and Dibenzofurans from Softwood Pulp2378-TCDD, ppt 2378-TCDF, pptExperi- Experi- Experi- Experi-ment ment ment ment#1 #2 Avg. #1 #2 Avg.______________________________________C-StageBrown-stockControl 123 93.6 108 1240 1230 1240EtOH- 20.7 33.8 27.3 203 230 217Washed% 83 64 75 84 81 83Reductionwith EtOHE-StageBrown-stockControl 48.9 34.9 41.9 555 510 533EtOH- 6.5 ND(10.3) 8.4* 70.9 97.8 84.0Washed% 87 71* 80* 87 81 81Reductionwith EtOH______________________________________ *These values are calculated using the detection limit of 10.3 ppt.
The averages of the formation of 2378-TCDD and 2378-TCDF in the two experiments are shown graphically in FIGS. 1 and 2, respectively. These results demonstrate the presence of solvent-extractable precursors for TCDD/Fs associated with this unbleached pulp. Washing unbleached, screened, softwood pulp with ethanol substantially reduced the formation of 2378-TCDD and 2378-TCDF in laboratory chlorination and extraction stages as compared to bleaching the pulp "as is" from the mill.
While the invention has been described and illustrated herein by reference to various specific materials, procedures and examples, it is understood that the invention is not restricted to the particular materials, combinations of materials, and procedures selected for that purpose. Numerous variations of such details can be employed, as will be appreciated by those skilled in the art. | In the method of chemical pulping of wood including a chlorination stage pulp bleaching step followed by alkaline extraction, a method of reducing the amount of dioxins and furans produced thereby is disclosed wherein the brownstock pulp is first washed with alcohol prior to bleaching. | 3 |
BACKGROUND OF THE INVENTION
1. Field of The Invention
This invention generally relates to image processing and more particularly to an image reading system for setting values indicated by signals (hereunder referred to as density signals) representing gray levels (namely, densities) at a point of a high-light portion of an original image (hereunder referred to simply as a high-light point) and a point of a shadow portion of the original image (hereunder referred to simply as a shadow point) for predetermined values and for reading a manuscript in accordance with gray scale transformation characteristics determined according to the kind of the manuscript.
2. Description of The Related Art
In a prior art image reading system, a manuscript is first irradiated by light and next a quantity of light reflected or transmitted by the manuscript (hereunder referred to as a quantity of reading-light) is measured. Subsequently, the prior art reading system generates a signal (hereunder referred to as a density signal) representing densities of the manuscript from the result of the measurement of the quantity of reading-light and outputs the generated density signal. A method of generating a density signal, which is employed by the prior art reading system, will be described hereinbelow. In case of this method, in order to freely establish a corresponding relation between quantities of reading-light and values indicated by a density signal, a quantity of reading-light is first converted into a luminance signal by a photoelectric conversion portion and a signal amplification portion of the prior art reading system and thereafter a density signal is generated by referring to a look-up table (hereunder abbreviated as an LUT).
Generally, the following three kinds of methods are employed for establishing the LUT:
(1) A first method which uses a quantity of reading-light measured when reading a gray scale chart;
(2) A second method which uses quantities of reading-light measured correspondingly to at least three points (namely, a high-light point, a point of a half-tone portion (hereunder referred to as a half-tone point) and a shadow point) of a manuscript when reading the manuscript; and
(3) A third method which uses quantities of reading-light measured correspondingly to a high-light point and a shadow point of a manuscript when reading the manuscript. Further, in case where a picture is read in conformity of the range of gray levels of picture elements of the picture, the second or third method is employed. As a result of making a comparison between the second and third methods, it is found that the latter method can be performed by an operator more easily than the former method.
Additionally, the third method of establishing the LUT by using the quantities of reading-light corresponding to the high-light point and the shadow point on the manuscript has the following two types. A first type of the third method is comprised of the steps of preparing first LUT data corresponding to a positive manuscript and second LUT data corresponding to a negative manuscript, then writing the first or second LUT data to the LUT in accordance with the kind of the manuscript and subsequently regulating the signal amplification portion such that the quantities of reading-light corresponding to the high-light point and the shadow point are adjusted to operator's desired amounts.
The other type of the third method is comprised of the steps of first modifying a plurality of standard tone curve data stored in a memory such that a signal indicating data outputted from the LUT when signals representing quantities of reading-light corresponding to the high-light point and the shadow point are inputted thereto indicate desired values, then selecting the most appropriate data therefrom and subsequently writing the selected data to the LUT (see Japanese Patent Application Provisional Publication No. 60-37878 Official Gazette). In case of this type of the third method, the modification of the standard tone curve data g i (X) is performed by first obtaining parameters a and b of modified tone curve data (namely, a standard tone curve function of X-coordinates) g i ' (X) by using signals inputted to the LUT respectively representing the gray level X yh of the high-light point having X and Y coordinates (X ho , Y h ) on the manuscript and that X ys of the shadow point having X and Y coordinates (X so , Y s ) thereon. The parameters a and b are defined as follows.
a=(X.sub.so -X.sub.ho)/(X.sub.ys -X.sub.yh)
b=X.sub.ho -a*X.sub.yh
Then, the modified tone curve data are obtained by the following equation.
g.sub.i '(X)=g.sub.i (a*X+b) (1)
Such a modification is performed on all of the standard tone curve data. Thereafter, the most appropriate data are selected and is written to the LUT.
In case where a manuscript is read by the image reading device, it is necessary to establish a reference point on the manuscript and set the system such that the difference (O-O H ) between the value O indicated by a density signal corresponding to a given point on the manuscript and that O H indicated by another density signal corresponding to the reference point thereon is obtained as a linear function of the difference (D-D H ) between the density D at the given point and that D H at the reference point. Hereunder, this condition will be referred to simply as a linear condition. Incidentally, in case of the third method of setting the LUT by using the quantities of reading-light corresponding to a high-light point and a shadow point, the high-light point is employed as the reference point. Further, the linear condition can be expressed as follows:
(D-D.sub.H)=S.sub.D *(O-O.sub.H) (2)
where S D is a proportional factor (hereunder referred to as a density step). Furthermore, let Ds denote the density at the shadow point. In order to set the value indicated by the density signal corresponding to the shadow point as a desired value Os, the density step S D needs to be determined by the following equation:
S.sub.D =(Ds-D.sub.H)/(Os-O.sub.H) (3)
Additionally, when a fixed quantity of light is irradiated on a point of a positive manuscript, the relation between a quantity L of reading-light and a corresponding density D is expressed as follows:
D=-log ((L-L.sub.O)/C)
where C denotes a constant determined depending on the kind of the manuscript and the quantity of the irradiated light; and L O a quantity of reading-light when the fixed quantity of the light is not irradiated. Generally, the value indicated by a luminance signal I is represented by the following equation:
I=K*L
where K designates a constant; L a quantity of reading-light. Therefore, ##EQU1## where α is a given constant. Thus, as is understood from the equations (2) and (4), the linear condition expressed by the equation (2) holds if the relation between the value O indicated by the density signal indicating data outputted from the LUT and that I indicated by the luminance signal inputted to the LUT is given as follows:
O={log ((I.sub.H -I.sub.O)/α)-log ((I-I.sub.O)/α)/S.sub.D +O.sub.H ( 5).
Incidentally, data indicating the relation of a type as expressed by the equation (5) are referred to as gray scale transformation curve data (hereunder sometimes referred to as density transformation curve data). Furthermore, in order to make the value indicated by the density signal corresponding to the density condition equal to the desired value Os, the density step S D is determined from the equations (3) and (4) as follows:
S.sub.D ={log ((I.sub.H -I.sub.O)/α)-log ((Is-I.sub.O)/α)/(Os-O.sub.H) (6)
Thus, in order to satisfy the linear condition and meet the requirement that a manuscript should be read in such a manner that the values indicated by reading-signals respectively representing the density of the high-light point and that of the shadow point become predetermined levels, it is necessary to write data satisfying the equations (5) and (6) to the LUT before the reading of the positive manuscript is started. Therefore, in order to satisfy the above described requirement, the data as given by the equation (5) (namely, the data obtained by first dividing opposite logarithmic curve data by the density step S D and next adding a constant to the result of the division) should be written to the LUT.
Further, if the difference (Os-O H ) between the desired values indicated by the reading-signals corresponding to the shadow point and the high-light point is considered to be a fixed value, the data of the LUT (hereunder sometimes referred to as the LUT data) are determined regardless of the difference (Ds-D H ) between the densities at the high-light point and the shadow point in case of the prior art method of setting the LUT by writing specific data to the LUT according to the kind of the manuscript. However, as can be understood from the equation (3), the density step S D varies with the difference (Ds-D H ) when the difference (Ds-D H ) changes. Therefore, it can be concluded from the equation (5) that the data of the LUT for satisfying the linear condition should be changed and thus the above described requirement cannot be met by performing the prior art method.
Similarly, in case of the LUT setting method disclosed in the Japanese Patent Application Provisional Publication No. 60-37878 Official Gazette, the data of the LUT for satisfying the linear condition vary with the difference (Ds-D H ) when the difference (Ds-D H ) changes. Hereinafter, it is studied whether or not the system can generate data of the LUT satisfying the equation (5) such that the linear condition holds for the positive manuscript. First, let A, I and B denote the number of data inputted to the LUT, a natural number equal to or less than A and a given positive constant, respectively. Further, the following function g i (I) is employed as standard data:
g.sub.i (I)=(-1)*B*log (I/A)
In this case, the modified data g i (I) are obtained from the equation (1) as follows: ##EQU2## Thus, there is established the following relation between the values indicated by an output signal O and an input signal representing I of the LUT generated by using the modified data:
O=-B*{log ((I-b/a)/A)+log (a/A)} (7)
However, the constant B of the equation (7) is peculiar to the standard data g i (I) and is not necessarily equal to the density step S D which is determined according to the difference (Os-O H ) between the desired values and the difference (Ds-D H ) between the densities at the shadow point and the high-light point. Thus, the data of the generated LUT do not always satisfy the equations (5) and (6). Therefore, this prior art method cannot meet the above described requirement. Moreover, even if a plurality of standard data are used, the constant B will take a plurality of values. The above described requirement cannot be met by employing this prior art method for the same reason as in case of the third method of setting the LUT.
Further, when a fixed quantity of light is irradiated on a point of a negative manuscript, the relation between a quantity L of reading-light and a corresponding density D in a positive manuscript is established as the following function:
D=F((L-L.sub.O)/(L.sub.M -L.sub.O)) (8)
where L M denotes a quantity of reading-light when the quantity of the irradiated light is directly read or measured. As is understood from the equations (2) and (8), the linear condition is satisfied if the density O indicated by the density signal meets the following equation:
O-O.sub.H =S.sub.D *{F((L.sub.H -L.sub.O)/(L.sub.M -L.sub.O))-F((L-L.sub.O)/(L.sub.M -L.sub.O))} (9)
Furthermore, as is seen from the equations (3) and (8), the density step S D should be determined by the following equations for the purpose of making the density signal corresponding to the shadow point indicate a desired value Os:
S.sub.D =(Os-O.sub.H)/{F((Ls-L.sub.O)/(L.sub.M -L.sub.O))-F((L.sub.H -L.sub.O)/(L.sub.M -L.sub.O))} (10)
Hence, in cases of the conventional methods of setting the LUT, a negative manuscript cannot be read in a manner in which the above described requirement is met.
The present invention is created to solve the above described problems of the prior art system.
It is accordingly a first object of the present invention to provide an image reading system which can satisfy the linear condition and meet the requirement that a manuscript should be read in such a manner that the values indicated by reading-signals respectively representing the density of a high-light point and that of a shadow point become predetermined values.
Further, it is a second object of the present invention to provide an image reading system which can omit an operation of inputting density transformation data for frequently used manuscript from an external device and achieve the first object.
SUMMARY OF THE INVENTION
To achieve the foregoing object and in accordance with the present invention, there is provided an image reading system which comprises a light irradiating portion for irradiating light onto a predetermined range of the surface of a manuscript to be read, an image reading portion for outputting a signal obtained by first converting light reflected or transmitted by the manuscript into a luminance signal and then referring to a look-up table, an interface portion for inputting a signal from and outputting a signal to an external computing device, a manuscript scanning portion for scanning the surface of the manuscript, a central processing portion for controlling the manuscript scanning portion, the light irradiating portion, the interface portion and the image reading portion and performing operations and a storage portion capable of storing at least one kind of density transformation curve data.
Thus, in the image reading system of the present invention, first, the image reading portion is controlled such that the values indicated by the luminance signal obtained by irradiating light from the light irradiating portion onto a point on the surface of the manuscript indicated by an operator become equal to a value indicated by the operator. Then, a value I O indicated by the luminance signal obtained when light is not irradiated from the light irradiating portion, as well as values I H and Is indicated by luminance signals respectively corresponding to a high-light and shadow points indicated by the operator, onto which light is irradiated from the light irradiating portion, are determined. Subsequently, the look-up table is generated by first determining a parameter a such that the value indicated by a signal outputted from the look-up table becomes equal to a value O H indicated by the operator when the luminance signal indicating the value I H is inputted to the look-up table and that of the signal outputted from the look-up table becomes equal to another value Os indicated by the operator when the luminance signal indicating the value Is is inputted to the look-up table and by next calculating the following expression by using density transformation curve data f(I):
a*{f(I-I.sub.O)-f(I.sub.H -I.sub.O)}+O.sub.H
Thereby, the linear condition is satisfied. Moreover, the manuscript can be read such that the values indicated by signals corresponding to the high-light and shadow points indicate desired values.
In a predetermined embodiment of the present invention, the storage portion of this image reading system, (1) data indicating a curve which represents the following relation between data inputted to and outputted from the look-up table:
O=(-1)*B*log (I/A)
where A, B, I and O designate the number of data inputted to the look-up table, a predetermined positive constant, a natural number inputted to the look-up table as input data and data outputted from the look-up table, respectively, and/or (2) data indicating at least a curve which represents the relation between a quantity of light transmitted by a negative manuscript and a corresponding density of a positive manuscript are stored as the density transformation curve data.
Thus, an operation of inputting density transformation curve data for frequently used manuscript from an external device can be omitted by preliminarily storing data representing the density transformation curve of frequently used manuscript in the storage portion of the image reading system of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features, objects and advantages of the present invention will become apparent from the following description of preferred embodiments with reference to the drawings in which like reference characters designate like or corresponding parts throughout several views, and in which:
FIG. 1 is a schematic block diagram for showing the construction of a first image reading system embodying the present invention;
FIG. 2 is a schematic block diagram for showing the construction of an image reading portion which is a primary part of the first image reading system of FIG. 1;
FIGS. 3a-3d are a flowchart of a program for performing an operation of the first image reading system of FIG. 1 in case of red light;
FIG. 4 is a graph for illustrating the characteristics of data of the LUT to be used in the first image reading system to find the value indicated by a luminance signal corresponding to a high-light point;
FIG. 5 is a graph for illustrating the characteristics of density transformation curve data and data of the LUT generated by using the density transformation curve data which are used in the first image reading system of FIG. 1;
FIG. 6 is a graph for illustrating the characteristics of density transformation curve data stored in a second embodiment of the present invention; and
FIG. 7 is a graph for illustrating the characteristics of standard data and data obtained by modifying the standard data in case of employing the conventional method of establishing the LUT.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention will be described in detail by referring to the accompanying drawings.
Before describing the construction and operations of the embodiments, it will first be explained hereinbelow how the above described linear condition is satisfied in cases of the systems of the present invention.
In case of reading a positive manuscript, by indicating the following curve data as the density transformation curve data:
(-1)*B*log (I/A) (11)
output data of the LUT to be generated are obtained by the following equation which holds for input data I thereof greater than I O :
O=a*{log ((I.sub.H -I.sub.O)/A)-log ((I-I.sub.O)/A)}+O.sub.H
Therefore, the linear condition expressed by the equation (5) is satisfied.
In contrast, in case of reading a negative manuscript, curve data representing the relation between a quantity of light transmitted by the negative manuscript and a corresponding density of a positive manuscript are indicated as density transformation curve data. Incidentally, the curve data are represented as follows:
B*F(I/A)
where A denotes the number of data inputted to the LUT; i a natural number equal to or less than A; B a given positive constant; and F a function used in the equation (8). Thus, output data O of the LUT are obtained by the following equation which holds for input data I thereof greater than I O :
O=a*{F((I-I.sub.O)/A)-F((I.sub.H -I.sub.O)/A)}+O.sub.H
If the value I H indicated by a signal to be inputted to the LUT in case of reading the density of a high-light point is determined by using a densitometer such that the determined level I H satisfies the following relation:
(L.sub.H -L.sub.O)/(L.sub.M -L.sub.O)=(I.sub.H -I.sub.O)/A
where L M designates an amount of light when reading the irradiated light; L H a quantity of reading-light of a high-light point; and L O a quantity of reading-light, output data O of the LUT are determined as follows: ##EQU3## Consequently, it can be said that the linear condition expressed by the equation (9) is satisfied.
Hereinafter, a first embodiment of the present invention will be described. Referring first to FIG. 1, there is shown the construction of the first embodiment (namely, a first image reading system) of the present invention. In this figure, reference numeral 101 a light irradiating portion; 102 an image reading portion; 103 an interface portion; 104 a manuscript scanning portion; 105 a central processing unit (CPU); and 106 a main memory.
Referring next to FIG. 2, there is shown the construction of an example of the image reading portion 102. In this figure, reference numeral 201 represents input light; 202 a color separation device; 203 red light separated from the input light in the color separation device; 204 blue light similarly obtained; 205 green light similarly obtained; 206, 207 and 208 photoelectric conversion devices; 209, 210 and 211 signal amplifiers; 212, 213 and 214 memories for storing the LUT; 215 signals output to the interface portion 103, the main memory 106 and the CPU 105; and 216 a signal conductor connected to the CPU 105.
Hereinafter, an operation of the embodiment having the configuration of FIGS. 1 and 2 will be described by referring to a flowchart of a program of FIG. 3. Incidentally, this embodiment performs the same operation for the red light 203, the blue light 204 and the green light 205 obtained by separating the input light 201. In addition, note that FIG. 3 illustrates an operation of the system for the red light for simplicity of description.
First, in step 301, a desired value indicated by a luminance signal inputted to the memories 212, 213 and 214 when reading the density at a high-light point, as well as desired levels O H (R), O H (G), O H (B), O S (R), O S (G) and O S (B) of signals outputted from the memories 212, 213 and 214 when reading the densities at a high-light point and a shadow point, is inputted from the interface portion 103. Incidentally, subscripts .sub.(R), .sub.(G) and .sub.(B) indicate that information or data indicated by reference characters below which the subscripts .sub.(R), .sub.(G) and .sub.(B) are written relate to the red light 203, the green light 205 and the blue light 204, respectively. Further, the input data indicating the desired values are written by the CPU 105 to the main memory 106.
Next, the program advances to step 302 whereupon the CPU 105 writes, for example, data as illustrated in FIG. 4 to the memories 212, 213 and 214.
Thereafter, the following processing is performed in step 303. First, the CPU 105 operates the light irradiating portion 101 and the manuscript scanning portion 104 to input light, which is reflected or transmitted by the manuscript when light corresponding to the color of a high-light point indicated by an operator is irradiated, to the image reading portion 102. This input light 201 is separated into the red light 203, the green light 204 and the blue light 205, which are inputted to the photoelectric conversion devices 206, 207 and 208, respectively, by the color separation device 202. Thereafter, the system performs the same operation for each of the three colors 203, 204 and 205. Thus, the operation of the system for the red light 203 will be described hereunder for simplicity of description. Then, the light 203 separated from the input light by the color separation device 202 is converted by the photoelectric conversion device 206 into an electric signal. Subsequently, the electric signal is amplified by the signal amplifier 209. Thereafter, the amplified signal is inputted to the memory 212 for storing the LUT. Further, the CPU 105 calculates the value to be indicated by a luminance signal inputted to the memory 212 by using the value indicated by a signal outputted from the memory 212. Then, the CPU 105 compares the calculated value to be indicated by the luminance signal with a desired value which is stored in the main memory 106. Further, the offset and gain of the signal amplifier 209 are changed by the CPU 105 such that the difference between the calculated value to be indicated by the luminance signal and the desired value become decreased.
Then, in step 304, the processing of step 303 is repeatedly performed until the value indicated by the luminance signal obtained when inputting the light corresponding to the color of the high-light point to the image reading portion 101 become equal to the desired value which is stored in the main memory 106. Moreover, this value of the desired value, which is stored in the main memory 106, as data I H (R).
Thereafter, in step 306, the CPU 105 stops the light irradiating portion 101 from irradiating. At that time, light inputted to the image reading portion 102 is converted into a signal and subsequently the signal is outputted from the memory 212 for storing the LUT, similarly as in case of inputting the light corresponding to the color of the high-light point. Then, in step 307, the CPU 105 calculates the value to be indicated by a luminance signal to be inputted to the memory 212 on the basis of the value indicated by the signal outputted from the memory 212. Moreover, the calculated value is stored in the main memory 106 as data I O (R).
Furthermore, in step 308, the CPU 105 operates the light irradiating portion 101 and the manuscript scanning portion 104 to irradiate light corresponding to the color of a high-light point indicated by an operator. Then, in step 309, the value to be indicated by a luminance signal is calculated and the calculated value is stored in the main memory 106 as data Is.sub.(R), similarly as in step 307.
After the above described operation is completed, density conversion curve data are read from the interface portion 103. The thus read density conversion curve data are written to the main memory 106. Then, three kinds of the data of the LUT are generated and further written to the memories 212, 213 and 214, respectively. Each of the three kinds of the data of the LUT is generated by performing the same operational procedure. Therefore, only the procedure of generating data to be written to the memory 212 for storing the LUT data relating to the red light will be described hereinbelow by way of example.
First, the CPU 105 reads the data I H (R), Is.sub.(R), I O (R), O H (R) and Os.sub.(R) from the main memory 106.
Next, the processing of step 310 is effected. In case of reading a positive manuscript, the data represented by the equation (11) are read from the interface portion 103 and inputted to the main memory 106 as density transformation curve data f.sub.(R) (I). In contrast, in case of reading a negative manuscript, data B * F(I/A) represented by using a density transformation function F, the number A of data inputted to the LUT, a natural number I equal to or less than A and a given positive constant B are read from the interface portion 103 and inputted to the main memory 106 as density transformation curve data f.sub.(R) (I).
Further, in step 311, the following equation is calculated regardless of the kind of the manuscript:
a.sub.(R) =(Os.sub.(R) -O.sub.H(R))/{f.sub.(R) (-I.sub.O(R))-f.sub.(R) (I.sub.H(R) -I.sub.O(R))}
Subsequently, the following equation is calculated:
b.sub.(R) =O.sub.H(R) -a.sub.(R) *f.sub.(R) (I.sub.H(R) -I.sub.O(R))
Then, data generated in accordance with the following equation in steps 312, 313, 314 and 315
O.sub.(R) (I+I.sub.O(R))=a.sub.(R) *f.sub.(R) +b.sub.(R)
as well as data generated in accordance with the following equation holding for I O (R) equal to or greater than 1 and inequality in steps 312, 313, 314 and 315
O.sub.(R) (I)=O.sub.(R) (1+I.sub.O(R))
are written to the LUT 212 in step 320. Thereby, the data O.sub.(R) of the LUT 212 as illustrated in FIG. 5 are generated.
As described above, in case of this embodiment, the value to be indicated by a luminance signal obtained when light is not irradiated and those I H and Is to be indicated by luminance signals respectively corresponding to a high-light point and a shadow point are measured after the value indicated by a luminance signal corresponding to a high-light point is adjusted to a desired value. Then, for the purpose of making the values indicated by output signals of the memory storing the LUT, which correspond to the high-light point and the shadow point, equal to desired values O H and Os, the parameter a is first calculated as follows by using the density transformation curve data f(I):
a=(Os-O.sub.H)/{f(Is-I.sub.O)-f(I.sub.H -I.sub.O) (13)
Then, the parameter b is calculated in accordance with the following equation:
b=O.sub.H -a*f(I.sub.H -I.sub.O) (14)
Subsequently, the LUT is generated by using data O obtained in accordance with the following equation:
O(I+I.sub.O)=a*f(I)+b (15)
The above described operation of generating the LUT is performed on each of the red, green and blue components of the input light. Further, in case of reading a positive manuscript, it is found from the equations (14) and (15) and the following equations:
S.sub.D =B/a
f(I)=(-1)* B* log(I/A)
that the equation (5) holds. Similarly, in case of reading a negative manuscript, it is found from the equations (12), (14), (15) and the following equations:
a=-B
f(I)=F(I/A)
that the equation (9) holds. Thus, the linear condition is satisfied in case of each of the red, green and blue components of the input light. Additionally, the equations (13), (14) and (15) holds for each of the red, green and blue components of the input light. Therefore, the manuscript can be read such that the values indicated by the signals representing the densities at the high-light point and the shadow point have the desired values.
Next, a second embodiment of the present invention will be described hereinbelow.
The second embodiment has the same construction as the first embodiment except that density transformation curve data representing frequently used density transformation curve as illustrated in FIG. 6 are written to the main memory 106. The curve P of FIG. 6 shows the following relation between an input value I and a corresponding output value P(I):
P(I)=(-1)* B* log(I/A) (16)
Further, the curves N 1 , N 2 and N 3 show the following relation:
Ni(I)=Fi(I/A), i=1,2,3 (17)
Incidentally, in the equations (16) and (17), A denotes the number of data inputted to the LUT; I a natural number equal to or less than A; B a positive constant; and Fi a density transformation characteristic function.
An operation of the second embodiment is the same as of the first embodiment except that after three kinds of density transformation curve data read from the interface portion 103 are written to the main memory 106, one kind of the density transformation curve data stored in the main memory 106 is selected according to the kind of the manuscript and subsequently three kinds of LUT data are generated from the selected kind of the density transformation curve data instead of generating three kinds of LUT data from the three kinds of the stored density transformation curve data, respectively.
Therefore, in case of the second embodiment, an operation of inputting the density transformation curve data from an external device can be omitted.
While preferred embodiments of the present invention have been described above, it is to be understood that the present invention is not limited thereto and that other modifications will be apparent to those skilled in the art without departing from the spirit of the invention. The scope of the present invention, therefore, is to be determined solely by the appended claims. | An image reading system with a light irradiating portion for irradiating light onto a predetermined range of the surface of a manuscript to be read, an image reading portion for outputting a signal obtained by first converting light reflected or transmitted by the manuscript into a luminance signal and then referring to a look-up table, an interface portion for inputting a signal from and outputting a signal to an external computing device, a manuscript scanning portion for scanning the surface of the manuscript, a central processing portion for controlling the manuscript scanning portion and a storage portion capable of storing at least one kind of density transformation curve data. | 7 |
This is a continuation, of application Ser. No. 026,359, filed Mar. 16, 1987 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a roadside beacon system. More particularly, this invention relates to a roadside beacon system which is used to calibrate the position of a vehicle and to perform data transmission in a navigation system in which, after data representing a departure point are inputted, vehicle speed data and direction data are inputted to enable the display of the present position of the vehicle.
2. Background of the Invention
A so-called "navigation system" for vehicles has been known in the art. In the system, a small computer and a small display unit are installed on a vehicle. A road map is read out of memory means such as a compact disk and displayed on the display unit. On the other hand, the vehicle speed data outputted by a vehicle speed sensor and the direction data provided by a direction sensor are inputted, so that calculation of the position of the vehicle and determination of the traveling direction of the vehicle are performed at all times. According to the results of the calculation and the determination, the vehicle is marked on the road map displayed on the display unit.
With the navigation system, the operator in the vehicle can visually detect the present position and the traveling direction of his vehicle therefore, he can reach his destination without losing his way.
However, the navigation system described above is disadvantageous in the following point. In the system, the errors inherent in the vehicle speed sensor and the direction sensor are accumulated as the vehicle runs. When the distance traveled by the vehicle exceeds a predetermined value (which is not always constant, being determined by the errors of the vehicle speed sensor and the direction sensor of each vehicle and by the environmental conditions of the positions where the sensors are installed), then the position of the vehicle displayed on the display unit is greatly shifted from the true position. That is, the system becomes unreliable and the vehicle operator may lose his way.
In order to overcome this difficulty, a so-called "roadside beacon system" has been proposed. In the system, as shown in FIG. 7, roadside antennas 2 are installed at intervals shorter than the distance within which the accumulated error exceeds the above-described predetermined value. The roadside antennas 2 are used to transmit signals including position data and road direction data to respective predetermined relatively small areas (R shown in FIG. 4). On the other hand, the signals thus transmitted are received through a mobile antenna 4 installed on a vehicle 3 so that the position and the traveling direction of the vehicle are calibrated with a computer (cf. FIG. 7).
With the above roadside beacon system, the accumulated error is smaller than the predetermined value, and the position of the vehicle 3 can be displayed according to the correct position data and the accurate direction data at all times. This means the navigation system is reliable. If the roadside antenna is installed, for instance, near a railroad or a railroad crossing where the direction sensor is liable to erroneously operate, then errors attributed to external factors can be effectively eliminated.
In the above-described roadside beacon system, roadside antennas of considerably high directivity are used to transmit the aforementioned signals. The vehicles receive the signals only when passing through the areas converted by the signals. A conventional mobile antenna is sensitive mainly in a horizontal direction and has a wide directivity. Therefore, the mobile antenna 4 receives, as shown in FIG. 7, not only a signal component E directly from the road-side antenna 2 (hereinafter referred to as "a directly received signal component" but also signal components F, D and C which are reflected by a sound insulating wall 5, a road 1, another vehicle 3a, a buildings, etc. (hereinafter referred to as "indirectly received signal components").
Accordingly, the time-dependent strength distribution of the signal received by the mobile antenna is greatly different form the time-dependent strength distribution of the original signal transmitted through the roadside antenna. Thus, the conventional roadside beacon system suffers from a difficulty that the position and the traveling direction of the vehicle are calibrated according to the signal which greatly deviates from the original signal.
This problem will be described in more detail. When compared with the directly received signal component, the indirectly received signal components, reaching the mobile antenna through various paths, are different in phase and in amplitude. Therefore, depending on the phases, the indirectly received signal components are received as signals much larger or smaller in amplitude than the directly received signals.
Whenever the present position for the vehicle is required, the vehicle is traveling. As the vehicle runs, the aforementioned number of signal paths change and accordingly the signal received by the mobile antenna also changes irregularly with time, as shown in FIG. 8, thus causing a great error in the calibration.
The above-described phenomenon will be referred to as "a multi-path fading phenomenon".
SUMMARY OF THE INVENTION
In view of the foregoing, an object of this invention is to provide a roadside beacon system in which the multi-path fading phenomenon is prevented, and the position of a vehicle can be calibrated with high accuracy.
The foregoing object of the invention has been achieved in a roadside beacon system in which according to the invention, a roadside antennas installed along roads at predetermined positions are larger in height than the vehicles and radiate signals obliquely downwardly. A mobile antenna for receiving signals transmitted through the roadside antennas is installed on each of the vehicles in such a manner that its directivity lies in an upward direction.
It is preferable that each of the roadside antennas have high directivity in a vertical plane crossing the road, and radiate signals substantially downwardly.
In the roadside beacon system of the invention, the roadside antennas installed along the roads at the predetermined positions transmit a variety of data to vehicles moving along the roads. In this operation, the roadside antennas radiate the signals obliquely downwardly and the signals are received by the mobile antennas which are directional in an upward direction.
Therefore, the signal component which is reflected by sound insulating walls or buildings or by the road, and the signal component which is reflected horizontally by another vehicle can be made much smaller in strength than the signal component which is directly received by the mobile antenna.
In the case where, as was described above, the roadside antennas are each highly directional in a vertical plane crossing a road, and radiate signals substantially downwardly, the signal component which is reflected by a sound insulating wall or building and then received directly by the mobile antenna can be decreased in signal strength when transmitted through the roadside antenna. That is, only the signal component transmitted from the roadside antenna directly to the mobile antenna can be made great in signal strength, whereas the other signal components reaching the mobile antenna through the other paths can be made much smaller in signal strength.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2 and 3 are schematic diagrams for a description of first, second and third examples of a roadside beacon system according to this invention.
FIGS. 4 and 5 are a plan view and a perspective view, respectively, outlining a roadside beacon system.
FIG. 6 is an explanatory diagram showing one example of a road map displayed on a display unit in the roadside beacon system.
FIG. 7 is a schematic diagram for a description of one example of a conventional roadside beacon system.
FIG. 8 is a diagram showing the waveform of a signal received by the conventional roadside beacon system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of this invention will be described with reference to the accompanying drawings in detail.
FIG. 6 is a schematic diagram showing one example of a road map displayed on a display unit. The present position and the traveling direction of a vehicle is indicated by the arrow A, and the positions of roadside antennas P 1 , P 2 , . . . and P n are also indicated (the indication of these roadside antennas being not always required). In addition, buildings or the like (not shown in FIG. 6) which can be utilized as guides are indicated.
FIGS. 4 and 5 are schematic diagrams for a description of the roadside beacon system according to the invention. A roadside antenna 2 is installed at a predetermined position near a road 1. The roadside antenna 2 is adapted to transmit a signal from a beacon signal source 2b. On the other hand, a mobile antenna 4 for receiving the aforementioned signal is installed at a predetermined position on a vehicle 3 which runs along the road 1. The signal received by the mobile antenna 4 is supplied to a navigation device (not shown) in the car. The roadside antenna 2 is so high in directivity that it covers only a relatively small area (R in FIG. 4 or 5). In addition, the roadside antenna 2 is so designed that it is non-directional in a horizontal direction and radiates in an obliquely downward direction, i.e., the strongest signals are directed obliquely downward.
This type propagation directivity is obtained by a well known antenna such as a dipole antenna having reflection plate, a slot antenna or the like, which is commercially available.
FIG. 1 shows the relation between the roadside antenna 2 and the mobile antenna 4 in detail. The roadside antenna 2 is supported by a post 2a installed near the road 1 in such a manner that the roadside antenna 2 is much greater in height than large vehicles such as trucks and buses. The mobile antenna 4 has a directivity in a obliquely upward direction, i.e., the sensitivity of the mobile antenna 4 is strongest in an upward direction, the antenna is installed on the roof of the vehicle 3.
The roadside antenna 2 shows a high directivity as indicated by B in FIG. 1, and is mounted on the supporting post 2a so as to transmit signals in a substantially downward direction.
Therefore, the signal highest in strength transmitted by the roadside antenna is reflected by the roof of another vehicle 3a toward the mobile antenna 4 as indicated by the line C in FIG. 1, or it is reflected by the ground and led to the mobile antenna 4 as indicated by the line D in FIG. 1. On the other hand, the signal lower in strength is transmitted directly to the mobile antenna 4 as indicated by the line E in the FIG. 1. A signal much lower in strength is reflected by a building 5 and led to the mobile antenna 4 as indicated by the line F in FIG. 1 or it is reflected by the building 5 and a road shoulder 1a and led to the mobile antenna 4 as indicated by the line G in FIG. 1.
In other words, the signals E and F are led to the mobile antenna 4 from above, the signal C is led horizontally to the mobile antenna 4, and the signals D and G are led to the mobile antenna 4 from below.
As was described above, the mobile antenna 4 receives all the signals C, D, E, F and G. In this case, the signal E is scarcely affected by the signals F and G, because the signals F and G are considerably low in strength because of the directivity of the mobile antenna. On the other hand, the signals C and D are higher in strength than the signal E. However, the signal E is scarcely affected by these signals C and D, because the signal C is horizontally led to the mobile antenna 4 and the signal D is led to the mobile antenna 4 from below while the directivity of the mobile antenna 4 lies in the obliquely upward direction as was described before.
Accordingly, the mobile antenna 4 receives the signal E with high sensitivity, but the other signals are received at the low levels which can be substantially disregarded. This effectively suppresses the aforementioned multi-path fading phenomenon, thus permitting the reception of signals in which the possibility of occurrence of errors is minimized.
The position data and the road direction data included in the signal received are utilized to cause a navigation device (not shown) to calibrate the vehicle position and vehicle traveling direction and to display this information.
FIG. 2 shows a second embodiment of the invention. The second embodiment of FIG. 2 is different from the first embodiment of FIG. 1 only in that the roadside antennas 2 used are not so high in directivity.
Therefore, in the second embodiment, the signals C, D, E, F and G transmitted through each of the roadside antennas 2 are substantially equal in signal strength to one another.
The signals C, D and G are received by the mobile antenna 4 with low sensitivity similarly as in the first embodiment, and therefore the signal E is scarcely affected by these signals C, D and G. On the other hand, the signal F is received with relatively high sensitivity, thus greatly affecting the signal E. However, since a building 5 is not always present near the antenna, it is not inherently necessary to seriously consider the signal F. That is, the effect by the signal F can be positively eliminated by installing the roadside antenna 2 at a position where the signal F is not reflected by any nearby building 5.
FIG. 3 shows a third embodiment of the invention. the third embodiment is different from the first and second embodiments only in that the directivity of the mobile antenna 4 lies in an upward direction.
In the third embodiment of FIG. 3, the mobile antenna 4 is substantially non-sensitive to signals in a horizontal direction and in an obliquely downward direction. Thus, similarly as in the above-described first and second embodiments, the multi-path fading phenomenon can be effectively suppressed.
As was described above, the roadside beacon system of the invention employs the mobile antenna the directivity of which is of an upward direction. Therefore, the signals reflected from a road, another vehicle and so forth are low in level when received by the mobile antenna. That is, the multi-path fading phenomenon is effectively suppressed. Therefore, the signals transmitted through the roadside antennas can be positively received with the occurrence of errors being minimized, and the number of pieces of data to be transmitted can be increased. | A roadside beacon system in which a plurality of roadside antennas transmit data to vehicles passing closely adjacent. The transmitting antennas are mounted high above the sides of the roads and have a gain pattern directed obliquely downward. The mobile antennas on the cars have gain patterns directed upwardly. | 6 |
CROSS REFERENCE OF RELATED APPLICATION
[0001] The disclosure of Japanese Patent Application No. 2006-302508 is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electronic appliance. More specifically, the present invention relates to an electronic appliance having a heat dissipating mechanism for dissipating a heat in a heat generating component.
[0004] 2. Description of the Related Art
[0005] As a conventional structure of such a kind, there is one disclosed in Japanese Patent Laying-open No. 1985-22398 (Patent Document 1). Acceding to Patent Document 1, heat dissipating fins are secured to a base to be attached to a heat generating component to allow air to flow through one end of the heat dissipating fin to the other. The heat dissipating fin group becomes higher from the entrance side from where air is taken in to the exit side from where the air is exhausted. Since the temperature of the air flowing along the heat dissipating fins is high as the exit is approached, the heat dissipating fin is formed so as to be higher to the exit side, capable of obtaining high heat dissipating efficiency.
[0006] Furthermore, there is one disclosed in Japanese Patent Laying-open No. 2004-186702 (Patent Document 2). According to Patent Document 2, a plurality of heat dissipating fins are arranged in series with each other on a base to be attached to a heat generating component. A wall surface is provided so as to face the base in such a manner that the plurality of heat dissipating fins are sandwiched therebetween, and an air duct is formed between the wall surface and the base. An exhaust fan is provided on the exit side of the air duct, and the air duct between the wall surface and the base becomes narrower as the exit side is approached. Thus, by widening the entrance side of the air duct, air being free from the heat dissipation by the heat dissipating fins at the entrance side is supplied with the heat dissipating fins at the exit side, capable of realizing a uniform cooling performance of each heat dissipating fin.
[0007] By the way, in electronic appliances like a game machine, etc., for the necessity of miniaturization and an optimal location, some members (wall member, component, or the like) may be arranged relatively near heat dissipating fins and heat generating components. In such a case, there is a problem of realizing a structure in view of the heat by the heat generating components.
[0008] For example, there is a case that some wall member (wall surface, component with wall part, or the like) are desired to be arranged on the entrance side of the air of the heat dissipating fin. In this case, an air intake channel to the heat dissipating fin may relatively be narrow due to the above-described wall member, and in such a case also, there is a problem of heightening the heat dissipating efficiency of the heat generating component.
[0009] Furthermore, there is a case that other components such as a disk drive, or the like is desired to be placed relatively near heat generating components, for example. In this case, there is a problem of preventing an adverse effect of the heat from the heat generating component on the other components.
[0010] In Patent Documents 1 and 2, there is no disclosure about means for solving the above described problems.
SUMMARY OF THE INVENTION
[0011] Therefore, it is a primary object of the present invention to provide a novel electronic appliance.
[0012] Another object of the present invention is to provide a structure taking heat of a heat generating component into consideration while responding to the necessity of miniaturization and an optimal location.
[0013] An electronic appliance according to a first aspect of the present invention comprises: a heat generating component; a base provided in a position being opposite to the heat generating component; a heat dissipating fin group which includes a plurality of fins arranged on the base in a manner that each of heat dissipating fins extends in a first direction (Y) and is arranged in spaced relation in a second direction (X) crossing the first direction, edge portions of the plurality of heat dissipating fins constituting edge portion groups on the side of the wall surface and on the side of the exhaust fan; and a exhaust fan and a wall surface being opposite to each other with which the heat dissipating fin group is sandwiched in the first direction. The edge portion group (T 2 ) of the heat dissipating fin group on the side of the wall surface is farthest from the wall surface at least one outermost position in the second direction and closest from the wall surface at a specific position different from the one outermost position in the second direction, and is farther from the wall surface between the specific position and the one outermost position as the one outermost position is approached.
[0014] In the first aspect, on the base being opposite to the heat generating component, a heat dissipating fin group including heat dissipating fins each of which extends in a first direction is arranged in spaced relation in a second direction. It should be noted that “the base being opposite to the heat generating component” includes a structure when a part of the heat generating component and a part of the base is being opposite. An exhaust fan and a wall surface are opposite to each other with which the heat dissipating fin group is sandwiched in the first direction.
[0015] The edge portion group of the heat dissipating fin group on the side of the wall surface is farthest from the wall surface at least one outermost position in the second direction and closest from the wall surface at a specific position different from the one outermost position in the second direction, and is farther from the wall surface between the specific position and the one outermost position as the one outermost position is approached.
[0016] According to the first aspect, one or two intake channels (QL, QR) is formed by the edge portion group of the heat dissipating fin group on the side of the wall surface and the wall surface. The (these) intake channel can take a large amount of outside air because of having a large opening, and can uniformly supply the taken air to the heat dissipating fin group because the width thereof is narrower at the depth. In such a case, the amount of air passing through the intake channel is gradually less, and therefore, the depth of the intake channel does not become a bottle neck. Thus, it is possible to obtain a high heat dissipating efficiency with respect to the heat dissipating component arranged near the wall surface.
[0017] As a result, it is possible to heighten heat dissipating efficiency of the heat generating component while responding to the necessity of miniaturization and an optimal location.
[0018] An electronic appliance according to a second aspect is dependent on the first aspect, and the edge portion group on the side of the wall surface is the farthest from the wall surface at both of outermost positions in the second direction, and the closest from the wall surface at an innermost position in the second direction.
[0019] In the second aspect, two intake channels having the same size are formed.
[0020] According to the second aspect, a total area of the opening is large, a large amount of air can be supplied with the heat dissipating fins, capable of obtaining a more heat dissipating efficiency.
[0021] An electronic appliance according to a third aspect is dependent on the second aspect, the edge portion group on the side of the wall surface is farthest from the wall surface at one outermost position in the second direction, and closest from the wall surface at the other outermost position in the second direction.
[0022] In the third aspect, one intake channel having a gentle inclination (that is, less difference between each of the edge portions on the side of wall surface) is formed.
[0023] According to the third aspect, a less ventilating resistance of the intake channel allows admission of a large amount of air, capable of obtaining a high heat dissipating efficiency.
[0024] An electronic appliance according to a fourth aspect is dependent on the second aspect, and the exhaust fan is placed at a position being opposite to the innermost position of the heat dissipating fin group in the second direction.
[0025] According to the fourth aspect, it is possible to suck out air from the heat dissipating fin group, capable of obtaining a more heat dissipating efficiency.
[0026] An electronic appliance according to a fifth aspect is dependent on the first to the fourth aspects, and the edge portion group of the heat dissipating fin group on the side of the exhaust fan (T 1 ) is placed at equal distances from the wall surface.
[0027] In the fifth aspect, a heat dissipating fin being placed at least one outermost position, and having an edge portion farthest from the wall surface becomes shortest while the heat dissipating fin group becomes gradually longer to the depth from the above-described outermost position, and becomes the longest at the heat dissipating fin having the edge portion being the closest from the wall surface.
[0028] Thus, it is structured that at the above-described outermost position, air can be easily taken in the heat dissipating fin group while the heat dissipating fin group is gradually longer to the depth from the above-described outermost position, and therefore, it is possible to efficiently dissipate heat by the heat dissipating fin group. As a result, it is possible to heighten heat dissipating efficiency of the heat generating component.
[0029] An electronic appliance according to a sixth aspect is dependent on the first aspect, and further comprises other component and a housing. The wall surface is a face of a partition for separating the heat dissipating fin group from the other component, and the housing houses the heat generating component, the base, the heat dissipating fin group, the exhaust fan, the partition, and the other component.
[0030] In the sixth aspect, the heat generating component, the base, the heat dissipating fin group, the exhaust fan, the partition, and other component are housed in the housing. The heat dissipating fin group is separated from the other component by the partition.
[0031] According to the sixth aspect, it is possible to prevent an adverse effect of the heat from the heat generating component on the other components.
[0032] An electronic appliance according to a seventh aspect is dependent on the sixth aspect, and the heat dissipating fin group is arranged only at a part of an area on the base, and at least a part of the other component is arranged on an area on which the heat dissipating fin group is not arranged on the base.
[0033] In the seventh aspect, there is an area where the heat dissipating fin group is not arranged on the base, and at least a part of the other component is arranged on the area.
[0034] According to the seventh aspect, it is possible to realize a space saving while preventing the heat of the heat dissipating component from being directly transmitted to the other component.
[0035] An electronic appliance according to an eighth aspect is dependent on the seventh aspect, and further comprises an exhaust hole and an intake hole both of which are provided to the housing, the exhaust hole is placed at a position being opposite to the heat dissipating fin group via the exhaust fan, and the intake hole is placed at a position being opposite to an opening of an intake channel (QL, QR) formed by the edge portion group on the side of the wall surface of the heat dissipating fin group and the wall surface.
[0036] In the eighth aspect, air taken out by the exhaust fan from the heat dissipating fin group is exhausted to the outside of the housing from the exhaust hole. As a result, an atmospheric pressure within the housing is reduced to allow outside air to be taken in the housing through the intake hole. The taken outside air is supplied to the heat dissipating fin group through the intake channel.
[0037] According to the eighth aspect, the exhaust hole is placed at a position being opposite to the heat dissipating fin group via the exhaust fan, and the intake hole is placed at a position being opposite to an opening of an intake channel, capable of realizing smooth air intake and exhaust, and heighten heat-dissipating efficiency.
[0038] An electronic appliance according to a ninth aspect comprises: a heat generating component; a base connected by heat to the heat generating component; a heat dissipating fin group arranged on the base; and other component. The heat dissipating fin group is arranged at only a part of an area on the base, and at least a part of the other component is arranged at an area where the heat dissipating fin group does not exist on the base.
[0039] In the ninth aspect, the heat dissipating fin group is arranged on a base provided in a position being opposite to the heat generating component. There is an area on the base where the heat dissipating fin group is not arranged, and at least a part of the other component is arranged on the area.
[0040] According to the ninth aspect, it is possible to prevent an adverse effect of the heat from the heat generating component on the other components while responding to the necessity of miniaturization and an optimal location.
[0041] According to the present invention, it is possible to realize a structure in view of the heat from the heat generating component while responding to the necessity of miniaturization and an optimal location.
[0042] The above described objects and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 is a perspective view of one embodiment of the present invention as seen from a front above;
[0044] FIG. 2 is a perspective view of FIG. 1 embodiment as seen from rear above;
[0045] FIG. 3 is a perspective view of FIG. 1 embodiment as seen from front below;
[0046] FIG. 4 is an illustrative view showing a hidden part by a cover of a right side surface in FIG. 1 embodiment;
[0047] FIG. 5 is an illustrative view showing a part of an assembly process of FIG. 1 embodiment;
[0048] FIG. 6 is a perspective view showing a result of FIG. 5 process (before the completion of the shield);
[0049] FIG. 7 is an illustrative view showing a process continued from the FIG. 5 process;
[0050] FIG. 8 is a perspective view showing a result of the FIG. 7 process (after completion of the shield);
[0051] FIG. 9 is an illustrative view showing a state in which a drive unit, a partition, and an exhaust fan are further mounted after the FIG. 7 process;
[0052] FIG. 10 (A) is a top view showing a structure of a heat dissipating member applied to FIG. 1 embodiment;
[0053] FIG. 10 (B) is a side view showing a structure of the heat dissipating member;
[0054] FIG. 10 (C) is a front view showing a structure of the heat dissipating member;
[0055] FIG. 11 (A)-(C) are illustrative views showing a part of a manufacturing process of the heat dissipating member applied to FIG. 1 embodiment;
[0056] FIG. 12 is an illustrative view showing a flow of air in the heat dissipating member of FIG. 1 embodiment;
[0057] FIG. 13 is an illustrative view showing a flow of air in a heat dissipating member of another embodiment;
[0058] FIG. 14 (A) is a top view showing the heat dissipating member of another embodiment;
[0059] FIG. 14 (B) is a top view showing a heat dissipating member of the other embodiment;
[0060] FIG. 14 (C) is a top view showing a heat dissipating member of a further embodiment;
[0061] FIG. 15 is a top view showing a heat dissipating member of another embodiment;
[0062] FIG. 16 is a top view showing a heat dissipating member of the other embodiment; and
[0063] FIG. 17 is a top view showing a heat dissipating member of a further embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0064] An appearance of a game apparatus 10 of one embodiment of the present invention is shown in FIG. 1-FIG . 3 . FIG. 1 is a perspective view of a game apparatus 10 as seen from above front, FIG. 2 is a perspective view of the game apparatus 10 as seen from above back, and FIG. 3 is a perspective view of the game apparatus 10 as seen from front below.
[0065] As shown in FIG. 1-FIG . 3 , the game apparatus 10 includes a substantially rectangular housing 12 . On a front surface 12 f of the housing 12 , disk slot 14 a , a SD card slot cover 14 b , a power button 16 a , a reset button 16 b , a disk eject button 16 c , etc. are formed.
[0066] On a right side surface 12 R of the housing 12 , a rubber foot 22 , an intake hole 24 , etc. are formed. On a back surface 12 b , a USB connector 26 , an exhaust hole 28 , a peripheral connector 30 , an AV connector 32 , a DC connector 34 , etc. are formed. On a bottom surface 12 u , a rubber foot 15 , an intake hole 25 , etc are formed. On a left side surface 12 L, an openable closeable covers 18 a and 18 b are formed.
[0067] FIG. 4 shows a part hidden under the covers 18 a and 18 b of the left side surface 12 L. Referring to FIG. 4 , the left side surface 12 L, a connector 20 a for various controllers (not illustrated), a memory card slot 20 b , an intake hole 27 , are provided.
[0068] FIG. 5 shows a part of an assembly process of the game apparatus 10 , and FIG. 6 shows a result of the FIG. 5 process. Referring to FIG. 5 and FIG. 6 , the housing 12 constructed as described above includes an electronic component like a CPU 38 , a GPU 40 , etc. and a substrate 36 mounted with the above-described connectors ( 20 a , 20 b , 30 , 32 and 34 ). The substrate 36 is secured with a bottom 46 (corresponding to the bottom surface 12 u of the housing 12 ) via a metal lower shield member 44 B.
[0069] Each of the CPU 38 and the GPU 40 being an exothermic electronic component has roughly the same thickness, and arranged at the back and the center of the substrate 36 . Then, on a top surface of the CPU 38 and GPU 40 , a metal (aluminum, for example) heat dissipating member 48 is arranged. The heat dissipating member 48 has a plurality of heat dissipating fins 48 a and a base 48 b for supporting these. The base 48 b takes a shape of rectangular, and has no more size than permit it to exactly cover the CPU 38 and GPU 40 . At each of the four corners of the base 48 b , a downward protrusion 48 c taking a shape of cylinder, and a tapped hole 48 d penetrating the base itself and the protrusion 48 c are formed. The height of the protrusion 48 c is slightly above the thicknesses of the CPU 38 and the GPU 40 . That is, the protrusion 48 c is a leg for supporting the heat dissipating member 48 at a top surface position of the CPU 38 and the GPU 40 .
[0070] Here, a structure of the heat dissipating member 48 is described in detail. The plurality of heat dissipating fins 48 a are arranged at roughly fixed intervals in parallel with a short side of the base 48 b as shown in FIG. 10 (A). It should be noted that at only the interval between the two heat dissipating fins sandwiching the tapped hole 48 d , a wider interval is ensured for attaching a screw 54 .
[0071] An edge: portion group T 1 on one side (upper side) of the plurality of heat dissipating fins 48 a is arranged along a long side (top) L 1 of the base 48 b . With respect to the other long side (lower side) of the base 48 b , an edge portion group T 2 on the other side (lower side) of the plurality of heat dissipating fins 48 a is arranged along a V-shaped line (C 1 ) such that the center thereof is closest, and the right and left thereof is the farthest. Out of the lower edge portion group T 2 , one along the line of the left side of the V-shaped letter is called a lower left edge portion group T 21 , and one along the line of the right side of the V-shaped letter is called a lower right edge portion group T 2 r.
[0072] Thus, as shown in FIG. 10 (B), it is possible to look through the entire lower right edge portion group T 2 r (or the lower left edge portion group T 2 l ) of the heat dissipating member 48 from the left side surface (or right side surface). Furthermore, the plurality of heat dissipating fins 48 a have the same height as one another as shown in FIG. 10(C) . It should be noted that the heights of the plurality of heat dissipating fins 48 a may be differentiated from one another, or the height of a single sheet of heat dissipating fin may be changed depending on the positions.
[0073] Such a heat dissipating member 48 is manufactured in a following process. First, an original member 48 A (see FIG. 11 (A)) having a base 48 Ab and a plurality of heat dissipating fins 48 Aa each having the same length as that of the base 48 Ab is molded by extrusion (not illustrated). Next, the original member 48 A on which the extrusion molding has been performed is subjected to a press work like cutting away a part of each of the plurality of heat dissipating fins 48 Aa with a press block (B 1 and B 2 ).
[0074] In the press work, first, as shown in FIG. 11 (A), the support member B 2 is inserted from the left between the first heat dissipating fin F 1 and the second heat dissipating fin F 2 , and the edge of the cutter member B 1 is placed at the left end of the V-shape line C 1 , and whereby, the heat dissipating fin F 1 is cut away by both of the members B 1 and B 2 .
[0075] Next, as shown in FIG. 11 (B), the support member B 2 is inserted from the left between the second heat dissipating fin F 2 and the third heat dissipating fin F 3 , and the cutter member B 1 is moved to the position of the heat dissipating fin F 2 along the V-shape line C 1 , and whereby, the heat dissipating fin F 2 is cut away by both of the members B 1 and B 2 . At this time, the cut-away position of the heat dissipating fin F 2 is lower than that of the heat dissipating fin F 1 , and therefore, the heat dissipating fin F 1 after the cut-away is never brought into contact with the cutter member B 1 .
[0076] Later, heat dissipating fins F 3 , F 4 . . . are sequentially cut away along the V-shape line C 1 in the similar manner. After completion of cut-away of the central heat dissipating fin F 5 , as shown in FIG. 11 (C), the direction of the cutter member B 1 is reversed to sequentially cut away the end of heat dissipating fins F 9 -F 6 along the V-shape line C 1 from the right at this time. The plurality of heat dissipating fins 48 Aa of the original member 48 A thus molded by extrusion is cut away along the V-shape line C 1 , which allows utilization of an extrusion with more simply shape than in a case that a die casting molding is directly performed on the heat dissipating member 48 , capable of reducing a manufacturing cost.
[0077] Additionally, as described above, the heat dissipating fins F 1 -F 5 are cut away from the left, and then the heat dissipating fins F 9 -F 6 are cut away from the right. Alternatively, cuttings are simultaneously made from the left and from the right. That is, the F 1 and F 9 are first cut away, the F 2 and F 8 are cut away next, the F 3 and F 7 are then cut away, the F 4 and F 6 are succeedingly cut away, and the F 5 is finally cut away. Thus, it is possible to shorten a manufacturing time.
[0078] As schematically shown in FIG. 5 , a thermal conduction sheet 50 is inserted between the heat dissipating member 48 , and the CPU 38 and GPU 40 . The thermal conduction sheet 50 is made of material high in flexibility and thermal conductivity (silicone, or the like), having the top surface thereof be closely brought into contact with the bottom surface of the heat dissipating member 48 , and the bottom surface thereof be closely brought into contact with the top surface of the CPU 38 and the GPU 40 . The heat of the CPU 38 and the GPU 40 is efficiently transmitted to the heat dissipating member 48 through the thermal conduction sheet 50 , and emitted from the heat dissipating member 48 . It should be noted that a heat conducting grease like silicone grease may be utilized in place of or in combination with the thermal conduction sheet 50 .
[0079] The substrate 36 is formed with four through holes 36 a respectively corresponding to four tapped holes 48 d of the heat dissipating member 48 . A lower shield member 44 B is formed with four tapped holes 44 Ba, and the bottom 46 is formed with four bearings 46 a . Also, four ferrite rings 52 are arranged between the heat dissipating member 48 and the substrate 36 . The ferrite ring 52 forms an inductor in cooperating with a protrusion 48 c , etc. of the heat dissipating member 48 to thereby prevent pulse like charge due to electrostatic discharge from entering the shield 44 .
[0080] Each of four metalic screws 54 for unitizing the heat dissipating member 48 , the substrate 36 , the lower shield member 44 B, and the bottom 46 is screwed from a corresponding tapped hole 48 d into the bearing 46 a through a ferrite ring 52 , a through hole 36 a and a tapped hole 44 Ba. Thus, the heat dissipating member 48 is fixed at a position be brought into contact with or be close enough to the top surface of the CPU 38 and GPU 40 as shown in FIG. 6 .
[0081] FIG. 7 shows a process continued from FIG. 5 , and FIG. 8 shows the result of the FIG. 7 process. As shown in FIG. 7 , after completion of the above-described integrating process, the upper shield member 44 A is mounted with the plurality of metalic screws 56 from the top surface side of the substrate 36 . As a result, as shown in FIG. 8 , the shield 44 is constituted by the upper shield member 44 A and the lower shield member 44 B to shield the inside electromagnetically.
[0082] The upper shield member 44 A is formed with a convex portion 44 Aa at a position corresponding to the heat dissipating member 48 . The convex portion 44 Aa has a height corresponding to the height of the base 48 b of the heat dissipating member 48 , and has slits 44 Ab for the plurality of heat dissipating fins 48 a on the top surface. The base 48 b is directly (or via the thermal conduction sheet 50 ) brought into contact with the CPU 38 , etc. in the shield, and the plurality of heat dissipating fins 48 a are exposed from the slits 44 Ab to the outside of the shield. Thus, heat emitted by the CPU 38 , etc. is efficiently transmitted to the base 48 b , and dissipated from the plurality of heat dissipating fins 48 a to the outside of the shield. That is, heat is not stopped within the shield, capable of obtain a high heat dissipating efficiency.
[0083] Then, as shown in FIG. 9 , a drive unit 54 is arranged at the front of the plurality of heat dissipating fins 48 a on the top surface of the shield 44 , that is, at a position corresponding to the disk slot 14 a of the front surface 12 f of the housing (see FIG. 1 ). A disk (not illustrated) inserted from the disk slot 14 a is housed and driven by the drive unit 54 .
[0084] Furthermore, since the drive unit 54 and the plurality of heat dissipating fins 48 a are proximity to each other, a partition 56 is provided between the drive unit 54 and the plurality of heat dissipating fins 48 a . Flow of air heartened by the plurality of heat dissipating fins 48 a to the drive unit 54 is prevented by the partition 56 , so that overheating of the drive unit 54 can be reduced.
[0085] Furthermore, an exhaust fan 58 is provided between the USB connector 26 and the peripheral connector 30 at the back of the shield 44 , that is, at a position corresponding to an exhaust hole 28 on the back surface 12 b of the housing (see FIG. 2 ). The air heated by the heat dissipating member 48 is exhausted by the exhaust fan 58 from the exhaust hole 28 to the outside of the housing 12 . In accordance with the exhaust, an atmospheric pressure within the housing 12 is reduced to allow cool outside air to be supplied to the inside of the housing 12 through the intake hole 24 on the right side surface 12 R and the intake hole 25 on the bottom surface 12 u . In a case that the covers 18 a and 18 b on the left side surface 12 L are opened, outside air is also sucked from the intake hole 27 .
[0086] At this time, in the vicinity of the plurality of heat dissipating fins 48 a , a flow of air shown in FIG. 12 occurs. Referring to FIG. 12 , the plurality of heat dissipating fins 48 a are arranged such that the longest heat dissipating fin F 5 is overlapped with a rotating shaft of the exhaust fan 58 . The partition 56 is arranged vertically to the rotating shaft at a position spaced a predetermined distance b from the lower edge of the heat dissipating fin F 5 .
[0087] Additionally, a positional relationship between the plurality of heat dissipating fins 48 a and the exhaust fan 58 is not limited to one shown in FIG. 12 , and may be changeable in view of adding other components thereto.
[0088] Here, when a Y axis is upwardly defined along the exhaust fan 58 , and an X axis is defined in the right direction along the partition 56 , the height of the lower edge of the longest heat dissipating fin F 5 is described to be “Y=b”, and the height of the lower edge of the shortest heat dissipating fin F 1 (or F 9 ) is described to be “Y=a”. Furthermore, the horizontal positions of the heat dissipating fin F 1 -F 9 can be described like X=−4, X=−3, . . . , X=0, . . . , X=4.
[0089] Between the plurality of heat dissipating fins 48 a and the partition 56 , an intake channel QL is formed along the X axis by the lower left edge portion group T 21 and the partition 56 , and an intake channel QR is formed along the X axis by the lower right edge portion group T 2 r and the partition 56 . Additionally, these two intake channels QL and QR form a single M-shaped channel. On the other hand, the heat dissipating fins F 1 -F 9 form the eight heat dissipating channels P 1 -P 8 along the Y axis.
[0090] Outside air enters the heat dissipating member 48 from two positions including a space (left opening) between the heat dissipating fin F 1 and partition 56 and a space (right opening) between the heat dissipating fin F 9 and the partition 56 . The air entered from the left opening flows through the intake channel QL in the right direction (X direction), and the air entered from the right opening flows through the intake channel QR in the left direction (−X direction).
[0091] The intake channel QL is narrower in the right direction, and therefore, the amount of air flowing through each position (X=−4, −3, . . . , 0) of the intake channel QL is less as the air progresses to the right. This means that the air entered from the left opening roughly equally flows into the heat dissipating channels P 1 -P 4 . Similarly, the intake channel QR is narrower in the left, and therefore, the amount of air flowing through each position (X=4, 3, . . . , 0) of the intake channel QR is less as the air progresses to the left. This means that the air entered from the right opening roughly equally flows into the heat dissipating channels P 8 -P 5 .
[0092] As understood from the above description, the lower edges of the plurality of heat dissipating fins 48 a (F 1 -F 9 ) are cut away along the V-shaped line C 1 in the heat dissipating member 48 of this embodiment to thereby form the M-shaped channel (intake channels QL and QR) between the plurality of heat dissipating fins 48 a and the partition 56 , allowing intake of the large amount of air through the large openings at the right and left. Furthermore, the left half (intake channel QL) of the M-shaped channel is narrower in the right direction, and the right half (intake channel QR) thereof is narrower to the left direction, and therefore, the taken air evenly is spread through the plurality of heat dissipating fins 48 a (heat dissipating channels P 1 -P 8 ). Thus, a high heat dissipating advantage can be obtained.
[0093] Additionally, in the heat dissipating member 48 of this embodiment, the lower edge portion group (T 2 ) of the plurality of heat dissipating fins 48 a is cut away along the V-shaped line C 11 as shown in FIG. 12 . On the other hand, as shown in FIG. 13 , the lower edge portion group (T 2 ) of the plurality of heat dissipating fins 48 a may be cut away along the single line C 2 inclined with respect to the partition 56 , and an intake hole may be formed at a position corresponding to the notch on the left side surface 12 L of the housing. In this case also, a large amount of air can mainly be taken from the left opening (the space between the heat dissipating fin F 1 and the partition 56 ) into the intake channel QL, and the air can evenly be spread into the entire heat dissipating fin 48 a (heat dissipating channels P 1 -P 8 ).
[0094] According to FIG. 13 configuration, the differences between the lower edge portion of the plurality of heat dissipating fins 48 a can be smaller than that shown in FIG. 12 while the lengths of spaces a and b are ensured as in FIG. 12 . That is, it is possible to make the slant of the single line C 2 gentle.
[0095] Therefore, in accordance with the configuration in FIG. 13 , it is possible to make a ventilating resistance less, and make an air flow from the above described intake hole on the left side surface 12 L of the housing to the intake channel QL smooth. Thus, it is possible to obtain a high heat dissipating effect.
[0096] Also, it may be possible that the space b shown in FIG. 13 is further large to make the slant of the single line C 2 gentler.
[0097] In addition, the V-shaped line C 1 at a time of cutting away the lower edges of the plurality of heat dissipating fins 48 a (F 1 -F 9 ) may be left-right asymmetry as shown in FIG. 14(A) . Furthermore, the pattern of cutting away may be U-shaped (or angular) as shown in FIG. 14 (B) without being limited to the V-shaped. In a case of utilizing a curve, the curvature may be changed depending on the position as shown in FIG. 14 (C).
[0098] Generally, if the lower edge portion group of the plurality of heat dissipating fins 48 a is cut away along a curve or a line which monotonously decreases on the left side and monotonously increases on the right side with respect to a minimum value, a large amount of air can be taken from the large openings at the right and left, and can be spread into the entire of the plurality of heat dissipating fins 48 a , capable of obtaining a high heat dissipating effect.
[0099] Furthermore, in this embodiment, the spaces of the plurality of heat dissipating fins 48 a (space between each of the heat dissipating channels P 1 -P 8 ) are equal, but may be changeable depending a position in the X direction. One example is shown in FIG. 15 . Referring to FIG. 15 , each of the widths d 1 -d 8 respectively corresponding to the heat dissipating channels P 1 -P 8 is longest at the channel P 4 and P 5 adjacent to the longest heat dissipating fin F 5 , and becomes narrower as the distance is away from the heat dissipating fin F 5 (that is, d 1 <d 2 <d 3 <d 4 , d 5 >d 6 >d 7 >d 8 ).
[0100] Generally, a fluid like air is difficult to flow in a longer channel in the same width. Here, it is though that it is possible to uniform the flow of air by making the heat dissipating channel P 1 -P 8 have a width corresponding to the length. It should be noted that by making the width of the heat dissipating channel wider, a heat dissipating area becomes small, and therefore, the heat dissipating advantage is not always heightened.
[0101] Furthermore, on the base 48 b of the heat dissipating member 48 , there is an area on which the heat dissipating fins 48 a are not arranged as a result of the cut-away, but such an empty area may be removed as shown in FIG. 16 . However, in this embodiment, the CPU 38 and the GPU 40 also exist directly under the empty area, and the empty area also functions so as to transmit heat of the CPU 38 , etc. to the plurality of heat dissipating fins 48 a . Furthermore, since a part of the drive unit 54 is placed above the empty area (see FIG. 10 (A)), the empty area functions so as to prevent the heat of the CPU 38 , etc. from being directly transmitted to the drive unit 54 . In such a case, it is preferable that the empty area is not removed.
[0102] It should be noted that the function of the above-described empty area is independent of the shape of the notch pattern (by extension, the alignment of the plurality of heat dissipating fins 48 a ). Thus, for example as shown in FIG. 17 , the lower edge portion group of the plurality of heat dissipating fins 48 a may simply be cut away in parallel with the bottom L 2 of the base 48 b . By arranging a part of components such as the drive unit 54 , etc. in the empty area, it is possible to realize space saving.
[0103] Furthermore, in this embodiment, the edge portion group T 1 of the plurality of heat dissipating fins 48 a on the side of the exhaust fan 58 is arranged on the line vertical to the plurality of heat dissipating fins 48 a (top L 1 of the base 48 b ) (see FIG. 10 (A)), but may be arranged along a inclined line or a curve with respect to the plurality of heat dissipating fins 48 a.
[0104] Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims. | In an electronic appliance, a base is thermally fused by a heat generating component. On the base, a heat dissipating fin group including heat dissipating fins each extending in a Y direction is arranged in spaced relation in an X direction. An exhaust fan and a partition between which the heat dissipating fin group is sandwiched in the Y direction are arranged so as to be faced with each other. The edge portion group of the heat dissipating fin group on the side of the partition is farthest from the wall surface at least one outermost position in the X direction and closest from the wall surface at a specific position different from the one outermost position, and is farther from the wall surface between the specific position and the one outermost position as the one outermost position is approached. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional application of application Ser. No. 08/178,326 filed Jan. 11, 1994 which, in turn, is a National Stage Application of PCT/International Application PCT/CH/93/00171 filed Jul. 12, 1993.
BACKGROUND OF THE INVENTION
The invention relates to a scaled flexible sachet, containing at least one powder substance for the preparation of a beverage including substances compacted into a cake, by extraction under pressure and to manufacture of the sachet.
The use of pre-metered and pre-packaged portions of ground coffee for the preparation of expresso-type coffee has the advantage that it facilitates the coffee preparation operations while ensuring that the quality of the product is relatively consistent.
These portions are currently provided in three main forms. According to a first version, the pre-packaged portions disclosed in Patent Specifications Swiss Patent No. 636 311, U.S. Pat. No. 5,012,629 and European Patent Application Publication No. 272 432 are formed by two sheets of filter paper sealed over their periphery and filled with ground coffee. This solution has the drawback that an oxygen-barrier outer packaging is required to prevent any oxidation of the product during storage, entailing additional costs and a supplementary operation for the consumer who has to remove it before the desired coffee can be extracted.
According to a second version, disclosed in Patent Application WO 92/07775, the portion is formed by a sealed capsule opening into its extraction device under the action of the introduction of the extraction fluid, after deformation and then perforation by pointed members.
This capsule, formed by a sealed envelope forming a lateral wall and two walls, one of which forms the base of the cartridge and the other of which closes the opposite end of the cartridge, has the drawback that it makes use of different packaging materials, some of which have to be thick enough to make them semi-rigid, and can be used only in one direction, i.e., with the cap surface upwards in an extraction device which is completely adapted to the capsule and to its arrangement.
According to a third version, U.S. Pat. No. 3,607,297 discloses sachets for the preparation of a beverage in the form of a strip having filling cavities and a flat cap on the upper surface. According to this patent, these sachets are adapted for gravity flow and have to be perforated on both surfaces by toothed plates, one of which is pushed by a spring.
SUMMARY OF THE INVENTION
The aim of the present invention is to provide a sealed flexible sachet containing ground roast coffee and adapted to be extracted under pressure for the preparation of a beverage, this sachet requiring no outer packaging and the extraction system being adapted solely to the sachet and not to the arrangement of the sachet, as it is fully adapted to be extracted in one or other direction.
The present invention also aims to limit to a minimum the quantity of material needed for the packaging of a portion.
The invention provides to a flexible sachet in the form of an individual portion formed by thin, sheets of circular, oval or polygonal shape, which provide between one another a space for the powder substance and which are sealed over their periphery so that the sachet is substantially symmetrical with respect to its plane of sealing. The material used for the flexible sheets is impermeable to oxygen and water vapour. The sheets used to form the sachet may be identical, but as a variant, for reasons relating to manufacture, the two flexible sheets may, however, differ slightly from one another as regards shape and/or material without thereby impairing the symmetry required for extraction.
The invention also includes embodiments wherein the powder substance suitable for preparation of a beverage is in a form of a compacted powder substance wherein one piece, which is compacted in a form of a cake, or more pieces of the compacted substance is/are contained between the sheets.
Also included in the present invention is a process for preparation of a beverage, wherein a compacted powder substance in a form of a cake is contained within a sachet and extracted in the sachet by an extraction fluid for preparation of a beverage, and the beverage is obtained from the sachet. The sachet containing the cake comprises two sachet sheets of material which, prior to extraction of the substance, protect the substance against oxygen and water vapor and which extend to sealed edges for containing the substance within the sheets prior to and during extraction. In effecting extraction, extraction fluid is injected under pressure, such as by perforating one sheet first to provide at least one opening for injection of extraction fluid, into the sachet for deforming the substance for extracting the substance, and the other sheet advantageously is deformed against a surface having portions forming, upon deformation of that sheet, local breakages in that sheet providing openings for obtaining the beverage. The cake and sheets advantageously are configured so that there is free space between at least one cake surface and one sheet for allowing the substance to expand between the sheets, and the surface positioned adjacent the at least one opening may have a concave shape or may have channel impressions therein.
DETAILED DESCRIPTION OF THE INVENTION
The method and the device used for the extraction of sachets of the invention may advantageously be of the type disclosed in European Patent Applications EP 92107548.7 or EP 92112364. The upper surface of the sachet is firstly opened by one or a plurality of perforating members provided under the upper surface of the device, and the lower surface is opened by local breakages following its deformation against raised and hollow portions which are not cutting or perforating disposed on the lower surface of the device, solely under the effect of the pressure increase during the injection of the extraction fluid. There is consequently no need to open the sachet in advance or to remove a portion of material therefrom prior to its use. After use, the sachet may be readily removed with a minimum of waste.
Therefore, since the sachet of the present invention is symmetrical, the user may insert it into the extraction system without paying attention to the direction of introduction. Moreover, the sachet is ready for immediate use and requires no prior preparation before insertion into the extraction system.
However, when the extraction device available is only partial with respect to the device described above, i.e., it does not comprise the means for opening one or other of the two surfaces, for instance a device of the type of conventional expresso machines, openings may be provided, just prior to positioning in this partial extraction device, in one and/or the other surface of the sachet, allowing the passage of the extraction fluid.
The inner diameter of the sachet is preferably between 25 and 70 mm and the sealed edge has a width of 3 to 15 mm. Once filled, the sachet preferably has a thickness of between 5 and 20 mm at its centre. The quantity of powder substance which it contains may vary between 5 and 20 g depending on its use.
The sachet is filled with a powder substance for the preparation of a beverage. This substance is preferably roast and ground coffee, but may also be tea, soluble coffee, a mixture of ground and soluble coffee, chocolate or any other dehydrated food substance.
The external shape of the sachet is preferably circular, but may also be oval or polygonal with four to ten sides possibly with rounded edges, or may be a combination of these three elements. Its section is preferably substantially in the form of a flattened hexagon, but it may also have a lenticular shape.
According to a variant, not illustrated, the sachet is provided with at least one lateral tongue facilitating its positioning. This tongue is simply produced when the sachet is cut out.
According to a first configuration, the sachet is formed by two sheets sealed over their periphery, the seal being provided as a plane surface.
According to a first production variant, the two sheets are stretched in advance (deformation in the plastic zone) in order to avoid any random folds due to the volume expansion of a material which is originally plane, either by means of compression in a die-piston assembly, or by means of pressurization by a gas of the inner surfaces and/or possibly suction of the outer surfaces in a mould of appropriate shape at a controlled temperature, in which the sheets are kept plane at their periphery.
According to a second variant, the material is simply pushed back as in the two examples above, but in this case, it is not held at its periphery and then has more or less random folds resulting from the volume expansion of a plane surface.
According to a second configuration, the two sheets are pre-formed in a systematic and controlled manner and sealing is carried out, after filling with the powder substance, in accordance with a three-dimensional device. The volume expansion of a plane surface, without elastic or plastic stretching, means that the apparent diameter of the material is modified with respect to its real diameter. This excess material has to be compensated by an appropriate geometrical shape in order to avoid any random folds.
In order to achieve this aim, systematic and controlled moulding takes place in a mould in which, at all locations, the principle of the equality of the apparent deployed diameter and the real diameter is ensured. This is obtained in the mould by creating corrugations of varying height which flare outwards. In the central portion of the sheets of the sachet, deformation is non-existent or small because this involves the reference plane. In contrast, as they develop towards the outer diameter, these corrugations increase in height and become flared. This corrugation depends on the ratio between the diameter of the sachet and the distance between the planes of the sealing zone and that in the central zone of the sachet, i.e., half the height of the sachet.
The two sheets of the sachet undergo equivalent volume expansion and are positioned during sealing, after filling, so that they are correctly superimposed on one another. The sealing zone of the two sheets thus takes the form of a corrugated circular strip.
This moulding of the sheets is carried out, either by means of compression in a die-piston assembly, or by means of pressurization by a gas of the inner surfaces and/or suction of the outer surfaces. In both cases the mould has the desired relief.
According to a third configuration, the sachet may have gussets on one or more sides. The gussets, resulting from folding prior to the sealing of the sheets, make it possible to provide the assembly with a specific volume, while eliminating random folds. The manufacture of sachets using this latter method may be carried out in a known manner.
The sheets may be made from a flexible material such as aluminium of a thickness of 5 to 40 μm or plastic such as PET. polyethylene-terepthalate (PET) or from polyethylene (PE), polypropylene (PP), polyamide (PA), polystyrene (PS), ethylene and vinyl alcohol copolymer (EVOH), polyvinylidene chloride (PVDC) and polyvinyl alcohol (PVA), and may be single layer sheets or multilayer sheets including paper. The sheets are preferably made from a flexible multi-layer material suited to sealing by conventional methods, while protecting the product adequately against oxygen and water vapour. The following combination of materials are recommended:
outer layer: PET (normal, woven or nonwoven), PE, PP, PA, PS or paper
high-barrier central layer: aluminium of a thickness of 5 to 20 μm, EVOH, PVDC, PET or PVA
inner layer: plastic, preferably PE or PP or OPP. The following multi-layer combinations can be envisaged: PET-EVOH-PE or PET-aluminium-PE. The use of biodegradable or hydrosoluble material is also possible as, a single layer or in combination with other materials.
In the case in which PET is used, it may take the form of a single layer combining the outer and central layers, particularly if it is filled with a layer of silicon oxide or if it is metallized.
According to a variant, the thermosealing operation is facilitated by the insertion between the two sheets of an intermediate material, such as a food glue or a coating of plastic material. This material can then form a further thickness advantageously used to provide complete leak-tightness during extraction.
The sachet of the invention preferably contains a compacted cake of the powder substance in the form of one or more pieces, the compacting rate being such that there is a reduction of volume of between 10% and 60% with respect to the non-compacted substance. This compacting is carried out so that the free space between the two flexible sheets and the substance accounts for between 1 and 20% of the total space between the flexible sheets. This free space is needed to allow the coffee to expand sufficiently, during extraction, to allow correct extraction.
The compacted substance further comprises, on at least one of its surfaces, impressions forming water circulation channels of appropriate shape (for instance crosses, circles) making it possible to improve the pre-moistening of the sachet and its extraction. The shape of these impressions is selected in accordance with the extraction device used.
The compacted material may also have, on at least one of its surfaces, a concave or convex shape making it possible, where necessary, to modify the compacted state during its positioning in the extraction device.
This shape is adapted to the arrangement of the extraction chamber and may be advantageously used to ensure a correct leak-tightness of the sachet in the peripheral zone of injection, i.e., between the upper surface of the extraction chamber and the upper sheet of the sachet.
The invention also relates to the method of manufacture of the sachet described above, in which two flexible sheets which are impermeable to oxygen and water vapour are deformed in a symmetrical manner by moulding or by stretching, a quantity of powder substance is metered, this substance is placed on one of the deformed flexible sheets and the two sheets are sealed over their periphery.
The powder substance is conventionally compacted during the manufacturing process.
According to a first embodiment, the substance may be compacted after it has been metered out and placed between the sheets of the sachet.
According to a second preferred embodiment, the substance is compacted and then metered out and placed between the sheets of the sachet. Depending on the shape and size of the pieces of compacted substance, one or several pieces are used to obtain the desired quantity.
Compacting at an appropriate pressure and into an appropriate shape may also be carried out after closure of the sachet.
Compacting is carried out in a conventional manner, either by rollers or by a die-piston assembly, the physico-chemical parameters such as pressure, temperature and moisture level of the substance being adapted to the nature of the substance to be compacted.
According to a particular embodiment, the compacted substance may be partially or completely decompacted after closure of the sachet, for instance by vibration or by any other known mechanical means.
When the powder substance is subject to oxidation, the manufacturing operations can be carried out under the protection of a current of inert, oxygen-free gas, for instance under nitrogen or CO 2 .
Some plastic materials have the property that they return substantially to their initial shape after temporary deformation. The sachet of the invention makes use of this property, together with an appropriate configuration of its extraction device. The lips of the openings formed by the perforated portions of the sachet consequently close about tapered perforating members such as needles, ensuring the desired leak-tightness about these members during extraction. After extraction, this property also limits discharges from the sachet during its removal, including those portions torn by the extraction system.
The symmetry of the sachet, in terms of both shape and material, its flexibility and the property mentioned above, make it possible at will to vary the method and the location of water introduction and extraction. Both may be, for instance, concentric, on the same surface or on opposite surfaces, the objective being to cause the water to travel an optimum path.
The flexibility of the walls of the sachet is also advantageously used to allow, by its deformation without breakage in the extraction device, a reconfiguration of the volume of the coffee which it contains. This controlled deformation is designed to improve the distribution of the flow in the bed of coffee and consequently the quality of extraction.
Moreover, taking account of the method of extraction for which it is designed, the sachet is formed by a combination of materials selected according to an additional criterion of plasticity. The deformability by elongation of its material must be sufficient to allow the shaping described above, but it must also, under the effect of the pressure of the fluid and at the location of the raised portions of the extraction device, break in the form of small tears without its elongation being too great.
The following description is made with reference to the accompanying drawings, given by way of non-limiting example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation in section of the sachet of the invention.
FIG. 2 is a diagrammatic representation in section of the sachet according to a second embodiment.
FIG. 3 is a perspective view of the moulded sheet used for the sachet of FIG. 2.
FIG. 4 is a plan view of a sachet according to a third embodiment.
FIG. 5 is a diagrammatic representation in section along the line A-A' of FIG. 4.
FIG. 6 is a perspective view of a sheet of the sachet according to a fourth embodiment.
FIG. 7 is a perspective view of the unpackaged compacted coffee.
DETAILED DESCRIPTION OF THE DRAWINGS
The sachet 1 of circular shape comprises two sheets of flexible material 2 and 3 sealed over their periphery 4 by thermosealing and containing a one piece cake of compacted ground roast coffee 5 for the preparation of a beverage. The compacted coffee has concave surfaces 35, the general shape of its section being a flattened octagon, whereas that of the sachet is hexagonal. The cylindrical edge 38 of the cake is designed to prevent the undesirable presence of grains in the sealing zone.
In terms of figures, the sachet has a total space between the two sheets of 15 cm 3 , the volume of the compacted coffee is 14 cm 3 and has a compacting rate of 30%.
The sachet 10 of FIG. 2, obtained from two moulded sheets 6, 7, has corrugations 8, 12 and 13 whose amplitude and distance from one another increase from the plane surface 11 towards the sealing edge 9. In this example, the cake of coffee has a single concave surface 35 and is not exactly symmetrical, but this difference is not connected with the shape of the sachet.
FIG. 3 shows a moulded sheet 7 with a flat base 11 and corrugations which become increasingly accentuated as the outer edge is approached. These corrugations have bosses 14 and hollows 15.
After placing the ground roast coffee on the base 11, the sheet 6 is positioned so that the bosses of 6 face the hollows of 7 and vice versa. Thermosealing may then be carried out.
In FIGS. 4 and 5, the sachet 18 is of square shape with two gussets on the opposite sides. The two sheets 20 and 22 are sealed along the two gussets at 19, 23, 24, 25 and on the edges 26, 27 where the two sheets are simply joined. The gussets make it possible to provide the sachet with a specific volume without the appearance of random folds.
FIG. 6 shows a sheet 30 having corrugations 31 on the edge and also on the base 32. Manufacture takes place in the same way as for the sachet of FIG. 2.
FIG. 7 shows the compacted substance 36 alone. On at least one surface it has zones 37 for water circulation in the form of channels allowing uniform pre-moistening and extraction. | A powdered substance, which is suitable for preparation of a beverage with an extraction fluid and which is compacted in a form of a cake, is extracted for preparation of a beverage. The compacted substance cake is contained within a sachet between two sachet sheets which, prior to extraction of the substance, protect the substance against oxygen and water vapor and which extend to sealed edges for containing the substance within the sheets prior to and during extraction. In effecting extraction, one sheet is perforated first to provide at least one opening for injection of extraction fluid, and extraction fluid is injected under pressure into the sachet for contacting the substance and for extracting the substance in the sachet, and the other sheet advantageously is deformed against a surface having portions forming, upon deformation of the second sheet, local breakages in that sheet for opening that sheet for flow of extracted beverage substance. The cake and sheets advantageously are configured so that there is free space between at least one of the cake surfaces and one sheet for allowing the substance to expand between the sheets, and the cake surface positioned adjacent the sheet which is opened for injection of extraction fluid may have a concave shape or may have channel impressions therein. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to generally to textile dyeing and more particularly to the introduction of dyes and other chemicals into a process for dyeing a textile material in a supercritical fluid.
BACKGROUND ART
[0002] It will be appreciated by those having ordinary skill in the art that conventional aqueous dyeing processes for textile materials, particularly hydrophobic textile materials, generally provide for effective dyeing, but possess many economic and environmental drawbacks. Particularly, aqueous dyebaths that include organic dyes and co-solvents must be disposed of according to arduous environmental standards. Additionally, heat must be applied to the process to dry the textile material after dyeing in an aqueous bath. Compliance with environmental regulations and process heating requirements thus drive up the costs of aqueous textile dyeing to both industry and the consuming public alike. Accordingly, there is a substantial need in the art for an alternative dyeing process wherein such problems are avoided.
[0003] One alternative to aqueous dyeing that has been proposed in the art is the dyeing of textile materials, including hydrophobic textile materials like polyester, in a supercritical fluid. Particularly, textile dyeing methods using supercritical fluid carbon dioxide (SCF—CO 2 ) have been explored.
[0004] However, those in the art who have attempted to dye textile materials, including hydrophobic textile materials, in SCF—CO 2 have encountered a variety of problems. These problems include, but are not limited to, “crocking” (i.e. tendency of the dye to smudge when the dyed article is touched) of the dye on the dyed textile article; unwanted deposition of the dye onto the article and/or onto the dyeing apparatus during process termination; difficulty in characterizing solubility of the dyes in SCF—CO 2 ; difficulty introducing the dyes into the SCF—CO 2 flow; and difficulty in preparing the dyes for introduction into the dyeing process. These problems are exacerbated when attempts to extrapolate from a laboratory process to a plant-suitable process are made.
[0005] PCT Publication No. WO 97/13915, published Apr. 17, 1997, designating Eggers et al. as inventors (assigned to Amman and Sohne GmbH and Co.) discloses a system for introducing dye into a CO 2 dyeing process which comprises a bypass flow system associated with the main circulation system that includes a color preparing vessel. The bypass is opened, after a certain temperature and pressure are reached, so that SCF—CO 2 flows through the color preparing vessel and dissolves the previously loaded dye(s). The SCF—CO 2 -containing dissolved dye flows from the bypass back into the main circulation system where it joins the bulk of the SCF—CO 2 flow that is used to accomplish dyeing.
[0006] PCT Publication No. WO 97/14843, published Apr. 24, 1997, designating Eggers et al. as inventors (assigned to Amman and Sohne GmbH and Co.) discloses a method for dyeing a textile substrate in at least one supercritical fluid, wherein the textile substrate is preferably a bobbin and the fluid is preferably SCF—CO 2 . The disclosed invention attempts to prevent color spots from forming on the textile substrate during dyeing and is directed to ways of incorporating the dye material into the supercritical fluid using the basic bypass system as described above in PCT WO 97/13915.
[0007] The method involves the use of at least one dye which is contacted with the supercritical fluid as a dye bed, dye melt, dye solution, and/or dye dispersion before and/or during actual dyeing in an attempt to form a stable solution of dye in the supercritical fluid. A stated goal is avoiding the formation of dye agglomerates having a particle size of more than 30 microns, preferably more than 15 microns, in the solution.
[0008] This invention attempts to accomplish these aims through a variety of embodiments. In one embodiment, the dye bed is provided with inert particles, in particularly glass and/or steel balls, to prevent agglomeration. Alternatively, the dye bed itself can consist of inert particles coated with the dye. SCF—CO 2 is then passed through the dye bed to incorporate the dye within the SCF—CO 2 .
[0009] However, there are a number of significant drawbacks to this embodiment of the dye introduction method disclosed by Eggers et al. PCT Publication No. WO 97/14843. For example, use of a fixed or fluidized bed to introduce dye into the dyeing system can be hindered if appropriate flow conditions are not present. The dye particles must be at all times in intimate and vigorous contact with the supercritical fluid for effective dissolution. If this is not the case, the dissolution rate will be low and will likely not be complete by the end of the dyeing cycle.
[0010] Moreover, promotion of a high convective mass transfer coefficient (i.e., intimate and vigorous mixing) can result in substantial pressure losses through the dye-add vessel. Because of their relatively low viscosity values, supercritical fluids are easily diverted to areas of lower resistance, which can lead to mechanical problems such as channeling and stagnation. Channeling refers to the development of a fluid path, or channel, through a particulate bed that circumvents uniform flow throughout the bed; i.e., a stream of fluid develops through the bed such that the flow in the region where the stream exists is greater than the flow of fluid in the rest of the bed. In this case, the particles not in the channel are not properly contacted by the fluid. These conditions, in turn, result in dye particles not being contacted in a manner that will allow substantially complete dissolution.
[0011] Insuring the proper flow conditions when using fluidized dye beds, fixed dye beds, or dye bed holding devices requires very careful and complex design of the internals of the dye-add vessel in order to assure good mixing and to avoid mechanical flow problems without excessive pressure drop. Indeed, it is likely that dye bed holding devices that are chambered to force uniform flow of fluid through the bed, such as those proposed for use in dye introduction by Eggers et al., PCT Publication No. WO 97/14843, also suffer very high pressure losses.
[0012] Another drawback arises when the fluidized and fixed dye bed is installed in the system in a bypass loop. Since the dye dissolution process is rate limiting, this arrangement couples the dyeing process to the dye dissolution process, which is generally undesirable. In contrast, the dye should be introduced at a rate consistent with dyeing the textile material as rapidly as possible but also in a level manner.
[0013] An alternative embodiment of the dye injection method disclosed by Eggers et al. PCT Publication No. WO 97/14843 involves injection of the dye as a melt incorporated in an inert gas, preferably nitrogen or carbon dioxide (with property of being inert for these two gases being a function of the process conditions). It has been observed by the present applicants that melting of disperse dyes can lead to decreased solubility in SCF—CO 2 . This circumstance indicates that the applicability of this embodiment of the disclosed dye injection method is limited.
[0014] Yet another embodiment of the dye introduction method disclosed by Eggers et al. PCT Publication NO. WO 97/14843 involves delivery of the dye into the supercritical fluid flow as a solution or suspension. When a solution is being injected and water-soluble dyes are being used, the recommended injection solvent is water. For water-insoluble dyes, a variety of common nontoxic injection solvents are suggested, with acetone, which readily dissolves disperse dyes, being foremost. The water-insoluble dyes are injected as a solution or suspension in the chosen solvent. In the case that a suitable nontoxic solvent cannot be found or the required amount of solvent is so great that it adversely affects the dyeing process, injection of a dispersion, preferably an aqueous dispersion, is recommended.
[0015] This embodiment of the method disclosed by Eggers et al. PCT Publication No. WO 97/14843 also suffers from several drawbacks. Firstly, water is an anti-solvent in SCF—CO 2 when used with disperse dyes. Thus, for SCF—CO 2 , the presence of water results in a significantly impaired dyeing process to the extent that it is questionable whether dyeing could be accomplished at all. At best, the action of water in the SCF—CO 2 would cause the dye to reside in the dyeing process as dispersion. In the worst case, the dye would exist as an unstable suspension with unsuitable properties for dyeing. Secondly, in the case that a suitable SCF—CO 2 /water/dye dispersion was obtained, the SCF—CO 2 dyeing process would be similar to the conventional aqueous process, the replacement of which is a desired goal in the art.
[0016] Poulakis et al., Chemiefasern/Textilindustrie, Vol. 43-93, February 1991, pages 142-147 discuss the phase dynamics of supercritical carbon dioxide. An experimental section describing an apparatus and method for dyeing polyester in supercritical carbon dioxide in a laboratory setting is also presented. Thus, this reference only generally describes the dyeing of polyester with supercritical carbon dioxide in the laboratory setting and is therefore believed to be limited in practical application.
[0017] U.S. Pat. No. 5,199,956 issued to Schlenker et al. on Apr. 6, 1993 describes a process for dyeing hydrophobic textile material with disperse dyes by heating the disperse dyes and textile material in SCF—CO 2 with an azo dye having a variety of chemical structures. The patent thus attempts to provide an improved SCF—CO 2 dyeing process by providing a variety of dyes for use in such a process.
[0018] U.S. Pat. No. 5,250,078 issued to Saus et al. on Oct. 5, 1993 describes a process for dyeing hydrophobic textile material with disperse dyes by heating the disperse dyes and textile material in SCF—CO 2 under a pressure of 73 to 400 bar at a temperature in the range from 80° C. to 300° C. Then the pressure and temperature are lowered to below the critical pressure and the critical temperature, wherein the pressure reduction is carried out in a plurality of steps.
[0019] U.S. Pat. No. 5,578,088 issued to Schrell et al. on Nov. 26, 1996 describes a process for dyeing cellulose fibers or a mixture of cellulose and polyester fibers, wherein the fiber material is first modified by reacting the fibers with one or more compounds containing amino groups, with a fiber-reactive disperse dyestuff in SCF—CO 2 at a temperature of 70-210° C. and a CO 2 pressure of 30-400 bar. Specific examples of the compounds containing amino groups are also disclosed. Thus, this patent attempts to provide level and deep dyeings by chemically altering the fibers prior to dyeing in SCF—CO 2 .
[0020] U.S. Pat. No. 5,298,032 issued to Schlenker et al. on Mar. 29, 1994 describes a process for dyeing cellulosic textile material, wherein the textile material is pretreated with an auxiliary that promotes dye uptake subsequent to dyeing, under pressure and at a temperature of at least 90° C. with a disperse dye from SCF—CO 2 . The auxiliary is described as being preferably polyethylene glycol. Thus, this patent attempts to provide improved SCF—CO 2 dyeing by pretreating the material to be dyed.
[0021] Despite extensive research into SCF—CO 2 textile dyeing processes, there has been no disclosure of a suitable method for introducing dyes or other textile treatment materials into such processes. An environmentally and economically sound method for introducing dyes or other textile treatment materials would be particularly desirable in the plant-scale application of a SCF—CO 2 textile dyeing process. Therefore, the development of such a method meets a long-felt and significant need in the art.
DISCLOSURE OF THE INVENTION
[0022] A process for introducing a textile treatment material into a textile treatment system is disclosed. The process comprises: (a) providing a preparation vessel in fluid communication with a textile treatment system; (b) loading a textile treatment material into the preparation vessel; (c) dissolving or suspending the textile treatment material in near-critical liquid carbon dioxide or supercritical fluid carbon dioxide in the preparation vessel; and (d) introducing the dissolved or suspended textile treatment material into a textile treatment system. A system suitable for use in carrying out the process is also disclosed.
[0023] The process and system of the present invention are preferred for use with a textile treatment system that utilizes SCF—CO 2 as a treatment medium. Optionally, the textile treatment material can be selected from a group including, but not limited to, a brightening agent, a whitening agent, a dye and combinations thereof.
[0024] Accordingly, it is an object of the present invention to provide an improved process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF—CO 2 textile treatment system.
[0025] It is another object of the present invention to provide an environmentally benign process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF—CO 2 textile treatment system.
[0026] It is another object of the present invention to provide a process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF—CO 2 textile treatment system, that reduces the loss of such textile treatment materials in a textile processing operation.
[0027] It is yet another object of the present invention to provide a process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF—CO 2 textile treatment system, that can be isolated from the textile treatment system to thereby facilitate addition of dyes and other textile treatment materials thereto.
[0028] It is a further object of the present invention to provide an improved process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF—CO 2 textile treatment system, in accordance with an introduction profile that facilitates correspondence between the introduction rate and an appropriate dyeing rate.
[0029] It is a further object of the present invention to provide an improved process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF—CO 2 textile treatment system, at an introduction point where there is high fluid shear to ensure proper mixing of the introduced treatment material into the textile treatment system.
[0030] It is yet a further object of the present invention to provide an improved process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF—CO 2 textile treatment system, that utilizes supercritical fluid and/or near-critical liquid carbon dioxide as a solvent for the dye or other textile treatment material.
[0031] Some of the objects of the invention having been stated herein above, other objects will become evident as the description proceeds, when taken in connection with the accompanying drawings as best described herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] [0032]FIG. 1 is a schematic of a prior art system for introducing textile treatment materials into a SCF—CO 2 textile dyeing process;
[0033] [0033]FIG. 2 is a schematic of a system for introducing textile treatment materials into a textile treatment system wherein the system utilizes a stirred dye-add vessel in accordance with a process of the present invention;
[0034] [0034]FIG. 3 is a schematic of a system for introducing textile treatment materials into a textile treatment system wherein the system utilizes a circulated dye-add loop in accordance with a process of the present invention;
[0035] [0035]FIG. 4 is a schematic of a syringe pump with mechanical piston and circulation pump for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention;
[0036] [0036]FIG. 5 is a schematic of a syringe pump with mechanical piston and magnetically coupled stirrer for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention;
[0037] [0037]FIG. 6 is a schematic of a syringe pump with mechanical piston and no agitation for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention;
[0038] [0038]FIG. 7 is a schematic of a syringe pump with an inert fluid piston and magnetically coupled stirrer for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention; and
[0039] [0039]FIG. 8 is a schematic of a syringe pump with an inert fluid piston and no agitation for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] While the following terms are believed to be well-understood in the art, the following definitions are set forth to facilitate explanation of the invention.
[0041] The terms “supercritical fluid carbon dioxide” or “SCF—CO 2 ” are meant to refer to CO 2 under conditions of pressure and temperature which are above the critical pressure (P c =about 73 atm) and temperature (T c =about 31° C.). In this state the CO 2 has approximately the viscosity of the corresponding gas and a density which is intermediate between the density of the liquid and gas states.
[0042] The terms “near-critical liquid carbon dioxide” or “NCL—CO 2 ” are meant to refer to liquid CO 2 under conditions of pressure and temperature which are near the critical pressure (P c =about 73 atm) and temperature (T c =about 31° C.).
[0043] The term “textile treatment material” means any material that functions to change, modify, brighten, add color, remove color, or otherwise treat a textile material. Examples comprise UV inhibitors, lubricants, whitening agents, brightening agents and dyes. Representative fluorescent whitening agents are described in U.S. Pat. No. 5,269,815, herein incorporated by reference in its entirety. The treatment material is, of course, not restricted to those listed herein; rather, any textile treatment material compatible with the introduction and treatment systems is envisioned in accordance with the present invention.
[0044] The term “dye” is meant to refer to any material that imparts a color to a textile material. Preferred dyes comprise sparingly water-soluble or substantially water-insoluble dyes. More preferred examples include, but are not limited to, forms of matter identified in the Colour Index, an art-recognized reference manual, as disperse dyes. Preferably, the dyes comprise press-cake solid particles which has no additives.
[0045] The term “disperse dye” is meant to refer to sparingly water soluble or substantially water insoluble dyes.
[0046] The term “sparingly soluble”, when used in referring to a dye, means that the dye is not readily dissolved in a particular solvent at the temperature and pressure of the solvent. Thus, the dye tends to fail to dissolve in the solvent, or alternatively, to precipitate from the solvent, when the dye is “sparingly soluble” in the solvent at a particular temperature and pressure.
[0047] The term “hydrophobic textile fiber” is meant to refer to any textile fiber comprising a hydrophobic material. More particularly, it is meant to refer to hydrophobic polymers which are suitable for use in textile materials such as yarns, fibers, fabrics, or other textile material as would be appreciated by one having ordinary skill in the art. Preferred examples of hydrophobic polymers include linear aromatic polyesters made from terephathalic acid and glycols; from polycarbonates; and/or from fibers based on polyvinyl chloride, polypropylene or polyamide. A most preferred example comprises one hundred fifty denier/34 filament type 56 trilobal texturized yarn (polyester fibers) such as that sold under the registered trademark DACRON® (E.I. Du Pont De Nemours and Co.). Glass transition temperatures of preferred hydrophobic polymers, such as the listed polyesters, typically fall over a range of about 55° C. to about 65° C. in SCF—CO 2 .
[0048] The term “crocking”, when used to describe a dyed article, means that the dye exhibits a transfer from dyed material to other surfaces when rubbed or contacted by the other surfaces.
[0049] Following long-standing patent law convention, the terms “a” and “an” mean “one or more” when used in this application, including the claims.
[0050] A critical step in the treating of textile materials in a supercritical fluid (e.g., SCF—CO 2 ) involves the introduction of textile treatment material (e.g., dyes and other chemicals). Current introduction methods employed in SCF-CO 2 textile dyeing systems are somewhat similar to those used in commercial aqueous dyeing systems.
[0051] An exemplary prior art system is shown schematically in FIG. 1 and generally designated 10 . As shown in FIG. 1, dyeing system 10 comprises a dyeing vessel 12 , a dyeing circulation loop 14 , a dyeing loop circulation pump 16 , a dye-add vessel 18 , and a series of SCF—CO 2 flow control valves 20 . Dye is introduced into system 10 by placing it in dye-add vessel 18 , which can accommodate flow of SCF—CO 2 . SCF—CO 2 flow is mediated by circulation pump 16 . At the appropriate time in the dyeing process, a portion of the main SCF—CO 2 flow (represented by arrows in FIG. 1) is diverted from dye circulation loop 14 via valves 20 into dye-add vessel 18 in order to effect dissolution of the dye. The diverted SCF—CO 2 flow, laden with dissolved dye, then re-enters and mixes with the main SCF—CO 2 flow in loop 14 for use in dyeing the textile material, which is placed in vessel 12 .
[0052] In marked contrast to prior art methods and systems, the textile treatment material introduction process and system of the present invention decouple the textile treatment material dissolution process from the treatment process. The dye introduction rate is used to effect control over the dyeing rate in order to minimize non-uniform dyeing behavior, such as shading and streaking. As such, the dye introduction rate is varied to achieve amounts of dye in solution ranging from near zero up to the equilibrium value at each set of dyeing conditions (CO 2 density and temperature). Though a variety of solvents or carrier fluids can be used in the method and system of the present invention, the preferred preparation fluid is pure CO 2 in supercritical or near-critical liquid form.
[0053] The dye is introduced as a solution or suspension (dispersion) in SCF—CO 2 or NCL—CO 2 , depending on the required dye injection rate and the degree of solvency of SCF—CO 2 in the textile treatment system at the existing treatment conditions. As such, the use of surfactants or dispersing chemicals is not required in the introduction process and system of the present invention. However, co-solvents or surfactants may optionally be used to enhance dye solubility and dispersing agents may optionally be used to facilitate the establishment of stable suspensions of textile treatment materials in CO 2 .
[0054] Preferably, the textile treatment material introduction process and system of the present invention is used in conjunction with a method for treating a textile material using supercritical fluid carbon dioxide (SCF—CO 2 ). More preferably, the textile treatment material introduction method and system of the present invention are used in the treatment of a hydrophobic textile material, such as polyester, in SCF—CO 2 . However, application of the process and system of the present invention to other textile treatment processes and systems is contemplated.
[0055] For example, the method and system of the present invention also can be used with conventional aqueous dyeing processes. This is particularly the case with respect to treatment materials that are sparingly soluble in water. The textile treatment material introduction method and system of the present invention are used to predissolve such treatment materials, and the treatment materials are then introduced into a conventional aqueous dyebath. The use of environmentally hazardous organic co-solvents is thus avoided.
[0056] The textile treatment material introduction process and system of the present invention facilitate introduction of a textile treatment material, such as a dye, into a textile treatment process in that the treatment material is already dissolved or suspended when it contacts the solvent used in the treatment process. Thus, problems, such as agglomeration of particles, that have been observed in prior art processes, including particularly prior art SCF—CO 2 dyeing processes, are avoided.
[0057] Referring now again to the drawings, a preferred embodiment of the textile treatment material introduction system of the present invention is generally designated 30 in FIG. 2. Referring to FIG. 2, system 30 introduces textile treatment materials dissolved or suspended in NCL—CO 2 or SCF—CO 2 into a textile treatment system 32 (similar to the prior art system shown in FIG. 1), which preferably comprises a SCF—CO 2 textile treatment system. System 30 comprises dye-add or preparation vessel 34 , positive-displacement metering pump 36 , line sections 38 and 40 , control valves 42 , 43 and 44 , filter 46 and return line 48 . Treatment system 32 comprises a treatment vessel 50 , a circulation loop 52 and a circulation pump 54 .
[0058] Continuing with reference to FIG. 2, a textile treatment material is placed in preparation vessel 34 , which is equipped with a stirring device 56 capable of thoroughly mixing the contents of vessel 34 . Stirring device 56 comprises a motor-driven fan, but may also comprise a motor-driven shaft, a rotatably mounted shaft, or any other suitable stirring device as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention. Other stirring devices include a fan, propeller or paddle that is magnetically coupled to a motor rather than coupled to the motor by a solid shaft. Another approach, though mechanically more difficult, comprises placing the dye bed within a holding container within the preparation vessel that is both permeable to flow of the SCF—CO 2 and capable of being agitated within the fluid. The permeable holding container can thus be adapted for rotation via the flow of SCF—CO 2 to provide mixing of the dye bed with the SCF—CO 2 . Such devices, and equivalents thereof, thus comprise “stirring means” and “mixing means” as used herein and in the claims.
[0059] Continuing with reference to FIG. 2, in operation the preparation vessel 34 of system 30 is sealed and charged with NCL—CO 2 or SCF—CO 2 . The amount of CO 2 initially charged and the state of CO 2 (i.e., NCL—CO 2 or SCF—CO 2 ) depends on the CO 2 density desired at the introduction conditions. If a co-solvent, surfactant or dispersing agent is to be used, it is charged along with the textile treatment material, or introduced with a metering pump (not shown in FIG. 2) into the preparation vessel 34 at some point in the textile treatment material preparation process. The contents of the preparation vessel 34 are then heated with mixing to the introduction conditions (i.e., CO 2 density and temperature), which is contemplated to be a pressure that is near the textile treatment system pressure.
[0060] Preferably, introduction system 30 , and particularly preparation vessel 34 , is isolated from treatment system 32 when the solution or suspension of textile treatment material is prepared. Control valves 42 , 43 and 44 are used to isolate preparation vessel 34 and thus can be opened and closed for reversibly isolating preparation vessel 34 . Any other suitable structure, such as other valves, piping or couplings, as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention may also be used to isolate, preferably to reversibly isolate, preparation vessel 34 . Such devices and structures, and equivalents thereof, thus comprise “isolation means” as used herein and in the claims.
[0061] Continuing with FIG. 2, depending on the introduction conditions and amount of textile treatment material present, the textile treatment material resides in a suspension or in a combination of solution and suspension. If introducing of a textile treatment material solution is desired, the fluid is removed from preparation vessel 34 via line section 38 , which is equipped with a filter 46 , and via control valve 42 . The filtering media of filter 46 has pore sizes predetermined from the particle size distribution and solubility characteristics of the textile treatment material. If introducing of a textile treatment material suspension or combination of textile treatment material solution and suspension is desired, the fluid is removed from the preparation vessel 34 via line section 40 and control valve 43 .
[0062] Continuing with reference to FIG. 2, positive-displacement metering pump 36 introduces the textile treatment material-laden NCL—CO 2 or SCF—CO 2 into the circulation loop 52 of treatment system 32 using a introducing rate profile that is consistent with producing uniformly-treated textile materials in minimum processing time. In a preferred embodiment, pump 36 shown in FIG. 2 comprises a positive displacement pump with a reciprocating piston. Other representative pumps include a syringe type pump employing a mechanical piston (FIGS. 4 - 6 ) as described below and a syringe type pump employing an inert fluid as a piston (FIGS. 7 and 8) as described below. Thus, devices such as pumps, nozzles, injectors, combinations thereof, and other devices as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention, and equivalents thereof, comprise “introducing means” as used herein and in the claims.
[0063] Mixing of the preparation vessel 34 is continued throughout the introduction cycle via mechanical stirring with stirring device 56 . Introducing of the textile treatment material-laden NCL—CO 2 or SCF—CO 2 occurs at an introduction point 58 in the circulation loop 52 where fluid shear is very high. For example, point 58 may lie before or after circulation pump 54 or in a mixing zone that contains static mixing elements (not shown in FIG. 2) in order to facilitate mixing with the treatment medium (e.g. SCF—CO 2 ) flowing in circulation loop 52 of treatment system 32 . The term “high fluid shear” refers to a turbulent flow or a flow with high rate of momentum transfer. Preferably, the term “high fluid shear” refers to a flow having a Reynolds number greater than 2300, and more preferably, greater than 5000.
[0064] When the textile treatment material is introduced as a solution from preparation vessel 34 into a SCF—CO 2 treatment system 32 , CO 2 makeup to introduction system 30 occurs via return line 48 . This action is taken in order to maintain the CO 2 density in introduction system 30 . Makeup of CO 2 involves opening the control valve 44 in the return line 48 such that SCF—CO 2 is diverted from circulation loop 52 to preparation vessel 34 in quantities sufficient to maintain the operating pressure of the introduction system 30 . Thus, control valve 44 and return line 48 , or any other suitable structure, such as other valves or couplings, as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention may be used to divert SCF—CO 2 to preparation vessel 34 . Such devices and structures, and equivalents thereof, thus comprise “diverting means” as used herein and in the claims.
[0065] When textile treatment material is dosed as a suspension into the treatment system 32 , introduction system 30 operates with full or partial CO 2 makeup via return line 48 . When textile treatment material introducing is performed without CO 2 makeup, the control valve 44 in return line 48 remains closed throughout the introduction cycle, and preparation vessel 34 is emptied of its contents during the introduction cycle. For introduction of suspension with full makeup, control valve 44 operates as described above. In the case of partial makeup, control valve 44 is operated intermittently to return SCF—CO 2 from circulation loop 52 to preparation vessel 34 ; i.e., preparation vessel 34 is partially emptied and then refilled with return SCF—CO 2 .
[0066] In the case of full or partial makeup to introduction system 30 when NCL—CO 2 is utilized in system 30 , the pressure of the returning SCF—CO 2 stream is reduced substantially across control valve 44 and return line 48 to match the near-critical liquid pressure in preparation vessel 34 .
[0067] Referring now to FIG. 3, an alternative embodiment of the textile treatment material introduction system 30 shown in FIG. 2 is disclosed and generally designated 60 . In alternative embodiment 60 , treatment materials are introduced in NCL—CO 2 or SCF—CO 2 into textile treatment system 62 , which preferably comprises a SCF—CO 2 textile treatment process. System 60 comprises dye-add or preparation vessel 64 , positive-displacement metering pump 66 , line sections 68 and 70 , control valves 72 , 73 and 74 , filter 76 and return line 78 . Treatment system 62 comprises a treatment vessel 80 , a circulation loop 82 and a circulation pump 84 .
[0068] Textile treatment material is placed in the preparation vessel 64 of system 60 . Preparation vessel 64 is equipped with a mixing loop 86 as shown in FIG. 3. Thus, mixing of the preparation vessel 64 is continued throughout the introducing cycle via fluid circulation (demonstrated by arrows in FIG. 3) by circulation pump 88 through mixing loop 86 . Such devices and structures, and equivalents thereof, thus comprise “circulation means” and “mixing means” as used herein and in the claims. Other aspects of alternative embodiment 60 function as described above, including the introduction of treatment material at high fluid shear introduction point 90 .
[0069] Referring again to FIGS. 2 and 3, the method and system of the present invention also contemplate treating a textile material after introduction of a textile treatment material from the introduction system to the treatment system. The treatment system comprises a treatment vessel, a circulation loop, and a circulation pump. In a preferred embodiment, the treatment system comprises a SCF—CO 2 treatment system. A textile material, such as a hydrophobic textile fiber, is placed in the treatment vessel. A solution or suspension of treatment material is introduced into the treatment system at an introduction point from the introduction system as described above. The flow, represented by arrows in FIGS. 2 and 3, of the medium used in the treatment system (e.g. SCF—CO 2 flow) is mediated by the circulation pump. The circulation pump directs the flow of treatment medium, which now includes the solution or suspension of treatment material, along the circulation loop to the treatment vessel. In accordance with a preferred embodiment of the present invention, if a suspension is introduced into the treatment circulation loop, the conditions in the loop are such that the suspended material is rapidly dissolved in the treatment flow of supercritical fluid and not carried further as a suspension. Thus, the introduction is preferably made into an area of high shear to promote rapid mixing and dissolution of any undissolved treatment material particles. Within the vessel the treatment material contacts the textile material for a suitable time to impart the desired characteristics to the textile material.
[0070] Referring now to FIG. 4, an embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 100 . Syringe pump 100 comprises syringe pump body 102 , piston 104 , high pressure hose section 106 , circulation pump 108 , and high pressure hose section 110 . Syringe pump body 102 comprises an internal void space 112 in which piston 104 is slidably mounted. Piston 104 comprises an axial channel 114 through which the flow 116 (represented by arrows in FIG. 4) of SCF CO 2 travels within syringe pump 100 .
[0071] Continuing with FIG. 4, circulation pump 108 is connected to syringe pump body 102 via high pressure hose sections 106 and 110 . Circulation within syringe pump 100 is thus provided via circulation pump 108 . Treatment material-laden SCF CO 2 118 enters syringe pump 100 from a preparation system via line 120 and valve 122 . Circulation, or other type of agitation, is preferred if further dissolution of the dye is being accomplished or if an unstable suspension of the dye is being introduced. If circulation or agitation is not required (e.g., when introducing a stable suspension of the dye), an inert gas piston might be substituted for the mechanical piston, as discussed below and as shown in FIGS. 7 and 8. Syringe pump 100 then propels treatment material-laden SCF CO 2 118 into a treatment system via line 124 and valve 126 .
[0072] Referring now to FIG. 5, an alternative embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 150 . Syringe pump 150 comprises a syringe pump body 152 having an internal void space 154 wherein a syringe pump piston 156 is slidably mounted. Syringe pump piston 156 comprises an axially mounted stirrer shaft 158 having a stirrer shaft magnet 160 mounted at the end of stirrer shaft 158 proximate to stirrer magnet 162 . Stirrer magnet 162 is also mounted within syringe pump piston 156 , and propeller stirrer 164 extends from stirrer magnet 162 into the internal void space 154 of syringe pump 150 .
[0073] Continuing with FIG. 5, treatment material-laden SCF CO 2 166 enters syringe pump 150 from a preparation system via line 168 and valve 170 . Agitation of treatment material-laden SCF CO 2 166 is accomplished within syringe pump 150 via propeller stirrer 164 . Syringe pump 150 then propels treatment material-laden SCF CO 2 166 into a treatment system via line 172 and valve 174 .
[0074] Referring now to FIG. 6, yet another alternative embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 200 . Syringe pump 200 comprises a syringe pump body 202 having an internal void space 204 , and a piston 206 slidably mounted within the interval void space 204 of syringe pump body 202 . Treatment material-laden dye 208 enters syringe pump 200 from a preparation system via line 210 and valve 212 . Syringe pump 200 then propels treatment material-laden SCF CO 2 208 into a treatment system via line 214 and valve 216 .
[0075] Referring now to FIG. 7, another alternative embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 250 . Syringe pump 250 comprises pump body 252 having an internal void space 256 , and a high pressure fluid inlet line 254 . A stirrer shaft 258 and a stirrer shaft magnet 260 are mounted at the end of the syringe pump body 252 opposite the line 272 and valve 274 that connect pump 250 with a treatment system. A stirrer magnet 262 is also mounted in pump body 252 proximate to stirrer shaft magnet 260 . A propeller stirrer 264 extends into the internal void space 256 of pump body 252 from stirrer magnet 262 .
[0076] Continuing with FIG. 7, treatment material-laden SCF C 2 266 enters pump 250 from a preparation system via line 268 and valve 270 . An inert material 278 (designated with a large arrow in FIG. 7), such as supercritical fluid nitrogen, is introduced into the internal void space 256 of pump body 252 via inlet line 254 while propeller stirrer 264 stirs the treatment material-laden SCF CO 2 266 . The in-flow inert material 278 drives treatment material-laden SCF CO 2 266 into a treatment system via line 272 and valve 274 .
[0077] Referring finally to FIG. 8, still another alternative embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 300 . Syringe pump 300 comprises pump body 302 having an internal void space 306 , and a high pressure inlet line 304 connected at the end of pump body 302 opposite from the line 314 and valve 316 that connect syringe pump 300 with a treatment system.
[0078] Continuing with FIG. 8, treatment material-laden SCF CO 2 308 enters syringe pump 300 from a preparation system via line 310 and valve 312 . An inert material 318 (designated with a large arrow in FIG. 8), such as supercritical fluid nitrogen, is introduced into the internal void space 306 of pump body 302 via high pressure line 304 . Inert material 318 thus drives treatment material-laden SCF CO 2 308 into a treatment system via line 314 and valve 316 .
[0079] The syringe pumps disclosed in FIGS. 4 - 8 can also be used in maintaining the SCF—CO 2 density in the preparation vessel by facilitating the addition of fresh SCF—CO 2 to the preparation vessel at the conditions in the preparation vessel without necessarily diverting SCF—CO 2 from the treatment system. For example, additional SCF—CO 2 can be introduced via high pressure lines 106 and/or 110 in FIG. 4. This approach also adds additional SCF—CO 2 to the treatment system, and the treatment process is altered to include a different treatment process control strategy to accommodate the additional SCF—CO 2 . Thus, the pumps disclosed in FIGS. 4 - 8 also provide an alternative embodiment of the present invention in which SCF—CO 2 density is maintained in the preparation system without diverting SCF—CO 2 to the preparation vessel from the treatment system.
[0080] An advantage of the textile treatment material introduction process and system of the present invention is that it is used to introduce a variety of chemicals for treatment of a textile material. Thus, multiple operations can be performed concurrently or sequentially. For example, once a first textile treatment material, such as a dye, is introduced, the introducing system can be isolated and depressurized. Then, another textile treatment material, such as a UV inhibitor, can placed in the preparation vessel for introduction into the treatment system in accordance with the steps described herein above.
[0081] It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims. | A process for introducing a textile treatment material into a textile treatment system, particularly a supercritical fluid carbon dioxide (SCF—CO 2 ) treatment system. The process includes the steps of providing a preparation vessel in fluid communication with a textile treatment system; loading a textile treatment material into the preparation vessel; dissolving or suspending the textile treatment material in near-critical liquid carbon dioxide or supercritical fluid carbon dioxide in the preparation vessel; and introducing the dissolved or suspended textile treatment material into the textile treatment system. The textile treatment material can be selected from a group including a brightening agent, a whitening agent and a dye. A system suitable for use in carrying out the process is also disclosed. | 3 |
[0001] This patent is a continuation of allowed U.S. Ser. No. 10/062,003 filed Feb. 1, 2002, which is a continuation of U.S. Ser. No. 09/697,070 filed Oct. 26, 2000, now U.S. Pat. No. 6,349,973, which is a continuation of U.S. Ser. No. 09/470,374 filed Dec. 22, 1999, now U.S. Pat. No. 6,158,778, which is a continuation of U.S. Ser. No. 09/305,966 filed May 6, 1999, now U.S. Pat. No. 6,068,300, which is a continuation of U.S. Ser. No. 09/031,191 filed Feb. 26, 1998, now U.S. Pat. No. 5,909,899, which is a continuation of U.S. Ser. No. 08/492,213 filed Jun. 19, 1995, now U.S. Pat. No. 5,813,700, which is a continuation-in-part of U.S. Ser. No. 08/324,350 filed Oct. 17, 1994, which is a continuation-in-part of U.S. Ser. No. 08/264,181 filed Jun. 1994, now U.S. Pat. No. 5,458,374, which is a continuation of U.S. Ser. No. 08/037,294 filed Mar. 26, 1993 and a continuation-in-part of U.S. Ser. No. 08/264,181 filed Jun. 22, 1994, which is a continuation of U.S. Ser. No. 08/037,294 filed Mar. 26, 1993. All of the patent applications and patents identified in this paragraph are incorporated by reference herein in their entirety.
BACKGROUND
[0002] This patent relates to methods of folding informational items which have printed information, such as instructions and/or warnings, relating to pharmaceutical products.
[0003] Informational items, such as outserts, are used to convey information to purchasers and users of pharmaceutical products. The information printed on an outsert typically includes instructions for use of a pharmaceutical product and medical warnings relating to the product. The outsert typically accompanies the product, such as by being affixed directly to the container in which the pharmaceutical product is provided or by being enclosed within a cardboard carton in which the pharmaceutical container is packaged.
[0004] A method of forming outserts is disclosed in U.S. Pat. No. 4,812,195 to Michael Vijuk. In that patent, outserts are manufactured by folding a relatively long sheet a number of times in a direction perpendicular to the length of the sheet and then cutting the folded sheet a number of times in a direction perpendicular to the folding direction to make a number of individual outserts. The result of the folding and cutting steps is a “ribbon” style outsert like the one shown in FIG. 1B.
[0005] [0005]FIG. 1A illustrates an example of an outsert 10 constructed in accordance with the prior art which has open edges 12 about its periphery. FIG. 1B illustrates a conventional ribbon style outsert 14 constructed in accordance with the prior art. The outsert 14 has a tail portion 16 which, prior to opening of the outsert by the purchaser of the associated pharmaceutical product, is glued to an interior portion of the outsert. The tail portion 16 consists of a single sheet having an unfolded, exterior sheet edge which lies in a direction parallel to the folding direction.
SUMMARY OF THE INVENTION
[0006] In one aspect, the invention is directed to a method of folding a sheet having printed information thereon to form a folded item for providing information to the user of a product. The method comprises (a) folding the sheet by making a first fold in the sheet, the first fold being made in a direction parallel to a first direction; (b) folding the sheet by making a second fold in the sheet, the second fold being made in a direction parallel to the first direction, the first and second folds resulting in a first folded article, the first folded article having a first end and a second end opposite the first end; (c) making a plurality of transverse folds in the first folded article, the plurality of transverse folds being made in a second direction perpendicular to the first direction, the transverse folds resulting in a second folded article having a first end and a second end, the first end of the second folded article comprising a folded end, the second folded article having a first portion adjacent the first end of the second folded article and a second portion adjacent the second end of the second folded article; (d) folding the second folded article by making an additional fold in a direction parallel to the second direction, the additional fold being made to produce a third folded article having a first end, a second end and a plurality of intermediate portions disposed between the first and second ends of the third folded article, the second end of the third folded article corresponding to the second end of the second folded article; (e) depositing an adhesive on a portion of the third folded article; and (f) making a final fold in the third folded article in a direction parallel to the second direction to form the folded item, the final fold being made so that a portion of the third folded article is wrapped around the intermediate portions of the third folded article.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1A illustrates an example of an outsert having open edges about its periphery constructed in accordance with the prior art;
[0008] [0008]FIG. 1B illustrates a ribbon style outsert constructed in accordance with the prior art;
[0009] [0009]FIG. 2A is a perspective view of a first embodiment of an outsert;
[0010] FIGS. 2 B- 1 through 2 B- 5 illustrate the method of forming the outsert illustrated in FIG. 2A;
[0011] [0011]FIG. 3A is a perspective view of a second embodiment of an outsert;
[0012] FIGS. 3 B- 1 through 3 B- 6 illustrate the method of forming the outsert illustrated in FIG. 3A;
[0013] [0013]FIG. 4A is a perspective view of a third embodiment of an outsert;
[0014] FIGS. 4 B- 1 through 4 B- 7 illustrate the method of forming the outsert illustrated in FIG. 4A;
[0015] [0015]FIG. 5 is a perspective view of an outsert applied to the outside of a container for a pharmaceutical product;
[0016] [0016]FIG. 6A is a perspective view of a fourth embodiment of an outsert;
[0017] FIGS. 6 B- 1 through 6 B- 10 illustrate the method of forming the outsert illustrated in FIG. 6A;
[0018] [0018]FIG. 7A is a perspective view of a fifth embodiment of an outsert;
[0019] FIGS. 7 B- 1 through 7 B- 10 illustrate the method of forming the outsert illustrated in FIG. 7A; and
[0020] [0020]FIG. 8 is a perspective view of an outsert applied to the top of a container for a pharmaceutical product.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] [0021]FIG. 2A is a perspective view of a universal, nonjamming, multi-ply outsert 20 having multiple folds, which is manufactured from an integral sheet of stock. FIGS. 2 B- 1 through 2 B- 5 illustrate the method of forming the outsert 20 depicted in FIG. 2A. Referring to FIGS. 2A and 2B, the method starts with web stock that is directly fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size of the individual sheet stock is variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 8.375 inches, and an overall width (W) of approximately 4.125 inches, an outsert can be manufactured having a total of four folds, twelve total ply thickness, and an overall size of approximately 2.438 inches wide, approximately 1.5 inches high, and approximately 0.125 inches thick (depending on the thickness of the individual sheet stock used).
[0022] To manufacture the outsert depicted in FIG. 2A, starting at FIG. 2B- 1 , and with the individual sheet stock 21 traveling in a predetermined first direction, an initial fold 22 is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIG. 2B- 2 ). This initial fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock). This initial fold results in the sheet stock having a top panel (W1) and an adjoining bottom panel (W2). If the initial fold is an even fold, the resulting width will be ½ of the initial width (i.e., W1=W2=½ W). Following completion of this initial fold, the sheet stock will have an overall thickness of two plies.
[0023] At FIG. 2B- 3 , and following the re-orientation of the individual sheet stock 21 to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a second fold 24 is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This second fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of the sheet stock). This second fold will result in the sheet stock having a top panel length (L1) and an adjoining bottom panel length (L2).
[0024] If the second fold is an even fold, the resulting length will be ½ of the initial length (i.e., L1=L2=½ L). Following completion of this second fold, the sheet stock will have an overall thickness of four plies. Also, after completion of this second fold, the resulting folded sheet stock will have two ends of orientation, one end being a folded closed-end, and the other end being an open-edge end, not having any fold.
[0025] At FIG. 2B- 4 , a third fold 26 is made across the entire width of the sheet stock at a right angle from the point of origin, the third fold being located at the open-edge end of the folded sheet stock. This third fold is equal to approximately ⅓ of the total panel length and will result in the sheet stock.now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=⅓ L and L2=⅔ L). Following completion of this third fold, the sheet stock will have an overall thickness of eight plies for the resulting top panel length, and four plies for the resulting bottom panel length.
[0026] Following the third fold (see FIG. 2B- 4 ), at a designated location on the resulting top panel length, a single glue spot 25 (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.
[0027] At FIG. 2B- 5 , a fourth fold 28 is made to complete the outsert. The fourth fold is made across the entire width of the sheet stock at a right angle from the point of origin, the fourth fold being located at the closed-end of the folded sheet stock. This fourth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=½ L and L2=½ L). This fourth fold is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panel lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of twelve plies.
[0028] [0028]FIG. 3A is a perspective view of a universal, non-jamming, multi-ply outsert 30 having multiple folds, which is manufactured from an integral sheet of stock. FIGS. 3 B- 1 through 3 B- 6 illustrate the method of forming the outsert 30 depicted in FIG. 3A. Refering to FIGS. 3A and 3B, the method starts with web stock that is fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size of the individual sheet stock is variable For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 12 inches, and an overall width (W) of approximately 11 inches, an outsert can be manufactured having a total of eight folds, forty total ply thickness, and an overall size of approximately 2.25 inches wide, approximately 1.5 inches high, and approximately 0.3125 inches thick (depending on the thickness of the individual sheet stock used).
[0029] To manufacture the outsert depicted in FIG. 3A, starting at FIG. 3B- 1 , and with the individual sheet stock 31 traveling in a predetermined first direction, an initial fold 32 , which consists of a number of substantially parallel folds (consisting of a series of tandem folds 32 ( a ), 32 ( b ), 32 ( c ) and 32 ( d ) comprising a four-fold accordion fold), is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIGS. 3 B- 2 A through 3 B- 2 D). This initial fold 32 may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock).
[0030] If the initial fold 32 is an even fold, the resulting width will be ⅕ of the initial width (i.e., W1=W2=W3=W4=W5=⅕ W). This initial fold is a four-fold tandem accordion fold and, assuming the initial fold has equal panels, each panel will consist of the four-fold tandem accordion fold that is equal to ⅕ the original width (i.e., W1=⅕ W). This initial fold results in the sheet stock having a tandem series of substantially equally-sized adjoining panels, with accordion folds (running length-wise) being positioned between adjacent panels. Following completion of this initial fold, the sheet stock will have an overall thickness of five plies.
[0031] At FIG. 3B- 3 , and following the re-orientation of the individual sheet stock 31 to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a second fold 33 is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This second fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of the sheet stock). This second fold will result in the sheet stock having a top panel length (L1) and an adjoining bottom panel length (L2).
[0032] If the second fold is an even fold, the resulting length will be ½ of the initial length (i.e L1≦L2=½ L). Following completion of this second fold, the sheet stock will have an overall thickness of ten plies. Also, after completion of this second fold, the resulting folded sheet stock will have two ends of orientation, one end being a folded closed-end, and the other end being an open-edge end, not having any fold.
[0033] At FIG. 3B- 4 , a third fold 34 is made across the entire width of the sheet stock at a right angle from the point of origin, the third fold being located at the open-edge end of the folded sheet stock. This third fold is equal to approximately ¼ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=¼ L and L2=¾ L). Following completion of this third fold, the sheet stock will have an overall thickness of twenty plies for the resulting top panel length, and ten plies for the resulting bottom panel length.
[0034] At FIG. 3B- 5 , a fourth fold 35 is made across the entire width of the sheet stock at a right angle from the point of origin, the fourth fold being located at the section of folded sheet stock that is adjacent to the open-edge end portion of the folded sheet stock. This fourth fold is equal to approximately ⅓ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=⅓ L and L2=⅔ L). Following completion of this fourth fold, the sheet stock will have an overall thickness of thirty plies for the resulting top panel length, and ten plies for the resulting bottom panel length.
[0035] At FIG. 3B- 5 , following the fourth fold, at a designated location on the resulting bottom panel length, a single glue spot 36 (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.
[0036] At FIG. 3B- 6 , a fifth fold 37 is made to complete the outsert. The fifth fold is made across the entire width of the sheet stock at a right angle from the point of origin, the fifth fold being located at the section of folded sheet stock that is next to the adjacent section previously discussed (i.e., the adjacent section being next to the open-edge end portion of the folded sheet stock). This fifth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L ½ L and L2={fraction (l/2)} L). This fifth fold is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panel lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of forty plies.
[0037] [0037]FIG. 4A is a perspective view of a universal, nonjamming, multi-ply outsert 50 having multiple folds, which is manufactured from an integral sheet of stock. FIGS. 4 B- 1 through 4 B- 7 illustrate the method of forming the outsert 50 depicted in FIG. 4A. Referring to FIGS. 4A and 4B, the method starts with web stock that is fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size of the individual sheet stock is variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall: length (L) of approximately 18 inches, and an overall width (W) of approximately 12 inches, an outsert can be manufactured having a total of eight folds, a sixty-four total ply thickness, and an overall size of approximately 2.25 inches wide, approximately 1.5 inches high, and approximately 0.25 inches thick (depending on the thickness of the individual sheet stock used).
[0038] To manufacture the outsert depicted in FIG. 4A, starting at FIG. 4B- 1 , and with the individual sheet stock 51 traveling in a predetermined first direction, an initial fold 52 is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIG. 4B- 2 ). This initial fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock). This initial fold results in the sheet stock having a top section (W1) and an adjoining bottom section (W2).
[0039] If the initial fold is an even fold, the resulting width will be ½ of the initial width (i.e., W1=W2=½ W). Following completion of this initial fold, the sheet stock will have an overall thickness of two plies.
[0040] At FIGS. 4 B- 3 A through 4 B- 3 C, a second fold 53 , which consists of a number of substantially parallel folds (consisting of a series of tandem folds comprising a three-fold accordion fold 54 ( a ), 54 ( b ) and 54 ( c )), is made across the entire length of the sheet stock and is at a right angle from the point of origin. This second fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock).
[0041] If the second fold is an even fold, the resulting width will be ¼ of the initial width (i.e., W1=W2=W3=W4=¼ W). This second fold is a three-fold tandem accordion fold, and assuming the second fold has four equal panels, each panel will consist of the three-fold tandem accordion fold that is equal to ¼ the original width (i.e., W1=¼ W). This second fold results in the sheet stock having a tandem series of substantially equally-sized adjoining panels, with accordion folds (running length-wise) being positioned between adjacent panels. Following completion of this fold, the sheet stock will have an overall thickness of eight plies.
[0042] At FIG. 4B- 4 , and following the re-orientation of the individual sheet stock 51 to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a third fold 55 is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This third fold is an uneven fold (i.e., a short fold); this third fold will result in the sheet stock having a top panel length (L1) having open edges and an adjoining bottom panel length (L2) having no open edges (but having one end with open edges). The third fold will create a top panel having open edges that is equal to ⅜ of the initial length (L1=⅜ L) and an adjoining bottom panel (L2=⅝ L). Following completion of this third fold, the outsert will have an overall thickness of sixteen plies. Also, after completion of this third fold, the resulting folded sheet stock will have two ends of orientation, one end longer than the other end.
[0043] At FIG. 4B- 5 , a fourth fold 56 is made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin at a location on the short panel lengths. This fourth fold is an uneven fold (i.e., a short fold) and is located at the shorter top panel end having open-edges of the folded sheet stock. This fourth fold will result in the sheet stock having a top panel length (L1) having no open peripheral edges and an adjoining bottom panel length (L2) having no open peripheral edges. The fourth fold will create a top panel that is equal to ⅖ of the initial length (L1=⅖ L) and an adjoining bottom panel that is equal to ⅗ of the initial length (L2=⅗ L). Following completion of this fourth fold, the outsert will have an overall thickness of twenty-four plies (and sixteen plies at the other portion of the outsert). Also, after completion of this fourth fold, the resulting folded sheet stock will have two ends of orientation, each end having no open edges.
[0044] At FIG. 4B- 6 , a fifth fold 57 is made across the entire width of the sheet stock at a right angle from the point of origin, the fifth fold being located at the section of folded sheet stock that is adjacent to the open-edge end portion of the folded sheet stock on the panel having the longer panel length. This fifth fold is equal to approximately ⅓ of the total panel length and will result in the outsert now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=⅓l L and L2=⅔ L). Each of the resulting adjoining bottom and top panels will now have closed ends (i.e., no open edges). Following completion of this fifth fold, the sheet stock will have an overall thickness of forty plies for the resulting bottom panel length, and twenty-four plies for the resulting top panel length.
[0045] At FIG. 4B- 6 , following the fifth fold, at a designated location on the resulting top panel length, a single glue spot 58 (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.
[0046] At FIG. 4B- 7 , a sixth fold 59 is made to complete the outsert. The sixth fold is made across the entire width of the sheet stock at a right angle from the point of origin. This sixth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=½ L and L2=½ L). This sixth fold is made and folded over the second end of the resulting panel length and is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panel lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of sixty-four plies.
[0047] [0047]FIG. 5 is a perspective view of an outsert 60 applied to the outside of container 62 for a pharmaceutical product.
[0048] [0048]FIG. 6A is a perspective view of a universal, nonjamming, multi-ply, multi-fold, reduced-size outsert 130 having increased copyspace, which is manufactured from an integral sheet of stock. FIGS. 6 B- 1 through 6 B- 10 illustrate the method of forming the outsert 130 depicted in FIG. 6A. Referring to FIGS. 6A and 6B, the method starts with web stock that is directly fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size and weight of the individual sheet stock are variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 11 inches, and an overall width (W) of approximately 6.625 inches, an outset can be manufactured having nine folds, a total thickness of sixty plies, and an overall size of approximately 1.125 inches long, approximately 1.125 inches wide, and approximately 0.188 inches thick (depending on the thickness of the sheet stock utilized).
[0049] To manufacture the outsert depicted in FIG. 6A, starting at FIG. 6B- 1 , and with the individual sheet stock 131 traveling in a predetermined first direction, an initial accordion fold is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIG. 6B- 2 ). This initial fold consists of a number of substantially parallel folds (consisting of a series of tandem folds 132 , 133 , 134 , 135 and 136 , comprising a five-fold accordion fold), and is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIGS. 6 B- 2 through 6 B- 6 ).
[0050] This initial fold is a five-fold tandem accordion fold and results in the sheet stock having a tandem series of substantially equally-sized adjoining panels, with accordion folds (running length-wise) being positioned between adjacent panels. The initial fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock). Assuming the initial fold has equal panels (e.g., the initial fold is an even fold), each panel will consist of the five-fold tandem accordion fold that is equal to ⅙ the original width (i.e., W1=⅙ W) and the resulting width of each panel will be ⅙ of the initial width (i.e., W1=W2=W3=W4=W5=W6=⅙ W). Following completion of this initial fold, the sheet stock will have an overall thickness of six plies.
[0051] At FIG. 6B- 7 , and following the reorientation of the individual sheet stock 131 to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a sixth fold 137 is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This sixth fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of the sheet stock). This sixth fold will result in the sheet stock having a top panel length (L1) and an adjoining bottom panel length (L2).
[0052] If the sixth fold is an even fold, the resulting panel length will be ½ of the initial length (i.e., L1=L2=½ L). Following completion of this sixth fold, the sheet stock will have an overall maximum thickness of twelve plies. Also, after completion of this sixth fold, the resulting folded sheet stock will have two ends of orientation, one end being a folded closed-end, and the other end being an open-edge end, not having any fold.
[0053] At FIG. 6B- 8 , a seventh fold 138 is made across the entire width of the sheet stock at a right angle from the point of origin, the seventh fold being located at the open-edge end of the folded sheet stock. This seventh fold is equal to approximately ⅖ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=⅖ L and L2=⅗ L). Following completion of this seventh fold, the sheet stock will have an overall maximum thickness of twenty-four plies (e.g., resulting in twelve ply thickness at one end of the outsert and resulting in twenty-four ply thickness at the opposite end of the outsert).
[0054] At FIG. 6B- 9 , an eighth fold 139 is made across the entire width of the sheet stock at a right angle from the point of origin. This eighth fold is equal to approximately ⅓ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=⅓ L and L2=⅔ L). Following completion of this eighth fold, the sheet stock will have an overall maximum thickness of forty-eight plies (e.g., resulting in twelve ply thickness at one end of the outsert and resulting in forty-eight ply thickness at the opposite end of the outsert).
[0055] At FIG. 6B- 10 , following the eighth fold, at a designated location on the outsert, a single glue spot 140 (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.
[0056] At FIG. 6B- 10 , a ninth fold 141 is made to complete the outsert. The ninth fold is made across the entire width of the sheet stock at a right angle from the point of origin. This ninth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=½ L and L2=½ L). This ninth fold is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panel lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of sixty plies.
[0057] The method of forming the outsert 130 depicted in FIG. 6A may be modified slightly to form an outsert having a slightly different structure. In particular, the method of forming the outsert 130 may be modified in the following respects: 1) the modified method utilizes a sheet of stock having an overall length (L) of approximately 18 inches and an overall width (W) of approximately 10 inches; 2) in the modified method, an accordion fold having eight tandem folds (to produce nine equal-length panels) is initially made (instead of an accordion fold with five tandem folds as shown in FIG. 6B- 6 ); 3) in the modified method, the accordion fold is made in the direction parallel to the width of the sheet stock (instead of parallel to the length of the sheet stock as shown in FIGS. 6 B- 1 through 6 B- 6 ); and 4) two spots of glue may be used (instead of the single spot 140 shown in FIG. 6B- 10 ). This modified method will form an outsert having twelve folds, a total thickness of ninety plies, and an overall size of approximately 2 inches long, approximately 1 inch wide, and approximately 0.25 inches thick (depending on the thickness of the sheet stock used).
[0058] [0058]FIG. 7A is a perspective view of a universal, nonjamming, multi-ply, multi-fold, reduced-size outsert 170 having increased copyspace, which is manufactured from an integral sheet of stock. FIGS. 7 B- 1 through 7 B- 10 illustrate the method of forming the outsert 170 depicted in FIG. 7A. Referring to FIGS. 7A and 7B, the method starts with web stock that is fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size and weight of the individual sheet stock are variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 10 inches, and an overall width (W) of approximately 7.5 inches, an outsert can be manufactured having a total of nine folds, a total thickness of forty-eight plies, and an overall size of approximately 1.375 inches long, approximately 1.375 inches wide, and approximately 0.188 inches thick (depending on the thickness of the individual sheet stock utilized).
[0059] To manufacture the outset depicted in FIG. 7A, starting at FIG. 7B- 1 , and with the individual sheet stock 171 traveling in a predetermined first direction, an initial accordion fold is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIG. 7B- 2 )). This initial fold consists of a number of substantially parallel folds (consisting of a series of tandem folds 172 , 173 , 174 , 175 and 176 , comprising a five-fold accordion fold), and is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIGS. 7 B- 2 through 7 B- 6 ).
[0060] This initial fold is a five-fold tandem accordion fold and results in the sheet stock having a tandem series of substantially equally-sized adjoining panels, with accordion folds (running length-wise) being positioned between adjacent panels. The initial fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock). Assuming the initial fold has equal panels (e.g., the initial fold is an even fold), each panel will consist of the five-fold tandem accordion fold that is equal to ⅙ the original width (i.e., W1=⅙ W) and the resulting width of each panel will be ⅙ of the initial width (i.e., W1=W2=W3=W4=W5=W6=⅙ W). Following completion of this initial fold, the sheet stock will have an overall thickness of six plies.
[0061] At FIG. 7B- 7 , and following the re-orientation of the individual sheet stock 171 to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a sixth fold 177 is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This sixth fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of the sheet stock). This sixth fold will result in the sheet stock having a top panel length (L1) and an adjoining bottom panel length (L2).
[0062] If the sixth fold is an even fold, the resulting panel length will be ½ of the initial length (i.e., L1=L2=½ L). Following completion of this sixth fold, the sheet stock will have an overall maximum thickness of twelve plies. Also, after completion of this sixth fold, the resulting folded sheet stock will have two ends of orientation, one end being a folded closed end, and the other end being an open-edge end, not having any fold.
[0063] At FIG. 7B- 8 , a seventh fold 178 is made across the entire width of the sheet stock at a right angle from the point of origin, the seventh fold being located at the open-edge end of the folded sheet stock. This seventh fold is equal to approximately ⅕ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=⅕ L and L2=⅘ L). Following completion of this seventh fold, the sheet stock will have an overall maximum thickness of twenty-four plies (e.g., resulting in twelve ply thickness at one end of the outsert and resulting in twenty-four ply thickness at the opposite end of the outsert).
[0064] At FIG. 7B- 9 , an eighth fold 179 is made across the entire width of the sheet stock at a right angle from the point of origin. This eighth fold is equal to approximately ⅓ of the, total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=⅓ L and L2=⅔ L). Following completion of this eighth fold, the sheet stock will have an overall maximum thickness of thirty-six plies (e.g., resulting in twelve ply thickness at one end of the outsert and resulting in thirty-six ply thickness at the opposite end of the outsert).
[0065] At FIG. 7B- 10 , following the eighth fold, at a designated location on the outsert, a single glue spot 180 (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.
[0066] At FIG. 7B- 10 , a ninth fold 181 is made to complete the outsert. The ninth fold is made across the entire width of the sheet stock at a right angle from the point of origin. This ninth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L1) and a resulting adjoining bottom panel length (L2) (i.e., L1=½ L and L2=½ L). This ninth fold is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panels lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of forty-eight plies.
[0067] The method of forming the outsert 170 depicted in FIG. 7A may be modified slightly to form an outsert having a slightly different structure. In particular, the method of forming the outsert 170 may be modified in the following respects: 1) the modified method utilizes a sheet of stock having an overall length (L) of approximately 24 inches and an overall width (W) of approximately 10 inches; 2) in the modified method, an accordion fold having seven tandem folds (to produce eight equal-length panels) is initially made (instead of an accordion fold with five tandem folds as shown in FIG. 7B- 6 ); 3) in the modified method, the accordion fold is made in the direction parallel to the width of the sheet stock (instead of parallel to the length of the sheet stock as shown in FIGS. 7 B- 1 through 7 B- 6 ); and 4) two spots of glue may be used (instead of the single spot 180 shown in FIG. 7B- 10 ). This modified method will form an outsert having eleven folds, a total thickness of sixty-four plies, and an overall size of approximately 1.25 inches long, approximately 3 inches wide, and approximately 0.188 inches thick (depending on the thickness of the sheet stock used).
[0068] [0068]FIG. 8 is a perspective view of an outsert 210 applied to the top of a container 212 for a pharmaceutical product.
[0069] Each of the outserts described above may optionally be imperceptibly scored at various positions intrinsic to the outsert (indicating that the outsert is folded in a particular direction along the score line), to assist in the folding of the outsert, and, accordingly, each score line is part and parcel of each outsert.
[0070] The methods of folding described above in connection with FIGS. 2 B- 4 B and 6 B- 7 B eliminate all unfolded exterior edges which lie in a direction parallel to the final fold direction, resulting in outserts having a more compact three-dimensional physical envelope. Inasmuch as the outserts depicted in FIGS. 2 A- 4 A and 6 A- 7 A are manufactured from a single sheet of stock, the outserts do not require any trimming step to be performed to achieve a certain size. The final size of the outserts is achieved by selecting a particular respective size of initial sheet stock to be utilized.
[0071] Although specific dimensions have been disclosed herein for the sheet stock from which outserts are formed and for the final outserts themselves, those particular dimensions are not considered important to the invention, and outserts having different dimensions may be formed from sheet stock having different dimensions.
[0072] Numerous additional modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. This description is to be construed as illustrative only, and is for the purpose of teaching those skilled in the ale the best mode of carrying out the invention. The details of the structure and method mav be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications which come within the scope of the appended claims is reserved. | A method of producing a folded item having printed information thereon to provide information to the user of a product is disclosed. The method comprises (a) folding the sheet by making a first fold in the sheet in a direction parallel to a first direction; (b) folding the sheet by making a second fold in the sheet in a direction parallel to the first direction to form a first folded article having a first end and a second end opposite the first end; (c) making a plurality of transverse folds in the first folded article in a second direction perpendicular to the first direction to form a second folded article having a first end, a second end, a first portion adjacent the first end of the second folded article, and a second portion adjacent the second end of the second folded article; (d) folding the second folded article by making an additional fold in a direction parallel to the second direction to produce a third folded article having a first end, a second end, and a plurality of intermediate portions disposed between the first and second ends of the third folded article; (e) depositing an adhesive on a portion of the third folded article; and (f) making a final fold in the third folded article in a direction parallel to the second direction to form the folded item so that a portion of the third folded article is wrapped around the intermediate portions of the third folded article. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a system, method and interface for evaluating the supply base of a supply chain. More particularly, the present invention relates to a system, method and interface for facilitating the evaluation of a base of suppliers forming a supply base for a supply chain. The evaluation entails providing a database of supplier performance and capabilities based on historical performance. The supply base evaluation system, method and interface of the present invention can be used to qualify and disqualify suppliers, and to improve supplier performance and capabilities.
[0003] 2. Description of the Prior Art
[0004] The channels that goods or resources travel through are known as a supply chain. These channels may extend from a manufacturing point to a retail sales location or from a point where a resource, such as raw ore, is harvested to a manufacturing location, where a product is made from that resource. In the manufacturing process or sales process, over-supply or under-supply of goods or resources is undesirable. An efficient supply chain maintains the optimum amount of goods and resources throughout the supply chain to avoid both overstocking and under-stocking.
[0005] In conventional supply chains it is difficult to assess the performance and capabilities of a supplier to find a supplier that can meet a retailer or manufacturer's needs. While a retailer, for instance, can contact a better business bureau to learn if complaints have been filed against a supplier, such information is anecdotal and not quantifiable. Furthermore, a better business bureau would only maintain negative information and not positive information, historical performance, or capabilities for a supplier. Consequently, the information available at a service such as a better business bureau is of limited utility.
[0006] In order to perform long term planning it would be very useful to members of a supply chain to be able to determine the performance and capabilities of a supplier and thereby better-forecast sales, inventories, replenishment intervals, seasonal variations, etc.
SUMMARY OF THE INVENTION
[0007] Advantageously, the system, method and interface for evaluating the supply base of a supply chain in accordance with embodiments of the present invention can provide a qualitative assessment of a supplier's capabilities and characteristics, comprehensive assessments of a supplier's historical performance and a way to evaluate the risks and benefits associated with working with supplier during sourcing decisions.
[0008] The system, method and interface for evaluating the supply base of a supply chain according to the present invention can identify gaps and surplus in a supplier database. An interface facilitates the collation of information in the supplier database. Cross functional opportunities can be found using a supplier database and an interface screens, which will potentially capture information on what products are produced by each supplier.
[0009] Suppliers that fail to meet minimum standards may be removed from the database, and thus from the supply chain. In conjunction with the removal of a supplier from the database, objective feedback may be provided to suppliers, the feedback including metrics captured and tracked by the system. Removal of a supplier from the supply chain should therefore come as no surprise to the suppliers, as they will have visibility of how their performance is perceived via the rankings and metrics. Potential new suppliers may be evaluated and added to the supplier database if they meet measured service levels. Similarly, suppliers may be able provide information to the system of their increased capacities and capabilities.
[0010] Proactive development plans may be implemented to improve the manner in which suppliers do business throughout the supply chain and thereby maintain high ratings. The information in the database is updated regularly to help to monitor supplier's performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other attributes of the present invention will be described with respect to the following drawings in which:
[0012] [0012]FIG. 1 is a block diagram illustrating a computer system upon which the system and method of the present invention may be embodied;
[0013] [0013]FIG. 2 is a flow chart illustrating activities and responsibilities involved in managing and maintaining the supplier database using the system, method and interface for evaluating the supply base of a supply chain according to the present invention;
[0014] [0014]FIG. 3 is a block diagram illustrating flow between interface screens according to the system, method and interface for evaluating the supply base of a supply chain of the present invention;
[0015] [0015]FIG. 4 is a logon screen for the system, method and interface for evaluating the supply base of a supply chain according to the present invention;
[0016] [0016]FIG. 5 is a home page screen for the system, method and interface for evaluating the supply base of a supply chain according to the present invention;
[0017] [0017]FIG. 6 is an actuals evaluation screen according to the present invention;
[0018] [0018]FIG. 7 is a supplier information screen according to the present invention;
[0019] [0019]FIG. 8 is a teams view evaluation screen according to the present invention;
[0020] [0020]FIG. 9 is bulletin board screen according to the present invention;
[0021] [0021]FIG. 10 is an actuals comparison screen according to the present invention;
[0022] [0022]FIG. 11 is a trend evaluation screen according to the present invention;
[0023] [0023]FIG. 12 is a teams view comparison screen according to the present invention;
[0024] [0024]FIG. 13 is a trend evaluation screen according to the present invention;
[0025] [0025]FIG. 14 is screen for linking a supplier to a specific product type, according to the present invention;
[0026] [0026]FIG. 15 is a screen showing suppliers ranked by their team scores according to the present invention; and
[0027] [0027]FIG. 16 is a flow chart of the method according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention may be embodied on a computer system, such as the system 100 shown in FIG. 2. Computer 100 includes a central processor 110 , a system memory 112 and a system bus 114 that couples various system components including the system memory 112 to the central processor unit 110 . System bus 114 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. The structure of system memory 112 is well known to those skilled in the art and may include a basic input/output system (BIOS) stored in a read only memory (ROM) and one or more program modules such as operating systems, application programs and program data stored in random access memory (RAM).
[0029] Computer 100 may also include a variety of interface units and drives for reading and writing data. In particular, computer 100 includes a hard disk interface 116 and a removable memory interface 120 respectively coupling a hard disk drive 118 and a removable memory drive 122 to system bus 114 . Examples of w removable memory drives include magnetic disk drives and optical disk drives. The drives and their associated computer-readable media, such as a floppy disk 124 provide nonvolatile storage of computer readable instructions, data structures, program modules and other data for computer 100 . A single hard disk drive 118 and a single removable memory drive 122 are shown for illustration purposes only and with the understanding that computer 100 may include several of such drives. Furthermore, computer 100 may include drives for interfacing with other types of computer readable media.
[0030] A user can interact with computer 100 with a variety of input devices. FIG. 2 shows a serial port interface 126 coupling a keyboard 128 and a pointing device 130 to system bus 114 . Pointing device 128 may be implemented with a mouse, track ball, pen device, or similar device. Of course one or more other input devices (not shown) such as a joystick, game pad, satellite dish, scanner, touch sensitive screen or the like may be connected to computer 100 .
[0031] Computer 100 may include additional interfaces for connecting devices to system bus 114 . FIG. 2 shows a universal serial bus (USB) interface 132 coupling a video or digital camera 134 to system bus 114 . An IEEE 1394 interface 136 may be used to couple additional devices to computer 100 . Furthermore, interface 136 may configured to operate with particular manufacture interfaces such as FireWire developed by Apple Computer and i.Link developed by Sony. Input devices may also be coupled to system bus 114 through a parallel port, a game port, a PCI board or any other interface used to couple and input device to a computer.
[0032] Computer 100 also includes a video adapter 140 coupling a display device 142 to system bus 114 . Display device 142 may include a cathode ray tube (CRT), liquid crystal display (LCD), field emission display (FED), plasma display or any other device that produces an image that is viewable by the user. Additional output devices, such as a printing device (not shown), may be connected to computer 100 .
[0033] Sound can be recorded and reproduced with a microphone 144 and a speaker 166 . A sound card 148 may be used to couple microphone 144 and speaker 146 to system bus 114 . One skilled in the art will appreciate that the device connections shown in FIG. 2 are for illustration purposes only and that several of the peripheral devices could be coupled to system bus 114 via alternative interfaces. For example, video camera 134 could be connected to IEEE 1394 interface 136 and pointing device 130 could be connected to USB interface 132 .
[0034] Computer 100 can operate in a networked environment using logical connections to one or more remote computers or other devices, such as a server, a router, a network personal computer, a peer device or other common network node, a wireless telephone or wireless personal digital assistant. Computer 100 includes a network interface 150 that couples system bus 114 to a local area network (LAN) 152 . Networking environments are commonplace in offices, enterprise-wide computer networks and home computer systems.
[0035] A wide area network (WAN) 154 , such as the Internet, can also be accessed by computer 100 . FIG. 2 shows a modem unit 156 connected to serial port interface 126 and to WAN 154 . Modem unit 156 may be located within or external to computer 100 and may be any type of conventional modem such as a cable modem or a satellite modem. LAN 152 may also be used to connect to WAN 154 . FIG. 2 shows a router 158 that may connect LAN 152 to WAN 154 in a conventional manner.
[0036] It will be appreciated that the network connections shown are exemplary and other ways of establishing a communications link between the computers can be used. The existence of any of various well-known protocols, such as TCP/IP, Frame Relay, Ethernet, FTP, HTTP and the like, is presumed, and computer 100 can be operated in a client-server configuration to permit a user to retrieve web pages from a web-based server. Furthermore, any of various conventional web browsers can be used to display and manipulate data on web pages.
[0037] The operation of computer 100 can be controlled by a variety of different program modules. Examples of program modules are routines, programs, objects, components, data structures, etc., that perform particular tasks or implement particular abstract data types. The present invention may also be practiced with other computer system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCS, minicomputers, mainframe computers, personal digital assistants and the like. Furthermore, the invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
[0038] Referring to the flow chart shown in FIG. 2, activities and responsibilities involved in managing and maintaining the supplier database are outlined using the system, method and interface for evaluating the supply base of a supply chain according to the present invention. The flow chart, shown in FIG. 2, includes the step 30 of creating and maintaining a database of suppliers. The information in the database is used to analyze departmental databases of suppliers in step 32 . The results of the analysis of step 32 is utilized in step 34 the select suppliers for each season. The results of the selections made in step 34 are tracked to develop evaluations of suppliers is step 36 . The evaluations of suppliers, developed in step 36 , are in turn utilized to maintain the database of suppliers in step 30 .
[0039] The system, method and interface for evaluating the supply base of a supply chain according to the present invention displays a number of screens on a display, such as the display device 142 of the computer system 100 . FIG. 3 illustrates a logical order in which these screens may be reviewed. In particular, the interface of the present invention begins with a logon screen 200 , shown in FIG. 4, described in detail below. After successfully logging on, a user is presented with the home page screen 210 , shown in FIG. 5. From the home page screen 210 , a user can select from: an actuals evaluation screen 220 , a supplier information screen 230 , a teams view evaluation screen 240 , and a bulletin board 250 , shown in FIGS. 6 - 9 , respectively, actuals comparison screen 260 shown in FIG. 10, or teams view comparison screen 280 , shown in FIG. 12, and described in detail below.
[0040] From the actuals evaluation screen 220 , a user can select a trend evaluation screen 270 shown in FIG. 11. A user can select a trend evaluation screen 290 , shown in FIG. 13 from the teams view evaluation screen 240 .
[0041] Referring to FIG. 4, when a user first begins to use the system of the present invention, the interface displays the logon screen 200 . Users are requested to enter their user ID into field 202 along with their password in field 204 on the logon screen 200 . Upon successful logon, achieved by selecting logon button 206 , most users will only have authorization to read information and no permission to enter information. In one embodiment, only users that are members of the quality assurance team (QA) will have write access to the system in order to maintain accurate assessments of the suppliers. Most users will be authorized to read all information in the application, but will have no write access. Once QA members launch the application they may be required to follow the same procedure for logging on, however they will be allowed to edit scores on the Teams View screen, described in detail below. Administrative users may be allowed to review, reject or submit Bulletin Board messages, input Supplier Turnover and Websites, add or delete product type or add or delete users.
[0042] Each user's permissions are established with the establishment of their account, and will be invisible to the user. The ID and password entered in the logon screen 200 will determine the level of user access to the information in the system. Members of the QA team will be allowed to edit scores in the team view evaluation screen 240 , discussed below. All users will be allowed to post messages on the bulletin board screen 250 , shown in FIG. 9.
[0043] Successful logon through screen 200 brings up the homepage screen 210 , shown in FIG. 5. The homepage screen 210 is a web page containing a list of suppliers 211 with corresponding status ratings. The status ratings include actuals 212 and team views 213 . The actuals 212 displays the status for each supplier based on actuals information from the actuals evaluation screen 220 . Similarly, the teams view fields 213 display the status (red, green or amber) of the supplier based on team set information from the team view evaluation screen 240 .
[0044] A specific supplier can be found by typing in the first letter(s) of the supplier's name in the Find Supplier field 214 , or by using the scrollbar 215 adjacent the supplier list 211 to arrive at the nearest match. A user can navigate to different screens in the system by using the hyperlink buttons 216 on the left-hand menu section 300 of screen 210 . The menu section 300 is repeated in all the subsequent screens.
[0045] The team view scores for each supplier in the supplier list 211 may be colored coded to provide a quick visual indication of the supplier's status. For example, If the team view is red the supplier's score is between 0-69.99 indicating poor performance. A team view colored amber corresponds to a score between 70 and 89.99 and indicates average performance. If the team view is green a supplier has a score of greater than 90 indicating above average performance. The actual value ranges for the scores may vary depending upon the situation being evaluated, and the foregoing scores are merely for illustrative purposes. The calculation of evaluation scores is described in detail below.
[0046] Homepage screen 210 also has a supplier status report button 217 that, when selected, brings up a supplier status report through which a user can rank the suppliers according to their team view score, in either ascending or descending order, discussed in detail below.
[0047] [0047]FIG. 6 shows the actuals evaluation screen 220 , accessed by selecting the actuals hyperlink button 216 on menu section 300 . The actuals evaluation screen 220 contains key performance indicators (KPI) by which suppliers may be measured. Supplier's KPI are viewed by channel (supply chain) either aggregated up to ‘All Suppliers’ or at a supplier, division, or department level. The supplier KPI may include Lateness of Order, Completeness of Order, and Service Level. The Trend button produces a Trend graph plotting Teams View scores overtime. The actuals data may be extracted from an RMS database. The foregoing list of possible KPI is not intended to be inclusive, and other performance indicators may be utilized.
[0048] The select channel field 221 provides a list box from which a user can select the supply chain. A select supplier field 222 provides a list of values from which a user may select a single supplier or ‘all suppliers’. The user may enter the first letters of the name and the nearest match will be found, or the scroll bar can be used. The select division field 223 and select department field 224 provide list boxes from which the user may select a division and the department, respectively.
[0049] The actuals evaluation screen 220 contains columns of data. The measure column 225 is a listing of the metrics for each supplier. In the illustrated embodiment, the measures include: returns, damaged returns, gross sales, net sales, buying margin, achieved margin, lateness of order, completeness of order, service level, supplier-current level, number of lines sold, annualized sales for the preceding 52 weeks, annualized profit for the preceding 52 weeks, and percentage of supplier turnover.
[0050] The second column 226 is a monetary value column. In the illustrated embodiment its monetary unit is pounds. Column 227 is a representation of the percentage of value of the measure. The last column is a units column 228 representing the value in units for the measure in column 224 .
[0051] Users can indicate how important each metric in column 225 is by assigning an appropriate weight in column 227 . One skilled in the art will appreciate that there are a number of different formulas that can be utilized to create an evaluation score. In one embodiment of the invention, the monetary values in column 226 may be multiplied by the corresponding weights in column 227 and the resulting products may be summed together to produce a raw score. The raw scores for each supplier may then be normalized to produce an evaluation score. Of course, one or more of the monetary values in column 227 may also be normalized or otherwise modified before being multiplied by the appropriate weight.
[0052] In one embodiment of the invention, each user or a group of users may be given the option of identifying which metrics to score for the suppliers. Furthermore, the user or group of users may be given the option of defining how the metrics will be combined to create an evaluation store. The QA users may designate the metrics to score for the suppliers and the general users will able to enter values for the designated metrics, but will not be able to change the chosen metrics.
[0053] By selecting the teams view hyperlink button 216 in menu section 300 , teams view evaluation screen 240 is displayed, as shown in FIG. 8. The teams view evaluation screen 240 allows users to view a supplier's performance as evaluated against five defined teams view measures, for both their pre-season and in-season performance, and can be rolled up or down the hierarchy (as in actuals). The five measures in the illustrated embodiment are: deliveries, quality, documentation, culture, and communication. The scores are on a scale of one to ten for each measure, yielding a maximum total score of 100. Trend button 241 brings up a trend graph plotting teams view scores over time. The teams view evaluation screen 240 may also launch an editable version of the page, allowing QA members to create/edit the scores for that supplier at the department level. Score creation/editing can be done by selecting the edit department scores button 242 . The five measures are merely intended to be illustrative of possible measures, and other factors may be used as measures of supplier performance.
[0054] The select supplier field 222 , select division field 223 , and select department field 224 are the same as discussed previously with regard to FIG. 6.
[0055] The subtotals in fields 243 and 244 are for pre-season and in-season performance, respectively, and the Season total field 245 displays the total score for the supplier. The date the score was created is indicated in date created field 246 . The new department button 247 associates a department to a supplier, if association does not already exist. Disassociation is not possible.
[0056] By selecting the supplier information hyperlink button 216 in the side menu 300 , a user is presented with supplier information screen 230 , shown in FIG. 7. Screen 230 contains a standard form displaying information relating to an individual supplier's contact and reference information. The supplier field 231 provides the name of the supplier. The turnover field 232 indicates the current turnover of the supplier. The website field 233 provides the URL of the selected supplier. Screen 230 may also contain the selected supplier's address, information relating to a contact person, information concerning the selected supplier's factories, and lead-time on orders from each factory. A user can go to the website displayed by clicking on the Go to web-site button 234 . The save, reset, edit, ok, and cancel buttons 235 - 239 , respectively, are all for use by specifically authorized personnel.
[0057] When a user selects the bulletin board hyperlink button 216 in the side menu 300 , the bulletin board screen 250 , shown in FIG. 9, is displayed. Screen 250 provides a basis for informal communication for assessing and evaluating the supply base. Users can use the bulletin board screen 250 to create and post a message, and to view messages that have been posted. Thus, the bulletin board screen 250 promotes cross-functional and cross-hierarchical communication, giving users the ability to present information that may not be communicated in the remaining prescribed screens. The bulletin board screen 250 includes a message window 252 that displays the title and subject of a message, and message text, which is the content of the message.
[0058] The bulletin board screen 250 is intended to promote cross-functional and cross-hierarchical communication, essentially giving users the ability to present information that may sometimes not be communicated outside of structured information. The bulletin board screen 250 may help facilitate informal communication, quickly spreading news on suppliers who may be struggling financially, quotas which are running out in various areas of the world, news of labour rate shifts, etc. Users who submit messages to the bulletin board screen 250 may define a removal time for the message. Messages may then be automatically removed after this time. The QA users have the ability to view, edit, delete, or publish the messages from the general users.
[0059] Referring to FIG. 10, an actuals comparison screen 260 is illustrated. The actuals comparison screen 260 may be selected using the actuals compare suppliers score button 216 in the side menu 300 . With the actuals comparison screen 260 , a user will be able to compare the actual performance metrics of multiple suppliers by stacking them up next to each other in a matrix. This can be done at department, division or channel level, and comparisons across levels of the hierarchy are possible (i.e. compare supplier A's performance at divisional level against supplier B's performance at company level).
[0060] Each supplier is identified in the channel field 261 , supplier field 262 , division field 263 , and department field 264 . The measure column 265 corresponds to the measure column 225 in FIG. 6 listing the quantitative KPIs. Similarly, the remaining columns for each supplier parallel the columns in FIG. 6.
[0061] The trend evaluation screens 270 and 290 , shown in FIGS. 11 and 13, respectively, allows users to see how a supplier has performed over a period of time. For screen 270 , the user selects a KPI, for example Culture, Communication, etc. and clicks on the trend graph button 216 , shown in FIG. 8, to display a graph in a screen 270 . For screen 290 , the user selects a KPI, for example Returns, damaged returns, etc. and clicks on the trend graph button 241 , shown in FIG. 10, to display a graph in a screen 290 .
[0062] By selecting the team view comparison button 216 in the side menu 300 , the team view comparison screen 280 is displayed, as shown in FIG. 12. The team view comparison screen 280 allows a user to compare the teams view performance metrics of multiple suppliers by stacking them up next to each other in a matrix. Such comparison can be done at department, division or company level, and comparisons across levels of the hierarchy will be possible (i.e. compare supplier A's performance at divisional level against supplier B's performance at company level).
[0063] Each supplier is identified by supplier field 281 , division field 282 , and department field 283 . The KPI column 284 corresponds to the five defined teams view measures, for both their pre-season and in-season performance set forth in FIG. 8. In the illustrated embodiment these measures are: deliveries, quality, documentation, culture, and communication. The subtotals are for pre-season and in-season performance, respectively, and the season total field displays the total score for the supplier, as was the case in FIG. 8. The date the score was created is also indicated.
[0064] [0064]FIG. 14 illustrates a screen 310 for linking a supplier to a product type. Screen 310 is accessed through the link supplier to product type button 216 in the side menu 300 , and authorized users to associate a product type with a supplier or add a product type to a suppliers product type list, or delete a product type from the suppliers product type list. From screen 310 , users can bring up a report screen, which once a supplier is selected, returns the different product types that the supplier provides.
[0065] Screen 310 has two basic fields. A supplier field 312 that includes a list of suppliers, and a product type field 314 , that includes a scrolling list from which an authorized user can select a product type to link with a supplier.
[0066] As discussed previously with regard to the homepage screen 210 , a supplier status report 320 , shown in FIG. 15, may be produced by selecting the status report button 217 . The supplier status report 320 allows users to rank the suppliers according to their team view score, in either ascending or descending order.
[0067] Referring to FIG. 16, a flow chart of the method for evaluating the supply base according to the present invention is illustrated. In step 400 the QA users can restrict the ability to input supplier data into the system to authorized personnel. Next, in step 402 the data concerning the suppliers is input. Performance indicators for the suppliers are displayed in step 404 . An evaluation score is produced in step 406 based upon the input data.
[0068] In step 408 the evaluation score produced in step 406 may be linked to a product type. The evaluation scores for multiple suppliers may be compared in step 410 and the performance indicators for multiple suppliers may be compared in step 414 . After step 410 , multiple suppliers may be ranked according to their evaluation scores, in step 412 . Finally, anecdotal information may be input in step 416 , and does not have to follow directly from steps 408 , 412 , or 414 . Rather, step 416 may be executed at almost any time in the flow chart shown in FIG. 16.
[0069] The illustrated embodiment of the system, method and interface for evaluating the supply base of a supply chain according to the present invention is designed to work with an Oracle® database. However, the present invention is not intended to be limited to Oracle® databases, and may be used with other relational database products such as Jasmine®, Sybase®, Informix®, or PowerBuilder®. The system according to the present invention may request data from the central Oracle Web Server, which will in turn source data from a main Oracle® database. Any time the system is updated the new information is fed back to the central web server and subsequently updates the Oracle® database. The system according to the present invention may be housed in an Oracles database, and may be accessed via a web-browser front end on a LAN using an Oracle® Web Server.
[0070] Having described several embodiments of the system and method of optimizing a supply chain in accordance with the present invention, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the description set forth above. It is therefore to be understood that all such variations, modifications and changes are believed to fall within the scope of the invention as defined in the appended claims. | A system, method and interface for evaluating the supply base of a supply chain. The system, method and interface facilitate the collation of information in a supplier database. The system, method and interface facilitate the evaluation of a base of suppliers forming a supply base of a supply chain. The evaluation includes providing a database of information relating to supplier performance and capabilities based on historical performance. The supply base evaluation system, method and interface can be used to qualify and disqualify suppliers, and to improve supplier performance and capabilities. Objective feedback may be provided to suppliers, the feedback including metrics captured and tracked by the system. Development plans may be implemented to improve the manner in which suppliers do business throughout the supply chain. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a system for preparing highly coherent textured yarn, and more particularly, it relates to a system for preparing such yarns with pressurized fluid in a jet having a deflector arrangement at its outlet end.
It is known to overfeed one, or more, ends of continuous multifilament yarns to a jet, in which pressurized fluid, such as air, acts on the filaments to splay them, curl them into crunodal loops, and entangle the looped filaments into coherent yarn.
Fluid jet processes are also known for texturing or bulking yarn that employ both movable and fixed baffles positioned at various distances from the outlet end of the jet and at various angles to the yarn path to deflect yarn and fluid from a straight path as they leave the jet.
In making a yarn having crunodal loops, the texturing jet must forward the overfed yarn under sufficient tension to keep the yarn from wrapping on the feed rolls, and this tension is provided by the drag of the pressurized air which is moving much faster than the yarn. The air opens the yarn, whips the filaments about, forms loops in the filaments, then entangles them together into a structure which can retain the loops under the tensions which such yarns encounter when made into fabrics. The tension must be low at the jet exit to accumulate loops and form the entangled structure. Immediately thereafter, higher tension is desired to tighten the entangled structure and stabilize it.
A baffle against which the air and yarn impinge is often provided at the jet exit to provide a controlled air zone and to change the direction of yarn movement abruptly. Such baffles are especially necessary at high texturing speeds and air pressures. However, with known baffle arrangements, the air divides around the baffle, and the portion of the air which follows the yarn continues to exert tension.
Textured yarn uniformity, in terms of appearance and loop stability, is highly critical for good fabric uniformity. Since many different packages are used to make fabrics, the yarn character must be the same from one package to the next and within a package from beginning at the core to the surface, including when a package is stopped for any reason.
A texturing position stops when either a take-up package is full or the feeder yarn supply is interrupted. In other cases, the positions are stopped at the time of shift change. The stop could be initiated either automatically or manually. In either case, the electric power that drives the motor and the rolls stops. The rolls continue to turn slowly, due to the inertia, before gradually slowing down and coming to a complete stop. When the rolls are completely stopped with no yarn movement through the jet, then the air supply to the jet is stopped, either automatically or manually, usually within 1-3 seconds. Stoppage of air prior to the stoppage of the rolls would result in totally untextured yarn, since the slow forward movement of rolls will continue to feed yarn to the jet without any air to texture it.
Textured yarn manufacturers have experienced small lengths of yarn (1 to 12 inches out of total approximately 500 inches of yarn during which the rolls slowly come to a full stop) with a varying degree of fluffy and partially or poorly textured yarn character immediately prior to stoppage of the rolls. This defect is called Partially Textured Yarn Defect or PTYD. The PTYD consists of loosely bulked or fluffed yarns having insufficient filament mixing and loop interlocking so that the yarn bulk will pull out easily and will show as defects in the fabric. Although the defect is present in a majority of the commercial texturing processes, the severity of PTYD varies, depending upon actual texturing process conditions. For years, the texturizers have coped with the problem by either (A) cutting off PTYD manually prior to re-string up or (B) leaving the PTYD at the core of a new package and rejecting the "heel" as waste in subsequent process. Both solutions are inefficient, wasteful, and subject to operator judgment and error.
SUMMARY OF THE INVENTION
The present invention is a system for texturing one or more yarns that includes a source of supply for said yarns, a yarn texturing jet through which yarn passes positioned between a feed means and a take-up means for taking textured yarn up onto a package. The jet includes a body having yarn inlet and outlet ends connected by a central bore along a central axis, means for introducing pressurized gas through a gas inlet into said bore between said ends to contact yarn passing through the jet at a location in said bore, said yarn and said gas following a path from said outlet end of said jet. A baffle is located adjacent the yarn outlet end of the jet, the baffle has a peripheral surface, the portion of the surface nearest said outlet end is a distance of 0.5 to 1.5 minimum diameters of the bore downstream of said location where the pressurized gas enters into the bore of the jet and the portion of the baffle surface nearest the central axis is a distance of from 0.7 to 2.5 of said minimum diameters from said central axis.
The baffle may have a circular, curvilinear, or polygon cross section.
In operation, upon exiting the jet orifice, the yarn travels axially straight out along with the exhaust air stream, and then sharply changes direction, forming a bend while the exhaust air continues its forward path. The yarn then continues to follow the contour of the baffle and travels back through the exhaust stream toward the take-up means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of one embodiment of the system of this invention.
FIG. 2 is a schematic illustration of an alternate embodiment of the system of this invention.
FIG. 3 is a perspective view of the jet used in this invention.
FIG. 4 is a sectioned view of FIG. 3 taken along line 4--4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In an embodiment chosen for purposes of illustration, in FIG. 1, feed yarns 10 from a plurality of packages 12, are threaded through tensioner 14 and feed roller 16 to a wetting bath 18 to the inlet of texturing jet 20. Jet is supplied by compressed air from air manifold 22.
Textured yarn exiting jet 20, around special baffle fitted to jet exit (not shown), is taken to nip roll 24, over traverse guide bar 26, onto wind up package 28. Speed of feed roll 16 is greater than nip roll 24 to effect a yarn bulking overfeed of from about 5 to about 200% or more. Wind up speed is slightly faster than nip roll 24 speed by about 1 to about 10% or more. Wind up tension is measured, by a suitable tensiometer, at location 25 on textured yarn 27, and an average reading is taken to avoid tension extremes generated by traversing the yarn onto take-up package.
In core-and-effect texturing, effect yarn (not shown) ends are fed to separate feed roll before running through jet 20 commonly without getting wetted. Yarn ends 10 from supply packages 12 taken to feed roll 16 serve as core. Core-and-effect ends are textured together by jet 20 but to different levels of overfeeds. A low overfeed level is applied to core yarn ends 10 by the speed ratio of rolls 16 and 24. A high overfeed level is applied to effect yarn ends by the speed ratio of their corresponding rolls.
In parallel yarn texturing the level of overfeed is the same for each yarn fed to the jet.
Commercial machine of the type shown in FIG. 1 is an Eltex AT, manufactured by Hirschburger GMBH of Reutlingen, Germany.
A more detailed system is shown in FIG. 2 wherein feed yarn packages 30 (one is shown) supply multifilament yarn ends 32 to feed rolls 35, which, in turn, overfeed the yarns to jet 37, after passing through water bath 36 both contained in compartment 37a. If feed yarns 32 are polymeric, such as polyester or polyamide, spun without being fully oriented (known in the industry as POY yarn, for being partially oriented yarn), it is common to draw said feed yarn in a drawing zone between rolls 33 and rolls 35. If yarn is polyester POY, it is common to draw it around a hot metallic pin 34, located between rolls 33 and 35. After feeding yarns to jet 37, textured yarn exits the jet around cylindrical baffle 38 to rolls 39. A mild cold stretching of 1 to 15% is sometimes applied in the zone between rolls 39 and rolls 40, often called the stabilization zone. High yarn shrinkage, either inherent in the supply feed yarn or generated by the drawing step between rolls 33 and rolls 35, is sometimes reduced by yarn relaxation step between rolls 40 and rolls 42 wherein yarn travels through heated tube 41. After exiting rolls 42, textured yarn is wound around take-up package 44. Wind up tension is measured at location 43, as far upstream of textured package 44 as possible, to reduce tension peaks generated by traversing the yarn in winding. An average tension reading is taken. Tension can also be measured in stabilization zone between rolls 39 and rolls 40 to evaluate the effectiveness of the texturing jet 37. Under otherwise identical speed ratios and conditions, the higher the tension in the stabilization zone, the more effective the jet 37 is in converting bulking overfeed to stable, more highly coherent, and bulky textured yarn.
For core-and-effect texturing, core yarns 32 (only one shown in FIG. 2) are fed through rolls 33 and 35 to water bath 36 and texturing jet 37 (FIG. 2). Effect yarns 52 from supply packages 51 (only one is shown in FIG. 2) are fed through rolls 53 and rolls 55 for drawing on hot pin 54 before guiding them around bar 56 to inlet of texturing jet 37. Commonly, core yarns 32 are wetted in bath 36 but effect yarns 52 are not wetted, by bypassing the bath. In other arrangements, wetting the core yarn 32 is done by dripping liquid from a suitable orifice (not shown) onto the yarn directly. A typical machine similar to that schematically shown in FIG. 2 is model FK6-T80, manufactured by Barmag Co., of Remscheid, Germany.
Texturing jet 37, with special exit baffle, is described in FIGS. 3 and 4.
In the system of this invention, POY feed yarns are not specifically necessary, but if used, it is common to pre-draw the yarn, with or without heat, before reaching pre-jet feed rolls. Also, a stabilization zone is not specifically necessary, but could be used. Also, a heat setting zone, shown between rolls 40 and 42, is not specifically necessary but could be used to modify thermal properties of textured yarn, e.g., boil off shrinkage.
The system of this invention is applicable to all types of filament yarns such as polyester, POY polyester, nylon, POY nylon, polypropylene, POY polypropylene, polyolefin, rayon acetate, glass, and aramid yarns.
The system of this invention is also applicable to yarn manufactured with free-end broken filaments protruding from yarn bundle, in which loops generated by texturing jet 37 are subsequently broken or abraded to single filaments so that yarn produced resembles a hairy spun yarn.
A closer view of the jet 37 in FIGS. 3 and 4 shows either yarn 10 (FIG. 1), or the combination of yarns 32 and 52 (FIG. 2) generally designated 100 enter the jet through inlet 60. Compressed air or other pressurized gas enters the jet through pipe 22 and impinges on the yarn in the entrance 62 of yarn outlet orifice block 64. The yarn and high velocity gas travel together through outlet end 66 of the jet and travel around baffle 38 which is fixedly mounted to bracket 68 attached to the outlet end of the jet.
The central axis of cylindrical baffle 38 is located with respect to the central axis of the jet such that the portion of the surface of the baffle nearest the central axis of the jet device is a distance A of from 0.7 to 2.5 minimum diameters of the bore downstream of the location where the pressurized gas contacts the yarn in the bore. More particularly, in the yarn outlet orifice block 64, said minimum diameter is the diameter indicated at location B. The baffle is also located a fixed distance C from the outlet end 66 of the jet's exhaust. This distance C is in the range of from 0.1 to 4.0 and is preferably in the range of from about 0.5 to about 1.5 of the minimum diameters referred to above.
In operation, yarn is passed through jet 37 where it is treated with pressurized gas, then propelled by the gas from the outlet end of the jet. Upon exiting the jet, the yarn travels axially straight out along with the exhaust air stream and then sharply changes direction forming a bend 100a while the air stream continues its forward path. The yarn then follows the contour of the baffle back through the air stream toward the take-up means.
EXAMPLE 1
One end of 300 denier--72 filament polypropylene yarn as core and two ends of the 300 denier--72 filament polypropylene yarns as effect, are fed into an air jet texturing jet as shown in FIGS. 2, 3, and 4. Size of minimum diameter B in FIG. 4 is 0.078 inches and needle has a central hole for yarn passage of 0.033 inches in diameter and air inlet hole of 0.093 inches in diameter. Core yarn overfeed between rolls 35 and 39 in FIG. 2 is +10%, effect yarn overfeed between rolls 55 and 39 is +30% to +118%. The underfeed to the wind up between rolls 39 and 44 is -5%. Distance C is 0.060 inches and the diameter of the baffle is 0.400 inches. Distance A is varied from -0.450 to +0.299 inches, where negative (-) sign indicates baffle surface above the jet axis. The textured yarn is wound up onto a package 44 at 280 meters per minute. The air pressure to the jet 37 is 130 psi and the air flow is 10 cubic feet per minute.
Presence of PTYD and severity are observed when the rolls and the air supply are stopped as normal practice. The unique relationship of the baffle to the yarn passageway in the system of this invention totally eliminated partial textured yarn defect under a wide range of texturing conditions as noted in Table I. By contrast, other baffle positions and yarn passageway, as practiced in the industry, show presence of PTYD.
TABLE I______________________________________ PRESENCE OF PTYD (YES/NO) ATDISTANCE A EFFECT YARN OVERFEED OF(INCHES) +30% +57% +118%______________________________________-0.450 Yes Yes Yes-0.200 Yes Yes Yes-0.021 Yes Yes Yes+0.050 Yes Yes Yes+0.086 No No No+0.121 No No No+0.157 No No No+0.193 No No No+0.228 Yes Yes No+0.264 Yes Yes No+0.299 Yes Yes No______________________________________
EXAMPLE 2
Four ends of 150 denier--34 filament polyester yarn as parallel ends are fed into an air jet texturing jet as shown in FIGS. 1, 3, and 4. Size of minimum diameter B in FIG. 4 is 0.070 inches, and the needle has a central hole for yarn passage of 0.033 inches in diameter yarn overfeed between rolls 16 and 24 in FIG. 2 is 26% and between rolls 16 and wind up 28 is 19.5%. Distance C is 0.060 inches and the diameter of the baffle is 0.400 inches. Distance A is varied similar to Example 1. The textured yarn is wound up onto a package 28 at 280 meters per minute. The air pressure to the jet is 130 psi and air volume is 9 cfm.
The elimination of the PTYD is indicated in Table II.
TABLE II______________________________________DISTANCE A(INCHES) PRESENCE OF PTYD (YES/NO)______________________________________-0.450 Yes-0.200 Yes-0.164 Yes-0.093 Yes-0.039 Yes-0.004 Yes+0.050 No+0.085 No+0.157 No+0.228 No+0.299 No______________________________________ | In a system for air-jet texturing yarn a yarn treating jet is modified to locate a baffle at the outlet end of the jet. The baffle is positioned a fixed distance from the central axis of the jet and away from the outlet end of the jet such that the yarn follows the surface of the baffle to a point where the yarn leaves the baffle to pass back through the air stream exiting the jet to eliminate partially textured yarn that normally forms when stopping the system. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of producing metal hydroxides in an easy-to-separate powder form, as well as to various applications of this method.
2. Discussion of Background Information
Metal hydroxides of the general formula Me (OH) n are usually prepared by the action of an alkaline solution on soluble metal salts, to precipitate hydroxides which have a finely divided and often a gelatinous appearence.
The gelatinous appearance obtained does not facilitate washing or the hydroxide and separating it by filtration from the starting solution and from the washing waters. It is therefore difficult to obtain the hydroxide in a powder form with an acceptable purity.
In some other cases, in particular when the hydroxides are soluble in an alkali medium, for example the hydroxides of amphoteric metals, they may in theory be obtained as precipitates by neutralizing a strong base with an acid. In many practical applications, the metals which are dissolved in strong base media are not recovered, but the solutions containing them are purely and simply discharged, with the consequent risks of pollution and toxicity.
SUMMARY OF THE INVENTION
The present invention aims to remedy these drawbacks and to produce metal hydroxides both from acid solutions and from alkaline solutions, in a finely divided and easy-to-wash form and, consequently, with a high degree of purity.
This method is characterized in that an electric current is passed through the solution in which the metal is dissolved to produce the formation of a precipitated hydroxide against a solid ion-exchange membrane, which membrane separates the anode compartment from the cathode compartment.
The expression "against a solid ion-exchange membrane" as used above means that the precipitation takes place on the membrane, or in the immediate proximity thereof, in a zone of the order of 1 mm thick from the membrane.
According to a first embodiment, the solution is an acid solution and the membrane is an anionic membrane, for example a membrane comprising quaternary ammonium groups. This embodiment enables the precipitation and the separation of the metal hydroxide from an acid solution.
According to a second embodiment, the solution is a basic solution and the membrane is a cationic membrane, for example a membrane comprising SO 3 H- groups.
In either case, the membrane is for example an insoluble polymer incorporating an ion-exchange resin, or an insoluble polymer, for example polytetrafluoroethylene, which has been irradiated in a manner to graft polystyrene carriers of charged groups, as those indicated above.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood with reference to the accompanying drawings, given by way of non limiting example. In the drawings:
FIG. 1 corresponds to the embodiment where the metal hydroxide is precipitated from an acid solution, and
FIG. 2 corresponds to the embodiment wherein the metal hydroxide is precipitated from an alkali solution.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a vat 1 in which an electric current is to be passed, and which is divided into two parts, a cathode compartment 2 and an anode compartment 3, by an anionic membrane 4. In this vat, a cathode 5 is placed in the cathode compartment 2 and an anode 6 is placed in the anode compartment 3.
The cathode compartment 2 is filled with a catholyte, for example a basic solution of caustic soda or caustic potash, and it is fitted with a cathode 5 made of a metal stable in alkali media, for example nickel.
The anode compartment 3 is filled with anolyte, namely a solution of the metal Me whose hydroxide is to be precipitated. The anode is for example made of the same metal, employing the soluble anode technique.
An electric current is caused to flow, advantageously at a potential difference comprised between 5 and 20 V, at a current density preferably comprised between 5 and 20 A/dm 2 , which produces the following movements.
The metal ions Me n+ in the anolyte move towards the cathode, but they are prevented from passing into the catholyte by the anion-exchange membrane; the OH - ions of the catholyte move towards the anode, pass through the anion-exchange membrane and come into contact with the ions Me n+ .
The formation of the hydroxide Me(OH) n thus takes place on the anionic face of the membrane, because the anionic face is highly basic, which is permanently maintained due to the constant regeneration of the membrane by the continuous supply of OH - ions.
The hydroxide formed is detached from the membrane and sinks in the anolyte. It has a powdered and dry appearance enabling it to be filtered and washed without any difficulty.
For the formation of the hydroxide, it is important that the anolyte be maintained at a pH comprised between 0.5 and a pH less than that which would cause hydrolysis of the anolyte solution, which would lead to an unwanted precipitation of the hydroxide in a gelatinous form. This pH is for example of the order of 4.5 when the anolyte is a ZnSO 4 solution, in which case the precipitate obtained is obviously Zn(OH) 2 . The concentration of metal Me in the anolyte is maintained constant by dissolution of the anode.
In a variation, instead of operating in the soluble anode mode, the concentration of the treated solution is reconstituted by the addition and dissolution of a salt of the metal whose hydroxide is to be produced, for example a carbonate. A non-soluble anode, for example of lead or ruthenised titanium is used.
It is also possible to produce hydroxides of metals such as chromium, nickel, cadmium, cobalt, zinc or uranium, or double or triple hydroxides such as nickel-cadmium hydroxide, or nickel-cadmium-cobalt hydroxide.
The applications of this method concern notably the treatment of uranium ore to recover the metal through its hydroxide, the starting acid solution containing the uranium salt being an acid feed solution of an uranium ore.
FIG. 2 shows a similar installation, comprising a vat 1, a cathode compartment 2 with a cathode 5 and an anode compartment 3 with an anode 6. In this instance, the cathode compartment 2 and the anode compartment 3 are separated by a cation-exchange membrane 7.
The anode compartment is filled with the solution to be treated, or anolyte, from which the hydroxide is to be precipitated and which, it should be recalled, is a solution of a metal in an alkaline medium. Advantageously a highly concentrated solution of caustic soda or caustic potash is used, for example 8N caustic soda or caustic potash. The cathode compartment is filled with the catholyte, for example a 0.5N solution of caustic potash and the anode and cathode compartments are fitted with respective electrodes of dimensionally-stable, insoluble metal, for instance as mentioned above.
The flow of electric current induces the following movements.
The alkaline cations, for example Na + or K + , move from the anode compartment 3 towards the cathode compartment 2 through the cation-exchange membrane 7. The catholyte becomes enriched with alkali as the flow of current continues, and, consequently, the pH of the anolyte is reduced. When the pH has dropped to a sufficiently low value, the metal hydroxide Me(OH) n precipitates in an easy-to-filter form. We may thus refer to this as an electro-dialysis phenomenom.
An advantageous application of this embodiment is the regeneration of strong basic solutions obtained during electrochemical forming of metals, for example, of aluminium. In this case, the starting solution containing aluminium in the form of AlO 2 - ions has a concentration of 8N, and its properties deteriorate when the concentration drops to a value of about 2N. At this point, an 8N alkaline solution has to be reformulated in the cathode compartment, and aluminium recovered in the form of hydroxide precipitated in the anode compartment.
Another application is the regeneration, by the recovery of metals dissolved therein, of basic solutions, namely basic solutions of batteries and accumulators, for example aluminium/air batteries.
The invention will now be illustrated by several non-limiting examples.
EXAMPLES 1 to 5
Using the conditions summarized on the following table where percentages (%) are indicated by weight, hydroxides are obtained in a easy-to-filter and purified form, it being understood that these hydroxides due to their powder form may easily undergo later purification cycles.
__________________________________________________________________________PreparedExampleHydroxide Anolyte Catholyte Current Product Efficiency__________________________________________________________________________1 Nickel Hydroxide 22 N nickel N caustic 10 A/dm2 Nickel 65 to 85% sulfate soda V 12 to 18 V hydroxide solution solution with 70% Nickel anode Nickel nickel cathode2 Cadmium Hydroxide 12 N cadmium N caustic 10 A/dm2 Cadmium 70 to 80% sulfate soda V 15 to 19 V hydroxide Solution solution with 81.5% Cadmium Nickel cadmium anode cathode3 Nickel and 12 N nickel N caustic 10 A/dm2 NickelCadmium hydroxide sulfate soda V 12 to 18 V cadmium solution solution hydroxide 0.3 N cadmium Lead cathode comprising sulfate 67.6% Ni, solution 3.3% Cd Cd/Ni 5% Cd/Ni 5% Nickel anode4 Triple Hydroxide 12 N nickel N caustic 10 A/dm2 Triple 65 to 85%of nickel, sulfate soda V 12 to 18 V hydroxide ofcadmium and solution solution nickel,cobalt 0.3 N cadmium Nickel cadmium and sulfate cathode cobalt solution comprising Cd/Ni 5% 62.6% Ni 1.2 N cobalt 3% Cd sulfate 6.2% Co Co/Ni 10% Cd/Ni 5% Nickel anode Co/Ni 10%5 Aluminium 2 N caustic 0.5 N caustic 15 A/dm2 AluminiumHydroxide potash potash V 6 to 15 V hydroxide Potassium Lead cathode comprising aluminate 39% 495 g/l aluminium in Lead anode the dry product of the anolyte 7 N caustic potash in the catholyte__________________________________________________________________________ | Metal hydroxides are produced in an easy-to-separate powder form from metal in solution, by passing an electric current through the solution to produce the formation of a preceipitated hydroxide against a solid ion-exchange membrane, which membrane separates the anode compartment from the cathode compartment. When the solution is acidic, the membrane is an anion exchange membrane. When the solution is basic, the membrane is a cation exchange membrane. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. § 119(e) from U.S. Provisional Patent Application No. 60/358,733, filed Feb. 25, 2002 and incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates, in general, to fail-safe modules and, more particularly, to fail-safe modules integral with sedation and analgesia systems.
BACKGROUND OF THE INVENTION
[0003] In response to, among other things, market conditions and popularity amongst cost-conscious patients, out-of-hospital procedures continue to experience rapid growth. For various reasons, clinicians such as, for example, in office, ambulatory center, dental, non-hospital and hospital settings sometimes administer or supervise the delivery of sedation and analgesia without the services of trained anesthesia providers. This development has led the American Society of Anesthesiologists to issue guidelines for the delivery of sedation and analgesia by non-anesthesiologists. Because the non-hospital setting is in general not as well equipped and staffed as hospitals, malfunctions and complications (such as unintended over-medication leading to loss of consciousness and airway reflexes) may lead to severe outcomes.
[0004] A sedation and analgesia system is described in commonly assigned and co-pending U.S. Patent Application Ser. No. 09/324,759, filed Jun. 3, 1999. This system safely provides patients undergoing painful, uncomfortable or otherwise frightening (anxiety inspiring) medical or surgical procedures with sedative, analgesic, and/or amnestic drugs in a way that reduces the risk of overmedication, in both non-hospital and hospital settings. As this system may be used in settings where users may not be trained anesthesia providers skilled in resuscitation and airway management and where complications or malfunctions may have more severe repercussions, the number of potential failure modes was systematically reduced by elimination and/or mitigation. Mitigation was partly accomplished by careful design of the fail safe module for the sedation and analgesia system. Thus, the sedation and analgesia system may be safer than anesthesia machines for use in both non-hospital and hospital environments and may be safely operated by individuals other than trained anesthesia providers such as, for example, trained physicians, or other licensed clinicians and operators.
[0005] Anesthesia machines are mainly designed for inhalational anesthesia. In general, as a legacy from earlier anesthesia machine designs that were entirely pneumatic and did not require electrical power to operate, loss of electrical power in current anesthesia machines will not interrupt delivery of anesthetic gases and vapors. In contrast, one embodiment of the sedation and analgesia system described in the '759 application uses only intravenous anesthetics and no inhalational anesthetics and requires electrical power to operate. During sedation and/or analgesia, continued safety in the absence of an anesthesia provider is paramount. These safety systems often employ a set of complicated features to prevent anesthesia machines from being switched off during an anesthetic.
[0006] Existing fail-safe systems used on anesthesia machines have the ability to fall back on an all-pneumatic operation mode of operation and may not be applicable to the needs of a sedation and analgesia or total intravenous anesthesia system requiring electrical power to operate. Furthermore, because the sedation and analgesia system is also designed for use by non-anesthesia providers, the consequences of equipment failure may be more severe and thus fail safe systems with a higher reliability that those used on anesthesia machines designed for use by anesthesia providers are required.
[0007] Due to the importance of patient safety, test modes for drug delivery devices have long been accepted as an important feature. However, existing fail-safe systems may not take into account the specific requirements that the fail-safe system itself may need to be tested to attain a high-reliability sedation and analgesia system. Simulating a failure to test the fail-safe system for a sedation and analgesia system may be disruptive and cause the system to power down upon detection of the simulated failure. Upon termination of the simulated failure, if the system was powered down, the system will power up and cause further disruption, especially if the power-up, including power-up on self test (POST) routines, takes a long time to complete. Therefore, a need has arisen for a fail-safe module that may be tested without untoward system disruption, in order to confirm proper function of the fail-safe system in a high-reliability sedation and analgesia system.
[0008] Further fail-safe systems implement methods of incorporating redundant constituent elements (modules) into the systems. A further need has arisen for a watchdog system integral with a sedation and analgesia system that powers down the sedation and analgesia system in the event of a detected malfunction.
SUMMARY OF THE INVENTION
[0009] The present invention provides a fail-safe module (FSM) integral with a sedation and analgesia system that meets the high-reliability needs of sedation and/or analgesia delivered by non-anesthetists. The FSM may operate in “real-time” in order to ensure optimal patient safety. The FSM may deactivate specific patient interfaces, user interfaces, and/or sedation and analgesia delivery in order to ensure patient safety and has redundant safety systems in order to provide the fail-safe module with an accurate assessment of controller functionality.
[0010] The present invention further includes a FSM measuring the functionality of software and/or hardware associated with critical patient interfaces and/or the sedation and drug delivery system. The FSM may reactivate patient interfaces, user interfaces, and/or sedation and analgesia delivery upon receipt of acceptable data indicating an operable controller. The FSM also may retain in memory a failure event in order to alert the next user that the machine has experienced a failure. The FSM may be included with a test mode capability that simulates a failure. During the simulated failure to test the FSM, automatic system powerdown may be bypassed to create minimum system disruption. The simulated failure may be programmed to occur only on power-up or during normal operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is an overall conceptual schematic block diagram of a system in accordance with the present invention;
[0012] [0012]FIG. 2 is an overall schematic block diagram of a fail-safe module system in accordance with the present invention;
[0013] [0013]FIG. 3 is a more detailed schematic block diagram of a fail-safe module illustrating associated inputs and outputs in accordance with the present invention;
[0014] [0014]FIG. 4 is a flow chart illustrating operation of a fail-safe module system in accordance with the present invention; and
[0015] [0015]FIG. 5 is a flow chart illustrating a method of operating a fail-safe test mode in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] [0016]FIG. 1 illustrates a block diagram depicting one embodiment of the present invention comprising sedation and analgesia system 22 having fail-safe module 23 , user interface 12 , controller 14 , peripherals 15 (which may include a memory device), power supply 16 , external communications 10 , patient interfaces 17 , and drug delivery 19 , where sedation and analgesia system 22 is operated by user 13 in order to provide sedation and/or drugs to patient 18 . An example of sedation and analgesia system 22 is described in co-pending and commonly assigned U.S. Patent Application Ser. No. 09/324,759, filed Jun. 3, 1999 and incorporated herein by reference. Patient interfaces 17 may comprise one or more physiological monitors, such as SpO2, ECG, CO2 and NIBP among others.
[0017] The sedation and analgesia system of Application Ser. No. 09/324,759 includes a patient health monitor device (such as patient interfaces 17 ) adapted so as to be coupled to a patient and generate a signal reflecting at least one physiological condition of the patient, a drug delivery controller supplying one or more drugs to the patient, a memory device storing a safety data set reflecting safe and undesirable parameters of at least one monitored patient physiological condition, and an electronic controller interconnected between the patient health monitor, the drug delivery controller, and the memory device storing the safety data set; wherein said electronic controller receives said signals and in response manages the application of the drugs in accord with the safety data set.
[0018] [0018]FIG. 2 illustrates a block diagram depicting fail-safe module system 60 having controller 14 , fail-safe module 23 , power supply 24 , controller input 25 , controller output 26 , drug delivery 19 , and patient interface 17 , where drug delivery 19 and patient interface 17 interact with patient 18 . Controller 14 receives input from patient interface 17 , drug delivery 19 , fail-safe module 23 , and other peripherals associated with sedation and analgesia system 22 . Data is inputted into controller 14 which executes a program designed in a language, such as, for example, C or C++, and functions within an operating system such as, for example, QNX. However other operating systems such as, for example, LINUX, VX Works, or Windows NT are contemplated. Preferred embodiments of the software operate in a “real time” operating system such as, for example, QNX, where programs relating to specific patient interfaces, user interfaces, and other features of sedation and analgesia system 22 are compartmentalized into separate program modules (not shown).
[0019] Controller 14 may be a CPU, or any other data processing system commonly known in the art. Controller 14 may further comprise, in one embodiment of the present invention, a health-check system (not shown) based, for example, on functionalities provided by the QNX operating system, where the health-check system sends a health check-request (not shown) to a program module (not shown) associated with a feature such as, for example, a system for the automated assessment of consciousness or responsiveness. Such an automated assessment system is described in the '759 application and in U.S. Patent Application Ser. No. 09/324,759 filed Dec. 28, 2002. Upon receipt of a health-check request, the program module is programmed to respond with a health check response. A malfunction of a program module will result in the failure of the module to deliver a health-check response to the health check system integral with controller 14 . The health-check request and health-check response may be in the form of a singe byte, a plurality of bytes, a pulse, a TTL or logic signal, or other forms of data transfer suitable for use with the present invention. If the health check system fails to receive a health check response from a program module within a given time window, controller 14 will alert fail-safe module 23 that a failure has occurred resulting in fail-safe module 23 transferring sedation and analgesia system 22 into safe state mode 107 (FIG. 4) as will be further discussed herein. The health check system is software based and exploits the inherent features of operating systems such as QNX, specifically the allocation of individual reserved memory space for each compartmentalized software program module.
[0020] In one embodiment of the present invention, data and/or commands may be outputted from controller 14 in the form of output 26 to peripherals associated with sedation and analgesia system 22 , fail-safe module 23 , and patient interface 17 . Depending on the functionality of controller 14 and program modules associated with controller 14 , controller 14 may be functioning properly, or may be outputting aberrant commands. In the event that controller 14 has malfunctioned and is outputting spurious commands and/or data, such as, for example, excessive drug delivery, fail-safe module 23 may detect improper operation in controller 14 associated with the failure and transfer sedation and analgesia system 22 into safe state mode 107 (FIG. 4).
[0021] In one embodiment of the present invention, controller 14 is programmed to deliver, or initiate delivery of, a strobe (not shown) to fail-safe module 23 within a predetermined window such as, for example, from between 900 to 1100 milliseconds. The strobe may be in the form of a byte, a plurality of bytes, a pulse, a TTL or logic signal or other forms of data transfer suitable for use with the present invention. Fail-safe module 23 , in one embodiment of the present invention, must receive the strobe initiated by controller 14 within the predetermined time window in order to maintain sedation and analgesia system 22 in an operation state mode 105 (FIG. 4). The failure of controller 14 to initiate and deliver the strobe within the specified window indicates to fail-safe module 23 that an anomaly has occurred in the health check system or in the program modules associated with sedation and analgesia system 22 , resulting in fail-safe module 23 transferring sedation and analgesia system 22 into safe state mode 107 . A further embodiment of the present invention comprises providing a direct communication (not shown) between the program modules associated with sedation and analgesia system 22 and fail-safe module 23 in order to provide redundancy in verifying the program modules are functioning properly. An even further embodiment of the present invention comprises providing direct communication between patient interface 17 and/or drug delivery 19 to provide redundancy in verifying that program modules associated with critical peripherals are functioning properly. FIG. 2 further illustrates one embodiment of the present invention, where power supply 24 is connected to and powers fail-safe module 23 . In one embodiment of the present invention, power supply 24 delivers 0.5-200 volts DC and preferably 4.75-5.25 volts DC, and is capable of sourcing 0.5-200 amps and preferably 12 amps, and may be referenced to a system ground. The present invention further contemplates the use of alternating current.
[0022] [0022]FIG. 3 illustrates a block diagram depicting one embodiment of the present invention comprising fail-safe module 23 , inputs 30 , 32 , 34 associated with fail-safe module 23 , outputs 31 , 33 , 35 associated with fail-safe module 23 , and power supply 24 . Fail-safe module 23 comprises memory 27 , state machine 28 , and communications (comm) switching 29 . Failsafe module 23 may be a central processing unit, a complex programmable logic device (CPLD), or any other suitable data processing device. In one embodiment of the present invention, state machine 28 receives state machine input 32 , where state machine input 32 comprises a fail-safe strobe, information relevant to controlling oxygen and drug delivery, information relevant to oxygen and drug enablement, information relevant to oxygen and drug disablement, and/or other suitable state machine input. Memory 27 receives memory input 30 , where memory input 30 includes, but is not limited to, information relevant to clearing fail-safe module 23 of a system fault event. Comm switching 29 receives input from comm switching input 34 , where comm switching input 34 includes, but is not limited to, commands to the drug delivery module, such as among others an IV pump, from the controller 14 , and commands to the non-invasive blood pressure module from controller 14 . In one embodiment of the present invention, comm switching 29 functions to convert RS-232 signals to transistor transistor logic (TTL).
[0023] Memory 27 outputs memory output 31 , where memory output 31 includes, but is not limited to, information related to a failure event occurring after the last clearing of the memory 27 via memory input 30 . State machine 28 outputs state machine output 33 , where state machine output 33 includes, but is not limited to, an indication of an unknown system fault, output related to fail-safe module 23 control of the flowrate of oxygen and drug, and output relating to fail-safe module 23 control of enabling or disabling oxygen and drug delivery. Comm switching 29 outputs comm switching output 35 , where comm switching output 35 includes, but is not limited to, information from controller 14 dictating function of the pump (not shown) associated with drug delivery 19 , where the fail-safe module disables, for example, grounds, the signal if a problem is detected, and information from controller 14 dictating function of the blood pressure cuff, where the fail-safe module disables the signal if a problem is detected so that the blood pressure cuff is not left in an inflated position where it may cut off blood circulation. Routing control of oxygen delivery, the non-invasive blood pressure module (not shown), and drug delivery 19 through fail-safe module 23 , allows failsafe module 23 to disable the non-invasive blood pressure module and drug delivery 19 in order to prevent potential harm to a patient due to error. Oxygen delivery may be maintained, at a predetermined flow-rate and for a predetermined period of time, by fail-safe module 23 , if oxygen was being administered at the time of the failure. A plurality of other inputs and outputs, such as those described in U.S. Patent Application Ser. No. 09/324,759, are consistent with the present invention, as well as a plurality of patient interfaces such as, for example, capnometry monitoring, that may be routed through the fail-safe module 23 in order to provide desired safe state mode 107 .
[0024] In one embodiment of the present invention, memory 27 functions to maintain a record of failure events occurring within controller 14 or in the program modules associated with controller 14 . Information related to a failure is transmitted to memory 27 via error output path 36 . Memory of the failure will be maintained within memory 27 until a command is entered acknowledging the failure and clearing the memory via memory input 30 . Memory 27 functions to alert a user, via memory output 31 , that sedation and analgesia system 22 has, in the previous case, experienced a failure. The recorded failure in memory 27 may be removed via memory input 30 . In one embodiment of the present invention, the user may not activate the sedation and analgesia system until the failure recorded in memory 27 is acknowledged and removed. Memory of a software failure may be held in memory 27 by encoding a simple memory bit, or by other suitable means of recording a failure. One embodiment of the present invention comprises a code retained in memory 27 indicating whether the failure occurred in the program modules associated with controller 14 or in the health-check system, if the health-check system is present.
[0025] State machine 28 is, in one embodiment of the present invention, programmed to anticipate a strobe from controller 14 within a specified time window. The time window may be any window desirable for use in detecting flaws within the sedation and analgesia system 22 . If the strobe is received by state machine 28 of fail-safe module 23 within the specified time window, fail-safe module 23 will maintain sedation and analgesia system 22 in operation state mode 105 . If the strobe is not received by state machine 28 within the specified time window, state machine 28 will output information related to the failure via state machine output 33 in the form of a visual alarm, an audio alarm, and/or other suitable means for alerting a user that a failure has occurred. In response to a failed strobe, state machine 28 will also send data indicating a failure to memory 37 via error output path 36 and transfer sedation and analgesia system 22 into safe state mode 107 . In one embodiment of the present invention, state machine 28 disables control of comm switching 29 by controller 14 , via disable output 37 , in order to transfer sedation and analgesia system 22 into safe state mode 107 independent of controller 14 .
[0026] A further embodiment of the present invention comprises controller 14 programmed to rapidly strobe state machine 28 in the event of a failure in the modules associated with controller 14 . State machine 28 is programmed, upon receipt of rapid strobing from controller 14 , to output an alarm signal indicator of a sedation and analgesia system 22 failure, record the failure in memory 27 , disable control of comm switching 29 by controller 14 , and transfer sedation and analgesia system 22 into safe state mode 107 .
[0027] [0027]FIG. 4 depicts a method illustrating one embodiment of the operation of fail-safe module 23 in this sedation and analgesia system 22 . Commencing from a fail-safe module system (FSM) inactive mode 100 , the sedation and analgesia system 22 only moves into initiation state mode 102 upon receipt of power (query 101 ) applied to fail-safe module 23 . For example, initiation state mode 102 will commence upon receipt of 5 volts of direct current from power supply 24 , however other voltages and means of delivering power to failsafe module 23 are consistent with the present invention. Any time power is removed from fail-safe module 23 , sedation and analgesia system 22 will return to fail-safe module system inactive mode 100 . Following reception of power, sedation and analgesia system 22 will operate in an initiation state mode 102 comprising fail-safe module 23 outputting safe state output in anticipation of a strobe from controller 14 . In one embodiment, fail-safe module 23 outputs safe state data until a valid strobe is received from controller 14 due to the fact that the condition of sedation and analgesia system 22 cannot be determined until valid strobing begins. Maintaining safe state output during the initiation state mode 102 ensures the controller 14 cannot send commands to important peripherals, such as, for example, drug delivery 19 or patient interface 17 , until fail-safe module 23 receives a valid strobe indicating controller 14 is healthy. Initiation state mode 102 further comprises disallowing user 13 from removing the record of a failure event stored in memory 27 until a valid strobe is received from controller 14 indicating sedation and analgesia system 22 is functioning properly. In the absence of a valid strobe, sedation and analgesia system 22 will remain in initiation state mode 102 . One embodiment of the present invention comprises powering down sedation and analgesia system 22 in the event that a valid strobe is not received during a predetermined window of, for example, five minutes.
[0028] Upon reception of a valid strobe from controller 14 by fail-safe module 23 (query 104 ), sedation and analgesia system 22 will be transferred to operation state mode 105 . Operation state mode 105 is maintained contingent on valid strobing (query 106 ) from controller 14 to fail-safe module 23 that falls within the allowed predetermined window. Consistent valid strobing from controller 14 to fail-safe module 23 maintains sedation and analgesia system 22 in an operation state mode 105 . Operation state mode 105 comprises allowing input received by fail-safe module 23 from controller 14 to control output relating to critical patient interfaces such as, for example, blood pressure cuff pressure, oxygen delivery, and drug delivery 19 . Operation state mode 105 further comprises indication to user 13 that sedation and analgesia system 22 is functioning properly. Data will continue to be displayed on the user interface 12 , backlighting of user interface 12 will remain active, and alarm signals relating to sedation and analgesia system 22 failure will remain quiet. One embodiment of the present invention comprises allowing user 13 or fail-safe module 23 to clear the memory unit held in memory 27 that previously indicated a failure in sedation and analgesia system 22 in order for a subsequent failure to recode the memory unit (not shown).
[0029] Failure to strobe, or rapid strobing of fail-safe module 23 (query 106 ) by controller 14 results in fail-safe module 23 transferring sedation and analgesia system 22 into safe state mode 107 . Strobes falling outside the predetermined response window, or rapid strobing from controller 14 indicate to fail-safe module 23 that a failure has occurred in sedation and analgesia system 22 . In order to protect the patient, it is necessary to convert sedation and analgesia system 22 into a safe state mode 107 to reduce potential harm caused by drug delivery 19 , patient interface 17 , or other critical peripherals that may include malfunctioning hardware or software. Safe state mode 107 comprises, in one embodiment of the present invention, ceasing transmission of command data from controller 14 to drug delivery 19 , patient interface 17 , oxygen delivery, and/or other critical peripherals related to patient safety. Safe state mode 107 further comprises deactivating drug delivery 19 in order to prevent possible patient overdose, deactivating the blood pressure cuff in order to prevent possible necrosis that occurs if the blood pressure cuff is left inflated for extended periods of time, and maintaining the flow of oxygen, if oxygen was being given during the procedure, in order to maintain suitable oxygen saturation of the blood. Safe state mode 107 further comprises triggering the memory bit located in memory 27 to indicate a sedation and analgesia system 22 failure 109 , sounding an audio alarm, signaling a visual alarm, and/or blanking the display such as, for example, by deactivating the backlight on user interface 12 . The backlight on user interface 12 may be deactivated in order to prevent display of spurious data that may be erroneously used to evaluate a patient's condition.
[0030] Following the transfer of sedation and analgesia system 22 to safe state mode 107 , fail-safe module 23 will continue to anticipate valid strobing from the main logic board or controller 14 (query 108 ). Absent valid strobing, fail-safe module 23 will maintain safe state mode 107 . In one embodiment of the present invention, alarms associated with fail-safe module 23 may be manually deactivated by user 13 . Upon reception of a valid strobe, or a predetermined number of valid strobes from controller 14 , fail-safe module 23 may transfer sedation and analgesia system 22 from safe state mode 107 to operation state mode 105 . A further embodiment of the present invention comprises sedation and analgesia system 22 remaining in safe-state mode for the duration of the medical procedure, even in the event of a valid strobe from controller 14 .
[0031] Query 110 relates to user 13 response to safe state mode 107 . If sedation and analgesia system 22 is turned off, sedation and analgesia system 22 will be transferred to failsafe module inactive mode 100 . If sedation and analgesia system 22 is not deactivated, failsafe module 23 will maintain sedation and analgesia system 22 in safe state mode 107 .
[0032] [0032]FIG. 5 depicts a method illustrating one embodiment of a test mode 210 for sedation and analgesia system 22 comprising the steps of: initiating a valid test strobe 200 , transferring sedation and analgesia system to the operation state mode 201 , setting inputs to the FSM 202 , outputting a test signal from the controller 203 , evaluating proper outputs of FSM in operation state mode given current inputs 204 , initiating valid test strobe 205 , transferring the sedation and analgesia system to the safe state mode 206 , evaluating proper outputs of FSM in safe state mode given current inputs 207 , initiating valid strobing from the controller 208 , and transferring the fail-safe module to the operation state mode 209 .
[0033] In one embodiment of the present invention, initiating a valid test strobe step 200 comprises transmitting one or a plurality of strobes from controller 14 to fail-safe module 23 that fall into the predetermined time window programmed into fail-safe module 23 , indicating that controller 14 is functioning properly. In one embodiment of the present invention, initiating a valid test strobe step 200 occurs during initiation state mode 102 after power has been delivered to controller 14 and fail-safe module 23 .
[0034] Transferring sedation and analgesia system to the operation state mode step 201 comprises, fail-safe module 23 receiving the valid strobe or strobes from controller 14 , where the valid strobe or strobes indicate to fail-safe module 23 that controller 14 is functioning properly, then converting sedation and analgesia system 22 to operation state mode 105 based on the valid strobe or strobes indicating that sedation and analgesia system 22 is functioning properly.
[0035] Setting initial inputs to FSM step 202 comprises inputting information related to oxygen delivery, drug delivery 19 , patient interface 17 , or other critical parameters relating to a desired safe state mode 107 . In one embodiment of the present invention, setting initial inputs to FSM step 202 occurs during operation state mode 105 , where controller 14 maintains control of critical parameters.
[0036] Outputting a test signal from the controller (step 203 ) comprises, user 13 inputting a test command into controller 14 , where the inputted test command decouples the power down functionality from detected failure of sedation and analgesia system 22 . One embodiment of the present invention comprises an automated system of initiating a test command, where the test command is initiated by controller 14 at a predetermined time before the beginning of a medical procedure, for example as part of the power-up routine of a sedation and analgesia system. In one embodiment of the present invention, a test bit (not shown) is triggered in fail-safe module 23 upon receipt of the test command from controller 14 . The triggered test bit of fail-safe module 23 may function to disable the power down capability associated with a failure, in order to test the functionality of fail-safe module 23 without initiating a power down. Providing a FSM test mode, absent a power down, obviates the need to retest fail-safe module 23 following a subsequent power up of the system had the system been powered down as part of the simulated failure.
[0037] Evaluating proper outputs of the FSM in the operation state mode given current inputs (step 204 ) comprises determining whether fail-safe module 23 is outputting data consistent with inputted data. In evaluating proper outputs of the FSM in the operation state mode given current inputs (step 204 ), outputted data should be consistent with inputted data due to the retention of control of critical parameters associated with fail-safe module 23 by controller 14 .
[0038] Initiating invalid test strobe (step 205 ) comprises outputting an invalid strobe from controller 14 to fail-safe module 23 , simulating a failure of sedation and analgesia system 22 . The invalid test strobe may be rapid strobing of fail-safe module 23 by controller 14 , strobing outside the predetermined time window, or other suitable means of communicating a failure of sedation and analgesia system 22 .
[0039] Transferring the sedation and analgesia system to the safe state mode step 206 comprises transferring sedation and analgesia system 22 to safe state mode 107 following receipt by fail-safe module 23 of an invalid strobe. In order to prevent the need for repetitive retesting upon power up of sedation and analgesia system 22 were it to be powered down during the simulated failure, sedation and analgesia system 22 is not powered down during test mode 210 .
[0040] Evaluating proper outputs of the FSM in the safe state mode given current inputs (step 207 ) comprises determining whether fail-safe module 23 is functioning properly in converting sedation and analgesia system 22 to safe state mode 107 . Evaluating proper outputs of the FSM in the safe state mode given current inputs (step 207 ) allows controller 14 to determine if fail-safe module 23 will function properly, in the event of an actual failure, in converting sedation and analgesia system 22 to safe state mode 107 .
[0041] Initiating valid strobing from the controller step 208 comprises outputting a valid strobe or strobes from controller 14 to fail-safe module 23 following the transfer of sedation and analgesia system to safe state mode 107 . Upon receipt of valid strobing, that is, strobing falls within the predetermined response window, fail-safe module 23 will transfer sedation and analgesia system 22 to operation state mode 105 , reallocating control of drug delivery system 19 , patient interface 17 , and oxygen delivery to controller 14 . Transfer of sedation and analgesia system 22 from safe state mode 107 to operation state mode 105 following successful strobing is consistent with transferring the sedation and analgesia system to the operation state mode (step 209 ).
[0042] Test mode 210 provides user 13 with a simulation of a failure event or message, where the response of fail-safe module 23 may be tested, in the absence of a power down, to determine whether it functions properly in transferring sedation and analgesia system 22 to safe state mode 107 and operation state mode 105 at the appropriate times. The memory bit recorded in memory 27 of the fail-safe module 23 may be reset upon transfer of sedation and analgesia system 22 to operation state mode 105 .
[0043] In one embodiment of the invention, the health check system polls each compartmentalized software module and verifies that each one indicates that it is operating properly. Upon receipt from all compartmentalized software modules that all is well, the health check system strobes the FSM to indicate that all system modules are functioning properly. This health check system occurs at all times that the system is running. The health check system is software based and the FSM is implemented via hardware such as a complex programmable logic device (CPLD). | The invention provides a fail-safe module (FSM) integral with a sedation and analgesia system that meets the high-reliability needs of sedation and/or analgesia delivered by non-anesthetist practitioners. The FSM may operate in “real-time” in order to ensure optimal patient safety. The FSM may deactivate specific patient interfaces, user interfaces, and/or sedation and analgesia delivery in order to ensure patient safety and has redundant safety systems in order to provide the fail-safe module with an accurate assessment of controller functionality. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a CVD film forming method of forming a metal thin film such as Ti film or TiN film by CVD on a substrate.
In forming semiconductor devices, it is known to include metal-based thin films such as a metal wiring layer, a buried layer for electrically connecting layers to each other through a contact hole for connecting a wiring layer situated in an upper layer to a device situated in a lower layer, or through a via hole for connecting an upper layer to a lower layer, and a barrier layer having a two-layered structure of Ti (titanium) film and TiN (titanium nitride) film, formed for the prevention of the diffusion, prior to the formation of the buried layer.
Such metal-based thin films are conventionally formed by physical vapor deposition; however it is becoming very difficult to form, especially, a Ti film or TiN film which constitutes a barrier film on the bottom of a hole by PVD due to the recent trends in command. That is, the devices need to be reduced in size, and the degree of integration should be increased. Further, the width of lines and the diameter of opening holes should be further decreased, and the aspect ratio must be increased.
To meet the above recent trends, a Ti film or TiN film which constitutes a barrier layer, is recently formed by chemical vapor deposition (CVD), with which formation of better quality films can be expected. In the case where a Ti film is formed by CVD, TiCl 4 (titanium tetrachloride) gas and H 2 (hydrogen) gas are generally used as reaction gas, whereas in the case where a TiN film is formed, TiCl 4 gas and NH 3 (ammonium) gas or MMH (monomethylhydrazine) are generally used as reaction gas.
In the case where a thin film described as above is formed directly or indirectly on a semiconductor wafer by the CVD, a high stress is caused on the film formed with the conventional recipe, and a crystal defect or warp is created in the semiconductor wafer after the formation of the film, due to the stress. If a wafer is warped, a crack is made in the film, which causes problems, for example, the center portion and peripheral portion having different values in the depth of focus of the exposing device in the photolithography step. When a crack is made in the film, a conduction error or overetching of an underlying layer is likely to occur.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention is to provide a method of forming a film by CVD, with less stress applied on the film formed.
In general, during the formation of a film, a to-be-processed substrate or a wafer is heated by a heater provided within a susceptor serving as a base on which a substrate is placed. Therefore, if the pressure in the chamber varies during the step of forming a film, or between before and after the step, the density of the gas in the chamber varies. Consequently, the quantity of heat supplied from the susceptor to the substrate changes. Thus, the temperature of the substrate varies in accordance with the change in pressure. In connection with this point, the inventors of the present invention have found the fact that there is, generally, a difference in thermal expansion coefficient between a substrate and a film formed thereon, and therefore a stress is created in the film due to the change in temperature, which occurs when the pressure varies. It has been further found that particularly, when the substrate is made of Si, and the thin film is a metal-based film such as Ti or TiN film, even a greater difference in the thermal expansion coefficient is created between the substrate and the film, thus causing a very high stress on the film.
In order to achieve the above-described object, there is provided, according to the first embodiment of the present invention, a method of forming a film by CVD, including the steps of:
placing a substrate to be processed, on a susceptor equipped with a heating member, situated in a chamber;
forming a film on the substrate-to-be-processed, by supplying a process gas into the chamber and heating the substrate to be processed, by the heating member while maintaining the inside of the chamber at a predetermined pressure by exhausting the gas from the chamber; and
annealing the substrate to be processed by heating the heating member under a pressure substantially the same as that of the predetermined pressure, either immediately before or after the film forming step.
With the above method, the variation of temperature, which occurs along with the change in pressure, can be suppressed, and therefore the stress on the thin film formed can be made very low.
Additional object and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The object and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a cross sectional view schematically showing a TiN film forming device which realizes a method of forming a film by CVD, according to the present invention;
FIG. 2 is a diagram showing the pressure in the chamber during each of the steps of the method according to an embodiment of the present invention;
FIG. 3 is a diagram showing the pressure in the chamber during each of the steps of a conventional method;
FIG. 4 is a diagram showing the variation in the temperature of the substrate when the pressure in the chamber is changed in accordance with the recipe of the conventional process;
FIG. 5 is a diagram showing the relationship between the thickness of the TiN film and the stress on the film, in each of the cases where the film is formed by the present invention method and the conventional method;
FIG. 6 is a diagram showing the relationship between the thickness of the TiN film and the amount of the wafer being warped after the formation of the TiN film, in each of the cases where the film is formed by the present invention method and the conventional method; and
FIG. 7 is a diagram showing the relationship between the thickness of the TiN film and the resistivity, in each of the cases where the film is formed by the present invention method and the conventional method.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the method of manufacturing a semiconductor device, according to the present invention will now be described with reference to accompanying drawings.
FIG. 1 is a cross sectional view schematically showing a TiN film forming device for practicing the CVD film forming method according to the present invention. The film forming device has an air-tight structure including a chamber 1 made of a metal having a high heat resistance, such as aluminum, and having substantially a cylindrical shape. In the chamber 1, a susceptor 2 for horizontally supporting a semiconductor wafer which is an object to be processed, for example, a silicon wafer W, is placed as it is supported by a cylindrical support member 3. The support member 3 has a plurality of permeating holes 3a formed therein so as to communicate the inner and outer sides of the support member, to each other. On the periphery portion of the upper surface of the susceptor 2, a guide ring 4 is provided such as to surround the semiconductor wafer W as a guide. The susceptor 2 is made of a material having a high thermal conductivity, such as aluminum, and it has a heater 5 built within itself. The heater 5 serves to heat the object to be processed, that is, the semiconductor wafer W, to a predetermined temperature, as a power is supplied to the heater from a power source 6 provided outside the device. A controller 7 is connected to the power source 6, and with the controller, the output from the heater 5 is controlled in response to a signal from a temperature sensor (not shown).
As an alternative to the case where the semiconductor wafer W is simply placed on the susceptor 2, the wafer may be supported on the susceptor by conventional means, such as a mechanical clamp, electrostatic adsorption and vacuum adsorption.
An upper end of the chamber 1 is opened, and a top wall 1a which can shut the opening is provided to be rotatable or detachable at the upper end. On the inner surface of the top wall 1a, a shower head 10 is provided to be situated in the chamber 1. A great number of gas discharge hole 10a and 10b are made in the shower head alternately in the diameter direction of the round-shaped shower head. The first group gas discharge hole 10a are connected to a plurality of (three in this example) annular channels formed in the head to be concentrical, with a predetermined distance therebetween in the circumferential direction. To these annular channels, a TiCl 4 gas source 21 is connected via a main pipe 13 and three branch pipes 11 branched off from the main pipe. The second group gas discharge hole 10b are connected to two empty rooms formed in the head 10. To these empty rooms, an NH 3 gas source 19 is connected via a main pipe 14 and two branch pipes 12 branched off from the main pipe. The shower head 10 having the gas discharge hole 10a and 10b arranged as above, is of a matrix type, which employs the post mix method, wherein TiCl 4 gas and NH 3 gas serving as reaction gases are discharged from different discharge pores alternately formed, and they are mixed together after being discharged. However, the gas supply means of the present invention is not limited to a shower head having the above-described structure, but it may be of any type of structure used in this field, as long as it can introduce a process gas to the chamber.
A main pipe 15 connected to a source 22 of ClF 3 gas which is a cleaning gas, and having an ON/OFF valve 23, is further connected to the main pipe 13. When the valve 23 is opened, the ClF 3 gas serving as a cleaning gas can be supplied into the chamber 1 via the branch pipes 11 and the discharge pores 10a. A pipe 16 connected to an N 2 gas source 20, and having an ON/OFF valve 24, is further connected to the main pipe 14. When the valve 24 is opened, the N 2 gas can be supplied into the chamber 1 via the branch pipes 12 and the discharge pores 10b. The pipe 16 for the N 2 gas is connected to the main pipe 13 via the ON/OFF valve 25. To the main pipe 14, a pipe 17 which extends from an MMH gas source 18 is connected, and therefore the MMH gas can be supplied into the chamber 1 from the gas discharge hole 10b via the main pipe 14 and the branch pipes 12. Each pipe extending from the gas sources 18 to 22 has a valve 26 and a mass flow controller 27 provided therefor.
An exhaust pipe 8 is connected to a bottom wall 1b of the chamber 1, and a vacuum pump 9 is connected to the exhaust pipe via a pressure control valve 30. Further, a pressure gage or manometer 32 is connected to this valve 30 via a pressure controller 31. This pressure gage detects the pressure inside the chamber 1, and the detection signal is sent to the pressure controller 31. The controller 31 controls the valve 30 in accordance with the signal received, so as to adjust the amount of exhaust within the chamber by the vacuum pump 9.
The formation of a TiN film by the device, is carried out in the following manner. First, a semiconductor wafer W is placed in the chamber 1, and while the wafer W is heated to a temperature of 450 to 600° C. by the heater 5, the inside of the chamber is evacuated by the vacuum pump 9 to create a high vacuum state. Subsequently, N 2 gas and NH 3 gas are introduced into the chamber 1 at a predetermined flow amount ratio of, for example, N 2 gas: 50 to 500 SCCM to NH 3 gas: 200 to 400 SCCM, so as to maintain the pressure inside the chamber 1, for example, about 0.3 Torr, and pre-annealing is carried out. Then, while supplying the N 2 gas and NH 3 gas into the chamber 1, a TiCl 4 gas is allowed to flow into the chamber 1 at a flow amount of, for example, 5 to 20 SCCM, as a pre-flow for about 5 to 20 seconds. Then, under the same condition, the formation of a TiN film is carried out for a predetermined time. During this period, MMH gas may be supplied together with the NH 3 gas. After that, only the supply of TiCl 4 is stopped, and an after-anneal is performed in the atmosphere of NH 3 gas for 20 seconds, for example, thus completing the formation of a film. It should be noted that N 2 gas, for example, should preferably be allowed to flow as a purge gas, during the period from when the semiconductor wafer W is placed in the chamber to the completion of the film formation. After the after-anneal, the chamber is once evacuated to vacuum, and then released to the atmosphere, and the semiconductor wafer W is unloaded.
The pre-anneal step, the film forming step including the pre-flow, and the after-anneal step are conducted at substantially a constant pressure (in this example, about 0.3 Torr initially set). In order to maintain the pressure at constant, it is necessary, when the TiCl 4 gas is supplied for forming a film, to reduce the flow of the N 2 gas and/or NH 3 gas, by the amount corresponding to the flow amount of the TiCl 4 , or increase the amount of exhaust from the exhaust pipe 8. The adjustment of the flow amount of each gas, and/or the exhaust amount, may be carried out automatically to follow a preset sequence or when necessary by measuring the pressure in the chamber 1 at all times with the pressure gage 32. At the stages where the MMH gas is co-used in the film forming step, and where the supply of the NH 3 gas is stopped for the after-anneal (note that when the MMH gas is also used, the supply of this gas is also stopped), the pressure in the chamber 1 is maintained at constant, that is, about 0.3 Torr.
FIG. 2 shows the pressure in the chamber at each of the steps, with the abscissa indicating time and the ordinate axis indicating the pressure in the chamber. As can be seen in this figure, in this embodiment, the pre-purge or pre-anneal step, the film forming step and the after-purge step are carried out continuously under substantially a constant pressure of 0.3 Torr. Therefore, in these steps, a change in the temperature of the semiconductor wafer W, which is caused by a change in pressure, barely occurs, and therefore the stress on the TiN film formed can be significantly reduced.
According to the conventional method, in order to increase the temperature of the semiconductor wafer to the film forming temperature in a short time, the pressure for the pre-anneal is set at about 1 Torr, which is about three times as high as the pressure for the film formation, evacuation is conducted before the after-anneal, and the pressure for the after-anneal is set high as well at 1 Torr, as can be seen in FIG. 3. In this conventional process, the variation of pressure is remarkably large, and consequently, the variation of the temperature of the semiconductor wafer becomes large. FIG. 4 shows the results of the measurements taken for this conventional process, with the abscissa indicating time and the ordinate indicating the temperature of wafer. As can be understood from this figure, the temperature becomes high during the pre-anneal and after-anneal steps where the pressure in the chamber is high, whereas the temperature becomes low during the film forming step where the pressure in the chamber is low, with a temperature difference of about 15° C.
The thermal expansion coefficient of Si which constitutes the semiconductor wafer is 2.6×10 -6 /° C., and that of the TiN film is 7.1×10 -6 /° C. Thus, the difference between these in thermal expansion coefficient is extremely large, and therefore a heavy stress is applied on the TiN film due to the variation in temperature, which occurs during the process.
In general, a metal-based material has a thermal expansion coefficient higher than that of Si, and therefore the difference between these members in thermal expansion coefficient is inevitably large. Consequently, in most of the cases, a heavy stress is created due to the variation in temperature. For example, the thermal expansion coefficient of Ti is 9.95×10 -6 /° C., and those of Al and W are 2.55×10 -5 /° C. and 4.76×10 -6 /° C., respectively, which are significantly higher than the thermal expansion coefficient of Si. Consequently, a similar problem would occur when the films of these elements are formed.
In the above-described embodiment, the variation in the temperature of the substrate is suppressed by maintaining the pressure in the chamber substantially at constant throughout the pre-anneal, film formation and after-anneal steps; however, there is a certain allowable range in the variation of the temperature, and therefore there is an allowable range in the variation of the pressure. As shown in FIG. 4, there is a difference in temperature of about 15° C. resulting between the cases of 0.3 Torr and 1 Torr, and therefore, approximately, when the pressure varies by 0.1 Torr, the temperature should vary by about 2° C. When the allowable range is set to about 3° C., the pressure for the film formation may be varied within a variation allowance of ±50%.
TiN films of various thicknesses were actually formed with the recipe of the embodiment process of the present invention shown in FIG. 2 and that of the conventional process shown in FIG. 3, and the stress created in each film was measured. FIG. 5 illustrates the relationship between the thickness of the film and the stress created in the film. As can be understood from this figure, for substantially the same thickness of film, the stress on the TiN film can be remarkably reduced by maintaining the pressure at substantially constant through the steps as in the present invention, as compared to the conventional case.
Further, with regard to these TiN films formed, the degree of warping and the resistivity after the formation of each film were measured. The relationship between the thickness of film and the distribution of the degrees of warping after the formation of TiN film is illustrated in FIG. 6, and the relationship between the thickness and the resistivity is illustrated in FIG. 7. It was confirmed from the results shown in these figures that, with the process of the present invention, where the pressure was set at constant, the distribution of the degrees of warping of the wafers occurring after the formation of the TiN film, was somewhat narrowed, and the resistivity was slightly increased by an amount which would bring no problem. In FIGS. 5 to 7, white circles are the results of the measurement of the films formed by the present invention, whereas black circles are those of the films formed by the conventional technique.
The present invention is not limited to the above-described embodiment, but can be modified into various version. For example, in the above-described embodiment, the pre-anneal, film formation and after-anneal steps are carried out continuously under substantially a constant pressure; however it is also possible that some other step is provided before or after those steps, or the after-anneal step may be omitted from the process. Further, the present invention is especially effective for the case where a thin film made of a metal-based material, such as TiN, Ti or Al film, is formed; however the application of the invention is not limited to this. As long as there is a difference in thermal expansion coefficient between a thin film and its substrate, a certain effect can be obtained. The substrate to be processed is not limited to a semiconductor wafer, but may be some other type, or it may be a substrate on which other layer is formed.
As described above, according to the present invention, the pressure in the chamber is maintained substantially constant during a series of steps including the formation of film, and therefore the variation in temperature, which is caused by the variation in pressure, can be suppressed, and the stress on the thin film formed can be significantly reduced. Further, the allowable range of the pressure in the chamber during a series of the steps including the film formation is set within ±50% of the pressure for the film formation, and therefore the variation in the temperature of the substrate, which is caused by the variation in pressure, can be made small, and the stress on the thin film formed can be significantly reduced, as compared to the conventional technique.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalent. | A CVD film forming method, includes the steps of placing a silicon wafer on a susceptor equipped with a heating member therein which is, situated in a chamber, evacuating the chamber, pre-annealing the silicon wafer while keeping pressure in the chamber substantially constant by supplying an anneal gas and a purge gas into the chamber and while exhausting gases from the chamber at a fixed rate, and heating the silicon wafer, there forming a metal film on the silicon wafer by CVD while keeping pressure in the chamber substantially constant by supplying a process gas into the chamber along with a purge gas with a controllable total supply rate while exhausting these gases from the chamber at a fixed rate, and heating the silicon wafer by the heating member, to follow immediately after the pre-annealing step, and then after-annealing the silicon wafer by heating the silicon wafer while maintaining pressure in the chamber substantially constant, by stopping supply of the process gas, supplying an anneal gas and a purge gas into the chamber by controlling the total rate of supplying these gases while and exhausting these gases from the chamber, to follow immediately after the film forming step. The film is one of a titanium nitride film, a titanium film and an aluminum film. | 2 |
LIST OF PRIOR ART REFERENCES (37 CFR 1.56(a))
The following references are cited to show the state of the art:
(1) Japanese Patent Application Kokai (Laid-Open) No. 50-153137, Dec. 9, 1975 Priority: British Patent Application No. 20148/74, Eric Harold Ford, May 7, 1974.
(2) Japanese Patent Application Kokoku (Post-Exam. Publn.) No. 46-3525, Hitachi Ltd., Jan. 28, 1971.
BACKGROUND OF THE INVENTION
The present invention relates to an electronic spark timing advancing apparatus of an internal combustion engine, and more particularly to an electronic spark timing advancing apparatus which provides an optimum spark timing advancement characteristic to the engine.
A prior art electronic spark timing advancing apparatus has been constructed to provide an optimum spark timing with respect to fuel consumption, exhaust gas and torque in accordance with an input signals such as rotation speed of the engine, manifold vacuum, temperature of cooling water or the like. Such a prior art apparatus, however, requires a complex function generator for determining an optimum spark timing in accordance with the input signals. Thus, when a sophisticated control is desired, the apparatus would be very expensive. Furthermore, because the apparatus does not function as a system to sense combustion state of the engine, a spark timing for an optimum combustion condition must be previously calculated. This requires considerable manpower and cost.
The Japanese Patent Application Kokai No. 50-153137 and Japanese Patent Application Kokoku No. 46-3525 disclose electronic spark timing advancing apparatus in which an internal pressure of a cylinder is sensed and an optimum crank angle at which the internal pressure of the cylinder is to assume a peak value under a normal operation is determined from a viewpoint that fuel consumption, exhaust gas and torque are maintained under best conditions in the normal operation, and a differential angle between the actual peak angle and the optimum peak angle of the internal pressure is fed back to control the spark timing so that the actual internal pressure assumes the peak value at the optimum crank angle. In this apparatus, the drawbacks described above have been overcome and the peak angle of the internal pressure is controlled to assure the optimum conditions of the fuel consumption, torque and exhaust gas under the normal operation. However, it had a drawback that much noxious exhaust gas is ejected under certain conditions such as rapid acceleration of the engine, warming-up of the engine or engine braking.
SUMMARY OF THE INVENTION
It is an object of the present invention to eliminate the drawbacks described above which were encountered in the prior art electronic spark timing advancing apparatus.
In accordance with the present invention, during the normal operation of the engine, a crank angle at which the internal pressure of the cylinder assumes a peak value is set to an optimum so that the fuel consumption, torque and exhaust gas are maintained at least conditions respectively, and under certain conditions such as rapid acceleration of the engine, wraming-up of the engine or engine braking, the crank angle at which the internal pressure assumes the peak value is controlled to reduce the noxious exhaust gas while paying primary attention to air pollution problem.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of an embodiment of an electronic spark timing advancing apparatus of the present invention;
FIG. 2 shows pressure curves for the embodiment of the present invention;
FIG. 3 shows a circuit diagram of a spark timing advancement control unit of the embodiment of the present invention;
FIG. 4 shows a time chart illustrating waveforms at various portions of the spark timing advancement control unit; and
FIGS. 5 and 6 show schematic views of embodiment of variable crank value generator used in the embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic view showing a typical embodiment of an electronic spark timing advancing apparatus of the present invention, which is implemented for a two-cycle, four-cylinder engine, as an example. A disk 1 attached to a crank shaft 14 of an engine having four cylinders 13 is provided with two projections 2 at 180° C. interval and a plurality of projections 3 at a pregiven interval, for example 1° interval. A pickup 4 interval for producing electrical signals detects the projections 2 and produces a reference signal J for each 180° revolution of the crank shaft, and a pickup 5 interval for producing electrical signals detects the projection 3 and produces an angle signal K indicating 1° revolution of the crank shaft. In the illustrated embodiment, the reference signal corresponds to a crank angular position when the piston of the associated cylinder reaches top dead center (TDC), but the pickup 4 may be arranged arbitrarily and the crank angular position at which the reference signal is produced (reference angular position) need not correspond to the top dead center. The angle signal is produced whenever the crank shaft is rotated by one degree after the reference signal has been produced so that the angular position of the top dead center relative to the reference angular position can be determined by the angle signal.
The angle signal and the reference signal are applied to a spark timing advancement control unit 6. A pickup 8 (piezoelectric element such as zircon lead titanate) arranged adjacent to an ignition plug 7 in the cylinder 13 for detecting the internal pressure of the cylinder to provide an electrical signal proportional to the internal pressure to the control unit 6, which in turn, determines an optimum advancement angle based on the angle signal, the reference signal and the internal pressure of the cylinder and applies that optimum value to an output unit 9. The output unit 9 includes an amplifier such as a power transistor to energize an ignition coil 10 which, in turn, selectively produces high voltage arcs at ignition plugs 7 and 12 through a distributor 11.
FIG. 2 shows the change in the cylinder internal pressure, versus crank angle and it is referred to as an index pressure chart.
In FIG. 2, a characteristic curve A is plotted for the engine ignition at the time I g1 . It exhibits a maximum pressure a at a crank angle θ 1 . Here, the crank angle is defined as a rotation angle of the crank shaft after the piston has reached the top dead center. An optimum angular position for θ 1 is determined by the engine per se and is not affected by the rotation speed of the engine or the loading conditions. In the prior art apparatus, the spark timing I g1 has been controlled such that the peak of the pressure curve occurred at the crank angular position θ 1 so that the fuel consumption, exhaust gas and torque conditions were optimum in the normal operation, and the crank angular position θ 1 was determined in dependence on the spark timing I g1 . However, when the spark timing is controlled such that the pressure is always to a peak at the crank angular position θ 1 , much exhaust gas is ejected during rapid acceleration of the engine, warming-up of the engine and engine braking.
When the spark timing is retarded from I g1 to I g2 , the peak of the pressure curve falls from the point a to a point b as shown by a characteristic curve B in FIG. 2, and the crank angular position at the peak is displaced to θ 2 . This displacement causes a reduction of the efficiency of the engine resulting in a reduction of the shaft torque, but also causes a reduction of the exhaust of NO x (nitrogen oxide) and a rise of the temperature of the exhaust gas. As a result of the rise of the temperature of the exhaust gas, HC (hydrocarbon) is re-burnt and the amount of exhaust thereof is reduced. Accordingly, an optimum operation will be attained by controlling the spark timing in the steady operation such that the pressure curve assumes the peak value at the crank angular position θ 1 which is optimum from the viewpoints of fuel consumption, exhaust gas and torque, while controlling the spark timing in the rapid acceleration of the engine, warming up of the engine and engine braking such that the pressure curve assumes the peak value at the retarded crank angular position θ 2 from the viewpoint of reducing the exhaust gas.
FIG. 3 shows a detailed circuit diagram of the spark timing advancement control unit 6 shown in FIG. 1. It controls the spark timing so that the pressure curve assumes the peak at the crank angular position θ 1 in the steady operation of the engine while the pressure curve assumes the peak at the crank angular position θ 2 in the rapid acceleration of the engine, warming up of the engine and engine braking. FIG. 4 shows waveforms at various points in the control unit 6, in which the abscissa represents time. The crank angle may be measured from the angle signal K from the pickup 5.
A presettable counter 15 receives the reference signal J of 180° interval from the pickup 4 and the angle signal K of 1° interval from the pickup 5. The presettable counter 15 indicates the position (crank angle) at which the pressure curve shown in FIG. 2 is to assume the peak. The content to be set in the presettable counter 15 is a variable crank value n 1 (which corresponds to a desired crank angle at which the pressure curve is to assume the peak and indicates the angle measured from the reference signal) generated by a variable crank value generator 16, and n 1 may be a binary coded signal. When the reference signal J as shown in FIG. 4 is applied to the presettable counter 15, it stores the variable crank value n 1 from the variable constant generator 16 and decrements the value n 1 by one in response to the angle signal K (shown in FIG. 4), and when the content reaches zero, the presettable counter 15 produces an output signal M as shown in FIG. 4. Thus, the number of the angle signals K applied to the presettable counter 15 from the application of the reference signal to the issuance of the output signal M indicates the crank angle at which the pressure curve is to assume the peak, and the crank angle at the time when the signal M is produced indicates the desired crank angle at which the pressure curve is to assume the peak. The output signal M and the reference signal J are applied to reset input R and set input S, respectively, of a flip-flop 17, a Q output of which produces a pulse signal N (shown in FIG. 4). The crank angle at the fall of the pulse signal N represents the desired crank angle G 1 at which the pressure crank is to assume the peak.
On the other hand, the output of the pickup 8 which has a voltage waveform as shown by the pressure curve A is differentiated by a differentiation circuit 18 to produce an output signal L as shown in FIG. 4 at the crank angles corresponding to the poles of the pressure curve A. The crank angle at which the output signal L is produced indicates the angle at which the actual pressure curve assumes the peak. Thus, a difference between the crank angle indicated by the output signal L and the crank angle indicated by the output signal M represents a deviation angle, which is controlled to be sufficiently small in accordance with the present invention. The output signal L from the differentiation circuit 18 and the reference signal J are applied to reset input R and set input S, respectively, of an R-S flip-flop 19, a Q output of which produces a pulse signal P (shown in FIG. 4). The duration of the pulse signal P extends from the time point at which the crank is positioned at the reference angular position producing the reference signal to the time point at which the internal pressure actually reaches the peak, and the crank angle at the fall of the pulse signal P represents the crank angle at which the actual internal pressure reaches the peak. A difference between the crank angle at the fall of the pulse signal P and the crank angle at the full of the pulse signal N indicates a deviation angle of the crank angle at the actual peak from the crank angle at the command peak. An AND gate 20 and a NOR gate 21 constitute a portion of means for producing that deviation. The AND gate 20 receives the pulse signal N from the Q output of the flip-flop 17 and a pulse signal P from a Q output of the flip-flop 19 to produce a pulse signal Q having a duration corresponding to the difference between the durations of the pulse signals N and P (when the duration of the pulse signal N is longer than that of the pulse signal P). The NOR gate 21 receives the pulse signals N and P to produce a pulse signal R having a duration corresponding to the difference between the durations of the pulse signals N and P (when the duration of the pulse signal N is shorter than that of the pulse signal P). The pulse signal Q indicates the earlier occurrence of the peak than the desired angle and the pulse signal R indicates the delayed occurence of the peak from the desired angle, and the duration thereof indicates the deviation angle. It is a presettable up/down counter 22 that corrects an error of the crank angle to the target. When the pulse signal Q is applied, the content of the up/down counter 22 is set to (D o +kQ), where D o is an initial count, and when the pulse signal R is applied, the content of the up/down counter 22 is set to (D 0 -kR) so that the spark timing is changed to coincide with the command timing, where k is a coefficient to convert the durations Q and R of the pulse signals Q and R to the number of the angle signals K. This operation is attained by ORing the pulse signals Q and R shown in FIG. 4 by an OR gate 23 and gating the angle signals K (shown in FIG. 4) through an AND gate 24 to the presettable up/down counter 22 only for a period during which the OR gate 23 is open, that is, for a period during which the pulse signal Q or R is being applied. The initial count D o of the presettable up/down counter 22 shown in FIG. 4 is given by a constant generator 25. The count D o may be a binary number corresponding to a certain number of angle signals K, and it is incremented or decremented to (D o +kQ) or (D o -kR) depending on the deviation. More particularly, when the pulse signal Q is applied, the content D 1 of the counter 22 is incremented by the number of the angle signals K supplied from the AND gate 24 to reach D 1 =D o +kQ, and when the pulse signal R is applied, the content D 1 is decremented by the number of the angle signals K supplied from the AND gate 24 to reach D 1 =D o -kR, where k is a coefficient to convert the signal Q or R representing the time duration to the number of the angle signals K. The content D 1 thus incremented or decremented is applied to a presettable down counter 26, which functions to generate a spark timing signal T in response to a constant angle counter 27, which in turn has a content corresponding to a predetermined crank angle. When the reference signal J is applied to the constant angle counter 27, it starts to decrement the content thereof each time the angle signal K is applied to an CL input thereof. After m angle signals K, which m is determined in accordance with the predetermined crank angle, have been applied, the content of the counter 27 reaches zero, at which time the counter 27 produces a signal S to the counter 26. When the signal S is applied, the presettable down counter 26 stores the content D 1 of the up/down counter 22 and decrements the content each time the angle signal K is applied to an CL input thereof. When the content of the down-counter 26 reaches zero, it produces the spark signal T as shown in FIG. 4 to the output unit 9. The predetermined number m is determined depending on the initial count D o of the up/down counter 23 and it is determined such that the spark signal T is generated at the crank angle of the command peak in the normal operation when the content of the counter is D o . The spark signal T functions to correct the deviation so that at the next ignition cycle the spark occurs at a correct position, that is, at a position at which the crank angle for the peak pressure corresponds to the desired crank angle preset by the variable constant generator 16. If the spark timing thereafter deviates from the command value, it is automatically corrected by a negative feedback loop. The desired crank angle at which the pressure curve is to assume the peak is determined by the preset count of the presettable down counter 15, which preset count is given by the variable constant generator 16, as described above. This will be explained below in further detail.
FIG. 5 is a block diagram illustrating the detail of an embodiment of the variable constant generator 16.
The temperature of the engine cooling water is sensed as a resistance of a thermistor 133 and a fraction of a power supply voltage Vcc divided by the thermistor 133 and a resistor 134 is applied to an operational circuit 130 as a first analog signal. An aperture of a throttle 136 is sensed by a potentiometer 137 as a voltage proportional to the aperture, and the voltage sensed is applied to the operational circuit 130 as a second analog signal. An engine rotation speed sensor 140 senses the rotation speed of the engine and applies a third analog signal proportional to the rotation speed of the engine to the operational circuit 130. The operational circuit 130 handles the first, second and third analog signals in a predetermined manner and determines whether the engine is in the steady state or at least one of the rapid acceleration state, the warming-up state and the engine braking state. When the steady state of the engine is determined, it produces a signal representing the number of the angle signals corresponding to the crank angle θ 1 as the binary signal n 1 such that the internal pressure of the cylinder assumes the peak at the crank angle θ 1 , and when one of the rapid acceleration state, the warming-up state and the engine braking state is determined, it produces a signal representing the number of the angle signal K corresponding to the crank angle θ 2 as the binary signal n 1 such that the internal pressure of the cylinder assumes the peak at the crank angle θ 2 .
In this manner, during the warm-up state of the engine, the crank angle for the peak pressure is retarded from the normal so that the exhaust gas temperature is raised to rapidly warm up the engine and reduce the exhaust of HC. During the rapid acceleration of the engine, the crank angle for the peak pressure is also retarded to reduce the peak value so that the exhaust of NO x is suppressed. Further, during engine braking, the crank angle for the peak pressure is also retarded to reduce the exhaust of HC.
FIG. 6 is a block diagram which shows the detail of another embodiment of the variable constant generator 16. Like numerals to those in FIG. 5 show like parts. A basic constant generator 131 produces a signal representing the number of the angle signals K corresponding to the desired crank angle θ 1 at which the internal pressure is to assume the peak in the steady operation, to an operational circuit 132 as a binary number n o . A temperature of engine cooling water is sensed by a thermistor 133 as a first analog signal, which is converted by an A/D converter 135 to a first binary signal, which in turn is applied to the operational circuit 132. An aperture of a throttle 136 is sensed by a potentiometer 137 as a voltage proportional to the aperture, which voltage is applied to a differentiation circuit 138, an output of which is proportional to the abruptness of opening of the throttle 136 and is converted by an A/D converter 139 to a second binary signal, which in turn is applied to the operational circuit 132. An engine rotation speed sensor 141 senses when the rotation speed of the engine is equal to or above a given speed to produce an output signal. On the other hand, throttle switch 142 senses when the throttle is fully closed to produce an output signal. Both output signals are applied to an AND gate 143 so that the engine braking state is detected when the AND gate 143 produces an "1" output, which in turn actuates a binary constant generator 144 such as a one-bit ROM to produce a third binary signal, which is applied to the operational circuit 132.
The operational circuit 132 determines the warm-up state of the engine when the first binary signal is equal to or below a given value to modify the binary signal n o from the basic constant generator 131 for producing a signal representing the number of the angle signals K corresponding to the crank angle θ 2 as the binary signal n 1 . When the second binary signal is equal to or above a given value, the operational circuit 132 determines the rapid acceleration state, and when the third binary signal is applied, it determines the engine braking state, and in both cases the operational circuit 132 produces a signal representing the number of the angle signals K corresponding to the crank angle θ 2 as the binary signal n 1 . In other cases, the operational circuit 132 determines the steady operation state and produces the binary signal n o from the basic constant generator 131 as the binary signal n 1 .
In this manner, during the warm-up state of the engine, the crank angle for the peak pressure is retarded from the normal so that the temperature of the exhaust gas is raised to rapidly warm up the engine and reduce the exhaust of HC. During the rapid acceleration of the engine, the crank angle for the peak pressure is also retarded to reduce the peak value so that the exhaust of NO x is suppressed. Further, during engine braking state, the crank angle for the peak pressure is also retarded to reduce the exhaust of HC.
While the digital implementation of the present invention has been shown and described, it should be readily understood to those skilled in the art that the present invention may be implemented in an analog system. | An electronic spark timing advancing apparatus for an internal combustion engine having an ignition device is disclosed, wherein a crank angle at which an internal pressure of a cylinder of the engine assumes a peak value is detected and a desired crank angle at which the internal pressure of the cylinder is to assume a peak value under a given condition is calculated in accordance with that condition, and a spark timing of the ignition device is controlled in response to a deviation therebetween to minimize the deviation. | 8 |
This application is a continuation of application Ser. No. 08/392,064 filed Feb. 22, 1995 now abandoned.
BACKGROUND OF THE INVENTION
Poly(ethylene terephthalate), PET is one of the main polymers used in the commercial production of fibers, films, bottles and injection molded goods. Although PET has higher melting point and superior mechanical and physical properties compared to other commercially used polymers like poly(propylene), poly(ethylene), poly(amide), poly(butylene terephthalate) etc., it exhibits poor dimensional stability at temperatures above the glass transition (70°-80° C.). PET fibers, and the products made from the fibers such as films and fabrics, may shrink up to 40% of the original length when subjected to these high temperatures. This shrinkage is due to the tendency of oriented amorphous molecules to relax on exposure to heat.
At commercial production rates, the polymer has little opportunity to form well developed crystallites. The slower crystallization rate of PET, as well as its homologues, such as poly(propylene), poly(ethylene), poly(amide), poly(butylene terephthalate) and poly(isopropyl terephthalate), and co-polymers, is described to its rigid aromatic structure compared to the more flexible aliphatic structures found in other commercial polymers. Thus articles made of PET usually have to go through an additional stage of drawing and heat-setting during the fiber spinning process to dimensionally stabilize the structure thus produced.
In conventional melt spinning, there is a high degree of control over individual filaments. The filaments formed are pulled downwards and wound on a take-up device that exerts some stress on the filaments. PET is very sensitive to stress-induced crystallization. But this effect is only seen when there is sufficient stress present during the processing such as that encountered in high speed spinning (take-up velocities of 5000-8000 m/min.). The critical stress required to induce crystallization on-line without any type of additives was shown to be 0.08 g/denier. In high speed spinning, winding of the filaments is a problem along with frequent yarn breaks and mechanical limitations. It would be ideal if one can produce the similar structures at low spinning speeds. It is generally proposed that the effect of on-line stress overrides that of the nucleating agents. This is the main reason for ignoring the use of nucleating additives in fibers or films.
In the spun bond process, the filament speeds tend to be much slower (1000-3000 m/min.) regardless of whether air drag or positive take-up roller drafting devices are utilized. The fiber drawing is accomplished through an aerodynamic device. There is lower stress and less degree of control over individual filaments compared to that in melt spinning. Spun bond fabrics are widely used as filter or pre-filter materials for hot liquid or gas, in textile garments as interlinings and in roofing applications. The fabrics/filters may be subjected to temperatures above 80° C. in these applications. The shrinkage of these materials can be prevented by having a dimensionally stable web.
In melt blowing, there is virtually no control over individual filaments because of the high degree of turbulence experienced by the fibers down stream during the process. Although the polymer melt is attenuated into very fine fibers, this is done when the polymer is still in a molten state (due to the action of high velocity hot air). Thus the stress developed during the process is very low eliminating the possibility of on-line crystallization. Incorporation of artificial nucleating sites would produce dimensionally stable webs. Melt blown webs are widely used as filters for hot liquid, gases and dust particles apart from face masks and interlinings. A melt blown web must have a larger surface area (smaller diameter fibers), moderate strength, flexibility and good textile hand. Drawing and heat-setting a melt blown or spun bond web is not possible without drastically altering the above mentioned characteristics. The main criteria for melt blown filters include finer fibers for improved filtration efficiency with minimal shrinkage (less than 5%) at elevated temperatures. The shrinkage was shown to be much below this level for PET fibers nucleated and reinforced with sodium benzoate and liquid crystalline polyester and a combination of both. The additives could be mixed at 0.1 to 3%. Fabric strength is not a main criterion for filters although a moderate strength to keep the webs coherent is desired. The success of producing dimensionally stable PET filters/fabrics lies in situations where the material has to be in contact with hot liquids or gases for prolonged period of time.
Melt blowing is a one step process to produce fabrics from thermoplastic polymers. A schematic depicting the melt blowing process is shown in FIG. 1. The plastic to be melt blown is fed to the extruder in the form of pellets, flakes or powder. The molten polymer is forced out of a die containing several spinneret holes. As soon as the molten polymer exits the die, a stream of high velocity, hot air attenuates the polymer into very fine fibers. The turbulence in the downstream helps in entangling the fibers to produce a coherent nonwoven web which is wound on a drum 1, 2!. Almost all thermoplastic polymers could be blown into a nonwoven web 3!. In principle, any fiber forming polymer of low melt viscosity can be processed on a melt blowing equipment. The most widely used polymer in melt blowing is the high melt flow rate poly(propylene). Poly(esters), nylons, poly(ethylenes) and poly(styrenes) have also been successfully processed 4, 5!. Meltblown webs have fine fibers with diameters in the range of 2-10 micrometers. This results in high surface area per unit volume of the web. The main application of melt blown webs is in the area of filtration, absorption and insulation.
The important variables in melt blowing are polymer throughput rate, melt temperature, die temperature, air temperature, air flow rate, screw speed and die-to-collector distance 6!. Melt blowing is a complex process that involves turbulence which is poorly understood by the scientists until today. Isolation of experimental factors is difficult because of interaction between different variables. The multifilament environment, and the environmental factors such as the humidity of the processing room, quench air temperature widely change the boundary conditions.
The process-structure-property relationships in melt blowing different molecular weight polypropylene resins (35-1000 MFR) were studied by Malkan et al. 6,7!. Polymer throughput rate had a noticeable effect on the physical characteristics of the melt blown webs. The mean fiber diameter, tensile strength, initial modulus, porosity, stiffness and web density increased with an increase in throughput rate. However, the breaking strain and the energy required to break decreased indicating the brittle nature of the webs produced at higher throughput rates. The increase in fiber diameter was attributed to die swell and the change in polymer-to-air ratio for a given air flow rate. The increase in air flow rate did not result in any significant change in mean fiber diameter. The die orifice size had only minimal effects on the average fiber diameter. Birefringence values ranged from 15.2×10 -3 for high throughput rates to 26.1×10 -3 for low throughput rates. The molecular weight and polydispersity index were found to decrease after processing the resins into webs. However, an increase in throughput rate did not result in any significant change in molecular weight of resins. The effects of throughput rate, air flow rate, and hole diameter on the percent crystallinity was observed to be insignificant. The webs produced at high throughput rate showed double melting peaks indicative of two different melting species. X-ray studies confirmed these results revealing the presence of α-form (monoclinic) and β-form (hexagonal) of crystals.
Using a single hole die, the effect of polymer throughput, air velocity, polymer and air temperatures on web properties were studied by Haynes et al. 8!. It was observed that the fiber was always continuous without any breakage in its flight and experienced flapping motion depending on the air velocity. An increase in air flow rate was found to decrease the mean fiber diameter for a fixed throughput rate and die geometry. A critical air velocity was observed, above which any increase in air flow rate had only little effect on the fiber diameter. Fiber diameter was also found to decrease on increasing the processing temperature.
Feasibility of melt blowing virgin and recycled PET has also been demonstrated 9, 10!. The shrinkage of PET webs was dependent on the air flow rate used. PET webs produced at high air flow rates shrank much more than those produced at low air flow rates because of the higher level of molecular orientation. Heat setting of melt blown PET webs or alternatively the use of PBT were suggested as the possible means of producing thermally stable melt blown polyester nonwovens 11, 12!. The effects of annealing on the web structure and the mode of failure of melt blown polyester webs were studied using SEM 13!. It was concluded that the greater extension of as-blown PET webs was due to their poor crystallization. Annealing resulted in brittle webs. The thermal effects on melt blown PET/PBT nonwovens was studied by that et al 14!. It was observed that the PET fibers tend to shrink on exposing to heat whereas that of PBT showed negligible shrinkage. Addition of up to 20 weight percent PET to PET resulted in only a slight change in the shrinkage behavior.
The properties of semicrystalline polymers are highly dependent on the crystallization conditions and crystallization mechanisms 15!. The ability of a polymer to crystallize is dependent on the chemical repeat unit, molecular weight and stereoregularity. Under suitable conditions of temperature and stress, molecular ordering takes place in all three directions in macromolecular systems. Thermodynamic and kinetic criteria should be met for polymer crystallization to take place. Thremodynamics provides information only about the initial and final states of the material under investigation. Since the crystallization process involves time, the way the molecular segments participate to form an ordered crystal structure is better explained by the relatively recent kinetic theories. A concise review of the polymer crystallization theories was provided by Armstead et al 16!. Under quiescent conditions, polymers generally form chain folded crystals when grown from solution or melt as shown in FIG. 2. The chain folded configuration is due to minimization of Gibbs free energy. This way the crystallization is very rapid 17!. Polymer crystals tend to form thin lamellae which are large in two dimensions but are bound in the third dimension by the folds that form the basal plane. Although, Frank 18! and Hoffman 19! suggested the non-adjacent reentry model (Switch board type) to accommodate the cilia and loops, and associated density changes, neutron scattering studies 20, 21! show that the adjacent reentry is the predominant mode of crystallization in polymers.
The crystallization behavior of polymers is highly dependent on the chemical structure and intermolecular forces. Polymers with simple and linear structures such as polyethylene and polypropylene have faster crystallization kinetics compared to PET that has a rigid backbone structure. The chain straightening and folding is a lot easier in the case of linear structures that form regular crystals. Chain folding is difficult in the case of PET which has rigid ring structures in the main chain. This limits the ability of the polymer to crystallize to the fullest potential during processing. Most of the polymer processing operations involve the stretching of the molecular segments to bring them to crystal register. A detailed account of the stress during crystallization will be provided in section 3.5. Although, PET has polar carbonyl groups, the polarity is not that strong as in the case of nylons for crystallization. Polymer crystallization is highly rate dependent. PET can be made crystalline by slow cooling or completely amorphous by rapid quenching. Isothermal processing, although produces a crystalline material with better mechanical and thermal properties, is rarely encountered in actual polymer processing. Thus polymer processing operations are non-isothermal situations that involve a large thermal gradient which is difficult to follow with any available experimental technique.
The overall crystallization rate of a polymer is usually divided into nucleation and growth rates. Both isothermal and non isothermal kinetics could be studied using Differential Scanning Calorimetry (DSC). Other techniques to study the crystallization kinetics of polymers include light scattering, optical microscopy and infrared spectroscopy. The bulk crystallization rate as determined by DSC is influenced by overall nucleation density, the rate of nucleation on the crystal surface and the rate of transportation of the molecules to the growth front.
PET fibers which are molten at 300° C. and quenched to room temperature show virtually no presence of crystallinity even after a year, which is indicative of the poor crystallizibility of PET polymer. In PET films which were isothermally crystallized between 120° and 240° C., the half-time of crystallization (time required for 50% crystallinity to develop) showed a minimum (maximum rate of crystallization) near 190° C.
Jabarin 28! investigated the nature of PET crystallization by using a combination of characterization techniques such as Differential scanning calorimetry (DSC), Density gradient column (DGC), Small angle light scattering (SALS) and Depolarized light intensity (DLI). PET films of intrinsic viscosity 0.81 were isothermally crystallized at 110°, 115°, 125° and 130° C. for various periods of time. For the same treatment time, the higher the crystallization temperature, the more was the volume degree of material crystallized and vice versa. To achieve the same degree of crystallinity as at 130° C., the treatment time had to be almost four times at 115° C.
There has been very little report on the crystallization kinetics of PET due to the fact that a slight change in the structure due to the different catalyst systems used alters the kinetics appreciably. Hence consistent results are not obtained while conducting kinetic experiments. The isothermal and non-isothermal kinetics of PET were performed by Jabarin 29-31!. The chemical factors that affect kinetics include molecular structure, catalyst system, molecular weight and side reactions during polycondensation of PET. The molecular weight affects viscosity and thus the rate of transportation of chain segments across the liquid-crystal interface. The physical factors that are important are the temperature, previous thermal history, nucleating additives, strain, orientation and pressure. It was concluded that the crystallization rate and mechanism of crystallization were dependent on the molecular weights, temperature and catalyst system. Of these, the catalyst system exhibited greater influence on the rate of crystallization. Among the catalyst systems investigated, titanium-based catalysts exhibited the lowest crystallization rate. The half-time of crystallization is not a true measure of crystallization as the exponent changes when crystallization proceeds. Isothermal crystallization mechanisms are easier to analyze theoretically than the dynamic non-isothermal crystallization mechanisms.
PET was extruded with several metal hydroxides 35! to study the effectiveness of nucleating additives in improving the crystallizibility of PET. An efficient nucleating additive would increase the maximum crystallization temperature (T cc ) on cooling from the melt and decrease the cold crystallization temperature (T ch ) on heating from the glassy state. Additives were compounded at temperatures above the T m of the polymer. Thermal analysis was carried out using DSC. It was found that the metal hydroxides, such as aluminum hydroxide Al(OH) 3 !, which released water over a narrow temperature interval spanning the processing temperature range of PET (260°-280° C.) were effective nucleants.
The effect of silica nucleants on the crystallization rate of PET was studied by Turturro et al. 36!. The maximum temperature of crystallization (T cc ) was found to increase with low loadings of silica (2 parts silica in 100 parts of PET). The trend was reversed and T cc decreased rapidly on increasing the concentration of silica particles. Thus the overall crystallization rate decreased at higher loading.
The influence of different catalyst systems and the molecular weight on the kinetics of crystallization of PET was studied by Gumther et al 37!. Two different catalyst systems, one with antimony trioxide and calcium acetate and the other with antimony trioxide with manganese acetate were used to produce PET of different molecular weights. The molar mass increased with manganese acetate thus slowing down the crystallization rate. The half-times of crystallization was smaller in the case of PET with calcium acetate catalyst systems.
Sodium salts of benzoic acid were tried successfully as nucleating agents for PET 38!. Sodium orthochlorobenzoate (SOCB) was used as a crystallization promoter. The nucleating efficiency of SOCB was found to be dependent on mixing temperature and time. Microscopic observations indicated that SOCB does not act like a classical heterogeneous nucleating additive. They rather dissolve and chemically react with PET molecules as true chemical reagents to form nucleating species.
Apart from organic and inorganic nucleating agents, polymeric additives were also tried for their ability to nucleate any other polymer. A liquid crystalline polyester (LCP--60 mole % PHB and 40 mole % PET) was solution blended and also melt mixed with PET at different ratios 40!. It was observed that the crystallinity was well developed in the solution cast films. As the amount of LCP was increased, the melting point remained unchanged but the heat of fusion decreased with increase in LCP content. The distinct exothermic peak of amorphous polymer was also missing in the case of solution cast PET. In the case of melt crystallized PET, the heating experiments showed that the T g remained unchanged while the T m and T ch decreased on increasing the LCP content from 0 to 70%. The `window of crystallization` decreased and the width of the crystallization exotherm narrowed. These results indicate that in fact the LCP acted like a nucleating agent for PET.
At high concentration levels of LCP (30% and above), the LCP component does not really act like a modifier but rather gets diluted by PET. Much lower concentrations (less than 10 weight percent) of LCP (60/40 PHB/PET) were used by Bhattacharya et al. 41!. Crystallization rate of PET with LCP was observed to be much higher than that of pure PET.
Linear low Density Polyethylene (LLDPE) and Polypropylene act as efficient nucleating agents for PET 43!. Low molecular weight polypropylene (LMWPP) was tried as a nucleating agent for PET 43!. Inherent transitions, the Tg and Tm were unaffected by the presence of these additives but the cold crystallization exotherm appeared at a much lower temperature for nucleated resins.
The crystallization kinetics of PET blended with naturally functionalized triglyceride oil was studied by Barrett et al 44!. The unsaturated ester group in the castor oil and Vernonia oil was used to chemically react with PET to form interpenetrating networks (IPNs). The crystallization rate of PET was improved when cooling from the melt and also when heating from the glassy state. Synergistic effects were obtained by adding sodium benzoate.
When a polymer melt, such as PET, is strained, linear primary nuclei are formed, reducing the entropy between the chains in the crystalline and amorphous phases 46!. The crystallization proceeds at a much faster rate compared to that in the unstrained melt. Thus under identical conditions of spinning, straining results in an increase in the nucleation and growth rates due to increased supercooling effect. The resulting morphology is also totally different. In fiber spinning, increasing the take-up speed above 3000 m/min. results in shish-kebab structures. The shish consists of extended linear polymer segments in the form of a bundle. The overgrowth kebab is assumed to be made of folded chain lamellae grown at right angles to the fiber axis in the form of a cylindrite thus making the structure highly anisotropic. The high strength and modulus of fibers spun at speeds above 3000 m/min. are the result of the above mentioned morphological feature. Drawing results in the transformation of spherulites into microfibrils. In fiber spinning, one observes a purely jet flow with a significant longitudinal gradient. Within the die of reducing cross-section, the material experiences both transverse and longitudinal velocity gradients. Once the material exits the die, the longitudinal velocity gradient takes over till the material solidifies. Thus at slow spinning speeds, the fiber has a predominantly spherulitic structure that transforms into shish-kebab structure at high take-up speeds 46!.
Strain induced crystallization (SIC), usually, does not occur in polymers when stretched from the glassy state because of the lack of molecular mobility. But polymers like PET and polycarbonate, show improvement in atomic packing on stretching. The molecular orientation is much higher in the glassy state because of limited relaxation. Thus there are distinct differences between SIC in melt and in glass. SIC nuclei were found to have limited dimensions along the stretch direction (100°-250 A°).
Spruiell et al. 50! has investigated the process of strain induced crystallization and crystallization during annealing treatments of deformed bulk PET films. The effects of deformation below and above T g on crystallization were studied. Straining the polymer below T g resulted in a neck formation and an increase in strain rate resulted in a corresponding increase in crystallinity. Samples strained and then annealed at 80°-105° C. at short times exhibited lower percent crystallinity than before annealing suggestive of crystallite melting and stress relaxation. The orientation of samples strained below T g and then annealed were retained.
PET has two macromolecular conformations, trans or extended chain conformation that exists in the crystalline phase, and gauche or coiled conformation that exists in the amorphous phase. It is the fraction, distribution and packing of these conformations that affect the crystallinity and associated mechanical and thermal properties of PET films. Crystallite length was found to increase with increase in stretch ratio.
A study on the superstructure of amorphous PET films drawn above and below T g using light scattering and optical microscopy was performed by Misra et al 52!. Cold drawing of PET produced a necked region with high amount of orientation and crystallinity and an unnecked region with little or no orientation and crystallinity. Thus cold drawing PET resulted in the formation of rod-like superstructures surrounded by imperfect extended chain crystals. Stretching PET above Tg provided information about that formed due to strain induced crystallization only since the thermal crystallization was negligible. At low elongations, a rod-like structure existed that did not contribute to crystallinity but was oriented in a direction perpendicular to stretching. At high elongations the rods changed into ellipsoidal spherulites that are elongated normal to the stretching direction.
The physical structure of fibers is drastically altered by changing the process conditions during melt spinning 58!. It was observed that little or no crystallization takes place at the highest spinning speed (10% at about 1500 m/min.) and this is little affected by throughput rate or the spinning temperature. The fibers spun at maximum speed cooled most rapidly. Considerable crystallinity levels were obtained during isothermal spinning especially when the take up speed was increased. The temperature at which the maximum rate of crystallization occurs was observed to be higher in the presence of stress in the spinline. The critical stress required for any crystallization to occur was found to be 0.08-0.09 g/denier 59!. Structure development during low speed isothermal spinning was observed to be similar to that of high speed spinning 60!. The windup speed and residence time of fiber in the oven influenced the final percent crystallinity value and orientation. The increase in rate of crystallization due to mechanical deformation above Tg was examined. An explicit equation for spherulite growth rate was developed in terms of experimentally measurable quantities.
The rate of crystallization of PET is highly dependent on orientation 61!. Nucleation and growth of crystallites occurred in milliseconds in oriented PET compared to minutes for unoriented PET. The main effect of orientation was to bring the molecular chain segments close together to reduce the configurational entropy thereby reducing the induction time for nucleation and crystal growth. The orientation of crystals in semicrystalline samples depends on the orientation of amorphous segments prior to crystallization.
The shrinkage and chain folding in drawn PET fibers was studied by Wilson 62!. The overall shrinkage process involved a rapid shrinkage due to the disorientation of frozen amorphous segments that results in fiber shrinkage. If the time and temperature are appropriate this is followed by crystallization.
The role of stress induced crystallization on the dimensional stability of uniaxially drawn PET films was studied by Mascia et al 63!. It was concluded that the level of shrinkage is independent of temperature up to 150° C. The thermal shrinkage was the highest for 2:1 draw ratio for a drawing temperature of 100° C. and below the glass transition temperature of PET. The drawn samples became dimensionally stable as indicated by the total percent crystallinity value of 43% that could be obtained only by annealing.
The thermotropic liquid crystalline polymers (TLCP) are widely used in blends with other compatible engineering polymers in the range of 5 to 30 weight percent 64!. The addition of LCP results in enhanced processing and reinforcement of the base polymer. The disadvantages are prohibitively high resin cost, special processing equipment and brittleness of the polymer blends. However, these LCPs find usage in high value added products where performance overrides the price. LCPs are commercially used in the form of films and fibers. The addition of small amounts of LCP significantly affects the processibility and a reinforcing microfibrillar morphology is obtained. However, the interfacial adhesion between the components was observed to be very poor resulting in highly anisotropic and brittle materials.
The high strength and modulus of fibers/films of PET/LCP blends is due to the molecular orientation of the mesophase during processing 67!. The unique properties of LCPs are their reinforcing nature and the ability to reduce the melt viscosity of the concerned polymer systems. Blending did not result in any change in transition temperatures (T m & T i ) of the components in the solid and the melt region. The PET and LCP components remain separate, thermodynamically stable, immiscible phases throughout the temperature changes.
Blends of PET with several LCPs were studied 69!. The crystallization temperature on heating (T ch ) decreased and the degree of crystallinity increased on adding LCP to PET indicative of LCPs nucleating effect.
The mechanical and thermal properties of PET fibers depend largely on the crystal structure, size and orientation of the crystallites and the amorphous regions within the fiber. The crystal structure of drawn PET fibers was studied by Daubney et al 74!. The high melting point of PET is due to the rigidity of the aromatic group and not due to intermolecular forces. At low draw ratios, a fiber of high orientation and little or no crystallinity was produced as determined by IR dichroic measurements. Drawing results in entanglements between molecules as determined by stress-strain curve as no crystallization or chemical crosslinks occurred. Evidence for this result was also obtained from NMR studies that showed close approach of neighboring atoms. At high draw ratios, reinforcement of structure could take place through stress-induced crystallization.
The effect of annealing on the structure of drawn PET fibers was studied by Fischer et al 76!. It was observed that the main effect was the perfection of crystals arranged normal to the fiber axis. The crystal size was also found to increase with increase in annealing temperature.
A three-phase model for PET was proposed by Fu 78!. This included a crystalline phase, an amorphous phase and an oriented amorphous phase known as "rigid amorphous" phase. Subtraction of the crystalline portion from the total X-ray diffraction pattern provided information about the structure of the non-crystalline phase. The azimuthal scattering pattern of the amorphous phase was observed to be isotropic whereas that of oriented non-crystalline phase was observed to be anisotropic. The rigid amorphous phase not only had the molecules aligned in the fiber direction but also correlated with crystal orientation. This intermediate phase is thought to be influential in the crystal growth, and the amount and structure is dependent on the mechanical and thermal history of the fiber. The structure-property correlation of PET is better explained by the three-phase model compared to the conventional two-phase model.
Melt blowing is one of the fastest growing processes for nonwoven production. Although poly(ethylene terephthalate) PET! is melt blowable, it has a disadvantage that melt blown PET fabrics exhibit poor dimensional stability at temperatures above T g . This is due to the negligible crystallinity in the final product, which is a result of the absence of stress induced crystallization. The spinline stress is very low due to the fact that there is no positive take-up mechanism unlike in melt spinning. Apart from this, the process is very rapid for any thermally induced crystallization and micro structure development to occur on the spinline.
Generally , PET has a very poor tendency to crystallize upon cooling from the melt. Although PET has polar groups, the rigidity of the benzene rings prevents the formation of regular chain folds and proper packing of molecular chains essential for crystal growth. Thus the overall crystallization rate of PET is slower than that of other common flexible polymers used in fiber production.
SUMMARY OF THE INVENTION
The nucleating ability of various commercially available additives can be exploited in situations where the level of spinline stress of a polyester fiber is low as in melt blowing. Kinetic studies confirm the fact that the overall crystallization rate of the system with potential nucleating additives is much higher than that of pure polymer, such as PET.
Improving the dimensional stability of melt blown and spun bond polyester fibers, and webs and fabrics made from these fibers, has been accomplished by enhancing the overall crystallization rate of the polyester, such as PET, by the incorporation of nucleating agents during processing. Fibers which can benefit from the invention include PET and homologues of PET, such as PPT and PIPT, and co-polymers thereof. Any polymeric fiber of the polyester series which undergoes shrinkage will benefit from the incorporation of nucleating agents into the polymer. Generally, fibers which are subject to dimensional stabilization by the method of the invention include fibers made of those polyester polymers which contain a benzene ring or side chain which inhibits the crystallization of the fibers.
Nucleating agents are incorporated into the fiber, such as PET, during processing of the fiber to act as seeds for crystallite formation. The percentages of crystalline and rigid amorphous material present in the fibers determine the shrinkage values at temperatures above glass transition. The presence of crystallites stabilizes the filaments within the fibers by acting as anchoring or tie points between filaments, thereby inhibiting the motion of filaments relative to one another, and thus preventing shrinkage of the fibers.
The incorporation of nucleating agents into the polymer also results in the practicability of higher speeds of formation of fibers. Rate of formation of fibers is limited by rate of crystallization because a too rapid draw will result in tearing. An increased rate of crystallization causes a decreased tendency of the fibers to tear at high processing speeds.
For purposes of the invention, a suitable nucleating agent is one which, when incorporated into a polymer, does not melt during polymer processing temperatures, provides good surface (with matching dimensions) for polymer molecules to deposit and grow, is able to chemically interact with the polymer, and is able to be finely dispersed in the polymer.
An effective screening method for determining whether a compound will function as a suitable nucleating agent to provide dimensional stability (prevent shrinkage) of a polymer fiber or fabric is as follows. The compound additive is added, or additives are added, to molten polymer, which is then allowed to cool. The Tcc is determined. A suitable nucleating agent will increase the observed Tcc of PET, that is it will shift the crystallization curve, illustrated by FIG. 3 for PET, to the left. If the Tcc does not increase, or if it decreases, the test additive is unsuitable as a nucleating agent. In a preferred embodiment, the nucleating agent is sodium benzoate.
An embodiment of the invention is a dimensionally stabilized polyester fiber which comprises a nucleating additive. In a preferred embodiment, the polyester is PET and the nucleating additive is sodium benzoate. Other suitable nucleating agents can be used in place of sodium benzoate. See Table 1, below. Other nucleating agents are disclosed in the references listed in the bibliography, each of which is expressly incorporated herein by reference. A multiplicity of nucleating agents can be used. In another preferred embodiment, the nucleating additive is a combination of sodium benzoate and a second nucleating agent.
Another embodiment of the invention is a shrink-resistant non-woven web or fabric, which may be a melt-blown or a spunbond web or fabric, which comprises dimensionally stabilized polyester fibers containing a nucleating additive or a multiplicity of nucleating agents, such as a combination of sodium benzoate and a second nucleating agent. The web or fabric may be a single layer or may be multi-layered. The multi-layered web or fabric may contain melt-blown or spunbond layers, or a combination of melt-blown and spunbond layers. The webs or fabrics produced from the fibers of the invention are suitable for use where the webs or fabrics might be exposed to high temperatures, that is above 70° to 80° C. Such products include but are not limited to filters, such as those used in automobiles, roofing materials, and apparel.
A third embodiment of the invention is a method for the compounding of a nucleating agent into a polymer. In a preferred embodiment, a co-rotating twin screw type extruder was used to thoroughly melt mix the polyester with the nucleating additive. In a preferred embodiment, the nucleating agent incorporated into the polymer is sodium benzoate and the polymer is PET.
In the following Detailed Description of the Invention, the method and compositions of the invention are exemplified using PET as the polyester and sodium benzoate as the nucleating agent. It is understood by those skilled in the art that other suitable polyesters and other suitable nucleating agents may be substituted in place of PET and sodium benzoate with similar results.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows Schematic of the Melt Blowing Process.
FIG. 2 shows Crystalline Model for polymers.
FIG. 3 shows Crystallization behavior of PET on cooling from the melt.
FIG. 4 shows Crystallization behavior of PET on hearing from the glassy state.
FIG. 5 shows Enthalpy Vs. Temperature for PET (Theoretical).
FIG. 6 shows Theoretical Delta H Vs. Temperature for PET.
FIG. 7 shows Non-isothermal Kinetics of PET injection molded samples with additives.
FIG. 8 shows Isothermal Kinetics of PET injection molded samples with additives.
FIG. 9 shows Percent Crystalline, Amorphous, Rigid Amorphous and Shrinkage of PET webs with additives.
FIG. 10 shows Fiber Models for PET/LCP blends.
FIG. 11 shows Fracture Surface of PET Melt Blown Fibers with no additives (×6000).
FIG. 12 shows Fracture Surface of PET Melt Blown Fibers with LCP Fibrils (×800).
FIG. 13 shows Fracture Surface of PET Melt Blown Fibers with LCP Fibrils (×3000).
FIG. 14 shows The effect of temperature on the shrinkage of PET melt blown webs with additives.
FIG. 15 shows The effect of temperature on the percent rigid amorphous content of PET melt blown webs with additives.
FIG. 16 shows The effect of temperature on the crystallinity of PET melt blown webs with additives.
FIG. 17 shows Relationship between shrinkage and rigid amorphous content for PET melt blown webs.
FIG. 18 shows Relationship between shrinkage and amorphous content for PET melt blown webs.
FIG. 19 shows Relationship between shrinkage and crystalline content for PET melt blown webs.
FIG. 20 shows Shrinkage behavior of PET melt blown fibers product under different process conditions.
FIG. 21 shows The effect of temperature on the percent rigid amorphous content of melt blown PET fibers with no additives.
FIG. 22 shows The effect of temperature on the crystallinity of PET melt blown webs with no additives.
FIG. 23 shows The effect of air pressure at the die on the shrinkage of PET melt blown webs.
FIG. 24 shows The effect of cooling length on the shrinkage of PET melt blown webs.
FIG. 25 shows The effect of air temperature on the shrinkage of PET melt blown webs.
FIG. 26 shows The effect of throughput rate on the shrinkage of PET melt blown webs.
FIG. 27 shows The effect of air-die temperature difference on the shrinkage of PET melt blown webs.
DETAILED DESCRIPTION OF THE INVENTION
Materials
A solid state polymerized PET of intrinsic viscosity 0.9 was used for this study. The additives compounded with the polymer include an organic salt, an inorganic compound, a thermotropic liquid crystalline polyester and an ionomer. The chemical structure, trade name and source are given in Table 1.
Procedure
4.2.1. Injection Molding
The additives were tested for their nucleating ability by injection molding with PET and characterizing the molded samples. The process conditions shown in Table 2 were kept constant for all samples to make an absolute comparison. A total of 12 samples were produced as shown in Table 7, below. Prior to the runs, PET and LCP were dried at 120° C. and the ionomer at 60° C. for 12 hours. At first, PET was injection molded without any additives. In the successive runs, PET was dry blended with different additives in appropriate weight percentages. In between the runs, neat PET was used to purge the materials in the screw to avoid any contamination. The injection molded samples were sealed air-tight for further characterization.
4.2.2. Compounding of PET with additives
The successful nucleation additives, sodium benzoate and LCP were compounded with PET pellets in a twin screw extruder. The conditions of extrusion were kept the same for all samples as shown in Table 3. A co-rotating twin screw type extruder was used to thoroughly melt mix PET with the nucleating additives. Initial runs of PET dry blended with additives in the hopper of a six-inch melt blowing equipment yielded poor quality webs. This is the reason for thoroughly mixing the solid additives with PET in a twin screw extruder. The compounded materials were quenched in a water bath prior to pelletizing. The pelletized samples were tightly sealed to prevent moisture uptake.
4.2.3. Melt blowing of PET compounded with additives
The compounded PET samples were melt blown into fine quality webs using a six-inch wide die. The process conditions as shown in Table 4 were kept constant for different samples produced to make an absolute comparison between samples. Prior to processing, the compounded PET pellets were dried at 120° C. for 12 hours. Unlike our previous experience on injection molding machine and the twin screw extruder, processing problems like flies and change in web density were encountered on switching from PET to PET with additives. Utmost care was taken to produce uniform and good quality webs. It was very difficult to control the web thickness and basis weight of the webs produced. This could be attributed to the poor draw down of the LCP component in the blends. When LCP was tried alone without any additives, poor quality mat with very large but strong fibers were obtained.
4.2.4. Melt blowing of PET without additives
In order to investigate the effect of process variables such as throughput rate, air pressure at the die, die temperature, air temperature and the die-to-collector distance on the properties of the melt blown webs, PET melt blown webs without any additives were prepared varying the above mentioned factors at two levels. The details of the melt blowing run are shown in Table 5. Due to the complexity of the process like the interaction between the air temperature, air velocity and throughput rate, production of controlled samples was difficult. However, efforts were made to produce control webs of almost same thickness and density.
Characterization Techniques
4.3.1. Thermal Analysis
Injection Molded Samples
A DSC 25 with Mettler TA 4000 controller was used to characterize the injection molded specimens of almost same thickness and a sample mass of approximately 15 mg. An inert environment was maintained throughout the scan to avoid thermal degradation. Both non-isothermal and isothermal kinetics were performed using the DSC. For non-isothermal studies, the samples were scanned at a rate of 20° C./min. PET samples were held at 300° C. in the DSC cell for 3 minutes for complete melting of crystals. Cooling rates of 20°, 40°, 60° C./min. were used. Isothermal studies were done by measuring the time taken for 50% crystallinity to develop at 232° C. A cooling rate of 20° C./min. from the melt kept at 300° C. for 3 minutes was used to reach the desired isothermal temperature.
Melt Blown Samples
A DSC 25 with Mettler 4000 control system was used for the thermal characterization of as-produced melt blown webs without any additives. A nitrogen atmosphere was used throughout the study. A sample mass of 10 mg was used. Samples were heated at a rate of 20° C./min. from 50° to 300° C. A DSC 20 was used for analyzing the melt blown samples with additives. The same conditions of testing was followed. The percent crystallinity from the heating and cooling DSC curves was calculated according to the formula
X.sub.c (%)= (ΔH.sub.ex /ΔH.sub.th)×(1/(1-b))×100!(17)
where X c is the percent crystallinity; ΔH ex is the experimental heat of fusion determined from the DSC curves; ΔH th is the theoretical heat of fusion determined from ATHAS tables 78! and b is the weight percent of the additive.
ΔH.sub.ex =ΔH.sub.m -ΔH.sub.c
where ΔH m is the heat of fusion of the melting endotherm in J/g and ΔH c is the heat of fusion of the crystallization exotherm in J/g.
ΔH.sub.th =H.sub.c -H.sub.a
where H c is the enthalpy in J/g for a 100% crystalline solid and H a is the enthalpy in J/g for a 100% mobile amorphous liquid.
4.3.2. Shrinkage Studies
The thermal shrinkage of melt blown PET webs was determined in the machine direction according to the formula
% Shrinkage= (Original length-Final length)/Original length!×100(20)
Samples were annealed without tension at 110°, 150° and 190° C. for 3 minutes in a vacuum oven. In the case of melt blown PET with additives, because of the difference in thickness of the webs, the samples were kept in the oven for the duration corresponding to the thickness of the samples as shown in Table 6. The mean thickness of 5 samples was determined. The samples annealed at different temperatures were tightly sealed for further analysis. The shrunk samples were characterized using DSC to study the amount of different entities present in the fibers.
Results and Discussion
Injection molded PET samples
The non-isothermal cooling behavior of PET from the melt is shown in FIG. 3. The polymer was cooled from 300° C. to 50° C. at a rate of 20° C./minute. As we know, ordering of polymer molecules results in a release of heat and thus the polymer crystallization is an exothermic process. As shown in the figure, two mechanisms become operative: the left hand portion of the curve is dominated by the nucleation mechanisms and the right hand portion of the curve by the growth and diffusion mechanisms (viscosity dependent). The effect of a nucleating additive is to shift the T cc , the temperature of maximum crystallization on cooling, to higher temperatures. The T cc values for injection molded PET samples with different additives are shown in Table 7. The samples were cooled at 20°, 40° and 60° C./minute from 300° C. to 50° C. after being held at 300° C. for 3 minutes. There was a shift of about 16.5° C. for PET mixed with 2% sodium benzoate. The trend is the same for increased cooling rates. Thus, it is evident that sodium benzoate acts as an efficient nucleating agent in commercial PET processing where the cooling rate is of the order of several hundred degrees per minute. LCP, ionomer and copper sulfate pentahydrate alone did not show any significant nucleating ability. But, when LCP was combined with sodium benzoate, a synergism in nucleation was seen with a temperature shift of 15.5° C. at a cooling rate of 20° C./minute. LCP alone crystallized at a temperature much higher than that of pure PET. However, the heat of fusion value was negligible when compared to that of PET.
FIG. 4 illustrates the typical heating curve (20° C./minute) for an injection molded amorphous PET sample. It consists of a T g at 80° C., a crystallization exotherm at 129° C. and a broad melting endotherm with a melting point at 257° C. The effect of nucleating additive is to decrease T ch and increase T m . As can be seen from Table 8, a decrease of about 11.8° C. was observed for PET sample injection molded with 2% sodium benzoate. The melting point increased by about 4.2° C. The synergistic effect of adding sodium benzoate with PET/LCP blends is also seen by the reduction of about 9.6° C. in T ch and an increase of 3.4° C. in T m . LCP, ionomer and copper sulfate pentahydrate alone did not haisotro visible influence on T ch or T m . LCP had an isotropization temperature (T i ) of 276° C. where the crystal to nematic transition took place. Table 8 also contains the percent crystallinity values from heating and cooling curves.
A frequent mistake made in calculating the percent crystallinity is the assumption that ΔH th is constant over a wide range of temperatures. But, according to the ATHAS table of thermal properties 80!, ΔH th is in fact a function of temperature. FIG. 5 illustrates the change in enthalpy of solid, a 100% crystalline material and that of a liquid, a 100% amorphous material with temperature. The liquid heat capacity is always higher than that of the solid because of the unrestricted motion of the molecular segments. The theoretical heat of fusion has a cubic function with temperature as shown in FIG. 6. Since the difference between the transition points (T m , T ch and T cc ) is only of the order of a few degrees, a linear function was assumed between consecutive points in calculating the percent crystallinity. A lower value of ΔH th was obtained at T ch . Assuming a constant value for ΔH th would result in an error of over 20%. This correction procedure was used for every temperature while calculating the percent crystallinity values. The contribution of additives in the calculation was eliminated by subtracting the weight percent of additives from the theoretical heat of fusion. This way, the crystallinity values obtained were that of the PET component only.
As shown in Table 8, no crystallinity was detected for pure PET injection molded specimens, suggesting that the samples were essentially amorphous. The PET sample with 2% sodium benzoate had the higher percent crystallinity values. No crystallinity was detected for samples with low weight percent LCP. Samples with the copper sulfate additives were brittle indicative of crystalline fraction although it was much smaller than that containing sodium benzoate. All the samples with more than two components showed synergistic effect. The additives were chosen for compounding with PET based on their nucleation efficiency. Thus it could be seen that sodium benzoate is the most successful additive followed by LCP, copper sulfate and the ionomer. The percent crystallinity values for different samples on cooling from the melt at 20° C./minute are almost the same indicative of the fact that although the nucleation rate increases in the case of additives, the growth rate remains the same.
The non-isothermal and isothermal kinetics determined from DSC are shown in FIGS. 7 and 8 respectively. The sigmoidal shape of the curves is typical of polymer crystallization. The relative crystallinity values were calculated by partitioning the area under the crystallization peak on cooling from the melt, in this case, cooled at a rate of 20° C./minute, into small areas and dividing each area by the total area of the peak. It can be seen from the figure that PET with sodium benzoate had considerably higher percent crystallinity values by the time the other samples started to crystallize. This indicates the increase in overall crystallization rate of PET with sodium benzoate, and PET with LCP and sodium benzoate. All other additives fall in the same area as that of pure PET. Isothermal kinetics were performed at 232° C. The exotherm was allowed to reach the base line before useful calculations were made. As can be seen from FIG. 8, crystallization rate of PET with successful additives was much higher than that of the unsuccessful additives. The potential nucleating additives and their combinations were thus obtained from these experimental investigations using the kinetic studies. It was tactfully assumed that the higher crystallization rate of PET samples with additives would prevent the shrinkage of PET during further thermal treatment.
PET Melt Blown webs with nucleating additives
Table 9 and FIG. 9 show the DSC results of different melt blown webs produced under identical processing conditions with nucleating additives. Almost all the additives showed nucleating ability as can be seen from the shift in T ch . PET with 1% sodium benzoate produced a moderately crystalline web with 9.82 percent crystalline fraction. Other webs had essentially no detectable crystalline fraction. The additives, in fact, acted like diluents as can be seen from the reduction in T g values (Table 10). The crystals have a regular three-dimensional ordering with a definite melting point. The amorphous fractions have no order and become mobile at T g . The rigid amorphous fractions resemble the crystallite in properties and become mobile between T g and T m . The as-produced PET melt blown webs have a large fraction of rigid amorphous content that may be responsible for their high shrinkage values on further heat treatment. The least shrinkage value was obtained in the case of melt blown webs with PET and sodium benzoate although they had higher rigid amorphous content. Thus the shrinkage behavior of melt blown PET webs was found to be very different depending on the type of additive used and the amount of crystalline, amorphous and rigid amorphous present in the sample.
In the case of amorphous PET melt blown webs, the shrinkage could be attributed to the presence of large amount of oriented rigid amorphous fraction. There is no restriction on the motion of these rigid segments on exposure to heat because of the absence of crystallites as tie links. The crystallites already present in the web restrict the motion of the amorphous or the rigid amorphous molecules in the case of melt blown webs that contain PET in combination with sodium benzoate. In the case of PET melt blown fibers that contain LCP, the LCP component being of lower viscosity at the processing temperature range compared to PET, might encapsulate the PET phase forming a sheath-core composite structure. Two model structures were proposed for melt blown fibers with PET and LCP as shown in FIG. 10. In both the cases, PET component is prevented from shrinking by the rigid LCP phase. Thus the shrinkage values of the melt blown webs produced from blends were lower in all the cases with LCP as reinforcing phase. In fact, fracture studies performed on the melt blown fibers made of PET and PET/LCP blends revealed the evidence of a matrix-fibril type of composite fiber as shown in the SEM pictures (FIGS. 11-13). The droplets of the LCP component gets elongated into discontinuous fibrils within the matrix of PET as shown in the SEM pictures.
The shrinkage studies were also performed at 150° and 190° C. There was a considerable increase in the percentage shrinkage values in the case of PET fibers that contained no additives as shown in FIG. 14. Even at 190° C. the fibers made of PET and additives had exceptional dimensional stability with shrinkage values less than 10%. The fibers made of PET/LCP/Sodium benzoate had higher shrinkage values compared to the rest of the samples in the figure that contained additives. DSC was used to determine the relative amounts of crystalline, amorphous and rigid amorphous contents of the shrunk melt blown fibers. FIG. 15 illustrates the change in the percent rigid amorphous content with increase in shrinkage temperature. In all the cases, the samples were annealed with no constraint for the same period of time. PET fibers had considerably higher amount of oriented amorphous fraction compared to PET fibers that contained additives. Among the fibers that contained additives, PET/LCP had the lowest value suggestive of very low shrinkage values. Although, the rigid amorphous content was higher in the case of fiber that had PET/Sodium benzoate, shrinkage was prevented by the crystallites present in the as-produced fibers.
The competing mechanisms of shrinkage and crystallization are very evident from the above figures. The reduction in the rigid amorphous content of all samples at temperatures at 110° C. is due to the disorientation of the oriented amorphous chains. At 110° C., this is presumed to be the dominant mechanism. At 150° C., the material is already crystalline (Tch being 130° C.), there is a further reduction in the rigid amorphous content. FIG. 16 illustrates the increase in crystallinity content of different samples on annealing. Crystallinity was detected only in the case of as-produced PET fibers that had sodium benzoate. The increase in crystallinity at 110° C. of all the samples other than PET is due to the presence of a greater number of nucleating sites on heating from the glassy state. This is also responsible for higher percent crystallinity values in the case of fibers that contained additives at higher shrinkage temperatures. Thus in the case of PET fibers that had no additives, the shrinkage is mainly due to disorientation at 110° C. and above and the level of shrinkage is determined by the shrinkage and crystallization temperatures and times during annealing. Presence of nuclei/additives influence a lot on the shrinkage and crystallization behavior the fibers. Thus having a crystalline material to begin with is crucial in further heat treatments like annealing to prevent thermal shrinkage.
A statistical correlation between percent shrinkage at 110° C. versus crystalline, amorphous and rigid amorphous contents of the fiber was obtained as shown in Table 11. Although the data points were limited, a clear trend was observed between percent shrinkage values and different entities present in the fiber structure. Shrinkage was found to be negatively correlated with the amount of crystalline and amorphous fractions present in the fiber. The rigid amorphous fraction was positively correlated with shrinkage indicating that an increase in rigid amorphous content would result in an increase of thermal shrinkage of the melt blown PET webs. This result was found to be significant at the 90% confidence level. Rigid amorphous content also had higher correlation values with shrinkage compared to crystalline and amorphous fractions. Several statistical models were analyzed for the observed data points and the one with significant F-value, in this case an exponential model was chosen as shown in Table 12. The observed trends were also plotted along with the predicted model in FIGS. 17-19.
Shrinkage studies were also performed at 150° and 190° C. The results are shown in FIG. 20. Three sets of samples are shown to have similar percent shrinkage values. The presence of crystallites in the as-produced fibers has considerable influence on the percent shrinkage values of fibers. The shrinkage was found to increase with shrinkage temperature in the case of fibers that had no detectable crystallinity. The shrinkage values remained the same in the case of fibers that had crystallites in the as-produced material. The rigid amorphous content was found to decrease on annealing as shown in FIG. 21. The reason being the participation of oriented amorphous molecules in shrinkage and disorientation at 110° C. and 190° C. At 150° C., the lowest values for the rigid amorphous content was observed. Participation of rigid amorphous material in the crystallization process is the reason for this reduction in the rigid amorphous content. At 150° C., the fibers undergo competing mechanisms of shrinkage and crystallization. The change in the rigid amorphous content is also determined by the initial status of the material such as the relative portions of the crystalline and rigid amorphous segments. Thus the trend observed is similar to the one observed in the case of PET fibers with nucleating additives. No appreciable crystallinity was detected in the case of essentially amorphous fibers annealed at 110° C. for 3 minutes. However, the crystallinity was found to rapidly increase at 150° C., the Tch being 129° C. or so and remained almost at the same value at 190° C. as shown in FIG. 22. Here again, the value of final percent crystallinity was dependent on the initial status of the material such as the presence of detectable crystallites/nuclei present in the fiber.
The mean, standard deviation and CV % of fiber diameters for PET melt blown fibers produced with nucleating additives are shown in Table 13. Mechanical and physical properties of melt blown webs with additives are shown in Tables 14 and 15. It was not possible to keep a constant basis weight and thickness of the samples because of the poor drawing action when LCP was blended with PET. However, loftier webs were produced in the case of blends. Webs that contained LCP had higher air permeability values because of larger fiber diameters. It is very evident that the lower fiber diameters is the reason for lower air permeability values and thus higher filtration efficiency of the PET melt blown webs that contained sodium benzoate. Bursting strength was observed to be lower in the case of webs that contained the additives.
PET Melt Blown webs produced under different processing conditions with no additives
In order to investigate the mechanism of shrinkage, PET samples were melt blown varying the process conditions such as the throughput rate, die-to-collector distance, air pressure at the die, air temperature and die temperature. The results from the as-produced fibers are shown in Tables 16 and 17 and also in FIGS. 23-27. An ice cooled amorphous PET film was taken as the reference material. The effect of orientation during melt blowing could be seen from the increase in the T g and the rigid amorphous content of the processed fibers. There was no appreciable difference in the T ch and T m values of the webs produced under different conditions. The crystalline fraction was found to slightly increase on increasing the air pressure at the die. This also resulted in a slight decrease in the rigid amorphous content. Interestingly, the shrinkage values were found to be much lower in the case of melt blown webs produced at 4 psi air pressure at a throughput rate of 0.3 ghm. Thus it can be seen that dimensional stability of webs could also be improved by processing PET at suitable conditions without any nucleating additive. Increasing the cooling distance, i.e. the die-to-collector distance resulted in a decrease in crystallinity and an increase in the rigid amorphous content. The shrinkage value was found to be close to 40%. An increase of about 20° C. in air temperature was not influential in reducing the shrinkage values. Although there was a reduction in rigid amorphous content, no on-line thermal crystallization or annealing was found to occur. The web crystallinity was found to increase slightly on reducing the throughput rate to 0.15 ghm from 0.3 ghm. However, only a slight reduction in shrinkage was observed. The slight increase in crystalline and rigid amorphous fraction at low throughput rate could be due to the increase in elongation rate due to reduction in velocity of polymer at the die tip for the same air pressure. It is not clear whether this would result in any on-line stress induced crystallization. The ideal condition for processing PET of 0.9 I. V. could be the last segment as shown in FIG. 27. The crystallinity was found to increase with reduction in rigid amorphous fraction and a simultaneous decrease in shrinkage on processing the polymer at equal die and air temperatures, in this case, 271° C.
The effect of changing different processing variables on the mechanical properties of the melt blown PET webs is shown in Table 18. It is evident that an increase in strength was obtained by increasing the air pressure at the die for the same throughput rate PET#1 to PET#3!. This is due to the orientation of the molecular chains and finer fibers. Finer the fibers, there are more number of fibers in a given cross section of the webs. This results in improved tenacity values. A slight increase in elongation and breaking energy indicates that the webs become tougher on increasing the air flow rate for the same throughput rate. A slight decrease in modulus was observed in the case of PET#3. An increase in cooling length or collection distance would reduce the thermal sticking or bonding between the fibers in the melt blown web. Similar results were obtained on increasing the air temperature. Although, the values of initial modulus were comparable, the webs became tougher as indicated by the higher breaking elongation and breaking energy values. The breaking tenacity showed a maximum for lower throughput rate samples. Almost all the samples produced had ductile failure except PET#8. The failure behavior of PET#8 webs was observed to be laminar type. There was very minimal thermal sticking between fibers that resulted in poor elongation and breaking energy values. Although, PET#8 is the ideal fabric for its improved thermal properties, it had poor mechanical properties. These samples also had much higher coefficient of variation when compared to the rest of the webs produced.
The mean, standard deviation and CV % of fiber diameters for PET melt blown fibers produced without nucleating additives is shown in Table 19. The physical properties of PET melt blown webs produced under different processing conditions without any type of additive are shown in Table 20. An increase in the air pressure at the die was found to decrease the basis weight and thickness of webs. Decrease in fiber diameter caused also a reduction in the air permeability and an increase in filtration efficiency. Bursting strength increased with an increase in air pressure at the die. The basis weight and thickness were found to increase on increasing the cooling length or collection distance. The air permeability increased and the bursting strength decreased. Similar results were obtained on increasing the air temperature for the same throughput rate, die to collector distance and air pressure at the die. A decrease in fiber diameter at lower throughput rate is manifested as a decrease in basis weight, thickness and air permeability when compared to webs produced at a higher throughput rate except in the case of PET#8. The web construction of PET#8 is quite different from webs produced at the same throughput rate. The webs were loftier and permeable with very soft hand and high bursting strength.
The references listed hereunder form part of the disclosure of this specification and are herein incorporated expressly by reference.
The methods and products of the invention are exemplified herein by use of PET and of the illustrated nucleating additives. These exemplified methods and products are for illustration purposes only. The methods of the invention can be practiced using other suitable polyesters, such as homologues and co-polymers of PET, including poly(propylene), poly(ethylene), poly(amide), poly(butylene terephthalate) and poly(isopropyl terephthalate), and other suitable nucleating agents, as determined by a suitable screening test, such as the test described herein.
TABLE 1__________________________________________________________________________Material, Structure, Trade Name and SourceMaterial Chemical Repeat Unit Trade Name Source__________________________________________________________________________PET ##STR1## SSP Hoechst CelaneseLCP ##STR2## VECTRA Hoechst CelaneseIonomer ##STR3## SURLYN DuPontSodium Benzoate ##STR4## -- Aldrich ChemicalsCopper CuSO.sub.4.5H.sub.2 O -- Aldrich ChemicalsSulfatePentahydrate__________________________________________________________________________
TABLE 2______________________________________Injection Molding Conditions______________________________________Machine Type ARBURG Model No: 221-55-250Die Temperature 300° C.Mold Temperature 25° C.Screw Speed 200 rpm______________________________________
TABLE 3______________________________________Compounding Conditions______________________________________Machine Type LEISTRITZ Twin Screw Extruder with co- rotating screws (34 mm diameter)Pelletizer KILLIONDie Temperature 215° C.Screw Speed 200 rpmHead Pressure 600 to 700 psiCooling Distance 4 to 5" in water______________________________________
TABLE 4______________________________________Melt blowing conditions for PET withnucleating additives______________________________________Samples Produced:(1) PET(2) PET + 10% LCP(3) PET + 1% Sodium Benzoate(4) PET + 10% LCP + 1% Sodium Benzoate(5) PET + 10% LCP + 1% IonomerConditions:Throughput Rate 0.4 grams/hole/min.Die-to-Collector Distance 9 inchesAir Pressure 3 psiDie Temperature 274° C.Air Temperature 264° C.______________________________________
TABLE 5______________________________________Melt blowing conditions for PET webs withoutany additives produced under differentprocess conditions Die-to- Air Pressure Throughput Collector at Air Tem- Die Tem-Sample Rate Distance the die perature peratureID (ghm) (inches) (psi) (°C.) (°C.)______________________________________PET #1 0.3 4 1.5 282 282PET #2 0.3 4 3.0 282 282PET #3 0.3 4 4.0 282 282PET #4 0.3 8 4.0 282 282PET #5 0.3 8 4.0 304 282PET #6 0.15 8 4.0 304 282PET #7 0.15 8 4.0 288 276PET #8 0.15 8 4.0 271 271______________________________________
TABLE 6______________________________________Shrinkage Studies Oven Type - Scientific Products DK 63 Temperature - 105° C. Original length - 12.7 cm Average TreatmentMaterial Thickness (μ) time (min.)______________________________________PET 211 3PET + 1% Sod. Benzoate 248 3PET + 10% LCP 863 12PET + 10% LCP + 1% Sod. Benzoate 1195 17PET + 10% LCP + 1% Ionomer 1479 21______________________________________
TABLE 7______________________________________Crystallization Temperatures of injectionmolded PET and PET with additives at differentcooling rates Cooling Rates 20° C./ 40° C./ 60° C./Material min. min. min.______________________________________PET 208.2 144.6 69.9PET + 1% Liquid Crystalline 207.5 139.1 57.8Polyester (LCP)PET + 10% LCP (Trade name - 203.9 145.7 57.4VECTRA)PET + 1% Ionomer (Trade name - 208.3 139.2 57.6SURLYN)PET + 10% Ionomer 207.2 137.8 59.9PET + 2% Sodium Benzoate 224.7 171.8 99.2PET + 2% Copper Sulfate 206.3 147.7 58.2Pentahydrate (Cu S)PET + 1% LCP + 2% Sodium 223.7 171.9 109.4BenzoatePET + 10% LCP + 1% Ionomer 210.3 144.6 53.8PET + 10% LCP + 3% Ionomer 204.1 140.6 55.7PET + 10% LCP + 2% Cu S 203.4 132.4 37.6LCP 234.0 190.5 139.3______________________________________ Note: The samples were held at 300° C. for 3 minutes and then cooled at rates of 20, 40 and 60 deg. C./min. The samples were also heate to 300° C. from 50° C. at a rate of 20° C./min.
TABLE 8__________________________________________________________________________Transition Temperatures and PercentCrystallinity of injection molded PET with additives DSC Parameters % Crystallinity % Crystallinity on heating on coolingMaterial T.sub.ch T.sub.m (ΔH.sub.m - ΔH.sub.ch) (ΔH.sub.cc)__________________________________________________________________________PET 129.2 257.0 N.D. 44.60PET + 1% Liquid Crystalline Polyester (LCP) 129.0 254.3 N.D. 46.66PET + 10% LCP (Trade name-VECTRA) 127.7 255.9 5.86 43.37PET + 1% Ionomer (Trade name-SURLYN) 127.8 255.8 2.43 45.95PET + 10% Ionomer 134.1 258.3 N.D. 46.76PET + 2% Sodium Benzoate 117.4 261.2 23.74 46.82PET + 2% Copper Sulfate Pentahydrate (Cu S) 134.8 258.1 8.21 47.16PET + 1% LCP + 2% Sodium Benzoate 119.6 260.4 10.8 48.66PET + 10% LCP + 1% Ionomer 129.0 261.2 2.83 49.49PET + 10% LCP + 3% Ionomer 129.0 255.9 2.03 44.11PET + 10% LCP + 2% Cu S 124.3 261.2 9.02 50.47LCP -- (T.sub.i) negligible negligible 276-280__________________________________________________________________________ NOTE: The samples were heated to 300° C. from 50° C. at a rate of 20° C./min. N.D. Not Detected Ti Temperature of isotropization
TABLE 9______________________________________Transition Temperatures and PercentCrystallinity of PET melt blown webs with additives DSC Parameters % Crystallinity on heatingMaterial T.sub.ch T.sub.m (ΔH.sub.m - ΔHch)______________________________________PET 130.4 258.6 N.D.PET + 10% LCP (Trade name-VECTRA) 124.1 256.3 N.D.PET + 1% Sodium Benzoate 116.2 259.2 9.82PET + 10% LCP + 1% Sodium Benzoate 120.3 258.2 N.D.PET + 10% LCP + 1% Ionomer 127.0 257.1 N.D.______________________________________ NOTE: The samples were heated to 300° C. from 50° C. at a rate of 20° C./min. N. D. means Not Detected
TABLE 10__________________________________________________________________________Tg, Percent Crystalline, Amorphous andRigid Amorphous Fractions and Shrinkage for PET withnucleating additives Percent Percent Percent Rigid Tg Crystalline Amorphous Amorphous ShrinkageMaterial (°C.) Fraction Fraction Fraction (%)__________________________________________________________________________PET 80.9 N.D. 18.30 81.7 30.70PET + 10% LCP 74.3 N.D. 64.74 35.25 3.31PET + 1% Sodium Benzoate 72.2 9.82 21.31 68.87 2.68PET + 10% LCP + 75.8 N.D. 54.75 45.24 7.091% Sodium BenzoatePET + 10% LCP + 78.3 N.D. 31.07 68.93 2.831% Ionomer__________________________________________________________________________
TABLE 11______________________________________Correlation between shrinkage anddifferent structural entities present in PET meltblown webs produced with no additives(annealing temperature - 110° C.) Correlation Coefficients SHRINK CRYST AMR RIGID______________________________________SHRINK 1.0000 -.4804 -.4020 .6172 (8) (8) (8) (8) P = . p = .228 p = .323 P = .103CRYST -.4804 1.0000 -.0591 -.5161 (8) (8) (8) (8) P = .228 P = . P = .889 P = .190AMR -.4020 -.0591 1.0000 -.8245 (8) (8) (8) (8) P = .323 P = .889 P = . P = .012RIGID .6172 -.5161 -.8245 1.0000 (8) (8) ( 8) (8) P = .103 P = .190 P = .012 P = .______________________________________ (Coefficient/(Cases)/2-tailed Significance) "." is printed if a coefficient cannot be computed
TABLE 12__________________________________________________________________________Different statistical models and theirsignificanceIndependent: RIGID UpperDependentMth Rsq d.f. F Sigf bound b0 b1 b2__________________________________________________________________________SHRINKLIN .381 6 3.69 .103 -107.90 1.6723SHRINKLOG .389 6 3.81 .099 -558.68 133.452SHRINKINV .396 6 3.94 .095 159.038 -10616SHRINKQUA .434 5 1.91 .241 -1020.2 24.7888 -.145SHRINKCUB .434 5 1.91 .241 -1020.2 24.7888 -.145SHRINKCOM .445 6 4.82 .071 .0032 1.1166SHRINKPOW .456 6 5.03 .066 3.6E-16 8.8149SHRINKS .466 6 5.23 .062 11.8722 -702.18SHRINKGRO .445 6 4.82 .071 -5.7574 .1103SHRINKEXP .445 6 4.82 .071 .0032 .1103SHRINKLGS .445 6 4.82 .071 . 316.514 .8956__________________________________________________________________________
TABLE 13______________________________________Mean, Standard deviation and CV % offiber diameters for PET melt blown fibers producedwith nucleating additives Standard Coefficient of Mean Deviation VariationSample ID (μ) (μ) (%)______________________________________PET 4.3 2.4 56PET + 1% SB 1.6 1.4 88PET + 10% LCP 17.7 10.3 58PET + 10% LCP + 1% SB 6.7 6.5 97PET + 10% LCP + 1% 28.0 9.8 35Ionomer______________________________________
TABLE 14______________________________________Mechanical properties of PET meltblown webs produced with nucleating additives Breaking Initial Breaking Tenacity Elongation Modulus EnergySample ID (mN/tex) (%) (N/tex) (Kg - m)______________________________________PET 16.2 42.0 0.68 0.097PET + 1% SB 16.2 3.4 0.73 0.003PET + 10% LCP 2.0 4.8 0.18 0.001PET + 10% LCP + 1% 2.1 5.1 0.10 0.003SBPET + 10% LCP + 1% 0.5 14.9 0.05 0.001Ionomer______________________________________
TABLE 15__________________________________________________________________________Physical properties of PET melt blown webswith nucleating additives Theoretical Basis Air Bursting Bending Filtration Weight Thickness Permeability Strength Rigidity EfficiencySample (GSM) (μ) (m.sup.3 /m.sup.2 /sec) (KPa) (mg - cm) (%)__________________________________________________________________________PET 45.27 211 0.38 35.94PET + 1% SB 23.16 248 0.29 11.06PET + 10% LCP 43.14 863 5.84 8.99PET + 10% LCP 137.62 1195 1.29 6.91+ 1% SBPET + 10% LCP 105.95 1479 4.19 13.13+ 1% IO__________________________________________________________________________
TABLE 16______________________________________Transition temperatures and percentcrystallinity values of PET melt blown websproduced under different processing conditions % Crystallinity on heatingMaterial T.sub.ch T.sub.m (ΔH.sub.m - ΔH.sub.ch)______________________________________PET (ice cooled amorphous film) 133.5 258.1 N.D.PET #1 130.5 254.2 N.D.PET #2 129.4 254.1 1.95PET #3 129.3 254.1 4.43PET #4 130.3 255.1 1.00PET #5 132.5 254.1 N.D.PET #6 132.5 255.3 4.35PET #7 135.3 254.2 4.42PET #8 131.1 255.4 8.13______________________________________ NOTE: The samples were heated to 300° C. from 50° C. at a rate of 20° C./min. N.D. means Not Detected
TABLE 17______________________________________Glass transition temperatures and amountof different structural entities present in as-produced PET melt blown webs produced with noadditives Percent Percent Percent Rigid Tg Crystalline Amorphous Amorphous ShrinkageSample ID (°C.) Fraction Fraction Fraction (%)______________________________________PET FILM 81.4 N.D. 70.79 29.21 --PET #1 83.5 N.D. 19.47 80.53 20.94PET #2 83.4 1.95 14.61 83.44 19.37PET #3 84.1 4.43 21.86 73.71 3.94PET #4 83.8 1.00 12.16 86.84 37.95PET #5 83.3 N.D. 24.35 75.65 36.69PET #6 82.5 4.35 14.64 81.01 33.39PET #7 83.8 4.42 14.59 80.99 36.85PET #8 85.3 8.13 19.37 72.50 8.98______________________________________
TABLE 18______________________________________Mechanical properties of PET meltblown webs produced with nucleating additives Breaking Initial Breaking Tenacity Elongation Modulus EnergySample ID (mN/tex) (%) (N/tex) (Kg - m)______________________________________PET #1 11.0 27.3 0.55 0.028PET #2 14.7 27.2 0.64 0.032PET #3 19.7 30.9 0.44 0.050PET #4 14.0 78.3 0.52 0.102PET #5 13.9 112.0 0.46 0.133PET #6 20.0 57.4 0.57 0.062PET #7 20.8 36.5 0.64 0.032PET #8 11.0 9.0 0.67 0.002______________________________________
TABLE 19______________________________________Mean, Standard deviation and CV % offiber diameters for PET melt blown fibers producedwithout nucleating additives Coefficient of Mean Standard Deviation VariationSample ID (μ) (μ) (%)______________________________________PET #1 19.4 9.8 50PET #2 6.6 2.4 36PET #3 4.7 1.8 38PET #4 6.7 3.0 45PET #5 7.7 3.6 57PET #6 4.4 2.4 54PET #7 3.2 1.5 36PET #8 4.4 1.7 38______________________________________
TABLE 20__________________________________________________________________________Physical properties of PET melt blown webswith no additives TheoreticalBasis Air Bursting Bending FiltrationWeight Thickness Permeability Strength Rigidity EfficiencySample(GSM) (μ) (m.sup.3 /m.sup.2 /sec) (KPa) (mg - cm) (%)__________________________________________________________________________PET #132.50 383 3.85 20.73PET #226.38 199 1.36 21.43PET #329.08 156 0.59 31.80PET #432.47 263 0.97 21.43PET #529.31 238 1.18 20.73PET #619.19 191 0.85 15.89PET #715.93 199 0.77 17.28PET #819.39 227 2.05 35.94__________________________________________________________________________
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Korean Patent Application No. 10-2011-0077777, filed on Aug. 4, 2011 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] Apparatuses and methods consistent with the exemplary embodiments relate to a display apparatus displaying broadcasting information of a three-dimensional (3D) image and a control method thereof, and more particularly, to a display apparatus and a control method thereof which extracts and displays broadcasting information of a 3D image and enables a user to efficiently select a 3D broadcasting channel if a 3D broadcasting channel or a normal broadcasting channel transmits 3D broadcasting.
[0004] 2. Description of the Related Art
[0005] In the current broadcasting environment, channels are being converted into a digital format and a 3D broadcasting signal is currently under testing. In the future, each broadcasting station will provide at least one channel having a 3D broadcasting signal. There are thousands of channels for satellite TVs in Europe, in which case the number of 3D channels could be more than double digits.
[0006] Currently, if a user changes a channel, he/she must put on or take off glasses whenever changing into a two-dimensional (2D) or a 3D channel until finding a desired 3D broadcasting channel. As TVs do not selectively provide 3D broadcasting channels, but also provide 2D broadcasting channels, it takes a lot of time to change channels. Thus the inconvenience to a user is increased.
SUMMARY
[0007] One or more exemplary embodiments may overcome the above disadvantages and other disadvantages not described above. However, it is understood that one or more exemplary embodiment are not required to overcome the disadvantages described above, and may not overcome any of the problems described above.
[0008] An aspect of an exemplary embodiment provides a display apparatus which displays broadcast information of a three-dimensional (3D) image, the display apparatus including: a signal receiver which receives the broadcasting signal comprising broadcasting information of each channel included in the broadcasting signal, wherein the received broadcasting information comprises the broadcast information of the 3D image; an image processor which processes the received broadcasting signal to display an image; a display unit which displays the image and the broadcasting information based on the received broadcasting signal; and a controller which, upon receiving a user request for displaying a 3D broadcasting list, searches the received broadcasting information of each channel, identifies the 3D image among the broadcasting information and displays the broadcasting information of the 3D image by channel on the display unit, and upon receiving a selection of a desired channel by a user, the controller changes to the desired channel selected by a user.
[0009] Each channel may display broadcasting information of the 3D image comprising an exclusive 3D broadcasting channel and a two-dimensional (2D) broadcasting channel.
[0010] The searching of the received broadcasting information by the controller may include searching the received broadcasting information by channel for broadcasting programs which are currently being broadcast.
[0011] If the user inputs time information or if a predetermined time is set automatically via the received broadcasting information, the searching of the received broadcasting information by the controller may include searching the received broadcasting information by channel for at least one broadcast corresponding to one of the predetermined time and the time information input by the user.
[0012] The broadcasting information of the 3D image may include a channel name, a broadcasting time and summary information of broadcasting programs.
[0013] The broadcasting information of the 3D image may further include rating information of the broadcasting programs.
[0014] The broadcasting information of the 3D image may include 3D information of the image.
[0015] The 3D information of the image may include 3D mode information, which comprises a side-by-side mode, a top-bottom mode, a checkerboard mode, a frame sequence mode and a frame package mode.
[0016] The display apparatus may further include a storage unit which stores broadcasting information of the searched for 3D image by channel.
[0017] An aspect of an exemplary embodiment provides a control method of a display apparatus displaying broadcasting information of a three-dimensional (3D) image, the control method including: receiving broadcasting information of each channel included in the broadcasting signal, wherein the broadcasting information comprises the broadcasting information of the 3D image; receiving a user request for displaying a 3D broadcasting list; searching the received broadcasting information of each channel for the 3D image; displaying the broadcasting information of the searched for 3D image by channel; and changing to a channel selected by the user.
[0018] Each channel may include an exclusive 3D broadcasting channel and a two-dimensional (2D) broadcasting channel.
[0019] The searching of the broadcasting information may include searching the broadcasting information by each channel for broadcasting programs which are currently being broadcast.
[0020] If the user inputs time information or a predetermined time is set automatically via the broadcasting information, the searching may include searching the broadcasting information by each channel for broadcasting programs broadcast at a time corresponding to one of the predetermined time and the time information input by the user.
[0021] The broadcasting information of the 3D image may include a channel name, a broadcasting time and summary information of broadcasting programs.
[0022] The broadcasting information of the 3D image may further include rating information of the broadcasting programs.
[0023] The broadcasting information of the 3D image may include 3D information of the image.
[0024] The 3D information of the image may include 3D mode information, which comprises a side side-by-side mode, a top-bottom mode, a checkerboard mode, a frame sequence mode and a frame package mode.
[0025] The method may further include storing the broadcasting information of the searched for 3D image by channel.
[0026] The 3D broadcasting list may be displayed in an OSD format.
[0027] The control method may further include displaying a 2D broadcasting list in the OSD format.
[0028] An aspect of an exemplary embodiment provides a display apparatus which communicates with a remote controller and displays broadcasting information of a three-dimensional (3D) image, the display apparatus including: a signal receiver which receives broadcasting information of each channel in a broadcasting signal, wherein the received broadcasting information comprises the broadcasting information of the 3D image; an image processor which processes the received broadcasting signal to display an image; a display unit which displays the image and the received broadcasting information; and a controller which searches the received broadcasting information of each channel, identifies a 3D image among the received broadcasting information, stores the broadcasting information of the 3D image by channel, receives a selection by a user through the remote controller for a desired 3D broadcasting channel and changes to the desired 3D broadcasting channel based on the received selection by the user through the remote controller.
[0029] An aspect of an exemplary embodiment provides a control method of a display apparatus which communicates with a remote controller and displays broadcasting information of a three-dimensional (3D) image, the control method including: receiving broadcasting information of each channel, wherein the broadcasting information comprises the 3D broadcasting information; searching the received broadcasting information of each channel for the 3D image; storing the broadcasting information of the 3D image by channel; receiving a selection by a user through the remote controller for a desired 3D broadcasting channel; and changing to the desired 3D broadcasting channel based on the received selection by the user through the remote controller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The above and/or other aspects will become apparent and more readily appreciated from the following description of the exemplary embodiments, taken in conjunction with the accompanying drawings, in which:
[0031] FIG. 1 is a block diagram of a display apparatus which displays broadcasting information of a 3D image according to an exemplary embodiment;
[0032] FIG. 2 illustrates an example of broadcasting information of a 3D image displayed in the display apparatus according to the exemplary embodiment;
[0033] FIG. 3 illustrates an example of broadcasting information of a 3D image displayed in the display apparatus according to another exemplary embodiment;
[0034] FIG. 4 illustrates an example of broadcasting information of a 3D image displayed in the display apparatus according to another exemplary embodiment;
[0035] FIG. 5 is a flowchart of a control method of the display apparatus displaying broadcasting information of a 3D image according to an exemplary embodiment; and
[0036] FIG. 6 is a flowchart of a control method of the display apparatus displaying broadcasting information of a 3D image according to another exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0037] Below, exemplary embodiments will be described in detail with reference to accompanying drawings so as to be easily realized by a person having ordinary knowledge in the art. The exemplary embodiments may be embodied in various forms without being limited to the exemplary embodiments set forth herein. Descriptions of well-known parts are omitted for clarity, and like reference numerals refer to like elements throughout.
[0038] FIG. 1 is a block diagram of a display apparatus which displays broadcasting information of a 3D image according to an exemplary embodiment.
[0039] Referring to FIG. 1 , a display apparatus 1 includes a signal receiver 10 , a controller 20 , a storage unit 30 , an image processor 40 and a display unit 50 . The display apparatus 1 may include a digital TV such as a liquid crystal display (LCD) television (TV), a light-emitting diode (LED) TV or plasma display panel (PDP) TV. The signal receiver 10 receives a broadcasting signal by channel in the form of wireless or wired signal. The broadcasting signal includes image information and broadcasting information. The image processor 40 processes a broadcasting signal input by the signal receiver 10 to display an image. The display unit 50 displays thereon image information and broadcasting information based on a broadcasting signal input by the image processor 40 . The controller 20 controls the storage unit 30 and the image processor 40 according to a broadcasting signal input by the signal receiver 10 . The controller 20 searches a field displaying a 3D image from the broadcasting information by channel and displays on the display unit 50 the broadcasting information by channel corresponding to a 3D image upon receiving an external input to display a 3D broadcasting list in an on-screen display (OSD) format on the display unit 50 . A user may select one of channel information displayed by channel on the display unit 50 and view the corresponding 3D image. A user may select one of channel information displayed by channel on the display unit 50 and view the includes image information and broadcasting info.
[0040] For example, if a user executes a “3D broadcasting list” by using a menu of the display apparatus 1 or a menu of a remote controller, 3D information is extracted from received broadcasting information of all channels. In the case of a broadcast under the Advanced Television Systems Committee (ATSC) standard, the 3D information is extracted by using program and system information protocol (PSIP) to be displayed in the OSD format on the display unit 50 . In the case of Digital Video Broadcasting (DVB), the 3D information is extracted by using a system information (SI) table to be displayed in the OSD format on the display unit 50 . A user may select one of the 3D information from the OSD menu by using a mouse or a channel moving key to view the 3D image of the channel.
[0041] The storage unit 30 stores therein the broadcasting information of the 3D image searched by the controller 20 by channel. The broadcasting information of the 3D image is displayed on the display unit 50 by channel after being stored in the storage unit 30 . Each channel includes an exclusive 3D broadcasting channel (i.e., a channel which is exclusively a 3D broadcasting channel) and a 2D broadcasting channel. Each broadcasting station may provide an exclusive 3D broadcasting channel as well as a 2D broadcasting channel as a normal broadcasting channel, and may transmit a 3D image by using a 2D broadcasting channel.
[0042] Upon receiving a request for displaying a 3D broadcasting list, the controller 20 searches broadcasting information by channel which is currently being broadcast. For example, based on the time at which the request for 3D broadcasting list is received, the controller 20 identifies whether the broadcasting program(s) provided at the current time by the exclusive 3D broadcasting channel and the 2D broadcasting channel is 3D, and displays broadcasting information corresponding to a 3D image by channel on the display unit 50 . According to another exemplary embodiment, a user may wish to view broadcasting information of a 3D image by channel at particular time instead of at the current time. If a user sets a desired time for the search by using a menu of the display apparatus 1 or a menu of a remote controller and executes the “3D broadcasting list”, the controller 20 searches broadcasting information of the time set for the exclusive 3D broadcasting channel and 2D broadcasting channel and displays broadcasting information of the 3D image by channel on the display unit 50 . According to another exemplary embodiment, if a user does not set the time and only executes the “3D broadcasting list”, not only broadcasting information of the 3D image by channel at the current time but also broadcasting information of all 3D images after the current time may be displayed on the display unit 50 .
[0043] In the foregoing exemplary embodiments, displaying broadcasting information upon a user's request has been described. However, broadcasting information may be displayed even without a user's request. For example, if the display apparatus 1 is turned on, the controller 20 may search broadcasting information of each channel and display broadcasting information of a 3D image by channel on the display unit 50 . Upon receiving a request for displaying a broadcasting list, but not the 3D broadcasting list, the controller 20 may search broadcasting information of each channel and separately display broadcasting information of a 2D image and of a 3D image. Then, a user may move channels in the 2D broadcasting list only or move channels in the 3D broadcasting list only to thereby conveniently select 2D or 3D broadcasting.
[0044] The broadcasting information of a 3D image includes a channel name transmitting a corresponding image, broadcasting time for the concerned image and a title of the corresponding image. The broadcasting information of the 3D image may further include summary information of the image other than the title of the image.
[0045] The broadcasting information of the 3D image may further include rating information of a corresponding image. If the rating information is displayed, the corresponding image may not be exposed to children and teenagers.
[0046] The broadcasting information of the 3D image may include 3D information of a corresponding image. For example, the broadcasting information of the 3D image may include 3D mode information (e.g., side by side, top-bottom, checkerboard, frame sequence and frame package) so that a user may set the 3D mode of the display apparatus 1 according to the 3D mode information of the corresponding image. For example, if the display apparatus 1 is set in top-bottom mode and the corresponding image is transmitted in side-by-side mode, a user may change the 3D mode of the display apparatus 1 to side by side based on the 3D mode information displayed on the display unit 50 .
[0047] In the foregoing exemplary embodiments, the broadcasting information of the 3D image is displayed on the display unit 50 and the channel is changed to a channel selected by a user. However, a user may select a 3D broadcasting channel while the broadcasting information of the 3D image is not displayed on the display unit 50 .
[0048] More specifically, upon receiving broadcasting information of each channel included in a broadcasting signal, the controller 20 searches broadcasting information of each channel, identifies a 3D image, automatically stores broadcasting information of the 3D image by channel and changes to a 3D broadcasting channel selected by a user through a remote controller.
[0049] For example, if the display apparatus 1 receives broadcasting information of each channel, the controller 20 searches which channel's image is 3D among broadcasting information of all channels being received, and automatically stores in the storage unit 20 the broadcasting information of the searched 3D image by channel. The broadcasting information of the 3D image automatically stored by channel may include not only broadcasting information of the 3D image by channel at the current time but also broadcasting information of all 3D images after the current time. If a user subsequently changes a plurality of channels which currently broadcast a 3D image by using an exclusive key for selecting a 3D broadcasting channel of a remote controller while viewing a 2D or a 3D broadcast, the controller 20 subsequently selects and changes to a channel which currently broadcasts a 3D image among channels broadcasting 3D images stored in the storage unit 30 .
[0050] FIG. 2 illustrates an example of broadcasting information of a 3D image displayed in the display apparatus according to an exemplary embodiment. FIG. 3 illustrates an example of broadcasting information of a 3D image displayed in the display apparatus according to another exemplary embodiment. FIG. 4 illustrates an example of broadcasting information of a 3D image displayed in the display apparatus according to another exemplary embodiment.
[0051] Referring to FIG. 2 , a 3D broadcasting list is displayed in an OSD format 60 on the display unit 50 . Upon receiving a user's request for displaying a 3D broadcasting list, the controller 20 searches broadcasting information of each channel at the current time (in this example, the current time is 18:20) and searches which channel provides a 3D image at 18:20. If the 3D image is searched, the controller 20 displays channel names (e.g., KBS, MBC, EBS and SBS) and displays 3D display, broadcasting title, and broadcasting schedule information 62 . A user may select a desired broadcasting program by using a mouse or a movement key 64 . In the foregoing exemplary embodiment, the display apparatus 1 displays the foregoing upon receiving a request for displaying the 3D broadcasting list. However, the foregoing may be displayed even without a user's request as described in FIG. 1 .
[0052] Referring to FIG. 3 , a 3D broadcasting list is displayed in an OSD format 70 on the display unit 50 . Upon receiving a user's request for displaying the 3D broadcasting list, the controller 20 searches broadcasting information of each channel at the current time (in this example, the current time is 3:45) and searches which channel provides a 3D image at 3:45. If the 3D image is searched, the controller 20 displays channel names (e.g., KBS 2-13, EBS 2-13, YTN 24-2, Channel CGV-3 and travel guide) 74 , and displays broadcasting time 76 , 3D mode information 74 and program summary information 80 of the corresponding broadcast. A user may select a desired broadcasting program by using a mouse or a movement key 86 . A user sets the 3D mode of the display apparatus 1 according to the 3D mode information 78 of the corresponding image. The 3D mode information 78 may include side side-by-side, top-bottom, checkerboard, frame sequence and frame package. A user may use the 3D mode information 78 to identify whether the corresponding image is a side side-by-side mode, a top-bottom mode, a checkerboard mode, a frame sequence mode or a frame package mode. If the display apparatus 1 is set in top-bottom mode, and a corresponding image is in a side-by-side mode, a user may set the display apparatus 1 in side by side according to the corresponding image. In the foregoing exemplary embodiment, the broadcasting information is displayed only upon request from a user. However, the broadcasting information may be displayed even without a user's request as described in FIG. 1 .
[0053] Referring to FIG. 4 , 2D and 3D broadcasting lists are displayed in an OSD format 90 on the display unit 50 . The broadcasting list may be displayed not only when the controller 20 receives a user's request but also when the display apparatus 1 is turned on and upon receiving a request for displaying the broadcasting list. A user may search and select a desired broadcasting list out of a 2D broadcasting list 92 and a 3D broadcasting list 94 .
[0054] FIG. 5 is a flowchart of a control method for displaying broadcasting information of a 3D image of the display apparatus according to an exemplary embodiment.
[0055] Referring to FIG. 5 , the display apparatus 1 receives broadcasting information of each channel through the signal receiver 10 (S 100 ). The display apparatus 1 receives a user's request for displaying a 3D broadcasting list through a menu of the display apparatus 1 or a remote controller (S 120 ). The controller 20 searches broadcasting information of each channel and stores the broadcasting information of the searched 3D image by channel in the storage unit 30 , and then displays the broadcasting information on the display unit 50 (S 140 ). A user may select and view a desired channel among broadcasting information of the 3D image of each channel displayed on the display unit 50 by using a mouse or a channel movement key.
[0056] FIG. 6 is a flowchart of a control method for displaying broadcasting information of a 3D image of the display apparatus according to another exemplary embodiment.
[0057] FIG. 6 illustrates a method of selecting a 3D broadcasting channel by a user while broadcasting information of the 3D image is not displayed on the display unit 50 .
[0058] The display apparatus 1 receives broadcasting information of each channel through the signal receiver 10 (S 200 ). The controller 20 of the display apparatus 1 searches received broadcasting information of each channel and identifies a 3D image (S 220 ). The controller 20 automatically stores in the storage unit 30 the broadcasting information of the identified 3D image by channel (S 240 ). Then a channel is changed to a 3D broadcasting channel selected by a user through an exclusive key for 3D broadcasting channel of a remote controller (S 260 ).
[0059] According to an exemplary embodiment, the display apparatus extracts broadcasting information of a 3D image only and displays the broadcasting information by channel. Thus, a user may easily and promptly changes a channel to a desired 3D broadcasting channel. The display apparatus displays 3D mode information in addition to the broadcasting information of the 3D image, and provides information on the type of 3D to which a user should set the display apparatus to view the corresponding program.
[0060] As described above, a display apparatus and a control method thereof which displays broadcasting information of a 3D image according to an exemplary embodiment may reduce a user's inconvenience in searching a 3D broadcasting channel by a user wearing 3D glasses if broadcasting stations provide 3D channels in the future.
[0061] Further, the display apparatus and the control method thereof according to an exemplary embodiment extracts broadcasting information of a 3D image only, displays broadcasting information of each channel and enables a user to easily and promptly change a channel to a desired broadcasting channel for viewing.
[0062] Further, the display apparatus and the control method thereof according to an exemplary embodiment displays 3D mode information in addition to broadcasting information of a 3D image, and provides information on setting a 3D mode to which a user should set the display apparatus to view the corresponding program.
[0063] Further, the display apparatus and the control method thereof according to an exemplary embodiment automatically stores broadcasting information of a 3D image by channel and enables a user to change and select a particular channel among channels broadcasting a 3D image by using an exclusive key of a remote controller even if broadcasting information of the 3D image is not displayed in the screen.
[0064] Although a few exemplary embodiments have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these exemplary embodiments without departing from the principles and spirit of the present inventive concept. | Disclosed are a display apparatus displaying broadcasting information of a three-dimensional (3D) image and a control method thereof, the display apparatus including: a signal receiver which receives broadcasting information of each channel comprised in a broadcasting signal; an image processor which processes the broadcasting signal to display an image; a display unit which displays thereon an image and broadcasting information based on the broadcasting signal; and a controller which searches the received broadcasting information of each channel, identifies a 3D image among the broadcasting information, displays the broadcasting information of the 3D image by channel on the display unit and changes into a channel selected by a user, upon receiving a user request for displaying a 3D broadcasting list. Accordingly, users are capable of changing into a desired broadcasting channel for viewing by extracting broadcasting information of a 3D image only and displaying broadcasting information of each channel. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the National Stage of International Application No. PCT/EP2014/075795, filed on Nov. 27, 2014, which claims priority to DE102013224507.6, filed Nov. 29, 2013, both of which are hereby incorporated by reference in its entirety.
FIELD
[0002] The disclosure relates to a detection method and device for localizing at least one particle moving in a flow.
[0003] The detection and localization of particles in a flow, and of particle clusters with an increased concentration in flows, plays an important role in many situations. An exemplary problem scenario is the monitoring and control of combustion processes. Here, for an ideal combustion process, a mass concentration of the fed substance that is homogeneous in time in the airflow is required. However, mechanical and flow-dynamic effects lead to the formation of inhomogeneities, so-called particle strands, and therefore to an inhomogeneous distribution of the mass flow. In order to introduce countermeasures, such inhomogeneities are identified and, the position thereof is determined.
[0004] Systems based on ultrasonic or microwave sensors are conventionally used for measuring a volume or mass flow without directly introducing a measurement apparatus into the airflow. Information about volume and mass distribution is obtained from the ratio of absorbed to reflected signal power. In the case of a plurality of coherent sensors, information about volume and mass distribution is obtained from transmitted power, and from a time-of-flight measurement. Here, microwave systems, for example, are based on a power measurement. Here, measurement errors occur more frequently when inhomogeneous substance concentrations occur, e.g. due to strand formation.
SUMMARY AND DESCRIPTION
[0005] It is the object of the disclosed embodiments for localizing a particle to improve the spatial resolution capability of a system for particle measurement, in particular of a microwave system.
[0006] The scope of the disclosed embodiments is defined solely by the appended claims and is not affected to any degree by the statements within this summary. The present embodiments may obviate one or more of the drawbacks or limitations in the related art.
[0007] One embodiment of a detection method for localizing at least one particle moving in a flow includes the acts of emitting a transmission signal by a transmitter and receiving a reflected reception signal. The reflected reception signal is frequency-modulated and phase-modulated in comparison with the transmission signal, by a receiver. In order to improve the spatial resolution capability, provision is made here for subsequently convolving the reception signal with at least one kernel that represents a conjugate, estimated channel pulse response. The reception signal may be convolved with an (integration) kernel to form a reconstructed particle position function, and the position of the particle is determined from the reconstructed particle position function. Thus, conversely, a convolution of the kernel or integration kernel with an ideal particle position function describes the reception signal. Below, the terms kernel and integration kernel are used synonymously. In particular, the transmission and reception signals can be microwave signals. A substantial advantage of the method described here lies in the employed deterministic signal model, enabling a high adaptability to different situations. Advantageously, individual positions in the flow may be “illuminated” in a targeted manner (e.g. the kernel fitting to a specific position can be used in a targeted manner for the convolution). Thus, specific spatial regions may be analyzed in a targeted and precise manner and, correspondingly, it is possible to detect particles that are localized there. A further advantage is that the processing leads directly to a specific image of the spatial coordinates such that a manual, visual interpretation is also possible. If a plurality of sensors are used for multidimensional localization or simply for increasing the detection reliability or detection accuracy, there is no need for a phase or frequency precise coherence of the sensors. Hence there is no need for adjustment of the sensors amongst themselves since the method only evaluates the data from a single sensor in each case. Extending the method by additional sensors or by the data of additional sensors can thus be readily carried out. Moreover, the method does not assume a specific transmission signal form or sensor architecture. A mono-frequency single-channel sensor is realizable with a low switching complexity and therefore in a cost-effective manner, is sufficient. By contrast, the method can likewise be applied in the case of more complicated architectures, for example in a sensor with a frequency-modulated continuous-wave (FMCW) signal form. Then, due to additional possibilities of signal processing, a correspondingly higher capability (e.g., a lower error rate and false detection rate and a higher localization accuracy) is to be expected. It is also advantageous that the required convolution operations can be represented compactly in the frequency domain and can be carried out efficiently with logarithmic complexity.
[0008] In a preferred embodiment, provision is made for the convolution to be carried out a number of times with a different kernel of a family of kernels in each case. A kernel of the family in each case corresponds to a different expected particle position function. The position is determined from the obtained family of reconstructed particle position functions. Individual positions in the flow are analyzed, as well as a plurality of positions are analyzed. Certain positions are also masked (e.g., cannot be analyzed) in a targeted manner. The number and form of the kernel functions is moreover variable, and the kernels are present per se in a separated form. Accordingly, the method can also be scaled and parallelized, depending on desired resolution capability and available computational power.
[0009] Here, provision is made in a further embodiment for the kernels to be assigned in each case to particle position functions that, in each case, describe particle positions that are distributed along a principal movement direction of the particles in the flow (e.g., at least substantially parallel to a principal movement direction of the particles). This is advantageous in that the expected inhomogeneities, in the form of particle strands along the principal movement directions of the particles in the flow, can be identified efficiently.
[0010] In a further embodiment, provision is made for determining the position to contain a superposition of the reconstructed particle position functions. For example, a superposition of the reconstructed particle position functions form a two-dimensional or three-dimensional image in spatial coordinates. Advantageously, an automatic particle detection based on such images is easily derivable and extendable as desired. To this end, many methods of image processing and pattern recognition (both statistical and deterministic methods) are conceivable and expedient. Naturally, a manual, visual interpretation is also possible in a simple manner.
[0011] In a particularly advantageous embodiment, provision is made for the detection method to be applied to a particle flow (e.g., a multiplicity of particles which move in a flow). After the positions of particles in the particle flow are determined, provision is made for those positions of particles belonging together due to an assumed, predetermined statistically-dependent distribution to be extracted. The positions are mapped onto a probability function. Advantageously, the employed deterministic signal model also allows conclusions to be drawn about the behavior of the present particle distribution in addition to the high adaptability to various situations. If the particle distribution follows a purely stochastic process, then the deviation from the specially defined, deterministic model is clearly identifiable in the result of the method. If a specific image in spatial coordinates arises within the scope of the method, detection of strand-shaped inhomogeneities in the flow is also efficiently performed based on the images via methods of image processing and pattern recognition.
[0012] Here, provision can be made for the probability function to be used to determine whether there is an inhomogeneous distribution of particles within the particle flow. If so, provision is made for the inhomogeneity to be localized based on at least one maximum of the probability function. For example, one possible maximum is the absolute maximum. This is advantageous in that localizing the inhomogeneity or the particle strand is automatable in a simple and efficient manner.
[0013] In accordance with a further embodiment, provision is made for reception signal and/or kernel (e.g., convolution kernels) to be each selected to have a complex value. The number of virtual positions of particles is advantageously reduced (e.g., the number of interferences induced by the convolution between the different functions when many particles are significantly reduced for image-based post-processing). That is, the virtual positions of particles are more readily manageable. A virtual position of a particle is understood here to mean a “false” particle position; the method suggests the existence of a particle even though none is situated there (e.g., a so-called “false positive”).
[0014] In a further embodiment, provision is made for spectral tapering of the reception signal or kernel to be undertaken in each case. This is advantageous in that the waviness of the convolution result, caused by a band-restriction of the modulation, is reduced. The number of virtual particle positions or virtual points or the possible particle positions occurring in spatial coordinates in a two-dimensional or three-dimensional image is reduced. The particle visibility significantly improves in such a representation in the movement direction of the particles.
[0015] Additionally, provision can be made here for high-pass filtering of reception signal and/or kernel after the tapering. This is advantageous in that a resolution capability in a direction perpendicular to the movement direction of the particles is improved.
[0016] Some embodiments include a detection device for localizing at least one particle moving in the flow. The detection device includes a sensor for emitting a transmission signal and for detecting a reception signal. The detection device also includes an evaluation unit. A frequency and a phase of the reception signal are detectable by the evaluation unit, and, in the evaluation unit, the reception signal is convolvable with at least one kernel representing a conjugated, estimated channel pulse response. A reconstructed particle position function is formed, and a position of the particle is determinable from the reconstructed particle position function. For example, a microwave sensor may be used.
DESCRIPTION OF THE FIGURES
[0017] Further features of the invention emerge from the following description of preferred exemplary embodiments of the invention, and from the figures. Here:
[0018] FIG. 1 illustrates an exemplary particle flow in accordance with an embodiment of detection for localizing a particle.
[0019] FIG. 2 illustrates an exemplary frequency and phase modulated reception signal corresponding to particle flow of FIG. 1 .
[0020] FIG. 3 illustrates a schematic of an exemplary embodiment with a plurality of used kernels;
[0021] FIG. 4 illustrates a simulation result for a particle flow with an inhomogeneity that can be localized with one embodiment of detection for localizing a particle; and
[0022] FIG. 5 illustrates a probability function extracted from the example in FIG. 4 .
[0023] In the Figures, the same or functionally equivalent elements are provided with the same reference signs.
DETAILED DESCRIPTION
[0024] FIG. 1 illustrates an exemplary particle flow that may be applicable to disclosed embodiments of detection methods for localizing a particle. Here, a particle 1 moves past a sensor 5 in a flow channel 10 in a manner parallel to the principal flow direction 3 . Flow direction 3 is symbolized by an arrow. The particle 1 successively assumes different positions 2 , that are all distributed parallel to the principal flow direction 3 . In addition to the current position x 2 of the particle 1 , two earlier positions x 0 and x 1 of the particle 1 are also marked separately. Thus, the position x 0 was taken up by the particle 1 at a time before the position x 1 , that was, in turn, taken up prior to the current position x 2 . In all of the positions assumed by the particle 1 , the latter reflects a reception signal 4 in the direction of the sensor 5 . The radial component of the movement of the particle relative to the sensor 5 (e.g. a microwave sensor) generates a frequency shift in the reflected reception signal 4 due to the Doppler effect. With the advancing movement of the particle 1 along the principal flow direction 3 , there is a change in the aspect angle relative to the sensor 5 . Consequently, there is a change in the radial component of the velocity relative to the sensor 5 , as well as in the resulting Doppler shift. While the particle 1 “flies by”, the reflected reception signal 4 experiences a continuous frequency and phase modulation (as illustrated in FIG. 2 ) that is characteristic and unique for the traveled trajectory of the particle 1 (e.g., for all previously taken up positions 2 of the particle 1 and the current position thereof).
[0025] FIG. 2 shows an exemplary frequency-modulated and phase-modulated reception signal 4 corresponding to the situation shown in FIG. 1 . The real part of the reception signal 4 is plotted along the x-axis. FIG. 1 illustrates that the x-axis is oriented parallel to the principal flow direction 3 . There is a different phase and frequency modulation in each case at the three positions x 0 , x 1 and x 2 , corresponding to the positions x 0 , x 1 and x 2 of FIG. 1 . Considered mathematically, the reception signal 4 therefore arises by convolving the channel pulse response or pulse response with a particle position function. The inverse problem is solved for reconstructing the position x 0 , x 1 , x 2 etc. of the particle 1 by deconvolving with a conjugated, estimated pulse response represented by the kernel.
[0026] The underlying principle of Doppler modulation as a result of target movement, in conjunction with imaging methods may be found in the field of the naval and air forces under the term “inverse synthetic aperture radar”. However, in those conventional methods, the target position is assumed to be known or explicitly measured; moreover, the dimensions of the considered objects have significantly larger sizes. The dimensions are more suitable for microwaves as a matter of principle, and different problems arise in that case.
[0027] FIG. 3 depicts a schematic of an exemplary embodiment using multiple kernels. A signal-adapted filter bank is based on a family of kernel functions (e.g., kernels 7 ) that correspond to a subset of the expected particle trajectories (e.g., the expected particle position functions and the corresponding phase-modulated reception signal 4 ). The flow channel 10 is initially subdivided into a plurality of sections 6 that all have an equal extent in the y-direction, i.e. perpendicular to the principal flow direction 3 . At the same time, each section 6 respectively covers the whole flow channel 10 in the x-direction, parallel to the principal flow direction 3 . However, in principle, the sections 6 can be selected in any way. What is important is a correct assignment of the kernels 7 , as illustrated in the center of FIG. 3 . Each of the kernels 7 corresponds to the section 6 directly to the left thereof. The kernels 7 are each convolved with the one reception signal 4 to form a particle position function. The individual results of the convolution are put together to form a two-dimensional image 8 . The results are sorted in accordance with the arrangement of the sections 6 or of the kernels 7 , as result of which a spatially accurate image of the particle position functions emerges. Large magnitudes of the reconstructed particle position function are depicted to be bright, and small magnitudes are depicted to be dark. Two lines 9 emerge, and the point of intersection determines the position of the particle. The position is made visible by way of the coordinates xP and yP. Thus, different convolution kernels (e.g., kernels 7 ) are formed within the flow. All convolution results are assigned to corresponding source positions and superposed with one another such that an two-dimensional image arises in spatial coordinates. An individual particle in this image may generate a x-shaped convolution result. What is decisive in this case for the obtained resolution is the modulation width and the exact reproduction of the modulation function in the kernel 7 . Here, the maximum of a convolution result represents the position of the particle in the x-direction (e.g., in the direction of the principal flow direction 3 ). The selected modulation function in the kernel 7 determines the direction in the y-direction (e.g., perpendicular to the principal flow direction 3 ). A deviation of the phase center of the actual pulse response from the estimated pulse response is expressed in an offset of the result in the x-direction. A deviation of the modulation function of the actual pulse response from the estimated pulse response is expressed here in an offset of the result (e.g., the particle position function) in the y-direction.
[0028] FIG. 4 depicts a simulation result for a particle flow having an inhomogeneity that can be localized using one embodiment of the detection method. A multiplicity of crossing lines 9 are plotted along the spatial coordinates in the x and y direction. To aid orientation, the location of the sensor 5 has also been plotted. The particle flow, the particles 1 that have been detected and depicted graphically, flows past the sensor 5 in a manner parallel to the x-direction. A homogeneous particle distribution in the flow follows a stochastic process. However, in the case of an inhomogeneity (e.g., a strand formation, a statistical dependence of the particles 1 that form the strands) arises in the y-direction. In accordance with the relationship illustrated in FIG. 3 , the modulation signal of such a strand consists of the superposition of all frequency and phase contributions of the individual particles 1 . In the case of a strand 11 , a succession of points of intersection of lines 9 emerges in the reconstructed image. When many particles 1 are present, many crossing line pairs that do not have physical particles as a cause arise. The crossing line pairs not associated with physical particles are also referred to as virtual points of intersection or virtual particles. The virtual particles may be identified and eliminated via suitable pre- and post-processing steps. It is expedient to select reception signals 4 and the kernel 7 to have complex values since the convolution requires the conjugate of the pulse response. Although particles 1 are detectable with real-valued basis signals, the number of virtual particles or the set of “convolution interference” in the case of many particles 1 is significantly more difficult to manage for image-based post-processing. It is also expedient to undertake spectral tapering of reception signal 4 and kernel 7 for reducing the waviness of the convolution result that is caused by the band-restriction of the modulation. This significantly reduces the number of virtual particles and significantly improves the particle visibility in such a representation in the transverse direction, e.g., in the x-direction. Finally, high-pass filtering of reception signal 4 and kernel 7 may be performed to improve the resolution capability in the y-direction again, that was made worse by tapering. High-pass filtering may be performed in advance, shifting a weighting toward a steady component; high-pass filtering can also be performed without tapering in advance. Then, it is possible to identify a strand 11 along the position Y. Hence, if related to the flow channel 10 (e.g. a feed line to the burner in a coal power plant) it is possible to carry out strand-independent mass flow determinations, detect inhomogeneities in an air-coal dust mixture, and introduce countermeasures in order to return to homogeneous mixing.
[0029] FIG. 5 depicts a probability function 12 extracted from the image of FIG. 4 . Here, a relative probability P is plotted along the y-direction, the direction perpendicular to the principal flow direction 3 . A maximum at the position Y, as illustrated in FIG. 4 , is the position of the strand 11 , can clearly be identified. Hence, the position Y of the strand 11 can also easily be identified automatically. Here, the probability function 12 was created via the points of intersection of the lines 9 . The points of intersection that belong together are the group of points with an assumed statistically dependent distribution initially extracted via suitable image-processing methods and subsequently mapped onto a probability function 12 . These probabilities then serve as a decision basis for a detection of the strand 11 . Since extraction of the points of intersection is based on spatial coordinates, the distance of the strand 11 , or of the particles 1 contained in this strand 11 , is known directly. By way of example, if the strand 11 should now be localized in a three-dimensional space, it is possible to uniquely determine the position of the strand 11 in the three-dimensional space via further sensors that are arranged distributed in space with the disclosed detection methods and, for example, by triangulating the distances.
[0030] It is to be understood that the elements and features recited in the appended claims may be combined in different ways to produce new claims that likewise fall within the scope of the present invention. Thus, whereas the dependent claims appended below depend from only a single independent or dependent claim, it is to be understood that these dependent claims may, alternatively, be made to depend in the alternative from any preceding or following claim, whether independent or dependent, and that such new combinations are to be understood as forming a part of the present specification.
[0031] While the present invention has been described above by reference to various embodiments, it may be understood that many changes and modifications may be made to the described embodiments. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting, and that it be understood that all equivalents and/or combinations of embodiments are intended to be included in this description. | Detection for localizing at least one particle moving in a flow includes emitting a transmission signal by a transmitter, and receiving a reflected reception signal. The reflected reception signal is frequency and phase modulated in comparison with the transmission signal. The reflected reception signal is convolved with at least one kernel representative of a conjugate estimated channel pulse response. A reconstructed particle position function is formed, and the position of the particle is determined from the reconstructed particle position function. | 6 |
FIELD OF THE INVENTION
The present invention relates, in general, to ultrasonic surgical clamping instruments and, more particularly, to an improved force limiting mechanism for an ultrasonic surgical clamping instrument.
BACKGROUND OF THE INVENTION
This application is related to the following copending patent application: Application Ser. No. 08/948,625 filed Oct. 10, 1997; Application Ser. No. 08/949,133 filed Oct. 10, 1997; Application Ser. No. 09/106,686 filed Jun. 29, 1998; Application Ser. No. 09/337,077 filed Jun. 21, 1999; Application Ser. No. 09/412,557 filed Oct. 5, 1999; Application Ser. No. 09/412,257 filed Oct. 5, 1999; Application Ser. No. 09/413,225 filed Oct. 5, 1999, which are incorporated herein by reference.
Ultrasonic instruments, including both hollow core and solid core instruments, are used for the safe and effective treatment of many medical conditions. Ultrasonic instruments, and particularly solid core ultrasonic instruments, are advantageous because they may be used to cut and/or coagulate organic tissue using energy in the form of mechanical vibrations transmitted to a surgical end-effector at ultrasonic frequencies. Ultrasonic vibrations, when transmitted to organic tissue at suitable energy levels and using a suitable end-effector, may be used to cut, dissect, or cauterize tissue. Ultrasonic instruments utilizing solid core technology are particularly advantageous because of the amount of ultrasonic energy that may be transmitted from the ultrasonic transducer through the waveguide to the surgical end-effector. Such instruments are particularly suited for use in minimally invasive procedures, such as endoscopic or laparoscopic procedures, wherein the end-effector is passed through a trocar to reach the surgical site.
Ultrasonic vibration is induced in the surgical end-effector by, for example, electrically exciting a transducer which may be constructed of one or more piezoelectric or magnetostrictive elements in the instrument hand piece. Vibrations generated by the transducer section are transmitted to the surgical end-effector via an ultrasonic waveguide extending from the transducer section to the surgical end-effector.
Solid core ultrasonic surgical instruments may be divided into two types, single element end-effector devices and multiple-element end-effector. Single element end-effector devices include instruments such as scalpels, and ball coagulators, see, for example, U.S. Pat. No. 5,263,957. While such instruments as disclosed in U.S. Pat. No. 5,263,957 have been found eminently satisfactory, there are limitations with respect to their use, as well as the use of other ultrasonic surgical instruments. For example, single-element end-effector instruments have limited ability to apply blade-to-tissue pressure when the tissue is soft and loosely supported. Substantial pressure is necessary to effectively couple ultrasonic energy to the tissue. This inability to grasp the tissue results in a further inability to fully coapt tissue surfaces while applying ultrasonic energy, leading to less-than-desired hemostasis and tissue joining.
The use of multiple-element end-effectors such as clamping coagulators include a mechanism to press tissue against an ultrasonic blade, that can overcome these deficiencies. A clamp mechanism disclosed as useful in an ultrasonic surgical device has been described in U.S. Pat. Nos. 3,636,943 and 3,862,630 to Balamuth. Generally, however, the Balamuth device, as disclosed in those patents, does not coagulate and cut sufficiently fast, and lacks versatility in that it cannot be used to cut/coaglulate without the clamp because access to the blade is blocked by the clamp.
Ultrasonic clamp coagulators such as, for example, those disclosed in U.S. Pat. Nos. 5,322,055 and 5,893,835 provide an improved ultrasonic surgical instrument for cutting/coagulating tissue, particularly loose and unsupported tissue, wherein the ultrasonic blade is employed in conjunction with a clamp for applying a compressive or biasing force to the tissue, whereby faster coagulation and cutting of the tissue, with less attenuation of blade motion, are achieved. However, for optimal tissue coagulation and cutting speed it is desirable to prevent application of excessive clamping force, while providing good tactile feedback to the instrument's user. A force limiting clamping mechanism has been described in U.S. patent application Ser. No. 08/949,133 filed Oct. 10, 1997, and previously incorporated herein by reference.
Improvements in technology of curved ultrasonic instruments such as described in U.S. patent application Ser. No. 09/106,686 previously incorporated herein by reference, have created needs for improvements in other aspects of curved clamp coagulators. For example, U.S. Pat. No. 5,873,873 describes an ultrasonic clamp coagulating instrument having an end-effector including a clamp arm comprising a tissue pad. In the configuration shown in U.S. Pat. No. 5,873,873 the clamp arm and tissue pad are straight.
Although the force limiting mechanism described in U.S. patent application Ser. No. 08/949,133 has proven eminently successful, it would be advantageous to provide an improved force limiting feature on an ultrasonic surgical instrument. It would be advantageous for the improved force limiting mechanism to be small and easily incorporated into the instrument, to facilitate small ergonomic instrument designs with ease of manufacturing and a robust design.
SUMMARY OF THE INVENTION
An improved force limiting feature is described for use with an ultrasonic surgical instrument. An ultrasonic clamp coagulator apparatus is described including a housing, an actuator, an outer tube having a proximal end joined to the housing, and a distal end. An actuating element is reciprocably positioned within the outer tube and operatively connected to the actuator. An ultrasonic waveguide is positioned within the outer tube, with an end-effector extending distally from the distal end of the outer tube. A clamp arm is pivotally mounted on the distal end of the outer tube for pivotal movement with respect to the end-effector for clamping tissue between the clamp arm and the end-effector. The clamp arm is operatively connected to the actuating element so that reciprocal movement of the actuating element pivots the clamp arm. There is an actuation mechanism within the housing, connected between the clamp arm and the actuator. The actuation mechanism is adapted to actuate the clamp arm pivotably with respect to the end-effector. In one embodiment the actuation mechanism includes a wave spring for limiting the force applied to the clamp arm from the actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to organization and methods of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates an ultrasonic surgical system including an elevational view of an ultrasonic generator, a sectioned plan view of an ultrasonic transducer, and a partially sectioned plan view of a clamp coagulator in accordance with the present invention;
FIG. 2A is an exploded perspective view of a portion of a clamp coagulator in accordance with the present invention;
FIG. 2B is an exploded perspective view of a portion of a clamp coagulator in accordance with the present invention;
FIG. 3 is a partially sectioned plan view of a clamp coagulator in accordance with the present invention with the clamp arm assembly shown in an open position;
FIG. 4 is a partially sectioned plan view of a clamp coagulator in accordance with the present invention with the clamp arm assembly shown in a closed position;
FIG. 5 is a side view of a collar cap of the clamp coagulator;
FIG. 6 is a front view of a collar cap of the clamp coagulator;
FIG. 7 is a side view of a force limiting spring of the clamp coagulator;
FIG. 8 is a front view of a force limiting spring of the clamp coagulator;
FIG. 9 is a side view of a washer of the clamp coagulator;
FIG. 10 is a front view of a washer of the clamp coagulator;
FIG. 11 is a side view of a tubular collar of the clamp coagulator;
FIG. 12 is a rear view of a tubular collar of the clamp coagulator;
FIG. 13 is a front view of a tubular collar of the clamp coagulator;
FIG. 14 is a side view of an inner knob of the clamp coagulator;
FIG. 15 is a front view of an inner knob of the clamp coagulator;
FIG. 16 is a bottom view of an inner knob of the clamp coagulator;
FIG. 17 is a rear view of an outer knob of the clamp coagulator;
FIG. 18 is a top view of an outer knob of the clamp coagulator;
FIG. 19 is a top view of a yoke of the clamp coagulator;
FIG. 20 is a side view of a yoke of the clamp coagulator;
FIG. 21 is a front view of a yoke of the clamp coagulator;
FIG. 22 is a perspective view of a yoke of the clamp coagulator;
FIG. 23 is a perspective view of an end-effector of the clamp coagulator;
FIG. 24 is a top perspective view of a clamp arm of the camp coagulator;
FIG. 25 is a top view of an end-effector of the clamp coagulator;
FIG. 26 is a side view of an end-effector of the clamp coagulator with the clamp arm open;
FIG. 27 is a top view of a tissue pad of the clamp coagulator;
FIG. 28 is a side view of a tissue pad of the clamp coagulator;
FIG. 29 is a front view of a tissue pad of the clamp coagulator;
FIG. 30 is a perspective view of a tissue pad of the clamp coagulator;
FIG. 31 is a bottom perspective view of a clamp arm of the camp coagulator;
FIG. 32 is a first cross-sectional view of the clamp arm illustrated in FIG. 31; and
FIG. 33 is a second cross-sectional view of the clamp arm illustrated in FIG. 31 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in combination with ultrasonic instruments as described herein. Such description is exemplary only, and is not intended to limit the scope and applications of the invention. For example, the invention is useful in combination with a multitude of ultrasonic instruments including those described in, for example, U.S. Pat. Nos. 5,938,633; 5,935,144; 5,944,737; 5,322,055, 5,630,420; and 5,449,370.
FIG. 1 illustrates a plan view of an ultrasonic system 10 comprising an ultrasonic signal generator 15 with a sectioned plan view of a sandwich type ultrasonic transducer 82 , hand piece housing 20 , and clamp coagulator 120 in accordance with the present invention. Clamp coagulator 120 may be used for open or laparoscopic surgery. The ultrasonic transducer 82 , which is known as a “Langevin stack”, generally includes a transduction portion 90 , a first resonator or end-bell 92 , and a second resonator or fore-bell 94 , and ancillary components. The ultrasonic transducer 82 is preferably an integral number of one-half system wavelengths (nλ/2) in length as will be described in more detail later. An acoustic assembly 80 includes the ultrasonic transducer 82 , mount 36 , velocity transformer 64 and surface 95 .
The distal end of end-bell 92 is connected to the proximal end of transduction portion 90 , and the proximal end of fore-bell 94 is connected to the distal end of transduction portion 90 . Fore-bell 94 and end-bell 92 have a length determined by a number of variables, including the thickness of the transduction portion 90 , the density and modulus of elasticity of the material used to manufacture end-bell 92 and fore-bell 94 , and the resonant frequency of the ultrasonic transducer 82 . The fore-bell 94 may be tapered inwardly from its proximal end to its distal end to amplify the ultrasonic vibration amplitude as velocity transformer 647 or alternately may have no amplification.
The piezoelectric elements 100 may be fabricated from any suitable material, such as, for example, lead zirconate-titanate, lead meta-niobate, lead titanate, or other piezoelectric crystal material. Each of the positive electrodes 96 , negative electrodes 98 , and piezoelectric elements 100 has a bore extending through the center. The positive and negative electrodes 96 and 98 are electrically coupled to wires 102 and 104 , respectively. Wires 102 and 104 are encased within cable 25 and electrically connectable to ultrasonic signal generator 15 of ultrasonic system 10 .
Ultrasonic transducer 82 of the acoustic assembly 80 converts the electrical signal from ultrasonic signal generator 15 into mechanical energy that results in primarily longitudinal vibratory motion of the ultrasonic transducer 82 and an end-effector 180 at ultrasonic frequencies. When the acoustic assembly 80 is energized, a vibratory motion standing wave is generated through the acoustic assembly 80 . The amplitude of the vibratory motion at any point along the acoustic assembly 80 depends on the location along the acoustic assembly 80 at which the vibratory motion is measured. A minimum or zero crossing in the vibratory motion standing wave is generally referred to as a node (i.e., where motion is usually minimal), and an absolute value maximum or peak in the standing wave is generally referred to as an anti-node. The distance between an anti-node and its nearest node is one-quarter wavelength (λ/4).
Wires 102 and 104 transmit the electrical signal from the ultrasonic signal generator 15 to positive electrodes 96 and negative electrodes 98 . A suitable generator is available as model number GEN01, from Ethicon Endo-Surgery, Inc., Cincinnati, Ohio. The piezoelectric elements 100 are energized by an electrical signal supplied from the ultrasonic signal generator 15 in response to a foot switch 118 to produce an acoustic standing wave in the acoustic assembly 80 . The electrical signal causes disturbances in the piezoelectric elements 100 in the form of repeated small displacements resulting in large compression forces within the material. The repeated small displacements cause the piezoelectric elements 100 to expand and contract in a continuous manner along the axis of the voltage gradient, producing longitudinal waves of ultrasonic energy. The ultrasonic energy is transmitted through the acoustic assembly 80 to the end-effector 180 .
In order for the acoustic assembly 80 to deliver energy to end-effector 180 , all components of acoustic assembly 80 must be acoustically coupled to the ultrasonically active portions of clamp coagulator 120 . The distal end of the ultrasonic transducer 82 may be acoustically coupled at surface 95 to the proximal end of an ultrasonic waveguide 179 by a threaded connection such as stud 50 .
The components of the acoustic assembly 80 are preferably acoustically tuned such that the length of any assembly is an integral number of one-half wavelengths (nλ/2), where the wavelength λ is the wavelength of a pre-selected or operating longitudinal vibration drive frequency f d of the acoustic assembly 80 , and where n is any positive integer. It is also contemplated that the acoustic assembly 80 may incorporate any suitable arrangement of acoustic elements.
Referring now to FIGS. 2A and 2B, an exploded perspective view of the clamp coagulator 120 of the surgical system 10 in accordance with the present invention is illustrated. The clamp coagulator 120 is preferably attached to and removed from the acoustic assembly 80 as a unit. The proximal end of the clamp coagulator 120 preferably acoustically couples to the distal surface 95 of the acoustic assembly 80 as shown in FIG. 1 . It will be recognized that the clamp coagulator 120 may be coupled to the acoustic assembly 80 by any suitable means.
The clamp coagulator 120 preferably includes an instrument housing 130 , and an elongated member 150 . The elongated member 150 can be selectively rotated with respect to the instrument housing 130 as further described below. The instrument housing 130 includes a pivoting handle portion 136 , and a fixed handle 132 A and 132 B coupled to a left shroud 134 and a right shroud 138 respectively.
The right shroud 138 is adapted to snap fit on the left shroud 134 . The right shroud 138 is preferably coupled to the left shroud 134 by a plurality of inwardly facing prongs 70 formed on the right shroud 138 . The plurality of prongs 70 are arranged for engagement in corresponding holes or apertures 140 , which are formed in the left shroud 134 . When the left shroud 134 is attached to the right shroud 138 , a cavity is formed therebetween to accommodate various components, such as an indexing mechanism 255 as further described below.
The left shroud 134 , and the right shroud 138 of the clamp coagulator 120 are preferably fabricated from polycarbonate. It is contemplated that these components may be made from any suitable material without departing from the spirit and scope of the invention.
Indexing mechanism 255 is disposed in the cavity of the instrument housing 130 . The indexing mechanism 255 is preferably coupled or attached on inner tube 170 to translate movement of the handle portion 136 to linear motion of the inner tube 170 to open and close the clamp arm assembly 300 . When the pivoting handle portion 136 is moved toward the fixed handle portion 130 , the indexing mechanism 255 slides the inner tube 170 rearwardly to pivot the clamp arm assembly 300 into a closed position. The movement of the pivoting handle portion 136 in the opposite direction slides the indexing mechanism 255 to displace the inner tube 170 in the opposite direction, i.e., forwardly, and hence pivot the clamp arm assembly 300 into its open position.
The indexing mechanism 255 also provides a ratcheting mechanism to allow the elongated member 150 to rotate about its longitudinal axis relative to instrument housing 130 . The rotation of the elongated member 150 enables the clamp arm assembly 300 to be turned to a selected or desired angular position. The indexing mechanism 255 preferably includes a tubular collar 260 and yoke 280 .
The tubular collar 260 of the indexing mechanism 255 is preferably snapped onto the proximal end of the inner tube 170 and keyed into opposing openings 168 . The tubular collar 260 is preferably fabricated from polyetherimide. It is contemplated that the tubular collar 260 may be constructed from any suitable material.
Tubular collar 260 is shown in greater detail in FIGS. 11 through 13. The tubular collar 260 preferably includes an enlarged section 262 , and a bore 266 extending therethrough. The enlarged section 262 preferably includes a ring 272 formed around the periphery of the tubular collar 260 to form groove 268 . The groove 268 has a plurality of detents or teeth 269 for retaining the elongated member 150 in different rotational positions as the elongated member 150 is rotated about its longitudinal axis. Preferably, the groove 268 has twelve ratchet teeth to allow the elongated portion to be rotated in twelve equal angular increments of approximately 30 degrees. It is contemplated that the tubular collar 260 may have any number of teeth-like members. It will be recognized that the teeth-like members may be disposed on any suitable part of the tubular collar 260 without departing from the scope and spirit of the present invention.
Referring back now to FIGS. 2 through 4, the pivoting handle portion 136 includes a thumb loop 142 , a first hole 124 , and a second hole 126 . A pivot pin 153 is disposed through first hole 124 of handle portion 136 to allow pivoting as shown by arrow 121 in FIG. 3 . As thumb loop 142 of pivoting handle portion 136 is moved in the direction of arrow 121 , away from instrument housing 130 , a link 128 applies a forward force to yoke 280 , causing yoke 280 to move forward. Link 128 is connected to pivoting handle portion 136 by a pin 129 , and link 128 is connected to base 284 by a pin 127 .
Referring back now to FIG. 2, yoke 280 generally includes a holding or supporting member 282 and a base 284 . The supporting member 282 is preferably semicircular and has a pair of opposing pawls 286 that extend inwardly to engage with the teeth 269 of the tubular collar 260 . It is contemplated that the pawls 286 may be disposed on any suitable part of the yoke 280 for engagement with the teeth 269 of the tubular collar 260 without departing from the spirit and scope of the invention. It will also be recognized that the yoke 280 may have any number of ratchet arms.
Yoke 280 is shown in greater detail in FIGS. 19 through 22. The pivoting handle portion 136 preferably is partially disposed in a slot 147 of the base 284 of the yoke 280 . The base 284 also includes a base opening 287 , an actuator travel stop 290 , and a base pin-hole 288 . The pivot pin 153 is disposed through the base opening 287 . Yoke 280 pawls 286 transfer opening force to inner tube 170 through tubular collar 260 , resulting in the opening of clamp arm assembly 300 .
The yoke 280 of the clamp coagulator 120 is preferably fabricated from polycarbonate. The yoke 280 may also be made from a variety of materials including other plastics, such as ABS, NYLON, or polyetherimide. It is contemplated that the yoke 280 may be constructed from any suitable material without departing from the spirit and scope of the invention.
As illustrated in FIGS. 3 and 4, yoke 280 also transfers a closing force to clamp arm assembly 300 as pivoting handle portion 136 is moved toward instrument housing 130 . Actuator travel stop 290 contacts pivot pin 153 at the bottom of the stroke of pivoting handle portion 136 , stopping any further movement, or overtravel, of pivoting handle portion 136 . Pawls 286 of yoke 280 transfer force to tubular collar 260 through a washer 151 , a force limiting spring 155 , and collar cap 152 . Collar cap 152 is rigidly attached to tubular collar 260 after washer 151 and force limiting spring 155 have been assembled onto tubular collar 260 proximal to enlarged section 262 . Collar cap 152 is illustrated in greater detail in FIGS. 5 and 6. Force limiting spring 155 is illustrated in greater detail in FIGS. 7 and 8, and washer 151 is illustrated in greater detail in FIGS. 9 and 10. Thickness of washer 151 may be adjusted during design or manufacturing of clamp coagulator 120 to alter the pre-load of force limiting spring 155 . Collar cap 152 is attached to tubular collar 260 by ultrasonic welding, but may alternately be press fit, snap fit or attached with an adhesive.
Referring to FIGS. 5 through 10, tubular collar 260 , a washer 151 , force limiting spring 155 , and collar cap 152 provide a force limiting feature to clamp arm assembly 300 . As pivoting handle portion 136 is moved toward instrument housing 130 , clamp arm assembly 300 is rotated toward ultrasonic blade 88 . In order to provide both ultrasonic cutting, and hemostasis, it is desirable to limit the maximum force of clamp arm assembly 300 to 0.5 to 3.0 Lbs.
FIGS. 5 and 6 illustrate collar cap 152 including a spring surface 158 . FIGS. 7 and 8 illustrate force limiting spring 155 including a cap surface 156 , a washer surface 157 , and a plurality of spring elements 159 . Force limiting spring 155 is described in the art as a wave spring, due to the shape of spring elements 159 . It is advantageous to use a wave spring for force limiting spring 155 because it provides a high spring rate in a small physical size well suited to an ultrasonic surgical instrument application where a central area is open for ultrasonic waveguide 179 . Force limiting spring 155 is biased between spring surface 158 of collar cap 152 and spring face 165 of washer 151 . Washer 151 includes a pawl face 167 (FIGS. 9 and 10) that contacts pawls 286 of yoke 280 after assembly of clamp coagulator 120 (see FIGS. 2 through 4 ).
Referring now to FIGS. 2 and FIGS. 14 through 18, a rotational knob 190 is mounted on the elongated member 150 to turn the elongated member 150 so that the tubular collar 260 rotates with respect to the yoke 280 . The rotational knob 190 may be fabricated from polycarbonate. The rotational knob 190 may also be made from a variety of materials including other plastics, such as a polyetherimide, nylon, or any other suitable material.
The rotational knob 190 preferably has an enlarged section or outer knob 192 , an inner knob 194 , and an axial bore 196 extending therethrough. Inner knob 194 includes keys 191 that attach cooperatively to keyways 189 of outer knob 192 . The outer knob 192 includes alternating longitudinal ridges 197 and grooves 198 that facilitate the orientation of the rotational knob 190 and the elongated member 150 by a surgeon. The axial bore 196 of the rotational knob 190 is configured to snugly fit over the proximal end of the elongated member 150 .
The inner knob 194 extends through an opening 139 in the distal end of the instrument housing 130 . Inner knob 194 includes a channel 193 to rotatably attach inner knob 194 into opening 139 . The inner knob 194 of the rotational knob 190 has a pair of opposing holes 199 . The opposing holes 199 are aligned as part of a passageway 195 that extends through the elongated member 150 , as will be described later.
A coupling member, such as, for example, pin 163 , may be positioned through opposing holes 199 of the passageway 195 . The pin 163 may be held in the passageway 195 of the elongated member 150 by any suitable means, such as, for example, trapped between ribs in housing 130 , or a silicone or cyanoacrylate adhesive. The pin 163 allows rotational torque to be applied to the elongated member 150 from the rotational knob 190 in order to rotate the elongated member 150 .
When the rotational knob 190 is rotated, the teeth 269 of the tubular collar 260 engage and ride up slightly on the corresponding pawls 286 of the yoke 280 . As the pawls 286 ride up on the teeth 269 , the supporting member 282 of the yoke 280 deflects outwardly to allow pawls 286 to slip or pass over the teeth 269 of the tubular collar 260 .
In one embodiment, the teeth 269 of the tubular collar 260 are configured as ramps or wedges, and the pawls 286 of the yoke 280 are configured as posts. The teeth 269 of the tubular collar 260 and the pawls 286 of the yoke 280 may be reversed so that the teeth 269 of the tubular collar 260 are posts, and the pawls 286 of the yoke 280 are ramps or wedges. It is contemplated that the teeth 269 may be integrally formed or coupled directly to the periphery of the elongated member 150 . It will also be recognized that the teeth 269 and the pawls 286 may be cooperating projections, wedges, cam surfaces, ratchet-like teeth, serrations, wedges, flanges, or the like which cooperate to allow the elongated member 150 to be indexed at selective angular positions, without departing from the spirit and scope of the invention.
As illustrated in FIG. 2, the elongated member 150 of the clamp coagulator 120 extends from the instrument housing 130 . As shown in FIGS. 2B through 4, the elongated member 150 preferably includes an outer member or outer tube 160 , an inner member or inner tube 170 , and a transmission component or ultrasonic waveguide 179 .
The outer tube 160 of the elongated member 150 preferably includes a hub 162 , a tubular member 164 , and a longitudinal opening or aperture 166 extending therethrough. The outer tube 160 preferably has a substantially circular cross-section and may be fabricated from stainless steel. It will be recognized that the outer tube 160 may be constructed from any suitable material and may have any suitable cross-sectional shape.
The hub 162 of the outer tube 160 preferably has a larger diameter than the tubular member 164 does. The hub 162 has a pair of outer tube holes 161 to receive pin 163 to allow the hub 162 to be coupled to rotational knob 190 . As a result, the outer tube 160 will rotate when the rotational knob 190 is turned or rotated.
The hub 162 of the outer tube 160 also includes wrench flats 169 on opposite sides of the hub 162 . The wrench flats 169 are preferably formed near the distal end of the hub 162 . The wrench flats 169 allow torque to be applied by a torque wrench to the hub 162 to tighten the ultrasonic waveguide 179 to the stud 50 of the acoustic assembly 80 . For example, U.S. Pat. Nos. 5,059,210 and 5,057,119, which are hereby incorporated herein by reference, disclose torque wrenches for attaching and detaching a transmission component to a mounting device of a hand piece assembly.
Located at the distal end of the tabular member 164 of the outer tube 160 is an end-effector 180 for performing various tasks, such as, for example, grasping tissue, cutting tissue and the like. It is contemplated that the end-effector 180 may be formed in any suitable configuration.
End-effector 180 and its components are shown in greater detail in FIGS. 23 through 33. The end-effector 180 generally includes a non-vibrating clamp arm assembly 300 to, for example, grip tissue or compress tissue against the ultrasonic blade 88 . The end-effector 180 is illustrated in FIGS. 23 and 26 in a clamp open position, and clamp arm assembly 300 is preferably pivotally attached to the distal end of the outer tube 160 . Ultrasonic vibrations are transmitted along the ultrasonic waveguide 179 in a longitudinal direction to vibrate the ultrasonic blade 88 .
Looking first to FIGS. 23 through 26, the clamp arm assembly 300 preferably includes a clamp arm 202 , a jaw aperture 204 , a first post 206 A and a second post 206 B, and a tissue pad 208 . The clamp arm 202 is pivotally mounted about pivot pins 207 A and 207 B to rotate in the direction of arrow 122 in FIG. 3 when thumb loop 142 is moved in the direction indicated by arrow 121 in FIG. 3 . By advancing the pivoting handle portion 136 toward the instrument housing 130 , the clamp arm 202 is pivoted about the pivot pin 207 into a closed position. Retracting the pivoting handle portion 136 away from the instrument housing 130 pivots the clamp arm 202 into an open position
The clamp arm 202 has tissue pad 208 attached thereto for squeezing tissue between the ultrasonic blade 88 and clamp arm assembly 300 . The tissue pad 208 is preferably formed of a polymeric or other compliant material and engages the ultrasonic blade 88 when the clamp arm 202 is in its closed position. Preferably, the tissue pad 208 is formed of a material having a low coefficient of friction but which has substantial rigidity to provide tissue-grasping capability, such as, for example, TEFLON, a trademark name of E. I. Du Pont de Nemours and Company for the polymer polytetraflouroethylene (PTFE). The tissue pad 208 may be mounted to the clamp arm 202 by an adhesive, or preferably by a mechanical fastening arrangement as will be described below.
As illustrated in FIGS. 23, 26 and 28 , serrations 210 are formed in the clamping surfaces of the tissue pad 208 and extend perpendicular to the axis of the ultrasonic blade 88 to allow tissue to be grasped, manipulated, coagulated and cut without slipping between the clamp arm 202 and the ultrasonic blade 88 .
Tissue pad 208 is illustrated in greater detail in FIGS. 27 through 29. Tissue pad 208 includes a T-shaped protrusion 212 , a left protrusion surface 214 , a right protrusion surface 216 , a top surface 218 , and a bottom surface 219 . Bottom surface 219 includes the serrations 210 previously described. Tissue pad 208 also includes a beveled front end 209 to ease insertion during assembly as will be described below.
Referring now to FIG. 26, the distal end of the tubular member 174 of the inner tube 170 preferably includes a finger or flange 171 that extends therefrom. The flange 171 has openings 173 A and 173 B ( 173 B not shown) to receive the posts 206 A and 206 B of the clamp arm 202 . When the inner tube 170 of the elongated member 150 is moved axially, the flange 171 moves forwardly or rearwardly while engaging the post 206 of the clamp arm assembly 300 to open and close the clamp arm 202 .
Referring now to FIGS. 24, 25 , and 31 through 33 , the clamp arm 202 of end-effector 180 is shown in greater detail. Clamp arm 202 includes an arm top 228 and an arm bottom 230 , as well as a straight portion 235 and a curved portion 236 . Straight portion 235 includes a straight T-slot 226 . Curved portion 236 includes a first top hole 231 , a second top hole 232 , a third top hole 233 , a fourth top hole 234 , a first bottom cut-out 241 , a second bottom cut-out 242 , a third bottom cut-out 243 , a forth bottom cut-out 244 , a first ledge 221 , a second ledge 222 , a third ledge 223 , a fourth ledge 224 , and a fifth ledge 225 .
Top hole 231 extends from arm top 228 through clamp arm 202 to second ledge 222 . Top hole 232 extends from arm top 228 through clamp arm 202 to third ledge 223 . Top hole 233 extends from arm top 228 through clamp arm 202 to fourth ledge 224 . Top hole 234 extends from arm top 228 through clamp arm 202 to fifth ledge 225 . The arrangement of holes 231 through 234 and ledges 211 through 225 enables clamp arm 202 to include both the straight portion 235 and the curved portion 236 , while being moldable from a process such as, for example, metal injection molding (MIM). Clamp arm 202 may be made out of stainless steel or other suitable metal utilizing the MIM process.
Referring to FIGS. 30 and 31, tissue pad 208 T-shaped protrusion 212 is insertable into clamp arm 202 straight T-slot 226 . Clamp arm 202 is designed such that tissue pad 208 may be manufactured as a straight component by, for example, injection molding, machining, or extrusion. As clamp arm 202 is inserted into straight T-slot 226 and moved progressively through curved portion 236 , beveled front edge 209 facilitates bending of tissue pad 208 to conform to the curvature of clamp arm 202 . The arrangement of holes 231 through 234 and ledges 211 through 225 enables clamp arm 202 to bend and hold tissue pad 208 .
FIGS. 32 and 33 illustrate how clamp arm 202 holds tissue pad 208 in place while maintaining a bend in tissue pad 208 that conforms to curved portion 236 of clamp arm 202 . As illustrated in FIG. 32, third ledge 223 contacts right protrusion surface 216 providing a contact edge 238 , while left protrusion surface 214 is unsupported at this position. At a distal location, illustrated in FIG. 33, fourth ledge 224 contacts left protrusion surface 214 providing a contact edge 239 , while right protrusion surface 216 is unsupported at this location.
Referring back now to FIG. 2 again, the inner tube 170 of the elongated member 150 fits snugly within the opening 166 of the outer tube 160 . The inner tube 170 preferably includes an inner hub 172 , a tubular member 174 , a circumferential groove 176 , a pair of opposing openings 178 , a pair of opposing openings 178 , and a longitudinal opening or aperture 175 extending therethrough. The inner tube 170 preferably has a substantially circular cross-section, and may be fabricated from stainless steel. It will be recognized that the inner tube 170 may be constructed from any suitable material and may be any suitable shape.
The inner hub 172 of the inner tube 170 preferably has a larger diameter than the tubular member 174 does. The pair of opposing openings 178 of the inner hub 172 allow the inner hub 172 to receive the pin 163 to allow the inner tube 170 and the ultrasonic waveguide 179 to transfer torque for attaching ultrasonic waveguide 179 to stud 50 as previously described. An O-ring 220 is preferably disposed in the circumferential groove 176 of the inner hub 172 .
The ultrasonic waveguide 179 of the elongated member 150 extends through aperture 175 of the inner tube 170 . The ultrasonic waveguide 179 is preferably substantially semi-flexible. It will be recognized that the ultrasonic waveguide 179 may be substantially rigid or may be a flexible wire.
The ultrasonic waveguide 179 may, for example, have a length substantially equal to an integral number of one-half system wavelengths (nλ/2). The ultrasonic waveguide 179 may be preferably fabricated from a solid core shaft constructed out of material which propagates ultrasonic energy efficiently, such as titanium alloy (i.e., Ti-6Al-4V) or an aluminum alloy. It is contemplated that the ultrasonic waveguide 179 may be fabricated from any other suitable material. The ultrasonic waveguide 179 may also amplify the mechanical vibrations transmitted to the ultrasonic blade 88 as is well known in the art.
As illustrated in FIG. 2, the ultrasonic waveguide 179 may include one or more stabilizing silicone rings or damping sheaths 110 (one being shown) positioned at various locations around the periphery of the ultrasonic waveguide 179 . The damping sheaths 110 dampen undesirable vibration and isolate the ultrasonic energy from the inner tube 170 assuring the flow of ultrasonic energy in a longitudinal direction to the distal end of the ultrasonic blade 88 with maximum efficiency. The damping sheaths 10 may be secured to the ultrasonic waveguide 179 by an interference fit such as, for example, a damping sheath described in U.S. patent application Ser. No. 08/808,652 hereby incorporated herein by reference.
Referring again to FIG. 2, the ultrasonic waveguide 179 generally has a first section 182 , a second section 184 , and a third section 186 . The first section 182 of the ultrasonic waveguide 179 extends distally from the proximal end of the ultrasonic waveguide 179 . The first section 182 has a substantially continuous cross-section dimension.
The first section 182 preferably has at least one radial waveguide hole 188 extending therethrough. The waveguide hole 188 extends substantially perpendicular to the axis of the ultrasonic waveguide 179 . The waveguide hole 188 is preferably positioned at a node but may be positioned at any other suitable point along the ultrasonic waveguide 179 . It will be recognized that the waveguide hole 188 may have any suitable depth and may be any suitable shape.
The waveguide hole 188 of the first section 182 is aligned with the opposing openings 178 of the hub 172 and outer tube holes 161 of hub 162 to receive the pin 163 . The pin 163 allows rotational torque to be applied to the ultrasonic waveguide 179 from the rotational knob 190 in order to rotate the elongated member 150 . Passageway 195 of elongated member 150 includes opposing openings 178 , outer tube holes 161 , waveguide hole 188 , and opposing holes 199 .
The second section 184 of the ultrasonic waveguide 179 extends distally from the first section 182 . The second section 184 has a substantially continuous cross-section dimension. The diameter of the second section 184 is smaller than the diameter of the first section 182 . As ultrasonic energy passes from the first section 182 of the ultrasonic wavegulide 179 into the second section 184 , the narrowing of the second section 184 will result in an increased amplitude of the ultrasonic energy passing therethrough.
The third section 186 extends distally from the distal end of the second section 184 . The third section 186 has a substantially continuous cross-section dimension The third section 186 may also include small diameter changes along its length. The third section preferably includes a seal 187 formed around the outer periphery of the third section 186 . As ultrasonic energy passes from the second section 184 of the ultrasonic waveguide 179 into the third section 186 , the narrowing of the third section 186 will result in an increased amplitude of the ultrasonic energy passing therethrough.
The third section 186 may have a plurality of grooves or notches (not shown) formed in its outer circumference. The grooves may be located at nodes of 25 the ultrasonic waveguide 179 or any other suitable point along the ultrasonic waveguide 179 to act as alignment indicators for the installation of a damping sheath 110 during manufacturing.
Still referring to FIG. 2, damping sheath 110 of the surgical instrument 150 surrounds at least a portion of the ultrasonic waveguide 179 . The damping sheath 110 may be positioned around the ultrasonic waveguide 179 to dampen or limit transverse side-to-side vibration of the ultrasonic waveguide 179 during ultrasonic waveguide 179 from the rotational knob 190 in order to rotate the elongated member 150 . Passageway 195 of elongated member 150 includes opposing openings 178 , outer tube holes 161 , waveguide hole 188 , and opposing holes 199 .
The second section 184 of the ultrasonic waveguide 179 extends distally from the first section 182 . The second section 184 has a substantially continuous cross-section dimension. The diameter of the second section 184 is smaller than the diameter of the first section 182 . As ultrasonic energy passes from the first section 182 of the ultrasonic waveguide 179 into the second section 184 , the narrowing of the second section 184 will result in an increased amplitude of the ultrasonic energy passing therethrough.
The third section 186 extends distally from the distal end of the second section 184 . The third section 186 has a substantially continuous cross-section dimension The third section 186 may also include small diameter changes along its length. The third section preferably includes a seal 187 formed around the outer periphery of the third section 186 . As ultrasonic energy passes from the second section 184 of the ultrasonic waveguide 179 into the third section 186 , the narrowing of the third section 186 will result in an increased amplitude of the ultrasonic energy passing therethrough.
The third section 186 may have a plurality of grooves or notches (not shown) formed in its outer circumference. The grooves may be located at nodes of the ultrasonic waveguide 179 or any other suitable point along the ultrasonic waveguide 179 to act as alignment indicators for the installation of a damping sheath 110 during manufacturing.
Still referring to FIG. 2, damping sheath 110 of the surgical instrument 150 surrounds at least a portion of the ultrasonic waveguide 179 . The damping sheath 110 may be positioned around the ultrasonic waveguide 179 to dampen or limit transverse side-to-side vibration of the ultrasonic waveguide 179 during operation. The damping sheath 110 preferably surrounds part of the second section 184 of the ultrasonic waveguide 179 . It is contemplated that the damping sheath 110 may be positioned around any suitable portion of the ultrasonic waveguide 179 . The damping sheath 110 preferably extends over at least one antinode of transverse vibration, and more preferably, a plurality of antinodes of transverse vibration. The damping sheath 110 preferably has a substantially circular cross-section. It will be recognized that the damping sheath 110 may have any suitable shape to fit over the ultrasonic waveguide 179 and may be any suitable length.
The damping sheath 110 is preferably in light contact with the ultrasonic waveguide 179 to absorb unwanted ultrasonic energy from the ultrasonic waveguide 179 . The damping sheath 110 reduces the amplitude of non-axial vibrations of the ultrasonic waveguide 179 . such as, unwanted transverse vibrations associated with the longitudinal frequency of 55,500 Hz as well as other higher and lower frequencies.
The damping sheath 110 is constructed of a polymeric material, preferably with a low coefficient of friction to minimize dissipation of energy from the axial motion or longitudinal vibration of the ultrasonic waveguide 179 . The polymeric material is preferably floura-ethylene propene (FEP) which resists degradation when sterilized using gamma radiation. It will be recognized that the damping sheath 110 may be fabricated from any suitable material, such as, for example, PIFE.
The damping sheath 110 preferably has an opening extending therethrough, and a longitudinal slit 111 . The slit 111 of the damping sheath 110 allows the damping sheath 110 to be assembled over the ultrasonic waveguide 179 from either end. It will be recognized that the damping sheath 110 may have any suitable configuration to allow the damping sheath 110 to fit over the ultrasonic waveguide 179 . For example, the damping sheath 110 may be formed as a coil or spiral or may have patterns of longitudinal and/or circumferential slits or slots. It is also contemplated that the damping sheath 110 may be fabricated without a slit 111 and the ultrasonic waveguide 179 may be fabricated from two or more parts to fit within the damping sheath 110 .
It will be recognized that the ultrasonic waveguide 179 may have any suitable cross-sectional dimension. For example, the ultrasonic waveguide 179 may have a substantially uniform cross-section or the ultrasonic waveguide 179 may be tapered at various sections or may be tapered along its entire length.
The ultrasonic waveguide 179 may also amplify the mechanical vibrations transmitted through the ultrasonic waveguide 179 to the ultrasonic blade 88 as is well known in the art. The ultrasonic waveguide 179 may further have features to control the gain of the longitudinal vibration along the ultrasonic waveguide 179 and features to tune the ultrasonic waveguide 179 to the resonant frequency of the system.
The proximal end of the third section 186 of ultrasonic waveguide 179 may be coupled to the distal end of the second section 184 by an internal threaded connection, preferably near an antinode. It is contemplated that the third section 186 may be attached to the second section 184 by any suitable means, such as a welded joint or the like. Third section 186 includes ultrasonic blade 88 . Although the ultrasonic blade 88 may be detachable from the ultrasonic waveguide 179 , the ultrasonic blade 88 and ultrasonic waveguide 179 are preferably formed as a single unit.
The ultrasonic blade 88 may have a length substantially equal to an integral multiple of one-half system wavelengths (nλ/2). The distal end of ultrasonic blade 88 may be disposed near an antinode in order to provide the maximum longitudinal excursion of the distal end, When the transducer assembly is energized, the distal end of the ultrasonic blade 88 is configured to move in the range of, for example, approximately 10 to 500 microns peak-to-peak, and preferably in the range of about 30 to 150 microns at a predetermined vibrational frequency.
The ultrasonic blade 88 is preferably made from a solid core shaft constructed of material which propagates ultrasonic energy, such as a titanium alloy (i.e., Ti-6Al-4V) or an aluminum alloy. It will be recognized that the ultrasonic blade 88 may be fabricated from any other suitable material. It is also contemplated that the ultrasonic blade 88 may have a surface treatment to improve the delivery of energy and desired tissue effect. For example, the ultrasonic blade 88 may be micro-finished, coated, plated, etched, grit-blasted, roughened or scored to enhance coagulation and cutting of tissue and/or reduce adherence of tissue and blood to the end-effector. Additionally, the ultrasonic blade 88 may be sharpened or shaped to enhance its characteristics. For example, the ultrasonic blade 88 may be blade shaped, hook shaped, or ball shaped.
Referring now to FIGS. 1-4, the procedure to attach and detach the clamp coagulator 120 from the acoustic assembly 80 will be described below. When the physician is ready to use the clamp coagulator 120 , the physician simply attaches the clamp coagulator 120 onto the acoustic assembly 80 . To attach the clamp coagulator 120 to acoustic assembly 80 , the distal end of stud 50 is threadedly connected to the proximal end of the transmission component or ultrasonic waveguide 179 . The clamp coagulator 120 is then manually rotated in a conventional screw-threading direction to interlock the threaded connection between the stud 50 and the ultrasonic waveguide 179 .
Once the ultrasonic waveguide 179 is threaded onto the stud 50 , a tool, such as, for example, a torque wrench, may be placed over the elongated member 150 of the clamp coagulator 120 to tighten the ultrasonic waveguide 179 to the stud 50 . The tool may be configured to engage the wrench flats 169 of the hub 162 of the outer tube 160 in order to tighten the ultrasonic waveguide 179 onto the stud 50 . As a result, the rotation of the hub 162 will rotate the elongated member 150 until the ultrasonic waveguide 179 is tightened against the stud 50 at a desired and predetermined torque. It is contemplated that the torque wrench may alternately be manufactured as part of the clamp coagulator 120 , or as part of the hand piece housing 20 , such as the torque wrench described in U.S. Pat. No. 5,776,155 hereby incorporated herein by reference.
Once the clamp coagulator 120 is attached to the acoustic assembly 80 , the surgeon can rotate the rotational knob 190 to adjust the elongated member 150 at a desired angular position. As the rotational knob 190 is rotated, the teeth 269 of the tubular collar 260 slip over the pawls 286 of the yoke 280 into the adjacent notch or valley. As a result, the surgeon can position the end-effector 180 at a desired orientation. Rotational knob 190 may incorporate an indicator to indicate the rotational relationship between instrument housing 130 and clamp arm 202 . As illustrated in FIGS. 17 and 18, one of the ridges 197 of rotational knob 190 may be used to indicate the rotational position of clamp arm 202 with respect to instrument housing 130 by utilizing, for example, an enlarged ridge 200 . It is also contemplated that alternate indications such as the use of coloring, symbols, textures, or the like may also be used on rotational knob 190 to indicate position similarly to the use of enlarged ridge 200 .
To detach the clamp coagulator 120 from the stud 50 of the acoustic assembly 80 , the tool may be slipped over the elongated member 150 of the surgical tool 120 and rotated in the opposite direction, i.e., in a direction to unthread the ultrasonic waveguide 179 from the stud 50 . When the tool is rotated, the hub 162 of the outer tube 160 allows torque to be applied to the ultrasonic waveguide 179 through the pin 163 to allow a relatively high disengaging torque to be applied to rotate the ultrasonic waveguide 179 in the unthreading direction. As a result, the ultrasonic waveguide 179 loosens from the stud 50 . Once the ultrasonic waveguide 179 is removed from the stud 50 , the entire clamp coagulator 120 may be thrown away.
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims. | The present invention relates, in general, to ultrasonic surgical clamping instruments and, more particularly, to an improved force limiting mechanism for an ultrasonic surgical clamping instrument. An ultrasonic clamp coagulator apparatus is described including a housing, an actuator, an outer tube having a proximal end joined to the housing, and a distal end. An actuating element is reciprocably positioned within the outer tube and operatively connected to the actuator. An ultrasonic waveguide is positioned within the outer tube, with an end-effector extending distally from the distal end of the outer tube. A clamp arm is pivotally mounted on the distal end of the outer tube for pivotal movement with respect to the end-effector for clamping tissue between the clamp arm and the end-effector. The clamp arm is operatively connected to the actuating element so that reciprocal movement of the actuating element pivots the clamp arm. There is an actuation mechanism within the housing, connected between the clamp arm and the actuator. The actuation mechanism is adapted to actuate the clamp arm pivotably with respect to the end-effector. In one embodiment the actuation mechanism includes a wave spring for limiting the force applied to the clamp arm from the actuator. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing the magnesium salt of olefin sulfonic acids, and more specifically, it relates to a process for producing the magnesium salt of olefin sulfonic acids which contain only a small amount of unreacted magnesium compounds and do not cause the generation of foreign odor and color change.
2. Description of the Prior Art
Olefin sulfonic acids have been heretofore used as a surface-active agent, generally in the form of the sodium salt. However, recently, the magnesium salts of olefin sulfonic acids have become of major interest as a surface-active agent due to the fact that they have an excellent frothing property.
In the production of the magnesium salts of olefin sulfonic acids, when magnesium hydroxide and/or magnesium oxide are employed as a neutralizing agent, there are disadvantages in that extremely long operations for the neutralization of a alkene sulfonic acids and for the hydrolysis of sultone contained in the neutralization products are required. This is because magnesium hydroxide and oxide are only slightly soluble in water. The above-mentioned neutralization reaction can be more or less accelerated by heating the reaction system or by vigorously agitating the reaction system. However, in order to accelerate the above-mentioned hydrolysis reaction, the heating or the vigorous agitation of the reaction system is not practically applicable, due to the fact that acidification of the reaction system occurs. That is to say, the hydrolysis of the sultone comprises the ring opening (or cleavage) reaction of the sultone ring, and the neutralization reaction of the hydroxyalkane sulfonic acids and alkene sulfonic acids which are formed by the cleavage reaction of the sultone ring. However, if the dissolving rate of the magnesium compound necessary for the neutralization reaction is slow, the reaction system necessarily becomes acidic since the cleavage reaction is faster than the neutralization reaction.
As is well-known, the hydrolysis of the sultone under an acidic condition causes the generation of foreign odor and color change in the reaction products. It has not been proposed heretofore that the hydrolysis of the sultone can be accelerated without causing the above-mentioned problems. In the case where the sultone is hydrolyzed in the presence of a large excess of the magnesium compound, the hydrolysis can be somewhat accelerated and the generation of foreign odor and color change can be more or less depressed. However, this method is still not preferable, because a large amount of the unreacted magnesium compound remains, as an insoluble material, in the reaction products.
SUMMARY OF THE INVENTION
The objects of the present invention are to obviate the above-mentioned disadvantage of the conventional process for producing the magnesium salts of olefin sulfonic acids, and to provide a process for producing the magnesium salts of olefin sulfonic acids, which is capable of accelerating the hydrolysis of the sultone without causing the acidification of the reaction system and producing the reaction product containing, if any, only a small amount of the unreacted magnesium compound or compounds.
Other objects and advantages of the present invention will be apparent from the following description.
In accordance with the present invention, the magnesium salts of olefin sulfonic acids are produced in a process comprising the steps of sulfonating and neutralizing an olefin having 10 to 20 carbon atoms and then heating the resulting neutralization product in the presence of magnesium hydroxide, magnesium oxide and a mixture thereof to thereby hydrolyze sultone present in the neutralization product; wherein the hydrolysis of the sultone is carried out in the presence of at least one additive selected from the group consisting of benzoic acid, citric acid, malic acid, phosphoric acid, polyphosphoric acid and water-soluble salts thereof, at a temperature of within the range from 110° C. to 180° C.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The olefins employed as a starting material in the present invention include α-olefins having 10 to 20 carbon atoms, such as dodecene-1, tetradecene-1, hexadecene-1, octadecene-1 and their mixtures; internal olefins having 10 to 20 carbon atoms, such as tetradecene-2, tetradecene-3, tetradecene-4, hexadecene-2, hexadecene-3, hexadecene-5, hexadecene-8, octadecene-2, octadecene-3, octadecene-6 and their mixtures and; vinylidene type olefins having 10 to 20 carbon atoms, such as 2-methyl-dodecene-1, 2-butyl-dodecene-1, 2-hexyl-decene-1, 2-hexyl-dodecene-1 and their mixtures. Among these olefins, α-olefins and internal olefins are preferable for use in the present invention.
According to the present invention, the olefins are first sulfonated by any known procedure, for example, with gaseous sulfur trioxide diluted by an inert gas. The sulfonation products of the olefins can be neutralized in the known manner. Thus, any known neutralizing agent and neutralizing conditions for converting acids, such as alkene sulfonic acids, contained in the sulfonation products of olefins to the corresponding salts thereof can be applied to the neutralization step of the present invention. The use of magnesium hydroxide and/or magnesium oxide as a neutralizing agent in the present invention is preferable.
The neutralized sulfonation products of olefins are then hydrolyzed in the presence of magnesium hydroxide and/or magnesium oxide. According to the present invention this hydrolysis is effectively carried out also in the presence of at least one additive, at a temperature within the range of from 110° C. to 180° C. Said additives include benzoic acid, citric acid, malic acid and the water-soluble salt thereof (e.g. sodium benzoate, sodium citrate, sodium malate, potassium benzoate and alkanol amine salt of benzoic acid, and; phosphoric acid, polyphosphoric acid and the water-soluble salts thereof (e.g. sodium phosphate, sodium pyrophosphate, sodium tripolyphosphate and potassium pyrophosphate). Thus, it has been found that, since an additive selected from benzoic acid, citric acid, malic acid, phosphoric acid, polyphosphoric acid and any water-soluble salts thereof has a function to accelerate the dissolving rate of magensium hydroxide and magnesium oxide into water, the sultone contained in the neutralization products of the sulfonated olefins can be hydrolyzed without causing the acidification of the reaction system when the hydrolysis of the sultone is carried out in the presence of both said additive and magnesium hydroxide and/or oxide.
The amount of the additive is 0.5% by weight or more, and more preferably within the range of approximately 1 to approximately 10% by weight, based on the weight of the magnesium salt of the olefin sulfonic acids to be produced from the sulfonation products of the olefins. When the amount of the additive is less than 0.5% by weight, the dissolving rate of magnesium hydroxide and/or oxide cannot be practically improved. The additive can be added to the reaction system either before or after the neutralization reaction if it is added prior to the hydrolysis reaction. It is, therefore, convenient to add said additive to the sulfonation products of the olefins prior to the neutralization step. This is because, when magnesium hydroxide and/or magnesium oxide are used as a neutralizing agent, said additive can also accelerate the dissolving rate of the neutralizing agent, so that the neutralization rate is increased.
The magnesium hydroxide and/or magnesium oxide can be used in an amount sufficient to completely convert the olefin sulfonic acids to the corresponding magnesium salts thereof. Although no critical amount of the magnesium hydroxide and/or magnesium oxide exists, the preferable amount is within the range of from the chemically equivalent amount to approximately 1.2 times thereof.
The hydrolysis reaction can be practically carried out at a temperature within the range of from approximately 110° C. to approximately 180° C. When the temperature is less than 110° C., the rate of the hydrolysis reaction is too slow for practical use. On the other hand, when the temperature is more than 180° C., the coloring or, in the extreme case, foreign odor, of the hydrolyzate is generated.
As is clear from the above description, according to the present invention, even if magnesium hydroxide and/or magnesium oxide only slightly soluble in water are used, the reaction system in which the sultone is hydrolyzed is not acidified and, moreover, the hydrolyzing rate can be accelerated. Accordingly, the utilization of the present invention can effectively produce magnesium salts of olefin sulfonic acids which do not cause the generation of foreign odor and color changes.
In order to further illustrate the present invention, the specific examples set forth below are presented. It is to be understood, however, that this is merely intended in an illustrative and not limitative sense. In the examples, all percents are by weight, unless otherwise indicated.
EXAMPLES 1 to 7
C 14 α-olefin sulfonic acid were prepared by sulfonating C 14 α-olefins with gaseous sulfur trioxide diluted by using a falling film type sulfonation reactor as disclosed in, for example, U.S. Pat. No. 4,036,596 under the conditions of mole ratio of SO 3 /olefin of 1.14 and a temperature of 55° to 60° C. 200 g of the C 14 α-olefin sulfonates thus obtained were charged into a 1000 ml beaker, and magnesium hydroxide or oxide and the additives listed in Table 1, below, were added thereto, in the amounts shown in Table 1, to neutralize the acids contained in the sulfonate. Thereafter, the sultones presented in the neutralization products were hydrolyzed in a 1000 ml autoclave under the conditions set forth in Table 1 to give an aqueous solution containing the magnesium salts of the olefin sulfonic acids. In Examples 1 to 3, no additive was used for the purpose of comparison.
The aqueous solution containing the magnesium salts of the olefin sulfonic acids (AOS-1/2 Mg) obtained in each Example was tested with respect to odor and color. The odor of the aqueous solution was olganoleptically tested and evaluated as follows.
O: no acidic odor
Δ: slightly acidic odor
X: heavy acidic odor
The color of the aqueous solution was checked by the naked eye and evaluated as follows.
O: slightly yellow
Δ: brown
X: black
The overall evaluation result was determined from the results of color check and odor test, in view of the hydrolysis time, and rated as follows.
O: good
X: poor
The results are shown in Table 1.
TABLE 1__________________________________________________________________________Example No. 1* 2* 3* 4 5 6 7__________________________________________________________________________Neutralizing Agent (g)Mg(OH).sub.2 24.1 24.1 24.1 24.1 24.1 24.1MgO 16.6Concentration ofNeutralizing Agent (%) 6.5 6.5 6.5 6.6 6.6 6.6 4.6Additive (g)Benzoic Acid 6Sodium Benzoate 6Citric Acid 6 6Hydrolysis Temperature (°C.) 120 130 140 140 140 140 140Hydrolysis Time (min) 120 60 20 20 20 20 20Property of ResultantAqueous AOS-1/2Mg SolutionOdor O Δ X O O O OColor O Δ X O O O OOverall Evaluation X X X O O O O__________________________________________________________________________ *Comparative Example
Examples 8 to 13
The hydrolysis tests were carried out in the same manner as in the previous Examples 1 to 7, except that 200 g of the suefonates of α-olefins, having 12 to 14 carbon atoms, were used. The used amounts of the neutralizing agent and additives, as well as the hydrolysis conditions, are shown in Table 2 below.
The aqueous solutions containing the magnesium salts of the olefin sulfonic acids (AOS-1/2 Mg) were evaluated by the method described in Examples 1 to 7. The results are shown in Table 2.
TABLE 2__________________________________________________________________________Example No. 8* 9* 10* 11 12 13__________________________________________________________________________Neutralizing Agent (g)Mg(OH).sub.2 25.6 25.6 25.6 25.6 25.6 25.6Concentration ofNeutralizing Agent (%) 8.6 8.6 8.6 8.8 8.8 8.8Additive (g)Sodium Citrate 6Malic Acid 6Sodium Phosphate 6Hydrolysis Temperature (°C.) 110 120 130 140 140 140Hydrolysis Time (min) 200 120 60 20 20 20Property of ResultantAqueous AOS-1/2Mg SolutionOdor O Δ X O O OColor O Δ X O O OOverall Evaluation X X X O O O__________________________________________________________________________ *Comparative Example
Examples 14 to 20
The hydrolysis tests were carried out in the same manner as in the previous Examples 1 to 7, except that 200 g of the sulfonates of α-olefins, having 16 to 18 carbon atoms, were used. The used amounts of the neutralizing agent and additives as well as the hydrolysis conditions are shown in Table 3, below.
The aqueous solutions containing the magnesium salts of the olefin sulfonic acids (AOS-1/2 lMg) were evaluated by the method described in Examples 1 to 7. The results are shown in Table 3.
TABLE 3__________________________________________________________________________Example No. 14* 15* 16* 17 18 19 20__________________________________________________________________________Neutralizing Agent (g)Mg(OH).sub.2 21.1 21.1 21.1 21.1 21.1 21.1MgO 14.6Concentration ofNeutralizing Agent (%) 5.7 5.7 5.7 5.8 5.8 5.8 4.0Additive (g)Sodium Benzoate 8Pyrophosphoric Acid 8Sodium Tripolyphosphate 8Sodium Citrate 6Hydrolysis Temperature (°C.) 120 130 140 140 140 140 140Hydrolysis Time (min) 120 60 20 20 20 20 20Property of ResultantAqueous AOS-1/2Mg SolutionOdor O Δ X O O O OColor O Δ X O O O OOverall Evaluation X X X O O O O__________________________________________________________________________ *Comparative Example
As is clearly indicated in Tables 1, 2 and 3, in the cases where the additives of the present invention were employed, aqueous solutions of the magnesium salts of olefin suefonic acids having no odor and no color were obtained for a short hydrolysis time of approximately 20 minutes. Contrary to this, when no additive of the present invention was used, a long hydrolysis time was required for obtaining a good aqueous solution of the magnesium salts of olefin sulfonic acids, as in Example 1, 8 or 14. When a short hydrolysis time was employed in the absence of the additives of the present invention, the generation of foreign odor and color change appeared, as in Example 2, 3, 9, 10, 15 or 16. | Disclosed is a process for producing the magnesium salt of an olefin sulfonic acid comprising the steps of:
sulfonating and neutralizing an olefin having 10 to 20 carbon atoms, and; then,
hydrolyzing sultone contained in the resulting neutralization product in the presence of,
(a) magnesium hydroxide, magnesium oxide and a mixture thereof and
(b) an additive selected from the group consisting of benzoic acid, citric acid, malic acid, phosphoric acid, polyphosphoric acid and water-soluble salts thereof,
at a temperature within the range of from 110° C. to 180° C. | 2 |
DEDICATORY CLAUSE
The invention described herein may be manufactured, used, and licensed by or for the Government for governmental purposes without the payment to us of any royalties thereon.
BACKGROUND OF THE INVENTION
In the past, an approach of a multiplicity of tubes has been to tie the tubes together at points along the length of the launch tubes to form a cluster of the individual tubes. This approach causes each individual tube to have its own individual strength for longitudinal stress as well as radial stress. Further, in this type construction, the tubes are geneally made of metal which adds undesirable weight to the launch tube cluster. Therefore, it can be seen that there is a need for a lightweight tube launching system that has a multiplicity of tubes of lightweight material that can withstand linear stress as well as radial stress and be clustered together in an accurate manner with each of the tubes aligned relative to each of the other tubes.
With the above needs in mind, it is an object of this invention to provide a system by which a compact, lightweight and economical launch tube arrangement is provided.
Another object of this invention is to provide a process by which a multiplicity of launch tubes can be accurately aligned and molded into a unitized structure to provide a lightweight and accurately aligned launch tube arrangement for small missiles.
Still another object of this invention is to provide a process by which a multiple launch tube arrangement can be made of all synthetic material.
A still further object of this invention is to provide a process which requires no specialized molding equipment outside of the mold.
A still further object of this invention is to provide a process by which the process is not limited to a specific tube configuration but a process that is flexible and can be expanded or contracted to accommodate the multiplicity of tube launchers desired for a specific configuration.
Other objects and advantages of this invention will be obvious to those skilled in this art.
SUMMARY OF THE INVENTION
In accordance with this invention, a process for producing a lightweight composite launcher pod includes filament winding a multiplicity of tubes on hollow steel mandrels using fiberglass wetted with epoxy resin, mounting the mandrels on a end structure of a mold, mounting tie rods to said end plate, heavily coating the tubes and the tie rods in a standing position with a high viscosity syntactic foam, securing a second end plate at the upstanding end of said mandrels and said tie rods to secure the mandrels and tie rods at each end, laying the secured assembly of the end plates, mandrels, and tie rods onto a bottom plate, securing side plates in place to said bottom plate and said end plates, securing a top plate to the side plates and the end plates, with the syntactic foam being applied and filling the spaces around the tubes and tie rods either as the bottoms, sides and tops are being secured or injected around these structures after they are all secured together as a unit. The top plate is provided with reservoir ports to allow excess resin to be squeezed out if the resin is applied to the tubes and tie rods before the sides and base and top are assembled, and also to serve the purpose of allowing the resins to be drawn in by contraction of resin during cure. The contraction is the result of resin cross-linkage during cure. The fabrication of this process produces a lightweight composite launch pod and the structure of the lightweight composite launch pod secured in the mold structure of the sides and end plates is first cured at room temperature and next in an oven for a second cure time which is followed by a cool-down period and ultimately the sides of the mold and end plates of the mold are removed. Finally the mandrels and tie rods are removed to leave the molded structure. The final product produces a multiplicity of launch tubes that are accurately aligned for launching of rockets therefrom and the structure produced requires no finish machining other than the drilling of detent insert holes for mounting rockets in the tubes of the launcher. In some instances, rough brush-up is required of the structure adjacent the reservoir ports after the cured structure has been removed from the mold.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the mandrel used in the process of this invention and illustrating the tube thereon that has been wound from fiberglass impregnated with epoxy resin,
FIG. 2 is a sectional view of a spacer rod used in the process of this invention,
FIG. 3 is a side view illustrating an end plate with mandrels and spacer rods mounted thereto with this structure illustrated on a reduced scale in comparison to that of FIGS. 1 and 2,
FIG. 4 is a cross-sectional view in a dis-assembled array of the mold and illustrating the spacing of the mandrels and spacer rods relative to the bottom portion of the mold,
FIG. 5 is an end view of the mold and illustrating the ends of the mandrels and the bolts which connect the spacer rods and other mold structures to the end plate,
FIG. 6 is a top view of one of the end structures of the mold,
FIG. 7 is a side view of the end structure of the mold,
FIG. 8 is a view partially cut-away and illustrating the top structure of the mold with alignment tabs at one end,
FIG. 9 is a view partially cut-away and of the bottom structure of the mold and also illustrating alignment tabs at one end,
FIG. 10 is a view of the composite launch pod structure after being removed from the mold and illustrated as partially cut-away, and
FIG. 11 is a sectional view along line 11--11 of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the process is begun by filament winding a tube 10 on each of the desired number of hollow steel mandrels 12 using E-glass filament tow wetted with epoxy resin. This filament winding is done in a conventional manner. In the process disclosed herein, six mandrels 12 with the wet tubes 10 are stood vertically on end into a six-hole end plate 14 (See FIG. 3). End plate 14 is attached to a support stand in a conventional manner so that mandrels 12 with filament wound tubes 10 thereon are in a vertical position. Prior to mandrels 12 being stood in end plate 14, a high viscosity syntactic foam is heavily coated onto each of the tubes. After the first three mandrels 12 have been stood in place in the vertical position, two tie rods 16 as illustrated in FIG. 2 are coated with high viscosity syntactic foam and set in place relative to end plate 14 and secured in place by bolts 18 as illustrated in FIG. 5. Then the other three coated mandrels 12 are mounted in end plate 14. The two tie rods 16 act to draw the end plates 14 and 20 together and hold the assembly in place. That is, each end of tie rods 16 are drawn into end plates 14 and 20 to cause the overall length of the structure to be defined. After the six mandrels 12 and the two tie rods 16 have been set in place and secured to end plate 14 by bolts 18, second end plate 20 is then placed over the upper exposed ends of mandrels 12. Two additional bolts similar to bolts 18 are used to secure end plate 20 to the other ends of tie rods 16. Bolts 18 and the corresponding bolts at the other end of tie rods 16 are tightened to pull in plates 14 and 20 against shoulders 22 and 24 at opposite ends of each mandrel 12 as illustrated to define the overall length of the structure. Tie rods 16 and their bolt securing means hold the assembly together so that the entire structure can be moved from a vertical position as illustrated in FIG. 3 to a horizontal position as illustrated in FIG. 4 and onto bottom plate 26. Before the structure of FIG. 3 is placed in the horizontal position as illustrated in FIG. 4, high viscosity syntactic foam is placed on the surface of the bottom plate 26. Then the structure of FIG. 3 is placed in the horizontal position relative to bottom plate 26 as illustrated in FIG. 4. Next, a side such as side 28 is chosen to be installed and side 28 is moved into position and clamped in place by bolts 30 that are inserted through holes in bottom plate 26 and screwed into threaded openings in side plate 28 to clamp these two structures together. Side 32 is now ready to be installed and side 32 is moved into position and clamped in place by bolts 34 that are spaced along the length of the structure. With this operation complete, high viscosity syntactic foam is applied from the top of tubes 12 in the horizontal position to completely fill any voids about tubes 12 and tie rods 16. Finally, top plate 36 is moved in position over tubes 12 and between end plates 14 and 20 to complete the generally rectangular box-shaped structure. Plate 36 is secured in position by bolts 38 along the length thereof by being screwed into threaded sockets in sides 28 and 32 to secure top plate 36 in position. Top plate 36, as illustrated, has a plurality of openings 40 therethrough to relieve any excess of the syntactic foam material as the structure is being assembled. Also, during cure the syntactic foam material tends to contract and ports 40 aide in allowing the syntactic material to freely contract. Contraction of the syntactic material is the result of resin cross-linkage. End plates 14 and 20 each have stepped bores 42 and 44 (See FIG. 6) that accommodate tubes 12 and spacer rods 16 and machined out openings 46 accommodate alignment tabs 48 and 50 that are located at opposite ends of side members 28 and 32 (See FIG. 4), alignment tabs 52 on base member 26 (See FIG. 9), and alignment tabs 54 on top member 36 (See FIG. 8). Together, alignment tabs 48, 50, 52, and 54 innerlock with grooves 46 of end plates 14 and 20 and contact the surface of either one or two of tubes 12 to align the four sides of the pod structure with the axis of each tube 12. That is, the axis of each tube 12 is mounted to be parallel or substantially parallel to the axis of each of the other tubes 12, and alignment tabs 48, 50, 52 and 54 contact the tubes to cause the side surfaces of the pod structure to be parallel to the axes of the tubes. Indented grooves 42 and 44 serve to accurately align each of fiberglass tubes 10 from each end and the structure of end plates 14 and 20 cause the exact length of the tubes to be defined in an ultimately cured structure with accurately aligned launching tubes in a pod arrangement. End plates 14 and 20 each have eight bolts 55 (See FIG. 5) therein that secure end plates 14 and 20 to top structure 36 and bottom structure 26. As previously stated, tubes 12 are filament wound of E-glass filament that is tow wetted. However, the filament could be any fiberglass material, Kevlar, graphite, or any other similar material of this type that has the strength and structural support needed for supporting a tube of this type. The high viscosity syntactic foam used in this process includes Epon 826 epoxy resin by Shell Chemical Company, in an amount of 2,400 grams per batch. Araldite epoxy RD2 accelerator catalyst in an amount of 600 grams per batch. Tonox 6040 curative in an amount of 720 grams per batch, 250 Microballoons in an amount of 470 grams per batch, and a Cab-O-Sil thickening agent in an amount of 140 grams per batch. In some applications, it may be desirable to omit the Tonox from the mixture. This particular mixture has been found to provide an especially good high viscosity syntactic foam that is readily usable in this process to make composite launch tube pods that are very accurate and aligned as required.
After the composite structure has been cast in the mold structure as set forth supra, the structure is allowed to cure at room temperature for about 8 hours. Next, the entire mold and the structure therein is placed in an oven at 125° F. for 5 hours which is followed by a 3-hour rise time to 300° F. The structure is then maintained at 300° F. for a final cure of about 3 hours. After a cool-down period, sides 28 and 32 of the mold are removed and mandrels 12 are extracted from the tubes as well as spacer tie rods 16. The final product has the desired surface features molded therein as illustrated in FIG. 10, and tubes 12 are accurately aligned for launching rockets therefrom. Also, this process requires no finish machining other than removing rough edges that may have existed at ports 40 of top cover 36 and by drilling 6 detent insert holes 56 as illustrated in FIG. 11. The lightweight composite launch pod structure 58 as illustrated in FIG. 10 is an especially accurate structure that can be used to launch rockets accurately at targets. It is pointed out that the above process requires no specialized molding equipment other than the specific mold structure disclosed and this process is not limited to the 6 tube configuration illustrated herein, but feasibly can be expanded to other multiple tube launcher configurations of various sizes. It is pointed out that the outer shape of the overall structure is balanced in thickness relative to tubes 10 to prevent warpage. That is, the structure is well balanced from side to side.
If desired, the process can be altered in the way the syntactic foam is applied relative to the overall structure. That is, tubes 10 on mandrels 12 and tie rods 16 can be stood in position and assembled as described supra with the remainder of the mold structure being assembled piece by piece as set forth above until the mold has been completely assembled with tubes 10 and spacers 16 in position inside the mold. Bolts 18 at the top and base that project through end plates 14 and 20 and into spacer rods 16 can be provided with openings as well as openings in rods 16 or other openings in end plates 14 and 20 can be provided to allow the high viscoisty syntactic foam to enter at the base of the mold and fill the space around tubes 10 and spacers 16 until the foam rises to the top end structure 20 and finally would be vented through the holes at the top. If this step is used, holes 40 must also be plugged when the foam is being injected into the mold, or a top cover is used that has no holes 40 therein. It has been found that all the syntactic material can be applied to the tubes in this injection manner to produce just as good a structure as the steps of the process set forth above. | A process for making lightweight composite launcher pods in which a multicity of launcher tubes are wound on a multiplicity of mandrels and mounted in end structures of a mold and assembled into a generally rectangular mold structure and applying syntactic foam about the tube and spacer structure within the mold and finally curing the structure within the mold to provide a unitary lightweight composite launcher pod. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a novel reactive dye composition with three-color combination.
[0003] 2. Description of the Related Art
[0004] As a conventional technique for three-color combination dyeing using a reactive dye, there is known a method using combination of a red dye such as C.I. Reactive Red 195 or C.I. Reactive Red 180 and yellow and blue dyes. In this case, the yellow and blue dyes exhibit excellent light fastness, but the red dye has suffered from problems associated with exhibiting physical properties which are required in dyeing. Recently, in dyeing materials using the reactive dyes, with increasing demand for light fastness by consumers, use of conventional reactive red dyes cannot keep pace with such requirements. As such, there is a need for development of a red dye having high fastness against light.
[0005] C.I. Reactive Red 195:
[0006] C.I. Reactive Red 180:
SUMMARY OF THE INVENTION
[0007] Therefore, the present invention has been made to solve the above problems, and other technical problems that have yet to be resolved.
[0008] As a result of a variety of extensive and intensive studies and experiments to solve the problems as described above, the inventors of the present invention have developed, as will be described hereinafter, a reactive red dye having superior fastness against light and moisture upon dyeing a fiber material and have discovered that combination dyeing using the above-developed dye enables provision of a fiber product having superior light fastness and a high-quality combined color. The present invention has been completed based on these findings.
[0009] In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of a reactive dye composition, comprising
[0010] (i) a reactive red dye represented by Formula 1;
[0011] (ii) one or more reactive dyes selected from the group consisting of a reactive yellow dye represented by Formula 2, a reactive orange dye represented by Formula 3 and a mixture thereof; and
[0012] (iii) one or more reactive dyes selected from the group consisting of a reactive blue dye represented by Formula 4, a reactive blue dye represented by Formula 5 and a mixture thereof.
[0013] The reactive dye-based composition in accordance with the present invention exhibits superior adsorptivity and fixability when dyeing a fiber material containing nitrogen or hydroxyl group, particularly a cellulose fiber material, and particularly very high light fastness and thus provides a variety of balanced physical properties which are required in dyeing.
[0014] wherein:
[0015] R1, R2, R5 and R7 are independently hydrogen, or C1-C4 alkyl which may be substituted or unsubstituted with hydroxyl, sulfo, sulfato or carboxyl group;
[0016] R3, R4, R6, R8, R9, R10, R11 and R13 are independenty hydrogen, C1-C4 alkyl, C1-C4 alkoxy, C2-C4 alkanoylamino, ureido, sulfamoyl, halogen, sulfo or carboxyl group;
[0017] R12 is hydroxyl, sulfo or carboxyl group;
[0018] Y1, Y2, Y3, Y4 and Y5 are independently a substituent group of Formula 6a, 6b or 6c:
wherein R14, R15 and R17 are independently hydrogen, or C1-C4 alkyl which may be substituted or unsubstituted with hydroxyl, sulfo, sulfato or carboxyl group; R16, R18 and R19 are independently hydrogen, C1-C4 alkyl, C1-C4 alkoxy, C2-C4 alkanoylamino, ureido, sulfamoyl, halogen, sulfo or carboxyl group; A1 and A2 are independently a vinyl group or a radical of —CH2-CH2-Q, wherein Q is a leaving group that can be removed under alkaline conditions, for example —Cl, —Br, —F, —OSO3H, —SSO3H, —OCO—CH3, —OPO3H2, —OCO—C6H5, —OSO2-C1-C4 alkyl or —OSO2N(C1-C4 alkyl), preferably —OSO3H; and
[0019] X1, X2, X3, X4 and X5 are independently a substituent group of Formula 6a, 6b or 6c, which is an N-heterocyclic group capable of further containing halogen, hydroxyl, 3-carboxypyridin-1-yl, 3-carbamoylpyridin-1-yl, C1-C4 alkoxy group, C1-C4 alkylthio group, unsubstituted or substituted amino group, or a hetero atom.
[0020] A dye ratio between the dye components (i), (ii) and (iii) in the composition may vary depending on a desired dyeing concentration.
[0021] Upon dyeing of the dye components (i), (ii) and (iii), a mixing ratio therebetween may be in a range of 0.1 to 99.9:0.1 to 99.9:0.1 to 99.9 and preferably 1 to 99:1 to 99:1 to 99.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Hereinafter, the present invention will be described in more detail.
[0023] Preferred examples of a reactive red dye of Formula 1 in accordance with the present invention may include compounds represented by Formulae 7, 8 and 9:
[0024] wherein X1 and Y1 are as defined in Formula 1; and
[0025] B is a substituent group of Formula 6a, 6b or 6c, provided that fluorine and chlorine are excluded unlike X1 in Formula 1.
[0026] The reactive red dye of Formula 1 in accordance with the present invention may be prepared via reaction involving many steps of condensation, and a preferred example of such a method includes the following reaction steps:
[0027] (1) condensing a compound of Formula 6a or 6b, or the following Formula 10 with 2,4,6-trihalogeno-s-triazine, thereby preparing a compound of the following Formula 11 or 12;
[0028] (2) condensing a compound of the following Formula 11 or 12 with a compound of Formula 6a, Formula 6b or the following Formula 10, thereby preparing a compound of the following Formula 13; and
[0029] (3) condensing the compound of Formula 13 prepared in step (2) with the compound of Formula 6c, thereby preparing a compound of Formula 1.
[0030] Unless otherwise specified, R1, R2, R3, R4, X1 and Y1 in Formulae 1, 10, 11, 12 and 13 are as defined in Formulae 1, 10, 11, 12 and 13.
[0031] Condensation (1) may be carried out in an organic medium, an aqueous medium, or an aqueous-organic medium, and is preferably carried out in the aqueous medium in the presence of an acid-binding agent. Preferred examples of the acid-binding agent may include carbonates, bicarbonates and hydroxides of alkali metals, carbonates, bicarbonates and hydroxides of alkaline earth metals, alkali metal acetates and mixtures thereof, and tertiary amines. Preferred examples of the alkali metals and alkaline earth metals may include lithium, sodium, potassium and calcium. Preferred examples of the tertiary amines may include pyridine, triethylamine and quinoline. Condensation (1) is carried out at a temperature of −10 to 40° C. and more preferably 0 to 10° C. and a pH of 1.0 to 9.0.
[0032] Similar to condensation (1), condensation (2) may also be carried out in an organic medium, an aqueous medium, or an aqueous-organic medium, and is preferably carried out in the aqueous medium in the presence of an acid-binding agent. Condensation (2) is carried out at a temperature of 10 to 70° C. and a pH of 2.0 to 9.0, and more preferably is carried out at a temperature of 20 to 60° C. and a pH of 2.0 to 8.0.
[0033] Further, similar to condensation (1), condensation (3) may also be carried out in an organic medium, an aqueous medium, or an aqueous-organic medium, and is preferably carried out in the aqueous medium in the presence of an acid-binding agent. Condensation (3) is carried out at a temperature of 50 to 100° C. and a pH of 1.0 to 9.0, and more preferably is carried out at a temperature of 20 to 60° C. and a pH of 2.0 to 5.0.
[0034] In addition to the above-mentioned methods, various methods for preparing the dye compound of Formula 1 can be employed. Those of ordinary skill in the art will apparently appreciate such methods through the methods as discussed above, without specific details thereof.
[0035] The reactive dye composition in accordance with the present invention may further optionally include a compound of Formula 14:
[0036] wherein R20, R21, R22 and R23 are independently hydrogen, or C1-C4 alkyl which may be substituted or unsubstituted with hydroxyl, sulfo, sulfato or carboxyl group;
[0037] Y6 is a substituent group of Formula 6a, 6b or 6c;
[0038] X6 is a substituent group of Formula 6a, 6b or 6c, which is an N-heterocyclic group capable of further containing halogen, hydroxyl, 3-carboxypyridin-1-yl, 3-carbamoylpyridin-1-yl, C1-C4 alkoxy group, C1-C4 alkylthio group, unsubstituted or substituted amino group, or a hetero atom; and
[0039] Z1 and Z2 are independently unsubstituted or substituted C2-C10 alkylene.
[0040] The dye composition in accordance with the present invention is suitable as a dye for dyeing a fiber material containing nitrogen or hydroxyl group. Such a fiber material that can be used in the present invention includes, for example natural cellulose fibers such as cotton, flax and hemp, pulp and recycled cellulose. Particularly preferred is cotton. The combination in accordance with the present invention is also suitable for dyeing a cellulose blended fabric, for example cotton/polyester, cotton/nylon blended fabric and the like.
[0041] An amount of the dye composition to be used may vary depending on a degree of desired coloration. The dye composition in accordance with the present invention may be used in an amount of 0.01 to 10% by weight, and preferably 0.01 to 6% by weight, based on the fabric to be dyed.
[0042] The dye composition in accordance with the present invention is particularly suitable for dyeing via an exhaustion method.
[0043] The exhaustion method of dyeing is usually carried out in an aqueous medium, at a reaction temperature of 20 to 105° C., preferably 30 to 90° C. and more preferably 40 to 80° C., using the dye and water in a weight ratio of 1:2 to 1:60 and preferably 1:5 to 1:20.
[0044] Alternatively, other suitable dyeing methods such as pad dyeing may be used. In pad dyeing, a fabric is typically impregnated and reacted in an aqueous solution, saline or a salt solution. Here, the pick-up rate is in a range of 20 to 150%, preferably 50 to 100%, based on the weight of the fiber material to be dyed. The aqueous solution may contain a fixing alkali in advance, or if necessary, the fiber material may be treated with the fixing alkali after impregnation. Examples of suitable alkali metals include sodium carbonate, sodium bicarbonate, sodium hydroxide, disodium phosphate, trisodium phosphate, sodium borate, aqueous ammonia, sodium trichloroacetate, sodium silicate, and a mixture thereof. Among these compounds, an alkali hydroxide and/or alkali carbonate, particularly sodium hydroxide and/or sodium carbonate are preferred.
[0045] Fixation of the dye may be carried out, for example by steam-treating the impregnated fiber material at a temperature of 100 to 120° C., particularly via thermal action such as by saturated steam. According to so-called cold pad-batch method, the dye and alkali metal are introduced to a padder, and they are stored and fixed at room temperature for several hours, for example 3 to 40 hours. After fixation, if desired, a dispersant is added to the resulting dyed product, followed by thorough rinsing.
[0046] The dyed product obtained according to the present invention exhibits superior build-up and levelness properties. In addition, the dyed product exhibits high fixability of the dye, capability to easily wash and remove the non-fixed dye, and a small difference between adsorptivity and fixability, that is, a low loss of soap. Further, the dyed product obtained exhibits a high degree of coloration, high stability of fiber-dye bonding, superior fastness against washing, brine, cross-dyeing and sweating, and high fastness against wrinkles, ironing and friction, and particularly superior light fastness.
EXAMPLES
[0047] Now, the present invention will be described in more detail with reference to the following Examples. These examples are provided only for illustrating the present invention and should not be construed as limiting the scope and sprit of the present invention.
Example 1
[0048] 51.8 g of a compound of Formula 15 as shown below was dissolved in 500 g of water, and 100 g of ice was added to the resulting solution which was then cooled. 19.0 g of cyanuric chloride was added to the solution and the mixture was stirred and reacted at 5° C. and pH 5 for 2 hours. Thereafter, 22.5 g of 2-aminoethyl-2′-sulfatoethylsulfone was added and condensation was carried out at 30° C. and pH 7.5. 31.0 g of 3-sulfatoethylsulfone-1-aminobenzene was added to the resulting solution and the reaction was completed at 70° C. and pH 2.5. The reaction solution was filtered to remove insoluble materials, followed by salting out using 150 g of sodium chloride. The resulting crystals were dried to obtain 92.5 g of a compound of Formula 16 as shown below:
Example 2
[0049] 51.8 g of the compound of Formula 15 was dissolved in 500 g of water, and 100 g of ice was added to the resulting solution which was then cooled. 19.0 g of cyanuric chloride was added to the solution and the mixture was stirred to complete the reaction at 5° C. and pH 5 for 2 hours. Thereafter, 22.5 g of 2-aminoethyl-2′-sulfatoethylsulfone was added, and condensation was carried out at 30° C. and pH 7.5. 9.0 g of morpholine was added to the resulting solution and the reaction was completed at 80° C. and pH 9. The reaction solution was filtered to remove insoluble materials, followed by salting out using 130 g of sodium chloride. The resulting crystals were dried to obtain 81.5 g of a compound of Formula 17 as shown below:
Example 3
[0050] 43.8 g of a compound of Formula 18 as shown below was dissolved in 500 g of water, and 100 g of ice was added to the resulting solution which was then cooled. 19.0 g of cyanuric chloride was added to the solution and the mixture was stirred to complete the reaction at 5° C. and pH 5 for 2 hours. Thereafter, 31.3 g of 2-(N-ethylamino)ethyl-2′-sulfatoethylsulfone was added thereto, and condensation was carried out at 25° C. and pH 7.5, thereby completing the reaction. The reaction solution was filtered to remove insoluble materials, and subjected to salting out using 130 g of sodium chloride. The resulting crystals were dried to obtain 83.5 g of a compound of Formula 19 as shown below:
Examples 4 Through 23
[0051] Based on procedures in Examples 1 through 3, it was possible to synthesize compounds listed in Table 1. A specific preparation method of these compounds can be sufficiently deduced through Examples 1 through 3 based on chemical structures of the products, and thus details thereof will be omitted herein.
[0052] For convenience to illustrate Table 1, n, X1 and Y1 were indicated in a compound of Formula 20 as shown below:
TABLE 1 Color of dyed Ex. No. n X1 Y1 product 4 0 Cl 4-(2- Yellowish sulfatoethylsulfonyl)phenylamino red 5 0 F 3-(2- Yellowish sulfatoethylsulfonyl)phenylamino red 6 0 Cl N-ethyl-N-(3-(2- Yellowish sulfatoethylsulfonyl)phenylamino red 7 0 3-(2- 2-(2-sulfatoethylsulfonyl)ethylamino Red sulfatoethylsulfonyl)phenylamino 8 0 Morpholino N-ethyl-N-(3-(2- Red sulfatoethylsulfonyl)phenylamino 9 0 Cl 3-(2- Yellowish sulfatoethylsulfonyl)phenylamino red 10 0 3-(2- 4-(2- Red sulfatoethylsulfonyl)phenylamino sulfatoethylsulfonyl)phenylamino 11 0 Morpholino N-ethyl-N-(4-(2- Red sulfatoethylsulfonyl)phenylamino 12 0 4-(2- 3-(2- Red sulfatoethylsulfonyl)phenylamino sulfatoethylsulfonyl)phenylamino 13 0 Morpholino 3-(2- Red sulfatoethylsulfonyl)phenylamino 14 0 Cl 3-(2- Yellowish sulfatoethylsulfonyl)phenylamino red 15 1 Cl 4-(2- Red sulfatoethylsulfonyl)phenylamino 16 1 F N-ethyl-N-(4-(2- Red sulfatoethylsulfonyl)phenylamino 17 1 Cl N-ethyl-N-(3-(2- Red sulfatoethylsulfonyl)phenylamino 18 1 4-(2- 2-(2-sulfatoethylsulfonyl)ethylamino Blue red sulfatoethylsulfonyl)phenylamino 19 1 F N-ethyl-N-(3-(2- Red sulfatoethylsulfonyl)phenylamino 20 1 Cl 3-(2- Red sulfatoethylsulfonyl)phenylamino 21 1 3-(2- 4-(2- Blue red sulfatoethylsulfonyl)phenylamino sulfatoethylsulfonyl)phenylamino 22 1 Morpholino N-ethyl-N-(4-(2- Blue red sulfatoethylsulfonyl)phenylamino 23 1 4-(2- 3-(2- Blue red sulfatoethylsulfonyl)phenylamino sulfatoethylsulfonyl)phenylamino
[0053] The compounds of Examples 1 through 23 are dyes having excellent fiber-reactive properties, and combination dyeing using such compounds exhibits superior adsorptivity/fixability and very high light fastness, when dyeing a fiber material containing nitrogen or hydroxyl group. The results of light fastness are shown in Table 2 below.
TABLE 2 C.I. Reactive C.I. Reactive Ex. 1 Ex. 3 Red 180 Red 195 Light fastness 4˜5 4 3 3
Application Example 1
[0054] 0.2 g of each compound of Formulae 16, 21 and 22 was dissolved in 400 g of water. The resulting solution was added to 1,500 g of a solution containing 53 g/L of sodium chloride, thereby preparing a dye bath. 100 g of a cotton fabric was added at 40° C. to the dye bath, and 100 g of a solution containing 16 g/L of sodium hydroxide and 20 g of sodium carbonate was added after 45 min. Additionally, the temperature of the dye bath was further maintained at 60° C. for 60 min. Next, the dyed fabric was rinsed, soaped with a nonionic detergent for 25 min upon bubbling, and then rinsed again and dried. The dyed product thus obtained exhibited very high light fastness.
Application Example 2
[0055] 0.3 g of each compound of Formulae 17, 23 and 24 was dissolved in 400 g of water. The resulting solution was added to 1,500 g of a solution containing 16 g/L of sodium hydroxide, thereby preparing a dye bath. 100 g of a cotton fabric was padded at 25° C. in the dye bath, and was wound on a padding roll and stored at room temperature for 1 hour. Next, the dyed fabric was rinsed, soaped with a nonionic detergent for 25 min upon bubbling, and then rinsed again and dried. The dyed product thus obtained exhibited excellent wash fastness and particularly very high light fastness.
Application Example 3
[0056] 0.1 g of each compound of Formulae 17, 25 and 26 was dissolved in 400 g of water. The resulting solution was added to 1,500 g of a solution containing 53 g/L of sodium chloride, thereby preparing a dye bath. 100 g of a cotton fabric was added at 40° C. to the dye bath, and 100 g of a solution containing 16 g/L of sodium hydroxide and 20 g of sodium carbonate was added after 45 min. Additionally, the temperature of the dye bath was further maintained at 60° C. for 60 min. Next, the dyed fabric was rinsed, soaped with a nonionic detergent for 25 min upon bubbling, and then rinsed again and dried. The dyed product thus obtained exhibited excellent wash fastness and particularly very high light fastness.
[0057] Based on procedures in previous Examples, it is possible to make an appropriate combination of the reactive dye compounds given in Examples 1 through 23. A variety of other mixing ratios can also be sufficiently deduced by those of ordinary skill in the art and thus details thereof will be omitted herein.
Comparative Example 1
[0058] 0.1 g of each compound of C.I. Reactive Red 180, and Formulae 27 and 28 was dissolved in 400 g of water. The resulting solution was added to 1,500 g of a solution containing 53 g/L of sodium chloride, thereby preparing a dye bath. 100 g of a cotton fabric was added at 40° C. to the dye bath, and 100 g of a solution containing 16 g/L of sodium hydroxide and 20 g of sodium carbonate was added after 45 min. Additionally, the temperature of the dye bath was further maintained at 60° C. for 60 min. Next, the dyed fabric was rinsed, soaped with a nonionic detergent for 25 min upon bubbling, and then rinsed again and dried, thereby obtaining the dyed product.
Comparative Example 2
[0059] 0.1 g of each compound of C.I. Reactive Red 195, and Formulae 24 and 29 was dissolved in 400 g of water. The resulting solution was added to 1,500 g of a solution containing 53 g/L of sodium chloride, thereby preparing a dye bath. 100 g of a cotton fabric was added at 40° C. to the dye bath, and 100 g of a solution containing 16 g/L of sodium hydroxide and 20 g of sodium carbonate was added after 45 min. Additionally, the temperature of the dye bath was further maintained at 60° C. for 60 min. Next, the dyed fabric was rinsed, soaped with a nonionic detergent for 25 min upon bubbling, and then rinsed again and dried, thereby obtaining the dyed product.
Comparative Example 3
[0060] 0.1 g of each compound of C.I. Reactive Red 195, and Formulae 25 and 26 was dissolved in 400 g of water. The resulting solution was added to 1,500 g of a solution containing 53 g/L of sodium chloride, thereby preparing a dye bath. 100 g of a cotton fabric was added at 40° C. to the dye bath, and 100 g of a solution containing 16 g/L of sodium hydroxide and 20 g of sodium carbonate was added after 45 min. Additionally, the temperature of the dye bath was further maintained at 60° C. for 60 min. Next, the dyed fabric was rinsed, soaped with a nonionic detergent for 25 min upon bubbling, and then rinsed again and dried, thereby obtaining the dyed product.
[0061] Light fastness of the dyed products obtained in Application Examples 1 through 3 and Comparative Examples 1 through 3 was measured according to an AATCC 16E test method. The results thus obtained are shown in Table 3 below.
TABLE 3 Appl. Appl. Comp. Comp. Comp. Ex. 1 Ex. 3 Ex. 1 Ex. 2 Ex. 3 Light 4˜5 4 2 2˜3 3 fastness Decol- Uniform Uniform Uniform Nonuniform Nonuniform oration
[0062] As apparent from the above description, fiber products using the fiber-reactive dye composition in accordance with the present invention exhibit superior adsorptivity and fixability, upon dyeing a fiber material, particularly a cellulose fiber material by a conventional fixation method, and display very high fastness against light and wet treatment.
[0063] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Provided is a reactive dye composition, comprising (i) a reactive red dye represented by Formula 1; (ii) one or more reactive dyes selected from the group consisting of a reactive yellow dye represented by Formula 2, a reactive orange dye represented by Formula 3 and a mixture thereof; and (iii) one or more reactive dyes selected from the group consisting of a reactive blue dye represented by Formula 4, a reactive blue dye represented by Formula 5 and a mixture thereof; and a method of dyeing a fiber material containing nitrogen or hydroxyl group using the same. Therefore, it is possible to provide fiber products having superior light fastness and combined colors. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to a gas separation assembly and membrane gas separation processes wherein the assembly is comprised of hollow fiber membranes capable of selectively permeating one component of fluid mixture over other components. More particularly, the invention relates to a membrane gas separation assembly which provides an internal countercurrent sweep and processes that utilize this assembly.
BACKGROUND OF THE INVENTION
[0002] It is known in the art to use various hollow fiber membrane gas separation devices for separating gas mixtures. Normally, these separation devices are designed so that the gas mixture can be brought into contact with the hollow fiber membrane therein under a partial pressure differential one or more highly permeable components of the fluid mixture are being separated from the less permeable components. The hollow fiber membrane allows the more readily permeable component of the fluid mixture to permeate into the permeate side of the hollow fiber membrane while retaining a substantial portion of the less readily permeable component of the fluid mixture on the non-permeate side of the hollow fiber membrane. The permeated and non-permeated components are removed through or recovered from at least one permeate outlet and at least one non-permeate outlet, respectively.
[0003] In some instances the membrane gas separation devices, (assemblies) are designed to provide a purge or a sweep gas on the permeate side of the membrane. The use of a sweep gas on the permeate side of the membrane is beneficial in certain gas separation processes, such as gas dehydration processes, since it decreases the permeate side partial pressure of the more highly permeable component thus allowing the gas mixture to be more thoroughly stripped of the more readily permeable component. The sweep gas is typically flown counter currently to the direction of the feed—non-permeate flow. The use of a dry sweep gas can improve the product gas dryness as well as the productivity of the membrane device. A portion of the dry product gas is frequently utilized as the sweep gas generating an internal reflux system.
[0004] The gas separation assembly that provides for sweep or purge gas introduction generally comprises an annular hollow fiber membrane bundle in an enclosure or a shell having a fluid feed inlet, a non-permeate outlet, a permeate outlet and a sweep or purge gas inlet. Examples of such membrane assemblies can be found in U.S. Pat. Nos. 3,499,062, 4,718,921, 5,108,464 and 5,026,479. These fluid separation devices, however, require external plumbing and valves to regulate the flow of the sweep gas to be fed to the sweep gas inlet port. In some gas separation applications, such as gas drying, a portion of the non-permeate product (the dry gas) is used as the sweep gas. The need to manifold the dry sweep gas external to the gas separation apparatus adds to the size and the complexity of the device.
[0005] Several attempts have been made to provide an internal sweep gas arrangement and an internal sweep gas flow control. U.S. Pat. Nos. 5,411,662 and 5,525,143 disclose such integral hollow fiber devices.
[0006] The hollow fiber membrane assemblies with integral internal purge arrangements, however, can have a number of disadvantages. The purge flow does not shut down automatically when the product (non-permeate) gas is not being withdrawn from the device. The feed flow to the assembly must be shut down or a valve on the purge flow line must be installed and closed to prevent a continuous loss of the feed gas through the purge conduit. Furthermore, the purge flow will remain constant irrespective of product draw or the required product dew point. Several attempts have been made to regulate the purge flow rate according to the feed or product flow rates or the level of product dryness required. Examples can be found in U.S. Pat. Nos. 5,160,514, 6,006,383 and the U.S. Pat. No. 5,411,662 referenced above and in JP09057043. However, these designs are complicated and difficult to implement. Thus, there still remains a need in the field for an improved hollow fiber gas separation assembly with internal reflux system.
[0007] Accordingly, it is an object of the invention to provide means by which the operation of the gas separation apparatus equipped with a reflux system can be carried out without external plumbing and valves. It is another object of the invention to provide means by which the gas separation apparatus having a purging means can be easily implemented and operated. It is a further object of this invention to provide a means to reduce gas losses through the purge gas conduit when the membrane separation assembly is not in operation. It is a further object of the present invention to provide a means to adjust the volume of the purge flow according to the amount of non-permeate gas withdrawn without the need for external intervention, outside energy sources or complicated peripheral devices.
SUMMARY OF THE INVENTION
[0008] The present invention provides a hollow fiber membrane gas separation assembly having a counter current sweep of the permeate side of the hollow fibers with a portion of the product gas wherein the sweep gas is introduced internally to the assembly. The assembly is comprised of an elongated casing or shell having a feed gas inlet and permeate and product gas outlets. The outlets are positioned essentially at the same end of the casing, and the feed inlet is appropriately located between the tubesheets. The casing encloses a multiplicity of hollow fiber membranes positioned around an inner, tubular core member. The hollow fibers extend between two tubesheets, each end of hollow fibers terminating in a tubesheet and being opened to allow unobstructed gas flow into and out of the hollow fiber bores. Means such as O-rings to secure and seal tubesheets to the casing in fluid tight relationship are further provided. The ends of the tubular core member are open through the ends of the tubesheets. The assembly is provided with at least one purge flow control orifice positioned in the tubular core member that directs predetermined amount of the product gas into hollow fiber bores as a counter current sweep. According to one embodiment of the present invention an on-off valve is positioned in the tubular core member that substantially shuts off the flow of the purge gas when the product gas is not withdrawn from the assembly.
[0009] According to another embodiment of the present invention a purge flow control valve is positioned in the tubular core member that regulates the volume of the purge gas in proportion to the amount of product gas withdrawn from the assembly.
[0010] The invention further provides for gas dehydration processes that utilize the disclosed novel gas separation apparatuses. The gas dehydration processes of this invention are designed to remove predetermined amounts of the water vapor contained in the feed gas wherein the amount of sweep gas utilized to purge the permeate side of hollow fiber membranes is minimized. The sweep gas flow is generally from about 1% to about 80%, preferably from 5% to about 60%, of the net flow rate of the dehydrated product gas.
BRIEF DESCRIPTION OF DRAWINGS
[0011] [0011]FIG. 1 is a sectional view of a shell side feed gas separation device having an internal purge control valve in accordance with one embodiment of the present invention.
[0012] [0012]FIG. 2 is a sectional view of a shell side feed gas separation device with an on/off type internal purge control valve in accordance with another embodiment of the present invention.
[0013] [0013]FIGS. 3 a and 3 b are enlarged fragmented views of the internal purge control valve of the embodiment in FIG. 2 in off and on operating positions, respectively.
[0014] [0014]FIGS. 4 a and 4 b are an enlarged fragmented view of the another embodiment of the present invention wherein the purge flow control means is a variable flow purge control valve shown in off and on positions, respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In FIG. 1 there is illustrated a sectional view of one preferred gas separation assembly. In this embodiment the gas is introduced to the shell side, i.e. the exterior of hollow fiber membranes. The fluid separation assembly comprises a casing ( 1 ) having at least one feed gas inlet ( 2 ) and at least one combined permeate and sweep gas outlet ( 3 ) and at least one dry product gas outlet ( 4 ) surrounding an annular hollow fiber membrane bundle ( 5 ). A novel feature of the present invention is that the permeate and product gas outlets (ports) are located essentially at the same end of the casing while the counter current flow configuration between the permeate/sweep and product/feed gas streams is still maintained.
[0016] The casing is an enclosure or a pressure shell that can be made of a metal, a plastic or other appropriate material. The casing ( 1 ) contains two end caps ( 8 and 9 ) sealed to the bundle ( 5 ) by means of o-rings to form a fluid tight seal. Other means of securing and sealing the hollow fiber bundle to the casting known to those in the art can also be employed. The hollow fiber bundle is uniformly arranged around a central core member ( 6 ). In one preferred embodiment the hollow fibers are wound around the central tubular core member to form a structured hollow fiber bundle. The use of wound or other structured hollow fiber configurations are well known in the art.
[0017] Examples of wound hollow fiber configurations and winding procedures can be found in U.S. Pat. Nos. 4,881,955 and 5,702,601. FIG. 1 shows a parallel, straight arrangement of hollow fibers. Both ends of the hollow fiber bundle are encapsulated in tubesheets ( 10 , 14 ) with both ends of the inner core member opening out through the ends of the tubesheets. The inner core member ( 6 ) may be an elongated tube having openings ( 12 ) near one of the tubesheets ( 14 ) to permit the flow of gas between the exterior surface of the hollow fibers and the interior of the inner core member. The size, number and location of these openings are dependent upon the size of the assembly and the volume of the gas transported. In an optimal counter current flow arrangement the openings are generally situated at the point from about one percent or less to a point up to 25 percent of the longitudinal length between the two tubesheets. The opening can be in the form of holes, cut slots or other perforations. The cross-sectional area occupied by the openings is essentially determined by pressure drop requirements and is preferably kept to an acceptable minimum cross-section. The central core member can be made from any tubular material, such as metal, plastic, composite laminate and the like. The ends of each tubesheet are severed and the hollow fiber bores are opened to allow unobstructed gas flow into and out of the hollow fiber bores.
[0018] In a preferred embodiment, the exposed hollow fiber bundle between the tubesheets ( 10 ) may be encased with an essentially non-permeable film barrier ( 7 ) except for a non-encased circumferential region ( 13 ) near one of the ends of the hollow fiber bundle ( 5 ) that is located at the end opposite to the end where the openings ( 12 ) are located. A purge flow control orifice, i.e. a fluid flow aperture, ( 11 ) is installed into the end opening of the inner core member ( 6 ).
[0019] The application of the assembly for gas dehydration is further discussed below. In practice of the gas separation assembly ( 1 ) the wet gas stream is fed through the gas inlet port ( 2 ) and then through the circumferential region ( 13 ) into hollow fiber bundle ( 5 ). The gas is flown along hollow fiber membranes wherein the water vapor is stripped from the gas. The dried gas is transported through openings ( 12 ) into the inner core member ( 6 ). The dry gas is split into two unequal streams. The major portion, the dry product is transported through the inner core member to the exit port ( 4 ), while a fraction of the dry gas is directed through the purge flow control orifice ( 11 ) into hollow fiber bores. The flow control orifice ( 11 ) is sized to direct a predetermined fraction of the dry gas as the sweep. The sweep stream enriched with the wet permeate gas is discharged through outlet ( 3 ) as a wet waste gas.
[0020] In FIGS. 2 through 3 a sectional view of one, preferred gas separation assembly equipped with an onoff purge flow controlling means ( 15 ) is illustrated. The fluid flow controlling means ( 15 ) comprises a valve stem ( 16 ) vertically extending through the internal core member ( 6 ) and positioned adjacent to the purge control orifice ( 11 ). The internal core member ( 6 ) forms the exterior body of the flow control means. The first end ( 17 ) of the valve stem ( 16 ) is positioned above openings ( 12 ) that provide for introduction of the dry gas into the internal conduit of the core member ( 6 ). The second end ( 18 ) of the valve stem is positioned below openings ( 12 ) that provide for introduction of the dry gas into the internal core member ( 6 ) and the purge control orifice ( 11 ). Thus the first and the second end of the valve stem are positioned in the dry product gas and the purge gas flow channels respectively.
[0021] The purge control means stays open when the dry gas is utilized by the user and is drawn through the exit port ( 4 ) from the membrane drying assembly. The pressure caused by the flow of the dry gas withdrawn from the assembly lifts the valve stem to allow for the purge gas to be delivered to the purge flow control orifice as shown in FIG. 3 b . The purge control means is biased by pressure so as to stay closed when the product dry gas is not withdrawn by the user. The closure can be actuated by mounting the assembly in a vertical position or by incorporating a counter spring (not shown). The counter spring provides for flexible directional mounting of the device. The second end ( 18 ) of the valve stem ( 16 ) is designed as to allow a small, controlled amount of bypass even when the dry gas is not withdrawn by the user and the purge flow control means is in the closed position as shown in FIG. 3 a . This is necessary to allow for the valve stem to be easily lifted to open the flow control means as the dry gas is withdrawn from the device. Furthermore, the bypass flow ensures continuous purge of the water vapor as it permeates through hollow fiber membranes, therefore the membrane dryer remains continuously ready for operation. The bypass flow should preferably be less than 20 percent of the amount of the purge flow through the purge control orifice ( 11 ) generated during the continuous drying operating of the device, most preferably less than 5 percent of the amount of the purge flow.
[0022] The purge control means can be further modified as shown in FIGS. 4 a and 4 b to provide a variable purge that is adjusted towards the amount of the product dry gas withdrawn from the device by the user. The purge control means ( 22 ) is biased so as to stay closed when the product dry gas is not withdrawn, FIG. 4 a . The closure can be preferably actuated by a counter spring (not shown). The first end ( 21 ) of the valve stem ( 20 ) is designed to be moved in a direct proportion to the amount of the dry gas withdrawn from the device. The movement of the first end of the valve stem in response to the flow of dry gas generates a corresponding movement in the second end of the valve stem and a corresponding change in the amount of the purge gas. The second end ( 19 ) of the valve stem ( 20 ) is designed so as to allow a small controlled amount of bypass even when the dry gas is not withdrawn from the device as discussed above.
[0023] The use of an additional fixed purge flow orifice ( 11 ) in this embodiment is optional, and the flow of purge gas can be controlled by the variable restriction (aperture) of the second end of the valve stem.
[0024] The membrane devices of this invention are particularly useful for gas separations that utilize a fraction of the product as a purge. These processes include gas drying processes such as air drying and natural gas drying.
[0025] Although this invention has been described in detail with reference to certain embodiments, those stilled in the art will recognize that there are other embodiments of the invention within the spirit and the scope of the claims. | The present invention provides a hollow fiber membrane gas separation assembly having an integral purge control aperture or purge reflux system which is internal to the hollow fiber apparatus. The assembly is particularly useful for separating water vapor from a gas stream. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2004-355240 filed on Dec. 8, 2004, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a piezoelectric driving type MEMS apparatus that is manufactured utilizing a MEMS (Micro-Electro-Mechanical Systems) technique.
[0004] 2. Related Art
[0005] In recent years, attention is paid to a technique for manufacturing such a high frequency element as a variable capacitor or a switch utilizing a MEMS. A variable capacitor obtained by the MEMS has such an advantage that a Q value thereof is higher than that of a variable capacitance diode. On the other hand, the MEMS switch has such merits that an insertion loss thereof is low and isolation property thereof is excellent compared to PIN diode and GaAsFET based-switch (for example, see U.S. Pat. No. 4,670,682). The merits come from a feature of the MEMS that can manufacture a mechanically movable portion.
[0006] In order to manufacture the mechanically movable portion, it is necessary to provide an actuator for converting an electrical signal to a mechanical behavior. Actuators can be classified to some types according to their driving systems. As well-known driving systems, there are ones of an electrostatic type, a thermal type, an electromagnetic type and a piezoelectric type. The piezoelectric type driving system is constituted to realize a movable structure utilizing a piezoelectric effect of piezoelectric material. The piezoelectric type actuator has such an advantage that both a low voltage operation and a low power consumption can be realized. Therefore, an MEMS variable capacitor or a MEMS switch utilizing a piezoelectric type actuator is suitable for a high frequency part for a portable device or equipment.
[0007] A conventional MEMS variable capacitor employs such a structure that a lower electrode for the variable capacitor is provided at a central portion of a substrate, supporting portions are provided at both ends of the substrate, and a beam which is supported by the supporting portions to displace toward the substrate is provided. The beam is provided with a first insulating film, a first electrode film that is provided on the first insulating film to extend from one end of the beam to the other end thereof, piezoelectric films which are provided on both end portions of the first electrode film except for a central portion thereof, second electrode films which are provided on the piezoelectric films, and a second insulating film which covers the first and second electrode films. As material for the piezoelectric film, PZT, AlN, ZnO, or the like is used. Incidentally, the first electrode film serves as an upper electrode for the variable capacitor.
[0008] When different voltages, V 1 and V 2 , are respectively applied to the first electrode film and the second electrode film the piezoelectric films strain so that the length of the beam in its extending direction (hereinafter, “X-axis direction”) varies. When it is assumed that a length L x of the piezoelectric film in the X-axis direction has changed to L x +ΔL x due to voltage application, a strain ε x =ΔL x /L x can be expressed by the following equation (1).
ε x =d 31 ( V 1 −V 2)/ t (1)
Here, t represents a thickness of a piezoelectric film, and d 31 represents a piezoelectric constant. The piezoelectric constant d 31 is a parameter which represents amounts of strain occurring in the X-axis direction and in a direction (hereinafter, “Y-axis direction) orthogonal to the X and Z axes and a film thickness direction of the piezoelectric film (hereinafter, “Z-axis direction”) when electric field is applied in the Z-axis direction, whose value varies according to piezoelectric material. The beam including the piezoelectric films flexes in the direction of the substrate due to strain in the piezoelectric film so that a distance between the first electrode (film) and the lower electrode changes. A change δ z of the distance between the electrodes meets the following relationship or equation (2).
δ z α d 31 (V1−V2)L x 2 (2)
[0009] Accordingly, according to increase of a length of the piezoelectric film in the X-axis direction, namely, a length of the beam, a variable range of the capacitor is increased.
[0010] Since a cavity is formed under the upper electrode in an MEMS variable capacitor with such a structure, there is such a drawback that, when an acceleration is applied to the MEMS variable capacitor, the upper electrode may move, which results in change in capacitance value. In order to make it harder for the upper electrode to move even when acceleration is applied to the MEMS variable capacitor, such a constitution can be employed that the beam and the upper electrode are reduced in weight and a width L y of the beam which supports the upper electrode is increased. When the MEMS variable capacitor is mounted to a portable device, there is a high possibility that the portable device is used under an environment where acceleration is applied to the portable device. Therefore, such a countermeasure as widening of the beam becomes important among others.
[0011] However, when the width L y of the beams is increased, the piezoelectric film also strains in the Y-axis direction at a time of application of voltage to the first and second electrodes. A strain ε y (=ΔL y /L y ) in the Y-axis direction can be expressed as follows:
ε y =d 32 ( V 1 −V 2)/ t (3)
Here, d 32 represents a piezoelectric constant. The beam flexes in the Y-axis direction toward the substrate due to the strain. As a result, such a problem occurs that the upper electrode and the lower electrode do not become parallel to each other so that a desired capacitance value can not be obtained. Incidentally, a displacement amount due to flexion, namely, δ y is proportional to square of the beam width L y .
[0012] The flexion of the beam also causes a problem in a piezoelectric type MEMS switch. In order to prevent the isolation property during turning-off of the MEMS switch from depending on acceleration, it is necessary to increase the width of the beam in the MEMS switch. As a result, however, the flexion of the beam also occurs in the Y-axis direction during voltage application. Therefore, when the switch turns on, the electrodes at a contact portion do not become parallel to each other, and they come in contact with each other at only one point. As a result, a resistance occurring when the switch turns on increases and an insertion loss increases so that a desired property can not be obtained. Further, the increase in resistance tends to cause malfunction in the switch due to melting of the electrodes at the contacting portion.
SUMMARY OF THE INVENTION
[0013] A piezoelectric driving type MEMS apparatus according to an aspect of the present invention includes: a supporting portion provided on a substrate; and a piezoelectric actuator, which is supported on the supporting portion, including a piezoelectric film and a driving electrode configured to drive the piezoelectric film, the piezoelectric film in the piezoelectric actuator having at least one slit extending along a longitudinal direction of the piezoelectric actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a plan view showing a piezoelectric driving type MEMS apparatus according to a first embodiment of the present invention;
[0015] FIG. 2 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 1 ;
[0016] FIG. 3 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 1 ;
[0017] FIG. 4 is a plan view showing a piezoelectric driving type MEMS apparatus according to modification of the first embodiment of the present invention;
[0018] FIG. 5 is a plan view showing a piezoelectric driving type MEMS apparatus according to a second embodiment of the present invention;
[0019] FIG. 6 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 5 ;
[0020] FIG. 7 is a plan view showing a piezoelectric driving type MEMS apparatus according to a third embodiment of the present invention;
[0021] FIG. 8 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 7 ;
[0022] FIG. 9 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 7 ;
[0023] FIG. 10 is a plan view showing a piezoelectric driving type MEMS apparatus according to a fourth embodiment of the present invention;
[0024] FIG. 11 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 10 ;
[0025] FIG. 12 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 10 ;
[0026] FIG. 13 is a plan view showing a piezoelectric driving type MEMS apparatus according to a fifth embodiment of the present invention;
[0027] FIG. 14 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 13 ;
[0028] FIG. 15 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 13 ;
[0029] FIG. 16 is a plan view showing a piezoelectric driving type MEMS apparatus according to a sixth embodiment of the present invention;
[0030] FIG. 17 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 16 ;
[0031] FIG. 18 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 16 ;
[0032] FIG. 19 is a plan view showing a piezoelectric driving type MEMS apparatus according to a seventh embodiment of the present invention;
[0033] FIG. 20 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 19 ;
[0034] FIG. 21 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 19 ;
[0035] FIG. 22 is a plan view showing a piezoelectric driving type MEMS apparatus according to a eighth embodiment of the present invention;
[0036] FIG. 23 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 22 ;
[0037] FIG. 24 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 22 ;
[0038] FIG. 25 is a plan view showing a piezoelectric driving type MEMS apparatus according to a first modification of the eighth embodiment of the present invention;
[0039] FIG. 26 is a plan view showing a piezoelectric driving type MEMS apparatus according to a second modification of the eighth embodiment of the present invention;
[0040] FIG. 27 is a plan view showing a piezoelectric driving type MEMS apparatus according to a third modification of the eighth embodiment of the present invention;
[0041] FIG. 28 is a plan view showing a piezoelectric driving type MEMS apparatus according to a fourth modification of the eighth embodiment of the present invention;
[0042] FIG. 29 is a plan view showing a piezoelectric driving type MEMS apparatus according to a ninth embodiment of the present invention;
[0043] FIG. 30 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 29 ; and
[0044] FIG. 31 is a sectional view showing the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 29 .
DETAILED DESCRIPTION OF THE INVENTION
[0045] Embodiments of the present invention will be explained below with reference to the drawings.
First Embodiment
[0046] A piezoelectric driving type MEMS apparatus according to a first embodiment of the invention will be explained with reference to FIGS. 1 to 3 . FIG. 1 is a plan view of the piezoelectric driving type MEMS apparatus according to the embodiment, FIG. 2 is a sectional view of the piezoelectric driving type MEMS apparatus according to the embodiment taken along line A-A shown in FIG. 1 , and FIG. 3 is a sectional view of the piezoelectric driving type MEMS apparatus according to the embodiment taken along line B-B shown in FIG. 1 .
[0047] The piezoelectric driving type MEMS apparatus according to the embodiment is a variable capacitor which has such a constitution that a lower electrode 4 is provided on a central portion of a substrate 2 made from silicon or glass, and a plurality of (for example, three) supporting portions 6 are provided at each of both end portions of the substrate 2 so as to be opposed to corresponding supporting portions 6 at the other end portion thereof. Further, the variable capacitor has a constitution that a beams 10 is spanned between the opposed supporting portions 6 over the lower electrode 4 .
[0048] The beams 10 is provided with an insulating film 11 made from, for example, SiO 2 , a first electrode 12 provided on the insulating film 11 , a piezoelectric film 13 provided on a region of the first electrode 12 except for a central portion of the first electrode 12 , a second electrode 14 provided on the piezoelectric film 13 , and a protective film 15 provided so as to cover the second electrodes 14 and the central portion of the first electrode 12 and made from, for example, SiO 2 . The beam 10 is formed such that a central portion thereof is wider than each end portions thereof (a vertical size or length in FIG. 1 ), and two slits 20 are provided at the end portion so as to extend along a longitudinal direction of the beam 10 so that three branched beams are formed on the each end portion by the slits 20 . Each slit 20 is formed such that a length thereof (a horizontal size or length in FIG. 1 ) is equal to or longer than that of each piezoelectric film 13 . Incidentally, such a constitution is employed that the three branched beams are respectively supported by the supporting portions 6 . Such a constitution is adopted that a height of each supporting portion 6 is larger than a film thickness of the lower electrode 4 , so that a clearance 7 is formed between the lower electrode 4 and the beam 10 (see FIG. 2 ).
[0049] In the embodiment, when a driving voltage V 1 and a driving voltage V 2 are respectively applied to the first electrode 12 and the second electrode 14 , the piezoelectric film 13 strains and a length thereof in its longitudinal direction (the horizontal direction in FIG. 1 ) changes so that the beam 10 flexes toward the lower electrode 4 . A distance between the lower electrode 4 and the first electrode 12 changes due to the flexion so that a capacitance also changes. That is, the beam 10 constitutes a piezoelectric actuator. The first electrode 12 doubles with an upper electrode for the variable capacitor.
[0050] A magnitude relationship between the driving voltages V 1 and V 2 changes according to such a factor as the kind of the piezoelectric film, orientation of polarization, film thickness sizes of films positioned above and below the piezoelectric film, or Young's modulus. For example, a case that an AlN film whose orientation ( FIG. 2 ) of polarization is directed upwardly is used as the piezoelectric film will be explained. A total film thickness of films positioned under the piezoelectric film, namely, the sum of film thicknesses of the insulating film 11 and the first electrode 12 is represented as t 1 , and a total film thickness of films positioned above the piezoelectric film, namely, the sum of film thicknesses of the second electrode 14 and the protective film 15 is represented as t 2 . For simplification, it is assumed that the insulating film 11 , the first electrode 12 , the second electrode 14 , and the protective film 15 are equal in Young's modulus. Since d 31 of AlN is negative, under the condition of t 2 >t 1 , when the driving voltage V 1 is larger than the driving voltage V 2 , the piezoelectric film shrinks so that the actuator moves downwardly and when the driving voltage V 1 is smaller than the driving voltage V 2 , the piezoelectric film stretches so that the actuator moves upwardly. The actuator moves in directions reversed to the above directions under the condition of t 2 <t 1 . Even when PZT is adopted as the piezoelectric film, moving directions of the actuator are similar to those in the above case. However, it is desirable that PZT is used under such a voltage condition that polarization reversal does not occur. This is because the piezoelectric performance of the piezoelectric film degrades due to polarization fatigue caused by repetition of polarization reversal.
[0051] As explained above, in the embodiment, the branched beams are formed by providing the slits 20 on the both ends of the beam 10 . Therefore, since a total sum of widths of the piezoelectric films 13 on the branched beams is smaller than a width of a piezoelectric film of a beam 10 which is not provided with the slits 20 , it is made possible to reduce flexion of the piezoelectric film 13 due to strain in the widthwise direction. For example, when n branched beams are formed by providing (n- 1 ) slits 20 on each of both ends of the beam 10 and a total sum of transverse widths of the n branched beams is set to be equal to a width of a beam where no slit is formed, a displacement amount δ due to strain of a piezoelectric film on one branched beam in a widthwise direction thereof can be reduced to 1/n 2 that in the case that the slits 20 are not provided. Accordingly, as shown in FIG. 3 , a section of the beam 10 takes an approximately flat shape without being deformed substantially. Thereby, the lower electrode 4 and the upper electrode 12 constituting the capacitor become substantially parallel to each other, so that a desired capacitance can be obtained.
[0052] When the total sum of the widths of the branched beams is set to be equal to the width of the beam where the slits are not provided, acceleration tolerance can be prevented from deteriorating.
[0053] As shown in FIG. 4 , the slits may be formed in such a manner that adjacent branched beams are connected to each other by a bridge portion(s) 18 . In that case, each bridge portion 18 may be constituted of a dielectric or insulating film, a first electrode, a piezoelectric film, a second electrode, and a protective film. When the shape shown in FIG. 4 is employed, acceleration tolerance can be further improved.
[0054] By forming slit(s) in the piezoelectric actuator, the following advantages can be achieved. (1) By removing a sacrifice layer from the slit portion at a time of removal of a sacrifice layer from a lower portion of the actuator, an etching depth may be made shallow, so that an etching time can be reduced as compared with that in case that no slit is formed. (2) Since air passes through the slit(s) during operation of the actuator, a damping effect (squeezed film damping effect) due to air resistance can be suppressed, so that operation of the actuator at a higher speed can be made possible.
[0055] As explained above, according to the embodiment, a desired capacitance can be obtained even during application of acceleration.
Second Embodiment
[0056] Next, a piezoelectric driving type MEMS apparatus according to a second embodiment of the invention will be explained with reference to FIGS. 5 and 6 . FIG. 5 is a plan view showing a constitution of a piezoelectric driving type MEMS apparatus according to the embodiment and FIG. 6 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 5 .
[0057] The MEMS apparatus according to the embodiment is an MEMS switch, which has such a constitution that a supporting portion 6 is provided at one end of a silicon substrate 2 , a pair of lower electrodes 37 and leading electrodes 38 are provided at the other end thereof, and a cantilever beam 30 is fixed on the supporting portion 6 . The cantilever beam 30 is provided with an insulating film 31 , a first electrode 32 provided on the insulating film 31 , a piezoelectric film 33 provided on the first electrode 32 , a second electrode 34 provided on the piezoelectric film 33 , a protective film 35 provided on the second electrode 34 , and an upper electrode 36 provided on a face of the insulating film 31 which is opposed from the first electrode. A slit 20 is formed at a central portion of the cantilever beam 30 so as to extend along a longitudinal direction thereof.
[0058] A height of the supporting portion 6 is set to be larger than a film thickness of the lower electrode 37 , so that a clearance 7 is formed between the lower electrode 37 and the upper electrode 36 .
[0059] In the embodiment, when a voltage V 1 and a voltage V 2 (<V 1 ) are respectively applied to the first electrode 32 and the second electrode 34 , the piezoelectric film 33 strains in the longitudinal direction of the cantilever beam 30 , the cantilever beam 30 flexes toward the substrate 2 due to the strain, and the upper electrode 36 comes in contact with the lower electrodes 37 , so that the switch turns on.
[0060] According to the embodiment, since the slit 20 is formed in the cantilever beam 30 , flexing in a widthwise direction of the beam 30 is reduced, so that when the switch is turned on, the upper electrode 36 comes in surface-contact with the lower electrodes 37 without substantially deforming in the widthwise direction of the beam 30 . Therefore, insertion loss can be reduced, as compared with a case that an upper electrode and a lower electrode come in point-contact with each other. Since the total sum of the width of the beam 30 is large, sufficient acceleration tolerance can be achieved. Thereby, a high frequency switch with reduced insertion loss and high acceleration tolerance can be realized.
Third Embodiment
[0061] Next, a piezoelectric driving type MEMS apparatus according to a third embodiment of the invention will be explained with reference to FIGS. 7 to 9 . FIG. 7 is a plan view of the piezoelectric driving type MEMS apparatus according to the embodiment, FIG. 8 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 7 , and FIG. 9 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 7 . Incidentally, FIG. 7 is a plan view where a protective film described later has been removed.
[0062] The piezoelectric driving type MEMS apparatus according to the embodiment is a T-shaped type unimorph variable capacitor, which is provided with a lower electrode 4 and a beam 10 . The lower electrode 4 is provided at a central portion of a substrate 2 made from silicon and formed thereon with an insulating layer 3 made from, for example, SiO 2 , and an insulating layer 5 made from, for example, SiN is formed on the lower electrode 4 . A plurality of supporting portions 6 are provided on both ends of the substrate 2 . The beam 10 is arranged so as to be spanned between the supporting portions 6 on the both ends of the substrate over the lower electrode 4 .
[0063] The beam 10 is provided with an insulating film 16 made from, for example, SiO 2 , an upper electrode 17 provided at a central portion of the insulating film 16 , an insulating film 11 made from, for example, SiO 2 and provided on a region of the insulating film 16 except for the central portion thereof, a first electrode 12 provided on the insulating film 11 , piezoelectric films 13 provided on the first electrodes 12 , second electrodes 14 provided on the piezoelectric films 13 , and a protective film 15 made from, for example, SiO 2 . Two slits 20 a are provided on each of both end portions of the beam 10 so as to extend along a longitudinal direction of the beam 10 , so that the beam is formed at each end portion with three branched beams by the slits 20 . The three branched beams are respectively supported by the supporting portions 6 (see FIG. 8 ).
[0064] The upper electrode 17 is electrically connected to a leading electrode 17 a extending in a direction orthogonal to the longitudinal direction of the beam 10 . The leading electrode 17 a is provided with a plurality of slits 18 such that its rigidity is reduced and the beam 10 is flexed easily. The leading electrode 17 a is supported by a supporting portion 6 (see FIG. 9 ). Incidentally, such a constitution is employed that a height of the supporting portion 6 is larger than a film thickness of the lower electrode 4 , so that a clearance 7 is formed between the lower electrode 4 and the beam 10 (see FIG. 8 ).
[0065] The first electrode 12 is electrically connected to a wire 12 b for applying a voltage to the first electrode 12 via a contact 12 a, and the second electrode 14 is electrically connected to a wire 14 b for applying a voltage to the second electrode 14 via a contact 14 a (see FIG. 7 ). The lower electrode 4 is also electrically connected to a leading electrode 4 b for applying a voltage to the lower electrode 4 via a contact 4 a (see FIG. 9 ). The leading electrode 4 b is also supported by a supporting portion 6 , as shown in FIG. 9 .
[0066] In the embodiment, when a driving voltage V 1 and a driving voltage V 2 are respectively applied to the first electrode 12 and the second electrode 14 , the piezoelectric film 13 strain and a length thereof in its longitudinal direction (the horizontal direction of the beam 10 in FIG. 7 ) changes so that the beam 10 flexes toward the lower electrode 4 . As a result, a distance between the lower electrode 4 and the first electrode 12 changes so that a capacitance changes.
[0067] In the embodiment, the branched beams are formed by providing the slits 20 on the both end portions of the beam 10 like the first embodiment. Therefore, a section of the beam 10 in a widthwise direction takes an approximately flat shape without being deformed substantially, and the lower electrode 4 and the upper electrode 12 constituting the capacitance become substantially parallel to each other, so that a desired capacitance can be obtained like the first embodiment. When the total sum of the widths of the branched beams is set to be equal to the width of the beam where the slits 20 are not provided, acceleration tolerance can be prevented from deteriorating.
[0068] As explained above, according to the embodiment, a desired capacitance can be obtained even during application of acceleration.
Fourth Embodiment
[0069] Next, a piezoelectric driving type MEMS apparatus according to a fourth embodiment of the invention will be explained with reference to FIGS. 10 to 12 . FIG. 10 is a plan view of the piezoelectric driving type MEMS apparatus according to the embodiment, FIG. 11 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 10 , and FIG. 12 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 10 . Incidentally, FIG. 10 is a plan view where a protective film has been removed.
[0070] The piezoelectric driving type MEMS apparatus according to the embodiment is an I-shaped type unimorph variable capacitor, which has such a constitution that the upper electrode 17 is put in an electrically floating state by removing the leading electrode 17 a for the upper electrode 17 and two lower electrodes 4 are arranged in the T-shaped type unimorph variable capacitor according to the third embodiment shown in FIGS. 7 to 9 .
[0071] In the embodiment, terminals 4 b and 4 d are capacitance-coupled via the floating electrode 17 . Therefore, a capacitance between the terminals 4 b and 4 b can be changed by moving the electrode 17 in a vertical direction. In the embodiment, since a leading wire such as the leading wire for the upper electrode 17 in the third embodiment is not provided, the upper electrode is difficult to flex.
[0072] In the piezoelectric driving type MEMS apparatus according to the embodiment, since the branched beams are formed by providing slits 20 on the both end portions of the beam 10 , a desired capacitance can be obtained even during application of acceleration like the third embodiment.
Fifth Embodiment
[0073] Next, a piezoelectric driving type MEMS apparatus according to a fifth embodiment of the invention will be explained with reference to FIGS. 13 to 15 . FIG. 13 is a plan view of the piezoelectric driving type MEMS apparatus according to the embodiment, FIG. 14 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 13 , and FIG. 15 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 13 . Incidentally, FIG. 13 is a plan view where a protective film has been removed.
[0074] The piezoelectric driving type MEMS apparatus according to the embodiment is an I-shaped type bimorph variable capacitor, which has such a constitution that a piezoelectric film 13 1 and an electrode 14 1 are provided on the electrode 14 of the beam 10 in the piezoelectric driving type MEMS apparatus according to the embodiment shown in FIGS. 10 to 12 . The electrode 14 1 is connected to a wire 14 b 1 via a contact 14 a 1 .
[0075] In the embodiment, according to application of voltages to the electrodes 12 , 14 , and 14 1 of the beam 10 , the beam 10 flexes, and a distance between the upper electrode 17 and the lower electrode 4 changes, so that a capacitance can be made variable.
[0076] In the embodiment, a large capacitance can be obtained and a desired capacitance can be obtained during application of acceleration like the fourth embodiment.
Sixth Embodiment
[0077] Next, a piezoelectric driving type MEMS apparatus according to a sixth embodiment of the invention will be explained with reference to FIGS. 16 to 18 . FIG. 16 is a plan view of the piezoelectric driving type MEMS apparatus according to the embodiment, FIG. 17 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 16 , and FIG. 18 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 16 . Incidentally, FIG. 16 is a plan view where a protective film 15 has been removed.
[0078] The piezoelectric driving type MEMS apparatus according to the embodiment is an I-shaped type unimorph variable capacitor, which has such a constitution that a beam 10 is constituted as a cantilever beam in the I-shaped unimorph variable capacitor according to the fourth embodiment shown in FIGS. 10 to 12 .
[0079] In the embodiment, a large capacitance can be obtained and a desired capacitance can be obtained during application of acceleration like the fourth embodiment.
Seventh Embodiment
[0080] Next, a piezoelectric driving type MEMS apparatus according to a seventh embodiment of the invention will be explained with reference to FIGS. 19 to 21 . FIG. 19 is a plan view of the piezoelectric driving type MEMS apparatus according to the embodiment, FIG. 20 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 19 , and FIG. 21 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 19 . Incidentally, FIG. 19 is a plan view where a protective film 15 has been removed.
[0081] The piezoelectric driving type MEMS apparatus according to the embodiment is an I-shaped type unimorph switch, which has such a constitution that a lower face of the insulating film 16 and a lower face of the upper electrode 17 are made flush with each other by removing the insulating layer 5 on the upper face of the lower electrode 4 to expose an upper face of the lower electrode 4 and removing the insulating film 16 on the lower face of the upper electrode 17 in the I-shaped unimorph variable capacitor according to the fourth embodiment shown in FIGS. 10 to 12 .
[0082] In the embodiment, since the slits 20 are formed in the beam 10 , flexing in a widthwise direction of the beam 10 is reduced, so that when the switch is turned on, the upper electrode 17 comes in surface-contact with the lower electrodes 4 without substantially deforming in the widthwise direction of the beam 10 . Therefore, insertion loss can be reduced, as compared with a case that an upper electrode and a lower electrode come in point-contact with each other. Since the total sum of the widths of the beam 10 is large, sufficient acceleration tolerance can be achieved. Thereby, a high frequency switch with reduced insertion loss and high acceleration tolerance can be realized.
Eighth Embodiment
[0083] Next, a piezoelectric driving type MEMS apparatus according to an eighth embodiment of the invention will be explained with reference to FIGS. 22 to 24 . FIG. 22 is a plan view of the piezoelectric driving type MEMS apparatus according to the embodiment, FIG. 23 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 22 , and FIG. 24 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 22 . Incidentally, FIG. 22 is a plan view where a protective film 15 has been removed.
[0084] The piezoelectric driving type MEMS apparatus according to the embodiment is an I-shaped type unimorph switch, which has such a constitution that the beam 10 is constituted as a cantilever beam in the I-shaped type unimorph switch according to the seventh embodiment shown in FIGS. 19 to 21 .
[0085] In the embodiment, since the slits 20 are formed in the beam 10 like the seventh embodiment, flexing in a widthwise direction of the beam 10 is reduced, so that when the switch is turned on, the upper electrode 17 comes in surface-contact with the lower electrodes 4 without substantially deforming in the widthwise direction of the beam 10 . Therefore, insertion loss can be reduced, as compared with the case that the upper electrode and the lower electrode come in point-contact with each other. Since the total sum of the widths of the beam 10 is large, sufficient acceleration tolerance can be achieved.
[0086] In the eighth embodiment, two slits 20 are provided in the beam 10 for each side thereof. Three or more slits may be formed in the beam, as shown in FIG. 25 . Such the number of slits can be applied to not only the eighth embodiment but also the first to seventh embodiments.
[0087] As shown in FIG. 26 , the slits 20 may be formed in such a manner that adjacent branched beams are connected to each other by a bridge portion(s) 18 . As shown in FIG. 27 , the slits 20 may be formed in a mesh manner. These shapes of the slits can be applied to not only the eighth embodiment but also the first to seventh embodiments.
[0088] As shown in FIG. 28 , the beam 10 may be formed in a spreading shape toward the end portion thereof. Such a shape can be applied to not only the eighth embodiment but also the first to seventh embodiments.
Ninth Embodiment
[0089] Next, a piezoelectric driving type MEMS apparatus according to a ninth embodiment of the invention will be explained with reference to FIGS. 29 to 31 . FIG. 29 is a plan view of the piezoelectric driving type MEMS apparatus according to the embodiment, FIG. 30 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line A-A shown in FIG. 29 , and FIG. 31 is a sectional view of the piezoelectric driving type MEMS apparatus taken along line B-B shown in FIG. 29 . Incidentally, FIG. 29 is a plan view where a protective film 15 has been removed.
[0090] The piezoelectric driving type MEMS apparatus according to the embodiment is an I-shaped type unimorph variable capacitor, which has such a constitution that the supporting layer or portion 16 for the upper electrode 17 is provided above the upper electrode 17 of the beam 10 in the I-shaped type unimorph variable capacitor according to the fourth embodiment shown in FIGS. 10 to 12 . Such a constitution is employed that the supporting portion 16 for the upper electrode 17 is provided above the upper electrode 17 and the electrode 14 via an interlayer insulating film 19 .
[0091] In the embodiment, a large capacitance can be obtained and a desired capacitance can be obtained during application of acceleration like the fourth embodiment.
[0092] In the above embodiments, the MEMS variable capacitors or the MEMS switches have been explained, but the structure of a beam having a piezoelectric actuator, namely a piezoelectric film can be applied to devices except for these capacitors and the switches.
[0093] As explained above, according to the respective embodiments of the invention, a piezoelectric driving type MEMS apparatus which can obtain desired characteristics even during application of acceleration can be provided. | A piezoelectric driving type MEMS apparatus includes: a supporting portion provided on a substrate; and a piezoelectric actuator, which is supported on the supporting portion, including a piezoelectric film and a driving electrode configured to drive the piezoelectric film, the piezoelectric film in the piezoelectric actuator having at least one slit extending along a longitudinal direction of the piezoelectric actuator. | 7 |
FIELD OF INVENTION
[0001] The present invention relates to the field of the synthesis of sugars, and in particular to a process for the preparation of N-Acetyl-D-mannosamine monohydrate having the formula (I) reported hereinafter.
PRIOR ART
[0002] N-Acetyl-D-mannosamine is an intermediate specific for the synthesis of N-Acetyl-neuraminic [A1] acid that, in its turn, is the starting material useful for the synthesis of various active ingredients, especially of antiviral products.
[0003] The N-Acetyl-neuraminic acid is a sialic acid existing as a component of mucolipids and mucoproteins, and as a component of oligosaccharides that can be found, for example, in milk in small quantities.
[0004] Therefore, there is the need to produce the N-Acetyl-neuraminic acid, by synthesis way and, therefore, to have a great availability of products such as N-Acetyl-D-mannosamine, from which the acid is obtained.
[0005] Up today various methods for the synthesis of N-Acetyl-D-mannosamine, either by enzymatic, or fermentative or chemical way are described in the literature.
[0006] Among the methods of enzymatic synthesis it is well-known, for example, the interconversion from N-Acetyl-D-glucosamine to N-acetyl-D-mannosamine using N-Acetyl-D-glucosammine-2-epimerase, as reported for example by Lee, Jeong-Oh et al. In Enzyme and Microbial Technology 2004, 35 (2-3), 121-125.
[0007] In the International Patent Application No. WO 00/52138, is instead reported an example of synthesis of N-Acetyl-D-mannosamine by fermentation with Klebsiella pneumoniae using N-Acetyl-D-glucosamine as substrate.
[0008] Among the methods of chemical synthesis in the literature is reported the alkaline epimerisation of N-Acetyl-D-glucosamine at pH>9 using different bases such as sodium or potassium hydroxide or a ionic exchange resin such as Duolite® A113, as described in the International Patent Application No. WO 94/29476. Other similar methods of chemical synthesis which use other bases such as calcium hydroxide or a basic resin, are also described in literature.
[0009] A different chemical synthetic method is described in Mack, Hans et al. Carb. Res., 1988, 175(2), 311-16 which consists in the cyclisation of the 2-Acetamide-2-deoxy-D-glucopyranoside product to oxazoline derivative, the subsequent hydrolysis to 2-Acetamide-2-deoxy-5,6-O-isopropylidene-D-glucofuranose and the isomerisation by treatment with Amberlite® IRA-68 basic resin to 2-Acetamide-2-deoxy-D-mannose. This method takes lot of time, is laborious and hard to be industrially exploited.
[0010] A further chemical synthesis of N-Acetyl-D-mannosamine is described in the European Patent No. 0 385 287; this synthesis requires the reaction of the N-Acetyl-D-glucosamine derivative with a phosphorous ylide (reaction of Wittig) and epimerisation to the corresponding olefinic derivative which is then oxidised with ozone to mannosamine derivative. This process requires the use of reagents and solvents that make it hard to be scaled up.
[0011] Moreover, any chemical synthesis known to the Applicant of N-Acetyl-D-mannosamine from N-Acetyl-D-glucosamine yields as the final product not the pure N-Acetyl-D-mannosamine, but a sugars mixture enriched in N-Acetyl-D-mannosamine which remains in the solution together with the reaction impurities and with a substantial amount of N-Acetyl-D-glucosamine.
[0012] Therefore, the need is still felt to have available a chemical preparation process of N-Acetyl-D-mannosamine, that can be industrially scaled up and that is suitable for the preparation of this sugar with a high purity degree.
SUMMARY OF THE INVENTION
[0013] Now the Applicant has found a process for the preparation of N-Acetyl-D-mannosamine monohydrate having the formula (I) herein below reported, that is particularly simple and economic, and allow to overcome the disadvantages above mentioned for the known processes, by synthesising N-Acetyl-D-mannosamine monohydrate in crystalline form with a purity higher than 98%.
[0014] It is therefore subject of the present invention a process for the preparation of N-Acetyl-D-mannosamine monohydrate in crystalline form with a purity higher than 98% having the formula (I)
[0000]
[0000] said process comprising the selective crystallisation by seeding a mixture of N-Acetyl-D-glucosamine and N-Acetyl-D-mannosamine with N-Acetyl-D-mannosamine monohydrate.
[0015] A further subject of the invention is the use of N-Acetyl-D-mannosamine monohydrate obtained by the above said process, for the preparation of N-Acetyl-neuraminic acid.
[0016] The features and advantages of the present process will be better described in the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In the following description the abbreviations NAG, NAM and NANA will be used to respectively indicate the compounds N-Acetyl-D-glucosamine, N-Acetyl-D-mannosamine and N-Acetyl-neuraminic acid.
[0018] The NAM monohydrate used as seed material in the present process can be obtained, for example, by following the preparation procedure described in Chava Telem Spivak et al. J. Am. Chem. Soc. Vol. 81, 2403-2404.
[0019] According to a preferred embodiment of the present process, the seeding is carried out by adding a quantity of NAM monohydrate comprised between 0.5% and 5% by weight in respect to the total weight of NAG and NAM in the starting mixture, and filtrating the so obtained solid product after a time comprised between 0.5 and 2 hours.
[0020] Optimal results in terms of purity of NAM monohydrate, are obtained with a quantity of the seed material equal to 2.6% by weight with respect to the total weight of NAG and NAM in the starting mixture, and filtrating the solid product obtained, after a time of 1 hour and 50 minutes from the seeding.
[0021] The starting mixture preferably consists of a mixture of NAG and NAM wherein the molar ratio NAG:NAM is comprised between 55:45 and 90:10; this mixture is preferably suspended in a n-propanol:water mixture having a volume ratio between 80:20 and 90:10, and the so obtained suspension is optionally subjected to warm filtration before the seeding.
[0022] According to a preferred embodiment of the present process, the starting mixture of NAG and NAM is obtained by base-catalysed epimerisation of NAG until the epimerisation balance between NAG and NAM is achieved, followed by two subsequent crystallisation steps of non reacted NAG, finally obtaining a mixture of NAM and NAG on which a selective crystallisation is carried out by seeding.
[0023] The above said epimerisation reaction of NAG can be carried out, for example, in water at a temperature comprised between 30 and 80° C., and preferably at the temperature of 60° C., using as base an organic base selected, for example, from the group consisting of Triethylamine, Diisopropylamine, N-Ethylbutylamine, N,N,N,N-Tetramethylethylendiamine, N-Methylpiperazine and diethanolamine. The preferred base of the invention is Triethylamine.
[0024] The quantity of water in which the starting NAG is suspended is typically the minimum quantity necessary to bring NAG in suspension, equal to 1.6 volumes; the quantity of organic base added is, for example, between 0.5 and 10% by moles with respect to the moles of the starting NAG, and preferably equal to 2.3%. The so obtained aqueous suspension of NAG is therefore warmed up at a temperature between 30 and 80° C. for the time necessary to reach the epimerisation balance, corresponding to a NAM/(NAM+NAG) ratio of approximately 20.
[0025] Once the epimerisation balance is obtained as above described, a first crystallisation of non reacted NAG can be carried out, for example, by neutralising the base used to catalyse the epimerisation reaction with a suitable quantity of acid, preferably acetic acid, and by concentrating the reaction mixture until a thick precipitate is obtained by slow cooling, from this precipitate a first portion of NAG is crystallised and recovered by filtration.
[0026] Then the second crystallisation is carried out on the NAG-depleted filtrate by concentrating the filtrate and adding a suitable seed of NAG to obtain a second NAG portion which is then recovered by filtration.
[0027] Both NAG portions are preferably washed with n-propanol:water mixtures having a ratio between 80:20 and 90:10, and/or with n-propanol, and the washings are added to the filtrate before the subsequent crystallisation.
[0028] The filtrate obtained from the second crystallisation of NAG consists therefore of a mixture of NAG and NAM in a mixture of water and n-propanol, that can be subjected to the selective crystallisation of the present process by seeding, to obtain the desired NAM in crystalline form, with a purity higher than 98% as described above.
[0029] Preferably, before the seeding, the filtrated product is warmed up at 65° C. to eliminate possible crystals of NAG, then quickly cooled at a temperature between 18 and 22° C., and preferably at 20° C.
[0030] Once the NAM monohydrate is recovered by filtration, concentration of the filtrated product and cooling, for example for 16 hours at 2° C., a mixture of NAM:NAG approximately 45:55 is obtained, that can be used in a further cycle.
[0031] Besides the high purity of the obtained NAM monohydrate, the present process as above described, has further considerable advantages: the final product has a high yield compared to the product in the reaction mixture, higher than 70%, and besides having a low NAG content, it does not contain those great quantities of by-products that are instead found in the products obtained according to the prior art processes.
[0032] Furthermore, the process of the is also easily industrially exploitable since the epimerisation reaction is carried out in water and the organic base is used in catalytic quantities.
[0033] The NAM monohydrate in crystalline form and having high purity, obtained according to the present process, can be used without further purification steps, for the preparation of NANA according to one of the procedures known in the prior art, for example according to the procedure described in WO 94/29476 in which NAM is incubated with sodium pyruvate in presence of NANA-aldolase enzyme.
[0034] The following non-limiting example of the present invention is given by way of illustration.
EXAMPLE 1
Synthesis of NAM Monohydrate (Compound of Formula I)
[0035] 6.67 kg of water are loaded in a 10 litres cleaned reactor and they are put under stirring. Then 4 Kg of NAG are loaded and warmed up at 60±2° C.; 60 ml of Triethylamine are added and kept at the temperature of 60±2° C. for two hours. Afterwards 31 ml of glacial acetic acid are added and a sample for the HPLC analysis is drawn, from which it comes out it has been achieved the ratio 80/20 between NAG and NAM, thereafter the reaction mixture is concentrated under vacuum at an internal temperature lower than 60° C. discharging 4.6 litres of water. The temperature is brought to 60±3° C. and maintained for 30 minutes; thereafter, with a gradient of around 10° C./h, it is cooled down to 20±3° C.
[0036] A centrifugation step is performed and the centrifuged syrup is uploaded and stocked aside from the washings.
[0037] A first washing is carried out with 1.09 litres of a mixture n-propanol/demineralised water in a ratio of 85/15 and a second washing with 1.640 ml of n-propanol.
[0038] 2.421 g of NAG are obtained from the first recovery. The centrifuged syrup is further concentrated till a residue of 2 Kg is obtained.
[0039] To the syrup so concentrated the NAG washings of the first recovery are added and then the mixture is warmed up at 60° C. A precipitation of a second recovery of NAG can take place and, in case that no precipitation takes place at 60° C., it is seeded with 0.5% of NAG compared to the quantity used in the epimerisation and all is maintained under stirring at 60±2° C. for 1 hour. The solid is filtrated and washed with a mixture 85/15 n-propanol/water (180 ml) and, thereafter, with 360 ml of n-propanol. 220 g of NAG from second recovery are recovered. The filtrated is warmed at 65±2° C., thereafter it is quickly cooled down to 20° C. and it is seeded with 11 g of NAM monohydrate. After 1 hour and 50 minutes it is filtrated and washed with 550 ml of 85/15 n-propanol/water mixture. The solid obtained under vacuum is dehydrated at 40° C. till a steady dry weight.
[0040] 278 g of NAM are obtained (without counting the amount of the seed they are 267 g) having a HPLC purity higher than 98%.
[0041] The mother-liquid have been concentrated till a residue of 2,174 g, cooled down to room temperature and after 12 hours at room temperature and 5 hours under stirring at 3±2° C., the solid has been filtrated, washed with n-propanol (700 ml) and dehydrated. A mixture of NAM monohydrate (335 g) and of NAG (300 g) is obtained, the same is suspended in filtration and washing mother-liquid of a subsequent NAM (see Example 2).
[0042] 1 H-NMR (DMSO, 300 MHz): δ ppm 7.15, 6.55, 4.78, 4.69-4.66 (40H), 4.38, 4.16, 3.75-3.64, 3.55-3.40 (m, 5H), 3.24, 3.14-3.02 (m, 2H), 1.89 (s, 3H, NHCOCH 3 )
[0043] 13 C-NMR (DMSO, 300 MHz): δ ppm 170.79 (NHCOCH 3 ), 93.47 (C-1), 77.47, 72.59, 67.08, 61.32, 54.05 (C-2, C-3, C-4, C-5, C-6) 23.01 (NHCOCH 3 ).
EXAMPLE 2
Synthesis of NAM Monohydrate (Compound of Formula I)
[0044] 6.29 kg of water are loaded in a 10 litres cleaned reactor and put under stirring. Thereafter 3.78 Kg of NAG are loaded and warmed up at 60±2° C.; 56.5 ml of Triethylamine are added and kept at the temperature of 60±2° C. for two hours. Afterwards 29.2 ml of glacial acetic acid are added and a sample for the HPLC analysis is drawn, from which it is found that the ratio 80/20 between NAG and NAM is achieved, thereafter the reaction mixture is concentrated under vacuum at an internal temperature lower than 60° C. until a residue of 5.1 Kg is obtained.
[0045] The temperature is brought to 60±3° C. and kept at said degree for 30 minutes; thereafter, with a gradient of around 10° C./h, it is cooled down to 20±3° C.
[0046] A centrifugation step is performed and the centrifuged syrup is uploaded and stocked aside from the washings.
[0047] A first washing is carried out with 1.04 litres of a mixture n-propanol/demineralised water 85/15 and a second washing with 1,550 ml of n-propanol.
[0048] 2,510 g of NAG are obtained from the first recovery. The centrifuged syrup is further concentrated till a residue of 1,650 g is obtained. The NAG washings of the first recovery are added to the syrup so concentrated and all is warmed up at 60° C., obtaining the precipitation of a second recovery of NAG. Thereafter, it is seeded with 0.5% of NAG compared to the quantity used in the epimerisation and it is kept under stirring at 60±2° C. for 1 hour.
[0049] The solid is filtrated and washed with a mixture n-propanol/water 85/15 (150 ml) and, thereafter, with 340 ml of n-propanol. 64 g of NAG from second recovery are recovered. The filtrated is warmed at 65±2° C., then it is quickly cooled down to 20° C. and it is seeded with 10 g of NAM monohydrate. After 1 hour and 50 minutes it is filtrated and washed with 530 ml of a n-propanol/water mixture 85/15. The solid obtained under vacuum is dehydrated at 40° C. till a steady dry weight. 465 g of NAM are obtained (without counting the amount of the seed they are 455 g) having a HPLC purity higher than 98%.
[0050] The mother liquids are added with the product recovered from the previous test (see EXAMPLE 1) consisting of 335 g of NAM and 300 g of NAG. They are warmed up at 55±2° C., they are filtered washing the solid with 180 ml of a n-propanol/water 85/15 mixture and, afterwards, with 300 ml of n-propanol. 280 g of NAG are obtained from the third recovery.
[0051] The mother liquids are cooled down to 20° C. and are seeded with 10 g of NAM. The suspension is kept under stirring at 20±2° C. for 2 hours and, afterwards, it is filtrated and the obtained is washed obtaining 316 g of NAM (without counting the amount of the seed they are 306 g) having a HPLV purity higher than 98%.
[0052] The collected mother liquids are added to the washings of NAG from the first recovery and have been concentrated till a residue of 1,884 g is obtained. All it has been left under stirring for 12 hours at room temperature and after it is cooled for 2 hours. The solid has been filtrated, washing it with 400 ml of n-propanol. 509 g of a mixing of NAG (45%) and NAM (56%) are obtained.
EXAMPLE 3
Synthesis of NAM Monohydrate (Compound of Formula I)
[0053] 27.6 Kg of water are loaded in a cleaned 100 litres-reactor and they are put under stirring. Thereafter 16.8 Kg of NAG are loaded and warmed up at 60±2° C.; 248 ml of Triethylamine are added and kept at the temperature of 60±2° C. for two hours. Afterwards 128 ml of glacial acetic acid are added and a sample is drawn for the HPLC analysis. From the HPLC analysis it is found that the ratio 80/20 between NAG and NAM is achieved, then the reaction mixture is concentrated under vacuum at an internal temperature lower than 60° C. discharging 19.3 litres of water.
[0054] The temperature is brought to 60±3° C. and kept at said degree for 30 minutes, then, with a gradient of around 10° C./h, it is cooled down to 20±3° C.
[0055] A centrifugation step is performed and the centrifuged syrup is uploaded and stocked aside from the washings.
[0056] A first washing is carried out with 4.6 litres of a n-propanol/demineralised water 85/15 mixture and a second washing with 6.9 litres of n-propanol. The centrifuged syrup is further concentrated discharging 4.1 litres of water. The NAG washings of the first recovery are added to the syrup so concentrated and all is warmed up at 60° C.
[0057] In this case, at the temperature of 60° C., there was no precipitation of a second recovery of NAG but a seeding is however carried out with 0.5% of NAG compared to the quantity used in the epimerisation step and it is kept under stirring at 60±2° C. for 1 hour.
[0058] The solid is filtered and washed with a n-propanol/water 85/15 mixture (2,310 ml). The filtrated is warmed at 65±2° C., thereafter it is quickly cooled down to 20° C. and it is seeded with 46 g of NAM monohydrate. After 1 hour and 50 minutes it is filtrated and washed with 2.5 litres of a 85/15 n-propanol/water mixture. The solid obtained under vacuum is dehydrated at 40° C. till a steady dry weight.
[0059] 1.5 Kg of NAM are obtained having a HPLC purity higher than 98%. The yield of first recovery of NAM is on the average of 8.9±2.5. The mother liquids have been concentrated till a residue of approximately 8 litres is obtained and the concentrated solution was cooled to room temperature.
[0060] After 12 hours at room temperature and 5 hours under stirring at 3±2° C., the solid has been filtrated, washed with n-propanol (3 litres) and dehydrated. It is obtained a mixture of NAM monohydrate (45%5%) and NAG (55±5%) which can be reprocessed as above described in Example 2.
EXAMPLE 4
Synthesis of NAM Monohydrate (Compound of Formula I)
[0061] 82 g of water are loaded in a 250 ml-flask with 4 necks and they are put under stirring. 50 g of NAG are loaded and warmed at 60±2° C., 0.75 ml of Diisopropylamine are added and kept at the temperature of 60±2° C. for 3 hours. The reaction is followed by the HPLC analysis. After 3 hours the NAM/(NAM+NAG) ratio is 21.6.
[0062] The NAM is then isolated as above described in Example 1.
EXAMPLE 5
Synthesis of NAM Monohydrate (Compound of Formula I)
[0063] 82 g of water are loaded in a 250 ml-flask with 4 necks and they are put under stirring. 50 g of NAG are loaded and warmed at 60±2° C., 0.75 ml of N-EthylButylamine are added and kept at the temperature of 60±2° C. for 3 hours.
[0064] The reaction is followed by the HPLC analysis. After 3 hours the NAM/(NAM+NAG) ratio is 19.5.
[0065] The NAM is then isolated as above described in Example 1.
EXAMPLE 6
Synthesis of NAM Monohydrate (Compound of Formula I)
[0066] 82 g of water are loaded in a 250 ml-flask with 4 necks and they are put under stirring. 50 g of NAG are loaded and warmed at 70±2° C.; 0.8 ml of N,N,N,N-TetraMethylEthylendiamine are added and kept at the temperature of 70±2° C. for 3 hours. The reaction is followed by the HPLC analysis. After 3 hours the NAM/(NAM+NAG) ratio is 21.2.
[0067] The NAM is then isolated as above described in Example 1.
EXAMPLE 7
Synthesis of NAM Monohydrate (Compound of Formula I)
[0068] 82 g of water are loaded in a 250 ml-flask with 4 necks and they are put under stirring. 50 g of NAG are loaded and warmed at 70±2° C.; 0.6 ml of N-Methylpiperazine are added and kept at the temperature of 70±2° C. for 3 hours. The reaction is followed by the HPLC analysis. After 3 hours the NAM/(NAM+NAG) ratio is 18.9.
[0069] The NAM is then isolated as above described in Example 1.
EXAMPLE 8
Synthesis of NAM Monohydrate (Compound of Formula I)
[0070] 82 g of water are loaded in a 250 ml-flask with 4 necks and they are put under stirring. 50 g of NAG are loaded and warmed at 80±2° C.; 0.6 ml of N-Methylpyperazine are added and kept at the temperature of 80±2° C. for 3 hours. The reaction is followed by the HPLC analysis. After 3 hours the NAM/(NAM+NAG) ratio is 20.8.
[0071] The NAM is then isolated as above described in Example 1.
EXAMPLE 9
Synthesis of NAM Monohydrate (Compound of Formula I)
[0072] 82 g of water are loaded in a 250 ml-flask with 4 necks and they are put under stirring. 50 g of NAG are loaded and warmed at 80±2° C.; 0.5 ml of Diethanolamine are added and kept at the temperature of 80±2° C. for 3 hours. The reaction is followed by the HPLC analysis. After 3 hours the NAM/(NAM+NAG) ratio is 21.6.
[0073] The NAM is then isolated as above described in Example 1.
EXAMPLE 10
Synthesis of NAM Monohydrate (Compound of Formula I)
[0074] 82 g of water are loaded in a 250 ml-flask with 4 necks and they are put under stirring. 50 g of NAG are loaded and warmed at 50±2° C.; 0.75 ml of Triethylamine are added and kept at the temperature of 50±2° C. for 7 hours. The reaction is followed by the HPLC analysis. After 7 hours the NAM/(NAM+NAG) ratio is 19.6. The NAM is then isolated as above described in Example 1. | A process is described for the preparation of N-Acetyl-D-mannosamine monohydrate of formula (I) a specific intermediate in the synthesis of N-Acetyl-neuraminic acid, that is an important starting product for the synthesis of various pharmaceutically active products. | 2 |
REFERENCE TO RELATED APPLICATIONS
This application is a continuation of Ser. No. 07/246,029 filed Sept. 14, 1988, now abandoned, which in turn is a continuation of Ser. No. 07/110,059 filed Oct. 15, 1987, now abandoned, which in turn is a continuation of Ser. No. 06/941,527 filed Dec. 17, 1986, now abandoned, which in turn is a continuation of Ser. No. 06/693,068 filed Jan. 22, 1985, now abandoned, which in turn is a division of Ser. No. 06/487,704 filed Apr. 21, 1983, now abandoned, which in turn is a continuation of Ser. No. 06/246,315 filed Mar. 23, 1981, now U.S. Pat. No. 4,415,673, all of which are relied on and incorporated herein by reference.
FIELD OF INVENTION
This invention relates to the use of a relatively stable acidic aqueous colloidal zirconia sol as the bonding medium for specific refractories.
BACKGROUND OF INVENTION
A procedure that is well-known has been used in the past for making ceramic shapes, namely mixing a binder and a gelling agent with a refractory and allowing the mix to chemically set or gel to form a bond and then firing the body. Typically many shapes have been made using sodium silicate, potassium silicate, colloidal silica, and hydrolyzed ethyl silicate as bonds. However, to obtain the greatest refractoriness of a body, a bond leaving a residue of a more refractory oxide is preferable. For example, alumina and zirconia produce high temperature bonds for refractories.
U.S. Pat. No. 4,025,350 shows the use of an aqueous solution of a zirconium salt with a gelling inducing agent and a gelling delaying agent and a refractory powder to form a refractory article. This composition requires additional gelling agents for control thereby increasing costs and control problems. Also the by-products of the gelation of the zirconium salt would need to be eliminated from the refractory during firing. There is also an added cost of the zirconium salt versus the oxide.
U.S. Pat. No. 4,201,594 describes the binding of refractory materials using zirconium salts and incorporating gelling agents and gel delaying agents. For the same reasons these compositions are less than desirable.
U.S. Pat. No. 2,984,576 describes an unfired mixture of a refractory material bonded with a zirconia or hafnia sol in which the percent of solids in the dispersed phase is at least 30%. This patent does not describe the specific refractories useful with the present stable acidic zirconia sol but only as a bond for a variety of refractories.
U.S. Pat. No. 3,758,316 describes the process for producing a refractory from a refractory powder and a binder precursor which would include colloidal zirconia, but also requires the addition of a gelling agent.
BRIEF SUMMARY OF INVENTION
The basic principle of the present invention is to make a refractory mix comprising a refractory material and a stable acidic zirconia sol having a fine particle size and acidic pH. The refractory is composed of an active portion and, if desired, a relatively inert portion.
DETAILED DESCRIPTION OF INVENTION
One would expect that highly refractory materials would be relatively inert to the zirconia sol. However, it has been found that a number of refractories are not totally inert to the sol and actually react with the sol to cause gelation of the sol. Very rapid gels or slow gels can be produced depending upon the particular type of active refractory, its particle size distribution, and its percentage in the refractory mix. Some examples of active refractories which will cause gelation with the zirconia sol are alkali and alkaline earth metal aluminates, silicates, zirconates, stannates, titanates, zirconium silicates and oxides. Specific examples include calcined magnesium oxide, electrically fused magnesium oxide, calcium oxide, electrically fused calcium oxide, mono calcium aluminate, calcium aluminate cements, fused cordierite, high alkali glasses, magnesium aluminate, magnesium aluminum silicate, magnesium zirconate, magnesium silicate, magnesium zirconium silicate, magnesium ferrite, magnesium titanate, magnesium stannate, calcium zirconate, calcium silicate, calcium zirconium silicate, calcium titanate, calcium stannate, barium zirconate, barium aluminum silicate, barium aluminate, barium zirconium silicate, barium stannate, barium titanate, barium silicate, strontium zirconate, strontium stannate, strontium zirconium silicate, strontium silicate, strontium aluminum silicate, strontium titanate, electrically fused calcium oxide stabilized zirconia, electrically fused magnesium oxide stabilized zirconia, iron chromite, Zeolex 23, wollastonite, bentonite, strontium aluminate, forsterite, calcium aluminum silicate, fluorspar, fluorbarite, lithium zirconate, lithium aluminate, lithium silicate, lithium aluminum silicate, lithium titanate, lithium zirconium silicate, and other refractory materials which are reactive with the zirconia sol. Some relatively non-reacting refractory materials are monoclinic zirconia, hafnia, alumina, bauxite, mullite, sillimanite, zircon, ceria, thoria, silicon nitride, silica and other minerals which do not contain any large amounts in their structure of the alkaline and alkaline earth metallic oxides or impurities present that may react with the sol.
It is also possible to use this system as a bond for various fibers made from aluminosilicates, low alkali glasses, alumina, zirconia, silica, and various organic fibers such as cotton, rayon, nylon, other synthetic fibers.
The aqueous zirconia sols used in the examples given in this specification are acidic in nature ranging in pH from about 0.3 to 6.0. The particle size of the zirconia particle is generally small, on the order of 25 millimicrons and smaller. The sol is stabilized by acids such as nitric, hydrochloric, acidic, etc. The gelling action of the sol with the "active" refractory is believed to be due to a reaction of the acid with the "active" refractory, producing a "salt", which reaction raises the pH thereby lowering the sol stability. Also, the salt formed possibly catalyzes the gelling of the sol. This gelling action bonds the refractory into a strong body.
Several factors govern the characteristics of the refractory body bonded with the zirconia sol The type of acid in the sol, the particle size and age of the sol, the percentage of zirconia in the sol, the percentage and type of "active" refractory in the mix, its particle size distribution, temperature, and mixing conditions.
The listing of potential "active" refractories shows the presence in many cases of an alkaline or alkaline earth type oxide present in the structure of the refractory or that the "active" refractory is subject to reaction with an acid. The presence of such "active" refractories, serving to react with the sol not only causes gelation but also might serve as sintering aids for certain refractory systems. The comparative scratch hardness of bonded refractory shapes after firing serves as a measure of sintering action by the "active" refractory.
One procedure for utilizing this invention is to produce cast refractory shapes by mixing the zirconia sol with at least one "active" refractory. The balance of the refractory may include a relatively inert refractory. In some instances, depending upon the nature of the active refractory, the total refractory may be of the active type. In other instances, the "active" refractory may be a very minor portion of the total refractory in the mix. Particle size distribution and chemical nature of the active refractory are two of the major factors in determining the amount of "active" refractory constituent.
Various refractory shapes can be cast using this invention to produce practical products, such as metal melting crucibles, boats, tundishes, pouring ladles, pouring cups, tubes, rods, slabs, bricks, saggers, kiln furniture, kiln car tops, open hearth door facings, kiln parts, pouring nozles, furnace liners, and others. Such mixtures can also be used to cast dental and jewelry molds for metal casting. In particular, some of these mixes are especially suitable for molds for casting superalloys, stainless steels, niobium, tantalum, titanium, and molybdenum. By selection of a high temperature inert refractory, or low-activity "active" refractory, such as zirconia, hafnia, ceria, alumina, yttria, lanthana, a foundry mold can be produced having an extremely high PCE value and having low reactivity to some of the above-mentioned reactive metals.
If desirable, pressing mixes can be made which will "set" or "gel" in predetermined times in order that a refractory shape may be made by pressing and then become set or gelled.
Thin or thick films may be made from mixes which may be cast on a belt or form and then becoming gelled or set. Coatings may be dipped or sprayed on to a form or shape, and then allowed to gel.
Mixes according to this invention may be formed into shapes by injection molding. Present ceramic injection molding techniques usually call for various temporary bonds for the refractory body to allow for ease of molding. Examples are costly waxes, resins, plastics, etc. These organic materials are burned out without leaving a high temperature bond, and shrinkage occurs during loss or organic material The present invention provides a "green" bond and a fired bond in the refractory body. This technique can be used to mold various intricate shapes such as spindles, nozzles, ceramic cores for metal castings, ceramic turbine blades and vanes, shell mold parts for metal casting, and various other shapes as desired.
A primary application for this invention is to make cast refractory bodies which will set or gel at controlled times. A proportion of "active" refractory may be adjusted according to the set time required for the mass. This percentage varies with the particular "active" refractory. The resulting refractory mix can be then mixed with a suitable amount of the zirconia sol to a heavy pouring consistency and poured or cast into a mold form and allowed to set. Particle size distribution of the refractory mix may be varied according to the desired results, strength, settling within the mold, and gel times. It is usually advantageous to allow adequate time for satisfactory mixing of the refractory before casting into a mold. This depends upon the size of the mold and the equipment used to handle the mix. If a small volume hand mix is used, mixing can usually be carried out in a very short period of time such as one to two minutes and then the mix can be adjusted to gel or set very rapidly. I prefer a relatively fast gel time of 5 to 30 minutes for relatively fast production of shapes. It may be desirable to remove bubbles from the mix and to incorporate suitable wetting and defoaming agents to make a relatively bubble-free or void-free mass. Time may be needed to completely wet in the mass and to deair before casting can be made. Ideally, gelation should occur as soon as practical after pouring.
To illustrate this invention, the data in Table 1 shows the percentage of active refractory that might be mixed with an inert refractory, such as tabular alumina, to produce specific set or gel times. The refractory is mixed with the zirconia sol containing 20% ZrO 2 and having a pH of 0.6. The alumina portion was composed of 50% 325 mesh and finer tabular alumina and 50% 60 mesh and finer tabular alumina as supplied by Alcoa. The active refractory percentage is calculated on the basis of the total amount of refractory used for the final mix.
The samples indicated in Table 1 all had good green strength and when fired separately to 1200° F., 1800° F., 2000° F., and 2500° F. had excellent fired strengths.
Another series of similar experiments to those in Table 1 were carried out according to Table 2 in which the tabular alumina refractory base was 25% 325 mesh and finer and 75% 60 mesh and finer. This Table shows the gel times for the various mixes using the active refractory. These were mixed with the same zirconia sol as was used in Table 1. After gelling these samples had excellent green strength and after firing to the same temperature conditions had excellent fired strength. In all cases, the strength at 2500° F. was greater than that fired to temperatures below 2500° F.
Some unique characteristics were noted about the compositions described in Table 1. A series of test specimens approximately 1" thick, 1" wide and 2.375" long were prepared in a mold using the same compositions as prepared in Table 1. They were allowed to set after gelation for 30 minutes and then removed from the mold. After removing from the mold, the specimen was set out in the air to air dry overnight and then oven dried for 4 hours at 120° C. to remove all the water from the shape and then placed into a dessicator for cooling. It was then removed and immediately measured. It was noted that all specimens showed some shrinkage from the mold dimension on the order of about one-half to one percent. After the specimens were dried, they were then heated to a temperature of 1200° F. and maintained at that temperature for 2 hours and then allowed to cool to room temperature and remeasured. After measuring, the specimens were then reheated to 1800° F. and held for 2 hours at temperature, cooled, and then remeasured. This same heating was carried out separately at 2000° F. and 2500° F., after which time measurements were made on the specimens. It was noted that on many specimens some very small to fairly sizeable permanent expansion occurred after cooling. The data in Table 2 shows the permanent expansion obtained on a number of the specimens cast. The negative value indicates shrinkage. The remainder of the figures indicate permanent expansion.
It can be observed from this Table that some substantial expansions occur on certain specimens. These expansions are not necessarily related to the proportion of active refractory but are definitely attributed to the presence of the active refractory. Each composition probably acts in a different manner and produces different reaction products which govern the amount of expansion obtainable. This may be a means for minimizing shrinkage during firing of refractory bodies utilizing this zirconia sol bonded system. Normally when considerable sintering occurs on firing a refractory to a high temperature, considerable shrinkage occurs with the sintering. It should be noted that several compositions in the tabulation show relatively low shrinkage even when fired at 2500° F. Table 3 shows a similar series of measurements made on specimens using the tabular alumina refractory containing 25% 325 mesh and finer and 75% 60 mesh and finer particle sizes with the corresponding "active" refractory.
The following are examples of other refractory mixes used with the acid stabilied zirconia sol and illustrating the use of "active" refractories.
EXAMPLE I
Composition:
______________________________________Electrically fused calcium oxide 30 gramsstabilized zirconium oxide - 325 meshFused Magnesium Oxide - 325 mesh 1 gramTabular alumina 60 mesh and finer 150 gramsTabular alumina - 28 + 48 mesh 120 grams______________________________________
This refractory composition was mixed with 35 ml acid stabilized zirconia sol containing 20% ZrO 2 . It was then poured into a rubber mold. The gel time was determined to be approximately 5 minutes. After 30 minutes, the sample was removed from the mold and by means of a diamond saw was cut into test specimens for modulus of rupture measurements. Unfired strength of this mix was approximately 57 psi. Samples were fired to 2500° F., held for two hours and cooled to room temperature, and modulus of rupture was determined as 575 psi. A similar firing to 2700° F. for two hours and then cooling showed a modulus of rupture of 910 psi. A firing to 2900° F. for two hours and cooled showed a modulus of rupture of 1888 psi.
EXAMPLE II
Composition:
______________________________________Tabular alumina - 325 mesh 240 gramsElectrically fused magnesium oxide 2 grams______________________________________
This was mixed with 45 ml of the same zirconia sol as in Example I. The gel time on this mix was approximately 41/2 minutes. The green modulus of rupture was not determined but specimens fired to 2000° F. for two hours and cooled showed a modulus of rupture of 234 psi. Firing to 2500° F. for two hours and cooled showed the modulus of rupture to be 1164 psi. Firing to 2700° F. for two hours and cooling showed a modulus of rupture of 2995 psi. A specimen fired to 2900° F. for two hours showed a modulus of rupture of 5674 psi.
EXAMPLE III
Composition:
______________________________________EF zirconium oxide, calcium 170 gramsstabilized, - 325 mesh50 + 100 mesh - 325 mesh 160 grams12 + 35 mesh - 325 mesh 80 grams______________________________________
This refractory composition was mixed with 30 ml of the zirconia sol used in Example I. The gel time was 8 minutes. The modulus of rupture measurements after firing specimens to the particular temperatures for two hours and testing after cooling are as follows:
______________________________________ Modulus of Rupture pounds per sq. inch______________________________________Unfired 2782000° F. 4792500° F. 18882700° F. 20192900° F. 2623______________________________________
Test specimens from Examples I, II and III were also measured before firing and after each firing and showed the following percentage permanent expansion (+) or shrinkage (-):
______________________________________Firing ExamplesTemperature °F. I II III______________________________________2000 +0.08 -0.09 -0.112500 +0.29 -0.46 -0.512700 +0.40 -1.60 -0.50______________________________________
The development of some permanent expansion could be helpful in eliminating or minimizing settling and drying shrinkage on some compositions, thereby increasing dimensional accuracy in making shapes.
The following is an example of typical shell mold system possible by the use of this invention:
Composition:
______________________________________Electrically fused calcium oxide 2000 gramsstabilized zirconium oxideZirconia sol containing 20% ZrO.sub.2 500 gramsConcentrated hydrochloric acid 17 ml.Wetting agent - Sterox NJ 15 drops______________________________________
This slurry was prepared to a viscosity of 34 seconds as measured by the Zahn #4 cup. Sheets of wax, approximately 1/8" thick and 21/2" wide by 51/2" long were dipped into this slurry and immediately stuccoed while wet with a -50+100 mesh zirconia of the same composition as used in the slurry. After dipping several specimens, the slurry was diluted with the zirconia sol to a viscosity of 15 seconds and further dip was applied after the first dip had dried overnight. While the second coating was still wet, it was stuccoed with a relatively coarse zirconia granule of a -12+35 mesh of the same composition as the material in the slurry. This was repeated for additional coatings and a final seal coat was applied, making a total of 6 stucco layers and 7 slurry layers. Two dips were applied per day through the final dip. The dipped specimens were then allowed to dry for 2 days and the wax was melted out. The specimens were then cut into strips 1" wide, dried, and then tested for unfired strength Six specimens were tested giving an average modulus of rupture value of 500 psi. Additional specimens were fired for 2 hours to various temperatures beginning at 2000° F. and cooled back to room temperature and tested. The MOR after firing to 2000° F. was 220 psi. The MOR firing to 2200° F. and cooling to room temperature was 300 psi. The MOR increased to 1200 psi after firing to 2500° F. This indicated a substantial strength was obtainable on a shell mold composition utilizing this invention.
TABLE 1______________________________________ Wt. % Type of Active ActiveSample Refractory Refractory Gel Time______________________________________1 Calcium Aluminate Cement 5.0 Immed.2 Calcium Aluminate Cement 1.0 8 min.3 Calcium Aluminate Cement 2.0 4 min.4 Calcium Aluminate Cement 0.5 45 min.5 Magnesium Zirconate 1.0 6 min.6 Magnesium Zirconate 0.5 2 hr. +7 Magnesium Zirconium Silicate 1.0 Overnight8 Magnesium Zirconium Silicate 5.0 55 min.9 Magnesium Zirconium Silicate 7.5 12 min.10 Magnesium Zirconium Silicate 10.0 10 min.11 MgO T-139.sup.1 - 325 Mesh 1.0 90 sec.12 MgO T-139 - 325 Mesh 0.8 2 min.13 MgO T-139 - 325 Mesh 0.6 4 min.14 MgO T-139 - 325 Mesh 0.4 10 min.15 Calcium Zirconium Silicate 1.0 Overnight16 Calcium Zirconium Silicate 5.0 20 min.17 Calcium Zirconium Silicate 3.0 28 min.18 Calcium Zirconium Silicate 7.5 7 min.19 Calcium Zirconate 1.0 Overnight20 Calcium Zirconate 5.0 1 hr. +21 Calcium Zirconate 7.5 90 sec.22 Calcium Zirconate 10.0 Immed.23 CaO 1.0 Instant24 CaO 0.1 1 hr. +25 CaO 0.25 60 sec.26 CaO 0.5 Instant27 Iron Chromite 1.0 Overnight28 Iron Chromite 5.0 30 sec.29 Iron Chromite 3.0 Overnight30 Iron Chromite 4.0 2 hrs.31 Iron Chromite 5.0 9 min.32 Iron Chroite 6.0 5 min.33 Zeolex 23.sup.2 1.0 Overnight34 Zeolex 23 5.0 Instant35 Zeolex 23 2.0 8 min.36 Zeolex 23 3.0 Instant37 Winco Cordierite.sup.3 - 200 Mesh 1.0 Overnight38 Winco Cordierite - 200 Mesh 5.0 1 hr. +39 Winco Cordierite - 200 Mesh 7.0 12-15 min.40 Winco Cordierite - 200 Mesh 8.0 8 min.41 Wollastonite 1.0 7-11 min.______________________________________ .sup.1 Manufactured by C. E. Minerals, King of Prussia, Pa. .sup.2 Trademark of J. M. Huber Corp., Baltimore, Md. .sup.3 Manufactured by Winco Minerals, E. Aurora, N.Y.
TABLE 2______________________________________ Permanent Expansion in Thousandths of Inch at Firing TemperatureSample Gel Time 1200° F. 1800° F. 2000° F. 2500° F.______________________________________3 4 min. .010 .003 .001- .005-2 8 min. .002 .001- .003 .004-5 6 min. .006 .004 .003 .006-7 Overnight .004 .003 .004 .009-10 10 min. .008 .001 .001- .03711 11/2 min. .005 .004 .011 .011-12 2 min. .008 .003 .002 .016-13 4 min. .002 .000 .002- .020-14 10 min. .002 .005 .003 .011-16 Overnight .016 .015 .016 .013-18 7 min. .006 .009 .005 .026-17 28 min. .005 .006 .004 .022-19 Overnight .004 .003- .001- .007-27 Overnight .008 .010 .000 .012-30 2 hrs. .002 .005 .009 .002-31 9 min. .003 .001- .008 .010-37 Overnight .002 .004 .002- .013-39 15 min. .001 .005 .007 .024-40 8 min. .004 .004 .021-41 11 min. .005- .004 .004 .025-24 60 min. + .004 .006 .015-______________________________________ | Refractory compositions comprising an acid stabilized aqueous zirconia sol and an active refractory material in an amount effective to gel said sol. A relatively non-active refractory material may also be present. The refractory mix can be made into molded articles or used to form casting molds. Methods of making fired refractory molds and methods of metal casting are disclosed. | 2 |
RELATED APPLICATIONS
This application claims the benefit of priority to European Patent Application No. 04 018179.4 filed Jul. 30, 2004 entitled “LEUCHTKÖRPER” for inventor Steve Becker, and is incorporated herein by reference in its entirety.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to light sources, and more particularly, a portable light source operable to illuminate a precision work area such as a medical or dental treatment field, or precision mechanical working area, such as those used in watch making.
BACKGROUND OF THE INVENTION
Specialized light sources are currently available for precision work. For example, lamps have been developed that are compact and lightweight such as those used or mounted on a user's head or helmet. In the medical field, such lamps are used during operations or other procedures in addition to operating theater lamps. This second light source provides increased illumination of the precision work area. The intensity of the light provided to the precision work area is extremely important.
Previously, two types of lamps were primarily used. First, optical fiber technology has been used to provide illumination to these precision work areas. These lamps may provide relatively intense localized light. However, a disadvantage associated with optical fiber technology is that in order to provide a relatively intense field of illumination, the lamp itself may be a heavy unit that is too cumbersome to be carried by the user. Additionally, the cables and optical fibers associated with this lamp restrict the freedom of movement of the user.
Another solution essentially provides a portable flashlight held in place, for example, on the head, by means of a strap. Such a lamp is equipped with a light bulb and, when powered by batteries, provides a relatively easy and portable solution with which to provide illumination to a precision work area. The disadvantage associated with this solution is that within normal light bulbs, 80 percent of the energy is transformed into heat while only 20 percent of the energy actually illuminates the work area. Therefore, such a solution typically uses oversized batteries or provides less intense light than expected to illuminate the precision work area or medical treatment area. In order to further increase the illumination in the work area, such conventional lights often become too hot causing discomfort for the user as well as negatively impacting the work area. This is because the increase in light intensity not only increases the visible light but also increases the 80 percent of the lamp's output that is converted to heat.
Another solution to increasing the light intensity involves the use of halogen lamps, however, this type of lamp also becomes too hot for use in a treatment field and can negatively impact the precision workspace, as well as causing discomfort to the user.
SUMMARY OF THE INVENTION
The present invention provides a portable light source that substantially addresses the above-identified needs and others. More specifically, the present invention provides an improved portable light source. This light source is operable to illuminate a medical or precision mechanical working area. The light source has a housing or casing, a light emitting diode (LED) diode, a primary focusing lens and a secondary focusing lens. The LED, primary focusing lens, and secondary focusing lens are arranged within the casing and oriented along an optional axis of the light emitted from the LED. The secondary focusing lens is positioned behind the primary focusing lens along the optical axis. The primary focusing lens mounts within a cylindrical recess within the casing. This cylindrical recess has a curved surface that is curved toward the primary focusing lens.
The use of a LED to provide the illumination allows a lighter and more efficient portable light source than was previously possible with fiber optics or conventional light bulbs. Additionally, the low energy consumption and a low thermal output provides a significant advantage over previous solutions.
To simultaneously maximize the light intensity in the precision work area, a secondary focusing lens is provided before the primary focusing lens wherein both the secondary focusing lens and primary focusing lens are aligned along the optical axis of the light emitted by the LED. The ratio of the secondary focusing lens's, radius of curvature, and that of the primary focusing lens will be discussed later in further detail. With the combination of the secondary focusing lens and primary focusing lens, it is possible to obtain a light intensity between about 19,000 LUX and 50,000 LUX at a distance of about 25 centimeters to 50 centimeters (cm) from the portable light source.
Furthermore, the use of the LED provides a significant advantage in that the maximum temperature experience is typically about 55° C. or less. This is significantly less than the heat load produced using conventional bulbs. This also increases the overall efficiency of the portable light source over previously available systems. The LED is operable to transform about 80% of the energy into light while the remainder is converted to thermal energy. As the LED more efficiently produces light, batteries or other portable power supplies' useful life are increased while maintaining the same light intensity. Therefore, the use of this portable light source can be extended by the lightweight efficient portable light source of the present invention.
The present invention provides another advantage in that LEDs previously have only been able to produce a light intensity of about 10,000 Lux. Therefore, the light intensity at the work area is typically less than 10,000 Lux due to the separation between the light source and the work area. Using the primary and secondary focusing lenses, the light intensity in the work area may be increased. Thus, one embodiment provides a light intensity at a distance between about 25 cm and 50 cm in excess of 10,000 Lux. For example, light intensities between 30,000 and 50,000 Lux have been provided using this light source.
The primary and secondary focusing lenses are also able to focus the light emitted by the LED in a narrower cone. Thus, one embodiment of the present invention is able to provide a focused intense cone of light with a diameter of about 3 centimeters to about 8 centimeters, at a distance between 25 centimeters and about 50 centimeters from the light source.
In one embodiment, the housing or casing subtends an angle α between about 40° and 80°. Additional embodiments may further limit the angle the opening subtends from about 50° to about 70°, or further yet, from 58° to 64°.
An air gap may separate the outer surfaces of the secondary focusing lens and the housing to help optimize the light intensity transmitted to the precision work area. This air gap may be between approximately one degree and two degrees.
Other features and advantages of the present invention will become apparent from the following detailed description of the invention made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings in which like reference numerals indicate like features and wherein:
FIG. 1 shows a cross-section of a portable light source in accordance with an embodiment of the present invention;
FIG. 2 provides an enlarged representation of the housing of FIG. 1 ;
FIG. 3 depicts the secondary focusing lens of the portable light source of FIG. 1 ;
FIG. 4 shows a cross-section of a portable light source in accordance with another embodiment of the present invention; and
FIG. 5 provides an enlarged representation of the housing of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the present invention are illustrated in the FIGUREs, like numerals being used to refer to like and corresponding parts of the various drawings.
FIG. 1 shows an embodiment of a portable light source or lamp 1 operable to illuminate a medical treatment or precision work area. The cross section of lamp 1 includes housing or casing 2 that is symmetrical about axis 2 A. Housing or casing 2 in three dimensions has a conical or funnel shaped form. LED 4 , primary focusing lens 6 , and secondary focusing lens 8 are arranged within housing 2 . LED 4 may be powered by a portable energy source (not shown) such as a battery coupled to LED 4 . Primary focusing lens 6 optically couples to LED 4 and is aligned along optical axis 2 A of LED 4 . Primary focusing lens 6 as depicted has a hemispherical profile which corresponds essentially to a Lambert-curve. This primary focusing lens is made of a transparent material such as glass, Plexiglas, or other like transparent or optically conductive material known to those skilled in the art.
Primary focusing lens 6 in one embodiment is a hemispherical lens having a radius of curvature of 2.5 millimeters (mm). The flat portion of the hemisphere optically couples to the LED to receive light emitted from LED 4 . Beneath the hemispherical portion of primary focusing lens 6 , a cylindrical portion 6 A of the primary focusing lens is provided and optically couples the primary focusing lens with LED 4 . The cylindrical portion 6 A of primary focusing lens 6 may be made of the same material as the hemispherical portion of lens 6 . In this embodiment, section 6 A has a diameter of 5 millimeters that matches the 2.5 millimeter radius of curvature of the hemispherical portion. LED 4 may be a single LED or an array of LEDs.
Secondary focusing lens 8 is provided within lamp or casing 2 . Secondary focusing lens 8 may be made of a PMMA crystal, glass, or other suitable transparent or optically conductive material known to those having skill in the art. A cylindrical recess 10 in secondary focusing lens 8 is aligned about the optical axis 2 A of LED 4 and primary lens 6 . Recess 10 has a depth p. As shown in FIG. 3 , primary focusing lens 6 may be completely located within recess 10 . In other embodiments, primary focusing lens 6 may only be partially located within recess 10 . The upper surface 12 of recess 10 is a curved optical surface aligned about optical axis 2 A. Optical surface 12 is a curved lens directed towards the hemispherical portion of lens 6 . The ratio of the radius of curvature of the hemispherical portion of primary lens 6 and the radius of curvature of curve surface 12 are such that the radius of curvature of surface 12 is substantially larger than that of the hemispherical portion of primary focusing lens 6 . In one embodiment, the radius of curvature of curved surface 12 is at least twice that of the radius of curvature of the primary focusing lens. In other embodiments, this ratio may be 3, 3.5, or even greater. For example, in one embodiment the radius of curvature of curve surface 12 is about 9 millimeters and is therefore substantially larger than the 2.5-millimeter radius of curvature of the hemispherical portion of primary focusing lens 6 .
A gap separates the top of the hemispherical portion of the primary focusing lens 6 and curved surface 12 . This gap may in fact be an air gap and have a separation distance in one embodiment of 1.8 millimeters. Other embodiments may have a gap A between about 1 and 3 millimeters. For example, one particular embodiment has a gap between about 1.8 to 2.3 millimeters.
FIG. 2 provides an enlarged representation of housing 2 . Inner walls 20 of section 28 subtend an opening angle α. Outer walls 34 of housing 2 subtend a larger angle β. The wall strength of housing 2 will also determine the inner diameter c and outer diameter i of the housing. These outer diameters correspond to the upper cylindrical portion 18 of housing 2 .
FIG. 3 provides a cross-section of secondary focusing lens 8 . Upper section 14 of secondary lens 8 is a cylindrical section that in this embodiment has a height d and diameter b. Diameter b may match the interior diameter C of the housing as shown in FIG. 2 . Additionally, the cylindrical section 14 may have a height d that matches the height e of the cylindrical upper portion 18 of the housing as shown in FIG. 2 . In one particular embodiment, the interior diameter c and cylindrical diameter b of secondary focusing lens is 26 millimeters. Other embodiments may have diameters between about 24 millimeters and 35 millimeters.
Secondary focusing lens 8 may also have a cylindrical portion having the height d that matches the height e of cylindrical portion 18 of housing 2 which, in one embodiment, is 7.7 millimeters. Alternatively, these heights may differ. For example d may be less than e. In one embodiment the height of cylindrical portion 18 is 7.7 millimeters while the height of cylindrical portion 14 of secondary focusing lens 8 has a length d of 5.9 millimeters. The relationship of these lengths can be varied as desired. The greater length of the cylindrical portion 18 of housing 2 may further protect the secondary optical lens. Frustum section 16 of secondary focusing lens 8 has a base which may optically couple or otherwise rest on LED 4 . Between the frustum section 16 of secondary lens 8 and conical section 28 of housing 2 , air gap 30 exists. This air gap tapers from a maximum delta between secondary lens 8 and housing 2 due to a difference in the angle of inclination of section 28 of the housing and section 16 of the secondary focusing lens.
LED 4 may have an adjustable height within recess 10 . This adjustable height may affect the optical coupling between primary focusing lens 6 and secondary focusing lens. For example, LED 4 may have a maximum height g which in one embodiment may be 6.8 millimeters while the LED is centered at 6 millimeters. These heights may be varied as desired.
Recess 34 depicted in FIG. 1 as being beneath LED 4 may contain power leads that couple to LED 4 and are not shown.
Specific dimensions associated with one embodiment are provided as follows: j—9 millimeters, k—13 millimeters, l—4.5 millimeters, m—10 millimeters and n—13 millimeters.
The secondary focusing lens 8 may have the following specific dimensions in one embodiment. It may an overall height o of 17.8 millimeters, a diameter b as discussed, a cylindrical portion having a height d, as previously discussed as well, and a frustum section 16 , having an interior cylindrical recess with a height p. Height p is selected such that the primary focusing lens sticks may be received within recess 10 , while providing an inner hole or gap A between the hemispherical portion of primary focusing lens 6 and a curved surface 12 . The inter-diameter q of recess 10 is selected, such that primary focusing lens 6 may be easily received within the recess without necessarily having direct contact between primary focusing lens 6 and secondary focusing lens 8 . Direct contact between the primary and secondary focusing lens may be undesirable.
FIG. 4 provides a cross section of a second embodiment 200 of the present invention. Parts having the same reference numerals may have the same functions as previously described in FIGS. 1 through 3 . The second embodiment will show different varying length and dimensions when compared to that of the embodiment depicted in FIGS. 1 through 3 . In this embodiment, the opening subtended by the housing inner walls α and outer walls β is increased when compared to that of the embodiment in FIGS. 1 through 3 . This larger angle also results in a larger air gap 30 between housing 2 and secondary focusing lens 8 .
Particular dimensions associated with this embodiment are that the length f is 1.4 millimeters, a=2.3 millimeters, g=7.3 millimeters, h=6 millimeters, the angles subtended are β 64 degrees and α of 60 degrees, length i is 28.4 millimeters, c is 26.1 millimeters, e=7.7 millimeters, j=9 millimeters, k=13 millimeters, l=4.5 millimeters, m=10 millimeters, and n=13 millimeters.
LED 4 may be between 0.5 and 5 watts, with one embodiment between about 2 and 4 watts. This will result in a maximum temperature of about 55° Celsius or, at least, a temperature less than 60° Celsius.
The embodiments of the portable light source, as shown in FIGS. 1 through 5 , are based on the particular dimensions. However, these dimensions may be modified by the user without changing the intention of the present invention. This will be understood by those having skill in the art.
The embodiments depicted in FIGS. 1 through 5 are operable to produce a cone of light at a distance of about 30 centimeters from secondary focusing lens 8 . This cone of light will be along optical axis 2 A, and have a diameter of about 3 centimeters to about 8 centimeters, with an intensity of up to about 30,000 Lus. Another embodiment having a different diameter secondary focusing lens, (i.e. about 30 mm) may produce a cone of light ranging between about 3 centimeters and 8 centimeters at a distance of 30 centimeters from the secondary focusing lens with an intensity of about 50,000 Lux.
In summary, the present invention provides a portable light source that may be used to illuminate a medical or precision mechanical working area. The light source has a casing or housing, an LED, a primary focusing lens and a secondary focusing lens. The LED primary focusing lens and secondary focusing lens are arranged within the casing and aligned along a common optical axis. The common optical axis is along the direction of the light emitted from the LED. The primary focusing lens optically couples to the LED and is received within a cylindrical recess of the secondary focusing lens. The secondary focusing lens has an optically curved surface facing the primary focusing lens that has a larger radius of curvature than that of the primary focusing lens.
This portable light source, by utilizing an LED, is able to more efficiently produce light and decrease the unnecessary production of thermal energy. This results in a portable light source having an extended life while using the same power supply. Additionally, the combination of the primary focusing lens and secondary focusing lens are able to illuminate a precision working area or medical treatment field with a light having an intensity greater than 10,000 Lux. The primary and secondary focusing lenses are also able to focus the emitted light into a narrower cone at a distance from the secondary focusing lens. This results in more intense illumination of the precision work area or medical treatment field from a more efficient, light weight, and more user friendly light source.
As one of average skill in the art will appreciate, the term “substantially” or “approximately”, as may be used herein, provides an industry-accepted tolerance to its corresponding term. Such an industry-accepted tolerance ranges from less than one percent to twenty percent and corresponds to, but is not limited to, component values, integrated circuit process variations, temperature variations, rise and fall times, and/or thermal noise. As one of average skill in the art will further appreciate, the term “operably coupled”, as may be used herein, includes direct coupling and indirect coupling via another component, element, circuit, or module where, for indirect coupling, the intervening component, element, circuit, or module does not modify the information of a signal but may adjust its current level, voltage level, and/or power level. As one of average skill in the art will also appreciate, inferred coupling (i.e., where one element is coupled to another element by inference) includes direct and indirect coupling between two elements in the same manner as “operably coupled”. As one of average skill in the art will further appreciate, the term “compares favorably”, as may be used herein, indicates that a comparison between two or more elements, items, signals, etc., provides a desired relationship. For example, when the desired relationship is that signal 1 has a greater magnitude than signal 2 , a favorable comparison may be achieved when the magnitude of signal 1 is greater than that of signal 2 or when the magnitude of signal 2 is less than that of signal 1 .
Although the present invention is described in detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as described by the appended claims. | The invention provides a light source ( 1, 200 ), especially a portable light source ( 1, 200 ) used to illuminate a medical or precision mechanical working area, with a casing ( 2 ), with a light diode ( 4 ) held by the casing ( 2 ), with a primary focusing lens ( 6, 6 a ) held by the casing ( 2 ) in the direction of emissions ( 2 a ) from the light emitting diode ( 4 ), with a secondary focusing lens ( 8 ) held by the casing ( 2 ) positioned behind the primary focusing lens ( 6, 6 a ) in the direction of emissions ( 2 a ) from the light emitting diode ( 4 ), and that has a largely cylindrical recess ( 10 ), with the characteristic that a floor ( 12 ) of the recess ( 10 ) facing the primary focusing lens ( 6, 6 a ) is curved in the direction of the primary focusing lens ( 6, 6 a ). | 5 |
The invention relates to a positive displacement machine which is formed by a male organ and a female organ (tubular body) that surrounds it.
In this machine, the outer surface of the male organ, which will be called the male surface, and the inner surface of the female organ, which will be called the female surface, are helicoidal surfaces whose axes are parallel and are spaced apart from one another by a length that will be designated as E.
These surfaces are defined about these axes by the nominal profile that they have in any section perpendicular to the axes (cross section) and by their respective pitches P m and P f .
The delimitation of the volume of the work chambers of the machine and the axial progression of these chambers, which characterizes this type of mechanism when P m and P f are finite, result from the fundamentally linear contacts between the male surface and the female surface; the relative motion of these two surfaces displaces these linear contacts spatially.
In the machines in question here, the directrix of the male surface, which will be called the male profile, has an order of symmetry n m about its center, which is the point O m of the axis of the male surface in the plane of the profile. This profile is inscribed in the circular ring with a center O m , of width 2E and having a mean radius R° m (ring containing the male profile).
The directrix of the female surface, which will be called the female profile, has an order of symmetry (n m +1) about its center, which is the point O f of the axis of the female surface in the plane of the profile. This profile is inscribed in the circular ring having the center O f , the width 2E, and the mean radius R° f =R° m +E (ring containing the female profile).
The mean radius R° m may be considered as the parameter that determines the scale of the cross section of the mechanism, and the parameter E may be considered as a parameter of shape.
The ratio between the pitches of the male and female surfaces is determined by the orders of symmetry of the profiles, in accordance with the equation P f /P m =(n m +1)/n m .
In the machines in question, the male organ is in planetary motion relative to the female organ. The first rotation of this planetary motion drives the axis of the male surface, at an arbitrary speed ω, to make this axis describe a cylinder of revolution having a radius E about the axis of the female surface. The second rotation composing the relative planetary motion drives the male organ to make it rotate about the axis of the male surface at the speed (-ω/n m ).
Finally, when P m and P f are finite, the fluid with which the machine exchanges energy can be admitted via a cross section at the end of the mechanism and can escape via its other end, without requiring any distribution contrivance.
The known machines that meet this description, (such as French Patent FR-A-997957 of Moineau, other previous Moineau patents, and U.S. Pat. No. 3,975,120 Tschirky) in which P m and P f are finite, are used in particular as downhole motors in petroleum, gas or geothermal drilling, where their slender cylindrical external shape is of direct benefit. In these motors, the female organ most often belongs to the stator, while the planetary motion of the male organ relative to this female organ is accordingly identified with its absolute motion. The male and female profiles of the helicoidal surfaces used in these machines are described by W. Tiraspolsky, in Les moteurs de fond hydrauliques, cours de forage (Hydraulic Downhole Motors in Drilling), pp. 258 and 259, published by Editions TECHNIP, Paris 15; the male profile is considered to be the curve at a uniform distance D from the ordinary trochoid having an order of symmetry n m , and the female profile of mean radius R°m+E is considered to be the curve at the same uniform distance D from the ordinary trochoid having the order of symmetry (n m +1).
If the curves at a uniform distance from the ordinary trochoids were strictly physically embodied, then these two profiles would permanently have (n m +1) points of contact, and as they periodically come into coincidence along the circular arcs of radius D centered on the cusps of the ordinary trochoids, would make it possible to permanently isolate the work chambers via the contacts between the male and female surfaces.
Unfortunately, the curves at a uniform distance from any ordinary trochoid always have cusps and accordingly cannot be strictly physically embodied; knowingly or unknowingly, male and female profiles are then manufactured with their cusps amputated, and the consequences are that these approximate profiles have slight angular points, but above all are not rigorously conjugated over their entire perimeter, and so in principle they are useless for constituting a mechanism where the contact surfaces are rigid. This difficulty is overcome as follows: the female profile is formed in an elastomer composition in which the local deformations prevent fluid leakage or interference of the profiles. Nevertheless, these parasitic deformations cause major organic losses and very hard operation of the machine, which limits its use to cases where there is no substitute for it.
SUMMARY OF THE INVENTION
The machines according to the invention eliminate these disadvantages by proposing male and female profiles whose association has novel or unexploited properties.
In the machines that are the subject of the invention, the male profile possesses the following properties:
it has an order of symmetry n m with respect to its center O m and a symmetry with respect to the axis originating in O m passing through the extreme polar radius points, these polar radii being determined with respect to O m ,
between two successive extreme polar radii, a running point U which traverses the profile from the point of maximum polar radius (R max ) to the point of minimum polar radius (R min ) determines a polar radius whose decrease is monotonous,
in its traversal defined above, the running point U passes via a fixed point A on the profile, whose polar radius R A0 , its first derivative R A1 with respect to the polar angle, and its second derivative R A2 with respect to the polar angle satisfy the following two conditions:
n.sub.m E=R.sub.A0 ·sin {arc tan (-R.sub.A1 /R.sub.A0)}
R.sub.A2 /R.sub.A0 =-(R.sub.A1 /R.sub.A0).sup.4
where
R.sub.max -R.sub.min =2E.
These analytical conditions are involved by the following two geometrical properties of the male profiles used in the machines according to the invention:
the normal g A to the male profile at A is tangent to the circumference C pm , centered on O m , of radius n m E, at a point A 1 ≡A 2 ,
the normal g U at any running point U different from A intersects the circumference C pm at two real, separate points U 1 and U 2 .
In the machines that are the subject of the invention, where P m and P f are finite, the female profile is identified with the complete physically embodiable outer envelope of a male profile meeting the above conditions in its relative planetary motion.
It may be noted that with the definition of the male profile of the machines that are the subject of the invention, (n m +1) points of contact permanently exist between the male and female profiles. Such points will be called driving points. These points traverse the entire male profile in a single direction, and each of them in a reciprocating motion traverses one among the (n m +1) separate arcs of the female profile, which will be called driving arcs. Furthermore, for only certain relative positions of the male and female organs, there is one additional point of contact between the male profile and the female profile. This point will be called the closure point. On the male profile, this point traverses all the segments such as R max A in a single direction; in the female profile, this point successively and in the same direction describes (n m +1) other separate arcs. These arcs will be called closure arcs; they join tangentially with driving arcs at 2(n m +1) junction points J.
In the machines that are the subject of the invention, each point such as A belonging to the male profile comes successively into contact with all the junctions points J belonging to the female profile, and only with them, in the relative planetary motion of the male profile with respect to the female profile.
From the properties of the male profile and the relationships between the points A of the male profile and the points J of the female profile, the following properties result for the driving arcs belonging to the female profiles used in the machines according to the invention:
the normal g J at a point J defining a driving arc is tangent to the circumference C pf , centered on O f , of radius (n+1)E, at a point J 1 ≡J 2 ,
the normal g C at any running point C different from J, belonging to the driving arc, intersects the circumference C pf at two real separate points C 1 and C 2 .
Applying the foregoing, there are two ways to define the male profiles of a machine according to the invention: a first way, which constitutes a general method and is indirect, and a second way which is direct but limited.
The general method will be introduced first. According to this method, the procedure is as follows:
A half-driving arc with ends M and J is constructed, such
1) that M is at the distance R° m from the center O f , the normal g M to the half-driving arc at M passing through O f and consequently intersecting the circumference C pf at two diametrically opposed points M 1 and M 2 [on the condition that R° m is greater than (n m -1)E, and that the angle (M O f J) is less than 2π/(n m +1)],
2) that J is at the distance R J (greater than R° m ) from the center O f and that the normal g J to the half-driving arc at J is at a tangent to the circumference C pf at the point J 1 coinciding with the point J 2 ,
3) and that for any point C included between M and J, the normal g C to the half-driving arc intersects the circumference C p at two points C 1 and C 2 , the point C 1 being displaced from M 1 to J 1 and the point C 2 being displaced from M 2 to J 2 when C traverses the segment MJ. Outside these constraints, the half-driving arc is selected freely.
The half-driving arc is reproduced symmetrically with respect to g M . A complete driving arc is thus defined.
This driving arc is repeated n m times, by rotation about O f of the angle 2π/(n m +1), in order to adhere to the order of symmetry of the female profile.
By conventional techniques in kinematics, the internal envelope Γ im of the set of driving arcs in the planetary motion imposed is determined. This envelope Γ im has an order of symmetry n m with respect to the center O m .
A check is made to verify that this envelope Γ im has no double points and that, if it is traversed from the maximum polar radius point to the minimum polar radius point immediately next to it, the polar radius decreases monotonously. If this condition is not met, then the definition of the driving arc must be modified, and the process of constructing the envelope Γ im must be started over again. Once that condition is satisfied, the envelope Γ im has all the characteristics that are imposed upon the male profiles in the scope of this invention and defines one possible male profile.
Next, the outer envelope Γ ef of the male profile in the planetary motion imposed is looked for. This envelope Γ ef obviously contains the set of (n m +1) driving arcs and the (n m +1) closure arcs. It is accordingly identified with the complete female profile.
It will be observed that the driving arc may in principle have points of abrupt variation in curvature and even angular points insofar as these points meet the symmetry imposed on the driving arc; in particular, the driving arc may be a polygonal line.
The simplest method for constructing a driving arc that is infinitely continuous at all points is as follows:
A first reference segment Γ f1 is defined, which is identified with a straight segment perpendicular at M to g M ; a second reference segment Γ f2 is defined, which is identified with a circumferential arc centered on g M at a distance R f2 from O f , such that R f2 is greater than R° m . The radius of this circumferential arc is equal to R f2 -R° m . The polar radii of the curves Γ f1 and Γ f2 are linearly composed, at a constant polar angle, with respective weighting coefficients μ 1 and μ 2 , such that μ 1 +μ 2 =1. The resultant segment is identified with one possible half-driving arc.
Next, the direct way to define machines according to the invention will be introduced. This way of proceeding involves experimentally searching for male profiles that meet the conditions given above. Necessarily, these are curves whose algebraic definition makes it possible to meet these conditions.
Experience leads to choosing the family of hypertrochoids, whose equation in the complex plane O m XY where O m X is carried by a half-axis of symmetry of the male profile at which its polar radius is maximal is written as follows:
Z.sub.U =X.sub.U +iY.sub.U =R°.sub.m exp i(κ)+E[1+(κ/2)(n.sub.m -1)]exp i](1-n.sub.m)κ]-kE[(1/2)(n.sub.m -1)]exp i[(1+n.sub.m)κ](I)
in which equation expi stands for the imaginary exponential function, in which the angle κ is the configuration parameter relative to the running point U, in which n m is set to be greater than 1, and in which selectively it will be, k=1, with E/R° m ≦1/(n m 2 -1), or k=0, with E/R° m <1/(n m -1). It will be observed that when k=0, the hypertrochoid degenerates into a curtate hypotrochoid, but this degeneration keeps the curve in the set of hypertrochoids that contains the subset of trochoids.
The choice of the relative eccentricity E/R° m is not completely free; when k=1 is chosen, the relative eccentricity is limited by the following condition:
E/R°.sub.m ≦1/(n.sub.m.sup.2 -1)
because the male profile becomes looped beyond the limit value, and when k=0 is chosen, the relative eccentricity is limited by the following condition:
E/R°.sub.m <1/(n.sub.m -1),
which means that the hypotrochoid must be curtate.
In these two profiles, the normal g U to the running point U passes via the point U 1 the affix of which is:
Z.sub.U1 =n.sub.m E exp i](1-n.sub.m)κ]
and this normal intersects the circumference C pm at a second point U 2 which is always real and which, when the point U traverses the profile, comes periodically to coincide with the point U 1 . This point U 2 determines an angle γ such that:
Z.sub.U2 =n.sub.m E exp iγ.
The affix (Z C ) of a running point C belonging to a driving arc is written, in the same complex plane as that in which the equation of the male profile is written and in which the center O f of the female profile occupies the particular position O* f defined by its affix Z O*f =-E:
Z.sub.C =Z.sub.U exp i[(-1/n.sub.m +1)γ-E{1-exp i[(n.sub.m /n.sub.m +1)γ} (II)
and the n m other driving arcs agreeing in the order of symmetry (n m +1) about the point O* f .
The closure arcs of the female profile belong to a hypertrochoid with double points, having the order of symmetry (n m +1) about O* f . The affix (Z F ) of a running point F belonging to this closure arc is written as follows, in the same complex plane as that in which the equation of the driving arcs is stated:
Z.sub.F =Z.sub.U exp i{[(n.sub.m -1)/(n.sub.m +1)]κ}-E+E exp i{[n.sub.m (n.sub.m -1)/(n.sub. +1)]κ} (III)
When k=0 in the equation (I), it is also possible for any curve at the uniform distance D from the male and female profiles defined by the equations above to be adopted as male and female profiles, for given values of R° m and E. It suffices for these thus-defined profiles to form a fictitious mechanism where the center distance of the axes E is identical to that of the real mechanism, where the ring containing profile has a mean radius equal to R° m =D and where the ring containing the female profile has a mean radius equal to R° m +E-D, the distance D being counted positively in the centrifugal direction and any curve at a negative distance D from the profiles forming the fictitious mechanism can be retained only if it has no double point whatever.
Extrapolation to the uniformly distant curves does not enlarge the set of possible solutions unless k=0, because if k=1, the curves at a uniform distance of the male hypertrochoids belonging to the fictitious mechanisms remain hypertrochoids that meet equation (I), which necessarily means the invariance of the female profile as well.
Regardless of how the machines according to the invention are defined, it is the motion of the closure point that, coming successively into contact in a predetermined and immutable order with all the driving points, makes it possible for the section of a work chamber to appear, grow, shrink, then disappear in each cross section of the mechanism. This property makes the association of profiles usable to constitute original helicoidal mechanisms that are distinguished in particular from the known ones in that the chambers close axially in tapered fashion, rather than by the entering into coincidence of two circumferential arcs. This tapered closure is produced at the moment where the joint J of a female profile comes to coincide with the point A of a male profile.
The male and female helicoidal surfaces of machines according to the invention are the only surfaces that have been discovered thus far that can both belong simultaneously to rigid parts. Both of them are machinable. They make it possible moreover to adapt shapes to particular requirements, because of the broadness in the definition of the male and female profiles that they use.
In the machines according to the invention, the helicoidal surfaces can degenerate into cylindrical surfaces, when the inverses of the male pitch (1/P m ) and female pitch (1/P f ) tend to zero. These surfaces are then entirely defined by their cross section. The work chambers are axially closed by end plates, and the fluid can be admitted radially into the mechanism and escape from it in the same way.
In the case of degeneration, those machines whose male profile is a hypertrochoid are excluded from the machines according to the invention.
In the cylindrical mechanisms of the machines according to the invention, the closure arcs are no longer indispensable for the closure of the chambers. They can be replaced with arcs which are outside them, and with which the male profile no longer comes into contact.
Either if they include a helicoidal or a cylindrical mechanism, the machines according to the invention may involve any combination of absolute motions making it possible to realize the relative planetary motion of the male organ with respect to the female organ. In fact, two possibilities have obvious practical importance.
In a first possibility, which is the one generally used to make downhole motors intended for petroleum, gas or geothermal drilling, the female organ belongs to the stator, and so the female surface and profile can then be categorized as statoric. The relative planetary motion of the male organ becomes absolute, and the male organ constitutes the rotor of the machine.
If, for tribological reasons in particular, the portion of the stator limited by the statoric surface must be constituted by a layer of elastomer, and the thickness of this layer may be limited to a minimum, since because the statoric and rotoric surfaces are rigorously conjugated by sliding, no local deformation need to be provided to overcome any gearing defect. The result in particular is a reduction and regularizing of parasitic resistances to the motion.
When the motion of the male organ is an absolute planetary motion, this motion can result in the only contacts between the male organ and the portions of the female surface whose directrix is the driving arcs. In that case, the male organ can be linked to a primary shaft coaxial with the female surface by an open kinematic chain constituted successively by a toric connection, an intermediate shaft, and a second toric connection, a thrust bearing being disposed between the primary shaft and the stator to prevent any translation of the male organ along its axis. It should also be noted that one does not depart from the scope of the invention if the open kinematic chain that has just been described is replaced with any mechanical system that gives the male organ and the primary shaft the same relative freedom as that of this kinematic chain.
In the same case where the motion of the male organ is an absolute planetary motion, this motion may result in the articulation of the male organ on a crankshaft rotoidally connected to the stator, about the axis of the female surface, and in the existence of a transmission having the ratio n m /n m +1 joining the male and female organs.
In a second possibility for creating the relative planetary motion, which in particular can be exploited to make screw-type compressors, the male organ is rotoidally connected with a stator about the axis of the male surface, and the female organ is rotoidally connected with the stator about the axis of its inner surface imposed by a transmission having the ratio n m /n m +1 (female surface), the relative planetary motion being joining the male and female organs.
In any machine according to the invention which includes a crankshaft, and in machines where the male and female organs are rotoidally connected to the stator, the transmission of the ratio n m /n m +1 joining the male and female organs can result from direct contacts between the male surface and the portions of the female surface whose directrix is the driving arcs, if the fluid with which the machine exchanges energy is a liquid having a lubricating action on the surfaces contacting one another, or a gas containing such a liquid. Otherwise, the tolerances on the male and female surfaces must allow slight clearance in their gearing, and the relative planetary motion must be imposed by a transmission outside the mechanism.
Regardless of the absolute motions driving the male and female organs, the female organ (tubular body) may be made up of a plurality of identical pieces, which are not very slender, defined by planes perpendicular to the axis, aligned and assembled to constitute a single device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-28 illustrate the particular features and applications of the above.
FIG. 1 relates to the prior art.
FIGS. 2-6 illustrate the general method of defining male and female profiles for machines according to the invention.
FIGS. 7 and 8 relate to the direct definition of male profiles for machines according to the invention.
FIGS. 9 and 10 relate to the construction of female profiles conjugated with the male profiles of FIGS. 7 and 8, respectively.
FIGS. 11-19, on a smaller scale, show the evolution of the cross section of a chamber defined by the profiles constructed with FIGS. 7 and 9, respectively, this evolution being an essential characteristic of any machine according to the invention, which identifies it unambiguously with respect to any known machine.
FIGS. 20 and 21, respectively, show a machine according to the invention in which the tubular body (female organ) is fixed in the stator, and on a larger scale, the corresponding helicoidal mechanism.
FIG. 22 is a detail of FIG. 21 and, on a still larger scale and with the stator removed, shows the lines of contact of the male surface with the female surface and the way in which these lines define the chambers of the mechanism.
FIGS. 23 and 24 show the essentials of a machine according to the invention, including a helicoidal mechanism in which the male organ and the female organ are each in rotoidal connection with the stator.
FIGS. 25 and 26 are two sectional views in a machine according to the invention, in which the tubular body (female organ) is fixed in the stator, which includes a crankshaft and whose mechanism is cylindrical.
FIG. 27 is a fragmentary section in a machine which differs from that shown in FIG. 25 and 26 by the lack of physical embodiment of the closure arcs.
FIG. 28 shows a machine according to the invention including a helicoidal mechanism whose tubular body is made of a plurality of identical pieces.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 recalls the construction of the running point U 0 of an ordinary trochoid Γ ord with the center O and having the order of symmetry n, for a configuration parameter value that locates the point U 0 in the vicinity of a retrogressive point B 0 . This drawing also shows the construction of the point U of the curve Γ eq at a uniform distance D from this trochoid Γ ord , for the same value of the configuration parameter kappa.
The base circumference Γ b with the center O and the rolling circumference Γ r of center O' can be seen, these two circumferences being tangent at I.
At the point U 0 , the normal g U to the ordinary trochoid passes through the point I, and the point U of the curve Γ eq is obtained by marking off the distance D=U 0 U on this normal.
A cusp B of Γ eq corresponds to the cusp B o of Γ ord ; however, between U and B the swing of the normal g U makes the existence of another cusp U* in Γ eq inevitable; the curve Γ eq accordingly has a reentrant arc U*B, and the profile containing Γ eq that extends it beyond B by a circumference Γ c having the center B 0 cannot be physically embodied in the strict sense.
FIG. 2 illustrates the properties imposed on the male profile 1. One can see the circumference C pm having the center O m and the radius n m E, the points U and A belonging to an arc of the male profile defined by two points of successive extreme polar radius, the normals g U and g A as well as the intersections of these normals with the circumference C pm at the respective points U 1 and U 2 , A 1 ≡A 2 .
FIG. 3 illustrates the properties of the driving arc 2 belonging to the female profile of the machine schematically shown in FIG. 4. Here the circumference C pf having the center O ff and the radius (n m +1)E, the points M, J and C belonging to a half-driving arc, the normals g M , g J and g C , and the intersections of these normals with the circumference C pf at the respective points M 1 and M 2 , J 1 ≡J 2 , C 1 and C 2 can all be distinguished in this figure.
FIG. 4 shows a computer model of male and female profiles in a machine according to the invention, where the half-driving arc is characterized by the following parameters defined according to the indirect method:
R° m =40 mm
E=10 mm
R f2 =100 mm
μ 2 =0.8
n m =2
The center O m of the male profile, the cross section 5 of the male organ, and the cross section 4 of the female organ appear in this figure.
FIGS. 5 and 6, with the same notations as FIG. 4, show two other models of machines according to the invention, characterized respectively by the following parameters defined according to the indirect method:
R° m =52 mm
E=24 mm
R f2 =200 mm
μ 2 =-0.5
n m =1
and
R° m =40 mm
E=4.5 mm
R f2 =100 mm
μ 2 =2
n m =3.
FIG. 7 shows the geometric construction of the running point U of a male profile 1 belonging to a machine according to the invention, in the particular case where the male profile is identified with a hypertrochoid satisfying equation (I), where n m =2, k=1, and E/R° m =1/4 (first example of the direct way of defining a male profile).
The profile is constructed within the system of axes O m XY, and the point U corresponds to a running value kappa of the configuration parameter. The vector O m U results from the composition in accordance with equation (I) of a first vector O m V of modulus R° m inclined by the angle kappa with respect to the axis O m X, a second vector VW of modulus 3E/2 inclined by the angle (-2κ) to the first, and a third vector WU of modulus E/2 inclined by the angle (4κ+π) to the second one. The normal g U at U passes through the point U 1 of the circumference C pm having the center O m and the radius n m E=2E, such that O m U 1 is inclined by the angle (-κ) to the axis O m X, and it intersects the circumference C pm a second time at the point U2 that determines the angle γ equals (O m X, O m U 2 ).
FIG. 8 shows the geometric construction of the running point U of a male profile 1 belonging to a machine according to the invention, in the particular case where the male profile is identified with a hypertrochoid satisfying equation (I), where n m =2, k=0, and E/R° m =1/4 (second example of the direct way of defining a male profile).
The profile is constructed within the system of axes O m XY, and the point U corresponds to a running value kappa of the configuration parameter. The vector O m U results from the composition in accordance with equation (I) of a first vector O m V of modulus R° m inclined by the angle κ with respect to the axis O m X, a second vector VU of modulus E inclined by the angle (-2κ) to the first. The normal g U at U passes through the point U 1 of the circumference C pm , and intersects the circumference C pm a second time at the point U2 that determines the angle γ as above.
FIG. 9 shows the construction of a running point C belonging to the driving arc 2 and of a running point F belonging to the closure arc 3 of the female profile 23, which come into contact at different times with the same point U of the male profile shown in FIG. 7. The female profile to which the points F and C belong is drawn in the same system of axes O m XY as the male profile. The vector O m C (not drawn) results from the composition, according to equation (II), of a first vector O m C 3 , which is the vector O m U of FIG. 7, rotated by the angle (-γ/3) a second vector C 3 C 4 of modulus E inclined by the angle π to O m X, and a third vector C 4 C of modulus E, inclined by the angle (2γ/3) to O m X.
The vector O m F (not drawn) results from the composition, according to equation (III), of a first vector O m F 3 , which is the vector O m U of FIG. 7, rotated by the angle (κ/3), a second vector F 3 F 4 of modulus E inclined by the angle π to O m X, and a third vector F 4 F of modulus E, inclined by the angle (-2κ/3) to O m X.
FIG. 10, in the same manner as FIG. 9, shows the construction of a running point C belonging to the driving arc 2 and of a running point F belonging to the closure arc 3 of the female profile 23, which come into contact at different times with the same point U of the male profile shown in FIG. 8.
In these two FIGS. 9 and 10, one has drawn entirely the hypertrochoid with double points to which the closure arcs belong, whose physical portion is limited to the points such as J where they are joined to the driving arcs. The portions not physically embodied of the hypertrochoid appear in dashed lines in these drawings.
FIGS. 11-19 describe the very characteristic evolution of the cross section of a chamber defined by the male and female profiles of FIGS. 7 and 9, in the planetary motion of the male profile relative to the female profile.
The cross section of the chamber which is considered is shaded in all the figures where this section has a sufficient area for this to be possible. In each figure, the direction of the two rotations that compose the relative planetary motion have been indicated. The arrow in solid lines symbolizes the rotation of the male profile (i.e., the second rotation) about the center O m , which is never so indicated but rather is identified by a small blackened circle. The arrow in dashed lines symbolizes the rotation of the center O m of the male profile (i.e., the first rotation) about the center O f of the female profile.
At each stage in the evolution of the section of the chamber in question, the shape of this section is that of a crescent, and the ends of the crescent are understood to be the points of contact of the two profiles, male and female.
A point of contact is designated by the symbol C i when it belongs to a driving arc (i=1, 2 or 3), and it is designated by the symbol F when it belongs to a closure arc.
During the relative motion of the two profiles, a point such as C i indefinitely describes the driving arc i, first in one direction and then in the other, while F traverses the hypertrochoid with double points, always in the same direction, but it is not material and hence useful to the closure of a chamber except during the period of time when it traverses the closure arcs, and it is not shown in FIGS. 11-19 except during its presence on a single closure arc, where it is useful to the reasoning.
In FIG. 11, the point C 1 arrives at the end of the driving arc that it describes at the moment when the point F enters the closure arc joined to it here. The two points C 1 and F coincide, and their separation will engender the chamber whose evolution is to be followed.
In FIG. 12, the points C 1 and F are separated, and F has reached an apex of the female profile. The section of the chamber in question has begun to grow.
In FIG. 13, the point F has reached the end of the closure arc at the moment when this same point, on the driving arc to which it also belongs, is reached by the point C 3 . The point F will disappear, and the point C 3 will replace it to close the section of the chamber in question, whose growth it promotes by retracing its path along its driving arc.
In FIG. 14, the section of the chamber in question is limited by the points C 1 and C 3 , which continue to move apart from one another along the female profile.
In FIG. 15, the section of the chamber in question has reached its maximum. It is still limited by the points C 1 and C 3 , but compared with the motion that drive it in FIG. 13, C 1 has retraced its path, while C 3 is still progressing in the same direction.
In FIG. 16, the points C 1 and C 3 still limit the section of the shaded chamber, but C 1 and C 3 approach one another along the female profile. The section of the chamber is decreasing in size.
In FIG. 17, the point F reappears at the end of the closure arc at the same moment when the point C 1 arrives at this end and stops there. The section of the chamber continues to shrink.
In FIG. 18, the point F has replaced the point C 1 as the end of the section of the chamber. F has reached the apex of the closure arc, and the points C 3 and F are progressing toward one another. The section of the chamber is about to disappear.
In FIG. 19, finally, points F and C 3 have rejoined one another, and the section of the chamber has vanished.
FIG. 20 shows an axial section in a machine according to the invention, including a helicoidal mechanism, where the female organ belongs to the stator--the female surface is identified with the statoric surface--and where the planetary motion of the male organ is accordingly absolute.
This involves a downhole motor used in deep drilling and driven by the pressurized drilling mud, in which the male profile corresponds to a hypertrochoid meeting equation (I), where k=1 and n m =2 (first example of the direct way of defining a male profile).
One can see, the rotor 5 limited on the outside by the rotoric surface 50 and the tubular statoric body 4 limited on the inside by the statoric surface 40 are seen. The rotor 5 is guided in its planetary motion by the linear contacts between statoric and rotoric surfaces, and it is linked with the primary shaft 6 by the intermediate shaft 7, which by way of toric connections physically embodied by Cardan joints 8 and 9, is linked respectively with the rotor 5 and the primary shaft 6. This primary shaft 6 prevents any axial translational motion of the rotor 5 via its rotoidal connection with the element 10 of the stator, a connection made by the plain radial bearings 11 and 12 and the thrust bearing 13 with multiple rows of rolling elements.
The drilling mud that enters the mechanism by its end open section 60, exhausts by its open end 70 and is then carried to the drilling tool fastened to the end collar 14 by the threaded assembly 15, passing through the orifices 16 and the bore 17 of the primary shaft.
FIG. 21 is a complete axial section on a larger scale of the mechanism of the motor of FIG. 20, supplemented with three cross sections in this mechanism.
The statoric tubular body 4 and the rotor 5 are seen here, whose respective profiles 23 and 1 appear in the cross sections, along with part of the intermediate shaft 7 and its toric connection 8 with the rotor.
FIG. 22, in axial section, shows part of the mechanism shown in FIG. 21, on a still larger scale to enable visualization of the lines of contact such as Γ 1 and Γ 2 , which intersect at a point J≡A. It appears that the lines of contact close axially in a tapered fashion the chambers that they define, which is the case for all the helicoidal machines that are the subject of the invention, but is not so for any other known machine of the same type where the order of symmetry of the female profile exceeds that of the male profile by one unit.
FIG. 23 is an axial section in a machine according to the invention, including a helicoidal mechanism, where the male and female organs of the mechanism are both in rotoidal connection with the stator.
FIG. 24 is a cross section along the line AA of the machine shown in FIG. 23. This machine is a screw-type compressor for gas containing a lubricant, such that the male organ 5 defined on the outside by the male surface 50 to which the male profile 1 belongs can directly drive the tubular body 4 defined on the inside by the female surface 40 to which the female profile 23 belongs, without intervention from any gearing external to the mechanism.
Furthermore, in these last two figures can be seen, the stator including a tubular portion 10, a flange 100, through the port 101 of which the fluid is admitted into the machine, and a flange 110 by which, at 111, the compressed fluid escapes towards the outside of the machine. The flange 110 is of course apparent in FIG. 23 only. In this same drawing, in the respective flanges 100 and 110, the rolling bearings 151 and 152 are also seen, which physically embody the rotoidal connection of the male organ 1 with the stator, and the rolling bearings 141 and 142 which physically embody the rotoidal connection between the tubular body 4 and the tubular body 10 of the stator.
The admission of the fluid into the mechanism from the flange 100 is done via the open end section 60 of the mechanism, and the exhaust of the compressed fluid via the flange 110 is done via openings such as 41, which are open in the female surface and are controlled by valves such as 42 (FIG. 24). The flange 110 completely plugs the terminal section 70 of the mechanism.
FIG. 25 is a cross section perpendicular to the axes of male and female surfaces 50 and 40, respectively, in a compressor according to the invention where the mechanism is cylindrical (in the case of degeneration).
FIG. 26 is a section via a plane containing the axis of the female surface 40 in the same compressor.
In the compressor shown in FIGS. 25 and 26, the female organ 4 (tubular body) can be seen, closed by flanges 503 and 504, as can the male organ 5, connected to a crankshaft 500 in rotoidal connection with the flanges 503 and 504 belonging to the stator. The needle roller bearings 501 and 502 physically embody the rotoidal connection of the male organ 5 to the crankshaft 500, and the roller bearings 505 and 506 physically embody the rotoidal connection between the crankshaft 500 and the flanges 503 and 504 belonging to the stator; the pulley 507 is connected with the crankshaft 500. The gas containing lubricant, compressed in this machine, is aspirated through valves such as 508, accommodated in the flange 504, and it is expelled through orifices such as 509, which are provided with valves such as 510.
In FIG. 25, among other features, the driving arcs 511, 512 and 513, the closure arcs 514, 515 and 516, and the junction points such as J at which the arcs are joined two by two can be distinguished. The set of these six arcs is identified with the female profile drawn on a different scale in FIG. 4.
FIG. 27 is a fragmentary section in a machine according to the invention which differs from that shown in FIGS. 25 and 26 only in the lack of physical embodiment of the closure arcs such as 3, which are replaced by arcs such as 603 outside them, since the contact corresponding to the closure point is no longer physical.
FIG. 28 shows the helicoidal mechanism of another machine according to the invention, where the female surface 40 belonging to the statoric tubular body 4 is physically embodied by a length equal to two pitches P f , and where this tubular body is cut into 6=2(n m +1) identical pieces 401-406. This figure is an axial section of the mechanism supplemented with a cross section in the joining plane 410. The pieces 401-406 are wedged into the tube 411 and are compressed there by the collars 412 and 413 screwed into the threaded ends of this tube 411. Each section is aligned angularly with respect to the adjacent sections via pins such as 414, engaging the bores such as 415 opening into the joining planes such as 410. Finally, the male organ 5 and the helicoidal male profile surface 50 can be seen in this figure.
While this invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention, as set forth herein, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as described herein and defined in the following claims. | A rotary positive displacement machine is formed by a male organ and a female organ that surrounds it. The male and female organs have helicoid surfaces of particular shapes and also have parallel axes. The male and female surfaces of the invention define a work chamber and the machine has n m +1 permanently existing points of contact between the male and female profiles. Furthermore, the work chambers of the machine are closed such that the male and female surfaces defining the chambers contain a single point defining a tapered closure in a section where the closure point comes into contact with the n m +1 permanently existing points of contact. | 5 |
This invention relates to the control and operation of electric motors and, more particularly, to method and apparatus for closed-loop microprocessor control of brushless DC motors to provide improved efficiency in motor operation.
BACKGROUND OF THE INVENTION
Brushless DC motors without permanent magnets often are interchangeably referred to as switched reluctance (SR) or variable reluctance (VR) motors. Reference to a VR motor herein is intended to include both terminologies. A VR motor has two sets of salient poles, one set on the stator which has phase windings around the poles and another set on the rotor which has no windings. The stator phase windings are sequentially energized with current pulses to rotate the rotor which is connected to a shaft output. The stator phase windings are sequenced, or commutated, by signals from a rotor position sensor. The rotor position sensing means may comprise optical sensors or magnetic sensors of the Hall effect type. The sensors typically are mounted in fixed position on the stator or motor housing adjacent the path of rotation of the rotor, and the sensed means are fixed for rotation with the rotor.
In a typical three-phase, VR motor, three Hall effect sensors may be located 120° arcuately apart, centered about the rotor shaft, and are fixed either directly to the stator or to some fixture which locates them according to some known relationship with respect to the stator. A magnetic ring with four North regions and four South regions alternating in 45° radial arcs of the ring are attached to the rotor or rotor shaft and serve as sensed means so that when the rotor rotates, sensor output signals can be used to directly commutate, i.e., cut on and off, the current to each of the motor phase windings as they locate each and every pole alignment.
VR motors have been proposed for driving the individual spindle assemblies of a textile yarn ring spinning frame. In such spindle assemblies, the rotor of the motor is mounted on the spindle shaft which supportably rotates a yarn collection member, such as a bobbin, during the spinning operation. A ring rail with ring and traveler reciprocates vertically along the support bobbin to wind the yarn package. The lower end of the spindle support shaft is supported for rotation in a bolster section which has an outer housing mounted in fixed position to a spindle assembly support rail of the spinning frame. The stator of the VR motor is disposed in surrounding relation to the rotor and is mounted in fixed position in a housing supportably attached in suitable manner to the bolster housing or support rail of the ring spinning frame.
It is known to provide control systems for adjusting various parameters of motor operation of a VR motor, such as speed, torque, phase commutation, phase advance, and efficiency of the motor. Certain of such systems employ analog or digital memory to store optimum control parameters relating to switching angles to demand speed and operating torque. Certain other control systems employ theoretical equations derived to predict optimum phase advance as a function of speed.
U.S. Pat. No. 4,835,448 discloses a method by which a phase advance control signal is used to control motor torque. The phase advance signal may be adjusted to provide an optimum efficiency of the motor.
U.S. Pat. No. 4,954,764 discloses a method and circuit for power efficiency improvements where a PWM waveform is adjusted to provide minimum current to an AC induction motor. Several PWM waveforms are used to operate the motor and the resulting current values are stored in memory. This sequence is repeated until a minimum current value is found according to variation of loading of the motor. This technique dynamically seeks the optimum operating point of the motor and uses current measuring equipment to determine actual efficiency.
U.S. Pat. No. 4,942,344 describes apparatus and method for controlling the amount of torque angle shift in a brushless motor. The stator winding voltage level is continuously monitored to determine the amount of torque angle shift to be implemented. This technique dynamically seeks the optimum operating point of the motor and uses stator voltage measuring equipment to determine actual efficiency.
BRIEF OBJECTS OF THE INVENTION
It is an object of the present invention to provide an improved method of control of a VR motor.
It is another object to provide improved apparatus for motor control of a VR motor.
It is a more specific object to provide method and apparatus for improved control of a VR motor comprising a closed-loop system is employed for adjusting various parameters of motor operation.
It is a further specific object of the present invention to provide method and apparatus for motor control of a VR motor to facilitate optimum efficiency of operation of the motor by monitoring the conduction angle, or pulse width, of the current supplied to commutate the phase windings of the motor and to automatically continuously adjust the phase advance of the conduction angle to facilitate the maintenance of a minimum conduction angle, or pulse width, and optimum efficiency of the motor during motor operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The above listed objects as well as other objects of the present invention will become more apparent and the invention will be better understood from the following detailed description of preferred embodiments of the invention, when taken together with the accompanying drawings, in which:
FIG. 1 is an elevation view of a motor-driven spindle assembly of a textile ring spinning frame, with a side cover plate of the spindle motor housing removed to show the motor and motor control circuit boards located in the housing;
FIG. 2 is a left side, partial elevation view of the motor-driven spindle assembly as seen in FIG. 1, with portions of the spinning frame elements, motor housing, and the circuit boards removed, and with portions of the motor and housing shown in vertical section taken generally along Line II--II of FIG. 1;
FIG. 2a is an enlarged view of a central portion of the vertical section view of the spindle assembly seen in FIG. 2;
FIG. 3 is a horizontal cross-sectional view of the spindle assembly, taken generally along Line III--III of FIG. 2a and looking in the direction of the arrows;
FIG. 4 is a horizontal cross-sectional view of the spindle assembly, taken generally along Line IV--IV of FIG. 2a and looking in the direction of the arrows;
FIG. 5 is a schematic representation of the spindle assembly, as seen in FIG. 4, illustrating the positional arrangement of the means for determining rotor/stator positions of the motor for commutation of the motor;
FIG. 5a is a waveform diagram illustrating the conduction angles, or pulse widths, which control the switching of current to one phase of the motor for commutation of the same under varying conditions of phase advance;
FIG. 6 is an illustrative block diagram showing principal sections of the motor control system of the present invention;
FIG. 7 is an illustrative block diagram showing components of the sensor section of the motor control system shown in FIG. 6;
FIG. 8 is an illustrative block diagram showing components of the controller section of the motor control system shown in FIG. 6;
FIG. 9 is an illustrative block diagram showing components of the power converter section of the motor control system shown in FIG. 6; and
FIG. 10 is an electrical schematic diagram of one of the switch means components of the power converter section of the motor control system showing the switch arrangement for supplying current to one phase winding of the spindle assembly drive motor.
SUMMARY OF THE INVENTION
The present invention is directed to method and apparatus employing closed-loop microprocessor control for a variable reluctance motor. A rotor position sensor provides waveforms to the microprocessor which generates signals used to control the switching of current to the phase windings of the motor. These control signals generated by the microprocessor have two states, on and off. The duration of the on state is identified herein as the conduction angle, or pulse width. The conduction angle supplied to control the current to the phases of the motor during commutation may be continuously monitored and the phase advance of the conduction angle continuously adjusted in response thereto during motor operation to attempt to maintain a minimum conduction angle. The phase advance which gives the smallest conduction angle is continously updated by the control loop, and the conduction angle is used as a measure of motor efficiency. The conduction angle was chosen to estimate efficiency because it is readily available in the system and because it is related to the motor copper losses.
The efficiency optimization algorithm for carrying out the method may be implemented as a subroutine in a closed-loop velocity control section of the microprocessor with program stored in program storage means, such as a ROM or EPROM. More specifically, this subroutine may be executed at desired intervals, e.g., every millisecond, and the inputs are phase advance and conduction angle. The conduction angle may be accumulated and stored for desired intervals, e.g., 250 milliseconds, and this sum compared to a previously stored 250 millisecond conduction angle sum. Incremental adjustments of some degree are made to the phase advance every 250 milliseconds, based on the result of the comparison of two sequential measurements of the conduction angle. In one embodiment, if the conduction angle increases between two sequential measurements, then the phase advance is made in a direction opposite from the preceding incremental adjustment. If there is a decrease or no change in the conduction angle between two sequentially measured conduction angles, then the incremental phase advance is further adjusted in the same direction as the previous direction of adjustment.
After completion of each 250 millisecond comparison and phase advance adjustment, the previous conduction angle is replaced with the subsequent conduction angle so that a new subsequent conduction angle may be accumulated and the process continued. This efficiency optimization algorithm continues to operate, constantly seeking a phase advance which will minimize the conduction angle and therefore maximize motor efficiency.
It should be noted that if no change in conduction angle occurs between two sequential measurements of the conduction angle, then no improvement in motor efficiency is achieved; however, the method of the present invention, to maintain continuity, applies a phase advance after every comparison of sequential conduction angles. This can be accomplished in the aforementioned one embodiment by programming the subroutine to continue phase advance in the same direction of adjustment upon measurement of a "no change," as above described, or, in a second embodiment, to reverse direction of adjustment of the phase advance when a "no change" comparison occurs, so as to ensure a phase advance change each time sequential conduction angle measurements are compared.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring more particularly to the drawings, FIG. 1 is an elevation view of a motor-driven spindle assembly 10, such as may be employed at each winding position on a textile ring spinning frame. Such a spinning frame is schematically illustrated in FIG. 1 and includes a support member 5 of a ring spinning frame, and a vertically reciprocatable ring rail, ring, and traveler 6.
As shown in FIGS. 1, 2, and 2a, the spindle assembly 10, portions of which have been removed for convenience, includes yarn package-receiving means comprising shaft means including a sheath 12, a rotor sleeve 14, and a spindle blade 16 mounted for rotation in a supporting bolster section 18. Bolster section 18 includes an outer housing 19 which is mounted in fixed position on horizontal support member 5 of a spinning frame. Surrounding the rotational axis of the spindle assembly are the conventional ring rail package builder 6 and shaft means drive means which includes a VR motor 20. Motor 20, and motor control means, the components of which are mounted on electrically connected electronic circuit boards 22, 24, and 26, are located in a protective housing 28 which is supportably attached in fixed position to a flange portion 18a of the bolster section.
As seen in FIG. 1, circuit boards 22 and 26 are supportably mounted in trackways 28a of the housing and circuit board 24 is supportably mounted on an upper end portion of bolster section 18 in spaced relation to the lower end of motor 20. The motor and motor control system components located on the circuit boards receive power and further control signals from a power supply and a master controller for the ring spinning frame (not shown), through a power and communication supply line 30.
FIG. 2 is a left side elevation view of the spindle assembly of FIG. 1, with circuit boards and portions of the motor housing removed. Portions of the motor 20, sheath 12, and rotor sleeve 14 are shown in vertical section. Referring to FIGS. 2, 2a, and 3, the VR motor 20 comprises a stator 32 and rotor 34. Stator 32 is composed of laminated sheets of steel and has six salient inwardly facing poles 36. Rotor 34 is composed of laminated steel sheets and has four outwardly facing salient poles 38 (FIG. 3). Stator poles 36 are provided with phase windings 40, with radially opposed pairs of salient stator poles being wound in series to form a three-phase motor. The phase windings of the stator are sequentially energized with current pulses to create a magnetic field and attract the rotor poles adjacent thereto, causing rotation of the rotor, rotor sleeve, and sheath.
As best seen in FIGS. 2 and 3, the stator is supported in fixed position in the motor housing 28 on inwardly protruding stator support ledges 42 of the housing. Rotor 34 of the motor is supportably mounted for rotation inside the stator through its fixed attachment to rotor sleeve 14 which is fixed for rotation with the sheath 12. Sheath 12 is in turn fixed for rotation with blade 16, the lower end which is supported for rotation in a bearing cup 44 located in a lower portion of bolster section 18.
Spaces between salient rotor poles are filled with nylon plastic material 46 (FIGS. 2a and 3) in which a metal ring 48 is supportably embedded for rotation with rotor 34. Adhesively secured within metal ring 48 are upper and lower magnetic rings 50, 52. Magnetic rings 50, 52 thus rotate with rotor 34 about the central longitudinal axis of the spindle assembly during motor operation.
Fixedly mounted to an upper end portion of an internal sleeve member 53 of bolster section 18 is a molded plastic ring 54 which serves to support sensing means which operate in conjunction with the rotating magnetic rings 50, 52 to provide signal information for velocity control and communication of the motor phase windings, respectively. Support ring 54 is positively fixed in its angular position surrounding an upper end portion of sleeve member 53 of bolster section 18 by mating, flattened sections, seen at 18b, on the sleeve member 53 and ring 54 (FIG. 4). Located in vertically spaced, horizontal planes in support ring 54 are arcuately disposed pairs of pockets 55, 56 (one of each pair seen in FIG. 2a). Each of the two pairs of pockets receive and positively fix the position of sensing means, such as conventional, latched Hall effect sensors, on sleeve 53. Two Hall effect sensors (not shown in pockets in FIG. 2a) are located in two 30° arcuately spaced pockets 55 adjacent the upper magnetic ring 50 for velocity sensing. Two Hall effect sensors 57, 58 (FIG. 4) are correspondingly located in 30° arcuately spaced pockets 56 adjacent the lower magnetic ring 52 to sense the passage of alternating magnetic poles of ring 52 for commutation of the motor phase windings. (See FIGS. 2a, 4, and 5).
Details of the means for mounting the sensing means on the upper end of sleeve member 53 and relative to the path of rotation of the magnetic rings 50, 52 during motor operation form the subject matter of a commonly assigned co-pending application entitled "Improved Motor Driven Spindle Assembly for Ring Spinning," Ser. No. 07/752,377 filed Aug. 30, 1991 concurrently herewith.
FIGS. 4 and 5, which are cross-sectional and schematic views taken generally along Line IV--IV of FIG. 2, show the rotor/stator position detection means which provide signal information for commutation of the phase windings of the three-phase VR motor 20. As illustrated in FIG. 5, magnetic ring 52 which is mounted for rotation with rotor 34 has alternating North and South poles of unequal arcuate pole lengths, i.e., 60° and 30°, throughout the 360° extent of the ring. During rotor rotation, the passage of the alternating poles of unequal length are sensed by the two arcuately spaced Hall effect sensors 57, 58 which are fixed against rotation in sensor support ring 54 attached to bolster sleeve insert 53. Sensors 57, 58 are arcuately spaced 30° apart, adjacent the path of rotation of magnetic ring 52.
Details of the use of a magnetic ring having unequal alternating North and South poles to permit communication of a three phase VR motor by the use of only two arcuately spaced sensors form the subject matter of commonly assigned, co-pending application entitled "Improved Apparatus for Communication of an Electric Motor," Ser. No. 07/752,377 filed Aug. 30, 1991 concurrently herewith.
The closed-loop motor control system for operating VR motor 20 may best be described and understood by reference to FIGS. 6 through 9 of the drawings which are block diagrams illustrating operative interconnection of the major sections and components of the control system. As seen in FIG. 6, the control system principally comprises three sections, a sensor section 60 for sensing rotor velocity and stator/rotor position of the motor, a controller section 62, and an amplifier, or power converter, section 64. The component parts of sensor section 60 are located conveniently on current board 24, as seen in FIG. 1. Controller section 62 component parts are located conveniently on circuit board 26, and component parts of power converter section 64 are located on circuit board 22.
As seen in FIG. 7, sensor section 60 for detecting velocity and rotor/stator position of the motor during operation contain sensor means, such as four Sprague UGN 3135 U, latched, Hall effect sensors, and four Allen-Bradley RC07 GF332J 3.3 KOHM, 1/4 watt resistors for pulling up the open collector output of the sensors. As described, these sensors sense the passage of the alternating North and South poles of the two ring magnets 50, 52 attached to the rotor. One set of two Hall effect sensors in 30° arcuately spaced pockets 55 (one pocket seen in FIG. 2a) sense passage of equal length North and South poles of a 60° pole ring magnet 50 to provide a 120 line quadrature encoder for motor velocity control. The second set of Hall effect sensors 57, 58 (FIGS. 4 and 5) in pockets 56 sense the North and South poles of magnet 52 to provide signals for communication.
Controller section 62 components, as seen in FIG. 8, include a filter circuit 66 for receiving input signals from the sensor section 60, and for transmitting such signals, after filtering, to a microcontroller 68 which processes and executes a control program supplied thereto from program storage means 70, such as a ROM or EPROM. Process information from microcontroller 68 is processed through an interface logic component 72 and transmitted via optical isolators 74 to power converter section 64 of the control system.
Controller section 62 contains the circuits which perform velocity control, input, output, and communication functions. Typically the filter circuit 66 in this section may comprise four Kemet C315C103M5U5CA 0.01 uF 50 Volt radial lead ceramic capacitors for filtering the incoming Hall effect sensor signals, and a National Semiconductor 74HC14N HEX Schmidt Triggered Inverter for sharpening the edges of the filtered signals from the Hall effect sensors and the output signal from a manual off/on switch 63 (FIG. 1) of the motor 20, such as an ITT-Schadow D602-01 momentary single-pole-single-throw (normally open) push-button switch. The Schmitt Triggered Inverter also buffers the control signal for an indicator light 65 (FIG. 1), such as a Light Emitting Diode.
Microcontroller 68 may be an Intel N80C194 16 bit, 12 MHz microcontroller processor which executes the control program stored in storage means 70, which may be a ROM storage device, such as an Intel N87C257-170V10 latched EPROM.
In the interface logic 72, a National Semiconductor 74HC08N quad AND gate provides multiplexing and interface functions for the output signals from the microcontroller to the four optical isolators 74, which may be Motorola MOC 5008 optical isolators. A National Semiconductor 74HC174N hex D flip flop is connected to the multiplexed address/data bus of the microcontroller 68 in order to latch outputs which control a differential transceiver 76, which may be a National Semiconductor UA 96176 RS-485 transceiver, and the LED 65. Three Allen-Bradley RC07GF332J 10 KOhm 1/4 Watt resistors are used to pull up two unused high impedance inputs and to bias the receive data line to a logical one. A Kemet T350B685MO10AS 6.8 uF tantalum 20 Volt radial lead capacitor is usd to provide the power-up reset RC time constant. Two Kemet C315C330K2G5CA 33pF ultra-stable ceramic 200 Volt radial lead capacitors are used in conjunction with a 12.0000 MHz crystal to form the oscillator circuit providing the 12 MHz timebase for the microcontroller. An Allen-Bradley RC07GF121J 120 OHm 1/4 watt resistor is used to terminate the differential pair communications line. Eight Kemet C315C104M5U5CA 0.1 uF 50 Volt ceramic radial lead capacitors, one Kemet T350A105M020AS1 uF tantalum 20 Volt radial lead capacitor and one Kemet T350F336M010AS 33 uF tantalum radial lead are used for general decoupling throughout the controller circuit to minimize noise transients.
As shown in FIG. 9, inputs from the four optical isolators 74 of the controller section 62 pass through an interface logic/decoder 76 of the power converter section 64 to upper and lower motor winding switch means 78, 80, which may consist of a plurality of field effect transistors each having an associated circuit for turn-on and turn-off. Operation of the switch means supplies current to the three phase windings of VR motor 20. Three of the four optically isolated signals from the controller section 62 control the motor phases directly and interface to a quad OR gate (such as a National Semiconductor 74C02N) in decoder 76 which allows the windings to be turned off in the event of over current. These phase control signals are buffered by a line driver (such as a National Semiconductor 74C240N) in decoder 76 and then operate switches S1 and S2 of each phase winding circuit PH1, as illustrated in FIG. 10. These switches may be three International Rectifier IRF 730 N channel Field Effect Transistors in the lower switch means 80 and three Motorola MTP2P45 P channel switch means (FIG. 9).
Ultra fast recovery diodes D1, D2, such as Motorola MUR 440 diodes, are used as regeneration diodes. They allow the energy stored in the winding to be returned to the supply when the winding is turned off.
The current limit component 82 of the power converter is implemented using four operational amplifiers such as a National Semiconductor LM324N quad operational amplifier integrated circuit. In conjunction with the appropriate commercially available resistors, a voltage, which is proportional to the current in the motor windings, is compared to some reference voltage and an output signal which causes switches S1 and S2 to be turned off is generated if the current in the motor windings exceeds the maximum allowed current.
FIG. 5a is a waveform diagram illustrating the conduction angles, or pulse widths, which control the switching of current to one phase of the motor for commutation of the same wherein rotor/stator position signal information from two Hall effect sensors, waveforms W1 and W2, provides "windows" of opportunity, e.g., 30° of rotor rotation, for commutation, as seen at A, B, and C. Waveforms 4a, 4b, and 4c for one phase winding of the motor illustrate situations of no-phase advance of the conduction angle, a phase advance in a first, or positive, direction, and a phase advance in an opposite, or negative, direction, respectively.
Motor control information is stored and transferred between different components of the controller section 62. The microcontroller 68 executes a program which is stored in external non-volatile ROM stoage means 70. The microcontroller has an internal volatile storage means, or RAM, which is used to store all variable data. An example of two separate modules of a program which use common information is a proportional integral derivative (PID) filter routine in the ROM for velocity control and a motor efficiency optimization routine in the ROM. The microcontroller inputs to the PID routine are a chosen reference velocity and the actual velocity of the motor, both values being stored in internal RAM memory locations. The output of the PID routine is a value which indicates the required conduction angle necessary to maintain actual velocity substantially equal to the chosen reference velocity for the motor.
After the PID routine has determined the required conduction angle for velocity control and has stored this value in the RAM, the efficiency optimization routine is executed. The inputs to the motor efficiency optimization routine are the present conduction angle and the present phase advance value. Both these values are stored in the RAM. The efficiency optimization routine uses the RAM to store an intermediate sum of conduction angles until a number of sequential conduction angle values have been summed together. This sum then is representative of the average conduction angle over a period of consecutive conduction angle values. The output value of the motor efficiency optimization routine is a new phase advance value which is also stored in the RAM for use by a commutation routine in the control program.
By monitoring the duration of the conduction angle, or pulse width, of signals sent to the switches of a phase, or multiple phases of the motor for commutation, and by adjusting the phase advance of the commutation angle, or pulse width, to minimize the same, optimum efficiency of the motor operation can be maintained. | Method and apparatus for closed-loop microprocessor control of an electric motor having one or more phase windings and commutation of the phases by rotor/stator position sensors to provide improved efficiency in motor operation wherein the conduction angle of a phase energization of the motor at a given speed of operation is measured, the phase advance adjusted in a positive or negative direction to obtain a subsequent conduction angle, and the two sequential conduction angles compared. Based on the comparison, further phase advance and comparison of sequentially measured conduction angles is carried out, in positive or negative directions of phase advance, to maintain a minimum conduction angle and improve operating efficiency of the motor. | 7 |
This invention relates to a drill boom arrangement with hydraulic parallel motion means for positioning an elongated rock drilling apparatus to different drilling positions with respect to a boom support.
There are prior art drill boom arrangements that incorporate a boom pivoted at the rear end thereof on the boom support for lateral and vertical swinging by means of a hydraulic cylinder (lift cylinder) for swinging the boom vertically and a hydraulic cylinder (swing cylinder) for swinging the boom laterally. A boom head carries the elongated rock drilling apparatus and is pivotably carried by the forward end of the boom for vertical and lateral swinging by means of a hydraulic cylinder for swinging the boom head and rock drilling apparatus vertically (tilt cylinder) and a hydraulic cylinder (swing cylinder) for swinging it laterally. The hydraulic lift cylinder of the boom is connected to the hydraulic tilt cylinder of the boom head and the hydraulic swing cylinder of the boom is connected to the hydraulic swing cylinder of the boom head in order to maintain parallel displacement of the elongated rock drilling apparatus during positioning. A drill boom arrangement of the above mentioned type is disclosed in Canadian Pat. No. 886,975.
It is an object of the invention to provide a drill boom arrangement which provides for parallel movement of the rock drilling apparatus and which holds the rock drilling apparatus very stable in position. Another object is to provide a slim and compact drill boom arrangement.
The above and other purposes of the invention will become obvious from the following description and from the accompanying drawings in which one embodiment of the invention is illustrated by way of example. It should be understood that this embodiment is only illustrative of the invention and that various modifications thereof may be made within the scope of the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a boom in two alternative positions in which the invention is applied.
FIG. 2 is a top view of the boom in FIG. 1 in two alternative positions.
FIG. 3 shows hydraulic circuitry for parallel displacement and operating of the boom in FIGS. 1 and 2.
FIG. 4 shows the fundamental construction of a manually one-handedly controlled operating lever according to the invention for actuation of control valves associated with the hydraulic cylinder means.
FIG. 5 shows the fundamental construction of hydraulic locks included in the hydraulic circuitry in FIG. 3.
FIG. 6 shows partly in section diagrammatically the one-handedly controlled operating lever.
FIGS. 7 and 8 are views corresponding to FIGS. 1 and 2 but showing a somewhat modified embodiment.
DETAILED DESCRIPTION
In FIGS. 1 and 2 a boom 10 is pivotally supported on a horizontal cross shaft 11 and a vertical cross shaft 12 which are carried by a boom support or bracket 13. The horizontal cross shaft 11 is journalled in a link 14 which is swingable together with the boom 10 about the vertical cross shaft 12. The boom support 13 is carried by an element 15 which forms part of a drill wagon or rig, not shown, on which several booms 10 can be mounted in a group.
The boom is swingable about the cross shafts 11, 12 by means of hydraulic lift and swing cylinders 16, 17. The cylinder 17 is pivotable about a horizontal cross shaft 18 and a vertical cross shaft 19 which are carried by the boom support 13. The horizontal cross shaft 18 is journalled in a link 20 which is swingable together with the cylinder 17 about the vertical cross shaft 19. The end of the piston rod of the cylinder 17 is pivotally connected to the boom 10 by means of a universal joint 21, which comprises a ball on a shaft. The cylinder 16 is connected to the boom support 13 and the boom 10 in the same manner as the cylinder 17. The cross shafts associated with the cylinder 16 are designated 18 1 , 19 1 , 21 1 . The cylinders 16, 17 are of equal size and have the same mounting geometry relative to the boom support 13 and the boom 10.
Due to the fact that the boom support 13 carries the cylinder 17 for swinging about the vertical shaft 19 which is laterally spaced from the vertical swinging plane of the boom 10 a variation in length of solely the cylinder 17 will cause the boom 10 to swing about both the vertical shaft 12 and the horizontal shaft 11.
An extension or contraction of the cylinders 16, 17 of equal amount causes the boom 10 to swing only about the horizontal cross shaft 11. An extension of the cylinder 17 and a contraction of the cylinder 16 of equal amount or vice versa causes the boom 10 to swing about only the vertical cross shaft 12. By differently varying the lengths of the cylinders 16, 17 the boom 10 will simultaneously swing about both cross shafts 11, 12.
In the illustrated embodiment the length of the boom 10 is fixed. The invention may, however, be applied also in extension booms, for instance of the type disclosed in U.S. Pat. No. 3,923,276.
The boom 10 carries a boom head 24. The boom head 24 is pivotally supported by the boom on a horizontal shaft 25 and a vertical shaft 26. The horizontal shaft 25 is journalled in a link 27 which is swingable together with the boom 10 about the vertical shaft 26.
The boom head 24 is swingable about the cross shafts 25, 26 by means of hydraulic tilt and swing cylinders 28, 29. The end of the piston rod of the cylinder 29 is swingable about a horizontal cross shaft 30 and a vertical cross shaft 31 which are carried by the boom head 24. The horizontal cross shaft 30 is journalled in a link 32 which is swingable together with the cylinder 29 about the vertical cross shaft 31. The cylinder 29 is pivotally connected to the boom 10 by means of a universal joint 33, such as a ball joint. The cylinder 28 is connected to the boom head 24 and the boom 10 in the same manner as the cylinder 29. The cross shafts associated with the cylinder 28 are designated 30 1 , 31 1 , 33 1 . The cylinders 28, 29 are of equal size and have the same mounting geometry relative to the boom head 24 and the boom 10.
Due to the fact that the vertical swinging axis of the cylinder 29 is laterally spaced from the vertical swinging plane of the boom head 24 a variation in length of solely the cylinder 29 will cause the boom head 24 to swing about both the vertical shaft 26 and the horizontal shaft 25.
An extension or contraction of the cylinders 28, 29 of equal amount causes the boom head 24 to swing only about the horizontal cross shaft 25. An extension of the cylinder 29 and a contraction of the cylinder 28 of equal amount or vice versa causes the boom head 24 to swing only about the vertical cross shaft 26. By differently varying the lengths of the cylinders 28, 29 the boom head 24 will simultaneously swing about both cross shafts 25, 26.
The boom head 24 carries a turning device 34. The turning device 34 can be of the type disclosed in U.S. Pat. No. 3,563,321. Since the construction of the turning device is not essential to the invention it is not described in detail.
A feed beam holder 35 is pivotally journalled in a casing 37 by means of a cross shaft 36. The casing 37 is coupled to the propeller shaft of the turning device 34. The feed beam holder 35 carries an elongated rock drilling apparatus which includes a feed beam 40 that supports a rock drill 41. The feed beam includes hydraulic power means for displacing the drill along the feed beam in a conventional manner. The rock drill 41 rotates a drill steel 42 and delivers longitudinal impacts on the drill steel. The drill steel 42 is guided by means of drill steel centralizers 43, 44. A hydraulic feed extension cylinder 38 for displacing the feed beam 40 is fixed to the feed beam holder 35 and it is also fixed to a bracket 39 which in its turn is fixed in the feed beam 40. The feed beam 40 is supported slidably in the longitudinal direction thereof on the feed beam holder 35 by means of guides fixed thereon. By extension or contraction of the feed extension cylinder 38 the feed beam 40 can be adjusted longitudinally with respect to the boom 10.
By actuating the turning device 34 the feed beam 40 can be rotated 360° about an axis 45. The feed beam 40 can be swung by means of a hydraulic cylinder 46 about the cross shaft 36 to a position substantially perpendicular to the axis 45. The hydraulic circuitry for controlling the cylinders 16, 17, 28, 29 is illustrated in FIGS. 3-5. It provides for parallel displacement of the feed beam 40 during positioning of the boom, i.e. the swinging movement of the feed beam 40 on the boom 10 is opposite to the swinging movement of the boom on the boom support 13.
As is evident from the circuitry in FIG. 3 each of the cylinders 16, 17, 28, 29 is provided with a hydraulic lock 50, 51, 52, and 53 respectively. The hydraulic locks are of conventional type, e.g. pilot operated double check valves provided with a reversing piston 54 which cooperates with a couple of check valves 55, 56 as is evident from FIG. 5. Through the hydraulic locks 50 and 53 the smaller cylinder chamber B of the cylinder 16 is connected to the larger cylinder chamber A of the cylinder 29. Through the hydraulic locks 51 and 52 the smaller cylinder chamber B of the cylinder 17 is connected to the larger cylinder chamber A of the cylinder 28. Through the connection between the chambers A and B the cylinder 16 becomes one-sidedly hydraulically bound to the cylinder 29 and the cylinder 17 one-sidedly hydraulically bound to the cylinder 28.
A common direction control valve 57 is coupled to the larger cylinder chamber A of the cylinder 16 and to the larger A and smaller B cylinder chambers of the cylinder 29 in order to control the cylinders 16, 29. A common direction control valve 58 is coupled to the larger cylinder chamber A of the cylinder 17 and to the larger and smaller cylinder chambers A and B respectively of the cylinder 28. Thus, the cylinders 17 and 28 are coupled in series to the direction control valve 58 and the cylinders 16 and 29 are coupled in series to the direction control valve 57.
The direction control valves 57, 58 are actuated by means of a manually one-hand controlled operating means 59. The operating means 59 is a lever of coordinate-type known per se (Joy-stick). Four normally closed pressure reducing pilot valves 60, 61, 62, 63 can be steplessly variably adjusted between a closed and a fully open position by means of the lever 59. The function is diagrammatically illustrated in FIGS. 4 and 6. When the pilot valves 60-63 are in a closed position the signal conduits 64-67 of the control valves 57, 58 are connected to tank through a conduit 68. The valves 60-63 are adjusted proportionally to the deflection of the lever 59 by means of a rod 70 and spring means 71. It is possible to either adjust only one of the valves 60-63 by means of the lever 59, or adjust two adjacent valves simultaneously, i.e. any of the valve-couples 62, 63; 63, 61; 61, 60 and 60, 62. Hydraulic fluid is supplied to the signal conduits 64-67 through a supply conduit 69.
Suppose that the common control valve 57 in FIG. 3 is moved to the right from its neutral position. Then, the chamber A of the cylinder 16 is pressurized. The reversing piston 54 opens the opposite check valve 55 of the hydraulic lock 50, thereby connecting chamber B of the cylinder 16 with the chamber A of the cylinder 29. Because of this, a one-sided connection arises between the cylinders 16, 29 which is utilized to parallel-displace the feed beam 40 for instance to the position shown in FIGS. 1 and 2 by dash and dot lines from the initial position shown by unbroken lines. During the one-sidedly bound movement, the chamber B of the cylinder 29 is contracted since it is open to low pressure via the check valve 55 of the hydraulic lock 53 and the control valve 57.
When the control valve 57 is moved to the left in FIG. 3 the chamber B of the cylinder 29 is pressurized. The cylinder 29 then forces fluid from its chamber A to the chamber B in the cylinder 16. The cylinder 16 is then contracted since its chamber A is open to low pressure via the check valve 56 of the hydraulic lock 50 and the direction control valve 57.
The cylinders 17, 28 are extended and contracted by means of the direction control valve 58 in the same manner.
The requirements which must be met in order to obtain an exact parallel displacement of the feed beam 40 during swinging of the boom 10 are that a triangle T 1 having its corners on the horizontal swinging axes 11, 18, 21 and 11, 18 1 , 21 1 , respectively, is similar to a triangle T 2 having its corners on the horizontal swinging axes respectively 25, 30 1 , 33 1 and 25, 30, 33, and that a triangle T 3 having its corners on the vertical swinging axes 12, 19, 21 and 12, 19 1 , 21 1 , respectively, is similar to a triangle T 4 having its corners on the vertical swinging axes respectively 26, 31 1 , 33 1 and 26, 31, 33. If the hydraulic fluid in the chambers B of the cylinders 16, 17 is transferred directly and unchanged to the chambers A of the cylinders 28, 29, then the ratio of the annular piston area in the chambers B of the cylinders 16, 17 to the piston area in the chambers A of the cylinders 28, 29 must be equal with the similarity ratios T 2 :T 1 and T 4 :T 3 .
Specifically, all the cylinders 16, 17, 28, 29 can be of equal size. The triangles T 1 and T 3 are then congruent with the triangles T 2 and T 4 , respectively. Due to the fact that the chambers A and B are of different size it is necessary to include a compensation device in the circuitries for parallel displacement. This compensation device has to accumulate or deliver surplus fluid dependent on whether the cylinders are contracted or extended.
According to the invention it is possible to simultaneously swing the boom 10 laterally and vertically by means of the lever 59. It is also possible to simultaneously swing the boom head 24 laterally and vertically by means of the lever 59 without swinging the boom 10. Due to this the feed beam 40 can be rapidly adjusted into a desired drilling position by means of a single operating means.
During swinging of solely the feed beam 40 the two chambers A and B of the cylinders 16, 17 are short-circuited by means of valves 72, 73. The valves 72, 73 are shifted by means of a pilot valve 74. In order to simplify the actuation of the valve 74, it can either be built-in in the operating lever 59 or be remotely controlled by means of another valve 77 which is built-in in the lever 59, as illustrated in FIG. 6. Means are also provided to ensure that, when the pilot valves 60-63 are actuated, the feed beam 40 is swung in the same direction by means of the cylinders 28, 29 when the cylinders 16, 17 are short-circuited as the boom 10 is swung by means of the cylinders 16, 17. This is effected by means of valves 75, 76 which cross-connect the two pilot lines 64, 65 and the two pilot lines 66, 67 respectively and thus reverse the action of the direction control valves 57, 58 when the valve 74 is actuated. As can be seen in FIG. 3 the valve 74 actuates the valves 72, 73 and the valves 75, 76 simultaneously.
In FIGS. 7 and 8, elements corresponding to elements in the preceding figures have been given the same numerals as in the preceding figures. In the modified embodiment shown in FIGS. 7 and 8, the cylinders 16, 17, and 28, 29 have been turned so that the cylinders are coupled to the four joints 21, 21 1 , 33, 33 1 and the piston rods of the cylinders are coupled to the four horizontal cross shafts 18 and 32. This mounting permits a wider angle of swinging of the boom 10 although the support plate 13 is not bigger. The link 14 has two lugs 90, 91 that will engage two stops 92, 93 on the support plate 13 to limit the horizontal swinging movement of the boom so that the piston rods of the cylinders 16, 17 cannot be forced against the boom 10 and destroyed. There are similar stops on the boom head.
The two shown embodiments are only illustrative of the invention. As examples of possible amendments can be mentioned that all joints associated with the boom and the cylinders can be constructed as ball joints. | A drill boom arrangement comprises a boom proper (10) that is universally pivotably mounted on a support plate (13). The boom is swingable by means of two hydraulic cylinders (16, 17) that are coupled between the support plate and the boom to form a tripod with the boom. The hydraulic cylinders are located on each side of a vertical plane through the boom. A boom head (24) is universally pivotably mounted on the outer end of the boom (10) and it carries a feed beam (40) for a rock drill (41). The boom head is swingable by means of two hydraulic cylinders (27, 28) that are coupled between the boom and the boom head to form another tripod with the boom. These two tripods have similar geometry but the hydraulic cylinders of one tripod is located under the boom and the hydraulic cylinders of the other tripod is located above the boom. The left hand hydraulic cylinder of one tripod is hydraulically coupled in series with the right hand hydraulic cylinder of the other tripod and vice versa so as to provide for parallel displacement of the feed beam when the boom is being swung. | 4 |
FIELD OF THE INVENTION
This invention relates to temperature control systems which heat and/or cool separate process equipment by circulating thermal transfer fluid at a temperature which may be selected within a wide range but precisely maintained.
BACKGROUND OF THE INVENTION
Applicant has previously developed temperature control units utilizing pressurized liquid refrigerant, expansion valve devices, and heat exchangers/evaporators to provide the thermal capacity needed for cooling or heating thermal transfer fluid that flows within a process tool, in order to maintain the tool at a selected temperature level. The units function with high thermal efficiency, provide precise control, and meet the demanding needs of modern high-capital intensive industries, such as semiconductor industries using cluster tools. For such applications, long life and high reliability are essential, but the requirements also include compactness and small footprint because of the high costs of floor footage in such facilities.
These industries are continually evolving and developing more demanding applications which need more versatile temperature controls but at the same time at lower cost. More particularly, such installations now demand selectable refrigeration and optional heating of thermal transfer fluid in the range from about −80° C. to about +60° C., with precision and efficiency. It should be intuitively evident that such a wide temperature range cannot be met economically by conventional refrigeration systems. One approach to the problem of operating over a range of refrigeration temperatures is that proposed by Mizuno et al in U.S. Pat. No. 4,729,424 wherein a cascaded series of refrigeration units are employed. Each unit supplies its own refrigeration capacity as commanded by a central system, to provide stepwise refrigeration capability. Temperature levels between the different refrigeration increments are established by heating within the incremental range. The use of a number of refrigeration units (four in the Mizuno et al proposal) presents particular problems in terms of space requirements, efficiency and reliability. Also, refrigeration units, for long life, should not be run intermittently. Any specific refrigerant further imposes some inherent limitation, depending upon its critical temperature, on the range of operation. In addition efficiency is inherently reduced when heating must be employed to counteract over-cooling.
SUMMARY OF THE INVENTION
Systems and methods in accordance with the invention utilize an intercoupled cascaded arrangement of at least two modular refrigeration units, the first of which operates with a refrigerant having a relatively higher evaporation point to provide a refrigeration capacity predominantly for midrange operation. A second refrigeration unit, interacting in key respects with the first refrigeration unit, adds to the refrigeration capacity of the first unit while controlling the temperature of a thermal transfer fluid that circulates through the process tool. The second refrigeration unit, which uses a refrigerant having a lower evaporation point, can lower the temperature of the thermal transfer fluid to as low as −80° C. The system operates both refrigeration units efficiently in an integrated manner while providing a smooth continuum of operating temperature levels. When ambient or above ambient temperatures are needed, for transient or steady-state operation, a heater in the thermal transfer fluid loop to and from the process tool can be employed independently as the refrigeration units function at low loads.
The two refrigeration units are both designed in compact modular form, and for efficiency interchange thermal energy between the refrigeration cycles although having only limited connections between them. Different combinations of modules can be employed, for different applications, with functions being controlled by a digital control system.
The inter-relationship between the first and second refrigeration units includes one or more expansion valves in each unit, with the first unit supplying a controlled liquid/vapor mixture to an interchange heat exchanger/evaporator in the second unit which functions as a condenser in that unit. In the first unit, the gaseous pressurized output of the compressor is condensed, as by an air-cooled condenser arranged so that cooling air can also extract heat energy from compressed gaseous refrigerant in the adjacent second refrigeration unit. Chilled second refrigerant from the interchange heat exchange/evaporator is fed via a thermal expansion system that is precisely controllable and free of flood back propensity to a heat exchanger/evaporator that cools the thermal transfer fluid in the loop including the process tool.
More specifically the expansion valve system in the second refrigeration unit includes a variable duty cycle solenoid expansion valve having a relatively large orifice. Varying the duty cycle integrates the flow to establish a chosen average level, while the orifice area is capable of supplying large flows for high demand conditions. The output of the solenoid expansion valve is fed to a thermal expansion valve having a variable orifice and incorporating a feedback input reflecting the temperature at the output of the interchange heat exchange/evaporator. Both the solenoid expansion valve and the thermal expansion valve in the second refrigeration unit as well as the expansion valve in the first refrigeration unit are responsive to command inputs which control the refrigeration capacity supplied by each subsystem.
The modular construction is such that each refrigeration unit can be used independently, with minimal connections between them being easily engaged when needed. In addition the first or upper refrigeration unit can employ a water-cooled condenser, if desired—in this case the first unit will also usually have a separate fan for extracting heat energy from the compressed gas conduit in the second or lower stage refrigeration unit.
A number of features are included in these modules to improve useful life, increase reliability and provide assurances against catastrophic failures. The refrigerant unit in the second refrigeration unit presents theoretical problems because of gas pressure buildup, due to the low boiling point, but this is obviated by the use of an excess gas chamber as well as a preset pressure burst disks. The thermal transfer loop is substantially confined within the second lower stage module, but nonetheless includes a storage reservoir, a differential pressure regulation system, and a gas purge system.
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 block diagram of a system in accordance with the invention including an associated control system and a process tool, and also showing how separate modules and units depicted in FIGS. 2A , 2 B and 2 C are interchangeable;
FIG. 2 is a set of four drawings in block diagram form, including respectively the composite system view in some detail ( FIG. 2 alone), with more detailed views of the upper stage module ( FIG. 2A ), the lower stage module ( FIG. 2B ) and a final module including the thermal transfer loop and process tool ( FIG. 2C );
FIG. 3 is a detailed view of a portion of the lower stage module showing an alternate form of expansion valve system that may be used in the lower stage module.
FIG. 4 is a perspective view of the exterior of a practical example of one combination of an upper stage module including an air cooled condenser, and a lower stage module with the exterior walls removed to show a part of the interior;
FIG. 5 is a perspective view of an implementation of the two modules of FIG. 3 , as seen from a different angle, and
FIG. 6 is a perspective view of the practical implementation of the lower stage module presented at a different angle than in FIGS. 3 and 4 to show a different part of the interior.
DETAILED DESCRIPTION OF THE INVENTION
Systems and methods in accordance with the invention are founded on the apparatus shown in FIGS. 1 and 2 , to which reference is now made. The primary units are, as seen in FIG. 1 , an upper (temperature) stage module 10 using a first refrigerant, and a lower (temperature) stage module 12 employing a different refrigerant and interchanging thermal energy with the upper stage module 10 in various ways. The lower stage module 12 exchanges thermal energy, at a final temperature level that is at, above or below ambient, with a thermal transfer fluid that feeds through a process tool 14 in a loop, via a supply line 16 and a return line 18 . Because of the number of individual units that are employed in the stages, details are depicted in added Figures by subdividing some principal elements of FIG. 1 into the composite system of FIG. 2 , then providing diagrams which delineate details of the two modules (upper and lower stage, respectively), as separate FIGS. 2A and 2B and the final thermal transfer loop of FIG. 2C . FIG. 1 also depicts a control system 20 that receives inputs from an operator, and from sensors and transducers in the system, and that provides control signals to controllable elements in the temperature control system. A control system which may advantageously be employed is that described by Matthew Antoniou et al in a pending patent application dated May 16, 2003 Ser. No. 10/439,299 and entitled “Systems and Methods of Controlling Temperatures of Process Tools”.
Referring now to FIGS. 1 and 2 , together with the more detailed views of FIGS. 2A , 2 B and 2 C, the upper stage module 10 includes a compressor 22 , here of nominally 7.5 kW capacity to meet the needs of a specific practical application. The compressor 22 pressurizes a refrigerant having a relatively high boiling point, such as R-507, raising its temperature. R-507 is a liquid at ambient pressure and temperature and after compression and condensation the refrigerant again becomes liquefied for use in a liquid/vapor state. After thermal energy exchange within the user system, expanded R-507 refrigerant in vapor state is returned to an input accumulator 24 at the suction input of the compressor 22 . An input valve, such as a Schrader valve 26 (“S.V” in the drawings), couples into the suction input line so that refrigerant volume can be restored if needed. A different Schrader valve 28 is also included in the pressurized output line from the compressor 22 .
In this example the compressed gaseous refrigerant in the upper stage 10 is liquefied in an air cooled condenser 30 . The condenser 30 is compact, such as 5″×12″×24″, and so configured relative to the compressor 20 and other elements as to fit within a standard form factor upper stage module 10 of 10″×24″×35″. The modular installation concept is described in a co-pending application of Kenneth W. Cowans entitled “Systems and Methods for Temperature Control”, Ser. No. 10/079,592 filed Feb. 22, 2002. As shown in that application, it is highly advantageous to be able to deploy modules of different capabilities with form factors that are either standard, or integral multiples of the standard. Such modules, mounted replaceably in a support frame, can then be used in different combinations to provide a variety of functions and meet a number of operative requirements that may change with time. In this example, both the upper stage module 10 and the lower stage module 12 are standard width units, fitting replaceably within receptacles in a standard frame or enclosure to form a double width assembly.
The air cooled condenser 30 includes a large fan 32 which blows cooling air across interior heat conductive conduits 33 transporting the compressed refrigerant gas from the compressor 22 , thus extracting sufficient thermal energy to condense it to a pressurized liquid. The cooling air flow, exterior to the upper stage module 10 , also flows into the adjacent lower stage module 12 ( FIG. 2B ) to pass over a finned conduit desuperheater heat exchanger 34 within that module 12 . The conduit 34 within the heat exchanger transfers the compressed gas refrigerant into the lower stage module 12 , so that substantial thermal energy is extracted by this means from the second refrigerant. Approximately 1250 watts of thermal energy is taken out in this example by cooling the gas exiting the low temperature stage compressor to a temperature not much warmer than the temperature of the ambient air.
At the input to the air cooled condenser 30 in the upper stage module 10 , referring again to FIG. 2A , a coupler 36 provides an additional shunt path to a conventional (Danfoss) hot gas bypass valve 38 which is responsive to the suction input pressure at the compressor 22 . When the input pressure is too low, the hot gas bypass valve 38 opens to add a flow of compressed gas into the chilled liquid/vapor refrigerant output that is fed from the upper stage module 10 to the lower stage module 12 ( FIG. 2B ). The output flow from the air cooled condenser 30 feeds into a refrigerant output loop 40 in the upper stage which includes, serially, conventional elements such as a high pressure switch 41 , a filter drier 42 and a sightglass 43 . The refrigerant then enters one input to a subcooler heat exchanger having a body 44 which internally receives expanded low temperature refrigerant that is being returned to the compressor 22 from the lower stage 12 . A coil 45 wrapped about the body 44 transports the pressurized and liquefied refrigerant from the condenser 30 , to further chill the refrigerant before it is controllably expanded by a thermal expansion valve (TXV) 48 , such as is described in the W. W. Cowans U.S. Pat. No. 6,446,446 issued Sep. 10, 2002 and entitled “Efficient Cooling System and Method”. The TXV 48 is responsive to pressure variations influencing the position of an internal diaphragm as determined by the temperature of the returning refrigerant. The gas of the latter temperature, which is detected at a sensor bulb 49 disposed before the gas refrigerant input to the subcooler body 44 communicates a pressure that may modify the effective size of the orifice in the TXV 48 . The output flow from the TXV 48 is a liquid/vapor mixture, in a ratio determined by the TXV 48 responsively to the input from the bulb 49 . There may also be a supplemental gas input, when the hot gas bypass valve 38 is open, via a T-coupling 50 . The injection of compressed gas via the hot gas bypass valve 38 and coupler 50 affects the temperature of the liquid/vapor output by raising the pressure of the liquid/vapor to a minimum value above that is predetermined by the setting of the hot gas bypass valve 38 .
Where fabrication facilities utilize tools that are to be temperature controlled by systems in accordance with the invention and that permit the use of water as a cooling fluid, a different modular construction may be used for the upper stage module 10 , as shown schematically in dotted line outline in FIG. 2A . In this example, the finned conduits 34 for SUVA 95 refrigerant are still employed in the lower stage module 10 , along with a small fan 32 ′ in the upper portion of the upper stage module 12 , and air flow slots in the sidewall. This arrangement enables a common lower stage module 12 to be used with either type of condenser in a modular system.
In the lower stage module 12 as seen in FIG. 2B , a compressor 62 , again of approximately 7.5 kW nominal capacity in this example, pressurizes a different refrigerant, such as SUVA 95 . This refrigerant has a substantially lower boiling point than R-507 and is a gas at ambient temperature and pressure. To assure reliability, therefore, special expedients are used to maintain unrestricted flow and protect against overpressure. The lower stage compressor 62 receives suction input flows via an accumulator 64 and provides pressurized output flows via an oil separator 66 . The oil that is filtered out by the separator 66 is returned by a shunt line through the accumulator 64 to the lower stage compressor 62 input. The oil separator 66 is useful because a refrigerant such as SUVA 95 used at temperatures as low as −55° C. or lower can be clogged with high viscosity lubricating oil if subsequent quantities of this oil are present at low temperature. The mass of SUVA 95 fluid may be supplemented via a Schrader valve 68 in the output line from the oil separator 66 . The SUVA 95 output line from the finned desuperheater exchanger 34 feeds a separate hot gas bypass valve 70 via a T-coupling 72 which initiates a hot gas bypass loop that includes the valve 70 . When the hot gas bypass valve 70 is opened in response to compressor input, the flow is directed through a shunt line 76 to the suction input to the lower stage compressor 62 . The shunt line 76 output from the valve 70 also includes a Schrader valve 74 . The same suction input line 76 containing SUVA 95 connects through a flow restricting orifice 78 to an excess volume cylinder 80 through a branch line 76 a , the volumetric capacity of which helps to assure that the internal gas pressure of the refrigerant does not become excessive during periods of time when the system is inoperative. A high pressure switch 73 in the return line from the exchanger 34 is used to protect the compressor 62 in the case of an excessively high pressure occurring in the compressor output line during operation.
The principal flow path of the compressed gaseous SUVA 95 refrigerant after the compressor 62 , oil separator 66 and finned heat exchanger 34 is to an interchange heat exchanger/evaporator 84 . Heat energy is extracted from gaseous SUVA 95 after the compressor 62 by air flowing from the fan 32 ( FIG. 2A ) past finned heat exchanger 34 to cool the refrigerant. Further thermal energy is extracted by exchange in the interchange HEX unit 84 with the controllably expanded liquid-vapor output from the TXV 48 of the upper stage module 10 . The evaporative cooling of the R-507 refrigerant in the HEX 84 assures efficient thermal energy extraction to at least partially liquefy the SUVA 95 refrigerant in the HEX 84 . In the lower stage module 12 , a subcooler body 86 receives the liquid SUVA 95 output from the interchange heat exchanger/evaporator 84 . Expanded gaseous R-507 from the interchange heat exchanger 84 is returned through the subcooler body 44 in the upper stage module 10 ( FIG. 2A ) to the compressor 22 suction input in that module 10 .
In FIG. 2B , the output of liquefied SUVA 95 is transported within a subcooler coil 90 disposed in thermal exchange relation about the subcooler body 86 , in which interior counterflow of returning and expanded SUVA 95 aids in further chilling of the refrigerant.
There are two potential methods of control that are used in the lower stage module 12 subsystem. Both employ liquid/vapor expansion to current temperature settings. In one approach, as seen in FIG. 2B , an SXV 107 (solenoid expansion valve) regulates the flow of expanding pressurized liquid SUVA 95 at the command of the control (module 20 of FIG. 1 ). A liquid thermistor 102 in the SUVA 95 flow path after the subcooler coil 90 senses the temperature in the suction line exiting evaporator 84 and provides a corresponding signal to the control circuits 20 , of FIG. 1 Whenever thermistor 102 senses that liquid SUVA 95 is in this line a signal is sent to control module 20 which causes SXV 107 to be shut.
The liquid output of SUVA 95 from the interchange heat exchanger 84 is passed through a filter drier 98 and a T-coupler 100 to the subcooler coil 90 for further cooling. The T-coupler 100 also has a side port communicating with a TXV functioning as a desuperheater valve 104 which is responsive to the temperature in the suction line input to the compressor 62 , as detected by a sensor bulb 106 . Opening of the desuperheater valve 104 injects liquid vapor refrigerant into the cold side input to the subcooler body 86 via a T-coupler 105 . The output from the external subcooler coil 90 about the subcooler body 86 is pressurized liquid refrigerant (SUVA 95 ) at a temperature level determined by the operative parameters of both the upper and lower stages 10 , 12 , respectively. This liquefied refrigerant may flow by a burst disk (not shown) coupled to the line, and set at 500 psi for release of overpressure.
In the second control method, shown in FIG. 3 , a SXV 201 controlled by control box 20 is used in series with a TXV 202 as shown in FIG. 6 . The use of a TXV, with its inherent feedback via the bulb 203 replaces the function of liquid thermistor 102 as described above.
In the example of FIG. 3 , the liquefied SUVA 95 is fed successively for controlled expansion through a solenoid expansion valve (SXV) 201 , which has a fixed orifice size and operates with a varying duty cycle under control signals from the control system 20 , and then a second, serially coupled thermal expansion valve (TXV) 202 . The second valve or TXV 202 has a variable orifice size to introduce an analog flow variation, determined by electrical signals from the control system 20 , which sets the temperature level of output provided to a second heat exchanger/evaporator 114 which controls system output temperature. The temperature of that output is sensed by a closed bulb element 203 ( FIG. 3 ) that converts the temperature to a variable pressure via a conduit 110 to the second valve or TXV 202 . The serially combined expansion valve functions have important operative advantages for evaporative thermal control units, as noted before.
When the SXV is used in conjunction with a TXV for control, the liquid thermistor 88 of FIG. 2B is not used. When only the SXV is used to regulate flow and thereby control the liquid thermistor is needed to prevent liquid exiting from the evaporator 114 .
The serial SXV 201 and TXV 202 combination of expansion valves shown in FIG. 3 is advantageous not only in achieving control of liquid/vapor flow but also in more general system terms. It is desirable in general to employ an expansion valve having a large orifice capability in order to meet maximum flow demands. A large orifice size, however, carries with it the danger of transferring some liquid refrigerant into the post-expansion line, because such a flooding condition introduces control instabilities, and the likelihood of compressor mechanism damage. To prevent or limit flooding, systems have been designed which sense the presence of liquid refrigerant in the compressor input, or regulate the capacity of the refrigeration loop. In the present system, however, a large orifice can be employed in the SXV 201 , making available increased cooling power at temperature levels above minimum. This feature enables the system to cool down rapidly. Flooding does not occur, and control is maintained, however, because the TXV 202 functions in an analog fashion limiting the amount of flow as necessary with a variable orifice. Feedback of a corrective pressure from the temperature responsive sensor bulb 203 to the TXV 202 assures maintenance of an opening optimized for the control setting. Consequently, the liquid-vapor mix fed into the second or output heat exchanger/evaporator 114 is boiled off in efficient heat exchange relation with the process fluid, while maintaining the temperature desired, and with no flooding under transient conditions.
The liquid-vapor SUVA 95 input from the SXV 107 of FIG. 2B (or, in the case of the control system shown in FIG. 3 , from SXV 201 and TXV 202 ), is supplied to the second heat exchanger/evaporator 114 . This is a selectively controlled flow for chilling the counter-flowing thermal transfer fluid, such as Galden HT-70.
The system also includes a thermal transfer fluid loop physically contained principally within the housing of the lower stage module 12 of FIG. 2B , but extending externally to the tool 14 , as shown schematically in FIG. 2C . The temperature controlled thermal transfer fluid output from the evaporative heat exchanger 114 is coupled via the supply line 16 to the tool 14 by way of a T-coupling 118 , a sideport of which leads to a pressure relief line 120 that terminates at an adjustable pressure relief valve 122 . Signals indicating the pressure of the thermal transfer fluid are provided to the control system 20 via a pressure transducer 132 open to the supply line 16 .
The return line 18 for process (i.e., thermal transfer) fluid from the tool 14 includes a check valve 134 which blocks flow in the reverse direction toward the tool 14 but allows flow of process fluid through a flow meter 136 that provides flow rate signals to the control system 20 . The return line 18 feeds through a T-coupling 138 into a reservoir 140 for the process fluid. Return flow is via a diverging internal cone or nozzle 142 that, in a reversible manner, reduces the flow velocity present in input flow within the enclosed reservoir 140 . The cone transfers almost all the velocity energy in the input flow to pressure energy, thus minimizing overflow effects. A level sensor 146 within the reservoir 140 and a pressure transducer 148 open to the reservoir signal the values of these parameters to the control system 20 . The reservoir 140 also is coupled to a pressure relief valve 150 which provides security against over-pressurization. Independently, as seen in FIG. 2B , a Schrader valve 152 to pressurize the reservoir 140 is coupled in common to a T-coupler 156 open to the reservoir 140 interior.
In the thermal transfer loop shown primarily in FIG. 2C , the outlet from the reservoir 140 feeds a pump 160 , typically of the regenerative turbine type, which inputs the process thermal transfer fluid to the second heat exchanger/evaporator 114 through a heater 162 , typically of the electrical resistive type. A cap tube bleed line 164 is coupled from the upper-most region of the reservoir 140 to a downstream location relative to the pump 160 and before the input to the evaporative heat exchanger 114 . A drain valve 166 ( FIG. 2B only), which may be of the Schrader type, is at the remote end of a separate bypass from the heater 162 outlet and at a lower elevation, to permit the entire system to be drained as desired.
The system of FIGS. 1 and 2 , in operation, provides continuous temperature control of the process tool 14 in the range from −80° C. to +60° C., and to higher levels above ambient if desired. Both upper and lower stage modules 10 , 12 operate continuously, as is needed for reliable, very long term precision performance, even though the cooling loads may be very low, as when the heating capability is being used. In most operative situations that require heat, short term heating is employed to restore temperature so that the process tool 14 can shift to another mode, as is done with semiconductor cluster tools. At times, steady state operation at above ambient is maintained for some duration to effect particular process sequences.
The upper stage 10 , operating with R-507 refrigerant, absorbs all of the heat of the lower stage load, insulation losses and all the power supplied to the lower stage refrigerator subsystem. The upper stage then pumps this heat to a higher temperature in order to reject it to the surrounding ambient cooling, shown as air cooling in the current example. As shown in dotted lines in FIG. 2A , the fan 32 and air cooled condenser 33 can alternatively be replaced by a supply of facility cooling water using a cascade chiller and a liquid-to-refrigerant heat exchanger/condenser of conventional design. When this mode of absorbing the condensing heat of the R-507 refrigerant is used, a small fan is employed to provide a flow of cooling air to pass by fined tube exchanger 34 .
In effecting this function of absorbing the heat output of lower stage 12 , expanded liquid-vapor R-507 mixture flows to one counterflow input of the interchange HEX/evaporator 84 in the lower stage 12 . The opposite counterflow input receives minimally chilled gaseous SUVA 95 refrigerant from the compressor 62 in the lower stage 12 after being partially desuperheated in finned tube exchanger 34 . After thermal energy exchange, the SUVA 95 is liquefied and passed to the entrance of subcooler coil 90 at the same temperature as the expanded R-507 that is returned to the upper stage module 10 . The SXV 107 (or in the alternate control system shown in FIG. 3 the SXV 201 and TXV 202 ) under command input from the control system 20 , then adjusts the liquid/vapor flow in the SUVA 95 through the evaporator heat exchanger 114 , to provide enough cooling to set the temperature level to which the process fluid is to be brought in the second heat exchanger/evaporator 114 .
The system can be considered both a chiller and heater with a controlled output that can cool or heat a flow of pumped liquid so as to control the temperature of that liquid. Heat is supplied by an electrical heater 162 as needed to raise the temperature of the pumped liquid.
Energy efficiency is enhanced by using air flow from the fan 32 in the upper module 10 to convectively cool the finned conduits 34 in the adjacent lower stage module 12 . This type of interchange eliminates two fluid/gas connections between the modules that would be needed if gaseous SUVA 95 from the output of compressor 62 were to be cooled of its superheat in the upper stage module 10 .
When operating in the temperature range above 20° C., the refrigeration capacity of the lower stage compressor 62 is called upon only to a limited extent. In the event that the return suction pressure as the lower stage compressor 62 is too low for proper compressor operation, the hot gas bypass valve 70 opens to supply more gaseous refrigerant into the suction line, preventing damage to the associated compressor 62 . As the output of valve 70 is warmer than the input of compressor 62 can effectively accept, the desuperheater valve 104 provides enough expanded SUVA 95 to maintain the input to compressor 62 at acceptable levels. In the variation of FIG. 3 , sensor bulb 204 is used to sense temperature input to the compressor and supply adequate liquid refrigerant to maintain correct temperature.
The reservoir 140 and the principal functioning elements of the process fluid supply and return system are contained within the lower stage module 12 , which also is designed to be sufficiently compact to fit within a standard width module is 10″×24″×35″. The thermal transfer fluid, here Galden HT-70, is fed from the reservoir 140 by the pump 160 and through the second heat exchange/evaporator 114 to be lowered to the temperature needed for maintaining the tool 14 at its then-desired temperature. The supply line 16 and return line 18 outside the lower stage module 12 can be, within limits imposed by flow impedance, an arbitrary length. External connections of these lines 16 , 18 can be made at input and output manifolds (not shown in FIG. 1 or 2 ) in the lower stage module 12 . After being circulated through the tool 14 , the thermal transfer fluid is transported on the return line 18 to be injected via the feeder cone 142 into the reservoir 140 .
In the lower level cooling range, for refrigeration to −80° C., the refrigeration capacity of the lower stage compressor 62 is utilized, up to a maximum. The upper stage module 10 continues to function as previously described to provide the regulated liquid-vapor mix of R507 to the lower stage module 12 . Compressed SUVA 95 refrigerant is first desuperheated by air cooling in the finned conduit 34 segment in the line adjacent the first module 10 and then fully condensed in the interchange heat exchanger/evaporator 84 . The SUVA 95 liquid/vapor input mixture, as modulated by the expansion valves 107 , or 201 , 202 , is applied to the second heat exchanger/evaporator 114 along with the oppositely flowing “Galden HT-70”. Cascading in this fashion employs the individual properties of the two different refrigerants to best advantage, and without anomalies or dead zones anywhere in the range of controllable temperatures. When heating the thermal transfer fluid to or above ambient temperature both the upper stage module 10 and the lower stage module 12 continuously operate but with minimal chilling. Heating of a process tool is most often utilized, as in semiconductor cluster tools, to restore temperature after a period of operation in a refrigeration cycle. It can, however, also be utilized to maintain the thermal transfer fluid and the process tool 14 at an elevated temperature for a period of time for a specific tool function. The level of heating achievable, and the rage of heating, are dependent upon the wattage rating of the heater 162 which can be arbitrarily selected. Typically, the heater 162 is an electrical resistance device of approximately 1000–1500 watts capacity.
The system includes a substantial number of sensing and command elements which operate in conjunction with the control system 20 of FIG. 1 to provide the desired control of tool 14 temperature. The pump 160 provides a given flow rate of thermal transfer fluid, although the rate can be varied if desired by using a variable speed driver. The tool 14 itself conventionally has its own control system which specifies the fluid temperature that is needed to maintain the tool 14 at a chosen level given a known flow rate for the thermal transfer fluid. Thus it is only required to assure that the supply line 16 or the tool 14 be at a given temperature, which may be sensed by a conventional transducer or transducers and supplied to the control system.
In response to the operative setting that is chosen, the control system 20 determines the refrigerant temperature levels that are to be established within the lower stage, and/or the heat to be added. The load on the lower stage will influence the temperature of the upper stage by means of the action of TXV 48 under the influence of sensor bulb 49 . Consequently, the input from the controller 20 is to the SXV 107 FIG. 2B (or 201 and TXV 202 of FIG. 3 ) in the lower stage 12 , or to the heater 162 to introduce a desired thermal transfer fluid increase in temperature. The heater 162 may also be used for the only control at above ambient temperature if no cooling is required of the system or even for vernier adjustments of temperature when the cooling system has slightly over-cooled the thermal transfer fluid.
Other sensed parameters are input to the controller 20 from the pressure transducer 124 in the supply line to the tool 14 , and the flow meter 136 in the return line 18 . These signals are used to indicate that the thermal transfer fluid is flowing without obstruction or leakage. For reliability, also, the level sensor 146 and the pressure transducer 148 at the reservoir 140 for thermal transfer fluid generate signals that warn of present or incipient problems.
Other operative features that are employed in the system are of practical importance to system life and reliability. Because SUVA 95 has characteristics that are optimized for lowest temperature operation it has a low boiling point and is above its critical temperature at ambient temperature. Its pressure can therefore build to a relatively high level when average system temperatures rise. In order to prevent catastrophic failure in the event of overpressure, gas in the suction line to the lower stage compressor 62 ( FIG. 2B ) is shunted through a small orifice 78 into the excess volume cylinder 80 which is of adequate strength to withstand high pressure and this path can also counterflow SUVA 95 gas to the compressor 62 if the input pressure drops. The burst disk 102 set to be actuated at 500 psi provides further assurance that internal damage will not occur.
The fluid characteristics of SUVA 95 are such that compressor 62 operation requires oil in the refrigerant, although the presence of substantial amounts of oil in the heat exchangers at very low temperatures is not desirable. Accordingly, the oil separator 66 extracts oil almost immediately from the pressurized compressor 62 output and returns the oil to the suction input manifold 64 to the compressor 62 .
As seen in FIGS. 2B and 2C , the lower stage module 12 includes a shunt line between the supply line 16 and the return line 18 , this shunt line 120 incorporating an adjustable pressure relief valve 122 which may correspond to the configuration described in the K. W. Cowans application entitled “Systems and Methods for Temperature Control”, Ser. No. 10/079,542 filed Feb. 22, 2002. In the event of a pressure imbalance, the pumped fluid is lowered in pressure in accordance with the adjustable setting of the relief valve 122 , which couples into the input cone 142 in the reservoir 140 .
Different views of parts of a practical exemplification of the system of FIGS. 1 and 2 are shown in FIGS. 4 , 5 and 6 which depict, in different perspectives two side-by-side modules with housings containing the upper stage 10 and lower stage 12 , and illustrating the air-cooled condenser version. In some process tool installations, water as a cooling medium must be avoided. Thus the air-cooled condenser with a fan 32 mounted on a transverse rotational axis, as seen in FIGS. 3 and 5 , provides air flow across conventional internal refrigerant flow conduits (not seen in FIGS. 4 , 5 and 6 ) toward an outlet screen extending across the module width. This fan 32 is also deployed to direct air centrifugally outward and laterally toward the lower stage module 12 through air slots in the housing well. Inasmuch as the internal configuration of the upper stage module 10 can be in accordance with the teaching of K. W. Cowans patent application Ser. No. 10/079,542, referred to above, these details are not described herein. However, the slots in the sidewall of the upper module 10 that faces the lower stage module 12 provide a flow cooling air transversely between the two modules 10 , 12 and over the finned conduits 34 for the SUVA 95 lines from the lower stage compressor 62 that can be seen adjacent these orifices.
FIGS. 4 , 5 and 6 also demonstrate that there are only two direct refrigerant couplings between the sidewall of the upper stage module 10 and the facing side of the lower stage module 12 . Furthermore, the modules 10 , 12 are also sufficiently compact, with this design, to meet the standard form factor. The compressor 62 , reservoir 140 , excess volume reservoir 80 and pump 60 are the largest volumetric elements within the lower stage module 12 . Manifolds or accumulators for coupling thermal transfer fluid to and from the supply and return lines 14 , 16 are disposed adjacent one end of the structure, and the electrical heater 162 is disposed adjacent the base of the unit and in communication with the output manifold.
Another advantage of this approach is that the modules can also function separately, if desired, although modifications would be employed for thermal energy interchange with the thermal transfer fluid and tool in each case.
Another advantage of the modular configuration described is that the two modules can be mounted in a vertical assembly with the high temperature module 10 mounted above the lower stage module 12 . This is desirable in some installations wherein a smaller footprint may be needed and height is acceptable.
Although a number of forms and variations have been described it will be appreciated by those skilled in the art that the invention is not limited thereto but encompasses all alternatives and expedites within the scope of the appended claims. | A system and method for maintaining the temperature of a thermal transfer fluid at a selectable level within a wide temperature range, so as to operate a process tool in a chosen mode employing at lease two cascaded stages, each operating with a different fluid in a separate refrigeration cycle. By interrelating energy transfers between parts of upper and lower stages, thermal efficiency is maximized and a smooth continuum of temperature levels can be provided. The refrigerants advantageously have vaporization points below and above ambient, for upper and lower stages respectively, and employs the upper stage for a constant refrigeration capacity, controlling the final temperature with the lower stage. The system allows for a further extension of range because the thermal transfer fluid can be heated for some process tool modes as the refrigeration cycles are run at low loads. | 5 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 62/129,180 filed on Mar. 6, 2015, the entire contents of which are incorporated by reference in their entirety herein.
TECHNICAL FIELD
[0002] The present disclosure provides compositions and methods relating to or derived from anti-JAG1 antibodies. More specifically, the present disclosure provides fully human antibodies that bind JAG1, JAG1-antibody binding fragments and derivatives of such antibodies, and JAG1-binding polypeptides comprising such fragments. Further still, the present disclosure provides nucleic acids encoding such antibodies, antibody fragments and derivatives and polypeptides, cells comprising such polynucleotides, methods of making such antibodies, antibody fragments and derivatives and polypeptides, and methods of using such antibodies, antibody fragments and derivatives and polypeptides, including methods of treating or diagnosing subjects having JAG1 related disorders or conditions. The present disclosure further provides a method for treating Notch-signaling tumors, including breast, prostate, colorectal, lung and other solid tumors.
BACKGROUND
[0003] The Notch signaling pathway is one of several critical regulators of embryonic pattern formation, post-embryonic tissue maintenance, and stem cell biology. More specifically, Notch signaling is involved in the process of lateral inhibition between adjacent cell fates and plays an important role in cell fate determination during asymmetric cell divisions. Unregulated Notch signaling is associated with numerous human cancers where it can alter the developmental fate of tumor cells to maintain them in an undifferentiated and proliferative state (Brennan and Brown, 2003 , Breast Cancer Res. 5:69). Thus carcinogenesis can proceed by usurping homeostatic mechanisms controlling normal development and tissue repair by stem cell populations (Beachy et al., 2004 , Nature 432:324).
[0004] The Notch receptor was first identified in Drosophila mutants with haploinsufficiency resulting in notches at the wing margin, whereas loss-of-function produces an embryonic lethal “neurogenic” phenotype where cells of the epidermis switch fate to neural tissue (Moohr, 1919 , Genet. 4:252; Poulson, 1937 , PNAS 23:133; Poulson, 1940 , J. Exp. Zool. 83:271). The Notch receptor is a single-pass transmembrane receptor containing numerous tandem epidermal growth factor (EGF)-like repeats and three cysteine-rich Notch/LIN-12 repeats within a large extracellular domain (Wharton et al., 1985 , Cell 43:567; Kidd et al., 1986 , Mol. Cell. Biol. 6:3094; reviewed in Artavanis et al., 1999 , Science 284:770). Four mammalian Notch proteins have been identified (Notch1, Notch2, Notch3, and Notch4), and mutations in these receptors invariably result in developmental abnormalities and human pathologies including several cancers as described in detail below (Gridley, 1997 , Mol. Cell. Neurosci. 9:103; Joutel & Tournier-Lasserve, 1998 , Semin. Cell Dev. Biol. 9:619-25).
[0005] Notch receptors are activated by single-pass transmembrane ligands of the Delta, Serrated, Lag-2 (DSL) family There are five known Notch ligands in mammals: Delta-like 1 (DLL1), Delta-like 3 (DLL3), Delta-like 4 (DLL4), Jagged 1 (JAG1) and Jagged 2 (JAG2) characterized by a DSL domain and tandem EGF-like repeats within the extracellular domain. The extracellular domain of the Notch receptor interacts with that of its ligands, typically on adjacent cells, resulting in two proteolytic cleavages of Notch, one extracellular cleavage mediated by an ADAM (A Disintegrin And Metallopeptidase) protease and one cleavage within the transmembrane domain mediated by gamma secretase. This latter cleavage generates the Notch intracellular domain (ICD), which then enters the nucleus where it activates the CBF1, Suppressor of Hairless [Su(H)], Lag-2 (CSL) family of transcription factors as the major downstream effectors to increase transcription of nuclear basic helix-loop-helix transcription factors of the Hairy and Enhancer of Split [E(sp1)] family (Artavanis et al., 1999 , Science 284:770; Brennan and Brown, 2003 , Breast Cancer Res. 5:69; Iso et al., 2003 , Arterioscler. Thromb. Vasc. Biol. 23:543). Alternative intracellular pathways involving the cytoplasmic protein Deltex identified in Drosophila may also exist in mammals (Martinez et al., 2002 , Curr. Opin. Genet. Dev. 12:524-33), and this Deltex-dependent pathway may act to suppress expression of Wnt target genes (Brennan et al., 1999 , Curr. Biol. 9:707-710; Lawrence et al., 2001 , Curr. Biol. 11:375-85).
[0006] Mammalian Notch receptors undergo cleavage to form the mature receptor and also following ligand binding to activate downstream signaling. A furin-like protease cleaves the Notch receptors during maturation to generate juxtamembrane heterodimers that comprise a non-covalently associated extracelluar subunit and a transmembrane subunit held together in an auto-inhibitory state. Ligand binding relieves this inhibition and induces cleavage of the Notch receptor by an ADAM-type metalloprotease and a gamma-secretase, the latter of which releases the intracellular domain (ICD) into the cytoplasm, allowing it to translocate into the nucleus to activate gene transcription. Cleavage by ADAM occurs within the non-ligand binding cleavage domain within the membrane proximal negative regulatory region.
[0007] Hematopoietic stem cells (HSCs) are the best understood stem cells in the body, and Notch signaling is implicated in their normal maintenance as well as in leukemic transformation (Kopper & Hajdu, 2004 , Pathol. Oncol. Res. 10:69-73). HSCs are a rare population of cells that reside in a stromal niche within the adult bone marrow. These cells are characterized both by a unique gene expression profile as well as an ability to continuously give rise to more differentiated progenitor cells to reconstitute the entire hematopoietic system. Constitutive activation of Notch1 signaling in HSCs and progenitor cells establishes immortalized cell lines that generate both lymphoid and myeloid cells in vitro and in long-term reconstitution assays (Varnum-Finney et al., 2000 , Nat. Med. 6:1278-81), and the presence of Jagged1 increases engraftment of human bone marrow cell populations enriched for HSCs (Karanu et al., 2000 , J. Exp. Med. 192:1365-72). More recently, Notch signaling has been demonstrated in HSCs in vivo and shown to be involved in inhibiting HSC differentiation. Furthermore, Notch signaling appears to be required for Wnt-mediated HSC self-renewal (Duncan et al., 2005 , Nat. Immunol. 6:314).
[0008] The Notch signaling pathway also plays a central role in the maintenance of neural stem cells and is implicated in their normal maintenance as well as in brain cancers (Kopper & Hajdu, 2004 , Pathol. Oncol. Res. 10:69-73; Purow et al., 2005 , Cancer Res. 65:2353-63; Hallahan et al., 2004 , Cancer Res. 64:7794-800). Neural stem cells give rise to all neuronal and glial cells in the mammalian nervous system during development, and more recently have been identified in the adult brain (Gage, 2000 , Science 287:1433-8). Mice deficient for Notch1; the Notch target genes Hes1, 3, and 5; and a regulator of Notch signaling presenilin1 (PS1) show decreased numbers of embryonic neural stem cells. Furthermore, adult neural stem cells are reduced in the brains of PS 1 heterozygote mice (Nakamura et al., 2000 , J. Neurosci. 20:283-93; Hitoshi et al., 2002 , Genes Dev. 16:846-58). The reduction in neural stem cells appears to result from their premature differentiation into neurons (Hatakeyama et al., 2004 , Dev. 131:5539-50) suggesting that Notch signaling regulates neural stem cell differentiation and self-renewal.
[0009] Aberrant Notch signaling is implicated in a number of human cancers. The Notch1 gene in humans was first identified in a subset of T-cell acute lymphoblastic leukemias as a translocated locus resulting in activation of the Notch pathway (Ellisen et al., 1991 , Cell 66:649-61). Constitutive activation of Notch1 signaling in T-cells in mouse models similarly generates T-cell lymphomas suggesting a causative role (Robey et al., 1996 , Cell 87:483-92; Pear et al., 1996 , J. Exp. Med. 183:2283-91; Yan et al., 2001 , Blood 98:3793-9; Bellavia et al., 2000 , EMBO J. 19:3337-48). Notch1 point mutations, insertions, and deletions producing aberrant Notch1 signaling have also been found to be frequently present in both childhood and adult T-cell acute lymphoblastic leukemia/lymphoma (Pear & Aster, 2004 , Curr. Opin. Hematol. 11:416-33).
[0010] The frequent insertion of the mouse mammary tumor virus into both the Notch1 and Notch4 locus in mammary tumors and the resulting activated Notch protein fragments first implicated Notch signaling in breast cancer (Gallahan & Callahan, 1987 , J. Virol. 61:66-74; Brennan & Brown, 2003 , Breast Cancer Res. 5:69; Politi et al., 2004 , Semin. Cancer Biol. 14:341-7). Further studies in transgenic mice have confirmed a role Notch in ductal branching during normal mammary gland development, and a constitutively active form of Notch4 in mammary epithelial cells inhibits epithelial differentiation and results in tumorigenesis (Jhappan et al., 1992, Genes & Dev. 6:345-5; Gallahan et al., 1996 , Cancer Res. 56:1775-85; Smith et al., 1995 , Cell Growth Differ. 6:563-77; Soriano et al., 2000 , Int. J. Cancer 86:652-9; Uyttendaele et al., 1998 , Dev. Biol. 196:204-17; Politi et al., 2004 , Semin. Cancer Biol. 14:341-7). Evidence for a role Notch in human breast cancer is provided by data showing the expression of Notch receptors in breast carcinomas and their correlation with clinical outcome (Weijzen et al., 2002 , Nat. Med. 8:979-86; Parr et al., 2004 , Int. J. Mol. Med. 14:779-86). Furthermore, overexpression of the Notch pathway has been observed in cervical cancers (Zagouras et al., 1995 , PNAS 92:6414-8), renal cell carcinomas (Rae et al., 2000 , Int. J. Cancer 88:726-32), head and neck squamous cell carcinomas (Leethanakul et al., 2000 , Oncogene 19:3220-4), endometrial cancers (Suzuki et al., 2000 , Int. J. Oncol. 17:1131-9), and neuroblastomas (van Limpt et al., 2000 , Med. Pediatr. Oncol. 35:554-8), suggestive of a potential role for Notch in the development of a number of neoplasms. Notch signaling may play a role in the maintenance of the undifferentiated state of Apc-mutant neoplastic cells of the colon (van Es & Clevers, 2005 , Trends in Mol. Med. 11:496-502). The Notch pathway is also involved in multiple aspects of vascular development including proliferation, migration, smooth muscle differentiation, angiogenesis and arterial-venous differentiation (Iso et al., 2003 , Arterioscler. Thromb. Vasc. Biol. 23:543). Furthermore, DLL1-deficient and Notch2-hypomorphic mice embryos show hemorrhaging that likely results from poor development of vascular structures (Gale et al., 2004 , PNAS, 101:15949-54; Krebs et al., 2000 , Genes Dev. 14:1343-52; Xue et al., 1999 , Hum. Mel. Genet. 8:723-30; Hrabe de Angelis et al., 1997 , Nature 386:717-21; McCright et al., 2001 , Dev. 128:491-502).
[0011] Accordingly, there is a need in the art for therapeutic antibodies that bind to Jagged-1 (JAG1) epitopes and could be used as therapeutic agents for treating Notch-signaling tumors, including breast, prostate, colorectal, lung and other solid tumors.
SUMMARY OF THE INVENTION
[0012] The invention generally provides novel antibodies and antibody fragments that bind to JAG1, e.g., human JAG1, including anti-JAG1 human antibodies.
[0013] In certain embodiments, the present disclosure provides a fully human antibody of an IgG class that binds to a JAG1 epitope with a binding affinity of at least 10 −6 M, which comprises a heavy chain variable domain sequence that is at least 95% identical to the amino acid sequences selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 6, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, and combinations thereof, and comprises a light chain variable domain sequence that is at least 95% identical to the amino acid sequence consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, and combinations thereof. In one embodiment, the fully human antibody has both a heavy chain and a light chain wherein the antibody has a heavy chain/light chain variable domain sequence selected from the group consisting SEQ ID NO. 1/SEQ ID NO. 2 (called JG1A1 herein), SEQ ID NO. 3/SEQ ID NO. 4 (called JG1A10 herein), SEQ ID NO. 5/SEQ ID NO. 6 (called JG1A12 herein), SEQ ID NO. 7/SEQ ID NO. 8 (called JG1A3 herein), SEQ ID NO. 9/SEQ ID NO. 10 (called JG1A4 herein), SEQ ID NO. 11/SEQ ID NO. 12 (called JG11A5 herein), SEQ ID NO. 13/SEQ ID NO. 14 (called JG1A6 herein), SEQ ID NO. 15/SEQ ID NO. 16 (called JG1A7 herein), SEQ ID NO. 17/SEQ ID NO. 18 (called JG1B1 herein), SEQ ID NO. 19/SEQ ID NO. 20 (called JG1B10 herein), SEQ ID NO. 21/SEQ ID NO. 22 (called JG1B11 herein), SEQ ID NO. 23/SEQ ID NO. 24 (called JG1B12 herein), SEQ ID NO. 25/SEQ ID NO. 26 (called JG1B4 herein), SEQ ID NO. 27/SEQ ID NO. 28 (called JG1B5 herein), SEQ ID NO. 29/SEQ ID NO. 30 (called JG1B6 herein), SEQ ID NO. 31/SEQ ID NO. 32 (called JG1B8 herein), SEQ ID NO. 33/SEQ ID NO. 34 (called JG1C3 herein), SEQ ID NO. 35/SEQ ID NO. 36 (called JG1C4 herein), SEQ ID NO. 37/SEQ ID NO. 38 (called JG1C5 herein), SEQ ID NO. 39/SEQ ID NO. 40 (called JG1C8 herein), SEQ ID NO. 41/SEQ ID NO. 42 (called JG1D1 herein), SEQ ID NO. 43/SEQ ID NO. 44 (called JG1D10 herein), SEQ ID NO. 45/SEQ ID NO. 46 (called JG1D11 herein), SEQ ID NO. 47/SEQ ID NO. 48 (called JG1D7 herein), SEQ ID NO. 49/SEQ ID NO. 50 (called JG1D8 herein), SEQ ID NO. 51/SEQ ID NO. 52 (called JG1E1 herein), SEQ ID NO. 53/SEQ ID NO. 54 (called JG1E11 herein), SEQ ID NO. 55/SEQ ID NO. 56 (called JG1E7 herein), SEQ ID NO. 57/SEQ ID NO. 58 (called JG1E8 herein), SEQ ID NO. 59/SEQ ID NO. 60 (called JG1F1 herein), SEQ ID NO. 61/SEQ ID NO. 62 (called JG1F10 herein), SEQ ID NO. 63/SEQ ID NO. 64 (called JG1F7 herein), SEQ ID NO. 65/SEQ ID NO. 66 (called JG1F8 herein), SEQ ID NO. 67/SEQ ID NO. 68 (called JG1G11 herein), SEQ ID NO. 69/SEQ ID NO. 70 (called JG1G5 herein), SEQ ID NO. 71/SEQ ID NO. 72 (called JG1H1 herein), SEQ ID NO. 73/SEQ ID NO. 74 (called JG1H11 herein), SEQ ID NO. 75/SEQ ID NO. 76 (called JG1H5 herein), SEQ ID NO. 77/SEQ ID NO. 78 (called JG1H7 herein), SEQ ID NO. 79/SEQ ID NO. 80 (called JH1A1 herein), SEQ ID NO. 81/SEQ ID NO. 82 (called JH1A11 herein), SEQ ID NO. 83/SEQ ID NO. 84 (called JH1A2 herein), SEQ ID NO. 85/SEQ ID NO. 86 (called JH1A4 herein), SEQ ID NO. 87/SEQ ID NO. 88 (called JH1B1 herein), SEQ ID NO. 89/SEQ ID NO. 90 (called JH1B3 herein), SEQ ID NO. 91/SEQ ID NO. 92 (called JH1B7 herein), SEQ ID NO. 93/SEQ ID NO. 94 (called JH1C10 herein), SEQ ID NO. 95/SEQ ID NO. 96 (called JH1C2 herein), SEQ ID NO. 97/SEQ ID NO. 98 (called JH1D7 herein), SEQ ID NO. 99/SEQ ID NO. 100 (called JH1E11 herein), SEQ ID NO. 101/SEQ ID NO. 102 (called JH1F3 herein), SEQ ID NO. 103/SEQ ID NO. 104 (called JH1F4 herein), SEQ ID NO. 105/SEQ ID NO. 106 (called JH1F6 herein), SEQ ID NO. 107/SEQ ID NO. 108 (called JH1H2 herein), SEQ ID NO. 109/SEQ ID NO. 110 (called JH1H7 herein), and combinations thereof.
[0014] In one embodiment, the present disclosure provides a Fab fully human antibody fragment, having a variable domain region from a heavy chain and a variable domain region from a light chain, wherein the heavy chain variable domain sequence that is at least 95% identical to the amino acid sequences selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 6, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, and combinations thereof, and that has a light chain variable domain sequence that is at least 95% identical to the amino acid sequence consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, and combinations thereof. In one embodiment, the fully human antibody Fab fragment comprises both a heavy chain variable domain region and a light chain variable domain region wherein the antibody has a heavy chain/light chain variable domain sequence selected from the group consisting SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, and combinations thereof.
[0015] In one embodiment, the present disclosure provides a single chain human antibody, comprising a variable domain region from a heavy chain and a variable domain region from a light chain and a peptide linker connection the heavy chain and light chain variable domain regions, wherein the heavy chain variable domain sequence comprises a sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 6, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, and wherein the light chain variable domain sequence comprises a sequence that is at least 95% identical to an amino acid sequence consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, and combinations thereof. In one embodiment, the fully human single chain antibody comprises both a heavy chain variable domain region and a light chain variable domain region, wherein the single chain fully human antibody comprises a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, and combinations thereof.
[0016] In one embodiment, the present disclosure provides a method for treating Notch-signaling tumors, comprising administering an anti-JAG1 polypeptide, wherein the fully human antibody comprises a heavy chain variable domain sequence that is at least 95% identical to the amino acid sequences selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 6, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, and combinations thereof, and comprises a light chain variable domain sequence that is at least 95% identical to the amino acid consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, and combinations thereof. In one embodiment, the fully human antibody comprises both a heavy chain and a light chain wherein the antibody has a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2 (called JG1A1 herein), SEQ ID NO. 3/SEQ ID NO. 4 (called JG1A10 herein), SEQ ID NO. 5/SEQ ID NO. 6 (called JG1A12 herein), SEQ ID NO. 7/SEQ ID NO. 8 (called JG1A3 herein), SEQ ID NO. 9/SEQ ID NO. 10 (called JG1A4 herein), SEQ ID NO. 11/SEQ ID NO. 12 (called JG11A5 herein), SEQ ID NO. 13/SEQ ID NO. 14 (called JG1A6 herein), SEQ ID NO. 15/SEQ ID NO. 16 (called JG1A7 herein), SEQ ID NO. 17/SEQ ID NO. 18 (called JG1B1 herein), SEQ ID NO. 19/SEQ ID NO. 20 (called JG1B10 herein), SEQ ID NO. 21/SEQ ID NO. 22 (called JG1B11 herein), SEQ ID NO. 23/SEQ ID NO. 24 (called JG1B12 herein), SEQ ID NO. 25/SEQ ID NO. 26 (called JG1B4 herein), SEQ ID NO. 27/SEQ ID NO. 28 (called JG1B5 herein), SEQ ID NO. 29/SEQ ID NO. 30 (called JG1B6 herein), SEQ ID NO. 31/SEQ ID NO. 32 (called JG1B8 herein), SEQ ID NO. 33/SEQ ID NO. 34 (called JG1C3 herein), SEQ ID NO. 35/SEQ ID NO. 36 (called JG1C4 herein), SEQ ID NO. 37/SEQ ID NO. 38 (called JG1C5 herein), SEQ ID NO. 39/SEQ ID NO. 40 (called JG1C8 herein), SEQ ID NO. 41/SEQ ID NO. 42 (called JG1D1 herein), SEQ ID NO. 43/SEQ ID NO. 44 (called JG1D10 herein), SEQ ID NO. 45/SEQ ID NO. 46 (called JG1D11 herein), SEQ ID NO. 47/SEQ ID NO. 48 (called JG1D7 herein), SEQ ID NO. 49/SEQ ID NO. 50 (called JG1D8 herein), SEQ ID NO. 51/SEQ ID NO. 52 (called JG1E1 herein), SEQ ID NO. 53/SEQ ID NO. 54 (called JG1E11 herein), SEQ ID NO. 55/SEQ ID NO. 56 (called JG1E7 herein), SEQ ID NO. 57/SEQ ID NO. 58 (called JG1E8 herein), SEQ ID NO. 59/SEQ ID NO. 60 (called JG1F1 herein), SEQ ID NO. 61/SEQ ID NO. 62 (called JG1F10 herein), SEQ ID NO. 63/SEQ ID NO. 64 (called JG1F7 herein), SEQ ID NO. 65/SEQ ID NO. 66 (called JG1F8 herein), SEQ ID NO. 67/SEQ ID NO. 68 (called JG1G11 herein), SEQ ID NO. 69/SEQ ID NO. 70 (called JG1G5 herein), SEQ ID NO. 71/SEQ ID NO. 72 (called JG1H1 herein), SEQ ID NO. 73/SEQ ID NO. 74 (called JG1H11 herein), SEQ ID NO. 75/SEQ ID NO. 76 (called JG1H5 herein), SEQ ID NO. 77/SEQ ID NO. 78 (called JG1H7 herein), SEQ ID NO. 79/SEQ ID NO. 80 (called JH1A1 herein), SEQ ID NO. 81/SEQ ID NO. 82 (called JH1A11 herein), SEQ ID NO. 83/SEQ ID NO. 84 (called JH1A2 herein), SEQ ID NO. 85/SEQ ID NO. 86 (called JH1A4 herein), SEQ ID NO. 87/SEQ ID NO. 88 (called JH1B1 herein), SEQ ID NO. 89/SEQ ID NO. 90 (called JH1B3 herein), SEQ ID NO. 91/SEQ ID NO. 92 (called JH1B7 herein), SEQ ID NO. 93/SEQ ID NO. 94 (called JH1C10 herein), SEQ ID NO. 95/SEQ ID NO. 96 (called JH1C2 herein), SEQ ID NO. 97/SEQ ID NO. 98 (called JH1D7 herein), SEQ ID NO. 99/SEQ ID NO. 100 (called JH1E11 herein), SEQ ID NO. 101/SEQ ID NO. 102 (called JH1F3 herein), SEQ ID NO. 103/SEQ ID NO. 104 (called JH1F4 herein), SEQ ID NO. 105/SEQ ID NO. 106 (called JH1F6 herein), SEQ ID NO. 107/SEQ ID NO. 108 (called JH1H2 herein), SEQ ID NO. 109/SEQ ID NO. 110 (called JH1H7 herein), and combinations thereof.
[0017] In one embodiment, the present disclosure provides a method for treating Notch-signaling tumors, comprising administering a Fab fully human antibody fragment comprising a heavy chain variable domain sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, and combinations thereof, and comprising a light chain variable domain sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, and combinations thereof. In one embodiment, the fully human antibody Fab fragment comprises both a heavy chain variable domain region and a light chain variable domain region wherein the antibody comprises a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2 (called JG1A1 herein), SEQ ID NO. 3/SEQ ID NO. 4 (called JG1A10 herein), SEQ ID NO. 5/SEQ ID NO. 6 (called JG1A12 herein), SEQ ID NO. 7/SEQ ID NO. 8 (called JG1A3 herein), SEQ ID NO. 9/SEQ ID NO. 10 (called JG1A4 herein), SEQ ID NO. 11/SEQ ID NO. 12 (called JG11A5 herein), SEQ ID NO. 13/SEQ ID NO. 14 (called JG1A6 herein), SEQ ID NO. 15/SEQ ID NO. 16 (called JG1A7 herein), SEQ ID NO. 17/SEQ ID NO. 18 (called JG1B1 herein), SEQ ID NO. 19/SEQ ID NO. 20 (called JG1B10 herein), SEQ ID NO. 21/SEQ ID NO. 22 (called JG1B11 herein), SEQ ID NO. 23/SEQ ID NO. 24 (called JG1B12 herein), SEQ ID NO. 25/SEQ ID NO. 26 (called JG1B4 herein), SEQ ID NO. 27/SEQ ID NO. 28 (called JG1B5 herein), SEQ ID NO. 29/SEQ ID NO. 30 (called JG1B6 herein), SEQ ID NO. 31/SEQ ID NO. 32 (called JG1B8 herein), SEQ ID NO. 33/SEQ ID NO. 34 (called JG1C3 herein), SEQ ID NO. 35/SEQ ID NO. 36 (called JG1C4 herein), SEQ ID NO. 37/SEQ ID NO. 38 (called JG1C5 herein), SEQ ID NO. 39/SEQ ID NO. 40 (called JG1C8 herein), SEQ ID NO. 41/SEQ ID NO. 42 (called JG1D1 herein), SEQ ID NO. 43/SEQ ID NO. 44 (called JG1D10 herein), SEQ ID NO. 45/SEQ ID NO. 46 (called JG1D11 herein), SEQ ID NO. 47/SEQ ID NO. 48 (called JG1D7 herein), SEQ ID NO. 49/SEQ ID NO. 50 (called JG1D8 herein), SEQ ID NO. 51/SEQ ID NO. 52 (called JG1E1 herein), SEQ ID NO. 53/SEQ ID NO. 54 (called JG1E11 herein), SEQ ID NO. 55/SEQ ID NO. 56 (called JG1E7 herein), SEQ ID NO. 57/SEQ ID NO. 58 (called JG1E8 herein), SEQ ID NO. 59/SEQ ID NO. 60 (called JG1F1 herein), SEQ ID NO. 61/SEQ ID NO. 62 (called JG1F10 herein), SEQ ID NO. 63/SEQ ID NO. 64 (called JG1F7 herein), SEQ ID NO. 65/SEQ ID NO. 66 (called JG1F8 herein), SEQ ID NO. 67/SEQ ID NO. 68 (called JG1G11 herein), SEQ ID NO. 69/SEQ ID NO. 70 (called JG1G5 herein), SEQ ID NO. 71/SEQ ID NO. 72 (called JG1H1 herein), SEQ ID NO. 73/SEQ ID NO. 74 (called JG1H11 herein), SEQ ID NO. 75/SEQ ID NO. 76 (called JG1H5 herein), SEQ ID NO. 77/SEQ ID NO. 78 (called JG1H7 herein), SEQ ID NO. 79/SEQ ID NO. 80 (called JH1A1 herein), SEQ ID NO. 81/SEQ ID NO. 82 (called JH1A11 herein), SEQ ID NO. 83/SEQ ID NO. 84 (called JH1A2 herein), SEQ ID NO. 85/SEQ ID NO. 86 (called JH1A4 herein), SEQ ID NO. 87/SEQ ID NO. 88 (called JH1B1 herein), SEQ ID NO. 89/SEQ ID NO. 90 (called JH1B3 herein), SEQ ID NO. 91/SEQ ID NO. 92 (called JH1B7 herein), SEQ ID NO. 93/SEQ ID NO. 94 (called JH1C10 herein), SEQ ID NO. 95/SEQ ID NO. 96 (called JH1C2 herein), SEQ ID NO. 97/SEQ ID NO. 98 (called JH1D7 herein), SEQ ID NO. 99/SEQ ID NO. 100 (called JH1E11 herein), SEQ ID NO. 101/SEQ ID NO. 102 (called JH1F3 herein), SEQ ID NO. 103/SEQ ID NO. 104 (called JH1F4 herein), SEQ ID NO. 105/SEQ ID NO. 106 (called JH1F6 herein), SEQ ID NO. 107/SEQ ID NO. 108 (called JH1H2 herein), SEQ ID NO. 109/SEQ ID NO. 110 (called JH1H7 herein), and combinations thereof.
[0018] In one embodiment, the present disclosure provides a method for treating Notch-signaling tumors, comprising administering a single chain human antibody comprising a heavy chain variable domain sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, and combinations thereof, and comprising a light chain variable domain sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, and combinations thereof. In one embodiment, the fully human single chain antibody comprises both a heavy chain variable domain region and a light chain variable domain region, wherein the single chain fully human antibody comprises a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, and combinations thereof.
[0019] In one embodiment, the invention provides an isolated anti-JAG1 fully human antibody of an IgG class, said antibody comprising a heavy chain variable domain sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142; and a light chain variable domain sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141.
[0020] In one embodiment, the fully human antibody comprises a heavy chain/light chain variable domain sequence selected from the group consisting of: SEQ ID NO. 1/SEQ ID NO. 2 (JG1A1), SEQ ID NO. 3/SEQ ID NO. 4 (JG1A10), SEQ ID NO. 5/SEQ ID NO. 6 (JG1A12), SEQ ID NO. 7/SEQ ID NO. 8 (JG1A3), SEQ ID NO. 9/SEQ ID NO. 10 (JG1A4), SEQ ID NO. 11/SEQ ID NO. 12 (JG11A5), SEQ ID NO. 13/SEQ ID NO. 14 (JG1A6), SEQ ID NO. 15/SEQ ID NO. 16 (JG1A7), SEQ ID NO. 17/SEQ ID NO. 18 (JG1B1), SEQ ID NO. 19/SEQ ID NO. 20 (JG1B10), SEQ ID NO. 21/SEQ ID NO. 22 (JG1B11), SEQ ID NO. 23/SEQ ID NO. 24 (JG1B12), SEQ ID NO. 25/SEQ ID NO. 26 (JG1B4), SEQ ID NO. 27/SEQ ID NO. 28 (JG1B5), SEQ ID NO. 29/SEQ ID NO. 30 (JG1B6), SEQ ID NO. 31/SEQ ID NO. 32 (JG1B8), SEQ ID NO. 33/SEQ ID NO. 34 (JG1C3), SEQ ID NO. 35/SEQ ID NO. 36 (JG1C4), SEQ ID NO. 37/SEQ ID NO. 38 (JG1C5), SEQ ID NO. 39/SEQ ID NO. 40 (JG1C8), SEQ ID NO. 41/SEQ ID NO. 42 (JG1D1), SEQ ID NO. 43/SEQ ID NO. 44 (JG1D10), SEQ ID NO. 45/SEQ ID NO. 46 (JG1D11), SEQ ID NO. 47/SEQ ID NO. 48 (JG1D7), SEQ ID NO. 49/SEQ ID NO. 50 (JG1D8), SEQ ID NO. 51/SEQ ID NO. 52 (JG1E1), SEQ ID NO. 53/SEQ ID NO. 54 (JG1E11), SEQ ID NO. 55/SEQ ID NO. 56 (JG1E7), SEQ ID NO. 57/SEQ ID NO. 58 (JG1E8), SEQ ID NO. 59/SEQ ID NO. 60 (JG1F1), SEQ ID NO. 61/SEQ ID NO. 62 (JG1F10), SEQ ID NO. 63/SEQ ID NO. 64 (JG1F7), SEQ ID NO. 65/SEQ ID NO. 66 (JG1F8), SEQ ID NO. 67/SEQ ID NO. 68 (JG1G11), SEQ ID NO. 69/SEQ ID NO. 70 (JG1G5), SEQ ID NO. 71/SEQ ID NO. 72 (JG1H1), SEQ ID NO. 73/SEQ ID NO. 74 (JG1H11), SEQ ID NO. 75/SEQ ID NO. 76 (JG1H5), SEQ ID NO. 77/SEQ ID NO. 78 (JG1H7), SEQ ID NO. 79/SEQ ID NO. 80 (JH1A1), SEQ ID NO. 81/SEQ ID NO. 82 (JH1A11), SEQ ID NO. 83/SEQ ID NO. 84 (JH1A2), SEQ ID NO. 85/SEQ ID NO. 86 (JH1A4), SEQ ID NO. 87/SEQ ID NO. 88 (JH1B1 n), SEQ ID NO. 89/SEQ ID NO. 90 (JH1B3), SEQ ID NO. 91/SEQ ID NO. 92 (JH1B7), SEQ ID NO. 93/SEQ ID NO. 94 (JH1C10), SEQ ID NO. 95/SEQ ID NO. 96 (JH1C2), SEQ ID NO. 97/SEQ ID NO. 98 (JH1D7), SEQ ID NO. 99/SEQ ID NO. 100 (JH1E11), SEQ ID NO. 101/SEQ ID NO. 102 (JH1F3), SEQ ID NO. 103/SEQ ID NO. 104 (JH1F4), SEQ ID NO. 105/SEQ ID NO. 106 (JH1F6), SEQ ID NO. 107/SEQ ID NO. 108 (JH1H2), SEQ ID NO. 109/SEQ ID NO. 110 (JH1H7), SEQ ID NO. 111/SEQ ID NO.112 (G1H73-2), SEQ ID NO. 111/SEQ ID NO.113 (JG1H7-2B2S), SEQ ID NO.111/SEQ ID NO.114 (JG1H7-2A5), SEQ ID NO. 111/SEQ ID NO.115 (JG1H73-2A7S), SEQ ID NO. 111/SEQ ID NO.116 (JG1H7-2A10S), SEQ ID NO.111/SEQ ID NO.117 (JG1H7-2A2S), SEQ ID NO. 111/SEQ ID NO.118 (JG1H73-2A9S), SEQ ID NO. 111/SEQ ID NO.119 (JG1H7-2A1S), SEQ ID NO.111/SEQ ID NO.120 (JG1H7-E11S), SEQ ID NO. 111/SEQ ID NO.121 (JG1H73-C11S), SEQ ID NO. 111/SEQ ID NO.122 (JG1H7-D10S), SEQ ID NO.111/SEQ ID NO.123 (JG1H7-2B7S), SEQ ID NO.124/SEQ ID NO.112 (JG1H7-1A8S), SEQ ID NO. 125/SEQ ID NO.112 (JG1H73-1A6S), SEQ ID NO. 126/SEQ ID NO.112 (JG1H7-1A2S), SEQ ID NO.127/SEQ ID NO.112 (JG1H7-1B1S), SEQ ID NO. 128/SEQ ID NO.112 (JG1H73-1A8S), SEQ ID NO. 129/SEQ ID NO.112 (JG1H7-5B5S), SEQ ID NO.130/SEQ ID NO.112 (JG1H7-3E5S), SEQ ID NO.127/SEQ ID NO.131 (JG1H7-G6C), SEQ ID NO. 132/SEQ ID NO.133 (JG1H73-A6C), SEQ ID NO. 132/SEQ ID NO.123 (JG1H7-E11C), SEQ ID NO.142/SEQ ID NO.123 (JG1H7-C6C), SEQ ID NO. 127/SEQ ID NO.123 (JG1H73-C9C), SEQ ID NO. 132/SEQ ID NO.134 (JG1H7-F4C), SEQ ID NO. 135/SEQ ID NO.133 (JG1H7-F2C), SEQ ID NO.132/SEQ ID NO.136 (JG1H7-F1C), SEQ ID NO.132/SEQ ID NO.137 (JG1H7-D4C), SEQ ID NO. 132/SEQ ID NO.138 (JG1H73-D5C), SEQ ID NO. 139/SEQ ID NO.123 (JG1H7-A5C), SEQ ID NO.139/SEQ ID NO.140 (JG1H7-B2C), and SEQ ID NO. 127/SEQ ID NO.141 (JG1H73-B6C).
[0021] In one embodiment, the invention features an anti-JAG1 fully human antibody Fab fragment, comprising a heavy chain variable domain comprising an amino acid sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142; and comprising a light chain variable domain comprising an amino acid sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of: SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141. In one embodiment, the fully human antibody Fab fragment comprises a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, SEQ ID NO. 111/SEQ ID NO.112, SEQ ID NO. 111/SEQ ID NO.113, SEQ ID NO.111/SEQ ID NO.114, SEQ ID NO. 111/SEQ ID NO.115, SEQ ID NO. 111/SEQ ID NO.116, SEQ ID NO.111/SEQ ID NO.117, SEQ ID NO. 111/SEQ ID NO.118, SEQ ID NO. 111/SEQ ID NO.119, SEQ ID NO.111/SEQ ID NO.120, SEQ ID NO. 111/SEQ ID NO.121, SEQ ID NO. 111/SEQ ID NO.122, SEQ ID NO.111/SEQ ID NO.123, SEQ ID NO.124/SEQ ID NO.112, SEQ ID NO. 125/SEQ ID NO.112, SEQ ID NO. 126/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.112, SEQ ID NO. 128/SEQ ID NO.112, SEQ ID NO. 129/SEQ ID NO.112, SEQ ID NO.130/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.131, SEQ ID NO. 132/SEQ ID NO.133, SEQ ID NO. 132/SEQ ID NO.123, SEQ ID NO.142/SEQ ID NO.123, SEQ ID NO. 127/SEQ ID NO.123, SEQ ID NO. 132/SEQ ID NO.134, SEQ ID NO. 135/SEQ ID NO.133, SEQ ID NO.132/SEQ ID NO.136, SEQ ID NO.132/SEQ ID NO.137, SEQ ID NO. 132/SEQ ID NO.138, SEQ ID NO. 139/SEQ ID NO.123, SEQ ID NO.139/SEQ ID NO.140, and SEQ ID NO. 127/SEQ ID NO.141.
[0022] In one embodiment, the invention provides an anti-JAG1 single chain human antibody, comprising a heavy chain variable domain and a light chain variable domain which are connected by a peptide linker, wherein the heavy chain variable domain comprises an amino acid sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142; and the light chain variable domain comprises an amino acid sequence that is at least 95% identical to an amino acid sequence selected from the group consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141.
[0023] In one embodiment, the single chain fully human antibody comprises a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, SEQ ID NO. 111/SEQ ID NO.112, SEQ ID NO. 111/SEQ ID NO.113, SEQ ID NO.111/SEQ ID NO.114, SEQ ID NO. 111/SEQ ID NO.115, SEQ ID NO. 111/SEQ ID NO.116, SEQ ID NO.111/SEQ ID NO.117, SEQ ID NO. 111/SEQ ID NO.118, SEQ ID NO. 111/SEQ ID NO.119, SEQ ID NO.111/SEQ ID NO.120, SEQ ID NO. 111/SEQ ID NO.121, SEQ ID NO. 111/SEQ ID NO.122, SEQ ID NO.111/SEQ ID NO.123, SEQ ID NO.124/SEQ ID NO.112, SEQ ID NO. 125/SEQ ID NO.112, SEQ ID NO. 126/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.112, SEQ ID NO. 128/SEQ ID NO.112, SEQ ID NO. 129/SEQ ID NO.112, SEQ ID NO.130/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.131, SEQ ID NO. 132/SEQ ID NO.133, SEQ ID NO. 132/SEQ ID NO.123, SEQ ID NO.142/SEQ ID NO.123, SEQ ID NO. 127/SEQ ID NO.123, SEQ ID NO. 132/SEQ ID NO.134, SEQ ID NO. 135/SEQ ID NO.133, SEQ ID NO.132/SEQ ID NO.136, SEQ ID NO.132/SEQ ID NO.137, SEQ ID NO. 132/SEQ ID NO.138, SEQ ID NO. 139/SEQ ID NO.123, SEQ ID NO.139/SEQ ID NO.140, and SEQ ID NO. 127/SEQ ID NO.141.
[0024] In one embodiment, the invention provides an isolated anti-JAG1 antibody, or an antigen-binding fragment thereof, comprising a heavy chain variable domain comprising complementarity determining regions (CDRs) as set forth in a heavy chain variable domain amino acid sequence selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142; and comprising a light chain variable domain comprising CDRs as set forth in a light chain variable region amino acid sequence selected from the group consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141.
[0025] In one embodiment, an anti-JAG1 antibody or an anti-JAG1 antibody fragment described herein may be used in a method for treating a Notch-signaling tumor in a subject in need thereof, said method comprising administering an effective amount of an anti-JAG1 antibody, or anti-JAG1 antibody fragment, to the subject in need thereof. In one embodiment, the tumor is selected from the group consisting of breast tumor, prostate, colorectal, lung, head and neck squamous cell carcinoma, T-cell acute lymphoblastic leukemia and melanoma and other solid tumors.
[0026] In one embodiment, the invention provides a method of treating cancer in a human subject in need thereof, comprising administering an effective amount of an anti-JAG1 antibody, or antigen-binding fragment thereof, disclosed herein to the subject, such that cancer is treated. In one embodiment, the cancer is associated with Notch-signaling. In one embodiment, the cancer is selected from the group consisting of breast, prostate, colorectal, lung, head and neck squamous cell carcinoma, T-cell acute lymphoblastic leukemia, melanoma, and a solid tumor.
[0027] In one embodiment, the method of the invention is for treating Notch-signaling tumors wherein the disease is selected from the group consisting of breast, prostate, colorectal, lung and other solid tumors.
[0028] In certain embodiments, the anti-JAG1 antibody, or antigen-binding fragment thereof, of the invention has a binding affinity (K D ) of at least 1×10 −6 M. In other embodiments, the antibody, or antigen-binding fragment thereof, of the invention has a K D of at least 1×10 −7 M. In other embodiments, the antibody, or antigen-binding fragment thereof, of the invention has a K D of at least 1×10 −8 M.
[0029] In certain embodiments, the antibody is an IgG1 isotype. In other embodiments, the antibody is an IgG4 isotype.
[0030] In certain embodiments, the antibody, or antigen-binding fragment, described herein is recombinant. In certain embodiments, the antibody, or antigen-binding fragment, described herein is a human antibody, or antigen binding fragment of an antibody.
[0031] In certain embodiments, the invention provides a pharmaceutical composition comprising an effective amount of an anti-JAG1 antibody, or antibody fragment disclosed herein, and a pharmaceutically acceptable carrier.
DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1A is a graph that shows the cytotoxic potential of anti-JAG-1 antibodies complexed with Protein G-DM1 molecules (PG-DM1) on JAG-1-overexpressing cancer cells. Corresponding naked antibodies were used as controls.
[0033] FIG. 1B illustrates the non-specific cell killing effect observed on normal human fibroblasts (HFF cells) with anti-JAG-1 antibodies complexed with Protein G-DM1 molecules. Corresponding naked antibodies were used as controls.
[0034] FIG. 2 is a graph that shows the results of a binding ELISA of two antibodies, JG1H7 and JG1B10, to human JAG-1.
[0035] FIG. 3 is a graph that shows the results of a binding ELISA of JG1H7 and variants (F2C, D4C, D5C, B6C, C6C, C9C) to human JAG-1.
[0036] FIG. 4 is a graph that shows the results of a binding ELISA of two antibodies, JG1H7 and B10, to human JAG-2. In FIG. 4 , the designation of antibody “B10” refers to “JG1B10.” The terms are used interchangeably. The designation of antibody “H7” refers to “JG1H7.” The terms are used interchangeably.
[0037] FIG. 5 is a graph that shows the results of a binding ELISA of JG1H7 and variants to human JAG-2.
[0038] FIG. 6 is a graph that shows the results of a binding ELISA of JG1H7 and variants to murine JAG-2.
[0039] FIG. 7A is a graph that shows the results of a binding ELISA of antibody JG1H7 to human JAG-1, human DLL1 and human DLL2.
[0040] FIG. 7B is a graph that shows the results of a binding ELISA of antibody JG1B10 to human JAG-1, human DLL1 and human DLL2. In FIG. 7B , B10JAG1 refers to the antibody “JG1B10.”
DETAILED DESCRIPTION
Definitions
[0041] The terms “peptide,” “polypeptide” and “protein” each refers to a molecule comprising two or more amino acid residues joined to each other by peptide bonds. These terms encompass, e.g., native and artificial proteins, protein fragments and polypeptide analogs (such as muteins, variants, and fusion proteins) of a protein sequence as well as post-translationally, or otherwise covalently or non-covalently, modified proteins. A peptide, polypeptide, or protein may be monomeric or polymeric.
[0042] A “variant” of a polypeptide (for example, a variant of an antibody) comprises an amino acid sequence wherein one or more amino acid residues are inserted into, deleted from and/or substituted into the amino acid sequence relative to another polypeptide sequence. Disclosed variants include, for example, fusion proteins.
[0043] A “derivative” of a polypeptide is a polypeptide (e.g., an antibody) that has been chemically modified, e.g., via conjugation to another chemical moiety (such as, for example, polyethylene glycol or albumin, e.g., human serum albumin), phosphorylation, and glycosylation. Unless otherwise indicated, the term “antibody” includes, in addition to antibodies comprising two full-length heavy chains and two full-length light chains, derivatives, variants, fragments, and muteins thereof, examples of which are described below.
[0044] An “antigen binding protein” is a protein comprising a portion that binds to an antigen and, optionally, a scaffold or framework portion that allows the antigen binding portion to adopt a confirmation that promotes binding of the antigen binding protein to the antigen. Examples of antigen binding proteins include antibodies, antibody fragments (e.g., an antigen binding portion of an antibody), antibody derivatives, and antibody analogs. The antigen binding protein can comprise, for example, an alternative protein scaffold or artificial scaffold with grafted CDRs or CDR derivatives. Such scaffolds include, but are not limited to, antibody-derived scaffolds comprising mutations introduced to, for example, stabilize the three-dimensional structure of the antigen binding protein as well as wholly synthetic scaffolds comprising, for example, a biocompatible polymer. See, for example, Korndorfer et al., 2003 , Proteins: Structure, Function, and Bioinformatics , Volume 53, Issue 1:121-129; Roque et al., 2004 , Biotechnol. Prog. 20:639-654. In addition, peptide antibody mimetics (“PAMs”) can be used, as well as scaffolds based on antibody mimetics utilizing fibronection components as a scaffold.
[0045] An antigen binding protein can have, for example, the structure of an immunoglobulin. An “immunoglobulin” is a tetrameric molecule composed of two identical pairs of polypeptide chains, each pair having one “light” (about 25 kDa) and one “heavy” chain (about 50-70 kDa). The amino-terminal portion of each chain includes a variable region of about 100 to 110 or more amino acids primarily responsible for antigen recognition. The carboxy-terminal portion of each chain defines a constant region primarily responsible for effector function. Human light chains are classified as kappa or lambda light chains. Heavy chains are classified as mu, delta, gamma, alpha, or epsilon, and define the antibody's isotype as IgM, IgD, IgG, IgA, and IgE, respectively. Preferably, the anti-JAG1 antibodies disclosed herein are characterized by their variable domain region sequences in the heavy V H and light V L amino acid sequences. Within light and heavy chains, the variable and constant regions are joined by a “J” region of about 12 or more amino acids, with the heavy chain also including a “D” region of about 10 more amino acids. See generally, Fundamental Immunology Ch. 7 (Paul, W., ed., 2nd ed. Raven Press, N.Y. (1989)). The variable regions of each light/heavy chain pair form the antibody binding site such that an intact immunoglobulin has two binding sites.
[0046] The variable regions of immunoglobulin chains exhibit the same general structure of relatively conserved framework regions (FR) joined by three hypervariable regions, also called complementarity determining regions or CDRs. From N-terminus to C-terminus, both light and heavy chains comprise the domains FR1, CDR1, FR2, CDR2, FR3, CDR3 and FR4. The assignment of amino acids to each domain is in accordance with the definitions of Kabat et al. in Sequences of Proteins of Immunological Interest, 5th Ed., US Dept. of Health and Human Services, PHS, NIH, NIH Publication no. 91-3242, 1991. Other numbering systems for the amino acids in immunoglobulin chains include IMGT® (international ImMunoGeneTics information system; Lefranc et al, Dev. Comp. Immunol. 29:185-203; 2005) and AHo (Honegger and Pluckthun, J. Mol. Biol. 309(3):657-670; 2001).
[0047] An “antibody” refers to an intact immunoglobulin or to an antigen binding portion thereof that competes with the intact antibody for specific binding, unless otherwise specified. In one embodiment, an antibody is an IgG and comprises four polypeptide chains including two identical heavy chains each comprising a heavy chain variable domain and heavy chain constant regions C H1 , C H2 and C H3 , and two identical light chains each comprising a light chain variable domain and a light chain constant region (C L ). In certain embodiments, the antibody is an IgG4. The heavy and light chain variable domain sequences may be selected from those described herein in SEQ ID Nos: 1 to 142.
[0048] Antigen binding portions of an antibody may be produced by recombinant DNA techniques or by enzymatic or chemical cleavage of intact antibodies. Antigen binding portions include, inter alia, Fab, Fab′, F(ab′)2, Fv, domain antibodies (dAbs), and complementarity determining region (CDR) fragments, chimeric antibodies, diabodies, triabodies, tetrabodies, and polypeptides that contain at least a portion of an immunoglobulin that is sufficient to confer specific antigen binding to the polypeptide.
[0049] A single-chain antibody (scFv) is an antibody in which a V L and a V H region are joined via a linker (e.g., a synthetic sequence of amino acid residues) to form a continuous protein chain. The linker is long enough to allow the protein chain to fold back on itself and form a monovalent antigen binding site (see, e.g., Bird et al., 1988 , Science 242:423-26 and Huston et al., 1988 , Proc. Natl. Acad. Sci. USA 85:5879-83).
[0050] In certain embodiments, antibodies can be obtained from sources such as serum or plasma that contain immunoglobulins having varied antigenic specificity. If such antibodies are subjected to affinity purification, they can be enriched for a particular antigenic specificity. Such enriched preparations of antibodies usually are made of less than about 10% antibody having specific binding activity for the particular antigen. Subjecting these preparations to several rounds of affinity purification can increase the proportion of antibody having specific binding activity for the antigen. Antibodies prepared in this manner are often referred to as “monospecific.”
[0051] The term “monospecific”, as used herein, refers to an antibody that displays an affinity for one particular epitope. Monospecific antibody preparations can be made up of about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%, 97%, 99%, or 99.9% antibody having specific binding activity for the particular antigen.
[0052] An “antibody fragment” or “antigen binding fragment of an antibody” comprises a portion of an intact antibody, and preferably comprises the antibody antigen binding or variable domains. Examples of an antibody fragment include a Fab, a Fab′, a F(ab′)2, an Fv fragment, and a linear antibody.
[0053] A Fab fragment is a monovalent fragment having the V L , V H , C L and C H1 domains; a F(ab′) 2 fragment is a bivalent fragment having two Fab fragments linked by a disulfide bridge at the hinge region; a Fd fragment has the V H and C H1 domains; an Fv fragment has the V L and V H domains of a single arm of an antibody; and a dAb fragment has a V H domain, a V L domain, or an antigen-binding fragment of a V H or V L domain (U.S. Pat. Nos. 6,846,634; 6,696,245, US App. Pub.20/0202512; 2004/0202995; 2004/0038291; 2004/0009507; 20 03/0039958, and Ward et al., Nature 341:544-546, 1989).
[0054] Diabodies are bivalent antibodies comprising two polypeptide chains, wherein each polypeptide chain comprises VH and VL domains joined by a linker that is too short to allow for pairing between two domains on the same chain, thus allowing each domain to pair with a complementary domain on another polypeptide chain (see, e.g., Holliger et al., 1993, Proc. Natl. Acad. Sci. USA 90:6444-48, and Poljak et al., 1994, Structure 2:1121-23). If the two polypeptide chains of a diabody are identical, then a diabody resulting from their pairing will have two identical antigen binding sites. Polypeptide chains having different sequences can be used to make a diabody with two different antigen binding sites. Similarly, tribodies and tetrabodies are antibodies comprising three and four polypeptide chains, respectively, and forming three and four antigen binding sites, respectively, which can be the same or different.
[0055] An antigen binding protein, such as an antibody, may have one or more binding sites. If there is more than one binding site, the binding sites may be identical to one another or may be different. For example, a naturally occurring human immunoglobulin typically has two identical binding sites, while a “bispecific” or “bifunctional” antibody has two different binding sites.
[0056] The term “human antibody” includes antibodies that have one or more variable and constant regions derived from human immunoglobulin sequences. In one embodiment, all of the variable and constant domains of the antibody are derived from human immunoglobulin sequences (referred to as “a fully human antibody”). These antibodies may be prepared in a variety of ways, examples of which are described below, including through the immunization with an antigen of interest of a mouse that is genetically modified to express antibodies derived from human heavy and/or light chain-encoding genes. In a preferred embodiment, a fully human antibody is made using recombinant methods such that the glycosylation pattern of the antibody is different than an antibody having the same sequence if it were to exist in nature.
[0057] A “humanized antibody” has a sequence that differs from the sequence of an antibody derived from a non-human species by one or more amino acid substitutions, deletions, and/or additions, such that the humanized antibody is less likely to induce an immune response, and/or induces a less severe immune response, as compared to the non-human species antibody, when it is administered to a human subject. In one embodiment, certain amino acids in the framework and constant domains of the heavy and/or light chains of the non-human species antibody are mutated to produce the humanized antibody. In another embodiment, the constant domain(s) from a human antibody are fused to the variable domain(s) of a non-human species. In another embodiment, one or more amino acid residues in one or more CDR sequences of a non-human antibody are changed to reduce the likely immunogenicity of the non-human antibody when it is administered to a human subject, wherein the changed amino acid residues either are not critical for immunospecific binding of the antibody to its antigen, or the changes to the amino acid sequence that are made are conservative changes, such that the binding of the humanized antibody to the antigen is not significantly worse than the binding of the non-human antibody to the antigen. Examples of how to make humanized antibodies may be found in U.S. Pat. Nos. 6,054,297, 5,886,152 and 5,877,293.
[0058] The term “chimeric antibody” refers to an antibody that contains one or more regions from one antibody and one or more regions from one or more other antibodies. In one embodiment, one or more of the CDRs are derived from a human anti-JAG1 antibody. In another embodiment, all of the CDRs are derived from a human anti-JAG1 antibody. In another embodiment, the CDRs from more than one human anti-JAG1 antibodies are mixed and matched in a chimeric antibody. For instance, a chimeric antibody may comprise a CDR1 from the light chain of a first human anti-PAR-2 antibody, a CDR2 and a CDR3 from the light chain of a second human anti-JAG1 antibody, and the CDRs from the heavy chain from a third anti-JAG1 antibody. Other combinations are possible.
[0059] Further, the framework regions may be derived from one of the same anti-JAG1 antibodies, from one or more different antibodies, such as a human antibody, or from a humanized antibody. In one example of a chimeric antibody, a portion of the heavy and/or light chain is identical with, homologous to, or derived from an antibody from a particular species or belonging to a particular antibody class or subclass, while the remainder of the chain(s) is/are identical with, homologous to, or derived from an antibody (-ies) from another species or belonging to another antibody class or subclass. Also included are fragments of such antibodies that exhibit the desired biological activity (i.e., the ability to specifically bind JAG1).
[0060] A “CDR grafted antibody” is an antibody comprising one or more CDRs derived from an antibody of a particular species or isotype and the framework of another antibody of the same or different species or isotype.
[0061] A “multi-specific antibody” is an antibody that recognizes more than one epitope on one or more antigens. A subclass of this type of antibody is a “bi-specific antibody” which recognizes two distinct epitopes on the same or different antigens.
[0062] An antigen binding protein “specifically binds” to an antigen (e.g., human JAG1) if it binds to the antigen with a dissociation constant of 1 nanomolar or less.
[0063] An “antigen binding domain,” “antigen binding region,” or “antigen binding site” is a portion of an antigen binding protein that contains amino acid residues (or other moieties) that interact with an antigen and contribute to the antigen binding protein's specificity and affinity for the antigen. For an antibody that specifically binds to its antigen, this will include at least part of at least one of its CDR domains.
[0064] The term “Fc polypeptide” includes native and mutein forms of polypeptides derived from the Fc region of an antibody. Truncated forms of such polypeptides containing the hinge region that promotes dimerization also are included. Fusion proteins comprising Fc moieties (and oligomers formed therefrom) offer the advantage of facile purification by affinity chromatography over Protein A or Protein G columns.
[0065] An “epitope” is the portion of a molecule that is bound by an antigen binding protein (e.g., by an antibody). An epitope can comprise non-contiguous portions of the molecule (e.g., in a polypeptide, amino acid residues that are not contiguous in the polypeptide's primary sequence but that, in the context of the polypeptide's tertiary and quaternary structure, are near enough to each other to be bound by an antigen binding protein).
[0066] The “percent identity” or “percent homology” of two polynucleotide or two polypeptide sequences is determined by comparing the sequences using the GAP computer program (a part of the GCG Wisconsin Package, version 10.3 (Accelrys, San Diego, Calif.)) using its default parameters.
[0067] The terms “polynucleotide,” “oligonucleotide” and “nucleic acid” are used interchangeably throughout and include DNA molecules (e.g., cDNA or genomic DNA), RNA molecules (e.g., mRNA), analogs of the DNA or RNA generated using nucleotide analogs (e.g., peptide nucleic acids and non-naturally occurring nucleotide analogs), and hybrids thereof. The nucleic acid molecule can be single-stranded or double-stranded. In one embodiment, the nucleic acid molecules of the invention comprise a contiguous open reading frame encoding an antibody, or a fragment, derivative, mutein, or variant thereof.
[0068] Two single-stranded polynucleotides are “the complement” of each other if their sequences can be aligned in an anti-parallel orientation such that every nucleotide in one polynucleotide is opposite its complementary nucleotide in the other polynucleotide, without the introduction of gaps, and without unpaired nucleotides at the 5′ or the 3′ end of either sequence. A polynucleotide is “complementary” to another polynucleotide if the two polynucleotides can hybridize to one another under moderately stringent conditions. Thus, a polynucleotide can be complementary to another polynucleotide without being its complement.
[0069] A “vector” is a nucleic acid that can be used to introduce another nucleic acid linked to it into a cell. One type of vector is a “plasmid,” which refers to a linear or circular double stranded DNA molecule into which additional nucleic acid segments can be ligated. Another type of vector is a viral vector (e.g., replication defective retroviruses, adenoviruses and adeno-associated viruses), wherein additional DNA segments can be introduced into the viral genome. Certain vectors are capable of autonomous replication in a host cell into which they are introduced (e.g., bacterial vectors comprising a bacterial origin of replication and episomal mammalian vectors). Other vectors (e.g., non-episomal mammalian vectors) are integrated into the genome of a host cell upon introduction into the host cell, and thereby are replicated along with the host genome. An “expression vector” is a type of vector that can direct the expression of a chosen polynucleotide.
[0070] A nucleotide sequence is “operably linked” to a regulatory sequence if the regulatory sequence affects the expression (e.g., the level, timing, or location of expression) of the nucleotide sequence. A “regulatory sequence” is a nucleic acid that affects the expression (e.g., the level, timing, or location of expression) of a nucleic acid to which it is operably linked. The regulatory sequence can, for example, exert its effects directly on the regulated nucleic acid, or through the action of one or more other molecules (e.g., polypeptides that bind to the regulatory sequence and/or the nucleic acid). Examples of regulatory sequences include promoters, enhancers and other expression control elements (e.g., polyadenylation signals). Further examples of regulatory sequences are described in, for example, Goeddel, 1990, Gene Expression Technology: Methods in Enzymology 185, Academic Press, San Diego, Calif. and Baron et al., 1995 , Nucleic Acids Res. 23:3605-06.
[0071] A “host cell” is a cell that can be used to express a nucleic acid, e.g., a nucleic acid of the invention. A host cell can be a prokaryote, for example, E. coli , or it can be a eukaryote, for example, a single-celled eukaryote (e.g., a yeast or other fungus), a plant cell (e.g., a tobacco or tomato plant cell), an animal cell (e.g., a human cell, a monkey cell, a hamster cell, a rat cell, a mouse cell, or an insect cell) or a hybridoma. Examples of host cells include the COS-7 line of monkey kidney cells (ATCC CRL 1651) (see Gluzman et al., 1981 , Cell 23:175), L cells, C127 cells, 3T3 cells (ATCC CCL 163), Chinese hamster ovary (CHO) cells or their derivatives such as Veggie CHO and related cell lines which grow in serum-free media (see Rasmussen et al., 1998 , Cytotechnology 28:31) or CHO strain DX-B11, which is deficient in DHFR (see Urlaub et al., 1980 , Proc. Natl. Acad. Sci. USA 77:4216-20), HeLa cells, BHK (ATCC CRL 10) cell lines, the CV1/EBNA cell line derived from the African green monkey kidney cell line CV1 (ATCC CCL 70) (see McMahan et al., 1991 , EMBO J. 10:2821), human embryonic kidney cells such as 293,293 EBNA or MSR 293, human epidermal A431 cells, human Colo205 cells, other transformed primate cell lines, normal diploid cells, cell strains derived from in vitro culture of primary tissue, primary explants, HL-60, U937, HaK or Jurkat cells. In one embodiment, a host cell is a mammalian host cell, but is not a human host cell. Typically, a host cell is a cultured cell that can be transformed or transfected with a polypeptide-encoding nucleic acid, which can then be expressed in the host cell. The phrase “recombinant host cell” can be used to denote a host cell that has been transformed or transfected with a nucleic acid to be expressed. A host cell also can be a cell that comprises the nucleic acid but does not express it at a desired level unless a regulatory sequence is introduced into the host cell such that it becomes operably linked with the nucleic acid. It is understood that the term host cell refers not only to the particular subject cell but also to the progeny or potential progeny of such a cell. Because certain modifications may occur in succeeding generations due to, e.g., mutation or environmental influence, such progeny may not, in fact, be identical to the parent cell, but are still included within the scope of the term as used herein.
[0072] The term “recombinant antibody” refers to an antibody that is expressed from a cell or cell line transfected with an expression vector (or possibly more than one expression vector) comprising the coding sequence of the antibody, or a portion thereof (e.g., a DNA sequence encoding a heavy chain or a light chain). In one embodiment, said coding sequence is not naturally associated with the cell. In one embodiment, a recombinant antibody has a glycosylation pattern that is different than the glycosylation pattern of an antibody having the same sequence if it were to exist in nature. In one embodiment, a recombinant antibody is expressed in a mammalian host cell which is not a human host cell. Notably, individual mammalian host cells have unique glycosylation patterns.
[0073] The term “effective amount” as used herein, refers to that amount of an antibody, or an antigen binding portion thereof that binds JAG1, which is sufficient to effect treatment of a disease associated with JAG1 signaling, as described herein, when administered to a subject. Therapeutically effective amounts of antibodies provided herein, when used alone or in combination, will vary depending upon the relative activity of the antibodies and combinations (e.g., in inhibiting cell growth) and depending upon the subject and disease condition being treated, the weight and age of the subject, the severity of the disease condition, the manner of administration and the like, which can readily be determined by one of ordinary skill in the art.
[0074] The term “isolated” refers to a protein (e.g., an antibody) that is substantially free of other cellular material. In one embodiment, an isolated antibody is substantially free of other proteins from the same species. In one embodiment, an isolated antibody is expressed by a cell from a different species and is substantially free of other proteins from the different species. A protein may be rendered substantially free of naturally associated components (or components associated with the cellular expression system used to produce the antibody) by isolation, using protein purification techniques well known in the art. In one embodiment, the antibodies, or antigen binding fragments, of the invention are isolated.
[0075] A “neutralizing antibody” or an “inhibitory antibody” is an antibody that inhibits the proteolytic activation of JAG1 when an excess of the anti-JAG1 antibody reduces the amount of activation by at least about 20% using an assay such as those described herein in the Examples. In various embodiments, the antigen binding protein reduces the amount of amount of proteolytic activation of JAG1 by at least 30%, 40%, 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%, 97%, 99%, and 99.9%.
JAG-1 Antigen Binding Proteins
[0076] The present invention pertains to JAG1 binding proteins, particularly anti-JAG1 antibodies, or antigen-binding portions thereof, that bind JAG1, and uses thereof. Various aspects of the invention relate to antibodies and antibody fragments, pharmaceutical compositions, nucleic acids, recombinant expression vectors, and host cells for making such antibodies and fragments. Methods of using the antibodies of the invention to detect human JAG1, to inhibit JAG1 activity, either in vitro or in vivo, and to prevent or treat disorders such as cancer are also encompassed by the invention. Methods of using the antibodies of the invention to detect human JAG2, to inhibit JAG2 activity, either in vitro or in vivo, and to prevent or treat disorders such as cancer are also encompassed by the invention.
[0077] As described in Table 5 below, included in the invention are novel antibody heavy and light chain variable regions that are specific to JAG1. In one embodiment, the invention provides an anti-JAG1 antibody, or an antigen-binding fragment thereof, that comprises a heavy chain having a variable domain comprising an amino acid sequence as set forth in any one of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142. In one embodiment, the invention provides an anti-JAG1 antibody, or an antigen-binding fragment thereof, that comprises a light chain having a variable domain comprising an amino acid sequence as set forth in any one of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141. In one embodiment, the invention provides an anti-JAG1 antibody, or an antigen-binding fragment thereof, that comprises a light chain having a variable domain comprising an amino acid sequence as set forth in any one of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141; and a heavy chain having a variable domain comprising an amino acid sequence as set forth in any one of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142.
[0078] Complementarity determining regions (CDRs) are known as hypervariable regions both in the light chain and the heavy chain variable domains. The more highly conserved portions of variable domains are called the framework (FR). Complementarity determining regions (CDRs) and framework regions (FR) of a given antibody may be identified using the system described by Kabat et al. supra; Lefranc et al., supra and/or Honegger and Pluckthun, supra. Also familiar to those in the art is the numbering system described in Kabat et al. (1991, NIH Publication 91-3242, National Technical Information Service, Springfield, Va.). In this regard Kabat et al. defined a numbering system for variable domain sequences that is applicable to any antibody. One of ordinary skill in the art can unambiguously assign this system of “Kabat numbering” to any variable domain amino acid sequence, without reliance on any experimental data beyond the sequence itself.
[0079] In certain embodiments, the present invention provides an anti-JAG1 antibody comprising the CDRs of a heavy and a light chain variable domain as described in Table 5 (SEQ ID Nos: 1 to 142). For example, the invention provides an anti-JAG1 antibody, or antigen-binding fragment thereof, comprising a heavy chain variable region having CDRs described in an amino acid sequence as set forth in any one of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142. In one embodiment, the invention provides an anti-JAG1 antibody, or antigen-binding fragment thereof, comprising a light chain variable region having CDRs described in an amino acid sequence as set forth in any one of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141. In one embodiment, the invention provides an anti-JAG1 antibody, or antigen-binding fragment thereof, comprising a light chain variable region having CDRs described in an amino acid sequence as set forth in any one of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141; and a heavy chain variable region having CDRs described in an amino acid sequence as set forth in any one of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142.
[0080] It should be noted that throughout, antibodies (and corresponding sequences) are referred to interchangeably with or without a “JG1” preceding the name. For example, the antibody name “JG1H7” is also referred to herein as “H7”.
[0081] One or more CDRs may be incorporated into a molecule either covalently or noncovalently to make it an antigen binding protein.
[0082] An antigen binding protein may incorporate the CDR(s) as part of a larger polypeptide chain, may covalently link the CDR(s) to another polypeptide chain, or may incorporate the CDR(s) noncovalently. The CDRs permit the antigen binding protein to specifically bind to a particular antigen of interest.
[0083] In one embodiment, the present disclosure provides a fully human antibody of an IgG class that binds to a JAG1 epitope with a binding affinity of 10 −6 M or less, that has a heavy chain variable domain sequence that is at least 95% identical to the amino acid sequences selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139, SEQ ID NO. 142, and combinations thereof, and that has a light chain variable domain sequence that is at least 95% identical to the amino acid sequence consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140, SEQ ID NO. 141, and combinations thereof.
[0084] In one embodiment, the fully human antibody has both a heavy chain and a light chain wherein the antibody has a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2 (called JG1A1 herein), SEQ ID NO. 3/SEQ ID NO. 4 (called JG1A10 herein), SEQ ID NO. 5/SEQ ID NO. 6 (called JG1A12 herein), SEQ ID NO. 7/SEQ ID NO. 8 (called JG1A3 herein), SEQ ID NO. 9/SEQ ID NO. 10 (called JG1A4 herein), SEQ ID NO. 11/SEQ ID NO. 12 (called JG11A5 herein), SEQ ID NO. 13/SEQ ID NO. 14 (called JG1A6 herein), SEQ ID NO. 15/SEQ ID NO. 16 (called JG1A7 herein), SEQ ID NO. 17/SEQ ID NO. 18 (called JG1B1 herein), SEQ ID NO. 19/SEQ ID NO. 20 (called JG1B10 herein), SEQ ID NO. 21/SEQ ID NO. 22 (called JG1B11 herein), SEQ ID NO. 23/SEQ ID NO. 24 (called JG1B12 herein), SEQ ID NO. 25/SEQ ID NO. 26 (called JG1B4 herein), SEQ ID NO. 27/SEQ ID NO. 28 (called JG1B5 herein), SEQ ID NO. 29/SEQ ID NO. 30 (called JG1B6 herein), SEQ ID NO. 31/SEQ ID NO. 32 (called JG1B8 herein), SEQ ID NO. 33/SEQ ID NO. 34 (called JG1C3 herein), SEQ ID NO. 35/SEQ ID NO. 36 (called JG1C4 herein), SEQ ID NO. 37/SEQ ID NO. 38 (called JG1C5 herein), SEQ ID NO. 39/SEQ ID NO. 40 (called JG1C8 herein), SEQ ID NO. 41/SEQ ID NO. 42 (called JG1D1 herein), SEQ ID NO. 43/SEQ ID NO. 44 (called JG1D10 herein), SEQ ID NO. 45/SEQ ID NO. 46 (called JG1D11 herein), SEQ ID NO. 47/SEQ ID NO. 48 (called JG1D7 herein), SEQ ID NO. 49/SEQ ID NO. 50 (called JG1D8 herein), SEQ ID NO. 51/SEQ ID NO. 52 (called JG1E1 herein), SEQ ID NO. 53/SEQ ID NO. 54 (called JG1E11 herein), SEQ ID NO. 55/SEQ ID NO. 56 (called JG1E7 herein), SEQ ID NO. 57/SEQ ID NO. 58 (called JG1E8 herein), SEQ ID NO. 59/SEQ ID NO. 60 (called JG1F1 herein), SEQ ID NO. 61/SEQ ID NO. 62 (called JG1F10 herein), SEQ ID NO. 63/SEQ ID NO. 64 (called JG1F7 herein), SEQ ID NO. 65/SEQ ID NO. 66 (called JG1F8 herein), SEQ ID NO. 67/SEQ ID NO. 68 (called JG1G11 herein), SEQ ID NO. 69/SEQ ID NO. 70 (called JG1G5 herein), SEQ ID NO. 71/SEQ ID NO. 72 (called JG1H1 herein), SEQ ID NO. 73/SEQ ID NO. 74 (called JG1H11 herein), SEQ ID NO. 75/SEQ ID NO. 76 (called JG1H5 herein), SEQ ID NO. 77/SEQ ID NO. 78 (called JG1H7 herein), SEQ ID NO. 79/SEQ ID NO. 80 (called JH1A1 herein), SEQ ID NO. 81/SEQ ID NO. 82 (called JH1A11 herein), SEQ ID NO. 83/SEQ ID NO. 84 (called JH1A2 herein), SEQ ID NO. 85/SEQ ID NO. 86 (called JH1A4 herein), SEQ ID NO. 87/SEQ ID NO. 88 (called JH1B1 herein), SEQ ID NO. 89/SEQ ID NO. 90 (called JH1B3 herein), SEQ ID NO. 91/SEQ ID NO. 92 (called JH1B7 herein), SEQ ID NO. 93/SEQ ID NO. 94 (called JH1C10 herein), SEQ ID NO. 95/SEQ ID NO. 96 (called JH1C2 herein), SEQ ID NO. 97/SEQ ID NO. 98 (called JH1D7 herein), SEQ ID NO. 99/SEQ ID NO. 100 (called JH1E11 herein), SEQ ID NO. 101/SEQ ID NO. 102 (called JH1F3 herein), SEQ ID NO. 103/SEQ ID NO. 104 (called JH1F4 herein), SEQ ID NO. 105/SEQ ID NO. 106 (called JH1F6 herein), SEQ ID NO. 107/SEQ ID NO. 108 (called JH1H2 herein), SEQ ID NO. 109/SEQ ID NO. 110 (called JH1H7 herein), SEQ ID NO. 111/SEQ ID NO.112 (called JG1H73-2 herein), SEQ ID NO. 111/SEQ ID NO.113 (called JG1H7-2B2S herein), SEQ ID NO.111/SEQ ID NO.114 (called JG1H7-2AS herein), SEQ ID NO. 111/SEQ ID NO.115 (called JG1H73-2A7S herein), SEQ ID NO. 111/SEQ ID NO.116 (called JG1H7-2A10S herein), SEQ ID NO.111/SEQ ID NO.117 (called JG1H7-2A2S herein), SEQ ID NO. 111/SEQ ID NO.118 (called JG1H73-2A9S herein), SEQ ID NO. 111/SEQ ID NO.119 (called JG1H7-2A1S herein), SEQ ID NO.111/SEQ ID NO.120 (called JG1H7-E11S herein), SEQ ID NO. 111/SEQ ID NO.121 (called JG1H73-C11S herein), SEQ ID NO. 111/SEQ ID NO.122 (called JG1H7-D10S herein), SEQ ID NO.111/SEQ ID NO.123 (called JG1H7-2B7S herein), SEQ ID NO.124/SEQ ID NO.112 (called JG1H7-1A8S herein), SEQ ID NO. 125/SEQ ID NO.112 (called JG1H73-1A6S herein), SEQ ID NO. 126/SEQ ID NO.112 (called JG1H7-1A2S herein), SEQ ID NO.127/SEQ ID NO.112 (called JG1H7-1B1S herein), SEQ ID NO. 128/SEQ ID NO.112 (called JG1H73-5A8S herein), SEQ ID NO. 129/SEQ ID NO.112 (called JG1H7-5B5S herein), SEQ ID NO.130/SEQ ID NO.112 (called JG1H7-3E5S herein), SEQ ID NO.127/SEQ ID NO.131 (called JG1H7-G6C herein), SEQ ID NO. 132/SEQ ID NO.133 (called JG1H73-A6C herein), SEQ ID NO. 132/SEQ ID NO.123 (called JG1H7-E11C herein), SEQ ID NO.142/SEQ ID NO.123 (called JG1H7-C6C herein), SEQ ID NO. 127/SEQ ID NO.123 (called JG1H73-C9C herein), SEQ ID NO. 132/SEQ ID NO.134 (called JG1H7-F4C herein), SEQ ID NO. 135/SEQ ID NO.133 (called JG1H7-F2C herein), SEQ ID NO.132/SEQ ID NO.136 (called JG1H7-F1C herein), SEQ ID NO.132/SEQ ID NO.137 (called JG1H7-D4C herein), SEQ ID NO. 132/SEQ ID NO.138 (called JG1H73-D5C herein), SEQ ID NO. 139/SEQ ID NO.123 (called JG1H7-A5C herein), SEQ ID NO.139/SEQ ID NO.140 (called JG1H7-B2C herein), SEQ ID NO. 127/SEQ ID NO.141 (called JG1H73-B6C herein), and combinations thereof.
[0085] In one embodiment, the invention provides an anti-JAG1 antibody, or an antigen-binding fragment thereof, comprising a heavy chain comprising a CDR3 domain as set forth in any one of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142, and comprising a variable domain comprising an amino acid sequence that has at least 95%, at least 96%, at least 97%, at least 98%, or at least 99% identical to a sequence as set forth in any one of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142. In one embodiment, the invention provides an anti-JAG1 antibody, or an antigen-binding fragment thereof, comprising a light chain comprising a CDR3 domain as set forth in any one of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141, and having a light chain variable domain comprising an amino acid sequence that has at least 95%, at least 96%, at least 97%, at least 98%, or at least 99% identical to a sequence as set forth in any one of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141. Thus, in certain embodiments, the CDR3 domain is held constant, while variability may be introduced into the remaining CDRs and/or framework regions of the heavy and/or light chains, while the antibody, or antigen binding fragment thereof, retains the ability to bind to JAG1 and retains the functional characteristics, e.g., binding affinity, of the parent.
[0086] In one embodiment, the substitutions made within a heavy or light chain that is at least 95% identical (or at least 96% identical, or at least 97% identical, or at least 98% identical, or at least 99% identical) are conservative amino acid substitutions. A “conservative amino acid substitution” is one in which an amino acid residue is substituted by another amino acid residue having a side chain (R group) with similar chemical properties (e.g., charge or hydrophobicity). In general, a conservative amino acid substitution will not substantially change the functional properties of a protein. In cases where two or more amino acid sequences differ from each other by conservative substitutions, the percent sequence identity or degree of similarity may be adjusted upwards to correct for the conservative nature of the substitution. Means for making this adjustment are well-known to those of skill in the art. See, e.g., Pearson (1994) Methods Mol. Biol. 24: 307-331, herein incorporated by reference. Examples of groups of amino acids that have side chains with similar chemical properties include (1) aliphatic side chains: glycine, alanine, valine, leucine and isoleucine; (2) aliphatic-hydroxyl side chains: serine and threonine; (3) amide-containing side chains: asparagine and glutamine; (4) aromatic side chains: phenylalanine, tyrosine, and tryptophan; (5) basic side chains: lysine, arginine, and histidine; (6) acidic side chains: aspartate and glutamate, and (7) sulfur-containing side chains are cysteine and methionine.
[0087] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having the antigen binding regions of any of the antibodies described in Table 5. The antibodies of the invention, including those described in Table 5, bind to human JAG1.
[0088] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 77, and a light chain variable domain sequence as set forth in SEQ ID NO: 78. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 77, and a light chain variable domain comprising the CDRs of SEQ ID NO: 78. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 77, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 78. The antibody may further be an IgG1 or an IgG4 isotype.
[0089] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7.3-2 In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 112. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:112. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 112. The antibody may further be an IgG1 or an IgG4 isotype.
[0090] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-2B2S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 113. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:113. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 113. The antibody may further be an IgG1 or an IgG4 isotype.
[0091] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-2A3S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 114. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:114. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 114. The antibody may further be an IgG1 or an IgG4 isotype.
[0092] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-2A7S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 115. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:115. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 115. The antibody may further be an IgG1 or an IgG4 isotype.
[0093] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-2A105. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 116. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:116. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 116. The antibody may further be an IgG1 or an IgG4 isotype.
[0094] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-2A2S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 117. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:117. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 117. The antibody may further be an IgG1 or an IgG4 isotype.
[0095] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-2A9S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 118. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:118. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 118. The antibody may further be an IgG1 or an IgG4 isotype.
[0096] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-2A1S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 119. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:119. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 119. The antibody may further be an IgG1 or an IgG4 isotype.
[0097] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-E11S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 120. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:120. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 120. The antibody may further be an IgG1 or an IgG4 isotype.
[0098] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-C11S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 121. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:121. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 121. The antibody may further be an IgG1 or an IgG4 isotype.
[0099] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-D10S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 122. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:122. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 122. The antibody may further be an IgG1 or an IgG4 isotype.
[0100] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-2B7S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 111, and a light chain variable domain sequence as set forth in SEQ ID NO: 123. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 111, and a light chain variable domain comprising the CDRs of SEQ ID NO:123. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 111, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 123. The antibody may further be an IgG1 or an IgG4 isotype.
[0101] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-1A8S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 124, and a light chain variable domain sequence as set forth in SEQ ID NO: 112. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 124, and a light chain variable domain comprising the CDRs of SEQ ID NO:112. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 124, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 112. The antibody may further be an IgG1 or an IgG4 isotype.
[0102] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-1A6S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 125, and a light chain variable domain sequence as set forth in SEQ ID NO: 112. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 125, and a light chain variable domain comprising the CDRs of SEQ ID NO:112. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 125, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 112. The antibody may further be an IgG1 or an IgG4 isotype.
[0103] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-1A2S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 126, and a light chain variable domain sequence as set forth in SEQ ID NO: 112. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 126, and a light chain variable domain comprising the CDRs of SEQ ID NO:112. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 126, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 112. The antibody may further be an IgG1 or an IgG4 isotype.
[0104] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-1B1S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 127, and a light chain variable domain sequence as set forth in SEQ ID NO: 112. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 127, and a light chain variable domain comprising the CDRs of SEQ ID NO:112. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 127, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 112. The antibody may further be an IgG1 or an IgG4 isotype.
[0105] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-5A8S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 128, and a light chain variable domain sequence as set forth in SEQ ID NO: 112. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 128, and a light chain variable domain comprising the CDRs of SEQ ID NO:112. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 128, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 112. The antibody may further be an IgG1 or an IgG4 isotype.
[0106] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-5B5S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 129, and a light chain variable domain sequence as set forth in SEQ ID NO: 112. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 129, and a light chain variable domain comprising the CDRs of SEQ ID NO:112. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 129, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 112. The antibody may further be an IgG1 or an IgG4 isotype.
[0107] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-3E5S. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 130, and a light chain variable domain sequence as set forth in SEQ ID NO: 112. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 130, and a light chain variable domain comprising the CDRs of SEQ ID NO:112. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 130, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 112. The antibody may further be an IgG1 or an IgG4 isotype.
[0108] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-G6C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 127, and a light chain variable domain sequence as set forth in SEQ ID NO: 131. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 127, and a light chain variable domain comprising the CDRs of SEQ ID NO:131. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 127, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 131. The antibody may further be an IgG1 or an IgG4 isotype.
[0109] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-A6C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 132, and a light chain variable domain sequence as set forth in SEQ ID NO: 133. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 132, and a light chain variable domain comprising the CDRs of SEQ ID NO:133. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 132, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 133. The antibody may further be an IgG1 or an IgG4 isotype.
[0110] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-E11C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 132, and a light chain variable domain sequence as set forth in SEQ ID NO: 123. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 132, and a light chain variable domain comprising the CDRs of SEQ ID NO:123. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 132, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 123. The antibody may further be an IgG1 or an IgG4 isotype.
[0111] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-C6C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 142, and a light chain variable domain sequence as set forth in SEQ ID NO: 123. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 142, and a light chain variable domain comprising the CDRs of SEQ ID NO:123. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 142, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 123. The antibody may further be an IgG1 or an IgG4 isotype.
[0112] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-C9C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 127, and a light chain variable domain sequence as set forth in SEQ ID NO: 123. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 127, and a light chain variable domain comprising the CDRs of SEQ ID NO:123. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 127, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 123. The antibody may further be an IgG1 or an IgG4 isotype.
[0113] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-F4C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 132, and a light chain variable domain sequence as set forth in SEQ ID NO: 134. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 132, and a light chain variable domain comprising the CDRs of SEQ ID NO:134. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 132, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 134. The antibody may further be an IgG1 or an IgG4 isotype.
[0114] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-F2C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 135, and a light chain variable domain sequence as set forth in SEQ ID NO: 133. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 135, and a light chain variable domain comprising the CDRs of SEQ ID NO:133. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 135, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 133. The antibody may further be an IgG1 or an IgG4 isotype.
[0115] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-F1C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 132, and a light chain variable domain sequence as set forth in SEQ ID NO: 136. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 132, and a light chain variable domain comprising the CDRs of SEQ ID NO:136. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 132, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 136. The antibody may further be an IgG1 or an IgG4 isotype.
[0116] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-D4C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 132, and a light chain variable domain sequence as set forth in SEQ ID NO: 137. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 132, and a light chain variable domain comprising the CDRs of SEQ ID NO:137. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 132, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 137. The antibody may further be an IgG1 or an IgG4 isotype.
[0117] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-D5C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 132, and a light chain variable domain sequence as set forth in SEQ ID NO: 138. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 132, and a light chain variable domain comprising the CDRs of SEQ ID NO:138. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 132, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 138. The antibody may further be an IgG1 or an IgG4 isotype.
[0118] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-A5C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 139, and a light chain variable domain sequence as set forth in SEQ ID NO: 123. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 139, and a light chain variable domain comprising the CDRs of SEQ ID NO:123. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 139, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 123. The antibody may further be an IgG1 or an IgG4 isotype.
[0119] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-B2C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 139, and a light chain variable domain sequence as set forth in SEQ ID NO: 140. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 139, and a light chain variable domain comprising the CDRs of SEQ ID NO:140. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 139, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 140. The antibody may further be an IgG1 or an IgG4 isotype.
[0120] In one embodiment, the present invention is directed to an antibody, or an antigen binding fragment thereof, having antigen binding regions of antibody JG1H7-B6C. In one embodiment, the invention provides an antibody, or antigen-binding fragment thereof, comprising a heavy chain variable domain sequence as set forth in SEQ ID NO: 127, and a light chain variable domain sequence as set forth in SEQ ID NO: 141. In one embodiment, the invention is directed to an antibody having a heavy chain variable domain comprising the CDRs of SEQ ID NO: 127, and a light chain variable domain comprising the CDRs of SEQ ID NO:141. In one embodiment, the invention features an isolated human antibody, or antigen-binding fragment thereof, that comprises a heavy chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 127, and comprises a light chain variable region having an amino acid sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical to the sequence set forth in SEQ ID NO: 141. The antibody may further be an IgG1 or an IgG4 isotype.
[0121] As described in Table 5, a number of heavy chain variable domains have amino acid sequences that are at least 95% identical to SEQ ID NO:111, including SEQ ID NO: 135 (as described for antibody JG1H7-F2C), SEQ ID NO: 142 (as described for antibody JG1H7-C6C), SEQ ID NO: 132 (as described for antibodies JG1H7-A6C, JG1H7-E11C, JG1H7-F1C, JG1H7-D4C and JG1H7-D5C), SEQ ID NO: 130 (as described for antibody JG1H7-3E5S), SEQ ID NO: 129 (as described for antibody JG1H7-5B5S), SEQ ID NO: 128 (as described for antibody JG1H7-5A8S), SEQ ID NO: 127 (as described for antibodies JG1H7-1B1S, JG1H7-G6C, JG1H7-C9C and JG1H7-B6C), SEQ ID NO: 132 (as described for antibody JG1H7-F4C), SEQ ID NO: 126 (as described for antibody JG1H7-1A2S), SEQ ID NO: 125 (as described for antibody JG1H7-1A6S), SEQ ID NO: 124 (as described for antibody JG1H7-1A8S) and SEQ ID NO: 139 (as described for antibodies JG1H7-A5C and JG1H7-B2C).
[0122] As also described in Table 5, a number of light chain variable domains have amino acid sequences that are at least 95% identical to SEQ ID NO:112, including SEQ ID NO: 140 (as described for antibody JG1H7-B2C), SEQ ID NO: 138 (as described for antibody JG1H7-D5C), SEQ ID NO: 137 (as described for antibody JG1H7-D4C), SEQ ID NO: 136 (as described for antibody JG1H7-F1C), SEQ ID NO: 134 (as described for antibody JG1H7-F4C), SEQ ID NO: 133 (as described for antibodies JG1H7-A6C and JG1H7-F2C), SEQ ID NO: 131 (as described for antibody JG1H7-G6C), SEQ ID NO: 123 (as described for antibodies JG1H7-2B7S, JG1H7-E11C, JG1H7-C6C, JG1H7-A5C and JG1H7-C9C), SEQ ID NO: 122 (as described for antibody JG1H7-D10S), SEQ ID NO: 121 (as described for antibody JG1H7-C11S), SEQ ID NO: 120 (as described for antibody JG1H7-E11S), SEQ ID NO: 119 (as described for antibody JG1H7-2A1S), SEQ ID NO: 118 (as described for antibody JG1H7-2A9S), SEQ ID NO: 117 (as described for antibody JG1H7-2A2S), SEQ ID NO: 116 (as described for antibody JG1H7-2A10S), SEQ ID NO: 115 (as described for antibody JG1H7-2A7S), SEQ ID NO: 114 (as described for antibody JG1H7-2A3S), SEQ ID NO: 141 (as described for antibody JG1H7-B6C), and SEQ ID NO: 113 (as described for antibody JG1H7-2B2S).
[0123] Antigen-binding fragments of antigen binding proteins of the invention may be produced by conventional techniques. Examples of such fragments include, but are not limited to, Fab and F(ab′)2 fragments.
[0124] In certain embodiments, the present disclosure provides a Fab fully human antibody fragment, having a variable domain region from a heavy chain and a variable domain region from a light chain, wherein the heavy chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to the amino acid sequences selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142 and combinations thereof, and that has a light chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to the amino acid sequence consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141, and combinations thereof. Preferably, the fully human antibody Fab fragment has both a heavy chain variable domain region and a light chain variable domain region wherein the antibody has a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, SEQ ID NO. 111/SEQ ID NO.112, SEQ ID NO. 111/SEQ ID NO.113, SEQ ID NO.111/SEQ ID NO.114, SEQ ID NO. 111/SEQ ID NO.115, SEQ ID NO. 111/SEQ ID NO.116, SEQ ID NO.111/SEQ ID NO.117, SEQ ID NO. 111/SEQ ID NO.118, SEQ ID NO. 111/SEQ ID NO.119, SEQ ID NO.111/SEQ ID NO.120, SEQ ID NO. 111/SEQ ID NO.121, SEQ ID NO. 111/SEQ ID NO.122, SEQ ID NO.111/SEQ ID NO.123, SEQ ID NO.124/SEQ ID NO.112, SEQ ID NO. 125/SEQ ID NO.112, SEQ ID NO. 126/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.112, SEQ ID NO. 128/SEQ ID NO.112, SEQ ID NO. 129/SEQ ID NO.112, SEQ ID NO.130/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.131, SEQ ID NO. 132/SEQ ID NO.133, SEQ ID NO. 132/SEQ ID NO.123, SEQ ID NO.142/SEQ ID NO.123, SEQ ID NO. 127/SEQ ID NO.123, SEQ ID NO. 132/SEQ ID NO.134, SEQ ID NO. 135/SEQ ID NO.133, SEQ ID NO.132/SEQ ID NO.136, SEQ ID NO.132/SEQ ID NO.137, SEQ ID NO. 132/SEQ ID NO.138, SEQ ID NO. 139/SEQ ID NO.123, SEQ ID NO.139/SEQ ID NO.140, SEQ ID NO. 127/SEQ ID NO.141, and combinations thereof.
[0125] Single chain antibodies may be formed by linking heavy and light chain variable domain (Fv region) fragments via an amino acid bridge (short peptide linker), resulting in a single polypeptide chain. Such single-chain Fvs (scFvs) have been prepared by fusing DNA encoding a peptide linker between DNAs encoding the two variable domain polypeptides (V L and V H ). The resulting polypeptides can fold back on themselves to form antigen-binding monomers, or they can form multimers (e.g., dimers, trimers, or tetramers), depending on the length of a flexible linker between the two variable domains (Kortt et al., 1997 , Prot. Eng. 10:423; Kortt et al., 2001 , Biomol. Eng. 18:95-108). By combining different V L and V H -comprising polypeptides, one can form multimeric scFvs that bind to different epitopes (Kriangkum et al., 2001 , Biomol. Eng. 18:31-40). Techniques developed for the production of single chain antibodies include those described in U.S. Pat. No. 4,946,778; Bird, 1988 , Science 242:423; Huston et al., 1988 , Proc. Natl. Acad. Sci. USA 85:5879; Ward et al., 1989 , Nature 334:544, de Graaf et al., 2002 , Methods Mol. Biol. 178:379-87.
[0126] In one embodiment, the present disclosure provides a single chain human antibody, having a variable domain region from a heavy chain and a variable domain region from a light chain and a peptide linker connection the heavy chain and light chain variable domain regions, wherein the heavy chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to the amino acid sequences selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142, and combinations thereof, and that has a light chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to the amino acid sequence consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141, and combinations thereof. In one embodiment, the fully human single chain antibody has both a heavy chain variable domain region and a light chain variable domain region, wherein the single chain fully human antibody has a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, SEQ ID NO. 111/SEQ ID NO.112, SEQ ID NO. 111/SEQ ID NO.113, SEQ ID NO.111/SEQ ID NO.114, SEQ ID NO. 111/SEQ ID NO.115, SEQ ID NO. 111/SEQ ID NO.116, SEQ ID NO.111/SEQ ID NO.117, SEQ ID NO. 111/SEQ ID NO.118, SEQ ID NO. 111/SEQ ID NO.119, SEQ ID NO.111/SEQ ID NO.120, SEQ ID NO. 111/SEQ ID NO.121, SEQ ID NO. 111/SEQ ID NO.122, SEQ ID NO.111/SEQ ID NO.123, SEQ ID NO.124/SEQ ID NO.112, SEQ ID NO. 125/SEQ ID NO.112, SEQ ID NO. 126/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.112, SEQ ID NO. 128/SEQ ID NO.112, SEQ ID NO. 129/SEQ ID NO.112, SEQ ID NO.130/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.131, SEQ ID NO. 132/SEQ ID NO.133, SEQ ID NO. 132/SEQ ID NO.123, SEQ ID NO.142/SEQ ID NO.123, SEQ ID NO. 127/SEQ ID NO.123, SEQ ID NO. 132/SEQ ID NO.134, SEQ ID NO. 135/SEQ ID NO.133, SEQ ID NO.132/SEQ ID NO.136, SEQ ID NO.132/SEQ ID NO.137, SEQ ID NO. 132/SEQ ID NO.138, SEQ ID NO. 139/SEQ ID NO.123, SEQ ID NO.139/SEQ ID NO.140, SEQ ID NO. 127/SEQ ID NO.141, and combinations thereof.
[0127] Techniques are known for deriving an antibody of a different subclass or isotype from an antibody of interest, i.e., subclass switching. Thus, IgG antibodies may be derived from an IgM antibody, for example, and vice versa. Such techniques allow the preparation of new antibodies that possess the antigen-binding properties of a given antibody (the parent antibody), but also exhibit biological properties associated with an antibody isotype or subclass different from that of the parent antibody. Recombinant DNA techniques may be employed. Cloned DNA encoding particular antibody polypeptides may be employed in such procedures, e.g., DNA encoding the constant domain of an antibody of the desired isotype (Lantto et al., 2002 , Methods Mol. Biol. 178:303-16). Moreover, if an IgG4 is desired, it may also be desired to introduce a point mutation (CPSCP->CPPCP) (SEQ ID NOS 143 and 144, respectively) in the hinge region (Bloom et al., 1997 , Protein Science 6:407) to alleviate a tendency to form intra-H chain disulfide bonds that can lead to heterogeneity in the IgG4 antibodies. Thus, in one embodiment, the antibody of the invention is a human IgG1 antibody. Thus, in one embodiment, the antibody of the invention is a human IgG4 antibody.
[0128] The present disclosure provides a number of antibodies structurally characterized by the amino acid sequences of their variable domain regions. However, the amino acid sequences can undergo some changes while retaining their high degree of binding to their specific targets. More specifically, many amino acids in the variable domain region can be changed with conservative substitutions and it is predictable that the binding characteristics of the resulting antibody will not differ from the binding characteristics of the wild type antibody sequence. There are many amino acids in an antibody variable domain that do not directly interact with the antigen or impact antigen binding and are not critical for determining antibody structure. For example, a predicted nonessential amino acid residue in any of the disclosed antibodies is preferably replaced with another amino acid residue from the same class. Methods of identifying amino acid conservative substitutions which do not eliminate antigen binding are well-known in the art (see, e.g., Brummell et al., Biochem. 32: 1180-1187 (1993); Kobayashi et al. Protein Eng. 12(10):879-884 (1999); and Burks et al. Proc. Natl. Acad. Sci. USA 94:412-417 (1997)). Near et al. Mol. Immunol. 30:369-377, 1993 explains how to impact or not impact binding through site-directed mutagenesis. Near et al. only mutated residues that they thought had a high probability of changing antigen binding. Most had a modest or negative effect on binding affinity (Near et al. Table 3) and binding to different forms of digoxin (Near et al. Table 2).
[0129] Thus, the invention also includes, in certain embodiments, variable sequences having at least 95% identity to those sequences disclosed herein.
[0130] In certain embodiments, an antibody, or antigen-binding fragment thereof, provided herein has a dissociation constant (K D ) of 1×10 −6 M or less; 5×10 −7 M or less' 1×10 −7 M or less; 5×10 −8 M or less; 1×10 −8 M or less; 5×10 −9 M or less; or 1×10 −9 M or less. In one embodiment, the antibody, or antigen-binding fragment thereof, of the invention as a K D from 1×10 −7 M to 1×10 −10 M. In one embodiment, the antibody, or antigen-binding fragment thereof, of the invention as a K D from 1×10 −8 M to 1×10 −10 M.
[0131] Those of ordinary skill in the art will appreciate standard methods known for determining the K D of an antibody, or fragment thereof. For example, in one embodiment, K D is measured by a radiolabeled antigen binding assay (RIA). In one embodiment, an RIA is performed with the Fab version of an antibody of interest and its antigen. For example, solution binding affinity of Fabs for antigen is measured by equilibrating Fab with a minimal concentration of ( 125 I)-labeled antigen in the presence of a titration series of unlabeled antigen, then capturing bound antigen with an anti-Fab antibody-coated plate (see, e.g., Chen et al., J. Mol. Biol. 293:865-881(1999)).
[0132] According to another embodiment, K D is measured using a BIACORE surface plasmon resonance assay. The term “surface plasmon resonance”, as used herein, refers to an optical phenomenon that allows for the analysis of real-time interactions by detection of alterations in protein concentrations within a biosensor matrix, for example using the BIACORE system (Biacore Life Sciences division of GE Healthcare, Piscataway, N.J.).
[0133] In particular embodiments, antigen binding proteins of the present invention have a binding affinity (K a ) for JAG1 of at least 10 6 M −1 . In other embodiments, the antigen binding proteins exhibit a K a of at least 10 7 M −1 , at least 10 8 M −1 , at least 10 9 M −1 , or at least 10 10 M −1 . In another embodiment, the antigen binding protein exhibits a K a substantially the same as that of an antibody described herein in the Examples.
[0134] In another embodiment, the present disclosure provides an antigen binding protein that has a low dissociation rate from JAG1. In one embodiment, the antigen binding protein has a K off of 1×10 −4 to −1 sec −1 or lower. In another embodiment, the K off is 5×10 −5 to −1 sec −1 or lower. In another embodiment, the K off is substantially the same as an antibody described herein. In another embodiment, the antigen binding protein binds to JAG1 with substantially the same K off as an antibody described herein.
[0135] In another aspect, the present disclosure provides an antigen binding protein that inhibits an activity of JAG1. In one embodiment, the antigen binding protein has an IC 50 of 1000 nM or lower. In another embodiment, the IC 50 is 100 nM or lower; in another embodiment, the IC 50 is 10 nM or lower. In another embodiment, the IC 50 is substantially the same as that of an antibody described herein in the Examples. In another embodiment, the antigen binding protein inhibits an activity of JAG1 with substantially the same IC 50 as an antibody described herein.
[0136] In another aspect, the present disclosure provides an antigen binding protein that binds to human JAG1 expressed on the surface of a cell and, when so bound, inhibits JAG1 signaling activity in the cell without causing a significant reduction in the amount of JAG1 on the surface of the cell. Any method for determining or estimating the amount of JAG1 on the surface and/or in the interior of the cell can be used. In other embodiments, binding of the antigen binding protein to the JAG1-expressing cell causes less than about 75%, 50%, 40%, 30%, 20%, 15%, 10%, 5%, 1%, or 0.1% of the cell-surface JAG1 to be internalized.
[0137] In another aspect, the present disclosure provides an antigen binding protein having a half-life of at least one day in vitro or in vivo (e.g., when administered to a human subject). In one embodiment, the antigen binding protein has a half-life of at least three days. In another embodiment, the antigen binding protein has a half-life of four days or longer. In another embodiment, the antigen binding protein has a half-life of eight days or longer. In another embodiment, the antigen binding protein is derivatized or modified such that it has a longer half-life as compared to the underivatized or unmodified antigen binding protein. In another embodiment, the antigen binding protein contains one or more point mutations to increase serum half life, such as described in WO2000/09560, incorporated by reference herein.
[0138] The present disclosure further provides multi-specific antigen binding proteins, for example, bispecific antigen binding protein, e.g., antigen binding protein that bind to two different epitopes of JAG1, or to an epitope of JAG1 and an epitope of another molecule, via two different antigen binding sites or regions. Moreover, bispecific antigen binding protein as disclosed herein can comprise a JAG1 binding site from one of the herein-described antibodies and a second JAG1 binding region from another of the herein-described antibodies, including those described herein by reference to other publications. Alternatively, a bispecific antigen binding protein may comprise an antigen binding site from one of the herein described antibodies and a second antigen binding site from another JAG1 antibody that is known in the art, or from an antibody that is prepared by known methods or the methods described herein.
[0139] Numerous methods of preparing bispecific antibodies are known in the art. Such methods include the use of hybrid-hybridomas as described by Milstein et al., 1983 , Nature 305:537, and chemical coupling of antibody fragments (Brennan et al., 1985 , Science 229:81; Glennie et al., 1987 , J. Immunol. 139:2367; U.S. Pat. No. 6,010,902). Moreover, bispecific antibodies can be produced via recombinant means, for example by using leucine zipper moieties (i.e., from the Fos and Jun proteins, which preferentially form heterodimers; Kostelny et al., 1992 , J. Immunol. 148:1547) or other lock and key interactive domain structures as described in U.S. Pat. No. 5,582,996. Additional useful techniques include those described in U.S. Pat. Nos. 5,959,083; and 5,807,706.
[0140] In another aspect, the antigen binding protein comprises a derivative of an antibody. The derivatized antibody can comprise any molecule or substance that imparts a desired property to the antibody, such as increased half-life in a particular use. The derivatized antibody can comprise, for example, a detectable (or labeling) moiety (e.g., a radioactive, colorimetric, antigenic or enzymatic molecule, a detectable bead (such as a magnetic or electrodense (e.g., gold) bead), or a molecule that binds to another molecule (e.g., biotin or streptavidin), a therapeutic or diagnostic moiety (e.g., a radioactive, cytotoxic, or pharmaceutically active moiety), or a molecule that increases the suitability of the antibody for a particular use (e.g., administration to a subject, such as a human subject, or other in vivo or in vitro uses). Examples of molecules that can be used to derivatize an antibody include albumin (e g, human serum albumin) and polyethylene glycol (PEG). Albumin-linked and PEGylated derivatives of antibodies can be prepared using techniques well known in the art. In one embodiment, the antibody is conjugated or otherwise linked to transthyretin (TTR) or a TTR variant. The TTR or TTR variant can be chemically modified with, for example, a chemical selected from the group consisting of dextran, poly(n-vinyl pyurrolidone), polyethylene glycols, propropylene glycol homopolymers, polypropylene oxide/ethylene oxide co-polymers, polyoxyethylated polyols and polyvinyl alcohols.
[0141] An alternative approach to antibody-targeted therapy is to utilize anti-JAG1 antibodies of the invention for delivery of cytotoxic drugs specifically to JAG1 antigen-expressing cancer cells. In one embodiment, an anti-JAG1 antibody, or fragment, of the invention is conjugated to a cytotoxic agent via a linker, to form an anti-JAG1 Antibody Drug Conjugate (ADC). Various cytotoxic drugs are known in the art which can be conjugated with any of the antibodies disclosed herein to form an ADC, including the cytotoxic drug maytansinoid. Maytansinoids, derivatives of the anti-mitotic drug maytansine, bind to microtubules in a manner similar to vinca alkaloid drugs (Issell B F et al (1978) Cancer Treat. Rev. 5:199-207; Cabanillas F et al. (1979) Cancer Treat Rep, 63:507-9. Antibody-drug conjugates (ADCs) composed of the maytansinoid DM1 linked to an anti-JAG1 antibody, as described in Example 2 below, show potent anti-tumor activity in JAG1-overexpressing tumor cell lines. Thus, in one embodiment, an anti-JAG1 antibody, or fragment thereof, of the invention is conjugated to an anti-mitotic tubulin inhibitor, e.g., maytansinoid N(2′)-deacetyl-N(2′)-(3-mercapto-1-oxopropyl)-maytansine (also referred to as “DM1”).
[0142] Oligomers that contain one or more antigen binding proteins may be employed as JAG1 antagonists. Oligomers may be in the form of covalently-linked or non-covalently-linked dimers, trimers, or higher oligomers. Oligomers comprising two or more antigen binding protein are contemplated for use, with one example being a homodimer. Other oligomers include heterodimers, homotrimers, heterotrimers, homotetramers, heterotetramers, etc.
[0143] One embodiment is directed to oligomers comprising multiple antigen binding proteins joined via covalent or non-covalent interactions between peptide moieties fused to the antigen binding proteins. Such peptides may be peptide linkers (spacers), or peptides that have the property of promoting oligomerization. Leucine zippers and certain polypeptides derived from antibodies are among the peptides that can promote oligomerization of antigen binding proteins attached thereto, as described in more detail below.
[0144] In particular embodiments, the oligomers comprise from two to four antigen binding proteins. The antigen binding proteins of the oligomer may be in any form, such as any of the forms described above, e.g., variants or fragments. Preferably, the oligomers comprise antigen binding proteins that have JAG1 binding activity.
[0145] Another method for preparing oligomeric antigen binding proteins involves use of a leucine zipper. Leucine zipper domains are peptides that promote oligomerization of the proteins in which they are found. Leucine zippers were originally identified in several DNA-binding proteins (Landschulz et al., 1988 , Science 240:1759), and have since been found in a variety of different proteins. Among the known leucine zippers are naturally occurring peptides and derivatives thereof that dimerize or trimerize. Examples of leucine zipper domains suitable for producing soluble oligomeric proteins are described in WO 94/10308, and the leucine zipper derived from lung surfactant protein D (SPD) described in Hoppe et al., 1994 , FEBS Letters 344:191. The use of a modified leucine zipper that allows for stable trimerization of a heterologous protein fused thereto is described in Fanslow et al., 1994 , Semin. Immunol. 6:267-78. In one approach, recombinant fusion proteins comprising an anti-JAG1 antibody fragment or derivative fused to a leucine zipper peptide are expressed in suitable host cells, and the soluble oligomeric anti-JAG1 antibody fragments or derivatives that form are recovered from the culture supernatant.
[0146] Antigen binding proteins directed against JAG1 can be used, for example, in assays to detect the presence of JAG1 polypeptides, either in vitro or in vivo. The antigen binding proteins also may be employed in purifying JAG1 proteins by immunoaffinity chromatography. Blocking antigen binding proteins can be used in the methods disclosed herein. Such antigen binding proteins that function as JAG1 antagonists may be employed in treating any JAG1-induced condition, including but not limited to various cancers.
[0147] Antigen binding proteins may be employed in an in vitro procedure, or administered in vivo to inhibit JAG1-induced biological activity. Disorders that would benefit (directly or indirectly) from activation of JAG1, examples of which are provided herein, thus may be treated. In one embodiment, the present invention provides a therapeutic method comprising in vivo administration of a JAG1 blocking antigen binding protein to a mammal in need thereof in an amount effective for reducing a JAG1-induced biological activity.
[0148] In certain embodiments of the invention, antigen binding proteins include fully human monoclonal antibodies that inhibit a biological activity of JAG1.
[0149] Antigen binding proteins, including antibodies and antibody fragments described herein, may be prepared by any of a number of conventional techniques. For example, they may be purified from cells that naturally express them (e.g., an antibody can be purified from a hybridoma that produces it), or produced in recombinant expression systems, using any technique known in the art. See, for example, Monoclonal Antibodies, Hybridomas: A New Dimension in Biological Analyses, Kennet et al. (eds.), Plenum Press, New York (1980); and Antibodies: A Laboratory Manual, Harlow and Land (eds.), Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., (1988).
[0150] Any expression system known in the art can be used to make the recombinant polypeptides, including antibodies and antibody fragments described herein, of the invention. In general, host cells are transformed with a recombinant expression vector that comprises DNA encoding a desired polypeptide. Among the host cells that may be employed are prokaryotes, yeast or higher eukaryotic cells. Prokaryotes include gram negative or gram positive organisms, for example E. coli or bacilli . Higher eukaryotic cells include insect cells and established cell lines of mammalian origin. Examples of suitable mammalian host cell lines include the COS-7 line of monkey kidney cells (ATCC CRL 1651) (Gluzman et al., 1981 , Cell 23:175), L cells, 293 cells, C127 cells, 3T3 cells (ATCC CCL 163), Chinese hamster ovary (CHO) cells, HeLa cells, BHK (ATCC CRL 10) cell lines, and the CV1/EBNA cell line derived from the African green monkey kidney cell line CV1 (ATCC CCL 70) as described by McMahan et al., 1991 , EMBO J. 10: 2821. Appropriate cloning and expression vectors for use with bacterial, fungal, yeast, and mammalian cellular hosts are described by Pouwels et al. (Cloning Vectors: A Laboratory Manual, Elsevier, N.Y., 1985).
[0151] The transformed cells can be cultured under conditions that promote expression of the polypeptide, and the polypeptide recovered by conventional protein purification procedures. One such purification procedure includes the use of affinity chromatography, e.g., over a matrix having all or a portion (e.g., the extracellular domain) of JAG1 bound thereto. Polypeptides contemplated for use herein include substantially homogeneous recombinant mammalian anti-JAG1 antibody polypeptides substantially free of contaminating endogenous materials.
[0152] Antigen binding proteins may be prepared, and screened for desired properties, by any of a number of known techniques. Certain of the techniques involve isolating a nucleic acid encoding a polypeptide chain (or portion thereof) of an antigen binding protein of interest (e.g., an anti-JAG1 antibody), and manipulating the nucleic acid through recombinant DNA technology. The nucleic acid may be fused to another nucleic acid of interest, or altered (e.g., by mutagenesis or other conventional techniques) to add, delete, or substitute one or more amino acid residues, for example.
[0153] Polypeptides of the present disclosure can be produced using any standard methods known in the art. In one example, the polypeptides are produced by recombinant DNA methods by inserting a nucleic acid sequence (a cDNA) encoding the polypeptide into a recombinant expression vector and expressing the DNA sequence under conditions promoting expression.
[0154] Nucleic acids encoding any of the various polypeptides disclosed herein may be synthesized chemically. Codon usage may be selected so as to improve expression in a cell. Such codon usage will depend on the cell type selected. Specialized codon usage patterns have been developed for E. coli and other bacteria, as well as mammalian cells, plant cells, yeast cells and insect cells.
[0155] General techniques for nucleic acid manipulation are described for example in Sambrook et al., Molecular Cloning: A Laboratory Manual , Vols. 1-3, Cold Spring Harbor Laboratory Press, 2 ed., 1989, or F. Ausubel et al., Current Protocols in Molecular Biology (Green Publishing and Wiley-Interscience: New York, 1987) and periodic updates, herein incorporated by reference. The DNA encoding the polypeptide is operably linked to suitable transcriptional or translational regulatory elements derived from mammalian, viral, or insect genes. Such regulatory elements include a transcriptional promoter, an optional operator sequence to control transcription, a sequence encoding suitable mRNA ribosomal binding sites, and sequences that control the termination of transcription and translation. The ability to replicate in a host, usually conferred by an origin of replication, and a selection gene to facilitate recognition of transformants is additionally incorporated.
[0156] The recombinant DNA can also include any type of protein tag sequence that may be useful for purifying the protein. Examples of protein tags include but are not limited to a histidine tag, a FLAG tag, a myc tag, an HA tag, or a GST tag. Appropriate cloning and expression vectors for use with bacterial, fungal, yeast, and mammalian cellular hosts can be found in Cloning Vectors: A Laboratory Manual , (Elsevier, N.Y., 1985).
[0157] The expression construct is introduced into the host cell using a method appropriate to the host cell. A variety of methods for introducing nucleic acids into host cells are known in the art, including, but not limited to, electroporation; transfection employing calcium chloride, rubidium chloride, calcium phosphate, DEAE-dextran, or other substances; microprojectile bombardment; lipofection; and infection (where the vector is an infectious agent). Suitable host cells include prokaryotes, yeast, mammalian cells, or bacterial cells.
[0158] Suitable bacteria include gram negative or gram positive organisms, for example, E. coli or Bacillus spp. Yeast, preferably from the Saccharomyces species, such as S. cerevisiae , may also be used for production of polypeptides. Various mammalian or insect cell culture systems can also be employed to express recombinant proteins. Baculovirus systems for production of heterologous proteins in insect cells are reviewed by Luckow and Summers, ( Bio/Technology, 6:47, 1988). Examples of suitable mammalian host cell lines include endothelial cells, COS-7 monkey kidney cells, CV-1, L cells, C127, 3T3, Chinese hamster ovary (CHO), human embryonic kidney cells, HeLa, 293, 293T, and BHK cell lines. Purified polypeptides are prepared by culturing suitable host/vector systems to express the recombinant proteins. For many applications, the small size of many of the polypeptides disclosed herein would make expression in E. coli as the preferred method for expression. The protein is then purified from culture media or cell extracts.
[0159] Proteins can also be produced using cell-translation systems. For such purposes the nucleic acids encoding the polypeptide must be modified to allow in vitro transcription to produce mRNA and to allow cell-free translation of the mRNA in the particular cell-free system being utilized (eukaryotic such as a mammalian or yeast cell-free translation system or prokaryotic such as a bacterial cell-free translation system.
[0160] JAG1-binding polypeptides can also be produced by chemical synthesis (such as by the methods described in Solid Phase Peptide Synthesis, 2nd ed., 1984, The Pierce Chemical Co., Rockford, Ill.). Modifications to the protein can also be produced by chemical synthesis.
[0161] The polypeptides of the present disclosure can be purified by isolation/purification methods for proteins generally known in the field of protein chemistry. Non-limiting examples include extraction, recrystallization, salting out (e.g., with ammonium sulfate or sodium sulfate), centrifugation, dialysis, ultrafiltration, adsorption chromatography, ion exchange chromatography, hydrophobic chromatography, normal phase chromatography, reversed-phase chromatography, gel filtration, gel permeation chromatography, affinity chromatography, electrophoresis, countercurrent distribution or any combinations of these. After purification, polypeptides may be exchanged into different buffers and/or concentrated by any of a variety of methods known to the art, including, but not limited to, filtration and dialysis.
[0162] The purified polypeptide is preferably at least 85% pure, more preferably at least 95% pure, and most preferably at least 98% pure. Regardless of the exact numerical value of the purity, the polypeptide is sufficiently pure for use as a pharmaceutical product.
[0163] In certain embodiments, the present disclosure provides monoclonal antibodies that bind to JAG1. Monoclonal antibodies may be produced using any technique known in the art, e.g., by immortalizing spleen cells harvested from the transgenic animal after completion of the immunization schedule. The spleen cells can be immortalized using any technique known in the art, e.g., by fusing them with myeloma cells to produce hybridomas. Myeloma cells for use in hybridoma-producing fusion procedures preferably are non-antibody-producing, have high fusion efficiency, and enzyme deficiencies that render them incapable of growing in certain selective media which support the growth of only the desired fused cells (hybridomas). Examples of suitable cell lines for use in mouse fusions include Sp-20, P3-X63/Ag8, P3-X63-Ag8.653, NS1/1.Ag 4 1, Sp210-Ag14, FO, NSO/U, MPC-11, MPC11-X45-GTG 1.7 and S194/5XX0 Bul; examples of cell lines used in rat fusions include R210.RCY3, Y3-Ag 1.2.3, IR983F and 48210. Other cell lines useful for cell fusions are U-266, GM1500-GRG2, LICR-LON-HMy2 and UC729-6.
[0164] Antigen-binding fragments of antigen binding proteins of the invention may be produced by conventional techniques known in the art.
Post-Translational Modifications of Polypeptides
[0165] In certain embodiments, the binding polypeptides of the invention may further comprise post-translational modifications. Exemplary post-translational protein modifications include phosphorylation, acetylation, methylation, ADP-ribosylation, ubiquitination, glycosylation, carbonylation, sumoylation, biotinylation or addition of a polypeptide side chain or of a hydrophobic group. As a result, the modified soluble polypeptides may contain non-amino acid elements, such as lipids, poly- or mono-saccharide, and phosphates. A preferred form of glycosylation is sialylation, which conjugates one or more sialic acid moieties to the polypeptide. Sialic acid moieties improve solubility and serum half-life while also reducing the possible immunogeneticity of the protein. See Raju et al. Biochemistry. 2001 31; 40(30):8868-76.
[0166] In one embodiment, modified forms of the subject soluble polypeptides comprise linking the subject soluble polypeptides to nonproteinaceous polymers. In one embodiment, the polymer is polyethylene glycol (“PEG”), polypropylene glycol, or polyoxyalkylenes, in the manner as set forth in U.S. Pat. Nos. 4,640,835; 4,496,689; 4,301,144; 4,670,417; 4,791,192 or 4,179,337.
[0167] PEG is a water soluble polymer that is commercially available or can be prepared by ring-opening polymerization of ethylene glycol according to methods well known in the art (Sandler and Karo, Polymer Synthesis, Academic Press, New York, Vol. 3, pages 138-161). The term “PEG” is used broadly to encompass any polyethylene glycol molecule, without regard to size or to modification at an end of the PEG, and can be represented by the formula: X—O(CH 2 CH 2 O) n —CH 2 CH 2 OH (1), where n is 20 to 2300 and X is H or a terminal modification, e.g., a C 1-4 alkyl. In one embodiment, the PEG of the invention terminates on one end with hydroxy or methoxy, i.e., X is H or CH 3 (“methoxy PEG”). A PEG can contain further chemical groups which are necessary for binding reactions; which results from the chemical synthesis of the molecule; or which is a spacer for optimal distance of parts of the molecule. In addition, such a PEG can consist of one or more PEG side-chains which are linked together. PEGs with more than one PEG chain are called multiarmed or branched PEGs. Branched PEGs can be prepared, for example, by the addition of polyethylene oxide to various polyols, including glycerol, pentaerythriol, and sorbitol. For example, a four-armed branched PEG can be prepared from pentaerythriol and ethylene oxide. Branched PEG are described in, for example, EP-A 0 473 084 and U.S. Pat. No. 5,932,462. One form of PEGs includes two PEG side-chains (PEG2) linked via the primary amino groups of a lysine (Monfardini et al., Bioconjugate Chem. 6 (1995) 62-69).
[0168] The serum clearance rate of PEG-modified polypeptide may be decreased by about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or even 90%, relative to the clearance rate of the unmodified binding polypeptide. The PEG-modified polypeptide may have a half-life (t 1/2 ) which is enhanced relative to the half-life of the unmodified protein. The half-life of PEG-binding polypeptide may be enhanced by at least 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%, 125%, 150%, 175%, 200%, 250%, 300%, 400% or 500%, or even by 1000% relative to the half-life of the unmodified binding polypeptide. In some embodiments, the protein half-life is determined in vitro, such as in a buffered saline solution or in serum. In other embodiments, the protein half-life is an in vivo half life, such as the half-life of the protein in the serum or other bodily fluid of an animal.
Therapeutic Methods, Formulations and Modes of Administration
[0169] The present disclosure features methods for treating Notch-signaling tumors, including breast, prostate, colorectal, lung and other solid tumors, comprising administering anti-JAG1 antibodies or antigen binding fragments of the present invention. As used herein, a “Notch-signaling tumor” or a “tumor associated with Notch signaling” refers to a tumor or malignant growth in which Notch signaling is detrimental. In one example, Notch signaling is associated with tumor growth. In other examples, Notch signaling is involved in tumor progression or metastasis. Exemplary tumors that may be treated by targeting the Notch pathway using the anti-JAG1 antibodies and antigen binding fragments of the invention, include, but are not limited to, head and neck squamous cell carcinoma (Zeng et al. 2005, Cancer Cell 8:13-23), T-cell acute lymphoblastic leukemia (Roy et al. Curr Opin Genet Dev 17: 52-59, 2007), breast cancer (Reedijk et al., Cancer Res 65: 8530-8537, 2005; Dickson et al., Mod Pathol 20: 685-693, 2007), melanoma (Pinnix and Herlyn, Pigment Cell Res 20: 458-465, 2007), lung adenocarcinoma (Chen et al., Cancer Res 67: 7954-7959, 2007), prostate (Leong et al., Differentiation Volume 76, Issue 6, July 2008, Pages 699-716) and colorectal (Guilmeau S. Adv Exp Med Biol. 2012; 727:272-88).
[0170] Any of the antibodies or antigen binding fragments disclosed herein may be used in such therapeutic methods.
[0171] The present disclosure further provides a method for treating Notch-signaling tumors, comprising administering an anti-JAG1 polypeptide selected from the group consisting of a fully human antibody of an IgG class that binds to a JAG1 epitope with a binding affinity of at least 10 −6 M, a Fab fully human antibody fragment, having a variable domain region from a heavy chain and a variable domain region from a light chain, a single chain human antibody, having a variable domain region from a heavy chain and a variable domain region from a light chain and a peptide linker connecting the heavy chain and light chain variable domain regions, including the heavy and light chain variable regions (and CDRs within said sequences) described in SEQ ID Nos. 1-142 (Table 5).
[0172] For example, in one embodiment, the methods disclosed herein include the use of a fully human antibody comprising a heavy chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to an amino acid sequence selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142, and combinations thereof, and that has a light chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to an amino acid sequence selected from the group consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141, and combinations thereof.
[0173] In one embodiment, the methods described herein include the use of a fully human Fab antibody fragment has a heavy chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to an amino acid sequences selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142 and combinations thereof, and that has the light chain variable domain sequence that is at least 95% identical to the amino acid sequence consisting SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141, and combinations thereof.
[0174] In one embodiment, the methods described herein include the use of a single chain human antibody comprising a heavy chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to the amino acid sequences selected from the group consisting of SEQ ID NO. 1, SEQ ID NO. 3, SEQ ID NO. 5, SEQ ID NO. 7, SEQ ID NO. 9, SEQ ID NO. 11, SEQ ID NO. 13, SEQ ID NO. 15, SEQ ID NO. 17, SEQ ID NO. 19, SEQ ID NO. 21, SEQ ID NO. 23, SEQ ID NO. 25, SEQ ID NO. 27, SEQ ID NO. 29, SEQ ID NO. 31, SEQ ID NO. 33, SEQ ID NO. 35, SEQ ID NO. 37, SEQ ID NO. 39, SEQ ID NO. 41, SEQ ID NO. 43, SEQ ID NO. 45, SEQ ID NO. 47, SEQ ID NO. 49, SEQ ID NO. 51, SEQ ID NO. 53, SEQ ID NO. 55, SEQ ID NO. 57, SEQ ID NO. 59, SEQ ID NO. 61, SEQ ID NO. 63, SEQ ID NO. 65, SEQ ID NO. 67, SEQ ID NO. 69, SEQ ID NO. 71, SEQ ID NO. 73, SEQ ID NO. 75, SEQ ID NO. 77, SEQ ID NO. 79, SEQ ID NO. 81, SEQ ID NO. 83, SEQ ID NO. 85, SEQ ID NO. 87, SEQ ID NO. 89, SEQ ID NO. 91, SEQ ID NO. 93, SEQ ID NO. 95, SEQ ID NO. 97, SEQ ID NO. 99, SEQ ID NO. 101, SEQ ID NO. 103, SEQ ID NO. 105, SEQ ID NO. 107, SEQ ID NO. 109, SEQ ID NO. 111, SEQ ID NO. 124, SEQ ID NO. 125, SEQ ID NO. 126, SEQ ID NO. 127, SEQ ID NO. 128, SEQ ID NO. 129, SEQ ID NO. 130, SEQ ID NO. 132, SEQ ID NO. 135, SEQ ID NO. 139 and SEQ ID NO. 142, and combinations thereof, and comprising a light chain variable domain sequence that is at least 95% identical, at least 96% identical, at least 97% identical, at least 98% identical, or at least 99% identical, to the amino acid sequence consisting of SEQ ID NO. 2, SEQ ID NO. 4, SEQ ID NO. 6, SEQ ID NO. 8, SEQ ID NO. 10, SEQ ID NO. 12, SEQ ID NO. 14, SEQ ID NO. 16, SEQ ID NO. 18, SEQ ID NO. 20, SEQ ID NO. 22, SEQ ID NO. 24, SEQ ID NO. 26, SEQ ID NO. 28, SEQ ID NO. 30, SEQ ID NO. 32, SEQ ID NO. 34, SEQ ID NO. 36, SEQ ID NO. 38, SEQ ID NO. 40, SEQ ID NO. 42, SEQ ID NO. 44, SEQ ID NO. 46, SEQ ID NO. 48, SEQ ID NO. 50, SEQ ID NO. 52, SEQ ID NO. 54, SEQ ID NO. 56, SEQ ID NO. 58, SEQ ID NO. 60, SEQ ID NO. 62, SEQ ID NO. 64, SEQ ID NO. 66, SEQ ID NO. 68, SEQ ID NO. 70, SEQ ID NO. 72, SEQ ID NO. 74, SEQ ID NO. 76, SEQ ID NO. 78, SEQ ID NO. 80, SEQ ID NO. 82, SEQ ID NO. 84, SEQ ID NO. 86, SEQ ID NO. 88, SEQ ID NO. 90, SEQ ID NO. 92, SEQ ID NO. 94, SEQ ID NO. 96, SEQ ID NO. 98, SEQ ID NO. 100, SEQ ID NO. 102, SEQ ID NO. 104, SEQ ID NO. 106, SEQ ID NO. 108, SEQ ID NO. 110, SEQ ID NO. 112, SEQ ID NO. 113, SEQ ID NO. 114, SEQ ID NO. 115, SEQ ID NO. 116, SEQ ID NO. 117, SEQ ID NO. 118, SEQ ID NO. 119, SEQ ID NO. 120, SEQ ID NO. 121, SEQ ID NO. 122, SEQ ID NO. 123, SEQ ID NO. 131, SEQ ID NO. 133, SEQ ID NO. 134, SEQ ID NO. 136, SEQ ID NO. 137, SEQ ID NO. 138, SEQ ID NO. 140 and SEQ ID NO. 141, and combinations thereof.
[0175] In one embodiment, the fully human antibody has both a heavy chain and a light chain wherein the antibody has a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, SEQ ID NO. 111/SEQ ID NO.112, SEQ ID NO. 111/SEQ ID NO.113, SEQ ID NO.111/SEQ ID NO.114, SEQ ID NO. 111/SEQ ID NO.115, SEQ ID NO. 111/SEQ ID NO.116, SEQ ID NO.111/SEQ ID NO.117, SEQ ID NO. 111/SEQ ID NO.118, SEQ ID NO. 111/SEQ ID NO.119, SEQ ID NO.111/SEQ ID NO.120, SEQ ID NO. 111/SEQ ID NO.121, SEQ ID NO. 111/SEQ ID NO.122, SEQ ID NO.111/SEQ ID NO.123, SEQ ID NO.124/SEQ ID NO.112, SEQ ID NO. 125/SEQ ID NO.112, SEQ ID NO. 126/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.112, SEQ ID NO. 128/SEQ ID NO.112, SEQ ID NO. 129/SEQ ID NO.112, SEQ ID NO.130/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.131, SEQ ID NO. 132/SEQ ID NO.133, SEQ ID NO. 132/SEQ ID NO.123, SEQ ID NO.142/SEQ ID NO.123, SEQ ID NO. 127/SEQ ID NO.123, SEQ ID NO. 132/SEQ ID NO.134, SEQ ID NO. 135/SEQ ID NO.133, SEQ ID NO.132/SEQ ID NO.136, SEQ ID NO.132/SEQ ID NO.137, SEQ ID NO. 132/SEQ ID NO.138, SEQ ID NO. 139/SEQ ID NO.123, SEQ ID NO.139/SEQ ID NO.140, SEQ ID NO. 127/SEQ ID NO.141, and combinations thereof.
[0176] In one embodiment, the fully human antibody Fab fragment has both a heavy chain variable domain region and a light chain variable domain region wherein the antibody has a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, SEQ ID NO. 111/SEQ ID NO.112, SEQ ID NO. 111/SEQ ID NO.113, SEQ ID NO.111/SEQ ID NO.114, SEQ ID NO. 111/SEQ ID NO.115, SEQ ID NO. 111/SEQ ID NO.116, SEQ ID NO.111/SEQ ID NO.117, SEQ ID NO. 111/SEQ ID NO.118, SEQ ID NO. 111/SEQ ID NO.119, SEQ ID NO.111/SEQ ID NO.120, SEQ ID NO. 111/SEQ ID NO.121, SEQ ID NO. 111/SEQ ID NO.122, SEQ ID NO.111/SEQ ID NO.123, SEQ ID NO.124/SEQ ID NO.112, SEQ ID NO. 125/SEQ ID NO.112, SEQ ID NO. 126/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.112, SEQ ID NO. 128/SEQ ID NO.112, SEQ ID NO. 129/SEQ ID NO.112, SEQ ID NO.130/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.131, SEQ ID NO. 132/SEQ ID NO.133, SEQ ID NO. 132/SEQ ID NO.123, SEQ ID NO.142/SEQ ID NO.123, SEQ ID NO. 127/SEQ ID NO.123, SEQ ID NO. 132/SEQ ID NO.134, SEQ ID NO. 135/SEQ ID NO.133, SEQ ID NO.132/SEQ ID NO.136, SEQ ID NO.132/SEQ ID NO.137, SEQ ID NO. 132/SEQ ID NO.138, SEQ ID NO. 139/SEQ ID NO.123, SEQ ID NO.139/SEQ ID NO.140, SEQ ID NO. 127/SEQ ID NO.141, and combinations thereof.
[0177] In one embodiment, the fully human single chain antibody has both a heavy chain variable domain region and a light chain variable domain region, wherein the single chain fully human antibody has a heavy chain/light chain variable domain sequence selected from the group consisting of SEQ ID NO. 1/SEQ ID NO. 2, SEQ ID NO. 3/SEQ ID NO. 4, SEQ ID NO. 5/SEQ ID NO. 6, SEQ ID NO. 7/SEQ ID NO. 8, SEQ ID NO. 9/SEQ ID NO. 10, SEQ ID NO. 11/SEQ ID NO. 12, SEQ ID NO. 13/SEQ ID NO. 14, SEQ ID NO. 15/SEQ ID NO. 16, SEQ ID NO. 17/SEQ ID NO. 18, SEQ ID NO. 19/SEQ ID NO. 20, SEQ ID NO. 21/SEQ ID NO. 22, SEQ ID NO. 23/SEQ ID NO. 24, SEQ ID NO. 25/SEQ ID NO. 26, SEQ ID NO. 27/SEQ ID NO. 28, SEQ ID NO. 29/SEQ ID NO. 30, SEQ ID NO. 31/SEQ ID NO. 32, SEQ ID NO. 33/SEQ ID NO. 34, SEQ ID NO. 35/SEQ ID NO. 36, SEQ ID NO. 37/SEQ ID NO. 38, SEQ ID NO. 39/SEQ ID NO. 40, SEQ ID NO. 41/SEQ ID NO. 42, SEQ ID NO. 43/SEQ ID NO. 44, SEQ ID NO. 45/SEQ ID NO. 46, SEQ ID NO. 47/SEQ ID NO. 48, SEQ ID NO. 49/SEQ ID NO. 50, SEQ ID NO. 51/SEQ ID NO. 52, SEQ ID NO. 53/SEQ ID NO. 54, SEQ ID NO. 55/SEQ ID NO. 56, SEQ ID NO. 57/SEQ ID NO. 58, SEQ ID NO. 59/SEQ ID NO. 60, SEQ ID NO. 61/SEQ ID NO. 62, SEQ ID NO. 63/SEQ ID NO. 64, SEQ ID NO. 65/SEQ ID NO. 66, SEQ ID NO. 67/SEQ ID NO. 68, SEQ ID NO. 69/SEQ ID NO. 70, SEQ ID NO. 71/SEQ ID NO. 72, SEQ ID NO. 73/SEQ ID NO. 74, SEQ ID NO. 75/SEQ ID NO. 76, SEQ ID NO. 77/SEQ ID NO. 78, SEQ ID NO. 79/SEQ ID NO. 80, SEQ ID NO. 81/SEQ ID NO. 82, SEQ ID NO. 83/SEQ ID NO. 84, SEQ ID NO. 85/SEQ ID NO. 86, SEQ ID NO. 87/SEQ ID NO. 88, SEQ ID NO. 89/SEQ ID NO. 90, SEQ ID NO. 91/SEQ ID NO. 92, SEQ ID NO. 93/SEQ ID NO. 94, SEQ ID NO. 95/SEQ ID NO. 96, SEQ ID NO. 97/SEQ ID NO. 98, SEQ ID NO. 99/SEQ ID NO. 100, SEQ ID NO. 101/SEQ ID NO. 102, SEQ ID NO. 103/SEQ ID NO. 104, SEQ ID NO. 105/SEQ ID NO. 106, SEQ ID NO. 107/SEQ ID NO. 108, SEQ ID NO. 109/SEQ ID NO. 110, SEQ ID NO. 111/SEQ ID NO.112, SEQ ID NO. 111/SEQ ID NO.113, SEQ ID NO.111/SEQ ID NO.114, SEQ ID NO. 111/SEQ ID NO.115, SEQ ID NO. 111/SEQ ID NO.116, SEQ ID NO.111/SEQ ID NO.117, SEQ ID NO. 111/SEQ ID NO.118, SEQ ID NO. 111/SEQ ID NO.119, SEQ ID NO.111/SEQ ID NO.120, SEQ ID NO. 111/SEQ ID NO.121, SEQ ID NO. 111/SEQ ID NO.122, SEQ ID NO.111/SEQ ID NO.123, SEQ ID NO.124/SEQ ID NO.112, SEQ ID NO. 125/SEQ ID NO.112, SEQ ID NO. 126/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.112, SEQ ID NO. 128/SEQ ID NO.112, SEQ ID NO. 129/SEQ ID NO.112, SEQ ID NO.130/SEQ ID NO.112, SEQ ID NO.127/SEQ ID NO.131, SEQ ID NO. 132/SEQ ID NO.133, SEQ ID NO. 132/SEQ ID NO.123, SEQ ID NO.142/SEQ ID NO.123, SEQ ID NO. 127/SEQ ID NO.123, SEQ ID NO. 132/SEQ ID NO.134, SEQ ID NO. 135/SEQ ID NO.133, SEQ ID NO.132/SEQ ID NO.136, SEQ ID NO.132/SEQ ID NO.137, SEQ ID NO. 132/SEQ ID NO.138, SEQ ID NO. 139/SEQ ID NO.123, SEQ ID NO.139/SEQ ID NO.140, SEQ ID NO. 127/SEQ ID NO.141 and combinations thereof.
[0178] In one embodiment, the anti-JAG1 antibodies and antibody fragments of the invention are used to treat Notch-signaling tumors. As discussed above, any tumor or malignant growth with detrimental Notch signaling pathway activity can be treated by the anti-JAG1 antibodies and antibody fragments of the invention. For example, in one embodiment, the tumor is selected from the group consisting of breast, prostate, colorectal, lung and other solid tumors.
[0179] In one embodiment, the anti-JAG1 antibodies and antibody fragments of the invention can be administered alone or in combination with one or more additional therapies such as chemotherapy radiotherapy, immunotherapy, surgical intervention, or any combination of these. Long-term therapy is equally possible as is adjuvant therapy in the context of other treatment strategies, as described above.
[0180] In certain embodiments of such methods, one or more anti-JAG1 antibodies and antibody fragments of the invention can be administered, together (simultaneously) or at different times (sequentially). In addition, anti-JAG1 antibodies and antibody fragments of the invention can be administered with another type of compounds for treating cancer or for inhibiting angiogenesis.
[0181] In certain embodiments, the anti-JAG1 antibodies and antibody fragments of the invention can be used alone.
[0182] In certain embodiments, the anti-JAG1 antibodies and antibody fragments of the invention can be labeled or unlabeled for diagnostic purposes. Typically, diagnostic assays entail detecting the formation of a complex resulting from the binding of a binding polypeptide to JAG1. The anti-JAG1 antibodies and antibody fragments of the invention can be directly labeled, similar to antibodies. A variety of labels can be employed, including, but not limited to, radionuclides, fluorescers, enzymes, enzyme substrates, enzyme cofactors, enzyme inhibitors and ligands (e.g., biotin, haptens). Numerous appropriate immunoassays are known to the skilled artisan (see, for example, U.S. Pat. Nos. 3,817,827; 3,850,752; 3,901,654; and 4,098,876). When unlabeled, the binding polypeptides can be used in assays, such as agglutination assays. Unlabeled binding polypeptides can also be used in combination with another (one or more) suitable reagent which can be used to detect the binding polypeptide, such as a labeled antibody reactive with the binding polypeptide or other suitable reagent (e.g., labeled protein A).
[0183] Techniques and dosages for administration vary depending on the type of specific polypeptide and the specific condition being treated but can be readily determined by the skilled artisan. In general, regulatory agencies require that a protein reagent to be used as a therapeutic is formulated so as to have acceptably low levels of pyrogens. Accordingly, therapeutic formulations will generally be distinguished from other formulations in that they are substantially pyrogen free, or at least contain no more than acceptable levels of pyrogen as determined by the appropriate regulatory agency (e.g., FDA).
[0184] Therapeutic compositions of the present disclosure may be administered with a pharmaceutically acceptable diluent, carrier, or excipient, in unit dosage form. Administration may be parenteral (e.g., intravenous, subcutaneous), oral, or topical, as non-limiting examples. In addition, any gene therapy technique, using nucleic acids encoding the polypeptides of the invention, may be employed, such as naked DNA delivery, recombinant genes and vectors, cell-based delivery, including ex vivo manipulation of patients' cells, and the like.
[0185] A therapeutically effective dose refers to a dose that produces the therapeutic effects for which it is administered. The exact dose will depend on the disorder to be treated, and may be ascertained by one skilled in the art using known techniques. In general, the polypeptide is administered at about 0.01 μg/kg to about 50 mg/kg per day, preferably 0.01 mg/kg to about 30 mg/kg per day, most preferably 0.1 mg/kg to about 20 mg/kg per day. The polypeptide may be given daily (e.g., once, twice, three times, or four times daily) or preferably less frequently (e.g., weekly, every two weeks, every three weeks, monthly, or quarterly). In addition, as is known in the art, adjustments for age as well as the body weight, general health, sex, diet, time of administration, drug interaction, and the severity of the disease may be necessary.
Example 1
[0186] A screen was performed to identify human anti-human JAG1 antibodies. The heavy and light chain variable sequences from the antibodies identified in the screen are provided below in Table 5.
[0187] This example provides an analysis of the cross-reactivity of JAG1 binders to recombinant mouse JAG1. A 96-well plate was coated with 25 μl recombinant mouse JAG1/Fc (2 μg/μL in PBS) at 4° C. overnight. Washed 3 times with PBS-Tween (PBST). Added 5 μl scFv phage soup that diluted in 20 μl Casein in each well and incubated 30 min with shaking. The plate was washed 3 times with PBST, then horseradish peroxidase (HRP)-conjugated M13 (1:2000 in casein) was added, then 3,3′,5,5′-Tetramethylbenzidine (TMB) was added as substrate and developed 30 min 2M H 2 SO 4 was used to stop the reaction and the OD was read at 450 nm. The results showed that more than 80% of the JAG1 binding antibodies can also bind to murine antigen.
[0188] The binding affinity of antibody JG1H7 for human JAG1 was tested using a BiaCore assay. Specifically, anti-human Fc antibody (GE, BR-1008-39) was immobilized on a CM5 sensor chip to approximately 700 RU using standard NHS/EDC coupling methodology. Antibodies (about 10 μg/ml) were captured for 60 s at a flow rate 10 μl/min. Recombinant human JAG1/His was serially diluted in running buffer (HBS-EP). All measurements were conducted with a flow rate of 30 μL/min Surfaces were regenerated with 3M MgCl 2 for 60 s. A 1:1 (Langmuir) binding model was used to fit the data. The results are shown in Table 1, where the K D of antibody JG1H7 was determined to be 2.08×10 −7 M for human JAW.
[0000]
TABLE 1
ka
kd
Rmax
KA
KD
name
(1/Ms)
(1/s)
(RU)
(1/M)
(M)
Chi2
JG1H7
1.97E5
0.0411
85.1
4.8E6
2.08E−7
0.147
Example 2
[0189] This example illustrates in vitro data showing the assessment of anti-JAG-1 antibodies in a cytotoxicity assay using secondary antibody-drug conjugate technique (“Secondary Antibody-Drug Conjugates As Tools for ADC Discovery”. Helen Mao, Poster, IBC 24 th Annual, 2013). This example demonstrates the potential of anti-JAG-1 to be used as antibody drug conjugates.
[0190] JAG-1 expressing cells (Calu-6; lung cancer cells) were harvested with enzyme-free Cell Dissociation Buffer (GIBCO), seeded into white 96-Well Clear Bottom plates (1,000 cells/well in 90 μl) and allowed to adhere overnight at 37° C. Anti-human JAG1 antibodies JG1B10, JG1H7, JG1C8 and JG1H11 were pre-complexed with Protein G-DM1 (DM1; maytansinoid N(2′)-deacetyl-N(2′)-(3-mercapto-1-oxopropyl)-maytansine (DM1)) (Concords Biosystems) in cell culture media, at a 1:4 molar ratio. The same anti-human JAG1 antibodies JG1B10, JG1H7, JG1C8 and JG1H11 were also used as naked antibodies (not complexed) as controls. After 10 min at room temperature, serial dilutions of the antibody-ProteinG-DM1 complex (as well as the un-complexed antibody controls) were prepared in cell culture media, incubated 10 more minutes at room temperature, and added to cells (10 μl/well) in triplicate. After 6 days incubation at 37° C., cells proliferation was analyzed as follows: 100 μl of Cell Titer Glo buffer (Promega) was added to each well. Plates were incubated with shaking at room temperature for 20 min Luminescence signal was then measured on a Flexstation 3 plate reader (Molecular Device). Data were reported as relative Luminescent Units. Dose-response curves were generated in GraphPad prism, and IC 50 values were calculated using non-linear regression fit (Log (inhibitor) vs. response—Variable slope equation).
[0191] The same method was also used with normal human fibroblasts (HFF) to assess the non-specificity of cell killing of anti-JAG-1 antibodies/Protein G-DM1 complexes.
[0192] The results are shown in FIGS. 1A (Calu-6 cancer cells) and 1 B (HFF cells), and Table 2. FIG. 1A shows that that anti-JAG-1 antibodies, especially antibodies JG1B10 and JG1H7, can induce cell killing when complexed with a cytotoxin such as DM-1, with IC 50 values of 1.35 and 3.89 nM respectively (Table 2). These data illustrate the potential of JAG-1 antibodies as antibody-drug conjugates. In FIG. 1B , data shows that very little non-specific cell killing was observed on normal HFF cells which do not overexpress JAG1, suggesting a good selectivity index for future JAG1 ADC.
[0000]
TABLE 2
Protein G-DM1+
JG1-B10
JG1-H7
JG1-C8
JG1-H11
IC50 (nM)
1.35
3.89
87.26
26.51
Example 3
[0193] An ELISA assay was carried out to determine antibody binding to human JAG1. A 96-well ELISA plate was coated overnight with goat anti-human lambda. The next morning the plate was blocked with casein solution for 1 hour, followed by addition of the JG1H7 and JG1B10 IgG antibodies at 0.3 μg/ml. After 1 hour, the plate was washed and serially diluted biotinylated human Jagged 1 (JAG1) was added. As a control, biotinylated JAG1 was added to wells that contained a control IgG. After an hour the plate was washed, labeled neutravidin was added and incubated for 30 minutes. The plate was washed, developed and the absorbance in each well measured by a spectrophotometer. As shown in FIG. 2 , both JG1B10 (i) and JG1H7 (ii) show specific binding to human JAG1. The control antibody used was an IgG1 that does not bind to JAG-1 or JAG-2.
[0194] A similar protocol was used to measure binding of selected JG1H7 variants JG1H7-F2C (i), JG1H7-B6C (ii), JG1H7-C9C(iii), JG1H7-D5C (iv), JG1H7-C6C(v) and JG1H7(vi). These results are shown in FIG. 3 . As shown in FIG. 3 , all of the tested variants bound more JAG1 than the control antibody. The control antibody used was an IgG1 that does not bind to JAG1 or JAG2. In the results shown in FIG. 3 , JG1H7-C4C almost perfectly overlays with JGH7-C9C, which is why it the line is not visible in the graph.
[0195] An ELISA assay was also carried out to determine the ability of the identified antibodies to bind to human JAG2. A 96-well ELISA plate was coated with human JAG2-Fc overnight. The next morning the plate was blocked with casein solution for 1 hour, followed by addition of serially diluted JG1H7 and JG1B10 IgG antibodies. As a control, antibodies were added to wells that were not coated with JAG2-Fc. After incubating for an hour, the plate was washed and labeled goat anti-human F D antibody was added for 30 minutes. The plate was washed, developed with substrate and the absorbance in each well measured on a spectrophotometer. As shown in FIG. 4 , both JG1B10 (i) and JG1H7 (ii) show specific binding to JAG2.
[0196] A similar protocol was used in an ELISA to show binding of JG1H7 variants with JAG-2. These results are shown in FIG. 5 . The control antibody used was an IgG1 that does not bind to JAG1 or JAG2. Similar to the results shown in FIG. 3 , all of the tested variants showed specific binding to JAG2.
[0197] An ELISA assay was also carried out to determine the ability of the identified antibodies to bind to murine JAG2. A high-binding 96-well plate was coated overnight with 1 μg/ml recombinant mouse Jagged-2 Fc Chimera protein (R&D Systems) in PBS. The plate was then blocked with a 1:1 mixture of casein:Super Block for several hours at room temperature. Each IgG was diluted to 10 μg/ml in the blocking solution, serially diluted 3-fold and added to the 96-well plate after washing. After 2 h incubation and washing, anti-human F D -HRP was added and incubated 1 hour. After washing, the plate was developed with TMB and stopped with 2M H 2 SO 4 and the absorbance measured at 450 nm. As shown in FIG. 6 , JG1H7 and the tested variants showed specific binding to murine JAG-2. The control antibody used was an IgG1 that does not bind to JAG1 or JAG2.
[0198] Finally, an ELISA assay was carried out to determine antibody cross-reactivity to delta-like 1 (DLL1) and delta-like 2 (DLL2). One ELISA plate was coated with anti-human lambda and another ELISA plate was coated with anti-human kappa overnight at 4° C. The next morning each plate was blocked with a 1:1 mixture of casein:Super Block for 2 hours at room temperature. The B10 IgG was diluted to 0.3 μg/ml in block and added to the anti-human lambda coated wells, while the JG1H7 IgG was diluted to 0.3 μg/ml in block and added to the anti-human kappa coated wells and incubated at room temperature for 3 hours. As a control, other wells were treated with only block. After washing, serially-diluted biotinylated antigen (JAG1, DLL1, DLL2) was added to a column with captured antibody and a control column with no antibody, and incubated 1 hour at room temperature. After washing, neutravidin-AP was added, incubated for 20 min at room temperature, the plate washed and developed with 1-step PNPP, and the plate analyzed in a plate reader. As shown in FIGS. 7A (JG1H7) and 7 B (B10), while each antibody specifically bound to human JAG-1, little binding was observed to human DLL1 or human DLL2 under these conditions. The control antibody used was an IgG1 that does not bind to JAG1 or JAG2.
Example 4
[0199] This example describes a cellular binding assay to determine the EC 50 for certain anti-JAG1 antibodies binding to K562 cells (ATCC CCL-243), where the concentration at which 50% binding saturation (EC 50 ) is reached. In this example, K562 cells were resuspended in FACS Buffer (2% Fetal Bovine Serum in PBS) at 1×10 6 cells/ml. 50 μl (0.5×10 5 cells) were aliquoted into the wells of a 96-well plate. Plated cells were spun down and the supernatant discarded. Cells were resuspended in serially diluted concentrations of each JAG1 IgG in 30 μl FACS Buffer done in triplicate. The antibodies and cells were incubated for 1 hr at 4° C. and then washed 2× with FACS Buffer. Cells were resuspended in 50 μl goat anti-human IgG (γ-chain specific)-PE-conjugated secondary antibody (Southern Biotech #2040-09) diluted 1:750 in FACS Buffer. Cells were further incubated in the dark for 30 min at 4° C. and then washed 1× with FACS Buffer. The cells were resuspended in a final volume of 30 μl FACS Buffer and analyzed using an Intellicyt Flow Cytometer. Median fluorescence in the FL-2H channel was determined using FlowJo software and EC 50 value was determined by a variable slope non-linear regression using ForeCyte software. Table 3, below, shows the EC 50 of anti-JAG1 antibodies to human JAG1.
[0000]
TABLE 3
Name
EC50 (nM), K562 cells
JG1A7
<1
JG1H7
16
JG1C8
16
JG1H11
27
JG1B10
32
JH-F4
97
Example 5
[0200] Having identified anti-JAG1 antibody JG1H7 as a therapeutic antibody given its high affinity for human JAG1 and neutralization characteristics, variants of the JG1H7 antibody were made.
[0201] Briefly, JG1H7 was used as the parent antibody for further mutation in an effort to further improve affinity characteristics. Briefly, single amino acids within the CDRs (defined by Chothia or Kabat numbering) of JG1H7 were mutated such that each position within each CDR was mutated to all possible 20 amino acids. These variant antibodies were then screened for affinity changes relative to the parent antibody and antibodies that showed improvement in binding by ELISA were sequenced. Mutations that improved binding were included in a combinatorial library, which was then expressed and screened for further improved affinity antibodies. The light and heavy chain variable domain amino acid sequences of JG1H7 variants are described below in Table 4.
[0202] The amino acid sequences of the improved JG1H7 clones are shown below in Table 4.
[0000]
TABLE 4
Heavy Chain variable
Light Chain variable
Clone
domain
domain
JG1H7 3-2
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
(germline
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
changed
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
variant)
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 112
SEQ ID NO: 111
JG1H7-2B2S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCPASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 113
SEQ ID NO: 111
JG1H7-2A3S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASHS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 114
SEQ ID NO: 111
JG1H7-2A7S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASPS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 115
SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
2A10S
AFTVSNFYMTWVRQAPGKGLEWV
TSTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 116
SEQ ID NO: 111
JG1H7-2A2S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
SSTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 117
SEQ ID NO: 111
JG1H7-2A9S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
FSTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO:118
SEQ ID NO: 111
JG1H7-2A1S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
PSTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 119
SEQ ID NO: 111
JG1H7-E11S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISASLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 120
SEQ ID NO: 111
JG1H7-C11S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISTTLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 121
SEQ ID NO: 111
JG1H7-D10S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSQNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 122
SEQ ID NO: 111
JG1H7-2B7S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 123
SEQ ID NO: 111
JG1H7-1A8S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
GFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 112
SEQ ID NO: 124
JG1H7-1A6S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFSMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 112
SEQ ID NO: 125
JG1H7-1A2S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFGMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 112
SEQ ID NO: 126
JG1H7-1B1S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFAMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 112
SEQ ID NO: 127
JG1H7-5A8S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
ALGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 112
SEQ ID NO: 128
JG1H7-5B5S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 112
SEQ ID NO: 129
JG1H7-3E5S
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 112
SEQ ID NO: 130
JG1H7-G6C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFAMTWVRQAPGKGLEWV
ISTTQNWYQQKPGKAPKLLIYAASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 131
SEQ ID NO: 127
JG1H7-A6C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASPS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 133
SEQ ID NO: 132
JG1H7-E11C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 123
SEQ ID NO: 132
JG1H7-C6C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFAMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 123
SEQ ID NO: 142
JG1H7-C9C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFAMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 123
SEQ ID NO: 127
JG1H7-F4C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASPS
AFTVSNFYMTWVRQAPGKGLEWV
ISASLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 134
SEQ ID NO: 132
JG1H7-F2C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASPS
AFTVSNFYMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
ALGYYYALDVWGQGTTVTVSS
SEQ ID NO: 133
SEQ ID NO: 135
JG1H7-F1C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
ISASLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 136
SEQ ID NO: 132
JG1H7-D4C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
TSASLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 137
SEQ ID NO: 132
JG1H7-D5C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFYMTWVRQAPGKGLEWV
PSTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 138
SEQ ID NO: 132
JG1H7-A5C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFAMTWVRQAPGKGLEWV
ISTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 123
SEQ ID NO: 139
JG1H7-B2C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFAMTWVRQAPGKGLEWV
PSASLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
SLGYYYALDVWGQGTTVTVSS
SEQ ID NO: 140
SEQ ID NO: 139
JG1H7-B6C
EVQLVESGGGLIQPGGSLRLSCAAS
DIQMTQSPSSLSASVGDRVTITCRASQS
AFTVSNFAMTWVRQAPGKGLEWV
SSTSLNWYQQKPGKAPKLLIYLASSLQ
SVIDSGGNTYYADSVRGRFTISRDN
SGVPSRFSGSGSGTDFTLTISSLQPEDF
SKNTLFLQMNSLRAEDTAVYYCAR
ATYYCQQSYSTPTFGQGTKLEIK
DLGYYYAMDVWGQGTTVTVSS
SEQ ID NO: 141
SEQ ID NO: 127
[0000]
TABLE 5
Anti-JAG1 Heavy and Light Variable Domain Amino Acid Sequences
Heavy chain variable
Light chain variable
domain sequence
domain sequence
JG1A1
EVQLVESGAEVKKPGASVKVSCK
DVVMTQSPSSLSASVGDRVTITCRASQ
ASGYTFTSYGISWVRQAPGQGLE
GISSWLAWYQQKPGKAPKLLIYDASSL
WMGWISAYNGNTNYAQKLQGRV
QSGVPSRFSGSGSGTDFTLSISSLQPEDF
TMTTDTSTSTAYMELRSLRSDDTA
ATYYCQQANSLPLTFGGGTKVEIK
VYYCARGTGGDGFDYWGQGTLV
SEQ ID NO. 2
TVSS SEQ ID NO. 1
JG1A10
EVQLVQSGAEVKKPGASVRVSCK
QSVLTQPPSVSAAPGQKVTISCSGSSSNI
ASGYNFRNFDINWVRQAPGQGLE
GKYFVSWYQQFPGTAPKLLIYDNDQRP
WMGWMNPSSGLTGFAPKFQGRVT
SGIPDRFSASKSGTSARLDITGLQTGDE
LTRDTSIRTAYMEVSSLRSEDTAV
ADYYCGTWDSSLSAGVFGGGTKLTVL
YYCVRQRSGLDSWGQGTLVTVSS
SEQ ID NO. 4
SEQ ID NO. 3
JG1A12
EVQLVQSGAEVKKPGASVRVSCK
SYELMQPHSVSESPGKTVTISCTGSSGSI
ASGYTFTNYYIHWVRQAPGQGLE
ASNYVQWYQQRPGSAPTTVIYEDNQR
WMGIIIPSGGSTNYPPKFQGRVTLT
PSGVPDRFSGSIDSSSNSASLTISGLKTE
RDTSTSTVYMELSSLRSEDTAVYY
DEADYYCQSYDSSIVVFGGGTKLTVL
CVREYQGGHFDYWGQGTLVTVSS
SEQ ID NO. 6
SEQ ID NO. 5
JG1A3
EVQLVESGGGLVKPGGSLRLSCAA
DIQLTQSPSSLSASVGDRVTITCRATQGI
SGFTFNDYYMSWIRQAPGKGLEW
GNYLAWYQQKPGKVPNLLIYAATTLQ
VSYISRSGSTMYYADSVKGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDV
DNAKNSLYLQMNSLRDEDTAVYY
ASYYCQKYNSAPLTFGGGTKVEIK
CATSVGHLEQWGQGTLVTVSS
SEQ ID NO. 8
SEQ ID NO. 7
JG1A4
QVQLVESGGVVVQPGGSLRLSCA
QAVLTQPASVSESPGQSITISCTGSSSDI
ASGFTFDDYTMHWVRQAPGKGLE
GGYNYVSWYQQHPGKAPKLIIYEVTK
WVSLISWDGGSTYYADSVKGRFTI
RPSGVPDRFSGSKSGNTASLTVSGLQA
SRDNSKNSLHLQMNSLRTEDTALY
EDEADYYCSSYVGSNDVYVFGTGTKL
YCAKDIDEYSSSTGPDYWGQGTLV
TVL SEQ ID NO. 10
TVSS SEQ ID NO. 9
JG1A5
QVQLVQSGAEVQKPGASVKVSCK
QAGLTQPPSASGTPGQRVTISCSGSSSNI
VSGYTLSELSIHWVRQAPGKGLEW
GSNTVNWYQRLPGTAPKLVVYSNNQR
MGGFDPEDGKIVYAQKFQDRVSM
PSGVPDRFSGSKSGTSASLVISGLQSED
TQDTSTDTAYLQLSSLTSGDTALY
EADYYCAAWDYDEEGLLFGGGTQLTV
YCATLAQWGDWFDRWGQGTLVT
L SEQ ID NO. 12
VSS SEQ ID NO. 11
JG1A6
QVQLVQSGAEVKKPGASVKVSCK
QSVLTQPPSVSVAPGKTARITCGGNNIG
ASGNTFTSYYMHWVRQAPGQGLE
SKSVHWYQQKPGQAPVLVIYYDSDRP
WMGIISPSGDSTSYAQKFQGRVTM
SGIPERFSGSNSGNTATLTISRVEAGDE
TKDTSTSTVSMELSSLRSEDTAVY
ADYYCQVWDSSSDHVVFGGGTKLTVL
YCARDQEGLRGSGYYGMDVWGQ
SEQ ID NO. 14
GTTVTVSS SEQ ID NO. 13
JG1A7
QVQLVESGGGLVKPGGSLRLSCAA
QSALTQPPSVSGAPGQTVTISCTGSRSN
SGFTFSDYYMSWIRQAPGKGLEW
IGTYDVHWYQQFAGSAPKLLIYHNND
VSYISSSGSTIYYADSVKGRFTISRD
RSSGVPDRFSGSKSGTSASLAITGLQAE
NAKNSLYLQMNSLRAEDTAVYYC
DEAVYFCQSHDNVLGGVFGGGTKLTV
ARVNSGYDAVDYWGQGTLVTVSS
L SEQ ID NO. 16
SEQ ID NO. 15
JG1B1
EVQLVQSGAEVKKPGSSVKVSCK
QSVVTQPPSVSGAPGQRITISCTGSSSNI
ASGDTFSSYGISWVRQAPGQGLEW
GAGYDVQWYLQFPGTAPKLLIHGSSN
VGRINSLLDRPDYAQNFQDRVTIT
RPSGVPARFQGSKSGTSASLVITGLQAE
ADKSTSTAYMELNTLGPEDTAMY
DEADFYCQSFDSSLNGYVFGGGTKLTV
YCATEHYYESSEDPFFDFVVGQGTL
L SEQ ID NO. 18
VTVSS SEQ ID NO. 17
JG1B10
EVQLVESGGGLVQPGGSLRLSCAA
LPVLTQPASVSGSPGQSITISCTGTSSDV
SGSTFSSYGMHWVRQAPGKGLEW
GGYNYVSWYQQHPGKAPKLMIYDVS
VAVIWYDGSNKYYADSVKGRFTIS
NRPSGVSNRFSGSKSGNTASLTISGLQA
RDNSKNTLYLQMNSLRAEDTAVY
EDEADYYCSSYTSSSTYVFGIGTKLTVL
YCARGYNHDYWGQGTLVTVSS
SEQ ID NO. 20
SEQ ID NO. 19
JG1B11
EVQLVQSGAEVKKPGASVKVSCK
QAGLTQPHSVSESPGKTVTISCTRSSGSI
ASGYTFTSYGISWVRQAPGQGLE
ASNYVQWYQQRPGSAPTTVIYEDNQR
WMGWISAYNGNTNYAQKLQGRV
PSGVPDRFSGSIDSSSNSASLTISGLKTE
TMTTDTSTSTAYMELRSLRSDDTA
DEADYYCQSYDSSNHLVVFGGGTKLT
VYYCARDPYSSSWYGAEYFQHWG
VL SEQ ID NO. 22
QGTLVTVSS SEQ ID NO. 21
JG1B2
EVQLLESGGGVVQPGRPLRLSCAG
QPVLTQPPSASGSPGQSVTISCTGTSSD
SGFAFSGFAMHWVRQAPGKGLEW
VGGYNYVSWYQQHPGKAPKLMIYDV
LAVISYDGRNNNYADSVKGRFTIS
SNRPSGVSNRFSGSKSGNTASLTISGLQ
RDNSKNTLFLDMDSLRPDDTALY
AEDEADYYCSSYTSSSTYVFGTGTKLT
YCARDRSSGWYGLSDYWGQGTL
VL SEQ ID NO. 24
VTVSS SEQ ID NO. 23
JG1B4
QVQLVQSGSELKKPGASVRVSCK
QLVLTQSHSVSESPGKTVTISCTGSSGSI
ASGYTFTNYYIHWVRQAPGQGLE
ASNYVQWYQQRPGSAPTTVIYEDDLRP
WMGIIIPSGGSTNYPPKFQGRVTLT
SGVPDRFSGSIDSSSNSASLTISGLKTED
RDTSTSTVYMELSSLRSEDTAVYY
EADYYCQSYDRYNVVFGGGTKLTVL
CVREYQGGHFDYWGQGTLVTVSS
SEQ ID NO. 26
SEQ ID NO. 25
JG1B5
QVQLVQSGAEVKKPGASVKVSCK
SYVLTQPPSVSVAPGKTARITCGGNNIG
ASGNTFTSYYIHWVRQAPGQGLE
SKSVHWYQQKPGQAPVLVIYYDSDRP
WMGIISPSGDSTSYAQKFQGRVTM
SGIPERFSGSNSGNTATLTISRVEAGDE
TKDTSTSTVSMELSSLRSEDTAVY
ADYYCQVWDSSSDHVVFGGGTKLTVL
YCARDQEGLRGSGYYGMDVWGQ
SEQ ID NO. 28
GTTVTVSS SEQ ID NO. 27
JG1B6
EVQLVESGGGVVQPGRSLRLSCAA
SSELTQDPAVSVALGQTLTITCQGDSLR
SGFPFSSYAMHWVRQAPGKGLEW
SYYASWYQQKPGQAPLLVFYGYNSRP
VAVISYDGSNKYYADSVKGRFTIS
SEIPDRFSGSFTGDTASLTITGAQAEDE
RDNSKNTLYLQMNSLRPEDTAVY
ADYYCSSMSGDLVVXGGGTKVTVL
YCARDLPACSGGSCYATWGGFDY
SEQ ID NO. 30
WGQGTLVTVSS SEQ ID NO. 29
JG1B8
QMQLVQSGAEVKKPGSSVKVSCK
DIVMTQSPSSLSASVGDRVTITCRASQG
ASGATFSSYAMSWVRQAPGQGLE
ITNSLAWYQQKPGKVPKLLIYAASTLQ
WMGAVIPIFGTTNYAPKFEGRVTIT
SGVPSRFSGSGSGTDFTLTISSLQPEDV
ADESTSTVYMELSSLTSEDTAVYY
ASYYCQKYDSAPLTFGGGTKVEIK
CARQIGEVVGGIMEDYWGQGTLV
SEQ ID NO. 32
TVSS SEQ ID NO. 31
JG1C3
QMQLVQSGAEVKKPGASVKVSCK
SYELMQPPSVSVAPGKTARITCGGNNI
ASGNTFTSYYMHWVRQAPGQGLE
GSKSVHWYQQKPGQAPVLVIYYDSDR
WMGIISPSGDSTSYAQKFQGRVTM
PSGIPERFSGSNSGNTATLTISRVEAGDE
TKDTSTSTVSMELSSLRSEDTAVY
ADYYCQVWDSSSDHVVFGGGTKLTVL
YCARDQEGLRGSGYYGMDVWGQ
SEQ ID NO. 34
GTTVTVSS SEQ ID NO. 33
JG1C4
QMQLVQSGADVKKPGASVKVSCK
SYELMQPPSVSVASGKTARITCGGNNI
ASGNTFTSYYMHWVRQAPGQGLE
GSKSVHWYQQKPGQAPVLVVYDDSD
WMGIISPSGDSTSYAQKFQGRVTM
RPSGIPERFSGSNSGNTATLTISRVEAG
TKDTSTSTVSMELSSLRSEDTAVY
DEADYYCQVWDSSSDHVVFGGGTKLT
YCARDQEGLRGSGYYGMDVWGQ
VL SEQ ID NO. 36
GTMVTVSS SEQ ID NO. 35
JG1C5
EVQLLESGGGLIQPGGSLRLSCAAS
QAVVTQPPSASGTPGQRVTISCSGSSSN
GFTVSSNYMTWVRQAPGKGLEW
IGSNPVSWYQQLPGTAPKLLIYSNNQR
VSVIYSGGNTFYADSVKGRFTISRD
PSGVPDRFSGSKSGTSASLAISGLQSED
NAKNSLYLQMNSLRAEDTAVYYC
EADYYCAAWDDSLNGDVIFGGGTKLT
AREMSGPYFDYWGQGTLVTVSS
VL SEQ ID NO. 38
SEQ ID NO. 37
JG1C8
EVQLVQSGAEVKKPGSSVKVSCK
NFMLTQPRSVSGSPGQSVTISCTGTSSD
ASGGTFSSYAISWVRQAPGQGLEW
VGGYHYVSWYQQHPGKAPKLIIYDVS
MGWISAYNGNTNYAQKLQGRVT
RRPSGVPDRFSGSKSGNTASLTVSGLQ
MTTDTSTSTAYMELRSLRSDDTAV
AEDEADYYCSSYGGSNNFVFGTGTKLT
YYCARSRYDFWSGYYSGMDVWG
VL SEQ ID NO. 40
QGTTVTVSS SEQ ID NO. 39
JG1D1
QVQLVESGGGVVQPGRPLRLSCA
QAGLTQPASVSGSPGQSITISCTGTSSD
GSGFAFSGFAMHWVRQAPGKGLE
VGRYDYVSWYQQHPGKAPKLMIYDVT
WLAVISYDGRNNNYADSVKGRFTI
KRPSGVSNRFSGSKSGNTASLTISGLQA
SRDNSKNTLFLDMDSLRPDDTALY
EDEADYYCISYTTSSTYVFGTGTKVTV
YCARDRSSGWYGLSDYWGQGTL
L SEQ ID NO. 42
VTVSS SEQ ID NO. 41
JG1D10
QVQLVQSGAEVKKPGASVKVSCK
EIVMTQSPATLSVSPGERATLSCRASQS
ASGYTFTSYNIHWVRQAPGQRFE
VRSNLAWYQQKPGQAPRLLIYGASTR
WMGWISTDNGYTEYSQKFQDRVT
ATGIPDRFSGSGSGTEFTLTISSLQSEDF
ITRDTSASTAYMELSSLRSEDTADY
AVYSCQQYENWPTFGQGTKVEIK
YCLSGYYFDYWGQGTLVTVSS
SEQ ID NO. 44
SEQ ID NO. 43
JG1D11
EVQLVESGAEVKKPGASVKVSCK
AIQLTQSPSSLSASVGDRVTISCQASQDI
ASGYTFTNYYMHWVRQAPGQGLE
SNFLNWYQQKPGKAPKLLIYAASKLQS
WMGIINPSSGSTTYAQKFQGRVTM
GVPSRFSGSGSGTDFSLTINSLQPEDFA
TRDTSTSTVYMELSSLRSEDRAVY
TYYCQQTNSFPLTFGQGTKVEIK
YCARGQGSSGWYTFDYWGQGTL
SEQ ID NO. 46
VTVSS SEQ ID NO. 45
JG1D7
QVQLVQSGAEVKKPGASVKVSCK
SYELMQPPSVSVAPGQTARITCGGKNI
ASGYTFTSYYMHWVRQAPGQGLE
GRKSVHWYQQKPGQAPVLVVYDDRD
WMGIINPSGGSTSYAQKFQGRVTM
RPSGIPERFSGSNSGNTATLTISRVEAG
TRDTSTSTVYMELSSLRSEDTAVY
DEADYYCQVWDSSTDHVVFGGGTKVT
YCARDVGGEGVVDYWGQGTLVT
VL SEQ ID NO. 48
VSS SEQ ID NO. 47
JG1D8
QVQLVQSGAEVKKPGATVKISCK
DIQMTQSPSSLSASVGDRVTITCQASQD
VSGYTFTDYYMHWVRQAPGQGLE
ISNYLNWYQQKPGKAPKLLIYDASNLE
WVGIINPNGDKAQYTQKLKGRVT
TGVPSRFSGSGSGTDFTFTISSLQPEDIA
MTRDTSTNTVYMELSSLTSEDTAV
TYYCQQYTTFGQGTRLEIK
YYCTTDHNWRFDSWGQGTLVTVS
SEQ ID NO. 50
S SEQ ID NO. 49
JG1E1
EVQLVQSGAEVKKPGASVKVSCK
SYELMQPPSVSVAPGKTARITCGGNNI
ASGNTFTSYYMHWVRQAPGQGLE
GSKSVHWYQQKPGQAPVLVVYDDSD
WMGIISPSGDSTSYAQKFQGRVTM
RPSRIPERFSGSNSGNTATLTISRVEAGD
TKDTSTSTVSMELSSLRSEDTAVY
EADYYCQVWDSSSDHVVFGGGTKLTV
YCARDQEGLRGSGYYGMDVWGQ
L SEQ ID NO. 52
GTMVTVSS SEQ ID NO. 51
JG1E11
QVQLVESGAEVKKPGASVKVSCK
DIVMTQSPSSLSASVGDRVTITCRASQS
ASGYTFTSYGISWVRQAPGQGLE
ISRSLNWYQKKPGKAPNLLIYGASSLQ
WMGWISAYNGNTNYAQKLQGRV
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
TMTTDTSTSTAYMELRSLRSDDTA
TYYCQQSYTMPISFGPGTKVDIK
VYYCARTNSDYYDSSGYTNAFDI
SEQ ID NO. 54
WGQGTMVTVSS SEQ ID NO. 53
JG1E7
QVQLVQSGAEVKKPGSSVKVSCK
QAGLTQPPSVSGAPGQRVSISCTGSDSN
ASGGTFSSYAISWVRQAPGQGLEW
IGAPYDVHWYQQLPGTAPRLLIYANTK
MGGIIPIFGTANYAQKFQGRVTITA
RPSGVPDRFSGWKSGTSASLAISGLQSE
DESTSTAYMELSSLRSEDTAVYYC
DEAAYYCAAWDDRLNAYIFGSGTKLT
AGYSGSYFGKFDYWGQGTLVTVS
VL SEQ ID NO. 56
S SEQ ID NO. 55
JG1E8
QVQLVQSGAEVKKPGASVKVSCK
QPVLTQPPSASGTPGQRVTISCSGSSSNI
ASGYTFTSYYMHWVRQAPGQGLE
GTNYVNWYQQFPGTAPKQLIYSNNHR
WMGIINPSGGSTSYAQKFQGRVTM
PSGVPDRFSGSKSGTSASLAISGLRSED
TRDTSTSTVYMELSSLRSEDTAVY
EADYYCAAWDDSLSGWVFGVGTKLT
YCARGGDSSGDYYYGMDVWGQG
VL SEQ ID NO. 58
TTVTVSS SEQ ID NO. 57
JG1F1
EVQLVQSGAEVKKPGASVKVSCK
QTVVTQPPSVSAAPGQKVTISCSGSSSN
ASGYTFTSYYMHWVRQAPGQGLE
IGNNYVSWYQQLPGTAPKLLIYDNNKR
WMGIINPSGGSTSYAQKFQGRVTM
PSGIPDRFSGSKSGTSATLGITGLQTGD
TRDTSTSTVYMELSSLRSEDTAVY
EADYYCGTWDNSLSAGVFGGGTKLTV
YCARGYYDSSGYGVGFDYWGQG
L SEQ ID NO. 60
TLVTVSS SEQ ID NO. 59
JG1F10
EVQLVQSGVEVKKPGATVKISCKV
QSVLTQPPSVSGAPGQRVTISCTGSSSNI
SGYTFTDYYMHWVRQAPGQGLE
GAGYDVHWYQQLPGTAPKLLIYDNNK
WMGIINPSGGSTSYAQKFQGRVTM
RPSGIPDRFSGSKSGTSATLGITGLQTG
TRDTSTSTVYMELSSLRSEDTAVY
DEADYYCGSWDASLSAAVFGGGTKLT
YCARDRVDSSAWSPGADYWGQG
VL SEQ ID NO. 62
TLVTVSS SEQ ID NO. 61
JG1F7
EVQLVQSGGEVKKPGASVKVSCK
SYELMQPPSVSVAPGKTARITCGGNNI
ASGNTFTSYYMHWVRQAPGQGLE
GSKSVHWYQQKPGQAPVLVIYYDSDR
WMGIISPSGDSTSYAQKFQGRVTM
PSGIPERFSGSNSGNTATLTISRVEAGDE
TKDTSTSTVSMELSSLRSEDTAVY
ADYYCQVWDSSSDHVVFGGGTQLTVL
YCARDQEGLRGSGYYGMDVWGQ
SEQ ID NO. 64
GTTVTVSS SEQ ID NO. 63
JG1F8
QITLKESGGGVVQPGRSLRLSCAA
QSVLTQPPSVSAAPGQKVTISCSGSSSNI
SGFTFSTYGMHWVRQAPGKGLEW
GNNYVSWYQQLPGTAPKLLIYDNNKR
VAVILNDGSQSHYADSLKGRFTISR
PSGIPDRFSGSKSGTSATLGITGLQTGD
DNSRNTLYLQMDSLRVEDTAMYY
EADYYCGTWDSSLSAWVFGGGTKLTV
CARDDDRAANAFDVWGQGTMVT
L SEQ ID NO. 66
VSS SEQ ID NO. 65
JG1G11
EVQLVQSGGEVKKPGASVKVSCK
SYELMQPPSVSVAPGKTARITCGGNNI
ASGNTFTSYYMHWVRQAPGQGLE
GSKSVHWYQQKPGQAPVLVIYYDSDR
WMGIISPSGDSTSYAQKFQGRVTM
PSGIPERFSGSNSGNTATLTISRVEAGDE
TKDTSTSTVSMELSSLRSEDTAVY
ADYYCQVWDSSSDHVVFGGGTQLTVL
YCARDQEGLRGSGYYGMDVWGQ
SEQ ID NO. 68
GTTVTVSS SEQ ID NO. 67
JG1G5
EVQLVESGAEVKKPGASVKVSCK
QPVLTQPASVSGSPGQSITISCTGTSSDV
ASGYTFTNYYLHWVRQAPGQGLE
GGYNYVSWYQQYPGKAPKLLIYDVNK
WVGLLNPSGGSTNYAQKFQGRVT
RPSGVSIRFSASKSGNAASLTLSGLQAE
MTTDTSTSTAYMELRSLRSDDTAV
DEADYYCSSYSSRRGVVFGGGTKLTVL
YYCARSPDDYYYGSGNYDYWGQ
SEQ ID NO. 70
GTLVTVSS SEQ ID NO. 69
JG1H1
EVQLVQSGAEVKKPGASVKVSCK
QPVLTQPASVSGSPGQSITISCTGINSNV
ASGYTFTSYYMHWVRQAPGQGLE
DGSDAVSWYQQHPGKAPKLIAFDVTQ
WMGIINPSGGSTSYAQKFQGRVTM
RPSGVPDRFSASKSGKTASLTISGLQPE
TRDTSTSTVYMELSSLRSEDTAVY
DEADYYCSSYTTSSTFVFGTGTKVTVL
YCARDRYSSSAAGYGMDVWGQG
SEQ ID NO. 72
TTVTVSS SEQ ID NO. 71
JG1H11
EVQLVESGGGVVQPGRSLRLSCAA
QPVLTQPASVSGSPGQSITISCTGTRSD
SGFTFSSYGMHWVRQAPGKGLEW
VGGYSYVSWYQQHPGKAPKLIYDVTK
VAVISYDGSNKYYADSVKGRFTIS
RPSGVSNRFSGSKSGNTASLTISGLQAE
RDNSKNTLYLQMNSLRAEDTAVY
DEADYYCSSYTSSSTYVFGTGTKVTVL
YCAKDDWNYALDYWGQGTLVTV
SEQ ID NO. 74
SS SEQ ID NO. 73
JG1H5
QVQLVESGGGLVQPGGSLRLSCAA
QSVLTQPPSASGSPGQSLAISCTGTSSD
SGFTFSSYAMSWVRQAPGKGLEW
VGGYNYVSWYQHHPGKAPKLIIYDVN
VSAISGSGGSTYYADSVKGRFTISR
KRPSGVPDRFSGSKSGNTASLTISGLQA
DNSKNTLYLQMNSLRAEDTAVYY
EDEADYFCSSYAVNNNSPYFFGTGTKV
CAKEDLAMRRGYSYGYPGYWGQ
TVL SEQ ID NO. 76
GTLVTVSS SEQ ID NO. 75
JG1H7
QVQLVQSGGGLIQPGGSLRLSCAA
DIVMTQSPSSLSASVGDRVTITCRASQS
SAFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO. 78
SS SEQ ID NO. 77
JH1A1
EVQLVQSGAEVKKPGASVKVSCK
QAGLTQPASVSGSPGQSITMSCIVSNIDI
ASGYTFTSYGISWVRQAPGQGLE
GGFHYVSWYQHRPGEAPKLLIYDVDK
WMGWISAYNGNTNYAQKLQGRV
RPPGVSNRFSASKSGHTASLTISGLHPE
TMTTDTSTSTAYMELRSLRSDDTA
DDAEYYCSSFTSRSVLFGGGTKVTVL
VYYCARDLAYSSGWLDYWGQGT
SEQ ID NO. 80
LVTVSS SEQ ID NO. 79
JH1A11
QVQLVQSGAEVKKPGASVKVSCK
QSVLTQPASVSGSPGQSITISCTETSSDV
ASGYTFTNYDISWVRQAPGQGLE
GTYNYVSWYQQHPGKAPQLIIFDVSNR
WMGWISTYNGDTIYAQKLQDRVT
PSGVSTRFSGSKSGNTASLTISGLQTED
MTTDTSTSTAYMEVRSLRSDDTAV
EADYYCSSYIATYTPLYVFGTGTKLTV
YYCARGNDLDYWGQGTLVTVSS
L SEQ ID NO. 82
SEQ ID NO. 81
JH1A2
EVQLVESGAEVKKPGASVKVSCK
SYELMQPPSVSVAPGKTAKITCGGDNI
ASGYTFTNYYMHWVRQAPGQGLE
GIKSVHWYQQKPGQAPILVIHHDRGRP
WMGIINPSDGNTSYAQKFQGRVT
SGIPERLSGSNSGNTATLTISRVEAGDE
MTKDTSTSTVYMELSSLRSDDTAV
ADYYCQVWDGTSDHVVFGGGTKLTV
YYCARESSSWETYFDYWGQGTLV
L SEQ ID NO. 84
TVSS SEQ ID NO. 83
JH1A4
QVQLVQSGAEVKKPGASVKVSCK
SSELTQDPAVSVALGQTVRITCQGDSL
ASGYTFTGYYMHWVRQAPGQGLE
RSYYASWYQQKPGQAPVLVIYGKNNR
WMGWINPNSGGTNYAQKFQGRV
PSGIPDRFSGSSSGNTASLTITGAQAEDE
TITADESTSTAYMELSSLRSEDTAV
ADYYCNSRDSSGNHPLVFGTGTKLTVL
YYCAREGPEYCSGGSCYSADAFDI
SEQ ID NO. 86
WGQGTMVTVSS SEQ ID NO. 85
JH1B1
EVQLVQSGAEVRKPGASVKVSCK
QAGLTQPPSVSGAPGQRVTISCSGSTSN
PSGYIFSSRYMHWVRQAPGQGLE
IGSNIVNWYQQLPGTAPKLLIFNNHHRP
WMGIVNPSGGSTKYAQKFQGRIT
SGVPDRFSGSKSGTSASLAISGLQSEDE
MTRDTSTRTFYMELNSLRSEDTAV
ADYYCAAWDDSQNAYVFGTGTKVTV
YYCARHTGNHGGWYMDGFDMW
L SEQ ID NO. 88
GQGTMVTVSS SEQ ID NO. 87
JH1B3
EVQLVQSGAEVKKPGASVKVSCK
NFMLTQPPSVSAAPGQRVTISCSGRSTN
ASGYTFTGYYMHWVRQAPGQGLE
IGKNDVSWYQQFPGAAPKLLIYDNNKR
WMGWINPNSGGTNYAQKFQGRV
PSGIPDRFSGSKSGTSATLGITGLQTGD
TMTRDTSISTAYMELSRLRSDDTA
EADYYCGTWDNGLGVVLFGGGTKLTV
VYYCAREEEGGRLGFDYWGQGTL
L SEQ ID NO. 90
VTVSS SEQ ID NO. 89
JH1B7
EVQLVQSGAEVKKPGASVKVSCK
QPVLTQPASVSGSPGQSITISCTGTSSDV
ASGYTFTSYGISWVRQAPGQGLE
GGYNYVSWYQQHPDKAPKLIIYDVSK
WMGWISAYNGNTNYAQKLQGRV
RPSGVSTRFSGSKSAYTASLTISGLRAE
TMTTDTSTSTAYMELRSLRSDDTA
DEADYYCSSFTNDSPVVFGGGTQLTVL
VYYCARDLAYSSGWLDYWGQGT
SEQ ID NO. 92
LVTVSS SEQ ID NO. 91
JH1C10
EVQLVESGAEVKKPGASVKVSCK
QSVVTQPPSVSAAPGQKVTISCSGSSSN
ASGYTFTGYYIHWVRQAPGQGLE
IGNNYVSWYQQVPGTAPKLLIYDNNER
WMGVINPSGGSTTYAEKFQGRITM
PSGIPDRFSGSKSGTSATLGITGLQTGD
TRDTSTKMLFMELSSLRSDDTAVY
EADYYCGTWDSSLSAGVFGGGTKLTV
YCARSPGAALFDYWGQGTLVTVS
L SEQ ID NO. 94
S SEQ ID NO. 93
JH1C2
QVQLVESGGGLVKPGGSLRLSCAA
QSVLTQPRSVSGSPGQSVTISCTGTSSD
SGFTFIDYSMHWVRQAPGKGLEW
VGGYNYVSWYQQHPGKAPKLMIYDV
VSSISSSSSYIYYADSVKGRFTISRD
SKRPSGVPDRFSGSKSGNTASLTVSGL
NAKNSLYLQMNSLRAEDTAVYYC
QAEDEADYYCSSYAGSNNLVFGGGTK
ARDGLYDSSVRDAFDIWGQGTMV
VTVL SEQ ID NO. 96
TVSS SEQ ID NO. 95
JH1D7
EVQLVESGAEVKKPGASVKVSCK
SYELMQPPSVSVAPGKTARITCGGNNI
ASGYTFTNYYMHWVRQAPGQGLE
GSKSVHWYQQKPGQAPVLVVYDDSD
WMGIINPSDGNTSYAQKFQGRVT
RPSGIPERFSGSNSGNTATLTISRVEAG
MTKDTSTSTVYMELSSLRSDDTAV
DEADYYCQVWDSSSDHVVFGGGTKLT
YYCARESSSWETYFDYWGQGTLV
VL SEQ ID NO. 98
TVSS SEQ ID NO. 97
JH1E11
QVQLVQSGGGLVQSGGSLRLSCA
VIWMTQSPSSLSASVGDRVTITCQATQ
ASGFSFRSHWMHWVRQAPGKGLE
DINNNLNWYQHRPGEAPTLLIYGASTL
WVASISPDGTDKYYVESLQGRFTIS
QSGVPSRFSGSGFGTDFTLTISSLQPED
RDNAKNSLYLQMNSLRAEDTAVY
VATYYCQKYDDDPLTFGGGTKVEIK
YCARDQVEQRGVYDMDVWGQGT
SEQ ID NO. 100
TVTVSS SEQ ID NO. 99
JH1F3
QVQLVQSGAEVKKPGASVKVSCQ
DVVMTQSPSTLSASVGDRVTITCRASQ
ASGYTFTSYDIHWVRQVPGQRLE
RISSWLAWYQQKPGKAPKSLIYAASSL
WMGIINPSGGSTSYAQKFQGRVTM
QSGVPSKFSGGGSGTDFTLTISSLQPED
TRDTSTSTVYMELSSLRSEDTAVY
FATYYCQQYIYYPPTFGQGTRLEIK
YCARDGYSYGPSDYWGQGTLVTV
SEQ ID NO. 102
SS SEQ ID NO. 101
JH1F4
QVQLVQSGAEVKKPGASVKVSCK
QPVLTQPPSASGTPGQRVTISCSGSSSNI
ASGYTFTSYAMHWVRHAPGQRLE
GSNIVNWYQQLPGTAPKWYSNNRRP
WMGWINAGNGNTKYSQKFQGRV
SGVPDRFSGSKSGSSASLAISGLQSEDE
TITRDTSASTAYMELSSLRSEDTAV
ADYYCAAWDATLGGLYVFGTGTKVT
YYCARDLDYYYGMDVWGQGTTV
VL SEQ ID NO. 104
TVSS SEQ ID NO. 103
JH1F6
EVQLVQSGAEVKKPGASVKVSCK
QPVLTQPPSVSVAPGKTARITCGGNNIG
ASGYTFTSYYMHWVRQAPGQGLE
SKSVHWYQQKPGQAPVLVIYYDTDRP
WMGIINPSDGNTSYAQKFQGRVT
SGIPERFSGSNSGNTATLTISRVEAGDE
MTKDTSTSTVYMELSSLRSEDTAV
ADFYCQVWDSSSDHVVFGGGTKLTVL
YYCARESSSWETYFDYWGQGTLV
SEQ ID NO. 106
TVSS SEQ ID NO. 105
JH1H2
EVQLVESGGGLVKPGGSLRLSCAA
QSALTQPPSVSAAPGQKVTISCSGSSSNI
SGFTFSDYYMSWIRQAPGKGLEW
ANNYVSWYQQLPGTAPKLLIYDNNKR
VSYISSSSSYTNYADSVKGRFTISR
PSGIPDRFSGSKSGTSATLGITGLQTGD
DNAKNSLYLQMNSLRAEDTAVYY
EADYYCGTWDGSLSAGVFGGGTKLTV
CAKHSSSWYGDLDYWGQGTLVT
L SEQ ID NO. 108
VSS SEQ ID NO. 107
JH1H7
QMQLVQSGAEVKKPGSSVKVSCK
DIVMTQSPSSLSPSIGDRVTITCRASQGI
ASGATFSSYAMSWVRQAPGQGLE
SSALAWYQQKPGKAPKLLIYHASTLQS
WMGAVIPIFGTTNYAPKFEGRVTIT
GVPSRFSGSGSGTDFTLTISSLQPEDVA
ADESTSTVYMELSSLTSEDTAVYY
TYYCQKYNSAPLTFGGGTKVEIK
CARQIGEVVGGIMEDYWGQGTLV
SEQ ID NO. 110
TVSS SEQ ID NO. 109
JG1H7
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
3-2
SAFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 112
SS
SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCPASQSI
2B2S
SAFTVSNFYMTWVRQAPGKGLEW
STSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 113
SS
SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASHS
2A3S
SAFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 114
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASPSI
2A7S
SAFTVSNFYMTWVRQAPGKGLEW
STSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 115
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
2A10S
SAFTVSNFYMTWVRQAPGKGLEW
TSTSLNWYQQKPGKAPKLLIYAASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 116
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
2A2S
SAFTVSNFYMTWVRQAPGKGLEW
SSTSLNWYQQKPGKAPKLLIYAASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 117
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
2A9S
SAFTVSNFYMTWVRQAPGKGLEW
FSTSLNWYQQKPGKAPKLLIYAASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 118
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
2A1S
SAFTVSNFYMTWVRQAPGKGLEW
PSTSLNWYQQKPGKAPKLLIYAASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 119
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
E11S
SAFTVSNFYMTWVRQAPGKGLEW
ISASLNWYQQKPGKAPKLLIYAASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 120
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
C11S
SAFTVSNFYMTWVRQAPGKGLEW
ISTTLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 121
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
D10S
SAFTVSNFYMTWVRQAPGKGLEW
ISTSQNWYQQKPGKAPKLLIYAASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 122
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
2B7S
SAFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 123
SS SEQ ID NO: 111
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
1A8S
SGFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 112
SS
SEQ ID NO: 124
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
1A6S
SAFTVSNFSMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 112
SS
SEQ ID NO: 125
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
1A2S
SAFTVSNFGMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 112
SS
SEQ ID NO: 126
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
IBIS
SAFTVSNFAMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 112
SS
SEQ ID NO: 127
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
5A8S
SAFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARALGYYYAMDVWGQGTTVTV
SEQ ID NO: 112
SS
SEQ ID NO: 128
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
5B5S
SAFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARSLGYYYAMDVWGQGTTVTV
SEQ ID NO: 112
SS
SEQ ID NO: 129
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
3E5S
SAFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYAASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYALDVWGQGTTVTVS
SEQ ID NO: 112
S
SEQ ID NO: 130
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
G6C
SAFTVSNFAMTWVRQAPGKGLEW
ISTTQNWYQQKPGKAPKLLIYAASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 131
SS
SEQ ID NO: 127
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASPSI
A6C
SAFTVSNFYMTWVRQAPGKGLEW
STSLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARSLGYYYALDVWGQGTTVTVS
SEQ ID NO: 133
S
SEQ ID NO: 132
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
E11C
SAFTVSNFYMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARSLGYYYALDVWGQGTTVTVS
SEQ ID NO: 123
S
SEQ ID NO: 132
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
C6C
SAFTVSNFAMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYALDVWGQGTTVTVS
SEQ ID NO: 123
S
SEQ ID NO: 142
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
C9C
SAFTVSNFAMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 123
SS
SEQ ID NO: 127
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASPSI
F4C
SAFTVSNFYMTWVRQAPGKGLEW
SASLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARSLGYYYALDVWGQGTTVTVS
SEQ ID NO: 134
S
SEQ ID NO: 132
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASPSI
F2C
SAFTVSNFYMTWVRQAPGKGLEW
STSLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARALGYYYALDVWGQGTTVTVS
SEQ ID NO: 133
S SEQ ID NO: 135
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
F1C
SAFTVSNFYMTWVRQAPGKGLEW
ISASLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARSLGYYYALDVWGQGTTVTVS
SEQ ID NO: 136
S
SEQ ID NO: 132
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
D4C
SAFTVSNFYMTWVRQAPGKGLEW
TSASLNWYQQKPGKAPKLLIYLASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARSLGYYYALDVWGQGTTVTVS
SEQ ID NO: 137
S
SEQ ID NO: 132
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
D5C
SAFTVSNFYMTWVRQAPGKGLEW
PSTSLNWYQQKPGKAPKLLIYLASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARSLGYYYALDVWGQGTTVTVS
SEQ ID NO: 138
S
SEQ ID NO: 132
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
A5C
SAFTVSNFAMTWVRQAPGKGLEW
ISTSLNWYQQKPGKAPKLLIYLASSLQS
VSVIDSGGNTYYADSVRGRFTISR
GVPSRFSGSGSGTDFTLTISSLQPEDFAT
DNSKNTLFLQMNSLRAEDTAVYY
YYCQQSYSTPTFGQGTKLEIK
CARSLGYYYALDVWGQGTTVTVS
SEQ ID NO: 123
S
SEQ ID NO: 139
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
B2C
SAFTVSNFAMTWVRQAPGKGLEW
PSASLNWYQQKPGKAPKLLIYLASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARSLGYYYALDVWGQGTTVTVS
SEQ ID NO: 140
S
SEQ ID NO: 139
JG1H7-
EVQLVESGGGLIQPGGSLRLSCAA
DIQMTQSPSSLSASVGDRVTITCRASQS
B6C
SAFTVSNFAMTWVRQAPGKGLEW
SSTSLNWYQQKPGKAPKLLIYLASSLQ
VSVIDSGGNTYYADSVRGRFTISR
SGVPSRFSGSGSGTDFTLTISSLQPEDFA
DNSKNTLFLQMNSLRAEDTAVYY
TYYCQQSYSTPTFGQGTKLEIK
CARDLGYYYAMDVWGQGTTVTV
SEQ ID NO: 141
SS
SEQ ID NO: 127
INCORPORATION BY REFERENCE
[0203] The contents of all references, patents, pending patent applications and published patents, cited throughout this application are hereby expressly incorporated by reference. | There is disclosed compositions and methods relating to or derived from anti-JAG1 antibodies. More specifically, there is disclosed fully human antibodies that bind JAG1, JAG1-binding fragments and derivatives of such antibodies, and JAG1-binding polypeptides comprising such fragments. Further still, there is disclosed nucleic acids encoding such antibodies, antibody fragments and derivatives and polypeptides, cells comprising such polynucleotides, methods of making such antibodies, antibody fragments and derivatives and polypeptides, and methods of using such antibodies, antibody fragments and derivatives and polypeptides, including methods of treating or diagnosing subjects having JAG1 related disorders or conditions. There is also disclosed a method for treating JAG1-expressing tumors, including hepatocellular carcinomas and squamous carcinomas, and non-oncology diseases selected from the group consisting of rheumatoid arthritis, experimental lung injury, atherosclerosis, chronic liver disease induced by hepatitis C virus, ischemic myocardial injury and heart failure. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to a structure of signal transmission line, especially to a structure of signal transmission line able to transmit signals fast, having lower radio frequency and magnetic field interference, less static electricity, lower attenuation rate and smaller distortion. It is suitable particularly for use in signal transmission lines such as those for speakers, guitar wires, microphones etc.
2. Description of the Prior Art
In conventional signal lines, conductors for transmitting signals generally are divided into the kinds of single conductors and conductors with multiple mutually entangled cores. A single conductor, for example, such as the structure of coaxial cable shown in FIG. 1, is characterized by: the insulation layer enveloping a conductor 1 is formed as a coaxial cable by combining with a cylinder member 2 made by press shaping of PE, a Mylar tape 3 made from aluminum foil, an obscuring layer 4 made by knitting copper lines and a PVC enveloping member 5 .
The coaxial cable is a round PE pipe made by press shaping, in order to lower its electric capacity and attenuation rate. However, the effect of insulation of PE is not the best, and the obscuring layer is not able to make 100% obscuring, it is still a problem to be solved that the degree of mutual interference among a magnetic field, radio frequencies and static electricity is still quite high, and refraction or reflection of transmitted signals can be induced during transmission.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a structure of signal transmission line to separately transmit signals of high and low frequencies to lower the skin effect.
The secondary object of the present invention is to provide a structure of signal transmission line able to transmit signals fast, having lower attenuation rate, smaller distortion and superior quality.
Another object of the present invention is to provide a structure of signal transmission line having the effect of reducing static electricity and lowering radio frequency and magnetic field interference.
To achieve the above stated objects, the present invention is comprised of a core portion, a middle material layer and a coating layer. The present invention is characterized by that: the core portion includes at least one transmission medium enveloped with an insulation layer; the coating layer includes at least one layer; the middle material layer is provided between the core portion and the coating layer, and is comprised of at least a metallic-wire knitting layer and a paper wrapping layer. By separated transmitting of signals of high and low frequencies with the core portion when the latter is a conductor unit with plural cores (transmission media), the skin effect is lowered; and by providing more than one obscuring layers, the degree of mutual interference among a magnetic field, radio frequencies and static electricity can be lowered, and thereby, transmission with lower attenuation rate, smaller distortion and superior quality can be obtained.
The present invention will be apparent after reading the detailed description of the preferred embodiment thereof in reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the structure of a conventional signal transmission line;
FIG. 2 is an analytical perspective view showing the structure of the first embodiment of the present invention;
FIG. 3 is an analytical perspective view showing the structure of the second embodiment of the present invention;
FIG. 4 is an analytical perspective view showing the structure of the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring firstly to FIG. 2, in the first preferred embodiment of the present invention, a guitar wire is shown in a perspective view, a core 20 is formed by coating an insulation PE layer 22 over a conductor 21 made of pure silver, the insulation PE layer 22 is covered thereover with a conductor 23 made of pure copper of single crystal in single direction coated with lacquer, and a PE foam layer 24 further covers the insulation PE layer 22 to make the two conductors be insulated from each other. The PE foam layer 24 then is enveloped sequentially with a PVC conductive layer 41 , a knitted layer 42 plated with silver and a paper wrapping layer 43 to form a middle material layer 40 . Finally, the middle material layer 40 is enveloped with a first coating layer 30 and the second coating layer 31 made of polyvinyl chloride to complete the structure of the signal transmission line of the present invention.
As shown in FIG. 3 which shows the structure of the second preferred embodiment, namely a visual signal transmission line, of the present invention, wherein, a core 20 is formed by coating an insulation PE layer 22 over a conductor 21 made of pure silver, the insulation PE layer 22 is covered thereover with a conductor 23 made of pure copper of single crystal in single direction coated with lacquer, and a PE foam layer 24 further covers the insulation PE layer 22 to make the two conductors be insulated from each other. The PE foam layer 24 then is enveloped sequentially with a PVC conductive layer 41 , a knitted layer 42 plated with silver, a foamed Teflon-tape (PTFE) wrapping layer 44 and another metallic-wire knitting layer 45 to form a middle material layer 40 . Finally, the middle material layer 40 is enveloped with a first coating layer 30 and the second coating layer 31 made of polyvinyl chloride to complete the structure of the signal transmission line of the present invention.
Referring to FIG. 4, in the third preferred embodiment of the present invention, a microphone wire is shown, a core portion is comprised of two cores (transmission media) 20 formed each by coating an insulation PE layer 22 over a conductor 21 made of pure silver, the insulation PE layer 22 is covered thereover with a conductor 23 made of pure copper of single crystal in single direction coated with lacquer, and a PE foam layer 24 further covers the insulation PE layer 22 to make the two conductors be insulated from each other. The two cores 20 then are enveloped sequentially with two PVC conductive layers 41 , a cotton yarn filled layer 46 (with this, the wire is softer and can be shaped more easier), a knitted layer 45 plated with silver and a paper wrapping layer 43 to form a middle material layer 40 . Finally, the middle material layer 40 is enveloped with a first coating layer 30 made of polyvinyl chloride to complete the structure of the signal transmission line of the present invention.
It can be known from the above embodiments that, the plural-core conductors of the core portion (the conductors made of pure silver and pure copper of single crystal in single direction coated with lacquer) are respectively insulated with an insulation PE layer 22 and an insulation PE foam layer 24 , in order that the two conductors are suitably separated from each other to separately transmit signals of high and low frequencies through the two conductors, so that the high and low frequencies are not interfered by each other to thereby lower the skin effect. And more, the middle material layer (including a PVC conductive layer, a knitted layer plated with silver and a PTFE layer) can have an effect of obscuring to thereby effectively prevent interference among a magnetic field, radio frequencies and static electricity, and the cotton yarn filled layer or the paper wrapping layer can increase the softness and easiness of shaping of a wire, and thereby attenuation rate of the wire can be reduced, distortion of the wire can be smaller, and quality of the wire can be better.
The cores of the plural-core conductor unit of the present invention are separately insulated, this can lower the skin effect, to render transmit signals of high and low frequencies to be transmitted separately without interfering with each other, the middle material layer can have an effect of obscuring to thereby lower interference among a magnetic field, radio frequencies and static electricity. This is innovative to wires of such kind available presently, and the effect in enhancing the functions thereof is evident. | A structure of signal transmission line has a core portion, a middle material layer and a coating layer. The core portion includes at least one transmission medium enveloped with an insulation layer. The coating layer includes at least one layer. The middle material layer is provided between the core portion and the coating layer, and has at least a metallic-wire knitting layer and a paper wrapping layer. | 7 |
BACKGROUND OF THE INVENTION
[0001] Plants processing foods, pharmaceuticals, biological and technological fluid materials generally require fluid piping systems that must be free from voids and crevices to prevent accumulations of materials. A typical fluid piping system includes multiple sections of pipe or tubing coupled together. To that end, each coupling joint of the system is of particular importance because it must provide a bacteria-tight seal without obstructing the flow of the material.
[0002] A coupling joint typically includes a pair of pipe ends having respective flanges, a gasket, and a fastening device. To assembly the coupling joint, care must be taken to ensure the gasket is properly seated between the pair of pipe ends. Improper seating of the gasket can lead to an improper seal. Further, in instances where too little contact pressure is applied by the fastening device, valleys in the inner diameter of the coupling joint surface will not be adequately filled by the gasket material to prevent accumulation of microorganisms. Furthermore, in instances where too much contact pressure is applied, the gasket material may be extruded into the pipe lumen thereby causing an obstruction or partial dam that could cause material to be trapped.
SUMMARY OF THE INVENTION
[0003] Many types of pipe gasket exist today, the vast majority of which are manufactured from elastomeric materials. When fitting/seating such gaskets between pipe ends of a pipe joint, it can be very difficult to keep the soft elastomer in position to ensure that it accurately forms a quality seal between the two pipe ends as the pipe ends are closed together. In practice, it is often impossible to tell whether the gasket is correctly aligned with the pipe ends following tightening of a pipe joint without first testing the integrity of the pipe joint by pressure testing the pipe bore itself. Further, it is difficult to hold the gasket in place when joining the two pipe ends. Furthermore, should the gasket fall off of the assembly, it can become contaminated. As such, assembly is clearly time consuming and can be expensive.
[0004] The present invention provides a pipe gasket for providing a seal between a pair of pipes, each pipe including a pipe flange having a grooved face and an outer face. The pipe gasket can be fixedly attached to one pipe flange to facilitate ease in assembly and to also provide proper seal alignment. The gasket includes a support element having at least two protrusions extending from an outer circumference toward an inner circumference, each protrusion for cooperatively engaging the outer face of at least one of the pipe flanges and a sealing element formed with the support element to provide a fluid tight seal between the pair of pipes.
[0005] According to one aspect, the support element defines a plurality of holes in close proximity to the inner circumference, outer portions of the sealing element couples through the holes. The holes can be evenly spaced around the inner circumference of the support element. The support element can be made from metal, plastic, or other suitable material and can be color-coded.
[0006] In one embodiment, the support element includes three inwardly directing protrusions. Each protrusion can be evenly spaced about the outer circumference of the support element. Further, each protrusion can have a width of between 1 and 49 percent of the outer circumference of the support element, and preferably approximately sixteen percent of the outer circumference of the support element. Furthermore, each protrusion can extend inwardly between 1 and 89 degrees from the outer circumference of the support element, and preferably approximately eight degrees from the outer circumference of the support element. Each protrusion can also include an engagement portion for engaging an outer face of at least one of the pipe flanges. The protrusions can include a surface for placing indicia representative of the pipe gasket.
[0007] The sealing element includes an alignment portion for aligning respective grooved faces of each pipe flange. The alignment portion can be an O-ring. The sealing element can be made from an elastomer. The elastomer can be an ethylene propylene diene monomer, a fluoroelastomer, or a perfluoroelastomer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0009] FIG. 1A is a cross-sectional side view of an embodiment of a pipe gasket of the present invention in engagement with a first pipe flange;
[0010] FIG. 1B is a cross-sectional side view of the embodiment of FIG. 1A in connection with a second pipe flange;
[0011] FIG. 1C is a cross-sectional side view of the embodiment of FIG. 1B coupled together;
[0012] FIG. 2A is a plan view of an embodiment of a pipe gasket of the present invention;
[0013] FIG. 2B is a cross-sectional side view of an embodiment of a pipe gasket of the present invention;
[0014] FIG. 2C is a cross-sectional exploded view of a gripper portion of the support element of FIGS. 2A and 2C ;
[0015] FIG. 2D is a cross-sectional exploded view of a support element of FIGS. 2A and 2C ;
[0016] FIG. 3A is a plan view of another embodiment of a pipe gasket of the present invention;
[0017] FIG. 3B is a cross-sectional side view of another embodiment of a pipe gasket of the present invention;
[0018] FIG. 3C is a cross-sectional exploded view of a gripper portion of the support element of FIGS. 3A and 3B ; and
[0019] FIG. 4 is a flow diagram for a process of making a pipe gasket of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] A description of preferred embodiments of the invention follows.
[0021] Generally, the present invention is directed toward a mechanism for retaining a pipe gasket on a pipe end during a pipe joint assembly process. The present invention also provides the following features: 1) proper seal alignment of the pipe gasket between the pipe joint; 2) a mechanical stop to prevent over-tightening of the pipe gasket; 3) color-coding and indicia marking means for preventive maintenance, material identification, and application identification purposes. The pipe gasket of the present invention should adhere to the Bioprocessing Equipment ASME BPE Standards. It should be understood by one skilled in the art that an form of “pipe” is synonymous with any form of “tube.”
[0022] FIGS. 1A-1C show a cross-sectional assembly 50 process for joining two sanitary pipe fittings 60 a , 60 b . Each sanitary pipe fitting 60 a , 60 b includes a flange 61 , a recess or annular groove 62 , an outer face 64 , and an inner diameter (ID) 66 . The flange 61 may be of the type designed to cooperate with a conventional hinged clamp 70 for securing the assembly 50 . A pipe gasket 100 of the present invention is used to provide a bacterial-tight seal between the two sanitary pipe fittings 60 a , 60 b.
[0023] The pipe gasket 100 includes a support element 110 and a sealing element 130 . The support element 100 include at least two protrusions 120 for coupling the gasket to either pipe fitting 60 a , 60 b . The protrusions 120 extend from the outer circumference toward the inner circumference of the support element 110 and cooperate with each other to provide sufficient retaining force against the outer face 64 of either pipe fitting 60 a , 60 b.
[0024] The support element 110 can be manufactured in one piece from engineering plastics material, such as polyphenylsulfone (Radel), metal, or other material known in the art.
[0025] In a preferred embodiment, the sealing element 130 can be manufactured from a soft material, such as rubber or an elastomer. For example, the sealing element 160 can be manufactured from ethylene propylene diene monomer (EPDM), fluoroelastomer (FKM), a perfluoroelastomer (FFKM), or although other elastomer known. In an alternative embodiment, the sealing element 130 can be manufactured from a fluropolymer resin. The sealing element 130 can include an alignment portion 132 , such as an O-ring, for seating grooves 62 of respective pipe fittings 60 a , 60 b . The sealing element 130 is preferably annular and has a inner diameter (ID) 68 which corresponds substantially to the ID 66 of the pipe fitting 60 a , 60 b . In some embodiments, the ID 68 of the sealing element 130 may be slightly larger than the ID 66 of the pipe fitting 60 a , 60 b . In yet another embodiment, the support element 110 and the sealing element 130 can be formed as a unitary piece.
[0026] When a hinged clamp 70 is tightened, it acts against tapered outside surfaces of the flanges 61 such that a seal is produced between the flanges 61 and the pipe gasket 100 . The support element 110 prevents the sealing element 130 from being destroyed or significantly distorted by over tightening of clamp 70 . In instances where the ID 68 of the sealing element 130 is slightly larger than the ID 66 of the pipe fitting 60 a , 60 b , the sealing element 130 expands radially until the ID 68 of the sealing element 130 substantially equals the ID of the pipe fitting 60 a , 60 b.
[0027] FIGS. 2A-2D show a detailed view of the pipe gasket 100 of the present invention. The support element 110 preferably includes three inwardly directing protrusions 120 about the outer circumference of the support element 110 . Preferably, each protrusion 110 is evenly spaced to cooperatively aid in engaging the outer face 64 of either pipe fitting 60 a , 60 b ( FIGS. 1A-1C ). In one embodiment, each protrusion extends inwardly approximately at angle θ from the outer circumference of the support element 110 . The angle θ is preferably 8 degrees but can range between 1 and 89 degrees. The degree in which the protrusion 120 is facing provides an amount of restoring force when the protrusion 120 is in mechanical connection with the outer face 64 of either pipe fitting 60 a , 60 b . That is, while each protrusion 120 flexes outwardly in a radial direction when engaging the outer face 64 of either pipe fitting 60 a , 60 b , a restoration force is applied in an equal but opposite direction which effectively secures the pipe gasket 100 to either pipe fitting 60 a , 60 b.
[0028] In another embodiment, each protrusion 120 has a width of between 1 and 49 percent of the outer circumference of the support element 110 and preferably approximately sixteen percent of the outer circumference of the support element 110 .
[0029] The width of the protrusion provides a larger contact/surface area for the engaging the outer face 64 of either pipe fitting 60 a , 60 b . The width also provides a stable surface area 124 for writing indicia representative of the pipe gasket 100 . The indicia can include, but is not limited to, material identification of the pipe gasket 100 , date and lot code the pipe gasket 100 was made, the type of application of the pipe gasket 100 is approved for, and/or the date the pipe gasket 100 is installed. In yet another embodiment, each protrusion can include an engagement portion or lip 122 for engaging the outer face 64 of either pipe fitting 60 a , 60 b.
[0030] In other embodiments, the support element 110 can be color-coded. The colors can be pre-assigned to aid with preventive maintenance of the pipe joints for a particular application. For example, a plant's protocol or the FDA may require replacement of each pipe gasket 100 every two months. As such, a different color can be assigned for each two month period. Quality control can check the color of the support element 110 of each pipe gasket 100 to determine if each pipe gasket 100 is within the plant's protocol without having to physically open the pipe joint. Further, colors can be assigned for material identification of the pipe gasket 100 and/or the type of application the pipe gasket 100 is approved for.
[0031] As shown in FIG. 2A , the support element 110 includes a series of holes 112 that allow the seating element 130 to couple through. Such coupling can include cross-linking, bonding, or any other type of coupling known in the art. In a preferred embodiment, the holes 112 are evenly spaced about the inner circumference of the support element 110 . Known pipe gaskets use adhesives that can contaminate the process stream by leaching out or breaking down over time. The present invention eliminates this risk by removing the adhesives.
[0032] FIGS. 3A-3C show a detailed view of another embodiment of the pipe gasket 100 ′ of the present invention. Each of the elements are essentially the same as the elements as described in FIGS. 2A-2D . However, sealing element 130 has been replaced with sealing element 130 ′. Sealing element 130 ′ provides a gasket membrane 131 ′ that protects instrumentation from caustic saline solutions. For example, the pipe gasket 100 ′ can be used to couple a pressure gauge to the piping system. The gasket membrane 131 ′ will not interfere with gauge operation or accuracy, the gasket membrane 131 ′ will work with most industry standard instruments, and the gasket membrane 131 ′ will help extend the life of gauges.
[0033] The orientation of the support element 120 provides accurate installation of the pipe gasket 100 ′. As shown in FIGS. 3B and 3C , the protrusions 120 are on the same side as the gasket membrane 131 ′. Improper installation of the pipe gasket 100 ′ will cause the gasket membrane 131 ′ to fail, thereby allowing potential damage to the gauges.
[0034] FIG. 4 shows a flow diagram of one embodiment of manufacturing a pipe gasket 100 of the present invention. In a first step ( 200 ), the support element 120 is placed in a pipe gasket mold. Next ( 210 ), an uncured sealing element is injected into the pipe gasket mold such that the pressure in the mold allows the uncured sealing element to flow through a plurality of holes in the support element. After which ( 220 ), the uncured sealing element is allowed to cure thereby coupling itself to the support element.
[0035] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | A pipe gasket for providing a sealing between a pair of sanitary pipes, each pipe including a pipe flange having a grooved face and an outer face. The pipe gasket can be fixedly attached to one pipe flange to facilitate ease in assembly and to also provide proper seal alignment. The pipe gasket includes a support element having at least two protrusions extending from an outer circumference toward an inner circumference, each protrusion for cooperatively engaging the outer face of at least one of the pipe flanges and a sealing element formed with the support element to provide a fluid tight seal between the pair of sanitary pipes. | 5 |
This invention relates to a computerised diagnostic system for internal combustion engines. In particular, the invention is directed to a method of, an apparatus for, computer aided diagnosis of electronically fuel injected (EFI) internal combustion engines.
BACKGROUND ART
EFI engines in automobiles are commonly controlled by an on-board computer, typically a microprocessor-based device, which controls the timing and duration of the fuel injection in response to operational parameters sensed by a number of sensors on the engine, e.g. temperature, engine speed, throttle position, air flow, etc. These operational parameters can be measured many times per second so that the engine is continually operated at optimum efficiency.
Many microprocessor or micro-computer based control circuits for EFI engines are programmed to accept measured values of sensed operational parameters only when such values fall within a predetermined range e.g. to avoid responding to spurious signals or to avoid acting on faulty measurements. If the value of an operational parameter as measured by a particular sensor is outside the predetermined range, the sensor may be judged by the computer control system to have failed (whether this is, in fact, correct or not), and the actual output signal of the sensor may be replaced by a standard value (as described, for example, in U.S. Pat. No. 4,780,826) . The use of a default value enables the engine to keep operating despite the failure of a sensor. However, although the engine will still operate, it will not perform as efficiently as it should. Since the fault in the engine may be masked by the default value inserted by the computerised electronic control system, it IS difficult, if not impossible, for mechanics to locate and correct the fault using conventional tools.
Complex and expensive diagnostic equipment is PG,3 normally required to locate the fault. Such equipment is often computer-based, requiring a computer device manufactured specifically for that particular application. The use of such complex and specialized diagnostic equipment and the need for trained technicians result in increased costs for motor vehicle repair.
It is the object of the present invention to provide apparatus for computer-aided diagnosis of EFI engines which is within the economic and technical reach of most motor mechanics.
It is a further object of the invention to provide a method of computer-aided diagnosis of EFI engines wherein a diagnostic computer program includes tutorial information to enable such diagnosis to be performed by most motor mechanics.
SUMMARY OF THE INVENTION
In one broad form, the present invention provides apparatus for diagnosing an internal combustion engine, the apparatus comprising computer means having an associated display; input means for connection to the engine under test; and an interface device operatively connected between the computer means and the input means; wherein the interface device comprises:
multiple mode measurement means connected to the input means, the measurement means being responsive to control data received from the computer means to switch to a selected measurement mode,
analog-to-digital converter means for converting a measured value of a selected operational parameter to digital form, and
output means for outputting the digitized measured
value to the computer means;
wherein in use, the computer means is programmed to perform a diagnostic comparison of the measured value with a predetermined operating range and to display the result of such diagnostic comparison.
In the event that the measured value of the operational parameter is outside the predetermined operating range, the computer means is preferably programmed to provide tutorial or similar information to assist the operator in locating and rectifying the possible fault. This procedure is repeated sequentially for all selected operational parameters.
Typically, the engine is an EFI engine and the operational parameters to be tested include battery voltage, ignition pulse, starter signal, throttle position sensor, air temperature sensor, air flow meter, coolant temperature sensor, fuel injectors.
The computer means may suitably be any one of a number of commonly available computers such as a standard laptop computer, or a personal computer, and no substantial hardware modification of such a computer is required. Thus the cost can be minimised. Further, the computer can be used for other applications when not required for EFI diagnosing.
The input means may be in the form of a probe which is placed in electrical contact with a selected sensor under test or other operational parameter, in accordance with instructions displayed on the computer display.
Alternatively, the input means may be in the form of a multipin socket which is connectable to the plug connected to the engine sensors. (This plug is normally connected to the on-board microcomputer found on modern vehicles having microcomputer-controlled EFI engines.) In this embodiment, the sensors are able to be examined rapidly and automatically for fault location.
In yet another embodiment, the input means is in the form of a multipin plug connected between the engine sensors and on-board microcomputer, and selectively switched under computer control. This enables rapid testing of not only the sensors, but also the on-board microcomputer.
To enable a standard portable or personal computer to be used in the diagnostic apparatus of this invention, an interface device is provided to interpret switching control data from the computer means and to convert the measured values of selected operational parameters into computer readable format. The interface device includes a multimode measurement device, analogous to a multimeter, which is controlled by the computer means to switch to the appropriate measurement mode for the selected operational parameter, e.g. voltmeter, ohmmeter, tachometer.
The measured value is converted to digital form and output by the interface device to the computer means, typically in serial data format.
The diagnostic comparison of the measured value with the predetermined range is then performed by the computer software and the results are displayed to the user, together with repair or troubleshooting instructions if necessary.
According to another aspect of the present invention there is provided a method of diagnosing an internal combustion engine using the above described apparatus, the method comprising the steps of sequentially measuring selected operational parameters of said engine, providing the measured values to the computer means, comparing the measured values with respective predetermined ranges stored in the computer means, displaying the results of such comparisons on the computer display, and displaying tutorial instructions for repair or troubleshooting in the event that measured values do not fall within their respective predetermined ranges.
In order that the invention may be more fully understood and put into practice, preferred embodiments thereof will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the basic components of the computer-aided diagnostic system of this invention;
FIG. 2 is a schematic circuit diagram of the interface device of FIG. 1 according to a first embodiment of the invention;
FIG. 3 is a schematic circuit diagram of the interface device of FIG. 1 according to a second embodiment of the invention;
FIGS. 4A-4G is a flow chart of the diagnostic and tutorial software for use with the apparatus of FIG. 1.;
FIG. 5 is a schematic block diagram of a third embodiment of the invention;
FIG. 6 is a circuit diagram of the coupling circuit of FIG. 5; and
FIGS. 7A and 7B is a schematic diagram of the interface current of FIG. 5.
DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 1, the diagnostic apparatus comprises computer means 10 which may suitably be a conventional portable or laptop computer. Alternatively, a standard personal computer (PC) may be used. Such computers are commonly available, and are within the financial reach of most motor repair garages. In the preferred embodiment, the computer means is a conventional portable computer 10 which is preferably housed in a robust casing designed to withstand the harsh environment of an engine workshop.
An interface device 20 is interposed between the engine 30 under test and the portable computer 10 to interpret switching control data from the computer means and to convert the measured values of operational parameters of the engine 30 into suitable digital form for input to, and processing by, the portable computer 10.
In a first embodiment of the invention (hereinafter referred to as the "manual" version), the interface device 20 is connected to the engine 30 by means of one or more probes 25. Typically, two probes are used, one probe being earthed, and the other probe 25 being placed manually at sensors at various locations on the engine 30 under test according to programmed instructions provided by the portable computer 10 on its associated display.
In a second embodiment of the invention, the input of the interface device 20 is connected to the multipin plug which normally connects the engine sensors to the on-board microprocessor controlling the operation of the EFI engine. In this embodiment, the input of the interface device 20 is switched automatically between the various sensors connected to the multipin plug, the switching being controlled by the portable computer 10. In this manner, in order to diagnose the engine 30, the operator need only remove the multipin plug from the microprocessor controller on board the vehicle and connect it, via a suitable connector lead or adaptor, to the interface device 20. The operational parameters measured by the individual sensors are then scanned sequentially and the measured data is fed via the interface 20 to the portable computer 10 for processing.
Operational parameters are measured in real time. Typically, the diagnostic software in the portable computer 10 is designed to compare the measured value of an operational parameter with a predetermined range. This range may be derived from manufacturer's specifications or by empirical determination. If the measured operational parameter is within the predetermined range, the diagnostic program will then proceed onto the next operational parameter. However, if the measured parameter is outside the allowable range, the program will then switch to tutorial mode to instruct the operator the required steps to locate and rectify the fault.
In a third embodiment of the invention, the input of the interface device 20 is interposed between the multipin plug and the on-board microprocessor so that not only can sensor information be received by the diagnostic computer, but also test valves can be fed to the on-board microprocessor to check the proper operation thereof.
A schematic circuit diagram of the interface device 15 of the manual version is shown in FIG. 2. The interface device 15 is basically a computer controlled multimeter which can operate as a voltmeter, ohmmeter or tachometer, together with an analog-to-digital converter 22 for converting measured valves to digital form. The interface circuit can be constructed at low cost and is suitable for small motor repair workshops.
In use, control data is fed from the portable computer 10 to the interface circuit 15 along "data in" line 21 in serial form. This control information is used to provide the required voltages at control outputs 1, 2, 3, 4 to actuate a switch, or combination of switches, 1', 2', 3', 4' to allow the interface 15 to operate in one of its voltmeter, ohmmeter or tachometer modes. (In the simplified schematic diagram shown in FIG. 2, the switches are shown in the form of solenoid relays. However, it will be appreciated by those skilled in the art that other suitable switching devices can be used, e.g. solid state switches.)
By way of example, if the battery is to be tested, the portable computer 10 will instruct the operator to connect the probe 25 to the positive battery terminal, the other probe (not shown) being earthed. The computer 10 will then transmit the required control data to the interface 15 via line 21 so that switch 1' will be closed, and the remaining switches 2', 3', 4' will be opened by control outputs 1, 2, 3, 4 respectively. In this manner, the voltage sensed by probe 25 will be fed directly to the analog-to-digital (A/D) converter 22 within the interface. (The interface device 15 suitably comprises appropriate ranging and shaping circuits (not shown) to place the measured voltage in a suitable condition for A/D conversion). The measured voltage is then converted to digital form and fed, in serial data format, to the computer 10 via line 23. The value of the battery voltage will then be compared with a predetermined range previously input to the computer.
If the measured battery voltage is outside the allowable range, a FAULT message is displayed on the screen. If not, the computer proceeds to the next test. For example, it may then display instructions to the operator to start the engine, with the probe 25 being left connected to the positive terminal of the battery. During this procedure, the battery starting and charging voltages will be measured and input to the computer 10 which compares them with predetermined ranges.
This procedure is continued, each operational parameter being checked sequentially to ensure that it is within a prescribed range.
If the operational parameter to be checked is in the form of a resistance (e.g. if it is necessary to test for open or short circuits), the interface device 15 is switched to ohmmeter mode. The control information fed by computer 10 along line 21 will cause the control outputs to close switches 1' and 4', and open all other switches. A reference voltage (Vref) is applied to a reference resistance 24 in order to derive a known current. This current is fed via switch 4' and probe 25 to the resistance being measured. The resulting voltage, which is proportional to the measured resistance, is input to the A/D converter 22 wherein it is converted to serial digital form and fed to computer 10 via output line 23. The reference voltage may be derived from a battery or reference voltage circuit within the interface device 15, or from an external source.
If engine speed is to be measured, the interface device 15 is switched to tachometer mode. In this mode, switches 2' and 3' are closed, and all other switches are open. The probe 25 is placed on a source of periodic pulses dependant on engine speed (e.g. by connecting to a spark plug, ignition coil or speed sensor). The periodic pulses sensed by probe 25 are fed to a pulse tachometer circuit 26 which provides an output voltage proportional to the frequency of the incoming pulses. The output voltage is fed via switch 2' to the input of the A/D converter 22 where it is again converted to serial digital form and fed to the computer 10.
The switching of the interface device 15 between its various voltmeter, ohmmeter and tachometer modes is performed automatically under computer control, and the transmission of control and measurement data between the interface 15 and computer 10 is governed by a suitable clock or timing mechanism. The operator need only shift the probe 25 as instructed by the programmed instructions displayed on the screen of the computer 10. No special training or expertise is required, and the required tutorial information is able to be displayed on the screen of computer 10.
The allowable range of selected operational parameters for various models of vehicles, together with diagnostic subroutines and tutorial information, can be stored on individual floppy discs, and purchased as and when required. This information can then be loaded into the computer before testing.
It will be apparent to those skilled in the art that the foregoing provides a low cost engine diagnostic system which is simple to use.
In the embodiment illustrated in FIG. 2, the probe is shifted manually from location to location to measure the required operational parameters sequentially. Although the interface circuit is of low cost design, the need to continually shift the probe 25 renders the diagnostic procedure somewhat lengthy. In order to obviate this problem, an automatic version of the interface circuit has been designed, and is illustrated schematically in FIG. 3.
The automatic interface 35 of FIG. 3 is adapted to receive control data in serial form from portable computer 10 along line 31. The serial control data is converted to parallel form by a serial-to-parallel converter in circuit 32 within the interface 35. More specifically, the incoming serial data is converted into eight bit parallel form. The first six bits are fed via lines 33 to an A/D converter 34, and are used to select one of a possible 64 input lines to the A/D converter 34. The seventh and eighth bits are used to control the switching of four switches 1", 2", 3", 4" to select the appropriate mode a multimeter circuit 36, in a similar manner to that described above with reference to FIG. 2. In other words, for the selected one of a possible 64 input lines, the circuit 36 will measure the input as a voltmeter, ohmmeter or tachometer as the case may be. The input lines are connected to a multipin socket 29.
In use, the multipin plug connected to the various sensors on the engine is disconnected from the on-board microprocessor, and reconnected to the multipin socket 29. Control data output from the computer is used to select an appropriate incoming sensor line, i.e. the desired operational parameter, and to switch the multimeter device 36 to the appropriate measurement mode for the selected operational parameter.
The measured value on the selected line is converted into digital form by A/D converter 34, and fed (in parallel format) along lines 37 to a parallel-to-serial converter within circuit 32. The output serial data is then fed to computer 10 along output line 38. The switching of the A/D converter 34 and S/P, P/S converters 32 is also controlled by a clock 39.
Using the automatic interface circuit 35 of FIG. 3, the computer 10 can rapidly measure the operational parameters of the engine under test since no manual relocation of the probe is necessary.
The measured values of the operational parameters can be processed immediately and/or stored for subsequent analysis.
The computer can automatically compare all measured operational parameters with their respective allowable ranges, and provide a summary and fault analysis at the end of the diagnostic routine. Alternatively, the computer may measure each operational parameter individually and display the results of the diagnostic comparisons on the screen sequentially. Moreover, using a Select Menu, a particular sensor or operational parameter can be checked.
The automatic interface 35 is simple to use since the operator need only connect it to the on-board plug. Suitable adaptor sockets can be provided to suit the various models of plugs found on on-board microprocessors.
A flow chart of an example of suitable software for the computer 10 is shown in FIG. 4. The software is both diagnostic and tutorial in nature. In other words, it not only locates the fault, but provides repair instructions and trouble shooting advice.
After the computer program is loaded and the connections tested, each operational parameter or device is tested sequentially. As shown in the flow chart for this example, the battery voltage is first checked. If the battery voltage is not within the prescribed range, instructions are provided for repairing the battery or the charging system of the vehicle. The earthing, ignition, starter, throttle sensor, air temperature sensor, air flow meter, coolant temperature sensor, the injectors, relay and power supply are then tested sequentially.
For each test, tutorial information is provided on the screen of the computer to assist the operator in understanding the test being conducted. The operational parameter of the particular device under test is measured and compared with a predetermined range which has previously been entered into the computer memory. If the measured parameter is within the prescribed range, the program proceeds to the next test. If not, repair or trouble shooting instructions are provided on the screen for the operator.
For operational parameters which can be measured by the operator, the operator is able to ascertain whether the particular sensor measuring that operational parameter is operating correctly. For example, if the reading obtained from a particular sensor is outside the prescribed range, the operational parameter can be measured directly to ascertain whether it is, in fact, incorrect or whether the sensor is faulty.
By the process of elimination, the diagnostic equipment of the present invention can also be used to ascertain whether the on-board microprocessor is faulty.
Furthermore, by suitable programming, the diagnostic apparatus of the present invention can be used to test itself, i.e. to test whether the interface circuit is operating correctly.
FIGS. 5 to 7 illustrate a third embodiment of the invention in which the input of the interface circuit is connected between the on-board microprocessor and the engine sensors. As shown in the schematic block diagram of FIG. 5, the interface circuit 40 of this embodiment is connected to a portable or personal computer ("PC") 41 via a coupling circuit and receiver/line interface 42, a circuit diagram of which is shown in FIG. 6. Circuit 42 provides optical isolation between the PC and the interface 40, and converts the signals to RS485 levels. The power for the RS485 signals is received from the interface circuit 40 via the data cable. The RS485 interface preferably has terminating resistors and a filtering network on each input line.
The interface 40 is connected, via coupling circuit 42, to a parallel input/output port of the PC, for example a printer port. In the illustrated circuit, the following signal lines of the parallel I/O port of the PC are used:
DO: Address/data line
D1: Data clock
D2: Address clock
D3: Power line for opto-isolators
D4): The system is enabled when these lines are
)
D5): high.
BUSY Return data (reads as BIT 7 on printer status)
The signals fed from the coupling circuit 42 to the interface 40 include ADDRESS/DATA, DATA CLOCK and ADDRESS CLOCK, while the signals received from the interface 40 include RETURN DATA.
The other end of interface 40 is connected between the plug or harness connector to which the engine sensors are connected, and the on-board microcomputer. A T-connector 43 is used to plug into the harness connector and the socket connected to the on-board computer. The T-connector 43 is typically provided in a variety of sizes and configurations to suit different models of automobile engine controllers.
The interface circuit 40 is shown in more detail in FIGS. 7A and 7B. In the illustrated embodiment, the circuit has forty-eight line control circuits 50 (FIG. 7B) for switching between the connections to the engine sensors and the on-board microcomputer. However, it will be apparent to those skilled in the art that the number of line control circuits can be varied to suit the particular application of the interface. The forty-eight line control circuits 50 are housed on six boards of eight circuits each. To connect the interface 40 to a particular one of the 48 lines, the computer sends the appropriate address data to interface 40 via coupling circuit 42. The address data is clocked and decoded and switched to the appropriate address lines by addressing circuit 51. Address lines EH1, EH2, EH3 are used to select the particular one of the six cards to which the line is connected, while address lines A, B, C are used to select the desired one of the eight lines connected to that card.
As can be seen in FIG. 7B, the line control circuits 50 each include two relays connected in series between the sensor harness connector 45 and the on-board computer connector 46 for each of the forty-eight lines. A connection (MUX) is also made to each line via a 100K ohm resistor. By appropriate switching of the pair of relays interposed in each line, various measurements of sensor outputs can be taken, and information can be fed to the on-board computer.
When both relays in the selected line are "OFF", there is a direct connection between the sensor of that line and the on-board computer, i.e. a normal connection. Voltage and pulse measurements can be taken on the line in this mode, the measurements being output on the MUX OUT line. For voltage measurements, the output voltage is fed to a first input of a two-input multiplexer 52, the output of which is connected to a 12 bit analog-to-digital converter (ADC) 53. The digitized voltage reading is fed into a 12 bit shift register 54 from which it is transmitted to the RETURN DATA line to the coupling circuit 42 and hence the PC 41.
If pulse frequency measurements are to be taken, the output pulses on the MUX OUT line are first compared with a threshold level, and valid pulses are then counted by a suitable counter/timer circuit in signal processing circuit 55. The counter/time circuit used in the illustrated embodiment is a triple counter/timer comprising: a first timer set up as a rate generator dividing a 1 MHz signal down to 10 KHz; a second timer set up as a hardware triggered monostable using the 10 KHz as a reference, to produce a one second output pulse; and a third timer set up as an event counter, gated, for one second, by the first timer and counting the valid pulses received. The pulse frequency is then provided by the number of pulses received in the one second interval.
The interface circuit 40 can also be used to measure pulse length. In this case, valid pulses are fed to the signal processing circuit 55 where the triple counter/timer is set up such that the first timer serves as a rate generator dividing 1 MHz down to 100 KHz, the second timer is not used, and the third timer is set up as a pulse counter, preloaded with a maximum count. When the rising edge of the pulse is detected, the 100 KHz pulses from the first timer decrement the count in the third timer, until the falling edge of the pulse is detected. (No further pulses are allowed through to the counter when the next rising edge is received unless the pulse length measuring circuit has been reset). To ascertain the length of the detected pulse, the final count in the third counter is deducted from the maximum count originally entered into the counter to obtain the length of the pulse in increments of 0.01 milliseconds. When the pulse length measuring circuit is reset, the third timer is again preloaded with its maximum count.
The pulse frequency and/or pulse width measurements are transferred to DATA TX shift register 56 for transmittal to the PC 41 via the RETURN DATA line.
Open circuit voltage and pulse measurements can be taken by leaving the first relay (left hand relay as depicted in FIG. 7) OFF, i.e. maintaining the connection to the on-board computer, while switching ON the second relay (the right hand relay as depicted in FIG. 7B) to break the connection between the sensor line and the on-board computer.
To measure resistances, the relay states are reversed. That is, the second relay is switched OFF to maintain the connection to the sensor line, while the first relay is switched ON to break the connection to the on-board computer and connect the sensor line to the COMMON LINE. Resistance measurements between the sensor line and ground are taken in this mode. To obtain a resistance measurement, a 2.5 volt reference voltage is switched, via switch 57, through a selected one of two known resistances to the COMMON LINE (which has been switched to the sensor line). Typically, the known resistance is switchable between 25K ohm and 250 ohm. The voltage on the COMMON line is fed to the second input of two-input multiplexer 52 and converted to 12 bit digital format by ADC 53. The digitized value is fed to shift register 54 for transmission to the PC 41 via the RETURN DATA line. The unknown resistance on the sensor line is calculated using the following formula: ##EQU1##
The interface 40 also has connections for four manual probes 60 which can be placed at desired locations on the engine under test. Either 12 volts or ground can be selectively switched to the probes under computer control by the interface 40. As shown in FIG. 7B, the probe connections 60 are each connected to addressing circuit 51 via a respective pair of relays 61, 62. If the relay 61 of a particular probe is operated, that probe is connected to the 12 volt battery voltage of the vehicle. On the other hand, if the relay 62 of a probe is operated, the respective probe is connected to the vehicle ground. All probe connections to the addressing circuit 51 are protected by five Amp thermal circuit breakers 63.
It will be apparent to those skilled in the art that the interface circuit 40 enables the computer to address a particular sensor line and take measurements of voltage, pulse width and/or frequency and resistance on that line simply by switching of the appropriate relays. Selected voltages can also be switched to the manual probes under computer control. Thus, under control of appropriate software on PC 41, the interface circuit 40 is able to automatically access all sensor lines and take the appropriate readings, which are then relayed back to the PC for diagnostic assessment.
Furthermore, the sensor lines can be isolated, and specified values can be fed to the on-board microcomputer with resultant monitoring of the microcomputer output as evidenced by the engine performance. In this manner, the diagnostic system of the abovedescribed embodiment is able to not only locate faults in the engine sensors, but also in the operation of the on-board computer.
The foregoing describes only some embodiments of the invention, and modifications which are obvious to those skilled in the art may be made thereto without department from the scope of the invention as defined in the following claims. | Diagnosis of an electronically fuel-injected engine equipped with sensors connected to an on-board microcomputer. Use of a standard personal or portable computer and a connector for electrical connection to the sensors and the on-board computer. An interface device is connected between the connector and the computer to enable the computer to read the values of the operational parameters of the engine as detected by the sensors, and to perform a diagnostic software comparison of the measured values with predetermined values or ranges. The interface device is switchable to a selected sensor or the on-board computer under software control from the computer, and includes a multiple mode measurement device which is also selectively switched to a desired measurement mode by the computer. The computer is then able to selectively measure the operational parameters of the engine, test for correct operation, and display the appropriate diagnostic or tutorial instructions for fault location and rectification. The computer is also able to feed data to the on-board computer for testing same. | 6 |
STATEMENT OF GOVERNMENT RIGHTS
Certain of the subject matter of the present application was developed under Contract Number N00014-02-C-0068 awarded by the Office of Naval Research. The U.S. Government has certain rights in this invention.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application discloses subject matter that is generally related to U.S. Ser. No. 10/917,151 filed Aug. 12, 2004, presently pending, which claims priority from U.S. provisional application No. 60/532,156 filed on Dec. 23, 2003, the disclosures of which are incorporated herein by reference. The present application is also generally related to the subject matter of concurrently filed U.S. application Ser. No. 11/140758, entitled “Antenna Apparatus and Method”.
FIELD OF THE INVENTION
The present invention relates to electrical coupling assemblies, and more particularly to an electrical coupling assembly that is especially useful for electrically coupling two miniature, independent circuit board assemblies, for example two electrical component subassemblies used in a phased array antenna module.
BACKGROUND OF THE INVENTION
The Boeing Company (“Boeing”) has developed many high performance, low cost, compact phased array antenna modules. The antenna modules shown in FIGS. 1 a - 1 c have been used in many military and commercial phased array antennas from S-band to Q-band. These modules are described in U.S. Pat. No. 5,886,671 to Riemer et. al. and U.S. Pat. No. 5,276,455 to Fitzsimmons et. al., both of which are incorporated by reference into the present application.
The in-line first generation module has been used in a brick-style phased-array architecture at K-band and Q-band. The approach shown in FIG. 1 a requires elastomeric connectors for DC power, logic and RF distribution but it provides ample room for electronics. As implemented in FIG. 1 a , the in-line module provides only a single beam, either linear or right-hand or left-hand circularly polarized. As Boeing phased array antenna module technology has matured, many efforts have resulted in reduced parts count, reduced complexity and reduced cost of several key components. Boeing has also enhanced the performance of the phased array antenna with multiple beams, wider instantaneous bandwidths and improved polarization flexibility.
The second generation module, shown in FIG. 1 b , represents a significant improvement over the in-line module of FIG. 1 a in terms of performance, complexity and cost. It is sometimes referred to as the “can-and-spring” design. This design provides dual orthogonal polarizations in a more compact, lower-profile package than the in-line module. The can-and-spring module forms the basis for several dual simultaneous beam phased arrays used in tile-type antenna architectures from S-band to K-band. The fabrication cost of the can-and-spring module has been reduced through the use of chemical etching, metal forming and injection molding technology. The third generation module developed by Boeing, shown in FIG. 1 c , provides a low-cost dual polarization receive module used in high-volume production at Ku-band.
Each of the phased-array antenna module architectures shown in FIGS. 1 a - 1 c require multiple module components and interconnects. In each module, a large number of vertical interconnects such as electrically conductive fuzz buttons and springs are used to provide compliant DC and RF connectivity between the distribution printed wiring board (PWB), ceramic chip carrier and antenna probes.
A further development directed to reducing the parts count and assembly complexity for single antenna modules is described by Navarro and Pietila in U.S. Pat. No. 6,580,402, assigned to Boeing. The subject matter of this application is also incorporated by reference into the present application and involves an “Antenna-integrated ceramic chip carrier” for phased array antenna systems, as shown in FIG. 1 d . The antenna integrated ceramic chip carrier (AICC) module combines the antenna probes of the phased array module with the ceramic chip carrier that contains the module electronics into a single integrated ceramic component. The AICC module eliminates vertical interconnects between the ceramic chip carrier and antenna probes and takes advantage of the fine line accuracy and repeatability of multi-layer, co-fired ceramic technology. This metallization accuracy, multi-layer registration can produce a more repeatable, stable design over process variations. The use of mature ceramic technology also provides enhanced flexibility, layout and signal routing through the availability of stacked, blind and buried vias between internal layers, with no fundamental limit to the layer count in the ceramic stack-up of the module. The resulting AICC module has fewer independent components for assembly, improved dimensional precision and increased reliability. The in-line module, can-and-spring module, the molded module, and the AICC have been realized as single element modules. So far, the AICC has been implemented by Boeing as a single element phased array module which is connected to the printed wiring board and honeycomb in much the same way as the can-and-spring and injection-molded modules. The AICC approach provides manufacturing scalability from single to multiple elements. As manufacturing/assembly process yields increase, the AICC can be scaled from single to multiple element sub-arrays to reduce parts count and assembly complexity.
A Boeing antenna which departs from a single element module is described by Navarro, Pietila and Riemer in U.S. Pat. No. 6,424,313, also incorporated by reference into the present application, which is shown in FIG. 1 e . This module is referred to within Boeing as the “3D flashcube”. It has been implemented as a four-element module to provide additional space for electronics. This approach also avoids the use of fuzz buttons and button holders for its vertical interconnects. It has been used successfully to provide two independent simultaneous receive beams at 21 GHz with +/−60° scanning. It has also been implemented at 31 GHz in a switchable transmit application with +/−60° scanning. The 3D flashcube model can also be used to implement more than two independent receive and/or transmit beams.
In FIG. 1 f , Boeing-Phantom Works further combines DC power, logic and the RF radiating probes into a phased array antenna into a single component through an approach known as the “Antenna Integrated Printed Wiring Board” (“AIPWB”). This approach is disclosed in U.S. Pat. No. 6,670,930, owned by Boeing, which is also incorporated by reference into the present application. This approach reduces parts count and further improves alignment and mechanical tolerances during manufacturing and assembly. The improved alignment and manufacturing tolerances improves yield and electrical performance while the reduced parts count shortens assembly time and reduces the number of processing steps required to manufacture the antenna module. This ultimately lowers the overall phased array antenna system costs. The AIPWB approach can be scaled to larger sub-arrays without degrading performance and represents an important step in the direction of more easily and affordably manufactured phased array antenna systems.
The first generation module in FIG. 1 a is the standard single polarization in-line or brick architecture used extensively for many electronic phased array systems because of the ample room provided for electronics. FIGS. 1 b , 1 c and 1 d use a tile-type or planar architecture which naturally provides dual polarization. A drawback of the tile architecture is that space is severely limited as frequency and scanning angle increases, since the electronics and input/output pads must fit within the physical area of the radiators in the array lattice. Because of the additional input and output pads required to connect to the RF/DC power/logic distribution, single element modules are further constrained in dimensions. As the array dimensions increase, the single element module pads require tighter dimensional tolerances to ensure alignment and connectivity.
The antenna module of FIG. 1 e has some of the benefits of tile-type architectures, namely providing dual polarization and broad-side interconnections to the printed wiring board. It also has some of the benefits of the in-line architectures by providing ample area for electronics and transitions. The 3D flashcube concept has been realized as a quad-module but the approach can be increased to 2×N modules as yield in electronics and packaging increase. The 3D flashcube uses a three layer flexible stripline to provide connections from the electronics to the antennas as well as connections from the electronics to the printed wiring board.
However, even with the 3D flashcube implementation, it is difficult to provide the extremely tight antenna module spacing between adjacent antenna modules that is needed to achieve +/−60° scanning in the microwave frequency spectrum (e.g., 60 GHz). The limitation of using the three layer flexible stripline for interconnections is that as scan angles and frequencies increase, the stripline must be bent at very, very tight (i.e., small) bend radii in order to achieve the extremely close antenna module spacing required for +/−60° scan angle performance in the microwave frequency spectrum. The stripline ground plane and conductor line becomes more susceptible to breaking apart at the very small bend radii needed to accomplish this extremely tight radiating element spacing.
Accordingly, there still exists a need for a dual polarized, phased array antenna which is able to operate within the V-band frequency spectrum (generally between 40 GHz-75 GHz), and more preferably at 60 GHz, while preferably providing +/−60° (or better) grating-lobe free scanning. Such an antenna, however, requires a new packaging scheme for coupling the electronics of the antenna to the radiating elements in a manner to achieve the very tight radiating element spacing required for 60 GHz operation, while still providing adequate room for the electronics associated with each antenna module.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus and method for forming an electrical connector assembly that is especially well suited for use in electrically coupling two or more small electrical circuit boards or subassemblies that are positioned in close proximity to one another. In one preferred implementation the present invention is used to electrically couple two small electrical subassemblies in a phased array antenna module.
In one preferred embodiment the connector apparatus comprises a flexible electrical circuit having at least one circuit trace with spaced apart first and second electrical contact portions. The flexible electrical circuit is secured over a compressible (i.e., elastomeric) substrate. In one form the compressible substrate has an elongated, cylindrical shape. A holder apparatus receives the compressible substrate with the flexible electrical circuit positioned over the substrate. The holder aligns and secures the compressible substrate against one of the printed circuit board assemblies such that the substrate is slightly compressed or deformed, thus causing the electrical contact portions on the circuit trace to be forced into contact, and held in contact, with circuit elements on each of the circuit board assemblies. The circuit trace and electrical contact portions thus form an electrically conductive path for coupling the electrical components of the two printed circuit board assemblies.
In one preferred form the holder assembly incorporates a plurality of alignment pins that engage with at least one of the printed circuit board assemblies. The alignment pins align the trace of the flexible electrical circuit with the electrical components on each of the printed circuit board assemblies. The alignment pins also hold the compressible substrate precisely positioned relative to the two printed circuit board assemblies.
The connector apparatus can be employed to make electrical connections between two or more printed circuit boards where the use of ribbon cables or point-to-point wiring would be impractical or impossible in view of the small size, the proximity, the spacing of the two printed circuit assemblies and/or the large number (i.e., density) of electrical connections that need to be made within a very small area.
Further areas of applicability of the present invention will become apparent from the following detailed description. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, in which:
FIG. 1 a illustrates a simplified schematic representation of the elements of an in-line antenna module;
FIG. 1 b illustrates a schematic representation of the elements of a can-and-spring antenna module;
FIG. 1 c illustrates a schematic representation of a molded antenna module;
FIG. 1 d illustrates a schematic representation of the elements used to construct an antenna integrated ceramic chip carrier module;
FIG. 1 e is a simplified schematic view of the elements of a three dimensional flash cube quad-module antenna;
FIG. 1 f is a perspective view of an antenna printed wiring board assembly in accordance with U.S. Pat. No. 6,670,930;
FIG. 2 is a perspective view of an antenna system in accordance with a preferred embodiment of the present invention;
FIG. 3 is a bottom perspective view of the antenna system of FIG. 2 taken from the opposite side of the module, relative to FIG. 2 ;
FIG. 4 is a bottom perspective view of the waveguide coupling element;
FIG. 5 is a cross sectional side view taken in accordance with section line 5 - 5 in FIG. 2 illustrating the 1×2 waveguide splitter formed in the mandrel, with a pair of waveguide coupling elements secured to opposite sides of the mandrel;
FIG. 6 is a side cross sectional view of the mandrel and antenna module interconnection, taken in accordance with section line 6 - 6 in FIG. 2 ;
FIG. 7 is a perspective view of an antenna system incorporating eight of the antenna modules shown in FIG. 2 ;
FIG. 8 is a perspective view of the waveguide distribution network component used with the antenna system of FIG. 7 ;
FIG. 9 is a bottom plan view of the waveguide distribution network component of FIG. 8 ;
FIG. 10 is a perspective view of a 16 element antenna in accordance with an alternative preferred embodiment of the present invention; FIG. 11 is an exploded perspective view of the components of the antenna module of FIG. 10 ;
FIG. 11 is an exploded perspective view of the components of the antenna system of FIG. 10 ;
FIG. 12 is an enlarged plan view of the aperture board of the antenna system;
FIG. 13 is an enlarged perspective view of the module core;
FIG. 14 is a cross sectional side view of the module core in accordance with section line 14 - 14 in FIG. 13 ;
FIG. 15 is a perspective view of a front side of one of the chip carrier assemblies;
FIG. 15 a is a perspective view of a rear surface of a cover that covers the waveguide backshort shown in FIG. 15 ;
FIG. 16 is a perspective view of the rear side of the chip carrier assembly of FIG. 15 ;
FIG. 16 a is a perspective view of one of the molytabs used to support each MMIC chip set on a heat spreader panel;
FIG. 17 is a perspective view of the antenna module used to form the antenna system of FIG. 10 ;
FIG. 18 is a bottom perspective view of the assembly shown in FIG. 17 ;
FIG. 19 is a perspective view of the flexible connector assembly secured to the aperture board;
FIG. 20 is an exploded perspective view of the flexible connector assembly;
FIG. 21 is an assembled, perspective view of the flexible connector assembly;
FIG. 22 is a plan view of a flexible circuit that is used to form a portion of the flexible connector assembly;
FIG. 23 is an enlarged perspective view of a pair of traces of the flexible circuit of FIG. 22 ;
FIG. 24 is a perspective view of an elastomeric member used with the flexible connector assembly;
FIG. 25 is an enlarged perspective view of one end of a portion of the flexible connector assembly;
FIG. 26 is a perspective view of a portion of the flexible connector assembly coupled to the aperture board and the chip carrier assemblies;
FIG. 27 is a cross sectional side view of the flexible connector assembly secured to the aperture board in accordance with section line 27 - 27 in FIG. 10 ;
FIG. 28 is a cross sectional end view of the assembly taken in accordance with section line 28 - 28 in FIG. 27 ; and
FIG. 29 is a perspective view of an antenna system incorporating a plurality of the chip carrier assemblies and module cores.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
FIGS. 2 and 3 illustrate a phased array antenna module 10 . The module 10 operates within the V-band spectrum, and more preferably at 60 GHz, with ±60° elevational scanning capability. The module 10 generally includes a core or mandrel 12 , a first electromagnetic wave energy distribution panel 14 secured to a first side 16 of the mandrel 12 , a second electromagnetic wave energy distribution panel 18 secured to a second opposing side 20 of the mandrel 12 , and a pair of subpluralities of antenna modules 22 a and 22 b . The mandrel 12 includes an input 24 and a pair of spaced apart interconnects 26 for coupling to a printed circuit board (not shown). The interconnects 26 and the input 24 are formed at a first end 28 of the mandrel 12 and the modules 22 a and 22 b are disposed in openings 30 a and 30 b , respectively, at a second end 32 of the mandrel 12 . The openings 30 a and 30 b are shown as hexagonal. Other shapes such as circular openings could readily be employed. The openings 30 a and 30 b receive the antenna components 22 a and 22 b in the desired orientation.
Components 22 a and 22 b may be AICC modules in accordance with the teachings of U.S. Pat. No. 6,580,402, the disclosure of which is incorporated by reference. It will be appreciated, however, that any other antenna component that provides the function of radiating electromagnetic wave energy could be implemented.
With further reference to FIGS. 2 and 5 , the mandrel 12 includes an opening 34 formed on side 16 and an opening 36 formed on side 20 opposite the opening 34 . With specific reference to FIG. 2 , a first waveguide coupling element 38 is secured over the opening 34 and a second waveguide coupling element 40 is secured over opening 36 . The two waveguide coupling elements 38 and 40 are identical in construction. The openings 34 and 36 are further in communication with the input port 24 and function to couple portions of the electromagnetic wave energy received through input port 24 with its associated distribution panel 14 or 18 .
Referring to FIG. 4 , the waveguide coupling element 38 is shown in greater detail. Waveguide coupling element 38 is preferably formed from a single block of electrically conductive material, for example aluminum, and essentially forms a cover for covering the opening 34 . The element 38 includes a recessed area 38 a having an angled surface 38 c at one end of the recessed area and a centrally disposed rib that forms a projecting stepped waveguide transition surface 38 b at the opposite end. One waveguide coupling element 38 is secured over each of openings 34 and 36 , such by gluing with a conductive compound, like an epoxy.
Referring now to FIG. 5 , the mandrel 12 includes a 1×2 waveguide splitter 42 formed internally adjacent the openings 34 and 36 . The waveguide splitter 42 is longitudinally aligned with the input port 24 to receive the electromagnetic wave energy traveling through the input port 24 and to split the energy into approximately two equal portions. Approximately 50% of the electromagnetic wave energy is directed toward opening 34 and the other 50% toward opening 36 . A step 38 b 1 of stepped surface 38 b contacts a circuit trace 14 a on distribution panel 14 to transfer the electromagnetic wave energy channeled through opening 34 into the distribution panel. Angled surface 38 c helps to channel electromagnetic wave energy received by the antenna system into the opening 34 during a receive phase of operation. During a transmit operation, openings 34 and 36 can be termed as “output” ports, while during a receive phase of operation they would form “input” ports, and input port 24 would instead function as an “output” port.
With further reference to FIGS. 2 and 3 , printed circuit boards 44 and 46 couple the interconnects 26 with the distribution panel 14 . A similar pair of interconnects (not shown) is disposed on the second side 20 of the mandrel 12 and serves to couple the interconnects 26 with the distribution panel 18 .
Referring to FIGS. 2 and 6 , each electronic module 48 in distribution panel 14 includes an application specific integrated circuit (ASIC) 50 , a power amplifier 52 and a phase shifter 54 . Each electronic module 48 is associated with a particular one of the antenna components 22 a or 22 b . With specific reference to FIG. 6 , an enlarged view of a portion of the distribution panel 14 illustrates the coupling of one electronic module 48 with one antenna component 22 a . A metallic wire or pin 56 extending from the antenna component 22 a contacts the circuit trace 14 a to make an electrical connection between the component 22 a and the distribution panel 14 . The wire or pin 56 is preferably epoxied to the circuit trace 14 a or otherwise fixedly secured to make an excellent electrical connection with the electronics module 48 . The wire or pin 56 also contacts one of radiating/reception elements (i.e., probes) 22 a 1 of the antenna component 22 a to electrically couple the distribution panel 14 to the radiating/reception element 22 a , of the antenna component 22 a . Each antenna component 22 a includes a pair of radiating/reception elements in the form of elements 22 a 1 , such as illustrated in FIG. 2 . Independent pins or wires 56 are independently coupled to each radiating/reception element 22 a 1 and 22 a 2 . This form of electrical coupling avoids the bending limitations of a stripline conductor that heretofore has prevented the tight antenna module spacing required for +/−60° scanning in the gigahertz bandwidth, and thus allows electrical connections to be made to extremely tightly spaced antenna components.
The mandrel 12 is preferably formed from a single piece of metal, and more preferably from a single piece of aluminum or steel. The first end 28 further includes a plurality of openings 58 for allowing a plurality of antenna systems 10 to be ganged together to form a larger antenna system composed, for example, of hundreds of thousands of antenna components 22 .
With reference now to FIG. 7 , an antenna system 100 incorporating eight antenna modules 10 is illustrated. The antenna system 100 includes a 1×8 waveguide distribution network 102 which is coupled to a DC power/logic distribution printed wiring board 104 . DC power/logic distribution printed wiring board 104 is in turn coupled to the first end 28 of each mandrel 12 of each antenna module 10 . The antenna system 100 thus forms a 128 element millimeter wave (i.e., V-band) phased array antenna system. An even greater plurality of antenna system 10 components can be coupled together to form a 128 element, 256 element, or larger 1×N (where “N” is 2 i and “i” is an integer) phased array antenna system. Accordingly, it will be appreciated that antenna systems having varying numbers of radiating elements can be assembled using various numbers of the module 10 of the present invention.
Referring to FIGS. 8 and 9 , the 1×8 waveguide distribution network 102 can be seen. Network 102 , in this example, functions to divide electromagnetic wave energy received through an input port 106 evenly between eight output ports 108 . Each output port 108 is longitudinally aligned with an associated input port 24 of the adjoining antenna modules 10 to allow a portion of the electromagnetic wave energy passing through the output port 108 to enter the input port 24 of each antenna module 10 . The printed wiring board 104 includes eight sections or areas which form conventional “pass throughs” (i.e., essentially waveguide structures) to enable the electromagnetic wave energy to pass from each of the outputs 108 through an associated pass through and into an associated input port 24 of one of the antenna modules 10 . Interconnects 26 ( FIG. 2 ) further electrically couple with portions of the DC power/logic board 104 on opposite sides of an associated one of the pass throughs so the DC power and logic signals can be provided to the distribution panels 14 and 18 of module 10 , and, accordingly throughout the entire phased array system.
Referring to FIGS. 10 and 11 , an antenna system 200 is shown. Antenna system 200 incorporates a flexible connector assembly in accordance with a preferred embodiment of the present invention.
The antenna system 200 is illustrated as a sixteen RF element system, but the system 200 could be formed with a greater or lesser plurality of radiating elements. The antenna system 200 includes a conventional honeycomb plate 202 , typically referred to in the industry as simply a “honeycomb”, secured over an aperture board 204 . The honeycomb plate 202 is preferably made from metal, and more preferably from aluminum. The honeycomb plate 202 and the aperture board 204 are secured to a hollow, metallic support frame 206 . The support frame 206 is secured to a heat sink assembly 208 . Heat sink assembly 208 is secured to a waveguide adapter 210 on an undersurface 212 of the heat sink assembly 208 . The heat sink assembly 208 includes a fluid carrying conduit 214 located within a channel 216 of a metallic cold plate 218 for providing liquid flow through cooling to the heat sink assembly 208 .
With specific reference to FIG. 11 , the honeycomb 202 includes a plurality of apertures 220 for receiving threaded fastening members 222 . Openings 202 a form waveguides for electromagnetic wave energy passing to/from the aperture board 204 . Each opening 202 a may be filled with a conventional dielectric plug, such as a plug made from REXOLITE® cross-linked, polystyrene, microwave plastic, or from ULTEM® polyetherimide thermoplastic.
Aperture board 204 likewise includes a plurality of apertures 224 , and the support frame 206 includes a plurality of blind threaded bores 226 opening from surface 206 a . The cold plate 218 includes a plurality of holes 228 . Fasteners 222 extend through apertures 220 and apertures 224 into threaded holes 226 . Fasteners 223 extend through apertures 228 of the cold plate 218 into four threaded blind holes 225 of the frame 206 that are co-linear with threaded holes 226 but on edge 206 b of support frame 206 . The cold plate 218 also includes a waveguide opening 230 . Opening 230 is aligned with a bore 232 within the waveguide adapter 210 when the waveguide adapter 210 is secured via fasteners 234 to the undersurface 212 of the cold plate 218 . Aperture 232 has the same rectangular geometry as aperture 230 on a top end 210 a of the adapter 210 . Also, aperture 230 has a constant cross section through the cold plate 218 while aperture 232 forms a tapered rectangular waveguide that changes height as it passes through adapter 210 . In this example, aperture 232 is designed to mate with a WR 19 standard waveguide on the bottom end 210 b of the adapter 210 , while mating with aperture 230 on the top end 210 a . Aperture 230 may be called a custom, “reduced height” waveguide based on the standard WR 19 size. The purpose of adapter 210 is to transform the signal from a WR 19 waveguide to a reduced height, WR 19 waveguide.
Referring further to FIG. 11 , within the support frame 206 , is housed a metallic module core or mandrel 240 that holds a module 242 . A flexible connector assembly 244 in accordance with a preferred embodiment of the present invention is also housed within the support frame 206 . The module 242 includes a pair of signal distribution panels in the form of chip carrier boards 246 a , 246 b , and a pair of retainer clips 248 a , 248 b . Chip carrier board 246 a and retainer clip 248 a form a first pair of components that are secured to one side of the core 240 , while chip carrier board 246 b and retainer clip 248 b form a second pair of components that are secured to the opposite side of the core 240 . The flexible connector assembly 244 is used to electrically couple the chip carrier boards 246 with the aperture board 204 .
Referring to FIG. 12 , the aperture board 204 is shown in greater detail. The aperture board 204 is preferably formed in accordance with the teachings of U.S. Pat. No. 6,670,930. The aperture board 204 essentially forms a multi-layer printed wiring board that combines a plurality of dual-polarized, electromagnetic wave radiating/reception elements 250 (in this example 16 such elements) with DC power distribution and logic distribution functions. For convenience, elements 250 will simply be referred to throughout as “radiating” elements 250 . Radiating elements 250 are aligned with the openings 202 a so that each opening 202 a forms a waveguide for a respective one of the sixteen radiating elements 250 . The aperture board 204 enables DC power and logic signals to be applied to drive ASICs and monolithic microwave integrated circuits (MMICs) on each of the chip carrier boards 246 a , 246 b . Each radiating element 250 includes a pair of RF elements (i.e., probes) to provide dual polarization transmit and receive capability to the antenna 200 . The aperture board 204 and the chip carrier boards 246 a , 246 b can be constructed to provide the antenna 200 with transmit and receive capabilities over a desired bandwidth, and in one specific implementation over a frequency bandwidth spanning at least between about 40 GHz-60 GHz.
Referring to FIGS. 13 and 14 , the module core 240 includes a waveguide input port 252 and a pair of output ports 254 formed on opposite surfaces. The module core 240 may comprise aluminum or any other highly thermally conductive material, such as brass or molybdenum. The module core 240 may be formed from a single piece of material, or from several pieces of material bonded or otherwise secured together. With reference to FIG. 14 , the module core 240 includes, in this embodiment, a 3 dB splitter 256 that divides the electromagnetic wave energy fed through input 252 evenly between the two output ports 254 . A channel 257 is formed at one end of the module core 240 for receiving a portion of the flexible connector assembly 244 when the module 242 is assembled.
As shown in FIG. 18 , this module core 240 also includes a flange 258 to help secure the core to the cold plate 218 and to increase the contact surface area between module core 240 and the cold plate 208 to facilitate heat-transfer. Four blind holes 253 a and 253 b are tapped in the module core 240 adjacent the port 252 . Holes 253 a are threaded and receive screws (not shown) that pass through holes 218 a in the cold plate 218 ( FIG. 11 ) to fasten these components together. The remaining pair of holes 253 b accept close fitting alignment pins 257 that also extend into holes 218 b in the cold plate 218 in order to align waveguide port 252 in the module core 240 with waveguide opening 230 in the cold plate 218 .
Referring to FIGS. 15 and 16 , one chip carrier board 246 a is shown in greater detail. Each chip carrier board 246 comprises a low temperature, co-fired ceramic (LTCC) substrate 262 having in this case eight holes 264 and four recesses 266 . A waveguide backshort 268 is formed on a front side 270 of the LTCC substrate 262 . The waveguide backshort 268 functions to provide a transition from a waveguide (i.e., waveguide adaptor 210 ) to a TEM transmission line such as a microstrip.
Reference numeral 268 a indicates an elongated, rectangular embedded waveguide coming to the surface of the ceramic chip carrier board 246 a , and forms part of the waveguide backshort 268 structure. Often waveguides are hollow cavities in metal structures, as in port 252 , but in this instance embedded waveguide 268 a is a continuous part of the ceramic substrate of chip carrier board 246 a . Metal traces and vias are arranged in the ceramic substrate so that the region electrically acts as a waveguide even though there is no actual slot cut in the ceramic that forms board 246 a . The actual shorting part of the waveguide backshort 268 consists of a rectangular plate of metal 259 (preferably KOVAR™ super alloy or ALLOY 42 iron-nickel alloy 42 ) approximately 0.010 inch (0.254 mm) thick, of sufficient size to cover this waveguide backshort 268 opening. Referring to FIG. 15 a , plate 259 is attached to the ceramic chip carrier board 246 a with conductive epoxy to cover waveguide backshort 268 . The waveguide backshort plate 259 may itself contain a very short length of waveguide 259 a on the order of 0.002 inches (0.0508 mm) long, corresponding to the size of the embedded waveguide 268 a and contiguous with waveguide backshort 268 . Waveguide 259 a forms a 0.002-inch-deep rectangular recess in one side of the waveguide backshort plate 259 . The purpose of this part is to terminate the waveguide 268 a with a short (that is, cover it with a conductor). Doing so is necessary to facilitate transmission of RF energy from waveguide port 254 in the module core 240 to trace 280 ( FIG. 16 ) in the ceramic package 246 a . Adjusting the length of the waveguide 259 a located in the waveguide backshort plate 259 tunes the transition so that efficiency of this transition is maximized. In some embodiments, the waveguide 259 a in the backshort plate 259 may be filled with a thin piece of dielectric material such as ceramic or plastic to further tune the transition.
In FIG. 16 , a rear surface 272 of the LTCC substrate 262 includes a metallic heat spreader panel 274 that is brazed or otherwise secured to the rear surface 272 . Panel 274 has a cutout 276 to avoid shorting an electrically conductive distribution network 278 formed on the rear surface 272 of the LTCC substrate 262 . The network 278 feeds microwave energy from a strip line transition portion 280 to various components on the chip carrier board 246 a . The microwave energy is that one-half portion of the input energy that flows through the port 254 ( FIG. 14 ) of the core 240 that the strip line transition portion 280 is positioned over when the module 10 is assembled. Input/output (I/O) portions 281 electrically couple the chip carrier board 246 a with the aperture board 240 . The chip carrier boards 246 are bonded directly to the core 240 to form an excellent and direct (conductive) thermal coupling that facilitates cooling of the module 10 . This allows for highly efficient cooling of the electronic components on the chip carrier assemblies 246 .
With further reference to FIGS. 15 and 16 , within each hole 264 is mounted a MMIC chip set 282 . Each MMIC chip set 282 consists of a power amplifier, a driver amplifier and a phase shifter MMIC. Each MMIC chip set 282 is supported on the heat spreader panel 274 and is electrically coupled to an associated radiating element 250 ( FIG. 12 ) via I/O lines 281 . An ASIC chip set 284 disposed within each recess 266 controls the phase shifter MMICs of an associated pair of MMIC chip sets 282 . In FIG. 15 , each ASIC chip set 284 controls the phase shifter MMICs of the two MMIC chip sets 282 located immediately above it. The distribution network 278 in FIG. 16 divides electromagnetic wave energy input to the strip line transition portion 280 evenly to each of the MMIC chip sets 282 so that each radiating element 250 receives 1/16 of the total energy input at port 252 .
The metallic heat spreader panel 274 is a thermally conductive metal plate preferably about 0.015 (0.381 mm) inch thick, composed of any material with a coefficient of thermal expansion similar to the ceramic substrate 262 , for example molybdenum, copper-tungsten, or copper-moly-copper laminate. The panel 274 has several purposes. Since holes 264 penetrate through the entire ceramic substrate, each hole 264 must have a floor on which MMIC chip set 282 may be directly or indirectly mounted. The heat spreader panel 274 covers the holes 264 and provides a surface on which the MMIC chip sets 282 may be subsequently mounted from the opposite side of the chip carrier board 246 a . Also, integrated circuit components may be indirectly mounted to the heat spreader panel 274 via a molytab 261 , as shown in FIG. 16 a . A small block of molybdenum (i.e., molytab 261 ) is affixed to the heat spreader panel 274 by means of conductive epoxy. The MMIC chip sets 282 are then mounted to the molytab 261 with conductive epoxy. The purpose of the molytab 261 is to make the top surface of each of the MMIC chip sets 282 coplanar with the top surface of the ceramic chip carrier board 246 a and to provide a direct thermal path from the chip sets 282 to the heat spreader panel 274 . The heat spreader panel 274 further provides a direct heat path from the molytab 261 to the module core 240 , with the module core 240 being in metal-to-metal contact with the cold plate 218 . Therefore a continuous heat transfer path is formed from the back of each chip set 282 to the cold plate 218 . The metals used have a high thermal conductivity, limiting MMIC chip set 282 operating temperature and providing for extended MMIC chip set life. If the MMIC chip sets 282 were mounted directly to the ceramic substrate without the use of a molytab and heat spreader panel 274 , the MMIC chip set operating temperature would likely be somewhat higher than it is with the present embodiment. Mounting the MMIC chip sets 282 to an all-metallic structure also reduces the probability that the chip sets will experience a feedback condition, commonly called oscillation, that causes MMIC amplifiers to output large amounts energy at undesired frequencies.
Referring to FIGS. 17 and 18 , the chip carrier assembly 242 is shown assembled to the core 240 . Each retainer clip 248 is preferably made from stainless steel tempered to a spring condition and includes a pair of curved arms 286 that interlock with one another. The arms 286 are secured from separating by pins 288 ( FIG. 18 ) that are inserted into each pair of interlocked arms 286 .
In FIG. 19 the flexible connector assembly 244 is shown coupled to an undersurface 205 of the aperture board 204 . The assembly 244 is used to electrically interconnect the I/O lines 281 of each chip carrier board 246 with circuit traces, indicated in highly simplified form by reference numeral 204 b , on the aperture board 204 . This enables electrical communication between the radiating elements 250 and the chip carrier boards 246 .
Referring to FIGS. 20 and 21 , the flexible connector assembly 244 includes a flexible circuit assembly 290 which is wrapped over an elongated, cylindrical compressible (i.e. elastomeric) member 292 to form a compressible electrical coupling subassembly 294 . The compressible subassembly 294 is supported on a holder subassembly 296 . The holder subassembly 296 includes a frame 298 having sleeves 300 formed at opposite ends. The frame 298 further has bores 302 to receive alignment pins 304 a , 304 b . Each sleeve 300 has a bore 301 that receives a threaded fastener 306 to secure the holder assembly 296 to the aperture board 204 . The frame 298 may be made from any suitably rigid material such as metal or plastic. Referring briefly to FIG. 19 , the aperture board 204 includes threaded blind holes 204 a that receive the threaded fasteners 306 .
With specific reference to FIG. 22 , the flexible electrical circuit 290 is illustrated before the circuit has been secured to the compressible member 292 . The flexible electrical circuit 290 includes a plurality of holes 308 a and 308 b adjacent the four corners of the circuit 290 . Holes 308 a overlay one another, and holes 308 b similarly overlay one another, when the circuit 290 is wrapped over the compressible member 292 . Hole 308 c is longitudinally aligned with the holes 308 a when the flexible circuit 290 is rolled over the compressible member 292 . Similarly, hole 308 d is longitudinally aligned with holes 308 b when the flexible circuit 290 is rolled and secured over the compressible member 292 .
The flexible circuit 290 includes a first plurality of circuit traces 310 formed in a longitudinal line, and a second plurality of circuit traces 312 also formed in a longitudinal line adjacent the first plurality of circuit traces 310 . The traces 310 and 312 are preferably formed on a sheet of polyimide having a thickness in the range of preferably about 0.0005 inch to 0.002 inch (0.0127 mm-0.0508 mm), excluding the thickness of the circuit traces 310 and 312 (typically copper having a thickness of between 0.0035 inch-0.0007 inch; 0.089 mm-0.018 mm). The above-described thickness range, as well as the width of each of the traces 310 and 312 , will need to be considered together to achieve the desired impedance (in the present embodiment about 50 ohms). While only two rows of circuit traces 310 and 312 are shown, a greater or lesser plurality of rows of circuit traces could be used to feed power at the desired impedance. Circuit traces 310 each include a pair of raised electrical contacts or pads 314 a and 314 b , while traces 312 similarly include raised electrical contacts or pads 316 a and 316 b . With brief reference to FIG. 23 , the raised electrical contacts 314 a and 314 b of one of the circuit traces 310 are illustrated in enlarged fashion.
With reference to FIG. 24 , the compressible member 292 is shown in greater detail. The compressible member 292 may be formed from any resilient, (i.e., elastomeric) deformable material, but in one preferred form comprises a silicone rubber cord of generally circular cross section with a Shore A durometer rating of approximately 60. Such material is manufactured by Parker Seal Co. of Lexington, Ky. The compressible member 292 includes a pair of bores 318 a and 318 b that are formed with a spacing in accordance with the spacing separating holes 308 c and 308 d of the flexible electrical circuit 290 . The diameter of the compressible member 292 may vary to suit the needs of a specific application, but in one preferred form comprises a diameter of between about 1.025-1.055 inch (2.6-2.67 mm). Similarly, the overall length may vary to accommodate electrically coupling to various pluralities of circuit traces on the aperture board 204 . Furthermore, the compressible member 292 may take other shapes besides a cylindrical shape. Spherical compressible members, oval shaped members or other shapes could be employed to suit the needs of specific applications, provided the flexible circuit assembly 290 can still be wrapped over the compressible member.
Referring to FIG. 25 , the flexible circuit assembly 290 is shown wrapped over the compressible member 292 . Preferably, the flexible electrical circuit 290 has an overall width that does not leave any overlaps. Hole 318 b aligns with holes 308 a , 308 c while hole 318 a aligns with openings 308 b , 308 d . Adhesive can be used to secure the flexible electrical circuit 290 to the compressible member 292 , but may not be required. Pins 304 a and 304 b lock the flexible electrical circuit 290 into place by passing through all the holes 308 .
Referring to FIG. 27 , a highly enlarged, cross sectional side view in accordance with section lines 27 - 27 of FIG. 10 illustrates the compressible subassembly 294 in electrical contact with just the aperture board 204 . A portion of the assembly 244 resides with the channel 257 in the module core 240 .
FIG. 28 is an enlarged, end, cross-sectional view of the flexible connector assembly 244 in accordance with section line 28 - 28 in FIG. 27 , with the assembly 244 coupled to the aperture board 204 and the chip carrier boards 246 a and 246 b . The circuit traces 310 and 312 are shown in representative form making electrical contact with the chip carrier boards 246 a , 246 b . The aperture board 204 includes traces 240 b 1 , and 240 b 2 , also shown in highly simplified, representative form. Chip carrier board 246 a includes a circuit trace 324 and board 246 b includes at least one trace 326 , where traces 324 and 326 are shown in simplified, representative form. The raised electrical contact pads 314 a and 314 b of trace 310 can be seen pressed into contact with the electrical traces 240 b 2 and 326 . Raised electrical contact pads 316 a , 316 b of circuit trace 312 are pressed into electrical contact with circuit traces 240 b 1 and 324 . The alignment pins 304 a and 304 b , in combination with the precisely located blind holes 204 b ( FIG. 25 ), provide highly accurate alignment of the raised electrical contact pads 314 a , 314 b and 316 a , 316 b relative to the electrical traces that they contact.
The precise dimensions of the raised contact pads 314 , as well as the spacing between the circuit traces 310 and 312 , can be tailored to accommodate a degree of misalignment of the raised contacts 314 , 316 . In one preferred form the raised contacts 314 , 316 are formed in accordance with GoldDot™ flexible circuit technology available from Delphi Connection Systems of Irvine, Calif. The raised contacts 314 , 316 , in one exemplary form, have a base diameter of about 0.007 inch (0.18 mm) and a height of about 0.0035 inches (0.089 mm). Raised contacts could also be formed by drilling vias in the contact locations and barrel plating the vias in such a way that barrel of the via extends beyond the surface of the flexible electrical circuit 290 forming a raised contact. Alternately metallic bumps could be soldered or compression bonded onto the flexible electrical circuit 290 .
Referring to FIG. 29 , a 256 element antenna aperture 300 incorporating sixteen of the modules 240 is illustrated. In a ganged embodiment, a suitably dimensioned honeycomb 302 having a plurality of 256 apertures (not visible) is disposed against an aperture board 304 . Aperture board 304 includes 256 antenna components (not visible) that interface with the sixteen modules 240 . Thus, apertures having 2 n (n being an integer) elements could be constructed to suit the needs of a wide range of applications. The systems 10 and 200 are ideally suited for phased array antenna applications where a large number (e.g., dozens, hundreds or thousands) of antenna electronics components must be coupled to a correspondingly large plurality of electromagnetic radiating elements in a relatively small area.
The antenna systems 10 and 200 that use distribution panels 14 and 18 , and chip carrier assembly 242 , provide ample room for the electronics required for a phased array antenna and enable the extremely tight radiating element spacing required for operation at V-band frequencies. The antenna systems 10 and 200 thus combine the advantages of previous “tile” type antenna architectures with those of the “brick” type architectures. The antenna systems 10 and 200 further include a module component that combines the use of a stripline waveguide with an air-filled waveguide to provide an antenna system with acceptable loss characteristics that still is able to distribute electromagnetic wave energy to a large plurality of tightly spaced radiating elements. This enables easy, modular expansion to create a larger overall antenna system. Additionally, the antenna systems 10 and 200 are readily suited for use with conventional waveguide distribution network components (e.g., a corporate waveguide component), thus making them especially well suited for use in larger (e.g., 128 element, 256 element, etc.) antenna systems. The system 200 is especially well suited to dissipating thermal energy generated by the chip carrier boards 246 .
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An electrical connector apparatus and method for connecting circuit traces on two or more independent circuit board assemblies. A compressible elastomeric member is wrapped with a flexible circuit assembly having a plurality of independent circuit traces, with each circuit trace including a pair of raised electrical contacts. The compressible member with the electrical circuit wrapped over it is supported by a holder assembly. The holder assembly is secured to one of a pair of adjacently positioned independent printed circuit assemblies. The compressible member is held by the holder assembly so that it is compressed against both of the printed circuit board assemblies. The raised electrical contacts electrically contact traces on each of the printed circuit assemblies to complete the electrical connections between the circuit assemblies. The apparatus is especially useful in applications where a large plurality of electrical connections need to be made between independent circuit board assemblies in a very limited space. | 7 |
FEDERAL SPONSORED RESEARCH
[0001] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0002] Not Applicable
FIELD OF INVENTION
[0003] This invention relates to a software application that is customizable by end-users of X-ray imaging equipment. It enables the end-user to easily customize the software by Patent selecting the software components required to operate the equipment for the intended application.
BACKGROUND OF THE INVENTION
[0004] Industrial X-ray machines exist at different levels of complexity and used in various applications such as automotive, aerospace, nuclear, food , oil and gas, defense, power generation and homeland security. One of the major concerns of the developers of X-ray imaging equipment is providing software that can meet the needs of the broad variety of end-users. Industrial X-ray machines vary from simple to the very complex, from manual to highly automated operations. As a result, systems software for such machines has wide ranging requirements in imaging, operational sequences and user-interfaces. Software in existing prior art is customized by the manufacturer of the equipment for the type of X-ray imaging machine as well as for the specialized end use the machine is designed for. Therefore, each machine sold for each application requires special software that requires significant software development resources by the manufacturer of the equipment. Industrial grade X-ray machines are constructed using imaging, mechanical, electrical, structural and computer hardware sub-assemblies and components. The requirements for X-ray functionality range from real-time detection similar to a video camera to linear array detection similar to a scanner or copier. Systems software needed for such machines provide for managing and controlling internal machine operations, for X-ray imaging and for image processing capabilities
[0005] Moreover, the end-user in most cases needs to employ the services of trained software engineers to operate the machine and to further customize the software for the intended application. End-users have distinct preferences on the workflow, the appearance of the user-interface and the operational needs of the equipment that can change for the different applications. Examples of applications range from a fully automated inspection system for high volume production of parts that need X-ray inspection requiring minimal user interactions to a specialized application for laboratory analysis that is operated by an expert user who requires ready access to many functions. End-users require different types of data to be captured for every part inspected. For example, pipe manufacturers need to store information on quality parameters such as thickness and other dimensional attributes whereas an automotive parts manufacturer may want to store information that is quite different such as Left-Hand v Right-Hand or All Wheel Drive v Front Wheel Drive. Prior Art requires that several distinct kinds of software exist, each suitable for a particular specification depending on the end-user requirements. This approach is expensive as there are an unlimited number of variations possible. Furthermore, new hardware such as improved X-ray detection equipment could be developed that will require new software to make them work. The greatest utility of the invention described in this specification is for X-ray imaging equipment, but the invention can be applied to other industrial equipment as well that depend on special customized software to control complex operations.
BRIEF SUMMARY OF THE INVENTION
[0006] The invention described below provides a system and method that utilizes a common software platform that addresses the varied needs of the end-users within a single environment. The invention reduces the software development efforts for the various applications. The invention is a systems software platform that consists of a collection of reusable software components, an environment for assembling such components, a control flow structure that enables custom sequencing and interaction of components, provides for the ability to configure the software workflow to application requirements, provides for customization of user-interface and provides for an extensible platform for adding or enhancing components, functions and features. According to the various aspects of the invention, the software platform provided is used to customize needed software components by loading these components into a tree data base structure for viewing and editing the Solution.
[0007] In the preferred embodiment the software components are advanced versions of software components like ActivX™ and Component Object Models (COM). The Solution is stored in an Extensible Markup language (XML) file. The customized Solution enables acquisition, processing, analysis, viewing, archiving, decision making and reviewing that are needed to operate X-ray imaging equipment. Thereby the invention enables the development of customized X-ray systems software for a wide range of applications of varied complexities with minimal software development, minimal resources expenditure, minimal effort, minimal time and at much reduced costs. The invention enables customized software construction by a field or applications engineer rather than by a specialized software developer. Any changes to workflow logic do not require expensive software engineering time. Service personnel and end-users can implement such changes themselves with minimum training. The invention facilitates on-site operational workflow and user-interface implementation as needed by the end-user. It allows for authentication of the operator as various levels of authority as set by the end-user.
[0008] Newer X-ray sources, detectors and image processing algorithms that are developed are accommodated into the common framework of the invention. The invention allows new requirements or enhanced features and functionality to be incorporated into existing and new machines without any significant operational disruption. For example, a new type of detector can replace an older type at the end-user and the new detector will work seamlessly in the old software platform.
[0009] The present invention and its advantages over the prior art of software systems used to operate X-ray machines will become apparent upon reading the following detailed description and the appended claims with reference to the drawings that are part of the specification of the invention. In the drawings and specification “software component” and component are used interchangeably.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows an exemplary flow diagram of the method used to select the individual software components in relationship to the workflow requirements and the user interface requirements to arrive at the customized solution tree for the intended application.
[0011] FIG. 2 shows an exemplary block diagram of the constituent components of a macro.
[0012] FIG. 3 shows an exemplary flow diagram of the viewing and editing components for a particular application.
[0013] FIG. 4 is an exemplary flow diagram for saving a solution tree for an application.
[0014] FIG. 5 is an exemplary block diagram of the software components.
[0015] FIG. 6 shows an exemplary flow diagram showing the addition of a software solution or folder to the solution tree.
[0016] FIG. 7 shows an exemplary flow diagram of an user defined macro sequence.
[0017] FIG. 8 shows an exemplary block diagram of software solution components needed for a particular application.
[0018] FIG. 9 shows an exemplary flow diagram of a macro specification for a particular application.
DETAILED DESCRIPTION OF THE INVENTION
[0019] According to the various aspects of the invention a software platform is provided that may be easily customized to meet the unique needs of end users of X-ray imaging machines without custom programming The end user uses the software platform to create a custom application for his use. The software platform contains defined components that are selected and are incorporated into the final custom application (Solution). The Solution provides for basic logical constructs and component interactions using software that work to provide the Solution without programming. The end-user is not required to be a software engineer.
[0020] A component is an executable entity that encapsulates a function or a set of functions. In the preferred embodiment these components are similar to, but are advancements on software components that have grown out of ActiveX™ and Component Object Model (COM) objects. These enhancements are not the subject of this invention. For example, the movie making function exposes parameters that are applicable to movie making like the frame rate and the file name. When executed, it outputs a movie file in accordance with the parameters set
[0021] Every component in the invention has a common interface that lets it be instantiated when the Solution starts up and executed when the Solution is run. After the components are loaded in the Solution, the properties of the component can be viewed and configured. This is done through smart draw down lists and parameter value controls that can automatically scan the entire Solution and propagate a list with all the components that are of the correct type to be linked to the selected component. After they are linked the components have the capability of dynamically working together. Components are serialized to an Extensible markup Language (XML) format that lets them be reconstituted identically every time the particular Solution is started up.
[0022] Examples of components used in the invention are: a) Database: that is used to map variables to the fields in a relational database such as SQL™ Server; b) Macros: that are used for building custom macros that can be run by the end-user to perform repetitive tasks. Macros are comprised of other components arranged in a logical order; c) Image-Boxes: that handle the core imaging for the software platform including storage and manipulation algorithms; d) Image-Devices: that provide base classes to interface to acquisition devices and cameras; e) Image-Display: is used to display and manipulate images. It also displays toolbars, annotations, statistical information, measurement tools and access to macros and filters; f) Image-Filters: contain image processing filters that are used to enhance images.
[0023] FIG. 1 shows an exemplary flow diagram of the system and method used to create the Solution for the end user. The end user selects the individual software components in relationship to the functional, workflow and the Graphical User Interface (GUI) requirements to arrive at the customized application (Solution) for the intended application. In the preferred embodiment the Solution is presented in the form of a tree display. The process stars with the selection of the user requirements for the custom application ( 101 ). The functional requirements ( 102 ) include the feature set required for inspection. Any external devices that the system platform is required to interact with such as X-ray detectors , Programmable logic Controllers (PLC) are specified in this category of requirements. Workflow requirements ( 103 ) include the sequence of operations desired by the end-user and the rules of operation or the business logic. GUI requirements include the desired look and appearance of the customized application such as the placement of user interface control, and the language and text for the control labels. The end-user has a selection device such as a pointer to be able to select, view and edit the various components needed for the application. An exemplary flow diagram of the process used to view and edit components is shown in FIG. 3 . Based on the functional requirements ( 102 ) that have been identified, components that encapsulate these requirements are selected from the component library. The component library exists as a set of files. A typical component related to the functional requirements would be an X-ray detector. Each functional component has a set of properties that is used to configure the component as per the requirements ( 106 ). The property values are set by either linking them to data variables or assigning static values to them. Based on the identified GUI requirements ( 104 ), components that encapsulate these requirements, such as for example (an image display window) are selected from the component library ( 107 ). The properties of the GUI components are set as per the requirements. GUI control behavior can be made to reflect the state of the system by dynamically linking display properties to data variables. As a result of the linkage the values of the variables decide one or more aspects of the GUI control. As an example a Boolean variable can be used to display or hide a particular control ( 108 ). The use of Boolean variables is shown in FIGS. 6 , 7 & 8 . Data components such as Integers, Booleans, and Structures serve as controllers for the workflow and the GUI status of the custom application ( 108 ). A number of components (such as “Copy”) exist in the software platform to handle data manipulation. Logic components such as ‘If Then Else“, “while loop” use the data components in the component library as shown in ( 109 ) to control the workflow ( 110 ). Triggers are used to provide event based control flow to the custom application. The events are generated by any change in the data component associated with the trigger ( 111 ). The components of a macro are shown in FIG. 2 . Macros are made of one or more functional, data and logical components, sequenced in a logical order to perform a desired function. A macro can invoke other macros in its sequence ( 112 ). Flow chart example of a macro is shown in FIG. 9 . An example of a macro creation is shown in FIG. 7 . Macros are associated with the triggers described in ( 111 ) such that the macro will be invoked in response to a change in value of the data variable associated with the trigger ( 113 ). Macros are also associated with certain GUI controls such as “button” so that an end-user indicating the ‘button” will cause the macro to be invoked. The flow charted process shown in FIG. 1 results in a custom application being developed for the X-ray imaging system. The custom application file (Solution) contains a listing of all of the functional, workflow, GUI and macro components that represent the X-ray imaging application in its entirety. The preferred embodiment saves this in an Extensible Makeup Language (XML) file.
[0024] FIG. 2 is an exemplary block diagram of the constituent components of a macro. Business Logic Constructs ( 201 ) provide conditional execution capability. An example is the “If Then” software component. For example this component has a property that can be linked to a Boolean data component. Based on the (True/False) value of the Boolean data component, the “If Then” component will either execute or ignore depending on the True/False value of the Boolean data component. Functional Component Calls ( 202 ) provide the desired actions of the macro. An example is the “X-ray Detector” component. When executed, this component makes a scan and stores the scanned image into the property that can be linked to an Image-Box component. Data variable Updates ( 203 ) provide the data variables that can be used by the Business Logic Constructs and the Functional Component Calls. Call Other Macros ( 204 ) provides the “Run Macro” component that has a property that can be linked to another macro. When executed the reference macro is invoked.
[0025] FIG. 3 is an exemplary flow diagram of the viewing and editing functions described in paragraph 0019. A person skilled in the art is easily able to understand through the flow diagram how the software to view and edit components has been developed.
[0026] FIG. 4 is an exemplary flow diagram for the process used to save a customized application (Solution) describe in paragraph 0019. A person skilled in the art is easily able to understand how the software to save the Solution has been developed. The Solution in the preferred embodiment is archived as an XML file. This flow chart describes the procedure for traversing the solution tree and archiving all the constituent components.
[0027] FIG. 5 is an exemplary block diagram of the various components that are used in the software platform. These include Data, Database, Custom Forms, Image-Boxes, Image-Devices, Image-Displayers, Image-Filters, Input and Output ( 10 ) devices, macros, Programs, Scan-Devices, Toolbox, Videos, and custom components described elsewhere in the Specification.
[0028] FIG. 6 is an exemplary flow diagram of the process used to add a component or a folder to a custom application (Solution) described in paragraph 0019. A person skilled in the art is easily able to understand how the software to add a component to the Solution is accomplished. The base software program provides the ability to load software components into a tree data base structure for viewing and editing the Solution. The tree structure contains folders, wherein each folder is a container for “like” components. For example, all X-ray detectors are grouped under the folder Image-Devices and all Integer Data variables are grouped under the folder structure Data/Integer. The software platform provides the ability to add, delete and rename components through the GUI. In order to add a component, the end-user highlights a folder from the tree structure using a selection device such as a mouse and then clicks on a control that adds components. This opens a Windows™ folder containing the software platform's component files. Each file is an assembly file that contains one or more software components. Upon choosing a file, a dialog box opens with a list of software components contained in the file that can be added to the highlighted folder. In order to delete a component, the end-user highlights the component by clicking on it and then clicks on a control that allows him to delete the component. The same process can be used to re-name a component.
[0029] The preferred embodiment displays the customized application (Solution) in the form of a solution tree. A typical solution contains one or more of the following components to enable the functionality specified by the end-user. 1. Data variables such as a) integer, date/time, double and Boolean variables to hold program data and logic; b) string variables to hold messages or user input and c) structures to hold a collection of primitive variables described in (a). 2. Image displays that provide for a customizable user interface to images and toolbar functionality. 3. Image-boxes that hold image buffers. 4. Macros that are min-solutions that run in response to a linked button or to data triggers. 5. Program logic such as a) If-Then constructs and b) process constructs that are mini-solutions that run in a separate thread. 6. User-interface elements comprising a) tool bar buttons that run macros when selected and b) tool bar labels that display contents of the variables.
[0030] FIG. 7 is a flow chart of a macro used in the software platform. The macro consists of executable components arranged in a logical order. When the macro is invoked, the components contained in the macro are sequentially executed. Logic components such as If-Then-Else and Loop provide the ability to conditionally execute particular components of the macro. Macros are thread safe and unlimited macros can be running at the same time on different threads or CPU cores.
[0031] FIG. 8 is a block diagram for an exemplary creation of a macro. This macro is required to scan an image and conditionally apply a filter to the scanned image. This task can be encapsulated via a macro component along with the following components. 1. Integer Data Component: Int. 2. Boolean Data Component: Enhance.3. Image Component: Img. 4.Enhancement Functional Component: Filter F. 5. X-ray Detector Functional Component: Detector D.
[0032] The flow chart in FIG. 9 shows the process of how the exemplary macro works. 1. Start the macro. 2. Use a logic component to set the variable (Int) to the value 5. 3. Perform a scan with the detector component Detector (D). Since the value of the integration time, a parameter of D is linked to the variable (Int), the Detector D will scan at the integration time of 5. The scanned image will be stored in the variable (Img). 4. Check the value of the variable (Enhance). If it is (TRUE) then invoke the functional component Filter (F). Since the value of the image, a parameter of (F) is linked to the variable Img, the component acts on Img. 6. If it is (FALSE), proceed to the next step without invoking the functional component Filter (F). 7. End of macro.
[0033] The above disclosure shows an invention of a software platform to develop a custom application for an X-ray imaging system, but it can be recognized that this invention can be used to develop applications for other industrial equipment that are utilized in complex ways for multiple applications. | The invention provides a software platform to customize the software programming needed to operate industrial X-ray imaging systems. Industrial X-ray systems require systems software for managing and controlling internal machine operation and exposing X-ray imaging and image processing capabilities. The various end users require different software programs to operate the equipment. The invention provides for a single software platform for developing a custom software program for the targeted end use. The customizing can be done without the need for software engineers. End-users can select from a stored list of software components that relate to the desired functional, workflow and graphical user interface requirements. Software components are provided that provide for the necessary linkages to create a customized application that is operable via a graphical user interface. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None
PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] None
REFERENCE TO A SEQUENCE LISTING
[0004] None
BACKGROUND OF THE INVENTION
[0005] 1. Technical Field of the Invention
[0006] The disclosure generally relates to razor maintenance devices, and more specifically to a razor maintenance device with olive oil, a dripping holder, and a removable mesh lining.
[0007] 2. Description of Related Art
[0008] The disclosure relates generally to razor maintenance devices, and the components thereof.
[0009] One previous approach to submerge used razor cartridges in a baby or mineral oil, enhanced with fragrances and germicides, and seal the container for transport. A problem with this approach was that, even with the sealable top, the contents would not always be fully prevented from spreading outside the container.
[0010] Another approach was to place a razor inside mineral oil and rapidly move the razor, thus hopefully removing any water from the razor. Similar to the previously described approach, a problem with this approach was that it would sometimes result in a mess of oil.
[0011] Another approach was to use a support that contained mineral oil to house the razor. The razor was subsequently leaned against the support to allow the oil to drip from the razor to the container. A problem with this approach is that oil dripping from the razor may drip into the container or it may drip down the handle of the razor.
[0012] Therefore, it is readily apparent that there is a recognizable unmet need for a razor maintenance device that is easy to use, minimizes the chance of making a mess, prevents corrosion of shaving razors, and is easy to clean.
SUMMARY
[0013] Briefly described, in a preferred embodiment, the present apparatus and method overcomes the above-mentioned disadvantages and meets the recognized need for such a device by providing an apparatus that is easy to use and clean, does not make a mess, minimizes corrosion of shaving razors. The razor maintenance device has a container, a dripping holder, oil, and a wire basket. The dripping holder is placed above the oil, thereby allowing a razor that had been in the oil to be dripped dry.
[0014] According to its major aspects and broadly stated, the present apparatus in its preferred form is a razor maintenance device, with a container filled with oil, and a dripping holder, the dripping holder being located within the container. The container also has a wire basket with a handle, the wire basket also located within the container.
[0015] The dripping holder preferably has a plurality of teeth, back supports and side supports, and empty channels between the teeth and back supports that allow oil to drip from the razor back into the container. The dripping holder further has neckwalls to provide stability to razors that have been placed therein. The dripping holder is preferably configured to be placed in the container such that the dripping holder is not disposed within the oil.
[0016] In a preferred method of use, after a razor is utilized, it is dried and then placed within the oil in the razor maintenance device. Subsequently, the razor is removed and placed in the dripping holder above the oil in the container. After most of the oil drips off the razor, thus returning to the container, the razor is ready to be utilized again. A wire basket is preferably disposed inside the container to catch any debris and/or whiskers that may become dislodged from the razor. The wire basket may periodically be emptied of debris.
[0017] More specifically, the present disclosure of a preferred embodiment is a razor maintenance device that has a container with oil, a dripping holder, and a wire basket. The container has a rim, an outer sidewall, and an inner sidewall. The dripping holder has a body, teeth, back supports, side supports, channel(s), an underside, an end, sides, and a neck, the neck having neckwalls. The wire basket has a handle, a bottom, a mesh-siding, and a top.
[0018] The neckwalls protrude from the neck to provide a razor stability as the razor is placed between the neckwalls in the dripping holder. The side supports provide the head of the razor similar stability.
[0019] The teeth and back supports protrude from the end, and the side supports protrude from the sides. The channels are vacant areas between the teeth and/or the back supports that allow the razor to drip-dry of oil. Depending on the orientation of the dripping holder, in use, after the razor is removed from the olive oil, the head of the razor is preferably disposed on the teeth of dripping holder. The dripping holder preferably has two side supports and three smaller teeth that are disposed approximately evenly between two larger back supports, thus creating four channels. Alternatively, the dripping holder may have two side supports and five smaller teeth that are disposed approximately evenly between two larger back supports, thus creating six channels. However, it will be recognized that variations of this arrangement may still provide the same or similar functionality.
[0020] The wire basket is preferably placed within the container, the mesh-siding of the wire basket being disposed near the inner side wall of the container. The oil level is preferably disposed below the top of the wire basket and above the head of the razor, when the razor is placed within the oil.
[0021] The razor is placed within the dripping holder, and the dripping holder is preferably placed within the container, wherein the contact between the dripping holder's sides and the container's inner sidewall prevent the dripping holder from falling in the olive oil. In an alternate disposition, the dripping holder is placed on the container, wherein the dripping holder's underside rests on the top of the container.
[0022] In use, the method of using the razor maintenance device involves placing oil, preferably olive oil, in the container of the razor maintenance device. After the razor is utilized, the razor is preferably dried then placed in the oil. Subsequently the razor is removed from the oil and placed in the dripping holder, which is preferably placed inside the container or above the container. The razor is removed from the dripping holder, and subsequently utilized. While the razor is removed from the container, the wire basket is removed so that the debris can be removed, preferably by a user grabbing the handle, removing the wire basket, and dumping the debris in the trash.
[0023] Accordingly, a feature and advantage of the razor maintenance device is protecting against corrosion of razor blades.
[0024] Another feature and advantage of the razor maintenance device is that it allows razors to naturally dry before use.
[0025] Still another feature and advantage of the razor maintenance device is that it can be refilled with easy to find products.
[0026] Yet another feature and advantage of the razor maintenance device is that it can be easily cleaned.
[0027] These and other features and advantages of the razor maintenance device will become more apparent to one skilled in the art from the following Summary, Brief Description of the Drawings, Detailed Description, and Claims when read in light of the accompanying Detailed Drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The present razor maintenance device will be better understood by reading the Detailed Description of the Embodiments with reference to the accompanying drawings, which are not necessarily drawn to scale, and in which like reference numerals denote similar structure and refer to like elements throughout, and in which:
[0029] FIG. 1 is a perspective view of an exemplary embodiment of a razor maintenance device;
[0030] FIG. 2 is a perspective view of the dripping holder of the razor maintenance device of FIG. 1 ;
[0031] FIG. 3 is an exploded view of the razor maintenance device of FIG. 1 ;
[0032] FIG. 4 is a cross-sectional side view of the razor maintenance device of FIG. 1 , with a razor submerged in olive oil;
[0033] FIG. 5 is a cross-sectional side view of the razor maintenance device of FIG. 1 , with a razor resting in the dripping holder above the olive oil;
[0034] FIG. 6 is a perspective view of an alternate disposition of the razor maintenance device of FIG. 1 ; and
[0035] FIG. 7 is a flow chart depicting how the razor maintenance device of FIG. 1 is preferably utilized.
[0036] It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the disclosure to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed invention.
DETAILED DESCRIPTION
[0037] In describing the exemplary embodiments of the present disclosure, as illustrated in FIGS. 1-7 , specific terminology is employed for the sake of clarity. The present disclosure, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions. Embodiments of the claims may, however, be embodied in many different forms and should not be construed to be limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples, and are merely examples among other possible examples.
[0038] Referring now to FIGS. 1-7 , by way of example, and not limitation, there is illustrated an example embodiment razor maintenance device 100 , wherein razor maintenance device 100 comprises olive oil O, container 120 , dripping holder 200 , and wire basket 300 . Container 120 comprises rim 130 , outer sidewall 140 , and inner sidewall 150 . Dripping holder 200 comprises body 220 , teeth 230 , back supports 240 , side supports 250 , channel 260 , underside 270 , end 280 , sides 290 , and neck 210 , wherein neck 210 comprises neckwalls 215 . Wire basket 300 comprises handle 310 , bottom 320 , mesh-siding 330 , top 340 , and second hook 350 . It will be recognized that second hook 350 is optional and thus need not be included in every embodiment of wire basket 300
[0039] Neckwalls 215 protrude from neck 210 to provide razor R stability as razor R rests between neckwalls 215 (best shown in FIG. 1 ). Similarly, side supports 250 provide razor-head RH stability as razor-head RH rests between side supports 250 (best shown in FIGS. 2 and 5 ).
[0040] Turning now more particularly to FIG. 2 , teeth 230 and back supports 240 are disposed protruding from end 280 , and side supports 250 are disposed protruding from sides 290 . Channels 260 are vacant areas between teeth 230 that allow olive oil O to exit dripping holder 200 . Depending on the orientation of dripping holder 200 , in use, after razor R is removed from olive oil O, razor-head RH of razor R is preferably disposed on teeth 230 of dripping holder 200 (best shown in FIG. 5 ). Dripping holder 200 preferably comprises two side supports 250 and three smaller teeth 230 that are disposed approximately evenly between two larger back supports 240 , thus creating four channels 260 (best shown in FIG. 2 ). In an alternate embodiment (not shown), dripping holder 200 comprises two side supports 250 and five smaller teeth 230 that are disposed approximately evenly between two larger back supports 240 , thus creating six channels 260 . However, it will be recognized that variations of this arrangement may still provide the same or similar functionality.
[0041] Turning now to FIG. 3 , wire basket 300 is preferably disposed within container 120 , wherein mesh-siding 330 is disposed proximate to inner side wall 150 of container 120 . Turning now to FIG. 4 , olive oil level OL is preferably disposed below top 340 of wire basket 300 , and above razor-head RH when razor R is placed within olive oil O.
[0042] Turning now to FIG. 5 , when razor R is placed within dripping holder 200 , dripping holder 200 is preferably placed within container 120 , wherein the contact between sides 290 of dripping holder 200 and inner sidewall 150 of container 120 prevent dripping holder 200 from contacting olive oil O. In an alternate disposition, turning now to FIG. 6 , dripping holder 200 is disposed on container 120 , wherein underside 270 of dripping holder 200 rests on container 120 .
[0043] It will be recognized by those skilled in the art that dripping holder 200 may be disposed in any position that is preferably not in contact with olive oil O, but still allows olive oil O and debris D, to fall into container 120 .
[0044] Turning now to FIG. 7 , method of using razor maintenance device 700 comprises placing olive oil O in razor maintenance device 100 via step 710 . After razor R is utilized, razor R is preferably dried then placed in olive oil O via step 720 (best shown in FIG. 4 ). Subsequently razor R is removed from olive oil O and placed in dripping holder 200 , which is preferably disposed inside container 120 (best shown in FIGS. 1 and 5 ) or above container 120 (best shown in FIG. 6 ) via step 730 . Razor R is removed from dripping holder 200 via step 740 , and subsequently utilized, via step 750 . While razor R is removed from container 120 , wire basket 300 is removed so that debris D can be disposed of via step 760 , preferably by grabbing handle 310 , removing wire basket 300 from container 120 , removing debris D from wire basket 300 , and replacing wire basket 300 in container 120 .
[0045] To dry wire basket 300 , wire basket 300 is suspended from container 120 via second hook 350 , wherein bottom 320 is thus preferably disposed above oil level OL.
[0046] The foregoing description and drawings comprise illustrative embodiments. Having thus described exemplary embodiments of the present disclosure, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present disclosure. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the present disclosure is not limited to the specific embodiments illustrated herein, but is limited only by the following claims. | A razor maintenance device with a container, a dripping holder, olive oil, and a mesh. The dripping holder is disposed above the level of the olive oil in the container, therein allowing a razor that had been soaking in the olive oil to be placed in the dripping holder and subsequently drip dry. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to the use of gene-specific oligonucleotide PCR primers that are uniquely expressed and can be used to identify particular cell lineages (types) of the placenta during development. Different placental cell lineages (trophoblasts) have very different cell functions. The present invention permits the analysis of trophoblast stem cells and monitoring of their differentiation and development into cells that, for example, may become invasive and serve to provide nutrients to the baby. The invention employs an analysis based on conserved gene expression and will therefore be useful in the analysis of placental development in many species.
BACKGROUND
[0002] Reverse transcription-polymerase chain reaction (RT-PCR)-based cell analysis and gene-profiling is well-known in the art. It is commonly considered the most sensitive technique for mRNA detection and quantization currently available. Compared to two other commonly used techniques for quantifying mRNA levels, Northern blot analysis and RNase protection assay, RT-PCR can be used to quantify MRNA levels from much smaller samples. In fact, this technique is sensitive enough to enable quantization of RNA from a single cell. Reverse transcription, also known as “Real-time”-PCR has become the preferred method for validating results obtained from array analyses and other techniques that evaluate gene expression changes on a global scale.
[0003] Some application of RT-PCR to the analysis of cell differentiation is also known. For example, Stanton et al disclose a descriptive microarray (gene chip) of genes up regulated or down regulated during human Embryonic Stem (ES) Cell differentiation. However this work is directed to ES and not placental trophoblast and cell lineage determination is not addressed.
[0004] Rossant et al discloses methods for isolation, culture and differentiation of a particular cell line, and discloses limited cell lineage analysis of the placental cells. Rossant also discloses a method of isolating placental trophoblast stem cells and further discloses methods utilizing RT-PCR to show that cells are trophoblast stem cells and can differentiate into giant cells by lineage. However there is no analysis of labyrinthine lineage and no method or suggestion for providing a method for comprehensive analysis via a combination of positive results and elimination of alternatives. The labyrinthine placenta is the main placental zone, where nutrient exchange largely occurs.
[0005] There is currently a need in the art for methods of comprehensively analyzing placental cell lineage and identifying specific placental cell lineages in a rapid and cost-effective manner. There is further a need in the medical arts for diagnostic kits which provide rapid, routine and accurate analysis of placental cell lineages in order to monitor and improve the outcomes of pregnancies. Further, there is a need in the animal husbandry arts for methods of cost-effectively monitoring the status, health or progression of pregnancies to maximize the quality and quantity of offspring.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention utilizes RT-PCR technology in novel methods which enable the rapid determination of a particular cell lineage. A panel of placental lineage markers is provided to identify a specific lineage as positive and to eliminate doubt of alternate lineage by negative expression. The determination all four placental trophoblast lineages is determinable at one time.
[0007] One embodiment of the present invention is directed to a method of comprehensively identifying a specific placental cell lineage of a placental cell sample. The method comprises: (1) isolating RNA of the cell sample to yield a total RNA isolate and subjecting the total RNA isolate to reverse transcription PCR (RT-PCR) to yield a placental cell genetic sample; (2) dividing the genetic sample into at least four portions, including a first, a second, a third and a fourth portion; (3) testing the first portion for presence of a trophoblast stem cell lineage marker; (4) testing the second portion for presence of a trophoblast giant cell lineage marker; (5) testing the third portion for presence of a syncytiotrophoblast/labyrinthine cell lineage marker; (6) testing the fourth portion for DNA contamination; (7) conducting an analysis of the results wherein the specific placental cell lineage is determined. PCR primers which may be suitably employed in the present invention are those which detect the unique markers.
[0008] Placental cell samples may derive from a variety of species, including human, and the markers contemplated as suitable for inclusion in the present invention should be selected to enable comprehensive determination of cell lineage for a given species. Positive identification combined with positive elimination of alternatives, in the same test, provides a cost-effective and time-efficient method for determining placental cell lineage of a sample.
[0009] Another embodiment of the present invention is directed to a panel of PCR primer pairs suitable for detecting at least one placental cell genetic lineage marker from each of the following: trophoblast stem cell lineage markers, trophoblast giant cell markers, and syncytiotrophoblast/labyrinthine cell lineage markers. The panel may also include at least one PCR primer pair suitable for detecting a spongiotrophoblast cell lineage marker. Any PCR primer pair suitable for detecting a unique marker may be employed.
[0010] A further embodiment is directed to a kit which may be used to monitor pregnancy over the course of a pregnancy, or, for example, to detect placental abnormalities early in pregnancy in order to provide opportunity for effective early intervention. The kit comprises a panel according to the present invention, and may also comprise genetic amplification technology and other components related to expression and detection of the genetic marker. The suitability of such components would be readily ascertained by a person of ordinary skill in the art.
[0011] One component of the kit may comprise any means, known or unknown, for amplifying RNA, DNA or attaching protein to a matrix or plastic for use as a substrate, including but not limited to RT-PCR, Northern Blot, Miningene array, Western Blot analysis, enzyme-linked immunoassays (ELISA), and dipsticks. The kits are directly capable of determining placental lineage in a placental cell sample. The kits may also be useful for diagnosis of placental disorders, including but not limited to pre-eclampsia, intrauterine growth retardation and trophoblast neoplasms. In some embodiments the inventive methods are adapted to provide monitoring the status and progression of pregnancy in both humans and other animal species.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Cells of the trophoblast lineage make up the epithelial compartment of the placenta, and their rapid development is essential for the establishment and maintenance of pregnancy. A diverse array of specialized trophoblast subtypes form throughout gestation and are responsible for mediating implantation, as well as promotion of blood to the implantation site, changes in maternal physiology, and nutrient and gas exchange between the fetal and maternal blood supplies. Trophoblasts originate as stem cells, differentiate into genetically identifiable lineages, and establish the maternal-fetal interface. Distinct trophoblast lineages make the placenta an attractive model to understand the control of stem cell growth and differentiation.
[0013] The inability of trophoblast cells to undergo proper differentiation is associated with intrauterine growth retardation and preeclampsia. Trophoblasts, therefore, provide a model to investigate fundamental mechanisms of stem cell differentiation. However, the availability of trophoblast stem cell lines is limited.
[0014] Previously, several systems have been used to analyze the major placental functions. Purified human cytotrophoblast cells represent a trophoblast stem cell population and become invasive on Matrigel, representing the extravillous trophoblast lineage. When purified human cytotrophoblast cells are grown on tissue culture plates, they spontaneously differentiate and fuse representing the syncytiotrophoblast lineage. Placental explants have been used to examine trophoblast outgrowth and invasion. The present invention is directed to the development of an RT-PCR-based lineage-specific profile as a method to identify the lineages of placental trophoblast cells routinely and specifically. For purposes of the present invention, the four trophoblast cell lineages comprise: (1) trophoblast stem cells (multipotent); (2) trophoblast giant cells (extravillous in humans, invasive); (3) spongiotrophoblast cells (rodent only); and (4) labyrinthine trophoblast cells (syncytiotrophoblasts in humans). Lineages (1), (2) and (4) have direct relevance to and perform similar functions in the human.
[0015] One embodiment of the present invention is directed to a method of comprehensively identifying a specific placental cell lineage of a placental cell sample. The method comprises: (1) isolating RNA of the cell sample to yield a total RNA isolate and subjecting the total RNA isolate to reverse transcription PCR (RT-PCR) to yield a placental cell genetic sample; (2) dividing the genetic sample into at least four portions, including a first, a second, a third and a fourth portion; (3) testing the first portion for presence of a trophoblast stem cell lineage marker; (4) testing the second portion for presence of a trophoblast giant cell lineage marker; (5) testing the third portion for presence of a syncytiotrophoblast/labyrinthine cell lineage marker; (6) testing the fourth portion for DNA contamination; (7) conducting an analysis of the results wherein the specific placental cell lineage is determined. A person of ordinary skill in the art will appreciate that step (1) may be readily achieved using one of several technologies commonly known in the art. It is also understood that reverse transcriptase-PCR is sometimes referred to as real time-PCR, and that both are commonly and interchangeably referred to by the RT-PCR acronym. It is also understood that steps 3-6 may include testing/coamplification of, for example, beta Actin or GADPH, as internal controls. “Isolating” is understood to be the equivalent of providing the genetic material in suitable amounts for investigation, such as via amplification, and does not necessarily require isolation
[0016] According to a specific embodiment, the presence of a lineage marker is detected by employing trophoblast cell lineage-specific PCR primers. A suitable list of such primers is set forth in Table 3, although any primer which functions to detect the specified marker is also suitably employable and within the scope of the present invention.
[0017] In another specific embodiment, the trophoblast stem cell lineage marker is selected from the group consisting of Id2, Cdx2 and ERRbeta. In yet another specific embodiment, the invasive extravillous/trophoblast giant cell marker is selected from the group consisting of Hand1, Mash2, P1-1 and Stra13, and according to a further specific embodiment, the syncytiotrophoblast/labyrinthine cell lineage marker is selected from the group consisting of Tfeb, Tec, Gcm-1, D1x-3, and Esx-1. Although specific genetic markers are expressly provided, the invention is contemplated to include all markers which meet the functional requirement that they designate genes which are uniquely expressed by a particular trophoblast cell lineage, and the inventive method comprises any and all permutations according to the selection scheme. In a very specific embodiment with particular relevance to human placental cell samples, the trophoblast stem cell lineage marker comprises Id2, the trophoblast giant cell marker comprises Stra13, and the syncytiotrophoblast/labyrinthine cell lineage marker comprises Gcm-1.
[0018] PCR primers which may be suitably employed in the present invention are set forth in Table 3. Table 3 lists the genetic marker along with one set of PCR primers capable of detecting that marker. It is understood that other primers may be manufactured that enable detection of a particular genetic marker, and that such manufacture is routine to one of ordinary skill in the art. Placental cell samples may derive from a variety of species, including human, and the markers should be selected to enable comprehensive determination of cell lineage for a given species. Positive identification combined with positive elimination of alternatives, in the same test, provides a cost-effective and time-efficient method for determining placental cell lineage of a sample.
[0019] Another embodiment of the present invention is directed to a panel of PCR primer pairs suitable for detecting at least one placental cell genetic lineage marker from each of the following: trophoblast stem cell lineage markers, trophoblast giant cell markers, and syncytiotrophoblast/labyrinthine cell lineage markers. According to a specific embodiment of the present inventive panel, the trophoblast stem cell lineage marker is selected from the group consisting of Id2, Cdx2 and ERRbeta, the trophoblast giant cell marker is selected from the group consisting of Hand1, Mash2, Pl-1 and Stra13, the syncytiotrophoblast/labyrinthine cell lineage marker is selected from the group consisting of Tfeb, Tec, Gcm-1, D1x-3, and Esx-1. In a more specific embodiment, the trophoblast stem cell lineage marker comprises Id2, the trophoblast giant cell marker comprises Stra13, and the syncytiotrophoblast/labyrinthine cell lineage marker comprises Gcm-1. The panel may also include at least one PCR primer pair suitable for detecting a spongiotrophoblast cell lineage marker. This panel is particularly relevant for non-human species. Any PCR primer pair suitable for detecting a unique marker may be employed. Table 3 sets forth suitable exemplary primer pairs for each trophoblast cell form.
[0020] A further embodiment is directed to a kit which may be used to monitor pregnancy over the course of a pregnancy, or, for example, to detect placental abnormalities early in pregnancy in order to provide opportunity for effective early intervention. Such a kit may be employed in the animal husbandry arts to minimize pregnancy loss, increase successful parturition and to increase overall newborn health. Atypical trophoblast differentiation is known to correlate to several placental failures, including, for example, intrauterine growth retardation and/or preeclampsia. In another embodiment, the methods and kits may be employed to monitor placental cell differentiation as an technique for early detection of placental/trophoblast cancers.
[0021] Another embodiment is directed to a method for comprehensively identifying a specific placental cell lineage of a placental cell sample. In this embodiment, it is understood that comprehensive identification may be possible by testing for the presence of as few as two unique markers, depending on, for example, the species, the cell form, the primer design, and the marker being detected. The method comprises: (1) isolating RNA of the cell sample to yield a total RNA isolate and subjecting the total RNA isolate to reverse transcription PCR (RT-PCR) to yield a placental cell genetic sample; (2) dividing the genetic sample into a plurality of portions; (3) testing a portion for presence of a trophoblast stem cell lineage marker; (4) testing a portion for presence of at least one of a trophoblast giant cell lineage marker, and/or a syncytiotrophoblast/labyrinthine cell lineage marker, and/or a spongiotrophoblast cell lineage marker; (5) testing a portion for presence of DNA contamination; and (8) conducting an analysis of the results wherein the specific placental cell lineage is determined.
EXAMPLES
[0022] The following example illustrates analysis and identification of placental trophoblast cell lineages according to one embodiment of the present invention.
[0023] The inventive profiling method was used to analyze the mouse SM10 and rat HRP-1 cell lines, isolated from a region of the placental labyrinth, but of previously unidentified lineage. Using this profile, the expression of trophoblast stem cell markers was detected in the SM10 and HRP-1 cells. In contrast, no expression of a marker of differentiated labyrinthine trophoblast was detected. Additionally, both cell lines expressed labyrinthine trophoblast-specific genes and did not express lineage-specific markers of spongiotrophoblasts or trophoblast giant cells. This suggests that SM10 and HRP-1 cell lines are trophoblast stem cell-like cell lines that can be maintained in undifferentiated but committed state in cell culture. These cell lines express labyrinthine-specific genes and are committed to differentiate solely into functional labyrinthine trophoblasts.
[0024] The inventive profiling method provides a new technique to identify stem cells and their lineage-specific differentiation. The novel method was further employed to additionally indicate that SM10 and HRP-1 cell lines provide new systems for future studies of stem cell differentiation, allowing investigation of basic mechanisms of differentiation, which may provide insights into the biophysics of development of a specialized system. This method is also useful for identification of other stem cell lines and examination of lineage-specific commitment.
[0025] Mouse trophoblast stem cell lines are capable of differentiating into all placental lineages simultaneously, while the rat Rcho-1 trophoblast cell line propagates as stem cells, differentiates into the trophoblast giant cell lineage, and is analogous to invasive human extravillous trophoblasts. The present inventors recently determined that the mouse SM-10 cell line can be propagated as a stem cell population, differentiates into the placental labyrinthine lineage, and is analogous to human syncytiotrophoblasts. The mechanisms, genes, and functions that can be studied in Rcho-1 and SM-10 cells are present and functionally conserved in the human placenta cell lineages. Therefore, the molecular mechanisms regulating trophoblast stem cell growth and differentiation in these cells provide model systems that have direct relevance and applicability to the events that occur in the human placenta. Identifying the signal transduction pathways that regulate trophoblast cell development provides enhanced understanding of the molecular mechanisms that control stem cell growth and differentiation. This new knowledge will provide new insights into potential causes, diagnosis, and treatments of preeclampsia and intrauterine growth retardation.
[0026] To evaluate the trophoblast lineage of the SM10 cells, an array of unique trophoblast lineage-specific PCR primers were designed (Table 1). Each of the genes listed in Table 1 has been shown to be exclusively expressed in specific trophoblast lineages during placental formation.
TABLE 1 Lineage-Specific Markers of Trophoblast Gene Expression PCR Primer Gene Species Expression Reference Id2 Rodent/Human Trophoblast Stem Cells (M) & 97 Villous Cytotrophoblasts (H) Dlx3 Rodent/Human Labyrinthine (M) & T L Brown Syncytiotrophoblasts (H) (unpublished) Esx1 Rodent/Human Labyrinthine cells 98 Tfeb Rodent Labyrinthine cells 99 Tec Rodent Labyrinthine cells 100 Gcm1 Rodent/Human Syncytiotrophoblasts 101 4311 Rodent Spongiotrophoblasts 27 PL1 Rodent Trophoblast Giant Cells 102 Stra13 Rodent/Human Trophoblast Giant Cells (M) & T L Brown Extravillous Trophoblasts (H) (unpublished) Hand1 Rodent Trophoblast Giant Cells (M) & 103 Extravillous Trophoblasts (H)
[0027] The genes set forth in bold represent genes that are present and restricted to specific lineages in both the mouse and human placenta (see Table 1). Analysis of gene expression in proliferative mouse SM10 cells express genes only present in the labyrinthine trophoblast lineage (D1x3, Esx-1, Tfeb, and Tec,). In addition, the D1x3 protein is present in proliferative SM10 cells as determined by Western blotting. Data indicates that the SM10 cell line can be maintained and passaged in culture in a proliferative state, and expresses a major stem cell regulator and lineage markers of labyrinthine trophoblast cells.
[0028] Table 2 sets forth exemplary primers according to the present invention.
TABLE 2 PCR PRIMER INFORMATION Ext. Expect. Expressed Primer tmp Length in control+ control− Notes Cdx2 542 bp Ts3.5 Mash2 369 bp Ts3.5 Id2 62 C. 497 bp Sm10 TS3.5 Actin Any 243 bp All — — Tfeb 62 C. 297 bp Sm10 Tec 62 C. 663 bp Sm10 Gcm-1 64 C. ˜700 bp Sm10 +B Brain RNA New primers Dlx-3 64 C. 408 bp Sm10 Hrp-1 Glut1 62 C. 697 bp Sm10 Hrp-1 Glut3 56 C. 527 bp Sm10 Hrp-1 Glut4 ˜60 C. 870 bp Sm10 4311 58 C. 458 bp Sm10 TS3.5 Sm10 Esx-1 56 C. 254 bp Sm10 TS3.5 Rcho-1 No actin simult. Mekk3 562 bp mGCNF 239 bp PL-1 62 C. 746 bp Rcho-1 Rcho-1 Sm10 HIF1-alpha 58 C. 373 bp Rcho-1 Hand-1 64 C. 746 bp Rcho-/always Ts3.5 Sm10 mmp-9 55 C. 769 bp Rcho-1/D7diff Stra 13 62 C. 596 bp Rcho-1/D7diff mSna 62 C. 496 bp Rcho-1/D3diff
[0029] The ability to specifically establish cell lineage was confounded by the lack of a cell line that would represent a suitable model of trophoblast stem cell-like cells capable of differentiating into the “transport” phenotype characteristic of human syncytiotrophoblasts or murine labyrinthine trophoblasts.
[0030] Hence, the present inventors investigated and recently identified a mouse cell line that serves as such a model, the mouse SM10 cell line. The SM10 cell line was provided by Dr. Joan Hunt, Kansas University Medical Center. SM10 cells were isolated from the labyrinthine region of the mouse placenta and established from explant outgrowths. Although of trophoblast origin, the specific identity of these cells, with regards to trophoblast lineage, has not been reported. Our preliminary data indicate that SMIO cells can be propagated as stem cell-like cells for many passages in cell culture. RT-PCR analysis using lineage and gene specific primers indicated that proliferative SM10 cells express a major inhibitor of cellular differentiation, the Inhibitor of differentiation 2 (Id2) gene. Id2 is a specific lineage marker of trophoblast term cells in humans and mice. As shown in FIG. 2, SM10 cells express Id2. As expected, Id2 expression was also confirmed in proliferative, mouse trophoblast stem (TS 3.5 ) cells provided by Dr. Janet Rossant, Mount Sinai Hospital. Our results indicate that SM10 cells express Id2 and represent a trophoblast “stem cell-like” cell line.
[0031] To further evaluate the trophoblast lineage of the SM10 cells, we designed an array of unique trophoblast lineage-specific PCR primers (Tables 2 and 3). Each of the genes listed in Table 2 has been shown to be exclusively expressed in specific trophoblast lineages during placental formation.
[0032] The genes (Table 1), in bold, represent genes that are present and restricted to specific lineages in both the mouse and human placenta. Analysis of gene expression in proliferative SM10 cells by RT-PCR indicates, that in addition to Id2, proliferative mouse SM10 cells express genes only present in the labyrinthine trophoblast lineage (D1x3, Esx1, Tfeb and Tec). In addition, the D1x3 protein is present in proliferative SM10 cells as determined by Western blotting. The data indicates that the SM10 cell line can be maintained and passaged in culture in a proliferative state, and expresses a major stem cell regulator and lineage markers of labyrinthine trophoblast cells.
[0033] Further lineage analysis on proliferative SM10 cells by RT-PCR using specific markers for spongiotrophoblast and “invasive” giant cell lineages, including spongiotrophoblast (4311) and giant cells (Hand1), were performed. Differentiated Rcho-1 cells express markers that are specifically present in trophoblast giant cells (PL1, Stra13). The data demonstrates that SM10 cells do not express genes of the spongiotrophoblast or trophoblast (invasive) giant cell lineages.
[0034] The lineage analysis indicates that the SM10 cell line is representative of proliferative trophoblast stem cells that will be committed to the labyrinthine lineage if differentiated. To further analyze SM10 and other placental trophoblast cell lines, several cell lines were treated with TGFβ, a major regulator of placental development, to determine the impact on trophoblast cell growth.
[0035] Trophoblast stem cell growth in serum containing media was inhibited in SM10 cells (40%) and TS cells (20%) in the presence of TGFβ. In SM 10 cells, dose response analysis indicated that TGFβ was maximally growth inhibitory at doses equal to or greater than 1 ng/ml (˜40 pM) (data not shown), consistent with physiological levels of TGFβ found in vivo. In addition, TGFβ specifically induced growth inhibition, as determined by TGFβ antibody neutralization experiments analyzing cell growth. The data demonstrates that TGFβ specifically inhibits the proliferation of SM10 cells.
[0036] TGFβ mediated growth inhibition in SM10 cells suggested that the cells may be growth arrested or undergoing apoptosis (cell death). SM10 cell viability, determined by trypan blue exclusion, indicated that in the present of TGFβ, nearly 100% of SMIO cells remained viable up to 10 days.
[0037] To further analyze the effects of TGFβ, SM10 cells were treated and examined morphologically. The data indicates that TGFβ induces a complete and dramatic morphological aggregation of nonproliferative SM10 cells with cellular fusion within 72 h and this can be maintained for at least 10 days in the presence of TGFβ. The results indicate that TGFβ induces the differentiation of trophoblast stem cell-like cells at the cellular (morphological) level.
[0038] Although TGFβ was capable of inducing substantial morphological aggregation and apparent cellular fusion, we examined a more definitive marker of fusion in labyrinthine or syncytiotrophoblasts, Gem-1. Gem-1 is the definitive lineage marker for and is expressed in the placenta only in differentiated human syncytiotrophoblasts and mouse labyrinthine trophoblasts. SM10 cells treated with TGFβ for 72 h dramatically induced the expression of Gem-1, coincident with morphological differentiation.
[0039] The Id proteins are major regulators of stem cells and cellular differentiation. Because SM10 cells express Id2 in the proliferative, stem cell-like state, it was determined whether TGFβ-induced differentiation could inhibit Id2 expression. In conjunction with the induction of Gem-1 expression, a corresponding loss of Id2 mRNA in the presence of TGFβ in SM10 cells was detected. The results of trophoblast lineage analysis at the molecular level indicate that TGFβ induces the differentiation of the SM10 trophoblast stem cell-like cells specifically to labyrinthine/syncytial trophoblasts.
TABLE 3 Exemplary PCR Primer Pairs suitable for detecting Placental cell lineage genetic markers Gene Forward Reverse Trophoblast stem cell lineage markers Id2 5′tctgagcttatgtcgaatgatagc3′ 5′cacagcattcagtaggctcgtgtc3′ Cdx2 5′cccagcggccagcggcgaaacctg3′ 5′ttctcgcagcgtccatactcctcat3′ ERRBeta 5′tcaagtgcgagtacatgctt3′ 5′gaaatctgtaagctcaggta3′ Invasive extravillous (human) and trophoblast giant cells (rodent) Hand1 5′gcgcctggctaccagttaca3′ 5′agcaacgccttccctctagg3′ Mash2 5′gaaggtgcaaacgtccacttc3′ 5′ccttactcagcttcttgttgg3′ PL-1 5′tgactttgactctttcgggct3′ gctctgaatacaccgagagcg3′ Stra13 5′tttccagachtgtgccc3′ 5′taccagcayttctccagca3′ Spongiotrophoblast lineage (rodent) 4311/TPBP 5′caggtacttgagacatgactc3′ 5′ggcagagatttcttagacaatg3′ Syncytiotrophoblasts (human) and labyrinthine (rodent) Tfeb 5′gcgcatgcagcagcaggctgtc3′ 5′ctggggatgctgctggggcagg3′ Tec 5′ataagaaagaccctgcctccc3′ 5′aagcctcaccactccaaaca3′ Gcm-1 5′agaccaagctggaagcagag3′ 5′gcatgttgctgtgagtagg3′ Dix-3 5′atctcaatgggctcgcag3′ 5′atggagtcactgttgttggg3′ Esx-1 5′gcaaccccaacaggagc3′ 5′ggactcatggcgactgga3′ Internal Controls Beta Actin 5′atcgtgggccgccctaggca3′ 5;tggccttagggttcagaggg3′ GAPDH 5′ggagtcaacggatttggt3′ 5′gtgatgggatttccattgat3′
[0040] | A method of comprehensively identifying a specific placental cell lineage of a placental cell sample, applicable to all placental species, is provided. The method employs RT-PCR technology and comprises detecting expression markers unique for each of four trophoblast cell lineages using specifically designed inventive PCR primer pair panels. Diagnostic and prognostic methods, as well as kits and panels related thereto, are also provided. | 2 |
CROSS REFERENCED TO RELATED APPLICATION
The present application is a divisional application of U.S. patent application Ser. No. 13/036,075 filed on Feb. 28, 2011, the entire content of which is herein incorporated by reference.
TECHNICAL FIELD
The described subject matter relates generally to gas turbine engines and more particularly, to rotor centralization in gas turbine engine assembly.
BACKGROUND OF THE ART
A gas turbine engine generally includes one or more rotors supported by bearing structures in the engine. During an engine maintenance operation, such as on-wing hot section inspections of an aircraft turbine engine, in some engines an aft engine portion including an aft shaft bearing support structure is removed to provide access to the interior of the engine. Once the bearing support is removed, however, the rotor which the bearing supports tends to droop down, under its own weight, at the unsupported side to thereby create misalignment relative to the remaining support structures within the engine. This misalignment may cause damage to the rotor components at tight fit locations and may also cause difficulties during re-assembly of the engine.
Accordingly, there is a need to provide an improved approach.
SUMMARY
In accordance with one aspect, the described subject matter provides a method for supporting a gas turbine rotor assembly during engine assembly/disassembly, the rotor assembly having a central shaft extending substantially horizontally and supported by at least one bearing support structure, the method comprising: a) extending at least one elongate support element radially through an opening defined in a casing of the engine, the casing surrounding the rotor assembly; b) contacting the at least one support element with a portion of the rotor assembly at a location spaced apart from the at least one bearing support structure; and c) rigidly connecting the at least one support element to the casing of the engine, wherein the at least one support element is configured and positioned such that the at least one support element and the at least one bearing support structure cooperate to centralize and at least partially support the weight of the rotor assembly when a second bearing support structure of the engine is absent.
In accordance with another aspect, the described subject matter provides an apparatus for supporting a rotor assembly in a substantially centered position in a gas turbine engine, the apparatus comprising: at least three elongate support elements each extending radially through an opening defined in an exterior of a casing surrounding the rotor assembly, an inner end of each support element contacting with a periphery of the rotor assembly, the support elements each being connected at an outer end thereof to said exterior of the casing, the at least three support elements thereby configured to centralize and support the rotor assembly when a bearing support structure of the rotor assembly is absent.
In accordance with a further aspect, the described subject matter provides a method for supporting first and second rotor assemblies during engine assembly/disassembly, the second rotor assembly having a hollow central second shaft extending substantially horizontally and supported by at least at one bearing support structure, a first central shaft of the first rotor assembly co-axially extending through the hollow central second shaft of the second rotor assembly, opposite front and aft end portions of each of the first and second shafts being supported by a respective front support structure and an aft support structure within the engine during engine operation, the method comprising: a) radially extending three rigid elongate support elements through respective openings circumferentially spaced apart in a casing surrounding the first and second rotor assemblies, to lock the second rotor assembly in a substantially horizontal and centered position in the engine; and b) inserting at least one spacer in an annulus between the first and second shafts to support the first rotor assembly on the second rotor assembly, thereby locking the first and second shafts in the coaxial relationship.
Further details of these and other aspects of the described subject matter will be apparent from the detailed description and drawings included below.
DESCRIPTION OF THE DRAWINGS
Reference is now made to the accompanying drawings depicting aspects of the present invention, in which:
FIG. 1 is a schematic cross-sectional view of a turbofan gas turbine engine according to one embodiment of the present description;
FIG. 2 is a simplified schematic transverse cross-section of the turbofan gas turbine engine taken along line 2 - 2 of FIG. 1 ;
FIG. 3 illustrates an enlarged area of the engine, as circled and indicated by numeral 3 in FIG. 1 , showing the adjustable connection of the bolt to the casing; and
FIG. 4 illustrates an enlarged area of the engine, as circled and indicated by numeral 4 in FIG. 1 , showing a spacer placed between the coaxial high and low pressure spool shafts when a bearing structure is removed, according to another embodiment.
DETAILED DESCRIPTION
FIG. 4 illustrates an enlarged area of the engine, as circled and indicated by numeral 4 in FIG. 1 , showing a spacer placed between the coaxial high and low pressure spool shafts when a bearing structure is removed, according to another embodiment.
Referring to FIG. 1 , a turbofan gas turbine engine which is taken as an exemplary application of the described subject matter, includes a fan case or engine nacelle 10 , a core casing 13 , a low pressure spool assembly 15 which includes a fan assembly 14 and a low pressure turbine assembly 18 connected by a central shaft 12 , and a high pressure spool assembly 23 which includes a high pressure compressor assembly 22 and a high pressure turbine assembly 24 connected by a central shaft 20 . The core casing 13 surrounds the low and high pressure spool assemblies 15 , 23 defining a main fluid path (gas path) therethrough (not numbered). In the main fluid path there is provided a combustor 26 to generate combustion gases in order to power the high and low pressure turbine assemblies 24 , 18 .
The shaft 20 of the high pressure spool assembly 23 is hollow to allow the shaft 12 of the low pressure spool assembly 15 to extend therethrough such that the shafts 12 and 20 and thus the low pressure and high pressure spool assemblies are disposed substantially coaxially within the engine. The common rotation axis of the shafts 12 and 20 defines the main central axis 30 of the engine.
A bearing support structure 16 which may be part of an intermediate case (not indicated) of the engine, supports the respective shafts 12 and 20 at a front or upstream portion thereof and a bearing support structure 32 which may be part of a mid turbine frame 28 positioned between the high pressure turbine assembly 24 and the low pressure turbine assembly 18 , supports the respective shafts 20 , 12 at an aft or downstream portion thereof. Therefore, the bearing support structures 16 and 32 assure the centered position of both shafts 12 and 20 , and thus the low and high pressure spool assemblies within the engine.
Referring to FIGS. 1-4 , one embodiment is shown for a method and apparatus for temporarily supporting or locking a gas turbine rotor assembly such that the respective shafts 12 and 20 are in their substantially centered positions within the engine during engine assembly/disassembly when the engine is disposed substantially horizontally and one of the bearing support structures 16 , 32 is absent. During an engine maintenance operation such as in a hot section inspection, an aft portion of the engine including the mid turbine frame 28 is removed to provide rear end access to the interior of the engine. The shafts 12 and 20 , particularly the aft portion thereof, tends to drop down, causing deviation from the main central axis 30 of the engine, which is not desirable and should be avoided. Therefore, an apparatus for temporarily supporting or locking the shafts 12 and 20 in their substantially centered position within the engine is desired.
The apparatus according to this embodiment includes three rigid elongate support elements such as metal bolts 34 which radially extend through respective openings 36 circumferentially spaced apart in the core casing 13 , to lock the high pressure spool assembly 23 in a substantially horizontal and centered position in the engine. At this moment, the substantially horizontal and centered position of the shafts 12 , 20 and thus the low and high pressure spool assemblies 15 , 23 are assured by the bearing support structures 16 and 32 . Each of the bolts 34 is releasably secured to an outside of the core casing 13 . For example, a nut 35 is welded to the outside of the core casing 13 , aligning with each of the openings 36 for engagement with a threaded section 38 of each bolt 34 .
The threading engagement of the threaded section 38 of the bolt 34 with the nut 35 also functions as a means for adjusting the radial position of each bolt 34 relative to the core casing 13 in order to ensure a firm contact between an inner end of the bolt 34 and the high pressure spool assembly 23 which is represented by the high pressure compressor assembly 22 in FIG. 2 . The threaded section 38 located in an outer end portion of each bolt 34 , may have a diametric dimension larger than the diameter of the remaining section of the bolt in order to allow the bolt 34 to conveniently extend through the opening 36 in the core casing 13 .
The three bolts 34 may be disposed in a same axial location of the engine and may in combination define a plane as shown in FIG. 2 , substantially perpendicular to the central axis 30 of the engine. Alternatively, the three bolts 34 may be disposed in different axial locations of the engine. The axial location of the bolts 34 may be selected differently for different types of engines. For example, in the embodiment shown in FIG. 1 , the bolts 34 are positioned in an axial location such that the inner ends of the bolts 34 are in contact with the high pressure compressor assembly 22 , such as in contact with a compressor platform (not numbered) thereof The compressor platforms in combination define an inner surface of the main fluid path of the rotor assembly.
The one or more openings 36 in the core casing 13 which receive the respective bolts 34 to radially extend therethrough, may be existing ports defined in the core casing 13 such as a borescope port, if one or more such existing ports are available at a desirable axial location(s) of core casing 13 . Otherwise, openings 36 dedicated for temporarily receiving the respective bolts 34 are provided in the selected locations of the core casing 13 and are sealingly covered during engine operation.
The axial location of the bolts 34 should also be convenient for access from the outside of the core casing 13 to place and remove the bolts 34 . In the embodiment illustrated in FIG. 1 , an aft section of the engine nacelle 10 is either openable or removable from the remaining section of the nacelle 10 which is mounted to the wing of an aircraft.
It should be noted that one of the bolts 34 as shown in FIG. 2 , is disposed substantially in a vertical direction, which may not be necessary. However, if one of the bolts 34 is vertically disposed under the high pressure compressor assembly 22 as in an inverted image of FIG. 2 , the bolt 34 in combination with the bearing support structure 16 will fully support the shaft 20 and thus the high pressure spool assembly 23 in its substantially horizontal and centered position within the engine when the bearing support structure 32 is removed. Therefore, the other two bolts 34 may not be in use. This single bolt support arrangement may be desirable in some circumstances according to various engine structures and/or tasks.
A spacer, for example a sleeve 40 according to this embodiment, may be provided to be inserted in an annulus 42 between the coaxial shafts 20 and 12 to support the inner shaft 12 on the outer shaft 20 in their coaxial relationship, thereby maintaining the low pressure spool assembly 15 in the substantially horizontal and centered position within the engine when the bearing support structure 32 is removed. The spacer 40 may have a small section (not numbered) having a thickness to allow easy insertion of the small section into the annulus 42 while substantially maintaining the coaxial relationship between the shafts 12 and 20 . The sleeve 40 may further include a large section (not numbered) having a diametric dimension larger than the diameter of the hole of the shaft 20 , to prevent over-insertion of the sleeve 40 from the aft end portion of the shaft 20 and to facilitate easy removal of the sleeve 40 .
It should be noted that placement of the bolts 34 and the sleeve 40 for temporarily locking the substantially horizontal and centered position of the respective shafts 20 and 12 within the engine during an engine maintenance operation, should be completed before removing the bearing support structure 32 and the bolts 34 and the sleeve 40 should be maintained in position until the maintenance operation is completed and the bearing support structure 32 is placed back in position.
In circumstances wherein the bearing support structure 16 which is located at the front portion of the high and low pressure spool assemblies 23 , 16 is to be removed, the sleeve 40 should be placed in the annulus 42 between the inner and outer shafts 12 , 20 at a front end portion of the shafts 12 , 20 . If use of a sleeve 40 is not applicable due to engine structure, individual spacers such as three spacer blocks (not shown) instead of the sleeve 40 may be used.
The method and apparatus described above for temporarily locking and/or supporting the rotors of a gas turbine engine in their substantially centered position within the engine are not limited to use in an engine maintenance operation. The described method and apparatus may also be used for engine production assembly. The described method and apparatus may allow an engine assembly procedure in a more “ergonomic friendly position” with regard to assembly steps conducted and assembly platforms used in a horizontal engine assembly procedure with respect to those in an vertical engine assembly procedure.
The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departure from the scope of the described subject matter. For example, although a turbofan gas turbine engine having coaxially positioned high and low pressure spool assemblies has been used as an exemplary application of the described method and apparatus, the method and apparatus may be applicable to various types of gas turbine engines. The bearing support structures may not necessarily be associated with a mid turbine frame or an intermediate case but could be applied to any support structures depending on the particular engine structure for which the described method and apparatus are used. The use of elongate support elements such as the metal bolts and the use of spacers such as the sleeves, may not necessarily be combined and can be applicable one without the other depending on the particular engine structure in which they are used. Although a horizontal arrangement is discussed, the approach may likewise be applied to a gas turbine engine vertically-oriented during assembly or maintenance. Still other modifications which fall within the scope of the described subject matter will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims. | One or more support elements radially extend through one or more openings defined in a turbine engine casing and are configured to centralize and at least partially support a rotor assembly of the engine during an engine disassembly or assembly procedure. The support elements are configured to transfer any rotor assembly weight loads to an engine casing while a bearing support of the rotor assembly is absent or removed. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 62/059,348 (“the '348 application”), filed on Oct. 3, 2014 and entitled “Trimless Door Frame.” The '348 application is hereby incorporated in its entirety by this reference.
FIELD OF THE INVENTION
Embodiments of the invention relate to door frames having energy absorbing door stops.
BACKGROUND
Door openings are generally surrounded about their perimeters or “trimmed” with heavy framing to absorb the forces and vibrations associated with repeatedly opening and closing a door mounted within a door opening. Heavy framing is necessary to withstand the day-to-day usage of a door without producing cracks in the surrounding wall due to stress or fatigue. However, door frames are visible and can prevent construction of doors with a smooth, modern appearance with no visible framing.
SUMMARY
Aspects of the present disclosure relate to door frames that incorporate an energy absorbing door stop to distribute the forces and vibrations associated with opening and closing a door. The energy absorbing door stop helps to absorb and distribute the forces so that lower levels of force are transferred into the surrounding wall and thus obviates the need for a traditional door frame or trim. Decreased levels of force applied to the surrounding wall reduces the likelihood of cracking the surrounding wall due to stress or fatigue over many opening or closing cycles of the door.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a trimless door frame installed in a wall according to certain embodiments of the present invention.
FIG. 2 is a perspective view a trimless door frame in isolation.
FIG. 3 is a front elevation view of the trimless door frame of FIG. 2 .
FIG. 4 is schematic end view of a trimless door frame.
FIG. 5 is a schematic end view of a flush mount plate.
FIG. 6 is a schematic end view of a door stop frame.
FIG. 7 is a schematic end view of a support plate.
FIG. 8 is a sectional end view of a hinge side trimless door frame with a traditional hinge.
FIG. 9 is a sectional end view of a hinge side trimless door frame with a concealed hinge.
FIG. 10 is a sectional end view of a hinge side trimless door frame with a flush mount plate.
FIG. 11 is a sectional end view of a strike plate side trimless door frame with a strike plate.
FIG. 12A is an assembly view of a hinge side trimless door frame.
FIG. 12B is an assembly view of a top side trimless door frame.
FIG. 12C is an assembly view of a plate side trimless door frame.
FIG. 13A is an assembly view of a trimless door frame with concealed hinges.
FIG. 13B is a detail perspective view of a support plate for a concealed hinge.
FIG. 14 is a perspective view of a hinge side trimless door frame assembly.
FIG. 15 is a perspective view of a plate side trimless door frame assembly.
FIG. 16 is a perspective view of an assembled trimless door frame.
DETAILED DESCRIPTION
The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
The described embodiments of the invention provide a trimless door frame assembly with an energy absorbing door stop. While the energy absorbing door stops are discussed for use with trimless door frames, they are by no means so limited. Rather, embodiments of the energy absorbing door stop may be used in any door including, but not limited to, fully framed or trimmed doors.
With reference to FIG. 1 , embodiments of the invention relate to a trimless door frame assembly 100 . The illustrated door frame is “trimless” in that it does not include the traditional exposed trim on the wall around the door opening that visibly frames the door positioned within the opening. As described in more detail below, the trimless door frame assembly 100 includes a door stop that absorbs shock and/or vibration from the door 500 opening and closing, which may prevent or reduce the amount of shock transferred to adjacent wall 600 (which may be constructed of drywall or any other suitable building materials). The trimless door frame assembly 100 may thus be installed around the perimeter of the door opening within or adjacent the wall 600 without the need for exposed trim on the wall 600 surrounding the door 500 .
FIGS. 2 and 3 are perspective and elevation views of a trimless door frame assembly 100 with a door 500 installed within it. As shown, the trimless door frame assembly 100 may be constructed such that the door 500 may be substantially flush with one side of the trimless door frame assembly 100 , and, consequently, the door 500 may be substantially flush with the wall or drywall when the trimless door frame assembly 100 is installed adjacent to the wall or drywall. In some embodiments, the trimless door frame assembly 100 may be used in conjunction with a door closer. The trimless door frame assembly 100 is compatible with both surface mounted and concealed door closing mechanisms.
FIGS. 4-7 are schematic end views of constituent components of a trimless door frame assembly 100 that, with other optional components, may be combined to form a trimless door frame assembly 100 . One embodiment of a trimless door frame assembly 100 includes a door frame 150 (formed of a top frame side 150 a , a hinge frame side 150 b , and a strike plate frame side 150 c ), flush mount plate 200 , floating door stop 250 , and support plate 300 , among other hardware or parts.
The door frame 150 , flush mount plate 200 , floating door stop 250 , and support plate 300 may be individual components that are assembled together as described below. In some embodiments, the door frame 150 , flush mount plate 200 , floating door stop 250 , and/or support plate 300 may be combined and/or formed from a single piece of material. Any of the below described parts may be constructed from metals, such as aluminum, steel, or other alloys, polymers, composites, or any other material selected for its ease of manufacturing, cost, durability in use, and resistance to corrosion or other environmental conditions. Furthermore, the parts may be produced by machining, casting, stamping, extrusion, any other applicable forming method, or any combination thereof.
FIG. 16 is a perspective view of an exemplary door frame 150 formed by a top frame side 150 a , a hinge frame side 150 b , and a strike plate frame side 150 c . In use, the door frame 150 is positioned around the perimeter of a door opening provided in a wall 600 .
The frames sides 150 a - c of door frame 150 may have different cross-sectional profiles tailored to their position within the door frame 150 . However, in other embodiments, the frame sides 150 a - c have the identical profile, an example of which is shown in FIG. 4 . In such embodiments, a single frame member bearing the profile may be formed and then cut to the desired length to serve as the top frame side 150 a , hinge frame side 150 b , and/or strike plate frame side 150 c . The door frame 150 may have a rear side 155 that is adjacent the wall or drywall 600 when the trimless door frame assembly 100 is installed and flanges 156 that wrap around or about the wall or drywall 600 . The door frame 150 may also include a hardware recess 160 with associated clearance gap 165 , an assembly recess 152 , and a door stop recess 170 with associated projections 175 . The various recesses and features of the door frame 150 are configured to accept or receive the flush mount plate 200 , floating door stop 250 , support plate 300 , and any additional parts or hardware as described below.
FIG. 5 is a schematic end view of a flush mount plate 200 with arms 210 . The arms 210 of the flush mount plate 200 are configured to mate with the hardware recess 160 of the frame sides 150 a - c so that the face surface 201 of the flush mount plate provides a level surface with other components or hardware that are installed in or near the hardware recess 160 . In certain embodiments, the flush mount plate 200 may be used as a spacer or stacking component in the construction of a trimless door frame assembly 100 , as described in more detail below.
FIG. 6 is a schematic end view of the door stop frame 252 of a floating door stop 250 , which may include a silencer recess 255 configured to receive a door silencer 260 (shown in FIGS. 8-12, 14, and 15 ), an optional hollow 275 for lightness, reduction in material usage, and/or ease of manufacturing, one or more absorber recesses 265 configured to receive absorbers 270 (shown in FIGS. 8-12, 14, and 15 ), and one or more locator arms 280 with optional extensions 281 . The door stop frame 252 may also include a strike face 251 as the region of contact between a door and the floating door stop 250 . The absorber recesses 265 are configured to receive an absorber (not shown) that forms the point of contact and connection between the floating door stop 250 and door frame 150 . The locator arms 280 and/or extensions 281 are adapted to mate with the door stop recess 170 of the door frame 150 , and the width W is sufficiently small to allow for clearance and lateral movement of the floating door stop 250 with respect to the door stop recess 170 of the door frame 150 .
FIG. 7 is a schematic end view of a support plate 300 that may comprise one or more protrusions 310 . The support plate 300 and its associated protrusions 310 are configured to mate with the contours of the hardware recess 160 of the door frame 150 . In certain embodiments, the trimless door frame assembly 100 may not include structural supports for hinges, strike plates, and other door hardware as with traditional door frames. The support plate 300 may be installed on the door frame 150 to provide hard mounting points for hinges, strike plates, or other door hardware. Similar to the flush mount plate 200 , the support plate 300 may be used alone or in conjunction with the flush mount plate 200 to stack components in the hardware recess 160 during construction of a trimless door frame assembly 100 .
FIGS. 8-11 are sectional end views of a hinge frame side 150 b and strike plate frame side 150 c with flush mount plates 200 , floating door stops 250 , support plates 300 , and additional hardware as typically installed to a hinge side stud 151 b and plate side stud 151 c , respectively. The frame side 150 b , 150 c may be affixed or otherwise attached to a stud 151 b , 151 c with drywall screws 153 that pass through the flanges 156 and wall or drywall 600 into the studs 151 b , 151 c . The flanges 156 may overlap the wall or drywall 600 to varying degrees to adjust the amount of spacing between the rear side 155 of the frame side 150 b , 150 c . The spacing between the rear side 155 of the frame side 150 b , 150 c may be used to compensate for variations in the size or trueness of the wall opening. The frame side 150 b , 150 c may then be adjusted to be plumb with respect to the ground and adjacent frame sides 150 a - c . In certain embodiments, the flanges may be left exposed, painted, anodized, or covered with mud, sanded, and painted to match the drywall to provide a smooth and clean appearance. In some embodiments, a decorative reveal 180 may be included in the frame side 150 b , 150 c.
A floating door stop 250 may be positioned along the length of each frame side 150 a - c and more particularly is positioned within the door stop recess 170 on each frame side 150 a - c and retained therein via locator arms 280 . The floating door stop 250 may include a door silencer 260 positioned within silencer recess 255 on the strike face 251 of the door stop frame 252 . The door silencer 260 may be formed of a gasket material, such as a rubber or other elastomeric material. One exemplary gasket material for the door silencer is a thermoplastic vulcanizate (TPV) material. The door silencer 260 acts to seal the door 500 (not shown) against the floating door stop 250 and silences the door 500 as it closes against the floating door stop 250 . The locator arms 280 may interact with the projections 175 of the door stop recess 170 to allow a loose-fit between the floating door stop 250 and door stop recess 170 . As shown, the locator arms 280 have clearance around their ends to allow the floating door stop 250 to move laterally relative to the door stop recess 170 . In certain embodiments, the locator arms 280 may have different end configurations to allow for additional degrees of freedom. For example, as shown in FIGS. 8-11 , the locator arms 280 allow for relative movement between the floating door stop 250 and door stop recess 170 , and subsequently the frame side 150 b , 150 c , in the direction perpendicular to the strike face 251 of the floating door stop 250 . However, the locator arms 280 have extensions 281 that restrict relative movement between the floating door stop 250 and door stop recess 170 in a direction parallel to the strike face 251 of the floating door stop 250 . In some embodiments, the locator arms 280 may not have the extensions 281 or otherwise be designed to allow for relative movement between the floating door stop 250 and door stop recess 170 in a direction parallel to the strike face 251 of the floating door stop 250 . Certain embodiments of the floating door stop 250 , locator arms 280 , extensions 281 , door stop recess 170 , and/or projections 175 may be configured to allow for relative movement between the floating door stop 250 and door stop recess 170 in one, two, or three dimensions, including rotation about any given axis.
The floating door stop 250 may also include one or more absorbers 270 positioned within or proximate to the door stop frame 252 and more particularly within the absorber recesses 265 of the door stop frame 252 . The absorbers 270 may be a spring or a component made from rubber, an elastomer, cellular material, a polymer, a thermoplastic vulcanizate, or any other material selected for its ability to deflect, compress, or elongate and regain its shape to absorb and distribute forces. The absorbers 270 function to stabilize the floating door stop 250 in an aligned position within door stop recess 170 of a frame side 150 a - c . When the floating door stop 250 encounters a force, such as when a door is closed against the strike face 251 of the door stop frame 252 , the floating door stop 250 will be laterally displaced relative to the door stop recess 170 , which compresses the absorber 270 distal the strike face 251 into a projection 175 of the door stop recess 170 such that the absorber 270 absorbs the energy of the door closure instead of the surrounding wall. More specifically, the motion and/or displacement of the floating door stop 250 distributes the impact of a door closure or other applied force over a larger amount of time as the absorber 270 deflects and extends the range of motion of the floating door stop 250 . The impact energy applied through the floating door stop 250 extends over a larger time with a correspondingly lower peak force. Also, the internal friction and deflection of the absorber 270 , along with any frictional losses due to the movement of the floating door stop 250 relative to any other parts of the frame side 150 b , 150 c may absorb and dissipate impact energy. The resulting force transferred through a trimless door frame assembly 100 to the studs 151 b , 151 c and wall or drywall 600 has a much lower peak magnitude relative to solidly mounted door stops. These lower peak forces greatly reduce the chances of cracking or fatigue, particularly of the wall or drywall 600 at or around the frame sides 150 a - c and/or drywall screws 153 , even through repeated cycles of opening and closing the door. While the floating door stop is shown equipped with two absorbers 270 , it is certainly contemplated to use a single absorber 270 or more than two absorbers 270 .
The floating door stop 250 may include any number of modifications or alterations to suit a particular application. For example, as shown in FIGS. 9-11 , an auxiliary absorber 271 may be included in the door stop recess 170 to support or otherwise cushion one or more of the locator arms 280 or extensions 281 . As shown, the auxiliary absorber 271 is disposed between the locator arm 280 and the door stop recess 170 on the opposite side of the floating door stop 250 as the strike face 251 . This auxiliary absorber 271 may be particularly beneficial for absorbing the forces associated with closing of a door. Furthermore, absorbers 270 and/or auxiliary absorbers 271 may be positioned in any orientation or relation between the floating door stop 250 , locator arms 280 , and or extensions 281 and the door stop recess 170 , projections 175 , and/or frame sides 150 a - c.
In order to adjust or optimize the amount of force absorption for a particular application, the floating door stop 250 (with absorber(s) 270 and optional auxiliary absorbers 271 ) may take on different materials, geometries, or characteristics. For example, the absorbers 270 or auxiliary absorbers 271 may be hollow or solid, and may be made from any material that is suitable for its characteristics to compress, deflect, or elongate in response to an applied load over a large number of loading cycles. In some embodiments, the absorber 270 and/or auxiliary absorber 271 may be cast or otherwise molded in place within the absorber recesses 265 or between the floating door stop 250 , locator arms 280 , extensions 281 , door stop recess 170 , and/or projections 175 . In certain embodiments, the absorbers 270 and/or auxiliary absorbers 271 may be asymmetrical so as to better adapt to differing levels of force applied in different directions. The absorber 270 and/or auxiliary absorber 271 may also be affixed or otherwise attached to the floating door stop 250 , locator arms 280 , extensions 281 , door stop recess 170 , and/or projections 175 by adhesives, directly molding the absorbers 270 and/or auxiliary absorbers 271 to a surface, or forming the absorbers 270 and/or auxiliary absorbers 271 in such a shape as to allow them to accept tensile loads between the floating door stop, locator arms, and/or extensions 281 and the door stop recess 170 and/or projections 175 in addition to compressive loads.
Referring to FIG. 8 , a hinge frame side 150 b may also include a hinge 320 coupled to a support plate 300 . The support plate 300 is installed in the hardware recess 160 of the hinge frame side 150 b . In certain embodiments, the support plate 300 may be slid along the length of the hinge frame side 150 b to the appropriate location for mounting the hinge 320 . As shown, the hinge 320 may be attached to a support plate 300 with standard fasteners 305 . In certain embodiments, the fasteners 305 may be sufficiently long that they extend into the clearance gap 165 .
FIGS. 9 and 10 are sectional views of a hinge frame side 150 b adapted for use with concealed hinges 321 taken above and below the concealed hinge 321 , respectively. Concealed hinges 321 may be substantially larger than traditional hinges, and may extend farther into the hinge frame side 150 b such that they impinge upon the hinge side stud 151 b and/or wall or drywall 600 . Notches or other clearance apertures (not shown) must be cut into the hinge frame side 150 b , hinge side stud 151 b , and/or wall or drywall 600 to provide adequate clearance and space for the concealed hinge 321 . In some embodiments, the weakening of the wall or drywall 600 , hinge side stud 151 b , and/or frame side 150 b may require the use of a secondary hinge side stud 322 affixed to the primary hinge side stud 151 b with an optional stud screw 154 . The concealed hinge 321 may be affixed or otherwise attached to a concealed hinge support plate 301 with bolts 306 or other fasteners. The concealed hinge support plate 301 mates with hardware recess 160 . The vertical positioning of the concealed hinge support plate 301 , and consequently the concealed hinge 321 , may be adjusted by stacking the concealed hinge support plate 301 in the hardware recess 160 with different lengths of flush mount plates 200 . The flush mount plates 200 , which may interact with the hardware recess 160 through arms 210 , may provide vertical support to the concealed hinge support plate 301 , and, as shown in FIG. 10 , provide a flush, aesthetically pleasing surface when face surface 201 is coplanar with one or more other portions or features of the hinge frame side 150 b and/or any other adjacent hardware. In certain embodiments, the flush mount plates 200 may be notched or cut to conform to the edge contours of a standard hinge 320 , concealed hinge 321 , or any other hardware that may impinge on the flush mount plates 200 .
FIG. 11 is a sectional end view of a strike plate frame side 150 c as installed with a strike plate 340 . The strike plate 340 is attached to a support plate 300 by one or more fasteners 305 . The support plate 300 is disposed within the hardware recess 160 of strike plate frame side 150 c . The vertical location of the support plate 300 , and the attached strike plate 340 , may be adjusted by stacking the support plate 300 in the hardware recess 160 with differing lengths of flush mount plates 200 (not shown). The flush mount plates 200 may be notched or otherwise cut or shaped to fit the contours of the strike plate 340 or any other hardware that may be in the vicinity of the flush mount plates 200 .
FIGS. 12A-C are assembly views of exemplary embodiments of the hinge frame side 150 b , top frame side 150 a , and strike plate frame side 150 c . The frame sides 150 a - c may be provided with a series of flush mount plates 200 interspersed with one or more support plates 300 . Each frame side 150 a - c may also include a door stop frame 252 with a door silencer 260 and absorber 270 . One exemplary method of installing the flush mount plates 200 , support plates 300 , door stop frames 252 , door silencers 260 , and/or absorbers 270 comprises sliding the individual parts into their respective recesses or channels of the frame side 150 a - c by aligning the part at the end of a recess and simply feeding it through.
As shown in FIG. 12B , the flush mount plate 200 and door stop frame 252 (with door silencer 260 and/or absorber 270 ) may be the same length as the top frame side 150 c so that only one component of each is required to span the length of the top of the door frame 150 . However, the flush mount plate 200 and door stop frame 252 (with door silencer 260 and/or absorber 270 ) may also be provided in multiple sections or pieces to facilitate installation, or to interact with other components of the trimless door frame assembly 100 . For example, the hinge frame side 150 b may require one or more support plates 300 to provide mounting points for one or more hinges 320 . The flush mount plates 200 and support plates 300 may be installed in series such that the flush mount plates 200 establish the vertical location and/or support for the support plates 300 . The positioning of the support plates 300 may be adjusted or otherwise altered by cutting the flush mount plates 200 to length and stacking the flush mount plates 200 and support plates 300 in order in the hardware recess 160 of the hinge frame side 150 b . The hinges 320 may then be affixed or otherwise attached to the support plates 300 in any vertical position as necessary for a particular application.
Similarly, the strike plate frame side 150 c may include a strike plate 340 affixed or otherwise attached to a support plate 300 . The flush mount plates 200 may be cut to length and stacked in the hardware recess 160 of the strike plate frame side 150 c along with the support plate 300 to vertically locate the support plate 300 and strike plate 340 . In certain embodiments, the flush mount plates 200 may be notched, cut, or otherwise shaped to conform to the peripheral contours of a hinge 320 , strike plate 340 , or any other hardware that may be in contact with the flush mount plates 200 .
Once the required components have been installed into individual frame sides 150 a - c , the frame sides 150 a - c may be connected with angle brackets 350 to form the door frame 150 . The angle brackets 350 may be installed into assembly recesses 152 to connect the top frame side 150 a with the hinge frame side 150 b and strike plate frame side 150 c on either side, respectively.
To further describe the operation and interaction of the flush mount plate 200 , support plate 300 , hinges 320 , and/or strike plate 340 , an exemplary installation method of strike plate frame side 150 c is described. A first flush mount plate 200 is first inserted longitudinally into the hardware recess 160 (not shown) and slid along strike plate frame side 150 c until the bottom of the flush mount plate 200 rests against the floor. As shown in FIG. 12C , the upper edge of the flush mount plate 200 towards the bottom of the figure may be notched such that it conforms to the strike plate 340 . This notch, and others, would typically be made prior to taking the strike plate frame side 150 c to the installation location, but they may also be made on-site. In other words, the flush mount plate 200 pieces are typically, but do not have to be, pre-cut. Next, a support plate 300 is inserted longitudinally into the hardware recess 160 and slid along the strike plate frame side 150 c until it abuts the first flush mount plate 200 , which prevents further translation of the support plate 300 within hardware recess 160 and locks support plate 300 in position. This position is where the strike plate 340 will be located. A second flush mount plate 200 is then inserted into hardware recess 160 and slide along strike plate frame side 150 c as described above until it abuts the support plate 300 . The strike plate 340 can then be secured (e.g., screwed) into the support plate 300 . A similar assembly method is performed for the hinge frame side 150 b , although this side may involve the installation of more flush mount plates 200 and support plates 300 depending on the number of hinges 320 used. The assembly of the top frame side 150 a may be simpler, as there may not be hinges 320 or strike plates 340 , and only a single flush mount plate 200 having substantially the same length as the top frame side 150 a need be inserted into hardware recess 160 . In much the same way, the floating door stop 250 may be installed into the frame sides 150 a - c by aligning the floating door stop 250 with the end of the door stop recess 170 . The floating door stop 250 may then be slid along the door stop recess 170 until it is fully installed within the frame side 150 a - c.
FIG. 13A is an assembly view of a hinge frame side 150 b and strike plate frame side 150 c with concealed hinges 321 . The assembly of the strike plate frame side 150 c may be similar to that described above, with a strike plate 340 mounted to a support plate 300 , which is located by flush mount plates 200 . The assembly of hinge frame side 150 b may be altered or changed to support the use of concealed hinges 321 that are considerably larger and bulkier than traditional hinges. To accommodate concealed hinges 321 , the hinge frame side 150 b may include hardware apertures 162 . The concealed hinge support plates 301 , as shown in FIG. 13B , may include protrusions 311 for aligning and/or locating the concealed hinge support plate 301 in the hinge frame side 150 b , a cavity 312 , hinge aperture 314 , and fastener holes 316 . The cavity 312 and hinge aperture 314 may be configured to accept the concealed hinge 321 so that it may be affixed or otherwise mounted to the concealed hinge support plate 301 via fastener holes 316 . Similarly, flush mount plate 200 may also include apertures 215 to provide clearance for the concealed hinges 321 . As shown, the flush mount plate 200 may be a single piece or may be separate pieces as described above. A single piece flush mount plate 200 may be installed by sliding it into the hardware recess 160 , before or after the installation of the concealed hinge support plates 301 .
Referring to FIGS. 12A-C and 13 A, the trimless door frame assembly 100 may take on a number of variations or alternative embodiments. For example, trimless door frame assemblies 100 may be fully or partially assembled in a factory or other production facility, including any necessary trimming or shaping of the flush mount plates 200 or any other parts, and installed on site. Alternatively, trimless door frames assemblies 100 may be provided as kits, as individual components cut to length, individual components provided in stock lengths and cut on site, or as bulk lengths of stock material to be cut into individual components on site. In any embodiment, features such as, but not limited to, hardware apertures 162 , apertures 215 , length, notches, or the like may be cut or formed either in a manufacturing facility or on site during door installation. Furthermore, components such as the flush mount plates 200 , door stop frames 252 , door silencers 260 , absorbers 270 , support plates 300 , 301 or the like may be installed by snapping them into place, retaining them with fasteners or adhesives, or sliding them into the applicable recesses as described above. Certain embodiments of the trimless door frame assembly 100 may include the floating door stop 250 and its associated hardware on only the top frame side 150 a , hinge frame side 150 b , strike plate frame side 150 c , or any combination thereof.
FIGS. 14 and 15 are perspective views of the hinge frame side 150 b and strike plate frame side 150 c . The frame sides 150 b , 150 c include a floating door stop 250 with door stop frame 252 , door silencer 260 , and absorbers 270 . The hinge frame side 150 b has a hinge 320 disposed on mounting plate 300 and between two flush mount plates 200 . Similarly, the strike plate frame side 150 c has a strike plate 340 installed on mounting plate 300 and between two flush mount plates 200 . As shown, the flush mount plates 200 have a face surface 201 that is coplanar with the hinge 320 and/or strike plate 340 . The flush mount plates 200 may also be notched or otherwise shaped to mate with the contours of the hinge and/or strike plate 340 to provide a relatively flat visible surface.
FIG. 16 is a perspective view of the trimless door frame assembly 100 as assembled from a top frame side 150 a , hinge frame side 150 b , and strike plate frame side 150 c . The flush mount plates 200 and hinges 320 are visible on the hinge frame side 150 b . The frame sides 150 a - c have been assembled by inserting angle brackets 350 into the assembly recesses 152 (not shown). The frame sides 150 a - c may be assembled into a trimless door frame assembly 100 in a wall or wall frame, or they may be assembled and then installed into a wall or wall frame.
Any of the above described components, parts, or embodiments may take on a range of shapes, sizes, or materials as necessary for a particular application of the described invention. The components, parts, or mechanisms of the described invention may be made of any materials selected for the suitability in use, cost, or ease of manufacturing. Materials including, but not limited to aluminum, stainless steel, fiber reinforced plastics, rubber, elastomers, carbon fiber, composites, polycarbonate, polypropylene, other metallic materials, or other polymers may be used to form any of the above described components.
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below. | Described are trimless door frames and energy absorbing door stops. The energy absorbing door stop allows for relative movement between the door stop and the surrounding door frame. The relative movement of the energy absorbing door stop helps to distribute and dissipate forces and vibrations from opening and closing a door, reducing the levels of force transferred into the surrounding wall. The reduction in forces applied to the wall allows for the elimination of heavy door framing and trim. Since door trim is no longer necessary, trimless door frames may be installed with a smooth appearance without cracks appearing in the surrounding wall due to stress or fatigue. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application No. 61/077,959 filed on Jul. 3, 2008, entitled “Vented Container and Method of Manufacturing,” which application is assigned to the same assignee as this application and whose disclosure is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to a container, or a cap for a container, which includes a venting mechanism that precludes the leakage of liquid or other flowable contents, e.g. particulates, from the container.
BACKGROUND OF THE INVENTION
The problem of container deformation in response to pressure differences existing between the inside of a closed container and the ambient pressure is well known in the packaging industry. Such container deformation may be non-recoverable for certain container materials, such as some rigid or semi-rigid structures made of plastics or metals. Thin-walled, flexible or partially flexible containers can be particularly sensitive to the problem.
While not wishing to be bound to any particular theory, there are a number of possible factors which may lead to the existence of the pressure differences between the interior and the exterior of the container mentioned above. The contents of the container may, for example, be chemically unstable or may be sensitive to certain contaminants such as might occur in a reaction between the gases which may exist in the head space of the container and the contents of the container, or alternatively, in certain specific circumstances, where the contents of the container may react with the container material itself. Any chemical reactions involving the contents may lead to either production of gases, and hence to overpressure in the container, or to the absorption of any head space gases thereby causing under pressure in the container. In addition, the solid contents may absorb moisture, such as created by condensation due to temperature differentials and become soggy or saturated.
Pressure differences between the pressure inside the container and the ambient atmospheric pressure may also occur when the temperature during the filling and sealing of the container is significantly different from external temperature during shipment, transportation and storage. Another possibility of a pressure difference may be caused by a different ambient pressure at the filling of the container from another ambient pressure at a different geographical location.
The prior art has proposed several solutions using valve systems which avoid pressure differences between the interior and the exterior of the container. Proposed solutions also relate to various venting caps which allow pressure generated inside the container to be released by escape of gas. U.S. Pat. No. 4,136,796 and EP 0 752 376 disclose self venting closures having a gas-permeable membrane covering an orifice to the exterior atmosphere. These membranes are made of a material which is impermeable to liquids, but permeable to gases. Therefore, these containers may have apertures to release gas to the exterior without losing their leak-tightness. U.S. Pat. No. 5,988,426 and EP 337677 disclose a vented lid that relies on a hydrophobic material to allow passage of air through the vent hole and prevent the passage of liquids through the vent hole. Another example U.S. Pat. No. 6,886,579 relies on a ball bearing mechanism to seal the vent and prevent spillage of liquid contents. Additionally, GB 1 146 972 discloses a venting cap to be fitted onto the mouth of a container. It allows the passage of gases while preventing passage of liquids through the venting membrane. This is achieved by choosing the size of the pores in the membrane.
The use of membranes in these applications can add a considerable expense to the venting system. Tests have shown that when containers are heated to sufficient temperature to cause internal pressures to develop, leakage through the membrane occurs. In the case of mechanical closures, these devices can also add complexity and cost to the vent system and can suffer from malfunction and breakage of the mechanical components. Therefore the need exists for a container for a flowable product such as liquid or particulate, or a cap for such a container, which allows venting of the container while preventing the leakage of the flowable contents from the container even under conditions where internal pressures exist.
BRIEF SUMMARY OF THE INVENTION
The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
The present invention relates to a container, or a cap that may be used a container, which includes a venting means and at the same time prevents leakage of liquid or other flowable contents from within the container.
In one embodiment of the presently described invention, a perforated cap structure is placed atop a vent hole that extends from the interior of a container to the exterior of the container, that is completely through the container wall. This cap is sealably affixed to the container wall. On top of the vented hole a dome like structure is positioned and is preferably constructed of a flexible, impervious material. The dome structure has an internal area and a radially extending venting area and a further radially extending external flange area. The flange area is fastened to the container in such a way so as to maintain coverage of the vent by the internal area of the dome. The venting area of the dome is located so as to not overlie the vent hole. The venting area of the dome has perforations sufficient to allow air flow through the dome. On top of the dome is positioned a porous expandable absorbent, which has an upper surface and a lower surface, so as to fill the area within the cap, but not to exert pressure upon the dome. The dome is positioned adjacent the lower surface. On top of the domed structure and the absorbent material is a perforated rigid cap that is sealably attached to the surface of the container. Thus, in a situation of normal usage or storage where the contents of the container were of higher pressure than the external atmosphere, gasses from within the container would flow through the vent hole, through the venting area of the dome, around and through the absorbent material and finally through the perforated area of the cap. Splashing or sloshing of the liquid or other flowable contents during use or shipment or handling is anticipated. Minor amounts of liquid splashing into the vent hole would be contained in the domed structure and would then drain back into the container. In situations of abnormal usage or storage wherein the liquid or other flowable contents of the container are brought in direct and prolonged contact with the vent hole, the contents would pass through the venting area of the dome and be absorbed into the expandable absorbent. Once moistened by the liquid, the absorbent would expand against the perforated cap and collapse the dome structure from a first open position to a second closed position, thereby pressing the interior area of the dome into direct contact with the vent hole and sealing the vent hole to further leakage.
In a further embodiment of the presently described invention, an additional domed structure is placed within the cap structure, on top of the perforations in the cap. That is, the invention may include first and second domed structures that move between a first open position and a second closed position. Upon expansion of the absorbent material, both the domed structures are collapsed and placed in direct contact with the vent hole and perforated area in the cap. As a result, the area between the container and the cap are sealed and isolated and leakage of the liquid material from the construction is prevented.
In yet another embodiment of the presently described invention, the venting device is preassembled and is sealably attached to the container such that the venting device overlies the vent hole in the container. In this case a dome like structure of flexible impervious material that has an internal area and a radially external venting area and a further radially extending external flange area is prepared. On top of the dome is placed a porous expandable absorbent so as to fill the area within the cap, but not to exert pressure upon the dome. On top of the domed structure and the absorbent material is a perforated rigid cap that is sealably attached to the flange area of the dome. The venting device can then be sealably attached to the container.
Other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description of the various embodiments and specific examples, while indicating preferred and other embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:
FIG. 1 is a perspective view depicting one version of a dome structure;
FIG. 2 is a perspective view of one embodiment of the presently described invention illustrating a dome structure and absorbent material configuration;
FIG. 3 is a perspective view of yet a further embodiment of the presently described invention providing a plural domed structure;
FIG. 4 is a perspective view of one embodiment of the presently described invention where the absorbent layer has expanded, crushing the dome structure and sealed the container from further leakage;
FIG. 5 is a perspective view of yet a further embodiment where the vent device is constructed as a screw cap for attachment to a container;
FIG. 6 is a perspective view of an embodiment where the vent device is a stand alone device that can subsequently be attached to a container;
FIG. 7 is a perspective view of the stand alone vent device attached to a container;
FIG. 8 provides a block diagram of an exemplary method for making a vented container; and
FIG. 9 is a flow chart of another exemplary method of making a vented container.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is now illustrated in greater detail by way of the following detailed description which represents the best presently known mode of carrying out the invention. However, it should be understood that this description is not to be used to limit the present invention, but rather, is provided for the purpose of illustrating the general features of the invention.
Referring to FIG. 1 , a perforated dome structure 5 is shown to have an internal area 10 and a radially extending external perforated venting area 20 and a further radially extending external flange area 30 .
FIG. 2 provides a vented container 100 that includes a vent 120 . On top of this vent 120 is affixed a domed structure 5 . A flange area 30 is fastened to the container 100 , such as by adhesive, sonic welding, in mold or the like, in such a way as to maintain coverage of the vent 120 by the internal area 10 of the dome. The venting area of the dome 20 is located such as to not cover or block the vent hole 120 . On top of the dome 5 is placed a porous expandable absorbent 130 . The absorbent 130 has an upper and lower surface and the dome 5 is positioned against the lower surface. Placed on top of the absorbent material 130 and attached to the container 100 is a rigid cap 140 with at least one perforation or opening 150 .
Reference is now directed to FIG. 3 , where an additional or second domed structure 200 is used in the container construction. The additional dome 200 is positioned immediately beneath the opening 150 , and adjacent the upper surface of the absorbent 130 so as to provide a further closure mechanism when the absorbent material expands to prevent either leakage of the contents or seepage from the environment. As seen from FIG. 3 , the second domed structure 200 is placed in an inverted position when compared to the first domed structure 5 . Each of the first and second domed structures, 5 and 200, respectively, can move between a first open position and second closed position.
The domed structure 5 is positioned to ensure that surface or flange 20 of the domed structure 5 does not come in cover or obscure the vent 120 until such time as the absorbent material 130 swells due to liquid contact and causes the dome 5 to collapse over the vent 120 thereby sealing the vent 120 from further leakage.
FIG. 4 , illustrates the container construction provided in FIG. 2 , showing the container closure after subjecting it to abnormal use conditions so that the expandable absorbent 130 has absorbed the leaking liquid and has expanded in order to collapse the domed structure 5 to a second closed position from a first open position shown in FIGS. 2 or 3 . The pressure exerted by the absorbent material causes the dome 5 to come in direct contact with vent hole 120 so as to prevent further leakage of the liquid contents of the container. The second position of the domed structure is substantially flat and forms a generally planar configuration with the top of the container on which it is seated.
Referring to FIG. 5 , the vent device is constructed as a screw cap 170 for the container showing a series of threads to fasten the cap 170 to the container. While FIG. 5 provides only a single domed structure 5 , it should be understood that a plural domed structure as provide in FIG. 3 could be provided.
Reference is now directed to FIG. 6 and 7 , the vented device is constructed as a preassembled unit 180 which can then be sealably attached to a container 100 such that it overlies the vent hole 120 in the container.
The absorbent material 130 provided in the exemplary embodiments of the presently described invention, can be of any material that expands when exposed to the liquid contents of the container. One example of such a material is compressed cellulose available from either (a) “The Color Wheel Company”, Philomath, Oreg. under the Trade Name of “Miracle Sponges” or (b) “The Absorene Manufacturing Company Inc”, St. Louis, Mo. under the Trade Name of Cellulose Discs. Another example of a suitable material for use with the present invention is a non-woven construction that is impregnated with super absorbent polymer available from Scapa North America of Windsor, Conn. under the product designations including WSD-244, L-550 and WSD-252. These materials were used in sufficient layers such that upon expansion of the materials, sufficient pressure was exerted on the domed structure so as to create a seal.
In order to compare materials provided in the prior art with those of the current invention, a test protocol was embraced. To simulate hair care products, ten ounce plastic bottles were filled to 90% of their volume with 3% hydrogen peroxide. In the case of non-woven materials and micro porous films, the test materials were affixed to the inside surface of a cap. This cap had a 16″ hole placed in its top surface. The cap was then attached to the bottle. In the case of the current invention, the constructions of FIG. 2 and FIG. 3 were tested. The bottles were then inverted to expose the test materials to the liquid contents of the bottle. The bottles, still in the inverted position, were then placed in an oven at 50° C. for twenty hours and observed for leakage.
The porous non-wovens tested were (a) product codes 18007, 12085, 17509 and 26402 from Alstrom of Windsor Locks, Conn.; and (b) product codes DP3930-100H and DP5001-140P from Delstar of Middletown, Del. The micro porous films tested were (a) product codes AC38 from Clopay of Mason, Ohio and (b) product codes PM-I020 and PM-3V for Mupor PTFE from Porex of Fairport, Ga. All of the non-wovens and films listed above did not pass the twenty hour test. Only the constructions of this invention passed the test by not allowing any of the liquid contents of the bottle to exit the container.
An exemplary method of making a vented container is illustrated in FIG. 8 . A method is described wherein at step 300 , a container 100 is provided and at step 400 a venting device 180 is sealably attached to the container. The venting device including: (a) a perforated domed structure that has an internal area and a radially extending venting area and a further radially extending external flange area beyond the vent area; (b) an absorbent material overlies the domed structure to absorb any liquid contents of the container; and (c) a perforated rigid cap is sealably attached to the flange area of the domed structure; over the opening and the venting device is sealably attached to the surface of a container such that it overlies a vent hole in the container.
Another exemplary method for making a vented container is illustrated in FIG. 9 . A method is described wherein at step 500 a perforated domed structure 5 is created and at step 510 a container 100 is provided. At step 520 the domed structure is sealably attached to the container so that the domed structure overlies the opening 120 and is not in direct contact with the opening, that is the domed structure does not block the opening. At step 530 an absorbent material 130 is placed so as to overly the domed structure and at step 540 a perforated rigid cap 140 is placed so as to overly the absorbent material. At step 550 the cap is sealably attached to the surface of the container.
It will thus be seen according to the present invention a highly advantageous vented container has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, and that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.
The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as it pertains to any apparatus, system, method or article not materially departing from but outside the literal scope of the invention as set out in the following claims. | A venting device that may be used directly with a container or via a vent cap for a container, includes a venting mechanism having one or more collapsible dome structures and an absorbent material to prevent leakage of liquid or flowable contents from within the container. The construction relies on a combination of venting domed structures and expandable absorbent material to seal one or more openings in a container and or cap. | 8 |
FIELD OF THE INVENTION
The invention relates to a jack-shaft operator assembly for powering a door comprising a movable door leaf and a drive tube or door shaft geared to the door leaf for common movement thereof, including a shaft connecting means for connecting a driven member of the jack-shaft operator assembly to the door shaft or drive tube. Such jack-shaft operators are commercially available for motorized door operation. In addition, the invention relates to a door provided with such a jack-shaft operator assembly as well as to a method for fitting such a jack-shaft operator assembly.
PRIOR ART
Some commercially available doors feature in addition to a movable door leaf also a drive tube or door shaft. Such a door shaft may be part of a means for counterbalancing a door to be moved vertically at least in part. In such a case, the drive tube or door shaft is connected to a torsion spring. The drive tube or door shaft is geared to the door leaf, for example via a lift cable or the like so that movement of the door leaf moves the drive tube or door shaft. Such doors have been on the market for a long time.
Likewise available on the market are direct or jack-shaft operators for powering such doors. These jack-shaft operators are connected directly to the door shaft or drive tube, i.e. the operator driving the door shaft or drive tube rotatingly. This rotation of the door shaft causes movement of the door leaf geared thereto. Accordingly, jack-shaft operators of this type make use of gearing already available on the door side, thus eliminating the need for additional gearing as required on other door operators, for instance on trolley-type systems. This is why such jack-shaft operators are of advantage as regards the labor and expense involved in production and assembly.
Jack-shaft operators available on the market are composed of a usually electric operator motor and a reduction gear, the reduction gear mostly featuring a worm gear. This kind of gearing is self-locking and the reason why jack-shaft operators as compared to trolley-type operators also feature better security against forced entry.
It has since been discovered in many applications that doors already provided with a door shaft or drive tube nevertheless need to be fitted with a trolley-type operator. The reason for this is the usually cramped space available in the surroundings of the door. It is particularly with doors to basement car parks, that to the left and right of the door only little—too little—sideroom is available to additionally mount a jack-shaft operator on the drive tube.
SUMMARY OF THE INVENTION
The invention is based on the object of configuring a jack-shaft operator assembly of the kind as cited at the outset such that it can now be put to use even where little space is available.
This object is achieved on the basis of a jack-shaft operator assembly of the kind as cited at the outset in that the shaft connecting means now comprises a connecting plate element secured to or integrally configured with the driven member and a shaft connecting element mountable non-rotatably, more particularly positively non-rotatably, on the door shaft or drive tube, the shaft connecting element including an axial opening extending through the shaft connecting element for receiving non-rotatably, more particularly positively non-rotatably, the door shaft and connectable or connected by a plate connecting portion located radial outside of the opening to the connecting plate element.
Fitting a jack-shaft operator apparatus may make even a centimeter or a few millimeters critical. The lack of a few millimeter space makes it necessary to decide whether additional gearing needs to be employed or even a change made to a totally different type of door operator. As compared to known jack-shaft operators a few centimeters can now be saved in accordance with the invention by the door shaft or drive tube being fully insertable into the tube connecting element. Now, between the drive tube and a casing accommodating the driven member merely the particularly thin configurable connecting plate element is provided, serving to transmit the torque to the tube connecting element.
The invention eliminates couplings located axially between the drive tube and a drive shaft serving as the driven member. Joining the tube connecting element to the connecting plate element is now achieved radially outside of the opening receiving the drive tube so that the drive tube itself can axially extend up to the connecting plate element.
Separating the system into a (connecting) plate element and a shaft connecting element is of advantage since this now makes it possible to initially fit only the plate element to the jack-shaft operator. The tube connecting element can be mounted on the door shaft or drive tube separately therefrom. Since the plate element is very thin (e.g. approx. 10 mm in one version) the jack-shaft operator including the connecting plate element fitted thereto can be shifted into the fitted position transversely to the axial direction of the door shaft or drive tube.
This surprisingly simple solution makes the jack-shaft operator apparatus in accordance with the invention compatible with a great many doors, formerly necessitating recourse having to be made to other types of door operator.
Advantageous aspects of the invention read from the dependent claims. An advantageous use as well as a method for fitting the jack-shaft operator assembly in accordance with the invention reads from the further independent claims.
The shaft connecting element and the connecting plate element may be combined in an integral, substantially pot-shaped component. For example, such a pot-shaped component itself could be put to use as the driven member of the jack-shaft operator assembly.
Preferably, however, the connecting plate element is a thin connecting plate configured separately from the tube connecting element, which is of advantage to production. Apart from this, when configured separately, a variety of tube connecting elements can be fitted to one and the same connecting plate, resulting in a wealth of handy sizes and shapes of the drive tube.
For reliable torque transmission preferably all components of the tube connecting means positively engage the adjoining component in each case. The opening in the tube connecting element is preferably configured to receive the door shaft positively non-rotatably. The plate connecting portion and the connecting plate preferably interengage positively and are further preferably connectable to each other, for example by cap screws or the like, to prevent axial displacement. The connecting plate is preferably connected to the driven member positively non-rotatably or configured integral therewith.
The positive engagement of the plate connecting portion with the connecting plate is achieved in one preferred embodiment by at least one axial protuberance and/or an axial recess in the plate connecting portion with a complementary configured structure at the connecting plate.
In fitting the jack-shaft operator as explained above with the connecting plate already mounted and pushing the jack-shaft operator into the fitted position, the door shaft needs to be shifted relative to the jack-shaft operator only by the axial extent of the protuberance/recess. In one embodiment the axial extent of the recess in the connecting plate for receiving the dog-like or claw-like protuberance amounts to roughly half the thickness of the connecting plate. For example, for a roughly 10 mm thick plate dog-like or claw-like protuberances extend 5 mm in the direction of the connecting plate. More end float for fitting the door operator is not needed, whilst nevertheless achieving a reliable positive connection for transmission of the rotary motion.
To permit adapting the jack-shaft operator assembly as regards its axial position relative to the drive tube to the constructional requirements of the site, it is provided for that the tube connecting element is shiftably mounted on the drive tube. Any unwanted axial displacement of the tube connecting element relative to the drive tube can then be prevented by friction contact. For this purpose the tube connecting element comprises, for example, a tapped hole extending radially for receiving a locking cap screw.
Many doors on the market are provided with a door shaft provided full-length with an axial extending slot in the outer circumference. In accordance therewith it is preferred when the inner axial receiving opening of the shaft connecting element comprises a radial protuberance extending inwardly for positively connecting an axial slot arranged in the contour of the door shaft.
To accommodate other shaft or tube contours or sizes as well, a set of assorted shaft connecting elements is preferably available.
The driven member is preferably formed by a hollow shaft fully accommodated in a gearcase. The inner portion of the hollow shaft can then be used as the power takeoff. This hollow shaft or quill shaft may also pass through the gearcase totally, i.e. for access on both sides of the gearcase. Such a configuration permits optionally fitting the jack-shaft operator assembly to the left or right end of the drive tube or door shaft with no additional complication.
The connecting plate could integrally comprise a mating pin for connecting it to the hollow shaft. Production is then simplified when the connecting plate is non-rotatably secured to the driven member via an intermediate member or adapter which could also be termed a screw- or lock-type member or adapter and which is termed coupler hereinafter. Thus, simply making the attachment with the coupler dispenses with space needed for further fastening means. One advantageous means of fastening the coupler and connecting plate is achieved by the coupler clasping the connecting plate and positively engaging a recess at the side of the connecting plate opposite the driven member. Then, simply by locking the coupler in the direction of the driven member the connecting plate can be locked to the driven member. Once the clasping portion of the coupler is fully home in the receiving recess of the connecting plate, hardly any sideroom is needed for securing the connecting plate.
Locking the connecting plate to the coupler also permits drawing the connecting plate on the hollow shaft such that a friction contact materializes between an axial end surface area of the hollow shaft and the axial surface area of the connecting plate facing the hollow shaft. This friction contact enhances torque transmission from the hollow shaft to the connecting plate. In one example aspect this thus achieves both a positive and non-positive connection between the hollow shaft and connecting plate. The positive connection is made via a first positive connection of the coupler and hollow shaft and a second positive connection between the coupler and the connecting plate. The friction contact is made via flat mating of axial surface areas of the connecting plate and hollow shaft.
The coupler is preferably provided with a flanged portion protruding radial circumferentially outwards from a member of the coupler forming an engaging portion at its one axial end. Such a flanged portion may be configured to extend less axially and more radially to thus permit transmisssion of high torque by engaging the corresponding contoured receiving recess in the connecting plate despite sideroom being saved. The engaging portion of the coupler may be configured substantially cylindrical and contoured outwards complementary to the inner contour of the quill shaft acting as the driven member. In one example the engaging portion is keyed to a slot in the quill shaft.
This keyed connection or other positive connection between the coupler and quill or hollow shaft is preferred where high torque transmission is needed, as in the case of industrial doors, for example. On smaller doors, such as, for instance, sectional garage doors the torque transmission requirement is very much less. In this case, the aforementioned friction contact achieved by locking the connecting plate to the hollow shaft may fully suffice for reliable torque transmission, in thus dispensing with expensive keyed or similar positive connection designs and accordingly saving on production costs.
Another advantage of locking the connecting plate element to the driven member is preventing tilting. Since the plate element is shrink fitted, it is maintained positioned perpendicular to the axial direction. Fastening is done preferably also by an axial central locking cap screw, resulting in locking being affected purely by axial forces. This eliminates unbalance and lop-sided biasing of the connecting plate, in thus preventing wobbling when the connecting plate element is connected to the driven member. Preventing tilting is of particular advantage with such drive tubes. Heavy torsion springs are usually fitted thereto, tending to cause the drive tube to bend. In practice it is often the case that drive tubes run out of round, all the more so, the longer their service. A connecting plate precisely aligned radially helps to support the drive tube in reducing wear induced by it running out of round.
Whilst the flanged portion itself preferably engages the connecting plate non-rotatably, it can, however, suffer axially displacement relative to the latter. Preventing this axial displacement is done by bracing the coupler to the driven member, resulting in the connecting plate being braced or locked in place between the flanged portion and the driven member or a mount on the gearcase.
The flanged portion may be contoured in various ways for configuring a positive engagement with the recess configured complementary in the connecting plate element. Conceivable, among other things, is a square, splined, star-shaped or octagonal profile. One type of outer contour of the flanged portion preferred for reasons of facilitated fabrication is formed by a modified hexagonal profile. Each corner of the hexagon is preferably spaced away from the longitudinal centerline of the coupler, coinciding with the axis of rotation, just sufficiently so that it can pass through the opening for receiving the drive tube in the tube connecting element. At least four of the edges of the outer circumference take the form of a regular hexagon which makes for facilitated gripping, for example, by a fork wrench or the like. Of the remaining two edges, one simulates the contour of a portion of the opening of the tube connecting element which is defined for positively engaging the drive tube. The remaining edge is flatter than the four other straight edges, but likewise configured straight and preferably finishing flush with an axial extending protuberance at the engaging portion. It is this protuberance at the engaging portion that serves as the tongue of a tongue and groove connection between the quill shaft acting as the driven member and the engaging portion of the coupler.
The form of the coupler as described has the advantage that, after assembly of the connecting plate and the tube connecting element, the coupler permits insertion through the receiving opening of the tube connecting element into the mating position. In this arrangement the portion of the receiving opening of the tube connecting element configured for positive attachment of the drive tube guides the coupler on insertion.
Bracing the coupler is preferably done by means of a cap screw extending centrally axial in the driven member. This cap screw extends preferably transversely through the driven member configured as quill or hollow shaft and is counterlocated at the opposite end of the driven member by means of a kind of washer. This allows the coupler to be drawn by the cap screw axially in the direction of the driven member to thus brace the connecting plate between the driven member and the flanged portion of the coupler.
In another preferred aspect a set of assorted connecting plates differing in size is available to permit fitting a variety of tube connecting elements. Each of the connecting plates of this assortment is configured the same as regards the portion engaged by the coupler so that one and the same coupler can be used for the various connecting plates.
The material preferred for the connecting plate and the tube connecting element is zinc die-cast.
Further sideroom can be saved by arranging the driven member on a gearcase which features a recess for receiving the connecting plate element arranged on the driven member at least in part.
Thus saving sideroom in the embodiment of the invention as most preferred is achieved by torque transmission via a flat plate to a plate connecting portion arranged radially outside of the door shaft or drive tube, securing this connecting plate via a recessed portion clasping the rear side of the connecting plate as well as locking the connecting plate in the direction of the driven member to draw the connecting plate as near as possible to the gearcase, partly receiving the connecting plate in the gearcase and configuring the opening full-length in the shaft connecting element. On top of this, in a further preferred embodiment, the coupler is provided with a central axial tapped hole for bracing it so that no screw caps or the like protrude at the side of the door shaft.
At the opposite side of the driven member configured as quill or hollow shaft the bracing cap screw is mounted on a washer in the form of a dished washer. The dished configuration of this washer results in the cap of the screw not protruding from the gearcase despite the edge of the dish contacting the end of the hollow shaft. The gearcase is shaped preferably cuboidal, the narrowest side of which is located parallel to the longitudinal centerline of the driven member. Protruding from one side of the gearcase is an operator motor housing. All units fitted to the gearcase are arranged on this motor side and protrude on no side from the gearcase, this applying also to a coupling lever via which the door shaft can be disconnected from the operator to permit manual movement in an emergency.
A door provided with the shaft operator assembly (also called direct operator) in accordance with the invention can thus be installed even in a cramped space location of a building or fencing entry zone. For fitting the shaft operator assembly the procedure is preferably to first secure the connecting plate element and shaft connecting element to the driven member before the jack-shaft operator assembly with the shaft connecting element is mounted on the drive tube. Where necessary, the door shaft is not fitted with the mounted jack-shaft operator assembly until on site, the jack-shaft operator assembly then being secured in situ, i.e. it is not until the relative axial position of the jack-shaft operator assembly and the drive tube has been defined in situ that the tube connecting element and the drive tube are bolted in place to prevent axial displacement.
When sufficient sideroom is available alongside the door shaft, fitting the connecting plate element and the shaft connecting element to the driven member is preferably done by first securing the connecting plate employed as the connecting plate element to the tube connecting element. This is done preferably by mating the two positively to ensure reliable torque transmission. Cap screws are used to secure the two elements axially in place. The resulting unit is then locked to the driven member by means of the coupler. For this purpose the coupler, due to the special configuration of its flanged portion, can be inserted through the receiving opening of the tube connecting element into its rear clasping position by inserting the engaging portion through a corresponding opening in the connecting plate, after which the connecting element formed by the tube connecting element and the connecting plate element is locked to the driven member.
When, however, only little sideroom is available, the procedures as described above of separately securing the connecting plate element, on the one hand, to the jack-shaft operator assembly and, on the other, the shaft connecting element to the door shaft, inserting the jack-shaft operator assembly at the axial end of the door shaft and subsequently securing the two elements to each other and to the door operator are all implemented in situ.
BRIEF DESCRIPTION OF THE DRAWINGS
An example embodiment of the invention will now be described in detail with reference to the attached drawing in which:
FIG. 1 is a view, partly broken away, from inside of an upper corner of a garage door showing a door shaft or drive tube and a jack-shaft operator or direct operator;
FIG. 2 is a partial view in perspective of the door shaft;
FIG. 3 is an exploded view in perspective of a shaft connecting means on a jack-shaft operator;
FIG. 4 is a view as shown in FIG. 3 with the shaft connecting means fitted to the jack-shaft operator;
FIG. 5 is an axial side view of a portion for inserting a coupler of the shaft connecting means;
FIG. 6 is a side view of the coupler as shown in FIG. 5 as seen from the opposite side;
FIG. 7 a is a rear view of a connecting plate of the shaft connecting means;
FIG. 7 b is a side view of the connecting plate as shown in FIG. 7 a ; and
FIG. 8 is a rear view of an axial end of a shaft connecting element of the shaft connecting means.
DETAILED DESCRIPTION
Referring now to FIG. 1 there is illustrated a door 2 comprising a door leaf 4 and a door shaft (also called drive tube) 6 as well as a jack-shaft operator assembly 8 .
In the example as shown the door 2 is a sectional door comprising a plurality of panels 10 hinged to each other. The door leaf 4 made up of the panels 10 moves, in its opening movement, from a vertical closed position upwards into a horizontal opened position. The door shaft 6 is part of a counterbalancing system 11 for compensating the weight of the door leaf. The door shaft 6 is geared via a traction means, in this case in the form of a traction cable 12 for winding on a cable drum 14 , to the door leaf 4 such that every movement of the door leaf 4 results in movement of the door shaft 6 . Mounted on the door shaft 6 is a torsion spring 15 . The door shaft 6 is secured in place at both ends via a mounting element 16 , for example to a frame (not shown) of the door 2 . The door shaft 6 protrudes at both ends from the mounting element 16 . At one of the protruding ends the jack-shaft operator assembly 8 is directly mounted on the end of the door shaft 6 .
The jack-shaft operator assembly 8 comprises a jack-shaft operator 18 and a shaft connecting means 20 . The shaft connecting means 20 connects the jack-shaft operator to the door shaft 6 . The jack-shaft operator assembly 8 is inserted between the mounting element 16 and the adjoining wall 21 .
Referring now to FIG. 2 there is illustrated a view of the door shaft 6 in perspective. The door shaft 6 is formed substantially by a tube 22 provided full-length with an axial slot 24 . The tube 22 has an outer diameter W. The slot 24 has an inner width U. The slot 24 serves to positively connect the tube 22 non-rotatably to the connecting elements, such as, for example, a spring washer 25 of the torsion spring 15 , the cable drum 14 or the tube connecting means 20 .
Referring now to FIG. 3 there is illustrated the shaft connecting means 20 which will now be described in more detail.
The shaft connecting means 20 has a coupler 27 , a shaft connecting element 28 , a connecting plate element in the form of a connecting plate 29 , a locking cap screw 30 and a washer 31 for the latter.
The jack-shaft operator has an electric motor accommodated in an operator housing 33 and a reduction gear, more particularly a worm gear (not shown) accommodated in a gearcase 34 . The gearing transmits the torque generated by the operator motor to a driven member 35 accommodated in the gearcase 34 .
The visible part of the driven member 35 in this case is configured as a quill shaft or hollow shaft 36 . The hollow shaft 36 may be formed by the inner stub of a driven worm shaft. The hollow shaft 36 extends transversely through the gearcase 34 . At the rear side (not shown in FIG. 3 ) the gearcase is configured just the same as the axial front side as shown in FIG. 3 .
In the example as shown in this case the shaft connecting element 28 and the connecting plate 29 are configured as separate items for positively connecting matingly via cap screws 38 . The shaft connecting element 28 has outwards substantially the shape of a truncated cone, it featuring a through opening 39 serving to receive the door shaft 6 . A protuberance 47 protruding radially inwards serves to engage the slot 24 . The protuberance 47 has a width which is only slightly less than the inner width U so that the door shaft 6 is positively received non-rotatably in the opening 39 . By means of a bracing cap screw 40 inserted in a radial tapped hole, the door shaft 6 can be located in an arrangement as selected axially with the shaft connecting element 28 . At the axial end 41 the larger diameters, the shaft connecting element 28 is provided radially outside of the opening 39 with a plate connecting portion 42 . The plate connecting portion 42 is formed substantially by a radial protruding annular plate-shaped portion.
From this annular plate-shaped portion three protuberances 43 protrude axially. Conically tapered lands 44 connect the plate connecting portion 42 to a substantially tubular shaft receiving portion 37 in reinforcing the latter.
Referring now to FIG. 8 there is illustrated a plan view of the axial end 41 to face the connecting plate 29 , clearly indicating the plate portion of the plate connecting portion 42 axial withdrawn relative to the protuberances 43 and the protuberances 43 . Also evident is how the opening 39 is axial throughout.
Referring now to FIG. 3 , as well as to FIGS. 7 a and 7 b there is illustrated the connecting plate 29 in more detail, it being substantially circular in circumference. Provided at the outer circumferential portion on a side 44 of the connecting plate 29 to face the tube connecting element 28 are three recesses 45 for positively receiving the protuberances 43 . A central recess 46 serves to positively receive a flanged portion 48 of the coupler 27 . The central recess 46 extends only up to roughly half the axial thickness of the connecting plate 29 . Provided at the bottom of the central recess 46 is a wall 49 defining a central through hole 50 . The contour of the central through hole 50 is adapted to receive an engaging portion 52 of the coupler 27 such that it is positively insertable through the central through hole 50 into the hollow shaft 36 .
The contour of the central recess 49 is configured like the contour of the flanged portion 48 to which detailled reference is made further on. The depth of the central recess 49 corresponds to the width of the flanged portion 48 . The flange portion 48 can thus be fully received in the central recess 49 in contacting the central through hole 50 . At the side 53 of the connecting plate 29 to face the gearcase 34 the central through hole 50 is defined by an axial protruding annular protuberance 55 . The free end of the annular protuberance 55 is configured to contact the one axial end of the quill shaft 36 of the driven member 35 .
When assembled, the annular protuberance 55 engages an annular recess 56 of the gearcase 34 surrounding the hollow shaft 36 . Three tapped holes 57 each in the shaft connecting element 28 and connecting plate 29 serve to receive one cap screw 38 each for connecting these two elements 28 , 29 .
Referring now to FIG. 3 as well as to FIGS. 5 and 6 there is illustrated the coupler 27 in more detail, it comprising substantially a tubular body 58 forming the engaging portion 52 provided with an axial protuberance 59 and the flanged portion 48 at one end. The axial protuberance serves to engage a corresponding groove 60 in the hollow shaft 36 in thus positively locating the coupler 27 non-rotatably with the driven member 35 by a tongue and groove connection.
Referring now to FIG. 6 there is illustrated how the flanged portion has a modified hexagonal form. Four of the edges are configured as flats 61 – 64 . Each of the corners of the flanged portion 48 defining these flats 61 – 64 has a radial spacing away from the longitudinal centerline corresponding to half the diameter W of the drive tube.
This permits the flanged portion 48 to be inserted through the opening 39 snugly adapted to the diameter W of the drive tube whilst nevertheless having the maximum possible radial extent for facilitated torque transmission. Each of the four flats 61 – 64 is thus likewise equispaced from the longitudinal centerline by the centerpoint in each case. These may also serve for application of a tool.
In the example embodiment as shown in this case a fifth edge 65 mimics the contour of the door shaft 6 surrounding the slot 24 , or, to put it better, is adapted to the complete structure of the opening 39 of the shaft connecting element 28 in the region surrounding the protuberance 47 (see FIG. 8 ).
When fitting the coupler 27 as indicated in FIG. 3 (see arrow 67 ) this edge portion 65 serves to guide the coupler 27 such that it matches insertion into the central through hole 50 and central recess 46 . The other flat flat 66 by contrast is configured flat for flush contact with the protuberance 59 , whilst being configured longer than the flat 64 . Although the corners defining the flat 66 also have a radial spacing of 0.5×W, since the flat 66 is configured longer, however, its centerpoint lies closer to the longitudinal centerline than the centerpoints of the flats 61 – 64 .
The tubular body 58 is provided over most of the end facing away from the flanged portion with a blind hole 68 . Communicating the bottom of the blind hole 68 to the other end is a through tapped hole 69 in which the locking cap screw 30 mates.
Again as evident from FIG. 3 the bracing cap screw 30 is supported by its cap 72 on the bracing cap screw washer 31 which is provided with an edge portion 70 for support at the other axial end of the hollow shaft 36 whilst featuring a dished central portion 71 for nesting the screw cap 72 so that it does not protrude from the gearcase 34 .
Referring now to FIG. 4 there is illustrated the jack-shaft operator assembly 8 assembled. Assembling the shaft connecting means 20 is done such that the shaft connecting element 28 and the connecting plate 29 are bolted together into a unit which is then locked to the hollow shaft 36 by means of the coupler 27 inserted through the opening 39 before being bolted by the bracing cap screw 30 and its washer 31 .
Fitting the jack-shaft operator assembly 8 to the door shaft 6 is done by mounting the jack-shaft operator assembly 8 in the arrangement as shown in FIG. 4 on the door shaft 6 . The configuration of the shaft connecting element 28 and connecting plate 29 is designed to ensure that the door shaft 6 can be inserted totally up to the connecting plate 29 through the shaft connecting element 28 in thus saving sideroom.
In other words, the shaft connecting element as described in this case features a domed connector (shaft connecting element 28 ) which is connected to the gearing via an intermediate plate (connecting plate 29 ) and a follower (coupler 27 ). The follower extends into the driven shaft 36 of the worm gear in slaving the rotation thereto and is braced at the other side by means of a cap screw 30 and its washer 31 .
After having bolted the domed connector 28 in place the door shaft 6 can be connected to this domed connector protruding directly into the gearing in thus saving sideroom between the gearing and the door shaft 6 to be connected. The connecting plate 29 for the domed connector employed as the shaft connecting element 28 and the latter itself are made of zinc die-cast, whilst the coupler or follower 27 is made of steel.
Proceeding as described above results in a tighter axial assignment of the transmission block and the drive tube to be powered thereby. | A shaft operator assembly for moving a door assembly which includes a movable door leaf and a door shaft attached to the door leaf for common movement together. A shaft connecting unit includes a shaft connecting element and a connecting plate element and connects a driven member of the shaft operator assembly with minimal space requirements to the door shaft. The connecting plate element, which can be secured to or integrally configured with the driven member, is relatively thin to permit the jack shaft operator and connecting plate element to be shifted into a fitted position even where little space is available. The shaft connecting element is mountable non-rotatably on the door shaft and includes an axial opening extending through the shaft connecting element for receiving the door shaft. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. patent application Ser. No. 11/799,784, filed on May 3, 2007 which claims priority to an application entitled “METHOD AND APPARATUS FOR SETTING AND EXECUTING FUNCTION PROFILES IN MOBILE COMMUNICATION TERMINAL,” filed in the Korean Intellectual Property Office on Nov. 9, 2006 and assigned Serial No. 2006-0110440, the contents of which are incorporated herein by reference.
BACKGROUND
1. Field
The present invention relates to a method and apparatus for extending the battery life of a mobile communication terminal.
2. Description of the Related Art
In a mobile communication terminal, it is desirable to extend the battery life. The mobile communication terminal typically uses a pre-charged battery as a power source, and according to the charge capacity of a battery, a maximum usage time thereof is determined.
Nowadays, the mobile communication terminal has various functions in addition to the conventional communication function. For example, the mobile communication terminal is now equipped for providing time information such as a time or date, electronic scheduler function, alarm function, game function, photographing function, or music file playing function. The additional functions are sometimes used as frequently as the conventional communication function.
In general, the mobile communication terminal operates the communication function and other additional functions in a power-up state, i.e. a state in which power is supplied to the entire device of the mobile communication terminal.
Accordingly, even when only a specific function of a mobile communication terminal is desired, the power is supplied to the entire device, thus unnecessarily shortening the battery life.
SUMMARY
The present invention has been made in an effort to solve the above problems and provides additional advantages, by providing a method and apparatus for setting and executing a function profile in a mobile communication terminal that can reduce the power consumption via selectively blocking power supply to unused or unnecessary components of the mobile communication terminal.
Another aspect of the present invention is to provide a method and apparatus for setting and executing a function profile in a mobile communication terminal that can execute a specific function in an optimal function profile.
In accordance with an aspect of the present invention, a method of setting and executing a function profile in a mobile communication terminal includes: determining whether a function profile setting function is set; selecting, if a function profile setting function is set, a specific function and executing the function according to a set function profile.
In accordance with another aspect of the present invention, a method of setting and executing a function profile in a mobile communication terminal includes: determining whether a function profile setting function exists; executing, if a function profile setting function exists, a function according to the function profile setting function; and executing, if another function is selected while executing the function according to the set function profile, the newly selected function according to the set function profile.
In accordance with another aspect of the present invention, a method of setting and executing a function profile in a mobile communication terminal includes: determining whether a function profile setting function exists; selecting, if a function profile setting function exists, a specific function; setting a function profile of the selected function; and selecting, if a function profile setting function is set, a specific function and executing the function according to a set function profile.
In accordance with another aspect of the present invention, a mobile communication terminal having a function profile setting function includes: a function profile setting unit for setting a function profile; and a controller for controlling to set the function profile necessary for driving each unit of the mobile communication terminal by the function profile setting unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and advantages of the present invention will be more apparent from the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram illustrating a configuration of a mobile communication terminal for setting and executing a function profile according to an exemplary embodiment of the present invention;
FIG. 2 is a flowchart illustrating a setting operation of a function profile in a mobile communication terminal according to an exemplary embodiment of the present invention;
FIG. 3 is a diagram illustrating an example of a screen showing the selection of a function profile in a mobile communication terminal in the setting operation of FIG. 2 ;
FIG. 4 is a diagram illustrating an example of a screen showing the setting of a function profile in a mobile communication terminal in the setting operation of FIG. 2 ;
FIG. 5A , FIG. 5B and FIG. 5C are diagrams illustrating examples of screens showing steps of setting a function profile in a mobile communication terminal in the setting operation of FIG. 2 ; and
FIG. 6 is a flowchart illustrating an executing operation of a function profile in a mobile communication terminal according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
Exemplary embodiments of the present invention are described with reference to the accompanying drawings in detail. The same reference numbers are used throughout the drawings to refer to the same or like parts. For the purposes of clarity and simplicity, detailed descriptions of well-known functions and structures incorporated herein may be omitted to avoid obscuring the subject matter of the present invention.
In exemplary embodiments of the present invention, a “backlight” represents a background light of a display unit or key pad of a mobile communication terminal and is configured to assist a user to see the displayed content or the key pad in a dark place. A “Hard Disk Drive (HDD)” is an auxiliary memory device for storing data and provided within the mobile communication terminal.
FIG. 1 is a block diagram illustrating a configuration of a mobile communication terminal for setting and executing a function profile according to an exemplary embodiment of the present invention.
Referring to FIG. 1 , the mobile communication terminal includes a radio frequency (RF) unit 101 , audio processor 103 , key input unit 105 , display unit 107 , controller 109 , memory unit 111 , HDD 113 , clock generator 115 , local area wireless communication module 117 , and function profile setting unit 119 .
The RF unit 101 performs a wireless communication function of the mobile communication terminal and includes an RF transmitter for up-converting a frequency of a signal to be transmitted and amplifying the signal, and an RF receiver for low-noise amplifying a received signal and down-converting a frequency thereof.
The audio processor 103 reproduces an audio signal output from an audio codec of the controller 109 through a speaker SPK and transmits an audio signal generated from a microphone MIC to the audio codec of the controller 109 .
The key input unit 105 receives a user's manipulation signal for controlling the operation of the mobile communication terminal. Further, the key input unit 105 receives a user's manipulation signal for setting a function profile and for performing communication and additional functions. Under the key pad of the key input unit 105 , a backlight including a plurality of Light Emitting Diodes (LED) is provided.
The display unit 107 displays output data under the control of the controller 109 . The display unit 107 may use an LCD, and in this case, the display unit 107 includes an LCD controller, memory for storing image data, and LCD display element. When the display unit 107 is a touch screen, the display unit 107 is used as an input unit. Under the liquid crystal screen of the display unit 107 , a backlight including a plurality of LEDs is provided.
The controller 109 controls the entire operation of the mobile communication terminal. The controller 109 also controls the profile setting function according to the teachings of the present invention. The controller 109 adjusts the backlights of the key input unit 105 and the display unit 107 by detecting an adjusted brightness value of the backlight stored in the memory unit 111 . Further, the controller 109 controls the operation of the HDD 113 and the local area wireless communication module 117 and controls a clock frequency of the clock generator 115 .
The function profile setting unit 119 stores function profiles optimally set for each function and enables, if a function profile function is set through the manipulation of the key input unit 105 , each function to be automatically executed in the set function profile.
The memory unit 111 includes a program memory and a data memory. The program memory stores programs for controlling the general operation of the mobile communication terminal and programs for performing a function profile setting function according to the present exemplary embodiment. The data memory temporarily stores data generated while performing the programs. Further, the memory unit 111 stores a backlight brightness value corresponding to each graduation of the backlight.
The HDD 113 is an auxiliary memory device for storing and reading data while rotating a circular aluminum substrate covered with a magnetic material. The HDD 113 has a form in which disks are stacked, and concentric circles called tracks are formed on the disk. Data are electromagnetically recorded within each disk. A head records data on, and reads data from, the tracks.
The clock generator 115 provides a clock necessary for driving the controller 109 that stably provides a high speed of clock signal and receives a control signal for determining the driving from the controller 109 . The clock generator 15 generally uses an oscillator, not the crystal or resonator frequently found in mobile communication terminals. The clock generator 115 can vary a clock frequency for each function by the setting of the function profile setting unit 119 according to the present exemplary embodiment.
The local area wireless communication module 117 performs a series of operations for transmitting and receiving a control signal and an audio signal through a wireless interface. The local area wireless communication module 117 can use a communication type such as Bluetooth, Infrared, or Zigbee and can use various wireless communication modules for transmitting and receiving a signal by forming a communication channel in a local area.
FIG. 2 is a flowchart illustrating the setting operation of a function profile in a mobile communication terminal according to an exemplary embodiment of the present invention. FIG. 3 is a diagram illustrating an example of a screen showing the selection of a function profile in a mobile communication terminal in the setting operation of FIG. 2 . FIG. 4 is a diagram illustrating an example of a screen showing the setting of a function profile in a mobile communication terminal in the setting operation of FIG. 2 . FIGS. 5 a to 5 c are diagrams illustrating examples of screens showing steps of setting a function profile in a mobile communication terminal in the setting operation of FIG. 2 .
Referring to FIGS. 1 to 5 c , the operation of setting a function profile in the mobile communication terminal of FIG. 1 is described hereinafter.
As shown in FIG. 2 , the controller 109 recognizes a standby state of the mobile communication terminal (S 201 ).
Next, the controller 109 determines whether a function profile setting function exists in the mobile communication terminal (S 203 ). If the function profile setting does not exist in the mobile communication terminal, the process ends because the present exemplary embodiment cannot be executed.
If the function profile setting exists in the mobile communication terminal, the controller 109 determines whether the function profile setting is selected (S 205 ). The function profile setting can be selected by a user through the key input unit 105 , and a screen for selecting the function profile setting is shown in FIG. 3 . As shown in FIG. 3 , a function profile setting option is selected from a ‘settings’ menu on the screen of the mobile communication terminal through the key input unit 105 .
If a function profile setting is selected, the controller 109 automatically sets the function profiles (S 207 ). If the user selects the function profile setting at step S 205 , a screen for selecting ‘set’ from the function profile menu is shown in FIG. 4 . The user sets the function profiles through the key input unit 105 . Accordingly, optimal function profiles for each function are automatically set.
The optimal function profiles for each function are shown in Table 1. The function profiles shown in Table 1 are for illustrative purposes, thus it should be noted that function profiles are not limited thereto.
TABLE 1
Function profile
Brightness
Clock
of display
Brightness
Function
frequency
unit
Bluetooth
HDD
of key pad
Phone
208 MHz
1
OFF
OFF
OFF
MP3
416/208 MHz
2
OFF
ON
OFF
Movie
416 MHz
5
OFF
ON
OFF
Text
208 MHz
4
OFF
ON
OFF
Game
416 MHz
4
OFF
ON
ON
Maximum
208 MHz
1
OFF
OFF
OFF
power
Saving
Custom
Random change by user
If the function profile setting is not selected at step S 205 , a user inputs a specific function and the controller 109 recognizes the specific function (S 209 ). When the user does not select the function profile setting from the screen shown in FIG. 3 through the key input unit 105 , the entire functions of the mobile communication terminal are displayed in the display unit 107 as shown in FIG. 5 a . The user can select a specific function, e.g. an MP3 & Music function, for setting a function profile from the several displayed functions.
After selecting a specific function, the user selects a specific function profile of the function and inputs a setting value, and the controller 109 recognizes the function profile (S 211 ). When the user selects the specific function from the screen shown in FIG. 5 a through the key input unit 105 , function profiles (e.g. a clock frequency, brightness of a display unit, operation state of Bluetooth, operation state of HDD, and brightness of keypad) of hardware provided within the mobile communication terminal are displayed in the display unit 107 , as shown in FIG. 5 b . The user can select a specific function profile for setting, e.g. Bluetooth, from the function profiles displayed in the display unit 107 .
As shown in FIG. 5 c , the user inputs a setting value for the selected function profile, e.g. whether to operate Bluetooth, through the key input unit 105 . As shown in FIGS. 5 a to 5 c , because the user selects the MP3 & Music function, it is unnecessary to operate Bluetooth and thus the user turns off the Bluetooth feature. In the present exemplary embodiment, the setting operation of the function profile is illustrated to set one function in a single function profile, however it should be noted that the setting operation according to the teachings of the present invention is not limited thereto.
Next, the controller 109 determines whether the selected function profile has at least one function profile (S 213 ). If the selected function profile does not have at least one function file, the controller 109 terminates the process of setting a function profile.
If the selected function has at least one function profile, the controller 109 determines whether to terminate the function profile setting function (S 215 ). Even though the selected function has at least one function profile, the user may, nevertheless, want to terminate the function profile setting function. Hence, even though function profiles are not set for each function, if a termination signal of the function profile setting function is received, the controller 109 terminates the process. If a termination signal of the function profile setting function is not received, the process returns to step S 209 , and the controller 109 continues to perform the process of setting the function profile.
FIG. 6 is a flowchart illustrating the operation steps of a function profile in the mobile communication terminal of FIG. 1 according to an exemplary embodiment of the present invention.
Referring to FIG. 6 , the controller 109 recognizes a standby state of the mobile communication terminal (S 601 ).
Next, the controller 109 determines whether a function profile setting function is set (S 603 ).
If a function profile setting function is not set, the controller 109 sets the function profile setting (S 617 ). The function profile setting may be set with a method described with reference to FIGS. 2 to 5 c.
If the function profile setting is set, the controller 109 recognizes a user input selection of a specific function (S 605 ). The specific function is selected through the key input unit 105 .
Next, the controller 109 executes the selected function with the corresponding set function profiles (S 607 ). As in the described method of setting a function profile, for example, an MP3 & Music function is executed with the function profiles shown in Table 1.
The controller 109 determines whether another function is selected while executing the selected function (S 609 ). If another function is selected while executing the selected function, the process returns to step S 605 and the controller 109 executes the newly selected function with the corresponding set function profiles.
If another function is not selected while executing the selected function, the controller 109 determines whether a call is received (S 611 ). The controller 109 determines whether a call is received, for example, while listening to music executed with the MP3 & Music function.
If a call is not received, the controller 109 determines whether a termination signal of the executing function is received (S 613 ). If a termination signal of the executing function is not received, the process returns to step S 607 and the controller 109 continues to execute the selected function.
If a termination signal of the executing function is received, the mobile communication terminal returns to a standby state (S 615 ). Here, the standby state of the mobile communication terminal is a standby state set in a function profile, e.g. a maximum power saving mode set in the described function profile setting process.
If a call is received at step S 611 , the controller 109 suspends the executing function and connects to establish a communication (S 619 ). When the call is received, the controller 109 suspends an execution of the MP3 & Music function and makes a call connection.
Next, the controller 109 determines whether the communication is terminated (S 621 ), and if the communication is terminated, continues to execute the suspended function with the set function profiles (S 623 ). When the communication is terminated, the controller 109 executes again the MP3 & Music function.
The process then returns to step S 609 , and the controller 109 determines whether another function is selected.
As described above, according to the present invention, each function of the mobile communication terminal can be executed in an optimal function profile by selectively blocking power supply to unused or unnecessary components so that unnecessary power consumption of the mobile communication terminal can be reduced.
Although exemplary embodiments of the present invention have been described in detail hereinabove, it should be clearly understood that many variations and modifications of the basic inventive concepts herein taught which may appear to those skilled in the present art will still fall within the spirit and scope of the present invention, as defined in the appended claims. While the present invention may be embodied in many different forms, specific embodiments of the present invention are shown in drawings and are described herein in detail, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated. | A method and apparatus for setting and executing a function profile in a mobile communication terminal to manage its battery usage. The method includes determining whether a function profile setting function is set; selecting, if a function profile setting function is set, a specific function and executing the function according to a set function profile. Therefore, each function of the mobile communication terminal can be executed in an optimal function profile which in turn reduces unnecessary power consumption of the mobile communication terminal. | 8 |
This application is a continuation-in-part of my application Ser. No. 08/295,369 filed Aug. 24, 1994, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an energizing circuit used for gaseous discharge lamps and, more specifically, to a transformerless ballast circuit for fluorescent lamps.
2. Description of the Prior Art
Ballast circuits in fluorescent lamp systems regulate the electrical current supply to the lamp. Without a ballast, a fluorescent lamp would burn out instantly because there would be no impedance to limit the current; noting in particular that once the lamp is ignited and the gas within is ionized, the impedance across the lamp drops dramatically. Additional ballast circuit functions include providing the proper voltage to start a fluorescent lamp and reducing such voltage to maintain the lamp in a stable and lit condition. Thus, in order to light a fluorescent lamp and maintain the lamp lit, the lamp system must incorporate a ballast circuit that elevates the supply voltage (and sometimes frequency) until it ignites the lamp and then quickly drop the voltage to the lamp.
The vast majority of ballast circuits in this well-known field of art use filaments that release free electrons into the tube (either by thermoionic emission, field emission or a combination of both) and ionize the gas within the lamp. Since these ballasts rely on the use of filaments to ionize the gas within the lamp, such systems limit the lamp's life to the life of its filaments. Thus, after a filament burns out the entire lamp must be discarded. Aside from having to continually replace these lamps, the refuse generated by discarding "burnt-off" lamps presents a serious ecological problem.
These lamps contain heavy metal elements (e.g. mercury) which are extremely dangerous to the environment and very costly to handle during the disposal process. Although it is known in the prior art that a lamp can be lit without a filament (e.g. see Summa, U.S. Pat. No. 4,066,930, column 5), such circuits are extremely expensive. For example, the Summa circuit requires the use of very specialized, and therefore very expensive, transformer components which strictly limit its application to high radio-frequency guns used to test fluorescent lamps at the factory.
In addition, almost all fluorescent lamps currently marketed rely on AC (alternating current) power of various frequencies to both ignite the lamps and maintain the lamps in a lit condition. Since alternating current necessarily cycles the filament, an undesirable fatigue factor is introduced that shortens filament life and overall lamp life. Moreover, in electronic ballasts, the AC power source also induces a 60 Hz "flicker" (or a flicker at whatever frequency the AC supply uses) which, although not noticeable in most domestic environments, may be extremely dangerous in industrial environments where machinery may also be running at 60 Hz or multiples thereof. Moreover, there are also adverse biological effects from a standard lamp's stroboscopic flicker which are discussed in the background of the Invention in Johnson, U.S. Pat. No. 4,260,932.
Known ballasts using DC power can eliminate the stroboscopic effect in applications where it simply cannot be tolerated, such as in high-speed photocopiers. However, maintaining a fluorescent lamp lit with DC current presents other problems. For instance, when a fluorescent lamp is operated at a constant DC current, the lamp goes through a particular process of "mercury migration." This phenomenon results in a non-uniform brightness of the lamp from one of its ends to the other. The mercury migration process has a very gradual effect starting early in the life of the lamp, but it eventually ends in an extremely noticeable difference in light intensity across the lamp. Another problem is an effect known as "anode darkening" that causes lamp's anode to overheat from the constant, excessive electron bombardment. Such overheating damages the phosphors at the lamp's anode end and results in no light being emitted near the anode end after only a few hours of operation on DC current.
It was also found that mercury migration and anode darkening are also dependent on lamp size, current requirements to maintain the lamp lit, and density of ionized gas. Thus, for smaller lamps such as compact fluorescents, or lamps where the mercury gas is denser, such as in T-8 lamps, mercury migration and anode darkening are less of a problem. However, for common T-12 lamps with a 40 Watt rating or above, anode darkening and mercury migration are always a problem.
Mercury migration and anode darkening are typically addressed by including a switching circuit, whereby the switching equalizes wear upon each lamp electrode as each electrode operates as the anode for 50% of the time. The switching process helps prevent phosphor coating migration and the accumulation of a lamp envelope inner surface charge (negative) at the anode end by changing the polarity of the lamp every time it is activated (e.g., every time the photocopier makes one copy) or during very short periods (e.g., every 10-20 seconds). However, these switching circuits also generate other problems such as: the noticeable amount of power consumption, the arcing of the electromechanical relays which are used (thereby causing a malfunction and possible shutdown of the whole system) and the prohibitive cost of the circuits when considered for other applications.
The present invention solves the problem of anode darkening and mercury migration by limiting the amount of the maintenance current to the bare minimum required to maintain the lamp lit. Johnson (U.S. Pat. No. 4,260,932) teaches that the amount of charge accumulation resultant from a unidirectional current is dependent upon the velocity of the electrons and negative ions within the lamp and upon the amount of current flow (density of electrons and negative ions) within the lamp. The velocity of the charged electrons and ions is, in turn, primarily dependent upon the discharge length of the lamp, (this determining the time period during which the negatively charged particles are accelerated), and accelerating voltage (operating voltage) of the lamp. In the case of the present invention, the current used limits the amount of electron and ion bombardment to a minimum, allowing the lamp to recuperate from minor migration during the time it is turned off. However, in conditions where use is continuous or lamp rating is greater than 40 Watts (T-12 lamps), it is desirable to use a switching circuit.
Yet another shortcoming of current ballasts is the use of inductive elements that promote inefficiencies in the system and prevent further miniaturization of the circuit into a chip. The use of coils and transformers, typically employed to step up the ignition voltage, introduces unwanted losses stemming from internal resistances, hysteresis, and Foucault current. Furthermore, these inductive elements also create unwanted electric noise and troublesome interference with radio signals and computer networks. Harmonic distortion and emanation of electromagnetic signals are also common complaints among the more recent "electronic" ballasts.
Practically all currently available ballasts use a transformer of some sort to perform the ballasting function. The older ballasts, termed "electromagnetic", used a simple circuit design wherein a transformer was the essence of the ballast. More recently, higher frequencies are being used (>25 kHz) in order to reduce the size of the transformer, ease ignition of the lamp by using less voltage, and basically eliminate any visible stroboscopic effects. Additionally, various parameters of the ballast have been optimized using electronic circuitry, to which end these newer ballasts are called "electronic" (e.g., making available a dimmer capability), but in the end a transformer is always used to ballast. The presence of this transformer naturally creates a loss since the manner in which the extra energy in the ballasting process is absorbed and converted into heat, not to mention losses due to Foucault currents etc.
The present invention does not use any inductive elements in the ballast circuit. This allows the ballast circuit to be manufactured in integrated circuit form, thereby reducing its size and weight to a point where one could incorporate the circuit into the lamps themselves. This would eliminate the use of specialized production assemblies for fluorescent lamps and create unlimited installation alternatives as well. Additionally, by not using any inductive elements, the losses and other disadvantages attributed to the use of coils in current ballasts are completely eliminated.
It is therefor an object of this invention to provide a transformerless ballast for gaseous discharge lamps.
It is a further object of this invention to provide a ballast for gaseous discharge lamps without either inductors or lamp filaments.
It is a still further object to provide a ballast responsive to fluctuations in supply voltage.
It is a still further object of the invention to provide a ballast powers the lamp responsive to lamp impedance.
It is therefore a general object of the present invention to economically ignite fluorescent lamps without the need for any ionizing filaments, thereby virtually eliminating the need for replacement lamps.
In addition, it is an object of the present invention to economically maintain a gaseous discharge lamp lit using DC current, thereby eliminating and stroboscopic AC effect and minimizing the lamp's energy consumption.
Another object of the present invention is to provide for the solid state integration of the complete ballast circuit and eliminate the use of any inductive elements.
Moreover, an additional object of the present invention is to provide an economical ballast using DC current without the need for expensive switching circuitry.
A related object of the present invention is to provide an improved integrated circuit ballast having such size and weight characteristics that it could be incorporated into the fluorescent lamp itself.
Further objects and advantages of the invention will become apparent to those of ordinary skill in the art upon review of the following detailed description, accompanying drawing, and appended claims.
SUMMARY OF THE INVENTION
The invention is a transformerless ballast for a gaseous discharge lamp comprising: a rectifier; a filter for the rectifier output; a voltage divider for the filter output; means for gating the filter output, the gating means output powering a lamp when the lamp is lit; means for controlling the gating means responsive to variations in lamp impedance and to variations in the voltage divider output; an oscillator generating an output for predetermined period of time until after the lamp is lit; and an amplifier receiving and amplifying the oscillator output for powering the lamp when the lamp is unlit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block circuit diagram showing the interconnection between the major components of the present invention.
FIG. 2 is an electrical schematic view of block 2 (the rectifier/voltage-doubler) and block 3 (the multiplying circuit) from FIG. 1.
FIG. 3 is an electrical schematic view of block 4 (the low power oscillator) from FIG. 1.
FIG. 4 is an electrical schematic view of block 5 (the amplifier) from FIG. 1.
FIG. 5 shows the entire electrical schematic diagram of the ballast circuit of the present invention.
FIG. 6 is a block circuit diagram showing the interconnection between the major components of the present invention in a second preferred embodiment.
FIGS. 7A-7E are circuit diagrams of the major components of the second preferred embodiment illustrated in FIG. 6.
FIG. 8 is a circuit diagram of the second preferred embodiment illustrated in FIG. 6 incorporating the detail of FIGS. 7A-7E instead of the blocks of FIG. 6.
FIGS. 9A-9C illustrate alternative embodiments of the voltage divider and electronic gate of FIG. 7B.
FIG. 10 illustrates the gated output of the voltage divider and electronic gate of FIG. 7B.
Notice must be taken that the drawings are not necessarily to scale and that the embodiments are sometimes illustrated by phantom lines and diagrammatic representations. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, there is shown the electrical connections between the major block-diagram components which constitute the entire invention. As indicated, the network AC source 1 has power leads to both the rectifier/voltage-doubler 2 and the multiplier circuit 3. The multiplier circuit 3 serves as a voltage multiplier during the ignition stage of the lamp 6. In accordance with the present invention, the ignition of the lamp 6 uses the principle of photoemission, rather than thermoionic or field emission. In doing so, no filament is required for the lamp 6 to be ignited. By obviating the need for a filament altogether, the life of the lamp 6 may be extended immeasurably. Lamp life now only depends on whether or not the gas within the lamp 6 leaks, which in many cases today can be more than 15 years.
The output from the rectifier/voltage-doubler 2 leads both into the multiplier circuit 3 and the low power oscillator 4. In turn, the outputs from the multiplier circuit 3 and low power oscillator 4 lead into the amplifier 5, which feeds the lamp 6. With regard to the normal operation of a fluorescent lamp, the invention basically functions in two stages. First, it permits the gaseous discharge lamp to be ignited using a high frequency/high voltage signal. Second, once the lamp is lit, a switch to DC current occurs, which maintains the lamp in a stable, lit condition.
Referring now to FIG. 2., the electrical detail of both the rectifier/voltage-doubler 2 and the voltage multiplier circuit 3 is indicated. The rectifier/voltage-doubler 2 is a full-wave bridge rectifier made up of diodes 9, 10, 11 and 12, and capacitors 13 and 14. When network AC source 1 energizes the entire circuit with voltage E in , the rectifier/voltage-doubler 2 outputs at node 200 a DC current having voltage 2√ 2 E in with a 60 Hz ridge caused by the network AC source 1. Capacitor 19 serves to filter out these 60 Hz ridges in the rectified power signal coming from the rectifier/voltage-doubler 2 before such signal enters the low power oscillator 4.
The output from the rectifier/voltage-doubler 2 connects at node 200 to voltage multiplier circuit 3. Multiplier circuit 3 elevates the voltage used to ignite the lamp 6 to a level of 3√ 2 E in at node 300. Multiplier circuit 3 elevates the ignition supply voltage by allowing capacitor 15 to be quickly charged via diodes 18 and 16 during the negative cycle of the network AC source 1. Capacitor 15 is charged up to a level of 3√ 2 E in since this is the net potential between the negative cycle of the network AC source 1 (-√ 2 E in ) and the value at node 300 (2√ 2 E in ). When the zero-point in the cycle comes through, the capacitor 15 discharges the stored 3√ 2 E in through resistor 17 which, given the minimal current during the ignition stage, presents a negligible drop in potential across itself thereby effectively presenting 3√ 2 E in at node 300.
FIG. 3 presents the circuitry and electrical components of the low power oscillator 4, including transistors 26 and 27, capacitors 24 and 25, and resistors 20, 21, 22, and 23. Low power oscillator 4 is a square wave oscillator which receives the filtered DC signal at node 200 (2√ 2 E in ) and outputs a 2√ 2 E in high frequency signal of 25 kHz at node 400.
FIG. 4 shows the amplifier 5 which includes capacitors 28, 29, 30 and 31, and diodes 32, 33, 34 and 35. Amplifier 5 receives as its input both the signal at node 300 (the output from multiplier circuit 3) with a voltage of 3√ 2 E in , and the 25 kHz high frequency signal from node 400 (the output from the low power oscillator 4). Amplifier 5 takes the average voltage from these two signals, 2√ 2 E in , and multiplies it by a multiplication factor of G. For the particular amplifier 5 diagrammed in FIG. 4, the value of G is equal to 4, thus producing a signal having a voltage of 8√ 2 E in (minus losses) and a 25 kHz frequency. This signal is then fed to the lamp 6 at node 500 which ionizes the gas within and ignites the lamp 6. No filament is necessary within the lamp 6 as the ignition depends only on the photoemission of ions, and not on thermoionic or field emission. All that is needed to ignite and maintain the lamp 6 lit is a conductor, preferably at each end of the lamp 6, in intimate contact with the gas within the lamp 6.
Turning now to FIG. 5, the entire ballast circuit may be observed. Once the lamp 6 is ignited, the impedance presented by it drops dramatically, which permits the entire circuit to switch over from a high frequency ignition current to a DC maintenance current (the current used to maintain the lamp lit). In order for this switch to take place, the following changes in the circuit occur automatically.
The drop in impedance of lamp 6 instantly increases the current running through the entire circuit. This increase in current creates a larger voltage drop across capacitor 37, which significantly lowers the voltage supply (E in ) which feeds the low power oscillator 4. This voltage drop puts it at a level where the low power oscillator 4 ceases to work (i.e. cease oscillating). This voltage drop at node 200 is further increased by the fact that the dielectric loss in capacitors 13 and 14 is increased such that these components can no longer maintain their charges to quite "double" the voltage.
This effect causes a DC current to flow through node 400, creates an open circuit across capacitor 28, and isolates amplifier 5 from the low oscillator. At the same time, given the increase in current throughout the circuit, the voltage drop across resistor 17 in multiplier circuit 3 becomes significant enough such that the voltage at node 300 is less than the voltage at node 200 (2√ 2 E in ). This difference causes diode 18 to become forward biased which, in turn, allows the DC current output at node 200 to flow through diode 18 and into the amplifier 5. Because this current is DC, capacitors 29, 30 and 31 create open circuits, which requires that the DC current flow through diodes 32, 33, 34 and 35, and then to the lamp 6, hence providing a DC maintenance current.
Table 1 gives illustrative values of circuit elements for use in the preferred embodiment of FIGS. 1-5. This particular ballast circuit 13 is used, ideally, with a 40 W fluorescent lamp and a 120 V, 60 Hz AC source. All diodes are type 1N4004 and both transistors (26 and 27) are type C2611.
TABLE 1______________________________________Capacitor 37 18 μF @ 250 VCapacitor 13 4.7 μF @ 250 VCapacitor 14 4.7μ @ 250 VCapacitor 19 22 μF @ 250 VCapacitor 15 3.3 μF @ 350 VCapacitor 28 0.15 μF @ 250 VCapaditor 29 0.15 μF @ 250 VCapacitor 30 0.15 μF @ 250 VCapacitor 31 0.15 μF @ 250 VCapacitor 24 0.033 μF @ 250 VCapacitor 25 0.0027 μF @ 250 VResistor 17 3.9 kΩ @ 1 WResistor 22 1 MΩ @ 0.5 WResistor 23 1 MΩ @ 0.5 WResistor 21 22 kΩ @ 1 WResistor 20 100 kΩ @ 0.5 W______________________________________
Using the above configuration, the power required for ignition of the lamp 6 is less than 1 watt. This minimal power requirement is primarily attributable to the fact that the low power oscillator 4 sees a high impedance load at its output, which permits its supply current to be quite low (around the order of 8 mA).
Once the lamp 6 is ignited, the DC maintenance current increases to approximately 200 mA and the voltage potential E in across rectifier/voltage-doubler 2 drops from approximately 116 volts to approximately 27 volts. This drop results in a DC maintenance voltage of 2√ 2 E in , or approximately 75 volts. Thus, in comparison to a conventional electromagnetic ballast system which consumes between 50 to 60 watts to maintain the lamp lit (on AC current), the ballast circuit of the present invention illustrated in FIGS. 1-5 only requires 24 to 27 watts.
The present invention in a second embodiment shown in FIGS. 6-10 can be used with lamps with or without filaments and replaces capacitor 37 as the ballasting element with electronic gate 37a shown in FIGS. 6 and 7B. Electronic gate 37a essentially eliminates losses attributable to heat dissipation in conventional ballasts and optimizes actual ballasting parameters with feedback. This loss elimination also permits ballast 110 to be made smaller and lighter than conventional ballasts, including electronic ones, for manufacture as an integrated circuit. In the preferred embodiment, the ballasting by electronic gate 37a responds to feedback from the input voltage, the lamp impedance (by measuring the load current) and, in some embodiments, temperature.
The alternative embodiment, ballast 110, as shown in FIG. 6 contains many features similar to those of the first embodiment shown in FIGS. 1-5, with like parts bearing like numbers. A 120 V, 60 Hz power signal is supplied to ballast 110 via leads 101-102 shown in FIGS. 6 and 7A to full-wave bridge rectifier 2a comprised, as shown in FIG. 7A, of diodes 104-107. FIG. 7A also shows filter 19a, which decreases the remaining ridge of the rectified power signal. Filter 19a and rectifier 2a are represented in FIG. 6 by block 90 and can be of any suitable design known in the art.
Returning to FIG. 6, the output of rectifier 2a and filter 19a is then used to power comparator 118 shown in FIG. 7B, of electronic gate 37a and to provide input thereto. Resistor 112, zener diode 114, and electrolytic capacitor 116 in FIG. 6 receive input via line 115 and then condition the received input to output a 24 volt power to comparator 118 of electronic gate 37a via line 117. Resistor 112 limits the current through diode 114 and capacitor 116 opposes quick voltage changes across diode 114. Again, resistor 112, zener diode 114, and electrolytic capacitor 116 may be replaced in alternative embodiments with any suitable design known in the art.
Voltage divider 3a shown in both FIG. 6 and in FIG. 7B comprises resistors 120-122, through which the inverting terminal of comparator 118 receives a negative feedback signal of the input voltage at node 154 via line 119. Feedback from the input voltage permits the ballast to respond adequately to even severe voltage transients as described below represented by variations in the voltage divider input. This feedback also allows the lamp to essentially maintain the same consumption at different voltage levels (within a certain range), which is not true for conventional electromagnetic or electronic ballasts. As shown in FIG. 9A, ballast 110 can be modified to include a dimmer by replacing resistor 121 with potentiometer 121a.
Still referring to FIGS. 6 and 7B, the operation of ballast 110 revolves around the electronic gate 37a comprised of gating elements and elements for controlling the gating elements. Comparator 118 is an LM307, a common integrated circuit well known to those in the art. The output of voltage divider 3a provides feedback permitting comparator 118, and hence electronic gate 37a, to output a signal inversely proportional to the voltage at node 154. The output of comparator 118 and consequently electronic gate 37a is therefore responsive variations in the voltage divider output and, consequently, to variations in the voltage supply.
The operation of electronic gate 37a is also responsive to the lamp impedance via feedback through line 152 shown in FIGS. 6 and 7B. When the lamp is struck and becomes lighted, lamp impedance is very low and the current in ballast circuit 110 becomes very high since electronic gate 37a receives the load current as feedback via line 152. The load current is sensed by comparator 118 through resistor 130 in parallel with capacitor 132 sending this signal through resistor 128 to the inverting terminal of comparator 118. This high load current is consequently limited by transistors 124 and 126. Transistors 124 and 126 are wired in a Darlington configuration while capacitor 156 helps transistor 124 out of saturation and resistor 158 limits current to transistor 124.
Generally, transistors 124 and 126 saturate, and therefore conduct, when comparator 118 output is high and do not conduct when comparator 118 output is low. In response to the feedback signals, comparator 118 and transistors 124 and 126 pulse-width and frequency modulate a signal output by electronic gate 37a to lamp 6a as shown in FIG. 10. When the voltage supply on leads 101-102 is steady, an increase in lamp impedance decreases the frequency and increases the pulse-width of the gated output and a decrease in lamp impedance increases the frequency and decreases the pulse-width of the gated output. When the lamp impedance is steady, increases in the voltage supply increase the frequency and decrease the pulse-width of the gated output and a decrease in the supply voltage decreases the frequency and increases the pulse-width of the gated output.
Electronic gate 37a therefore essentially comprises a means for gating an output to lamp 6a and means for controlling the gating means. In the embodiment shown in FIG. 7B, the gating means includes transistors 124 and 126, but may alternatively include a power MOSFET 124a as shown in FIG. 9B. Likewise, the control means in FIG. 7B includes comparator 118 and is responsive to variations in supply voltage and in lamp impedance, but may also be responsive to temperature by replacing resistor 120 of voltage divider 3a with limiting resistor 120a and thermistor 120b as shown in FIG. 9C.
Preferably, one can simply take advantage of the thermal variation of the null offset of the inverter pin on comparator 118 in order to introduce a temperature feedback. In order to do this, one can run a thermally conductive strip between the ballast box and the comparator chip, sealing both ends with a bonder having good thermal conduction characteristics. In this manner, the comparator 118 chip will heat up and cool down in response to external temperature changes, which will in turn cause the null offset at the inverting terminal to go up or down. Depending on the calibration given, one can arrange the thermal feedback system to shut off the ballast and the lamp until reasonable operating temperatures are re-obtained. This characteristic of the ballast gives it some very important fire safety features such as an automatic shut-off during a fire.
Although electronic gate 37a performs the ballasting once lamp 6a is lit, oscillator 4a is in charge of igniting the lamp when the ballast is initially energized and when the lamp is still unlit. The embodiment of oscillator 4a shown in FIG. 7C includes the well-known LMC556 integrated circuit, which contains two astable multivibrators (astables). In accord with well known principles, the frequency of the output signals is governed by two external resistors and one capacitor. In the case of the astable 134 used for igniting the lamp, the corresponding resistors and capacitors are resistors 136 and 138 and capacitor 140 as seen in FIG. 7C. The other astable 135 is used to control the switching frequency of the polarity switching means for the lamp when required, and is described more fully below. It will be appreciated by those versed in the art that if no switching means are used, or a switching means where no oscillator is required, then one could simply use an LMC555 (which includes only one astable oscillator) for astable 134.
A stable 134 generates an output signal of approximately 25 kHz (this frequency can be optimized depending on the type of lamp) to the amplifier 5a, shown in FIGS. 6 and 7D, via transistor 148 on line 149. Amplifier 5a then amplifies the voltage of the output from the oscillator 4a to a level sufficient to strike lamp 6a shown in FIG. 7E.
A small predetermined time after the ballast is energized, which is determined by resistor 174 and capacitor 176, transistor 178 begins conducting when capacitor 176 charges to the saturation level of transistor 178. Transistor 178's output is wired to the "reset" of astable 134 and switches low to turn off astable 134 when transistor 178 conducts. Diode 180 ensures that transistor 178 turns off at this time even when the output of astable 134 is not exactly zero volts. Capacitors 184 and 186 then switch out of amplifier 5a when transistor 178 is turned off because of the shorter path between nodes 170 and 151 through diode 188, which is half that present across diodes 190 and 192. Thus, what happens generally is that a short period after the ballast is energized, preferably between 0.5 to 1.5 seconds, period during which the lamp will ignite, the oscillator shuts off, switching out the amplifier, and allowing electronic gate 37a to take over and maintain the lamp lit.
One will note that in the oscillator 4a circuit drawn in FIG. 7C there is a diode 175 in parallel with resistor 174. The purpose of this diode is to allow capacitor 176 to discharge completely and practically immediately when the lamp turns off (e.g. the ballast circuit is turned off, low voltage supply feedback, high ambient temperature feedback, etc.). The purpose of allowing capacitor 176 to discharge immediately is to permit the ballast circuit to ignite the lamp immediately when it is shut-off and then re-energized shortly thereafter. If capacitor 176 was not fully discharged, the period of time during which astable 134 would be turned on would not be long enough to permit it to achieve full amplitude and thus insufficient to ignite the lamp. The reason is because the capacitor's voltage level, not having fully discharged, would be closer to the saturation level of transistor 178, and thus would reach that saturation level quicker, which would in turn zero the astable 134's trigger quicker. In some cases it may be desirable to eliminate diode 175 in order for ensure that the conditions which caused the lamp to turn off (e.g. a fire in the ceiling) had subsided.
When lamp 6a is unlit, lamp impedance is very high and load current in ballast circuit 110 is practically zero as is the voltage across resistor 130 shown in FIG. 7B in parallel with capacitor 132. When ballast circuit 110 is first energized, the feedback to comparator 118 via resistor 122 is still too low to switch comparator 118 to low, so transistors 124 and 126 are saturated and conducting. Further, in lamping circuit 150 shown in FIG. 7E, switch 194 is set to pole 196 and switch 198 is set to pole 202.
Once lamp 6a is struck and lit, a load current output to transistors 124 and 126 via line 152 begins circulating from the emitter to the collector of transistor 126 as both of transistors 124 and 126 are conducting. As lamp 6a remains lit, the load current increases, which increase comparator 118 senses through resistor 130 and 128. The sum of the feedback across resistors 122 and 128 charges capacitor 164, such that comparator 118 switches to low as the voltage at the inverting terminal of comparator 118 exceeds that of the voltage at the non-inverting terminal. It may be noted that under ideal (theoretical) conditions the feedback arrangement at the inverting terminal of comparator 118 would not be adequate to switch the electronic gate 37a because one would have to have a voltage below the reference voltage at the non-inverting terminal, which is impossible. Thus, I take advantage of the real-world null offset present between the comparator 118's inverting and non-inverting terminals, which is approximately 0.7 volts. Likewise, I use this offset in order to calibrate a temperature feedback when using the comparator 118 as the temperature transducer for the temperature feedback.
Transistors 124 and 126 then stop conducting when comparator 118's output switches low, thus causing the load current to drop to zero. The drop in load current across resistor 130 enables capacitor 164 to discharge and comparator 118's output switches high. Larger load currents therefore charge capacitor 164 more quickly and transistors 124 and 126 conduct for shorter periods of time. This increases the gating frequency and, thus as shown in FIG. 10, the number of zero-intervals and their corresponding periods increases with the load current and the output of voltage divider 3a.
Using the electronic gating method described above, there is no need to limit or regulate the current by dissipation through resistive or reactive elements. Instead, the T off /T on period is regulated to vastly improve the lamp's efficiency. The preferred embodiment also includes means for switching the polarity of the signal through lamp 6a for use with lamps in which mercury migration or anode darkening is a concern. In lamps in which these effects are negligible, this switching means may be omitted completely. In FIG. 7E, the switching means includes relay 162, which receives a second and separate output from astable 135 in oscillator 4a via transistor 164 on line 165. Relay 162 controls the operation of switches 194 and 198 of lamping circuit 150 that determine the polarity of the signal through lamp 6a. When ballast circuit 110 is first energized, switches 194 and 198 shown in FIG. 7E of lamping circuit 150 are set to poles 196 and 202, respectively, and astable 135 controls relay coil 204 of lamping circuit 150 via transistor 164. Resistors 142 and 144 and capacitor 146 control the switching frequency of transistor 164 and thus the on/off period of relay coil 204. Typical switching periods used in this embodiment vary between 3 to 6 hours for T-12 40W lamps. As relay coil 204 switches, switches 194 and 198 also switch between alternate poles. Of course, it will be understood by those versed in the art that other switching arrangements besides relays can be used to perform the switching when necessary.
It should be understood that the above described embodiments are intended to illustrate, rather than limit, the invention and that numerous modifications could be made thereto without departing from the scope of the invention as defined by the appended claims. Thus, while the present invention has been illustrated in some detail according to the preferred embodiment shown in the foregoing drawings and description, it will become apparent to those skilled in the art that variations and equivalents may be made within the spirit and scope of that which has been expressly disclosed. Accordingly, it is intended that the scope of the invention be limited solely by the scope of the hereafter appended claims and not by any specific wording in the foregoing description. | A transformerless ballast for a gaseous discharge lamp is disclosed. The ballast comprises: a rectifier; a filter for the rectifier output; a voltage divider for the filter output; an electronic gate modulating the filter output to power a lamp when the lamp is lit; a controller controlling the electronic gate responsive to variations in lamp impedance and to variations in the voltage divider output; an oscillator generating an output for predetermined period of time until after the lamp is lit; and an amplifier receiving and amplifying the oscillator output for powering the lamp when the lamp is unlit. | 7 |
This application claims benefit of U.S. provisional patent application Ser. No. 60/052,135, filed Jul. 10, 1997.
This invention relates to systems remotely identifying electronically coded articles, e.g., tags or badges. More particularly, the invention provides an ability to rapidly identify a coded article, even when multiple articles are simultaneously present in an interrogation area.
BACKGROUND OF THE INVENTION
Commonly assigned U.S. Pat. No. 5,502,445, issued Mar. 26, 1996 and 5,491,482, issued Feb. 13, 1996 disclose a system and method for remotely identifying electronically coded articles (e.g., tags, badges and the like). Each of these patents is herein incorporated by reference. The interrogation and identification (I/I) system is comprised of an interrogator/reader (I/R) unit (also referred to as simply an interrogator) and a plurality of badges. The interrogator sends a microwave signal to the badges within a defined area near the interrogator, i.e., the interrogation area. Circuitry within each of the badges processes the interrogation signal and, in response to the interrogation signal, the badges transmit a signal back to the interrogator. From the responsive signal, the interrogator identifies each of the badges by analyzing certain modulation encoded onto the return signal.
More specifically, each of the badges contains a plurality of ID registers (e.g., an A-register, a B-register, and so on) that store unique identification values, i.e., although a particular value in a particular register is not unique, the values in a plurality of registers taken together uniquely identify the badge. The interrogator causes each badge to retrieve the identification values and send the values to the interrogator. To accomplish badge identification, the system performs a "two pass" process. During the first pass, the system generates an interrogation beam to activate the badges within the interrogation area. The system repeatedly sends an interrogation signal that causes the badges to transmit values from their ID registers. This pass causes all the values from each register to be sent, i.e., request the data in all the A-registers of all the badges within the interrogation area, then request data from all the B-registers, then all the C-registers, and so on. The identification values are stored in a computer coupled to the interrogator. The computer then categorizes the values into groups defined by the specific register within the badge from which the value was retrieved, i.e., each returned value is stored in an array that correlates the various values with the various registers. During a "second pass", the categorized groups are sorted by sending particular coding combination to the badges where the coding combination is derived from an analysis of the categorized values. The specific coding combinations uniquely identify the badge that responds to the second interrogation signal.
To accumulate the data from the ID registers, the present system repeatedly polls the badges that are within in the interrogation area to retrieve the register data one register at a time, i.e., all the A-registers are polled, then all the B-registers, and so on. This one-value at a time process is relatively slow.
Therefore, there is a need in the art for a system and method for rapidly identifying a plurality of electronically coded badges.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages heretofore associated with the prior art by providing an improved transceiver badge that substantially improves the speed of a remote identification system. Specifically, the invention is a system, and a concomitant method of operation for the system, comprising a electronically coded article (e.g., a badge, tag, and the like), an interrogator, and a computer. The interrogator transmits predefined commands using a microwave signal, i.e., the interrogator transmits an interrogation signal. The badge interprets the commands and transmits a responsive signal. The computer then processes the returned data to identify the badge.
More specifically, the badge contains a demodulator, a signal processor and a modulator, where the demodulator and modulator are coupled to a common antenna for receiving interrogation signals from an interrogator. The demodulator is capable of demodulating the interrogation signal and providing an encoded instruction to the signal processor. The signal processor contains a counter, an instruction decoder, a comparator and a plurality of ID registers containing codewords that uniquely identify the badge. Although many instructions are decoded by the instruction decoder, the instruction of interest is the instruction that "sets up" the signal processor components for responding to the interrogation signal. When the unique set up instruction is received, the instruction decoder resets the counter to zero, selects a particular ID register, and enables the comparator to compare the counter's count value to the selected ID register content. After the set up instruction is sent by the interrogator, the interrogator transmits a carrier wave (CW) signal that is demodulated by the demodulator and produced as a square wave signal having the same frequency as the CW signal. The square wave signal is divided by N and used to clock the counter. Thus the counter increments on every Nth count. Similarly, the interrogator, which is providing the CW signal, contains a similar circuit that increments on every Nth count of transmitted CW cycles. As such, the badge counter and interrogator counter are synchronized.
At each count of the counter, the badge's counter value is compared to the selected ID register value (codeword). When a match occurs, the comparator enables the modulator for the duration of the clock period and the modulator sends a pulse to the interrogator. When the interrogator detects this modulation signal, it stores its internal count value (which is the same as the current badge count value) in memory. This process is repeated for each ID register until they have all been polled.
The computer then correlates the received ID register values of all the badges that responded to the interrogation signal with the specific registers that were polled. From that information, the interrogator can perform a second scan of the badges to uniquely identify each badge. The second scan process is disclosed in detail in U.S. Pat. No. 5,502,445.
BRIEF DESCRIPTION OF THE DRAWINGS
The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is an illustrative schematic diagram of a remote identification system that utilizes the transceiver badge of the present invention;
FIG. 2 is a block diagram of the transceiver badge of the present invention;
FIG. 3 is a flow diagram of a process of identifying a remotely coded article in accordance with an embodiment of the invention;
FIG. 4 is a waveform and timing diagram for the transceiver badge; and
FIG. 5 is a block diagram of an interrogator of the present invention.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
FIG. 1 depicts a schematic illustration of an electronic interrogation and identification (I/I) system 100 that comprises one or more interrogator/reader (I/R) units 102, one or more badges (tags) 104, respective transmit and receive antennas 108 and 109, and a central computer 122. The I/R units operate at a suitable radio frequency or microwave frequency (e.g., 13.56 MHz) and transmit microwave (radio frequency) beams 106. The badges 104 (which uniquely identify individual employees) are interrogated by the beams 106 transmitted from the directional antenna 108 of the I/R units 102 positioned at selected locations. Each I/R unit 102, in addition, has a receiving antenna 109 which is closely similar to the transmitting antenna 108. The I/R units 102 are connected via respective cables 120 to a computer 122. In the course of being interrogated via a microwave beam 106 from an I/R unit 102, a badge or badges 104 reply electronically by transmitting a modulated signal back to the receiving antenna 109 of the I/R unit 102. The modulated signal contains various identification values that are stored in each badge. The badges 104 thus uniquely identify themselves in accordance with their respectively coded, electronically stored ID numbers. As will be explained below, each badge may be coded with any one of 2 N ×B different numbers, where N is the number of ID data registers and B is the number of bits per register. As soon as a badge has been identified, its electronic circuit is placed in an inactive or "power down" mode such that the badge does not continue to respond to the I/R unit 102 for so long as that badge (once it has been identified) remains within the range of the beam 106.
FIG. 2 depicts a block diagram of the transceiver badge 104 of the present invention. The transceiver badge 104 contains an antenna 200, a squarer 202, a demodulator 204, a signal processor 206 and a modulator 210. The antenna 200 receives an interrogation signal transmitted by the I/R unit. The antenna 200 is coupled to squarer 202 within which the interrogation signal is converted into a logic level signal. The logic level signal is coupled to the demodulator 204 which extracts binary encoded commands or data from the received signals. The demodulator is coupled to the signal processor 206. The signal processor 206 processes the demodulated signals to decipher any particular instructions contained in the received interrogation signal. The signal processor 206 also produces a responsive signal (e.g., modulator enable signal) in response to the decoded information in the interrogation signal. The responsive signal is coupled to the modulator 210. The modulator 210 is coupled to the antenna 200 for transmitting a responsive signal to the I/R unit.
More specifically, the signal processor contains an instruction decoder 212, a frequency divider 214, a counter 216, a comparator 218, and a plurality of ID registers 220 containing codewords that uniquely identify the badge. The demodulator 204 is coupled to the instruction decoder 212. The instruction decoder 212 sends control signals to other devices, such as the counter 216, the comparator 218 and the ID registers 220, based on commands received from demodulator 204. A comprehensive list of instructions that are processed by the instruction decoder are provided in U.S. Pat. No. 5,491,482.
The frequency divider 214 divides demodulated signals by N before they are received by counter 216. The counter 216 is capable of counting each Nth cycle and can be reset by the instruction decoder 212 to a count of zero. The comparator 218 can compare the counter value (DATA-A) to the contents (DATA-B) of any one of the data registers in ID registers 220 based on control logic from instruction decoder 212. ID registers 220 are data storage registers that contain the identification code, e.g., a 32-bit code can be stored in four 8-bit codeword registers. In response to a modulator enable signal produced by the comparator 218, modulator 210 applies a modulated signal to antenna 200 that is transmitted to the I/R unit.
In the following example, reference is made to ID registers A, B, C and D, each of which is 8-bits wide. It should be understood, however, that the invention can use any number of registers or register widths. Referring now also to the flow diagram of FIG. 3 and the timing diagram of FIG. 4, the operation of the invention begins at step 302 and proceeds to step 304 wherein a set-up instruction is sent from the interrogator 102 which, when decoded by the instruction decoder 212, sets up the comparator 218 to compare the value of the counter 216 to the contents of the A register in ID registers 220. This set up instruction also resets counter 216 to zero. Immediately after transmitting the setup instruction, an unmodulated rf signal (known as a carrier wave (CW) signal) is transmitted by the interrogator 102 (step 306). This CW signal is converted by squarer 202 and demodulator 204 into a square wave version of input signal F 0 (i.e., signal F 0 '). The divider 214 divides the square wave signal F 0 ' by N and, as such, the counter 216 begins to count each Nth cycle. Simultaneously, a divider 501 and counter 502 in the interrogator 102 (see FIG. 5) also counts each Nth cycle of the transmitted CW signal. Since the counter 216 is counting based on the signal transmitted by the interrogator, counters 216 and 502 are synchronized. As such, the transceiver badge counter generates a count value and the interrogator generates a count value "copy" that is identical to the count value generated by the transceiver badge.
When, at step 308, the value in the counter 216 equals the value in register A, the comparator 218 produces a signal (modulator enable) to the modulator 210. The modulator 210 applies a signal to the antenna 200 (antenna modulation signal) for the duration of the Nth time interval (step 310). This signal applied to antenna 200 can be related to F 0 ', such as by being some multiple of F 0 ' or a quotient in which F 0 ' is a dividend. However, if two or more tags have identical values in like registers, each will be transmitting this identical signal at substantially identical times. Whereas the signal transmitted by the two or more tags could be different in phase by 180° with respect to each other, cancellation of the signals could occur. Preferably, therefore, the signal is generated by some other means known to those having skill in the art, such as by including separate oscillators in each badge. In another embodiment, individual tags could transmit at random times during the duration of an Nth time interval. The antenna modulation signal applied to the antenna 200 is transmitted to and detected by detector 503 of interrogator 102. When the interrogator 102 detects the modulated signal, its counter indicates the value contained in the A register of ID registers 220. For example, the timing diagram of FIG. 4 depicts the modulator enable signal occurring on a count of three, as such the A register contains the value of three.
At step 312, the interrogator continues transmitting a CW signal until N×256 cycles have been transmitted (256=2 8 =the number of values that can be represented in an eight-bit register). If there are multiple badges 104 in the field of operation, the interrogator 102 may receive multiple responses during this period. As noted above, if multiple badges 104 have the same value in their A register, they will activate their modulators 210 simultaneously. The interrogator 102 need not distinguish between one or multiple badges 104 simultaneously. At this point the interrogator 102 only needs to determine that some badge 104 responded at a particular time corresponding to a particular A-register value.
At step 314, the interrogator 102 determines whether all the registers have been interrogated. If not, steps 304 through 312 are repeated, except that the instruction transmitted in step 304 is now changed such that the comparator 218 in the badge 104 is set up to compare the counter 216 output to the contents of the B-register. Similarly, steps 304 through 312 are repeated for the C- and D-registers, i.e., until the condition at step 314 is true.
After this scan sequence has been performed for all the ID registers 220, the interrogator 102 contains a list of the possible register contents for each register and for all badges 104 located within the field of operation, i.e., the interrogation area. However, if multiple badges 104 are present, the interrogator 102 does not know which set of register values all belong to a particular badge 104 . In order to determine which set of values belong to each badge 104 within the operating field, a sorting routine is performed at step 316. This part of the process is identical to the "second pass" portion of the identification routine described in the prior U.S. Pat. No. 5,502,445.
The time required to "scan" each ID register 220 is the time required to transmit a scan instruction, T t , plus the time required for the badge to respond, T r . For 8-bit wide registers, the response time T r =256(N)(1/f), where f is the frequency in Hertz of the CW signal. For the example discussed above, the entire pass of the ID routine is therefore performed in approximately 4(T t +T r ) seconds. The product (N)(1/f) is actually the bit period, P r , for receiving data from the badge. Assuming the commands have a length of 8-bits, the time to transmit the scan command from the interrogator 102 to the badge 104 is approximately (8)(P t ), where P t is the bit period for transmission of data to the badge 104 . For the four registers, the entire scan time is therefore (1024)(P r )+(32)(P t ). The actual time will be somewhat longer due to sync bits and gaps between commands.
Depending on the transmit and receive bit rates of the system, this could significantly reduce the time required to perform a first scan routine as compared to the process disclosed in U.S. Pat. No. 5,502,445. In that method, for each possible register value, and for each register, a multi-byte command sequence is transmitted from the interrogator 102 to the badge 104, and most of these commands require time for a response from the badge 104 . For the example given here using four 8-bit registers, the interrogator 102 would have to send the following command sequence 255 times:
Data byte follows
Data byte (0-255)
Any Yes:
Match A?
Match B?
Match C?
Match D?
For the case where one badge is present, having four different values in its registers, the prior art method requires a minimum of 784 commands must be transmitted to the badge. Of these, 272 commands (those with a "?") must wait for a response from the badge. Assuming 8-bit commands, a transmission bit period of P t , and a single bit response time of P r , the time required is 6272(P t )+272(P r ). For comparable bit rates, this prior art approach requires considerably more time than the technique described above, i.e., the prior art scan time of 6272(P t )+272(P r ) compared to the scan time of the invention of 32(P t )+|1024|(P r ).
Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings. | Apparatus, and a concomitant method of operation for the apparatus, for responding to an interrogation signal transmitted by a remotely located interrogator comprising: a demodulator for demodulating the interrogation signal; a signal processor, coupled to the demodulator, for interpreting a set up instruction contained in the interrogation signal and for initiating a counter to count cycles of a carrier wave signal contained in the interrogation signal; and a modulator, coupled to the signal processor, for transmitting a pulse when the signal processor indicates that the counter has attained a count value that matches a codeword stored in the signal processor. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a soundproofing material made of nonwoven materials containing thermoplastic fibres for the acoustic frequency range of 100 to 5000 Hz. Also disclosed is a method of using the soundproofing material in secondary soundproofing.
Many acoustic problems cannot be solved satisfactorily merely by using primary soundproofing measures which are applied to a sound source, and additional secondary measures are required. Secondary measures are those which, as a rule, intervene in the transmission path of the acoustic energy. Either the energy is reflected, that is to say deflected, or the energy is converted into a different energy form, mostly heat. In the first case, insulation is used, and in the latter case, the sound is attenuated.
The prior art in conventional sound insulation uses secondary reduction measures at some distance from the source by disposing reflecting walls into the propagation path of the acoustic energy. Examples are cellular walls, partition walls or acoustic screens.
Also, in conventional sound attenuation, the prior art methods convert the acoustic energy in the medium frequency to high-frequency range into heat through the use of porous sound absorbers, wherein the extent of conversion depends on the frequency range of the sound. For example, artificial mineral fibres, open-cell foamed materials, porous inorganic bulk materials or natural fibres are used. In order to avoid abrasion of the materials, and to prevent them from escaping, they are often laminated with pourable protective materials based on a nonwoven textile.
The fact that porous absorbers are generally tried and tested only in the medium to high-frequency range is based on their physical attenuation properties. In order to attenuate an acoustic wave with the highest possible absorption, the thickness of the attenuating material must be at least one quarter of the wavelength λ to be attenuated, since the displacement range of a sound wave is the greatest over that range. Therefore, low frequencies determine the required thickness of insulating material due to their longer wavelength. This effect can also be achieved by means of thinner material thicknesses in combination with an air gap. The insulating material is in this case arranged at a distance corresponding to λ/4. However, degree of absorption of airborne sound α describing the attenuation capacity is in such a configuration marked by dips in the higher-frequency range.
A significant requirement for secondary soundproofing materials, in particular in spatial acoustics, is the lowest possible insulating material thickness, in order to lose as little spatial volume as possible. In the case of these absorbers, even at a thickness of 10 cm, a distinct reduction in the absorption properties below about 800 Hz is observed. In order to achieve broadband absorption properties, even down to the low-frequency range, absorbers are used in combination with resonators which, on the basis of oscillation processes, withdraw energy over a narrow band from the acoustic wave at a resonant frequency. Their effect is primarily observed in the lower frequency range.
Since secondary soundproofing primarily concerns combating noise in the frequency range of about 200 to 4000 Hz, it is generally the case that neither porous absorbers nor resonators are on their own able to achieve efficient, broadband sound attenuation over the entire frequency range of interest. However, the possible combinations of the two types of soundproofing take up a great deal of space and are expensive.
The applications for nonwoven materials in soundproofing vary. Nonwoven materials often are used in combination with other flat materials or as supports for sound-absorbing materials. Pure nonwoven materials in needled form have been investigated for sound absorption by P. Banks-Lee, H. Peng and A. L. Diggs (TAPPI Proceedings 1992 Nonwovens Conference, pp. 209-216). It was established that, in spite of variations in various trial parameters, the nonwoven materials exhibit a sound absorption which is only insufficient for practical use in the frequency range of <1000 Hz.
EP 0 607 946 contains a description of pure nonwoven materials with thermoplastic fibres as a sound-insulating material. Table 2 of the reference shows that the absorption values in the lower frequency range are at a level which is inadequate for practical use.
SUMMARY OF THE INVENTION
The invention has the objective of providing a soundproofing material which, in addition to having a low requirement for space, exhibits a broadband absorption in the frequency range from 100 to 5000 Hz.
According to the invention, this object is achieved by a nonwoven material containing thermoplastic fibres being permanently compacted to a specific flow resistance of RS=800-1400 Ns/m 3 in two stages by a mechanical compaction process and a subsequent pressure/heat treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical representation of a degree of sound absorption versus frequency of an embodiment of the present invention.
FIG. 2 is an illustration of a three-dimensional arrangement of a soundproofing material of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A surprising effect of the present invention is depicted in FIG. 1 . FIG. 1 shows a graphic representation of a degree of sound absorption versus frequency for an exemplary embodiment of the present invention.
It can be seen from the overall shape of the curve (identified by B in FIG. 1 ), that, because of high absorption values in a low frequency range (e.g. 80% at 315 Hz), combined with absorption values of 40-85% in a higher frequency range, there is a combination of a resonator and an absorber in one material. In comparison, the overall curve shape of a nonwoven material (identified by A in FIG. 1) without subsequent pressure/heat treatment is reproduced. This curve shows the behaviour of a purely porous absorber without the supplementary resonator influenced absorption in the low frequency range.
The nonwoven material, which is suitable for the invention, is formed of natural and/or synthetic organic or inorganic primary fibres, to which 10-90% of thermoplastic secondary fibres are added. The latter have a softening range of at least 5° C., which in any case lies below any possible softening or decomposition range of the primary fibres.
The two fibre types used are those having linear densities of 0.5-17 dtex, preferably 0.9-6.7 dtex, and staple lengths of 20-80 mm, preferably 30-60 mm. The primary fibres which have been particularly tried and tested are polyethyleneterephthalate fibres in combination with copolyester fibres as secondary fibres. The primary and/or secondary fibres are optionally formed by suitable fibre mixtures. The addition of recycled fibres is of particular interest. At a density of 250 to 500 kg/m 3 , preferably 270 to 330 kg/m 3 , the thickness of the nonwoven materials according to the invention is 0.3 to 3.0 mm and, particularly preferably, 0.8 to 1.2 mm.
A first stage of compaction of the nonwoven material comprises a mechanical compaction, which is brought about by needling using needles with barbs, or in accordance with the spun-laced process, by means of water jets. Also, the compaction may be carried out by a stitch-bonding process by means of looping needles. Needling is particularly preferred and is carried out with 40 to 150 punctures/cm 2 , preferably 60 to 80 punctures/cm 2 .
A pressure/heat treatment, as a second stage of the compaction, may be configured discontinuously (cyclic) or continuously. In the first case, heated presses are suitable and, in the second case, heatable calenders. The temperature range to be selected lies within the softening range of the secondary fibres which, in turn lies below the softening or decomposition range of the primary fibres. The line pressure in calenders is in the range of 0.5 to 3.0. KN/cm, preferably 1.5 to 2.0 KN/cm.
Specific flow resistance of the compacted nonwoven materials is particularly significant, since it is directly correlated with the degree of sound absorption. Specific flow resistance values of RS=800-1400 Ns/m 3 , and particularly those of 1100±150 Ns/m 3 have proven to be useful. Following the first compaction stage, the specific flow resistance values are approximately one fifth of these values.
The nonwoven materials according to the present invention are optionally laminates and/or other two-dimensional structures. For special purposes, fibres are used which have had a colorant and/or flameproofing agent and/or electrically conductive components added to them as early as during the production process. In addition, there is a possibility of finishing the finished nonwoven material by making the nonwoven material flame-retardant, using, for example metal hydroxides and/or ammonium polyphosphate and/or melamine and/or red phosphorus. Also, the nonwoven material may be dyed and antioxidation agents and/or antistatic agents may be added.
The invention is explained in more detail below in an exemplary embodiment of the invention. Using a card, a nonwoven material with a uniform weight per unit area is produced from a homogeneous mixture of 50% by weight of 1.7/38 PES fibres (dtex/staple length) and 50% by weight of 2.2/50 COPES fibres. After being processed through a carding and transverse-laying device, the nonwoven material has a weight per unit area of about 300 g/m 2 . The nonwoven material is lightly needled with two needling passes of 40 to 150 punctures/cm 2 in each case, and is compacted by a pair of smooth rollers heated to approximately 135° C. and a line pressure of about 1.7 KN/cm. This nonwoven material, produced in this way, has a specific flow resistance of about RS=1100 Ns/m 3 .
The way in which the degree of sound absorption depends on the frequency is illustrated graphically in FIG. 1 . Curve A refers to the nonwoven material following the first compaction stage, and curve B refers to the final product of the present invention.
FIG. 2 shows a schematic illustration of a three-dimensional arrangement of the soundproofing material of the present invention. A broadband sound absorption effect of the material is achieved by combining resonator and porous absorption mechanisms at the same time in unified form in the nonwoven material according to the invention, in conjunction with an air gap whose width depends on the lowest frequency to be countered. The air gap is behind the nonwoven material layer C according to the present invention. FIG. 2 shows, by way of example, an arrangement of the nonwoven material layer C in front of a reflective wall element E. Dips in the degree of absorption in the frequency range of interest are optionally avoided by adding further nonwoven material layers of the material layer D according to the invention.
The nonwoven materials according to the invention can be used primarily in the area of secondary soundproofing indoors, for example, as an acoustically effective layer in soundproofing cabinet walls and screens or as an acoustically effective layer in suspended ceiling constructions (acoustic ceilings). They are distinguished by a dual function, since they intrinsically unify resonance and absorption effects. It therefore becomes possible to achieve a broadband sound absorption, even in the low acoustic frequency range, using only one material.
The following test methods set forth below were performed on the present invention. The degree of absorption of airborne sound was measured according to DIN 52 215 ( Determination of the degree of sound absorption and of the impedance in a pipe). The airborne sound absorption values in FIG. 1 were measured in accordance with the above-mentioned method. The specific flow resistance was measured according to DIN EN 29053, method B. Commercially available thickness measuring instruments using sensor surfaces of 20 cm 2 , a contact pressure of 10 cN/cm 2 and an action time of 5 seconds were used to measure thickness. | A soundproofing material made of nonwoven materials containing thermoplastic fibers for the acoustic frequency range of 100 to 5000 Hz is characterized in that the nonwoven material is permanently compacted to a specific flow resistance of RS=800-1400 Ns/m 3 in two stages by a mechanical compaction process and a subsequent pressure/heat treatment. | 8 |
FIELD OF THE INVENTION
[0001] The invention concerns a solid state voltage-controlled oscillator arrangement with two oscillator stages coupled by switching elements so as to generate quadrature phase outputs. In addition to switching elements that operate alternately to couple and decouple the oscillator stages, additional switching elements are provided alternately to apply or to decouple operational bias that produces tail current. The stage-coupling and tail current switching elements operate in phase with one another but in opposite directions. The result is reduced overall power consumption.
BACKGROUND
[0002] It is known to couple together two substantially identical resonant LC voltage controlled oscillators (VCO) as a unit that produces quadrature outputs. The oscillation frequency of the unit can be tuned by adjusting the coupling coefficients between the two oscillators.
[0003] FIG. 3 , labeled “prior art,” is a block diagram schematic showing two coupled LC oscillators. Each has a positive feedback loop with a transfer function “G i ” between a respective input and an output coupled back to the input. The outputs of the two oscillators respectively are each coupled to a summing node at the input of the other oscillator, through a controllable coupling block. The coupling coefficients of these blocks are scalar factors m 1 and m 2 . The outputs are shown as signals X and Y, which are to be quadrature-phase related signals at a nominal oscillation frequency.
[0004] In this arrangement, assuming steady state oscillation wherein the two oscillators are synchronized to a single oscillation frequency w, the outputs of the two oscillators must satisfy the following equations:
[0000] ( X+m 2 Y ) G 1 ( j ω)= X
[0000] ( Y+m 1 X ) G 2 ( j ω)= Y
[0005] The two VCOs are identical, and can be assumed to have equal transfer functions (G 1 =G 2 =G). Further assuming equal coupling coefficients (m 1 =−m 2 =m), then it can be shown that X 2 +Y 2 =0, and therefore, X=±jY. This demonstrates that the coupled identical oscillators as shown and described produce quadrature outputs X and Y. Substituting X=±jY into one of the foregoing equations produces:
[0000] (1± jm ) G ( j ω)=1
[0006] The impedance Z(jω) of the oscillator resonator is proportional to G(jω) the gain of the oscillator stage. There are two possible oscillation frequencies, ω 1 and ω 2 , namely where
[0000] φ( Z ( jω 1 ))=−tan −1 m and φ( Z ( jω 2 ))=tan −1 m
[0007] For a typical resonator with a lossy inductor having a tank arrangement as modeled in FIG. 4 (also labeled as prior art), an impedance magnitude peak occurs at a frequency higher than the resonator frequency:
[0000]
ω
0
=
1
2
π
LC
1
-
CR
s
2
L
[0008] Assuming that a stable oscillation is obtained at one frequency ω 1 associated with the impedance peak (which inherently requires a loop gain of unity and a 180 degree phase difference), then a sustained oscillation at a second frequency ω 2 is not possible because the loop gain is less than unity at frequencies other than ω 1 . A stable oscillation is obtained just at one frequency. Based on the foregoing equations, stable oscillation is obtained where (1+jm)G(jω)=1 and the oscillation frequency at ω 1 is determined by φ(Z(jω 1 ))=−tan −1 m. These relationships suggest that the oscillation frequency of the coupled oscillators can be tuned from a frequency ω 0 to a frequency ω 1 as defined, by varying the coupling coefficients (m 1 =−m 2 ) between zero and m. The output frequency can be tuned to a selected point in a frequency range by varying the coupling coefficient between the two LC oscillators (i.e., by varying the absolute value of the coupling coefficient up to a maximum m).
[0009] The frequency tuning range is determined by the phase-frequency characteristics of G(jω) and by the range of deviation of the coupling coefficient m. An upper bound of m is reached at a limit resulting from phase noise performance. A lower bound of m is reached due to a multi-mode oscillation phenomenon. In practice it is not possible to have two perfectly-matched oscillators. Each oscillator will have a slightly different natural oscillation frequency (i.e., when no coupling is applied). If the extent of coupling (m) is made smaller and smaller, a point is reached when the coupling becomes too weak to prevent the oscillators from seeking their different natural frequencies, giving rise to a multi-tone output signal as a result of nonlinear limiting in the feedback loops. The minimum value of the coupling coefficient m is a function of the extent of mismatch between G 1 and G 2 .
[0010] Generally, the aim of an LC oscillator of this type (i.e., either single LC oscillator as opposed to the coupled pair) is to provide NMOS and/or PMOS cross coupled transistor pairs that switch between conducting and nonconducting states at a frequency determined by the resonant tank circuit. The pairs are arranged so as to shift currents back and forth between capacitive and inductive elements in a complementary way. Some energy is lost in every cycle, including energy dissipated in parasitic resistances of the LC tank. As a result, an LC resonator by itself could not maintain steady oscillation over time. However, in an appropriate configuration, cross-coupled differential transistors can provide the negative resistance necessary to replenish the energy that is lost. Oscillation can continue indefinitely.
[0011] In order to provide stable oscillation, the negative resistance (or transconductance) of such an oscillator must cancel out the energy dissipated by the resonant LC tank. To ensure start-up oscillation, transconductances are advantageously chosen to be two or three times the minimal acceptable value. To provide transconductance as necessary, the VCO necessarily dissipates a current. The serial current through each VCO is known as the VCO “tail current.” The transconductance value is proportional to the square-root of the tail current.
[0012] In the cross coupled oscillator stage described above, the tuning elements that control the coupling coefficients between the two stages (m 1 =−m 2 ) between zero and m, likewise require bias and contribute to the current load on the power supply. The bias on the coupling and switching controls produces a bias current that can be termed the coupling circuit tail current.
[0013] In a known VCO unit described in “A 6.5 GHz monolithic CMOS voltage controlled oscillator,” Liu T. P., et al., ISSCC, Feb, 1999, pp. 404-405, a technique is disclosed wherein transistor elements vary the extent of coupling between two VCO stages, for tuning the frequency of the coupled pair. A control voltage is applied to the transistor coupling elements for obtaining a selected coupling coefficient in a tuning range. The VCO tail currents of the coupled oscillators are equal because the oscillators are equal (insofar as practically possible). The tail currents dissipated by two couplers are equal because the coupling coefficients have equal absolute values (m 1 =−m 2 ). As discussed in Liu T. P.'s paper, the coupling coefficient m=(I 1 /I 0 ) n , where I 1 is the coupler tail current, I 0 is the VCO tail current, and n=0.5 to 1.0. In the Liu paper, I 1 is tuned; and I 0 remains constant. The coupling elements may carry more or less coupling circuit tail current, depending on the point at which the circuit happens to be tuned in its operational range. The VCO tail currents and the coupling circuit tail currents both load the power supply. Under tuning conditions where the coupling circuit tail current is high, the sum of the constant VCO tail current and the variable coupling circuit tail current may be such that the device dissipates considerable power.
[0014] What is needed is a way to control oscillation frequency that is similarly convenient, i.e., by controlling the driving current applied to coupling components, without suffering undue tail current dissipation in the steady state and/or at any particular operational state over a tuning range.
SUMMARY OF THE INVENTION
[0015] It is an aspect of the invention to provide a cross coupled VCO oscillator pair wherein the coupling coefficients on cross coupled paths between two complementary PMOS/NMOS switches are controlled and switched synchronously with oscillation. The oscillators produce periodic outputs at a controllable frequency, in quadrature phase relationship. According to an inventive aspect, VCO tail current levels and coupler circuit tail current levels are balanced against one another by sharing a current mirror control wherein two sides share a current supply in a manner that when one of the coupler circuit and an associated VCO is driven to increase its tail current level, the other of the coupler circuit and VCO is driven to decrease its tail current. The two are driven in a coordinated manner in opposite directions. In this way, the sum of the tail currents of the coupler circuit and VCO are controlled over the range of frequency control, instead of providing points in the control ranges wherein the total current dissipation is distinctly higher that at other points, due to driving the coupler circuit particularly hard.
[0016] The invention couples the two types of elements leading to tail current and associated power dissipation, namely VCO tail current controls and coupling circuit tail current controls, and balances the VCO and coupling circuit controls against one another. A tuning variation leading to increased tail current and power dissipation in one type, causes decreased tail current and power dissipation in the other, and vice versa. In a device of this type as described in the background, the coupling coefficient is related to the ratio of coupler tail current to VCO tail current (i.e., m=(I 1 /I 0 ) n , where I 1 is the coupler tail current, I 0 is the VCO tail current). According to the invention, when tuning for an increase in the coupling coefficient, an increase in coupler tail current and a decrease in VCO tail current, both contribute toward the desired increase in the coupling coefficient. Likewise, a decrease in coupler tail current and an increase in VCO tail current both contribute toward a decrease in the coupling coefficient. Good tuning capability is achieved while limiting total power dissipation over the full operational range.
[0017] The invention permits efficient generation of quadrature oscillation signals over a control range while limiting the total biasing current of the oscillator pair and its associated coupling elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] There are shown in the drawings certain exemplary and nonlimiting embodiments of the invention as presently preferred. Reference should be made to the appended claims, however, in order to determine the scope of the invention in which exclusive rights are claimed. In the drawings,
[0019] FIG. 1 is a schematic block diagram illustrating quadrature cross coupled voltage controlled oscillators (VCOs) according to the invention.
[0020] FIG. 2 is a schematic illustration of quadrature cross coupled voltage controlled oscillators (VCOs) according to the invention.
[0021] FIG. 3 is a block diagram, labeled “prior art,” used in explaining the general operation of cross coupled quadrature VCOs with tunable coupling paths as provided in the background section above.
[0022] FIG. 4 , also labeled “prior art,” is an excerpt of illustrations from a published technical description of the theory of cross coupled quadrature VCOs, namely “A 6.5 GHz monolithic CMOS voltage controlled oscillator,” Liu T. P., et al., ISSCC, Feb, 1999, pp. 405.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] FIG. 1 is a block diagram that illustrates the structure and function of the invention. FIG. 2 is a schematic diagram illustrating a practical embodiment.
[0024] A pair of voltage controlled oscillators VCO 1 and VCO 2 are connected to one another including through couplers 21 , 22 , so as to operate as described in the background section above, producing two quadrature outputs X and Y, namely periodic signals that are synchronous but 90 degrees out of phase. The frequency of the outputs is controlled by a control voltage input Vc, the same voltage input level defining the maximum coupling proportion at both couplers 21 , 22 associated with summing nodes 31 , 32 .
[0025] As shown in FIG. 2 , each of the two VCOs can comprise a cross-coupled differential pair amplifier and an LC resonant tank. The transistor members of the cross-coupled pairs, for example Q 1 and Q 2 , and Q 5 and Q 6 (for VCO 1 ) behave like an amplifier and provide negative resistance sufficient to compensate for the LC tank parasitic resistance loss. Two loops couple the two LC oscillators so as to generate quadrature VCO outputs, with frequency tuning provided by varying the coupling coefficient m. The coupling coefficient is equal for coupling VCO 1 to VCO 2 and vice versa, but with negative sign relationship (m 1 =−m 2 ), achieved by properly connecting the VCO outputs to the coupler circuit inputs as shown in FIG. 2 . The outputs of oscillators VCO 1 and VCO 2 are synchronous and in quadrature phase relationship, at a frequency determined by varying the coupling coefficient m as discussed in the background section above. The coupling coefficient is varied over a control range by varying the applied input control voltage Vc.
[0026] In addition to the capability of selecting a frequency in a range by varying the coupling coefficient through the applied control voltage Vc, in the example shown, the varactor value is likewise controllable, e.g. varying the capacitance of the varactor through one or more control voltage inputs Vc 1 . . . Vcn can provide additional tuning by changing the basic period ω 0 . The VCO can have a substantial tuning range by combining these two tuning capabilities. However, this disclosure focuses on varying the coupling coefficient rather than varactor capacitance to illustrate the inventive technique for frequency control with limited power consumption.
[0027] As shown in FIG. 2 , couplers 21 , 22 can be configured as analog differential pair amplifiers. Coupler 21 takes VCO 2 's output as input, and coupler 21 's output is connected to VCO 1 . Thus, coupler 21 couples VCO 2 to VCO 1 . The extent of coupling m=g m11,12 /g m5,6 which is proportional to the square root of (I 18 /I 20 ), where I 18 is the current flowing through transistor Q 18 (e.g., the coupler circuit tail current), and I 20 is the current flowing through transistor Q 20 (e.g., the VCO 1 tail current). The expression “g m,n ” is the transconductance of transistor #n). Coupler 22 operates in a comparable manner to couple VCO 1 to VCO 2 .
[0028] According to an aspect of the invention, the coupling coefficient m is tuned in a power conserving manner. In a preferred embodiment, if I 18 is increased by a tuning variation in input Vc, that same variation causes I 20 to be decreased at the same time (and vice versa). The coupling coefficient m is proportional to the square root of the ratio I 18 /I 20 . Therefore, either increasing I 18 or decreasing I 20 will increase the coupling coefficient m. The invention provides a control that does both, enhancing the extent that such a control change increases the coupling coefficient, while limiting total power consumption. (Similarly, decreasing I 18 and/or increasing I 20 decreases the coupling coefficient while limiting power consumption.) Changing the coupling coefficient (tuning m) varies the oscillation frequency of the two VCOs as discussed in the background section above. The VCO frequency can be adjusted continuously to set a desired frequency over a tuning range.
[0029] In the embodiment shown, the tail current levels coupled to oscillators VCO 1 and VCO 2 are controlled by transistors Q 20 , Q 21 , in series with the VCOs across the power supply voltages (shown, for example, as a more positive level V DD and a more negative level at ground potential. The tail current levels available to the coupling control differential amplifier pair Q 11 , Q 12 is controlled by transistor Q 18 . The tail current for differential amplifier pair Q 13 , Q 14 is controlled by transistor Q 19 .
[0030] FIG. 1 generally shows a common controller 70 , which serves to balance the bias applied to the couplers, which are also subject to the VCO frequency control input Vc, versus the bias applied to the VCOs. More particularly, controller 70 balances the biasing of these two categories (coupling coefficient controls 21 , 22 versus VCO tail current controls 61 , 62 ) so that when one is increased, the other is decreased, and vice versa.
[0031] FIG. 2 shows the circuit level implementation of the invention. Insofar as possible, the reference numbers employed in FIG. 1 are used to identify the same elements in FIG. 2 . Two identical LC oscillators VCO 1 and VCO 2 are provided. In this embodiment, the oscillators comprise PMOS and NMOS transistors in complementary pairs (Q 1 -Q 2 with Q 5 -Q 6 , and Q 3 -Q 4 with Q 7 -Q 8 ). The cross coupled PMOS and NMOS pairs provide a negative resistance to cancel the parasitic loss of the LC resonant tank. It would be possible to use either PMOS or NMOS pairs in a similar embodiment. However using both PMOS and NMOS pairs provides good negative resistance and better VCO phase noise characteristics.
[0032] The LC tank circuits alternately shift between accumulation and discharge of electric charge versus current in capacitive and inductive elements, substantially in a manner known with respect to oscillators of this type. The two oscillators are cross coupled to produce quadrature outputs. The oscillators operate in a manner reflected generally by FIGS. 1 and 3 and discussed in the background section above.
[0033] Each oscillator VCO 1 and VCO 2 operates as an amplifier with a transfer function G 1 , G 2 . The transfer functions are equal (G 1 =G 2 ). The coupling coefficients of coupling paths m 1 , m 2 between the VCOs are also equal (m 1 =−m 2 =m). Two outputs X and Y are produced at the same frequency, 90 degrees out of phase (i.e., quadrature phase related synchronous signals). The frequency of the output can be determined by changing the coupling coefficients via a control input Vc, as shown in FIG. 2 .
[0034] In FIG. 2 , the coupling between the two oscillators VCO 1 and VCO 2 is provided by NMOS transistors Q 11 , Q 12 , Q 13 , Q 14 . Transistors Q 11 , Q 12 form a differential pair that is in series with a coupler tail current control transistor Q 18 and together form coupler control 21 . Likewise, transistors Q 13 , Q 14 form a differential pair in series with Q 19 in coupler control 22 . Current levels are controlled by input Vc. The current in Q 18 and Q 19 is determined in part by the transconductance of the coupler circuits 21 and 22 . The variation in control voltage (Vc in FIG. 1 ) defines the span of the coupling coefficient and thus the VCO tuning frequency range.
[0035] The VCO tail current control 61 comprises transistor Q 20 , coupled between the VCO transistors Q 5 , Q 6 and the negative supply voltage Vss. The VCO tail current control 62 likewise comprises transistor Q 21 , coupled to VCO transistors Q 7 , Q 8 .
[0036] The coupling coefficient “m” is varied to tune the frequency. The coupling coefficient is tuned by the control voltage Vc. The coupling coefficient is given by m=g m11,12 /g m5,6 =g m13,14 /g m7,8 . The coupling coefficient also is proportional to the square root of the ratio of the coupler circuit tail current to the VCO tail current. (As noted above, “g m,n ” refers to the transconductance of transistor #n.)
[0037] Thus the coupling coefficients are determined by the control voltage Vc, applied to transistors Q 17 , Q 15 , Q 16 . The coupler circuit tail currents in Q 18 and Q 19 are mirrored from the current in Q 15 . The VCO tail currents in Q 20 and Q 21 are mirrored from the current from Q 16 .
[0038] The VCO tail current and the coupling circuit tail current conventionally would be independent variables. Assuming a given VCO tail current, then an increase in coupling tail current results in a higher coupling coefficient but does not inherently require a change in the VCO tail current. Such an approach can result in greater power consumption than the approach taken according to the present invention, where increasing the coupling tail current also decreased the VCO tail current. The permits the VCO to cover a large range of m without consuming excessive power.
[0039] One aspect is to ameliorate the possibility that varying coupling of the oscillation signals between the VCOs by varying the tail current at the coupling controls 21 , 22 alone, could result in a relatively high coupler tail current when the coupling coefficient is at its maximum. This is simply to say that the coupling controls will dissipate more current when driven harder and less current when not driven so hard, which seems a foregone conclusion. However according to the invention, an increase or decrease in the bias of the coupling control is balanced, respectively, by a decrease or increase in VCO tail current. For example, when increasing the coupling tail current, the VCO tail current is decreased, and vice versa.
[0040] According to the execution of this inventive aspect in FIG. 2 , an NMOS transistor Q 15 is driven from the control voltage Vc. Transistor Q 17 provides a current source for transistors Q 15 , Q 16 , forming a current mirror. The current at the drain of Q 17 is shared by Q 15 , Q 16 . When the current from Q 17 is directed more to either Q 15 or Q 16 , the current available to the other is decreased. Transistor Q 15 is driven together with the coupling tail current controls Q 18 , Q 19 from the control voltage Vc. Transistor Q 16 is coupled to the VCO tail current controls Q 20 , Q 21 and is indirectly controlled by control voltage Vc because the current available to transistor Q 16 is decreased when control voltage Vc instead causes transistor Q 15 to sink current available from Q 17 . In this way Q 18 and Q 19 , namely the coupling tail current controls, are driven in the opposite direction as compared to the drive on Q 20 , Q 21 , namely the VCO tail current controls, so that if the tail current of the coupling controls increases, then the tail current of the VCOs decreases, and vice versa.
[0000] In this embodiment, the voltage control input is supplied at Vc to transistor Q 15 and to the gate of coupling current transistors Q 18 , Q 19 . As the level of Vc increases, the tail currents (e.g., the drain-source current of transistors Q 18 and Q 19 ) of the coupling circuits 21 and 22 increase. On the other hand, as the control voltage at Vc is increased, the drain-source current of transistor Q 15 increases. The increase of the drain-source current of Q 15 consumes an increment of the drain-source current of Q 17 which results in an increment of the gate-source voltage (Vgs) drop of Q 17 . The increased Vgs voltage drop at Q 17 reduces the gate voltage applied to Q 16 . The reduced gate voltage at Q 16 results in a smaller drain-source current of transistor Q 16 and thus a smaller tail current for the VCO (e.g., drain-source current of Q 20 and Q 21 ).
[0041] To summarize, the inventive circuit is configured such that varying Vc simultaneously increases the level of current in the coupling circuits and decreases the level of current in the VCO tail current path, and vice versa. The coupling coefficient is proportional to the square root of the respective current ratios. Increasing the control voltage Vc enhances the change in the ratio by increasing the numerator and decreasing the denominator. An increased value for the coupling coefficient is thus obtained without necessitating a proportionately equal increase in VCO tail current. The same considerations apply to both VCO stages as shown.
[0042] According to the invention as shown in FIG. 2 , the coupling circuit tail current tuning elements and the VCO tail current tuning elements are operated alternately. In addition, according to the invention, the coupling circuit tail current tuning and the VCO tail current tuning are coordinated to occur in opposite directions (increasing one while decreasing the other and vice versa), achieving an enhanced effect (increase or decrease) on the coupling coefficient.
[0043] The invention is applicable to an oscillator arrangement having two voltage controlled oscillators, each with an amplifier producing an output signal an dissipating a series current (tail current), and a summing node through which a control signal and the output signal are coupled in a feedback loop, wherein the two oscillators are cross coupled by two couplers. This coupling is such that the couplers controllably insert a portion of the output signal from one of the oscillators into the summing node of the other of the oscillators to achieve output signals synchronously with a phase difference, in particular the quadrature phase conditions described in the background section above.
[0044] Two pairs of bias current controls are provided. One pair of bias current controls adjusts the tail current through the oscillators. The other pair of bias current controls adjusting the current through the coupling circuits and thereby adjusts the coupling coefficient. As stated above, the controls are operated at equal levels.
[0045] However according to an inventive aspect, a controller is coupled to these bias current controls. The controller proportions available control currents so that the tail current levels of the oscillators and the coupling circuits are alternately and oppositely varied so that if one is caused to increase, the other is caused to decrease and vice versa.
[0046] In the exemplary embodiment, the oscillators each comprise complementary PMOS and NMOS negative resistance pairs coupled to at least one tank circuit. However, the invention is applicable to other coupled oscillator arrangements wherein oscillator current dissipation and coupling circuit current dissipation can be balanced against one another as described. Similarly, the output signals of the respective oscillators are synchronous quadrature signals. This is a useful but nonlimiting application of the invention.
[0047] Although exemplary circuits are shown for purposes of illustration, the invention can be considered a method for operating a complementary voltage controlled oscillator of the type having oscillators that are cross coupled by couplers defining coupling coefficients and are current controlled by tail current switches. This method includes the steps of providing couplers that are driven to alter the coupling coefficient between the oscillators and providing tail current controls for the couplers and also for the oscillators themselves. The couplers and the tail current transistors are operated in opposite directions during changes in the control level (i.e., when tuning for oscillator frequency). That is, increasing the coupler tail current is arranged, preferably using the same control circuit, to decrease the oscillator tail current. The invention as discussed above uses the proportioning of available current between two sides of a current mirror to accomplish this coordination. The effect is that the total current loading (the sum of all the biasing currents drawn from the power supply) remains limited over the range of controllable frequencies of oscillation, rather than having certain points in the range where the power dissipation is greater than at other points.
[0048] In the example discussed, the variation of the control bias (tail current) in an opposite direction from the oscillator bias (tail current) is accomplished by proportioning a common current supply in a current mirror arrangement. It would be possible to employ other particular circuits to achieve the same desired effect of opposite tuning of the coupling control tail currents versus the oscillator tail currents.
[0049] The invention has been disclosed in connection with exemplary embodiments that demonstrate the invention and its representative functions. The invention is not limited to these examples. Reference should be made to the appended claims rather than the discussion of examples in order to determine the scope of the invention in which exclusive rights are claimed. | A voltage controlled oscillator unit is provided with cross coupled voltage controlled oscillators to generate quadrature phases. One control stage adjusts coupling between the oscillators. Another control stage adjusts the tail current that applies operating bias to the oscillators and to the couplers, respectively. The cross coupling and tail current control stages are arranged so that tuning one simultaneously and oppositely tunes the other for simultaneous adjustment in opposite directions. This limits the power consumption of the oscillator unit throughout the range of frequency control. | 7 |
BACKGROUND OF INVENTION
This invention is concerned with a method and apparatus for conservation of water.
The invention is particularly concerned with the reduction of evaporation losses from water storages having a high ratio of surface area to water depth.
In many regions of Australia and elsewhere in the world, the capacity for sustainable horticulture is dependent on the availability of water.
In arid and semi-arid regions, a level of sustainable horticulture has been achieved by building large but relatively shallow water storage dams covering many hectares.
Water levels in such dams can be topped up in rainy seasons by drainage from catchment areas where the topography is appropriate or otherwise by pumping water from creeks or rivers when water is flowing therein.
A major disadvantage of such water storage systems is the high rate of water loss due to evaporation due to the combined effects of wind and water surface temperature.
Evaporative losses are generally measured in megalitres/hectare where a 100 mm reduction in water depth per hectare equals one megalitre.
In semi-arid areas where average annual rainfall may be of the order of 600 mm, evaporative losses during the summer are typically of the order of 18 megalitre/hectare or a reduction in water depth of 1.8 metres.
In more arid areas where average annual rainfall may be 200 mm or less, evaporative water losses of up to 30 megalitres/hectare have been recorded.
While the proportion of water lost by evaporation in water storage facilities can be reduced by increasing the depth/surface are ratio, this is generally uneconomical.
For large capacity water storage dams of many hectares in surface area, these are usually constructed on flat land (without a surrounding catchment area) by pushing up a perimetral wall of 2-3 metres in height with a bulldozer. It generally is not economically feasible to excavate large volumes of earth to form a water storage facility.
As far as the cost of evaporative losses are concerned, these may be measured by the cost of water purchased and/or the value of lost agricultural production.
Typically, in an irrigation area where water is pumped from a stream, the cost of a water allocation license may cost from $1000-$3000 as an initial fee and a seasonal pumping cost of about $25 per megalitre subject to volumetric limits. These costs are steadily increasing as water becomes scarcer due to seasonal variations and increased levels of horticulture.
If evaporative losses were to be measured in terms of lost agricultural production otherwise possible, the value per megalitre of water could range between $500 for a cotton crop up to $1000 or even higher for high value crops such as vegetables or the like.
Another problem associated with evaporative losses from open storage ponds is the risk of increased salinity in water applied to crops as water levels diminish due to evaporation. This problem can be exacerbated where the water is constantly held in storage i.e. the storage pond is never completely emptied to remove accumulated salt concentrations.
Over the years there has been extensive research into reduction of evaporative water losses.
Prior art proposals have included chemical, physical, and structural methods.
Typically, chemical methods comprise the use of a chemical monolayer on the water surface to reduce the evaporation rate. The most well known of these is the use of cetyl alcohol.
While chemical monolayers have proven useful in pilot studies on small surface areas, there are real practical difficulties in maintaining the integrity of the monolayer due to wind actions well as contamination and biodegration of the monolayer.
Physical methods of evaporation control include destratification to bring cooler water to the surface, however, this is of little value in reducing evaporative losses due to wind action.
Other physical methods have involved floating covers made from:
expanded perlite ore
polystyrene beads
foamed wax blocks
white spheres
butyl rubber sheets painted white
polystyrene sheets and rafts
white foamed wax in continuous layers
foamed butyl rubber
light grey asphaltic concrete blocks.
While encouraging results have been obtained with some of these systems (up to 80% reduction with floating concrete rafts) none are suited to very large water storages having a surface area of many hectares due to cost.
Structural methods including roofing of reservoirs have shown evaporation reductions of up to 90% but again, the cost of such structures is not feasible for large surface areas.
SUMMARY OF INVENTION
Accordingly, the present invention seeks to overcome or ameliorate at least some of the disadvantages of prior art water evaporation reducing systems and to provide, if not a more cost effective system, at least a useful alternative choice.
According to one aspect of the invention, there is provided, a system for reducing evaporation losses in a large surface area water storage, said system comprising:-a buoyant flexible membrane extending over a substantial portion of the surface of a body of water, said membrane being anchored by flexible anchoring means spaced about the periphery thereof and connected to a peripheral wall of said water storage, said membrane characterized in that it comprises a plurality of membrane elements engageable along respective adjacent edges thereof, said membrane further characterized in the provision of spaced apertures to prevent, in use, accumulation of rain water on an upper surface thereof.
Suitably, the flexible membrane is comprised of a natural or synthetic polymeric material.
If required, the flexible membrane may comprise a closed cell foam structure for buoyancy.
Alternatively the flexible membrane may comprise spaced buoyancy chambers.
Preferably the spaced buoyancy chambers extend over at least one surface of said membrane.
Most preferably the buoyancy chambers extend over a surface of said membrane, in use, in contact with the surface of the body of water.
The buoyancy chambers may be interconnected if required.
The membrane elements suitably comprise parallel sided members having telescopically engageable connection means extending adjacent opposed longitudinal edges.
Suitably the telescopically engageable connection means comprises an elongate socket-like element extending adjacent one edge of said membrane element and an elongate spigot-like element extending adjacent an opposite edge, each said socket-like element and spigot-like element being telescopically engageable in a respective complementary connection means of an adjacent membrane element.
Alternatively the membrane elements may comprise connection members spaced along opposite sides thereof. If required, the connection members may comprise apertured eyelets, interengageable hooks and eyes or hooks and eyes engageable by a cord member.
The flexible anchoring means suitably comprises cord-like members adapted for attachment to spaced anchor members located about the peripheral wall of said water storage.
According to another aspect of the invention there is provided a method of reducing the evaporative losses in a water storage, said method comprising the installation in a large surface area water storage of a system according to the first aspect of the invention.
BRIEF DESCRIPTION OF DRAWINGS
In order that the invention may be more readily understood and put into practical effect, reference is now made to a preferred embodiment illustrated in the accompanying drawings in which:
FIG 1 shows a water storage embodying a water evaporation reducing system according to the invention.
FIG. 2 shows schematically a method of installing the system illustrated in FIG. 1 .
FIG. 3 shows an enlarged cross-sectional view of the telescopically interengageable connection means of the buoyant membrane.
FIG. 4 shows an alternative connection between adjacent membrane elements.
DETAILED DESCRIPTION
In FIG. 1 the water storage 1 comprises a raised earthen bank 2 with a buoyant membrane 3 anchored to the earthen bank 2 by flexible cords 4 secured at one end to the parallel sided membrane elements 5 by means of eyelets 5 or the like.
The other end of each cord 4 is secured to a peg 7 or other suitable anchor in the bank 2 .
The flexible cords may comprise some degree of elasticity to accommodate movement of the membrane 3 as the water level rises or falls thereunder. Generally speaking however it is considered that there is sufficient resilience in the plastics or rubber membrane 3 to maintain sufficient tension in the cords 4 .
If required, the membrane 3 may include one or more openings 8 about its periphery to permit stock to drink or otherwise to accommodate an inlet or outlet conduit (not shown).
FIG. 2 shows one method of installing the system shown in FIG. 1 .
A roll 10 of buoyant membrane material 11 of any suitable width typically from 3-5 metres or more is initially set up on a roll stand 12 outside the earthen bank 13 of the water storage 14 and at one end 15 thereof.
Using a rope or the like tied to the free end of the buoyant membrane 11 , the free end is drawn over the surface of the water thereunder until the first roll 10 is nearly exhausted.
A second roll 16 of membrane material 11 is set up on a roll stand 17 behind the first roll 10 with a thermal welding device 18 such as a radio frequency welder therebetween, the welder being powered by a portable electric generator 19 .
The tail of first roll 10 is welded to the beginning of roll 16 and the strip of membrane 11 is drawn across the surface of the water with further rolls of membrane material being added as required until the membrane strip reaches the opposite bank (not shown) of the water storage.
As an alternative, mechanical fastening means may be employed to join the ends of membranes 11 .
Both ends of strip 11 and edge 11 a are secured to the bank 13 by flexible cords 20 connected to eyelets 20 along the side and ends of the sheet 11 , the cords 20 being secured at their opposite ends to pegs or stakes 22 in the earthen bank 13 .
Roll-stands 10 and 17 with associated rolls of buoyant material 11 a , 16 , together with the strip welder 18 are then aligned with the free edge of the strip 11 floating on the surface of the water in storage 14 .
An elongate spigot shaped telescopic connection means (not shown) along one side of new roll 11 is connected with an elongate socket shaped telescopic connection means (not shown) associated with an adjacent side of already installed strip 11 a.
By means of a rope 23 , new strip 11 a in telescopic engagement with adjacent strip 11 , is drawn out over the surface of the water and the process is continued until substantially the entire surface area of the water storage 14 is covered by a continuous buoyant membrane comprising membrane elements joined along adjacent edges.
Suitably cord 23 is passed around a pulley (not shown) on the opposite earthen bank to enable a one person operation and otherwise to provide a free end of cord 23 for connection of a subsequent strip of membrane material.
The free ends of each strip are anchored progressively as they are installed and the free edge of the last strip is also anchored after installation to provide a secure integral barrier against evaporation due to thermal and/or wind effects.
The simplicity of the apparatus needed for installation enables ease of installation in remote areas with a minimum of labour content in order to minimize the cost/hectare of installation.
Over very large distances the friction between the telescopically engaging connection members may exceed the tensile strength of the strip of membrane and/or the connection member(s) under tension notwithstanding the presence of water as a lubricant.
In such circumstances a shorter panel may be drawn to the middle of the water storage from one side of the water storage and thereafter additional short panels are drawn from the same side of the water storage to abut the previous panel. The process is then repeated from the opposite side of the water storage to form an effective cover over the entire width of the water storage.
FIG. 3 shows schematically the telescopic connection between adjacent strips of buoyant membrane material.
Suitably the membrane 30 comprises a laminated thermoplastics material having a plurality of air filled buoyancy chambers 31 extending from a lower surface.
Alternatively as shown by membrane 30 a , the buoyancy chambers 31 a may comprise spaced transversely and/or longitudinally extending air filled chambers.
Secured along opposing sides of the membrane are extruded members 32 , 33 in the form of elongate socket and spigot shaped telescopically engageable connection members.
The connection members 32 , 33 may be secured to the membrane sides by any suitable means such as stitching, adhesive material or by thermoplastic welding.
Located between the buoyancy chambers 31 (or 31 a ) are apertures 34 at spaced intervals. These apertures, in use, prevent ponding of rainwater on the upper surface of the membrane which might otherwise cause the membrane to sink in parts and apply excessive tension in the anchoring means.
The clearance between the complementary socket and spigot connectors is sufficiently great as to permit low friction telescopic engagement, particularly in the presence of water as a lubricant, but otherwise to maintain sufficient structural integrity to prevent being pulled apart in high wind conditions.
By placing the protruding buoyancy chambers on the underside of the membrane, the contact area with the water is increased substantially to reduce the wind lift factor.
In addition by providing a relatively smooth upper surface to the membrane, collection of dust, leaves and other debris is minimized and the smooth upper surface will be cleaned by rain and wind action.
FIG. 4 shows an alternative method of connecting adjacent membrane elements 40 , 41 .
As shown, elements 40 , 41 comprise laminates of plastic film having spaced buoyancy chambers 42 over at least a lower surface 43 thereof.
Opposite side edge regions 44 , 45 of the membrane elements may be free of buoyancy chambers and permit free overlapping of regions 44 , 45 .
A fastener 46 of a type similar to that used in the aircraft industry for joining thin sheets of aluminum alloy or the like is inserted from one side (typically the top) of the overlapped region to form a pierced aperture 47 and the fastener 46 is then actuated by an actuating tool to cause finger-like elements 48 to frictionally engage against the underside of fastener 46 in the region of collar 49 to securely clamp the membrane elements 40 , 41 together.
A suitable type of fastener may be a “BULBEX” type rivet-like fastener available from Textron Inc. or a similar fastener suitable for plastic sheets, with or without localized reinforcing e.g., washers.
Although the membrane may be comprised of any suitable polymeric material such as polyvinyl chloride, polyethylene butyl rubbers or any other polymeric material having suitable mechanical and physical properties, the raw material costs and manufacturing methods for sheet like membranes will mitigate against many of these polymers.
It is considered that “layflat” polyethylene film provides the best compromise between cost and available film width.
Moreover, as film appearance is unimportant it is considered that reclaimed polyethylene, pigmented black or white, with or without an appropriate ultra-violet light stabilizer will provide a cost effective membrane material with adequate resistance to weathering of between 2-5 years before replacement becomes necessary.
To further reduce costs, it is considered that the buoyant membranes according to the invention may be manufactured on site from rolls of “layflat” polyethylene film and rolls of extruded socket and spigot telescopic connector means.
Layflat film up to 3 metres in width is available as a flattened tube in rolls in excess of 100 metres.
A portable laminator could for example comprise say a 3 metre wide hollow drum having a pattern of perforations in its outer surface in fluid communication with a vacuum pump.
As the double layer of film passes over a region of reduced internal pressure in the drum, the lower layer of film is vacuum formed with a plurality of hollow protrusions extending partly into the drum perforations.
An oil heated laminating roller then fuses the upper layer of the film to the lower layer thereby forming closed cell buoyancy chambers.
The 3 metres wide strips may then be welded together along adjacent edges by a simple continuous thermal welding device to form membrane elements of from say, 9-15 metres in width.
The extruded socket and spigot strips may be attached again by a continuous thermal welding process in a separate step or as the membrane elements are drawn across the surface of the water during installation.
It will be readily apparent to a skilled addressee that many modifications and variations may be made to the invention without departing from the spirit and scope thereof.
For example, instead of a telescopic engagement between adjacent strips of membrane, the strips may be secured along adjacent edges by lacing or by any other suitable spaced mechanical connectors such as aligned eyelets, sheet material fasteners or the like, the connection being effected from a small floating platform or boat moving between the edges of adjacent membrane strips.
In another embodiment each strip of membrane may be formed with apertured eyelets spaced along one longitudinal edge and transversely aligned hook members spaced along an opposite edge.
Adjacent strips of membrane may then be connected by engaging the adjacent hooks and eyes of respective strips of membrane from a floating platform or alternatively by connecting a cord, laced through the spaced eyes along one edge of a strip of membrane, with hooks spaced along an adjacent edge of an adjacent strip of membrane.
Throughout this specification and claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers. | A method and system for water conservation relies upon the reduction of evaporative losses from water storages having a high ratio of surface area to depth. The system comprises a plurality of buoyant flexible membrane strips interconnected along adjacent edges and anchored by anchor members about the periphery of the water storage. The membrane strips include spaced apertures to prevent accumulation of rain water on upper surfaces thereof. | 4 |
This application is a continuation-in-part of U.S. application Ser. No. 08/181,504 filed Jan. 14, 1994 which is U.S. Pat. No. 5,427,709.
BACKGROUND OF THE INVENTION
This invention relates to cleaning compositions and more particularly to a method of making those compositions, hereinafter referred to as oxygen cleaning agents, which are employed in cleaning the surfaces of oxygen or oxygen-enriched liquid and gas generating, handling, transport and storage equipment used for life support, propulsion, and other functions and the parts and assemblies thereof, such as hoses, pipes, valves, tanks, flasks, connectors, pumps, regulators, face masks and the like.
The standards of the Department of Defense (DOD), National Aeronautical and Space Administration (NASA), National Fire Protection Agency (NFPA), American Society of Testing and Materials (ASTM) and Society of Automotive Engineers (SAE) all specify that the rigorous removal of organic and particulate contamination from oxygen and oxygen enriched handling equipment is absolutely necessary to prevent a fire hazard. Failure to thoroughly clean oxygen and oxygen enriched handling equipment will and has resulted in catastrophic fires. The DOD, NASA, NFPA, ASTM and SAE all have records of equipment damage and personnel injuries and death from fires caused by the failure to adequately clean oxygen and oxygen enriched handling equipment. Testing by NASA has demonstrated that, in the presence of an ignition source caused by the presence of particulate contamination or organic material, many metals will burn in an oxygen atmosphere; and that the rate of burning will be extremely fast. For example, ASTM document G94-88, "Standard Guide for Evaluating Metals for Oxygen Service" reports 6061 aluminum in 100% oxygen at 276 bars burned at an average propagation rate of 13.86 centimeters per second and 316 stainless steel in 100% oxygen at 276 bars burned at an average propagation rate of 1.24 centimeters per second. NASA has high-speed video footage of a 690 bars rated valve operating with 276 bars gaseous oxygen as it fails due to particulate contamination. The conflagration penetrated and expanded beyond a 7.62-centimeter-thick stainless steel valve in 0.25 seconds. Accompanying the fire hazard is a toxicity hazard associated with oxygen and oxygen-enriched handling equipment used in providing life support functions. The organizations previously referred to all have reports of personnel injury and death from toxic residue remaining in life-support equipment that was cleaned with a cleaning agent which was inadequate, either because it failed to remove toxic contaminants or because it contained toxic contaminants itself. As an example, the use of chlorinated hydrocarbon solvents is prohibited in underwater diving life support equipment because these compounds release chlorine in carbon dioxide scrubbers, forming highly toxic and flammable dichloroacetylene.
The requirements for oxygen cleaning agents include the capability of removing common hydrocarbon soils such as lubricating oils and greases, since the presence of these soils represents an extreme fire hazard. Further, oxygen cleaning agents must be capable of removing particulate contamination, since the presence of excessive particulate contamination provides a potential ignition source in oxygen and oxygen-enriched handling equipment. Further, oxygen cleaning agents must be capable of removing halogenated lubricants approved for use with oxygen storage and delivery equipment. Although halogenated lubricants are used in oxygen-enriched handling equipment because they are not flammable, the failure to remove these lubricants during cleaning provides a mechanism for trapping particulate and/or hydrocarbon contamination. Further, the oxygen cleaning agent itself must be non-flammable in a gaseous or liquid oxygen environment so as not to present a fire hazard in the event the cleaner is not completely removed. Further, the oxygen cleaning agent itself must be either non-toxic or of an acceptable low level of toxicity as determined by a medical evaluation (such as trichlorotrifluoroethane solvent (also identified as CFC-113)) in the event the cleaner is not completely removed during the cleaning process. Further, the oxygen cleaning agent must be capable of being analyzed for residual total hydrocarbon contamination with a sensitivity of at least 1 part per million (ppm) to permit accurate, certifiable verification of hydrocarbon cleanliness. Finally, Department of Defense (DOD), National Aeronautical and Space Administration (NASA), and various commercial standards require oxygen-enriched handling equipment to be certified hydrocarbon clean. The DOD standard (MIL-STD-1330C) certifies hydrocarbon cleanliness when the effluent cleaning agent, that is, the cleaning agent following its use in cleaning the oxygen enriched handling equipment, measures less than 5 ppm total hydrocarbon contamination. A conversion factor is applied to convert the DOD standard to the NASA hydrocarbon cleanliness standard of 1 milligram per square foot.
The two principal existing oxygen cleaning agents are trichlorotrifluoroethane solvent (also identified as CFC-113) and tribasic sodium phosphate solution (also identified as TSP). CFC-113 is an ozone depleting substance, and a replacement will become necessary because its production is banned after Dec. 31, 1995. TSP has the disadvantage that it is a hazardous environmental waste. Further, TSP is corrosive to amphoteric metals such as aluminum. Further, TSP is of marginal effectiveness in removing the halogenated lubricants which can trap particulate and hydrocarbon contaminants. Further, TSP must be applied at relatively high temperatures in the range of 71.1° C. to 87.8° C. Further, at temperatures below the above-noted range, TSP precipitates leaving harmful deposits. Further, TSP leaves a phosphate conversion coating on the surface being cleaned which may deleteriously affect the finish (smoothness) of that surface even after rinsing with water. Finally, the use of TSP as a cleaner requires extensive rinsing to prevent the formation of hard phosphate residues which are not readily soluble in water and which are detrimental to critical components.
In addition, there are numerous aqueous or solvent based biodegradable cleaners available which claim to have oxygen system cleaning capabilities. However, these cleaners contain hydrocarbon derivative components (such as organic surfactants) and thus have the disadvantages associated with hydrocarbons previously noted. Specifically, they have the fire hazard associated therewith, a potential toxicity hazard in life-support systems and an inability to analyze the effluent cleaning agent for residual total hydrocarbon contamination with a sensitivity of at least 1 part per million (ppm) to permit accurate, certifiable verification of hydrocarbon cleanliness. Finally, alternate chlorinated solvents such as perchloroethylene and methylene chloride are unusable in any life-support equipment because these solvents are highly toxic, having been identified as suspected human carcinogens.
As disclosed in U.S. Pat. No. 5,427,709 issued on Jun. 27, 1995, to the assignees of the present application (hereinafter the '709 patent), the preferred oxygen cleaning agent made according to the invention disclosed and claimed in the '709 patent is an aqueous inorganic solution comprising silicon dioxide (SiO 2 ) and an inorganic oxide compound (X 2 O) at a SiO 2 :X 2 O mole ratio in the range of 1.8 to 2.2 with a polysilicate anion concentration in the range of 2 to 18% by weight; an inorganic fluoroborate compound (XBF 4 ) in the range of 0.01 to 1.0% by weight; an inorganic molybdate compound (X 2 MoO 4 ) in the range of 0.01 to 1.0% by weight and the balance by weight demineralized water wherein X is a member of the group consisting of sodium and potassium. The pH of the final aqueous solution is 11.5 to 12.0. The purity of each constituent previously described must be such that the final cleaner composition meets the following requirements: the visual clarity shall be clear with no visible contamination, the total carbon contamination (including hydrocarbons minus any carbon present as carbon dioxide) shall not exceed 1.0 ppm, the total insoluble matter shall not exceed 0.5 ppm, and the total chloride contamination shall not exceed 2.0 ppm. The preferred elements, ranges and pH for optimum performance are as follows: a SiO.sub. 2 :X 2 O mole ratio in the range of 1.8 to 1.9; a polysilicate anion concentration in the range of 9.0 to 10% by weight; an inorganic fluoroborate compound (XBF 4 ) in the range of 0.4 to 0.6% by weight; an inorganic molybdate compound (X 2 MoO 4 ) in the range of 0.4 to 0.6% by weight and the pH of the final aqueous solution in the range of 11.9 to 12.0; where X is either sodium or potassium.
In an alternate form of the cleaning agent, the resulting cleaning agent can also be supplied with organic surface wetting agents (surfactants) such as the fluorosurfactants "Zonyl", manufactured by Dupont Company, to enhance the removal of thick soil deposits. However, this form of the cleaning agent will not be acceptable for final cleaning of oxygen enriched handling equipment for the reasons previously noted. Specifically, the presence of organic surfactants has an associated potential fire and toxicity hazard and results in inability to analyze the effluent cleaning agent for residual total hydrocarbon contamination with a sensitivity of at least 1 part per million (ppm) to permit accurate, certifiable verification of hydrocarbon cleanliness.
It should be noted that the X component referred to previously could be chosen from a group also including: ammonium, barium, beryllium, calcium, cesium, lithium, magnesium, rubidium and strontium. However, while the compound resulting from such additional possibilities would be inorganic and might have acceptable cleaning performance, the resulting toxicity, reduction of corrosion inhibition, and difficulty in rinsing would severely limit the use of the cleaner, making it impractical in practice.
This invention relates to the manufacture of an aqueous inorganic cleaning agent comprising a silicate solution of SiO 2 and X 2 O in a SiO 2 :X 2 O mole ratio in the range of 1.8 to 2.2 with a polysilicate anion concentration in the range of 2 to 18% by weight, a corrosion inhibitor material selected from the group consisting of XBF 4 with a weight concentration in the range of 0.01 to 1.0% and X 2 MoO 4 with a weight concentration in the range of 0.01 to 1.0% and mixtures thereof and the balance demineralized water wherein X is chosen from the group consisting of sodium and potassium.
The prior art defines many uses of silicates for heat silicates are commonly added for corrosion resistance, alkalinity and dispersive functions. The prior art also defines the manufacture of the various silicated end products. However, common among these are the always present organic (defined for the purposes herein as any C--H bonded material) additives. Further, when presented as an aqueous solution, rarely is the silicate concentration greater than 2%. Further, acids are rarely if ever added to silicate solutions because of their propensity to form gels and sols rendering any solution useless. Further, it is common chemical mixing practice to dilute concentrated bases or acids by adding them to water, thus preventing any deleterious exothermic/thermodynamic reaction. Further, common practice limits extensive mixing because of the inherent foaming characteristic of the organic additives.
The prior art of manufacturing aqueous based silicated fluids using low silicate concentrations, organic additives, no acids, and little mixing is not applicable for the aqueous inorganic precision cleaning agent of this invention comprising silicates, molybdates, and fluoroborates.
Wilhelm Eitel, in Silicate Science, Academic Press, (1964) discusses at length the stability of aqueous silicate solutions as a function of pH. Specifically, as pH drops below 11.0, silicate polymerization occurs leading to high molecular weight silicate compounds that will eventually exceed the solubility of the parent solution. This results in silicates precipitating out of solution generating the commonly known silicate gels and sols. The dissolution is not thermodynamically reversible. Eitel further indicates that the rate of polymerization is a maximum between a pH of 8.0 and 9.0. A particular concern is that silicate solutions intended for the manufacture of precision cleaning agents are generally supplied as a concentrate. Common practice would dilute the concentrate by adding it to water. However, this has the effect of causing the concentrated silicate solution to undergo a pH transition from 7, that of the base demineralized water, up to 12 as the solution reaches the desired silicate concentration. This cycles the silicate between polymerization and depolymerization, with the hope that the later will be 100%. However, experience indicates that for high concentrations of silicates (defined for the purposes herein of greater than 2%), depolymerization is not complete. Previously polymerized material remains, leading to subsequent dissolution characterized as a white flocculent or precipitate in an otherwise clear solution. The polymerization is accelerated at the higher temperatures common to the application temperatures of alkaline cleaning agents. The primary cause of this increased polymerization is the inverse pH-temperature relationship noted in the cleaning composition. Between 25° C. and 75° C., the pH of the cleaning composition drops by 0.75 pH units. Thus, cleaning agent that appears clear and stable at room temperature can become unstable in a few hours when heated to the application temperature leading to complete dissolution.
The instability of silicate solutions is addressed in the prior art as is evident in Meyer et al U.S. Pat. No. 5,118,434, Dubin U.S. Pat. No. 4,532,047, and Mohr et al U.S. Pat. No. 4,772,408. However, three factors have mitigated the instability. First and foremost, existing silicated products contain organic additives. Review of the many applicable Military Specification formulas, as well as formulas in W. G. Cutler and R. C. Davis, Detergency Theory and Test Methods, Marcel Dekker, Inc. (1972), all include organic additives. These organic additives function to prevent aggregation of the large molecular weight silicates that may have polymerized thereby preventing dissolution. However, while the appearance is that of a stable silicate solution, the molecular structure of the silicate has changed rendering its function as a cleaning agent essentially useless. Second, the silicated fluids rarely exceed 2% and when they do, the pH is always very high at 12.5 or above. Higher pH presents a more soluble environment for the silicates. However, pH greater than 12.0 is severely corrosive to amphoteric metals such as aluminum, and presents difficult and costly environmental disposal issues. Third, the common use of silicates in prior art is for corrosion resistance, alkalinity and dispersive properties which can all be achieved using sodium metasilicates (SiO 2 : Na 2 O mole ratio of 1.0) at low concentrations. Where higher concentrations are used, the high pH silicated solution, with organic additives, is provided with the intent of being diluted.
Prior art in text books and vendor literature discusses the limited solubility of acids with silicate solutions. The addition of strong acids to silicate solutions generally results in the immediate polymerization and/or precipitation of silicate material leading to the formation of silicate gels and sols. Hydrofluoric acid is one of the very few acids soluble with silicates. However, the hazardous properties of this acid preclude any significant use.
Dr. Manohar S. Grewal, "Switch to Aqueous Technology Gives Gillette Edge in Blade Manufacturing", Precision Cleaning, April 1995 discusses considerable variability in the performance of aqueous cleaners in the precision cleaning of razor blades. One of the inherent problems lie with how aqueous cleaners are manufactured. The common manufacturing method is to mix components in large drums or containers employing a large paddle wheel to obtain homogeneous mixing. Aggressive mixing with a centrifugal pump is generally excluded because of the potential for foam generation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The cleaning agent of this invention cleans oils, greases, fats, including halogenated oils and greases, and particulate matter from metallic, rubber and plastic surfaces when applied hot at temperatures of from 37.8° C. to 93.3° C. The cleaning agent can be used as a pumped pipe-line cleaner, batch tank cleaner, spray impingement cleaner, steam cleaner and ultrasonic tank cleaner. The cleaner, being an alkaline solution, will remove common organic fat based soils by emulsification or solubilization. The cleaner removes the more difficult industrial based hydrocarbons and halogenated mineral oil and mineral grease soils from a surface by displacement. The principle displacing agent is the polysilicate anion. At the SiO 2 :X 2 O mole ratio in the range of 1.8 to 2.2, these polysilicate anions exist as charged cyclic silicate molecules. These structures include the more numerous [Si 3 O 9 ] n- molecules and less numerous [Si 4 O 12 ] n- molecules with charges of -6 and -8 respectively. At the 2 to 18% by weight polysilicate anion concentration, the charged cyclic silicate molecules develop electrostatic forces that displace and disperse the soil from the substrate while depositing an inorganic amorphous glass surface. The inorganic amorphous glass surface prevents redeposition of the soil and is easily hydrated and removed by rinsing with water. The electrostatic forces and subsequent displacement ability previously described are not inherent with the more commonly used orthosilicate and disilicate species because these molecules share all the oxygen resulting in no net electrical charge yielding a poor cleaner, but good alkaline builder.
EXAMPLE I: Soil removal performance of oxygen cleaning agent as described in EXAMPLE I was as follows: a MONEL (NiCu) metallic sample of dimensions 2.54 centimeter by 5.08 centimeter by 0.635 centimeter thick was coated with military specification MIL-L-17331 hydrocarbon mineral oil at a concentration of 15.5 milligrams per square centimeter and allowed to soak fully immersed in 100 milliliters of oxygen cleaning agent at 71.1° C. for 30 minutes with no agitation. The oxygen cleaning agent removed 95.9% of the oil; a MONEL (NiCu) metallic sample of dimensions 2.54 centimeter by 5.08 centimeter by 0.635 centimeter thick was coated with federal specification A-A-50433 hydrocarbon mineral grease at a concentration of 15.5 milligrams per square centimeter and allowed to soak fully immersed in 100 milliliters of oxygen cleaning agent at 71.1° C. for 30 minutes with no agitation. The oxygen cleaning agent removed 92.7% of the grease; a MONEL (NiCu) metallic sample of dimensions 2.54 centimeter by 5.08 centimeter by 0.635 centimeter thick was coated with military specification DOD-L-24574 Halocarbon Products HP4.2S halogenated oil at a concentration of 15.5 milligrams per square centimeter and allowed to soak fully immersed in 100 milliliters of oxygen cleaning agent at 71.1° C. for 30 minutes with no agitation. The oxygen cleaning agent removed 99.9% of the oil; a MONEL (NiCu) metallic coupon of dimensions 2.54 centimeter by 5.08 centimeter by 0.635 centimeter thick was coated with military specification MIL-G-47219 Halocarbon Products HP25-5S halogenated grease at a concentration of 15.5 milligrams per square centimeter and allowed to soak fully immersed in 100 milliliters of oxygen cleaning agent at 71.1° C. for 30 minutes with no agitation. The oxygen cleaning agent removed 100.0% of the grease.
Other advantages of the oxygen cleaning agent of this invention are described as follows: it is non-flammable; is non-toxic; contains no environmentally hazardous material; is compatible with non-metallic material; is easily rinsed leaving no residue; does not separate when subjected to freeze-thaw or boiling; does not produce a stable foam which would affect its use as a pump line or spray cleaner; and is capable of being analyzed by various techniques for residual total hydrocarbon contamination with a sensitivity of at least 1 part per million (ppm) to permit accurate, certifiable verification of hydrocarbon cleanliness. The analysis techniques include solvent extraction with subsequent infrared analysis, solvent extraction with subsequent gravimetric analysis of non-volatile residue, total carbon analysis of the cleaner directly, and ultraviolet analysis of the cleaner directly. These analysis techniques are possible because of the very low organic content (less than 1.0 ppm) and optical clarity (maximum insoluble matter of 0.5 ppm and filtered through 3 micron filters) of the cleaner of this invention in comparison to other cleaners. Silicate solutions with SiO 2 :X 2 O mole ratios (wherein X is either sodium or potassium) of less than or equal to 2.0 do not show any evidence of aggregating into micron or sub-micron sized colloidal particles. Therefore, the turbidity (measure of reflected light) of the cleaning agent is very low in comparison to other cleaners. The resulting advantage is the ability to quickly and easily evaluate the presence of extremely low levels of organic and inorganic contaminates which will exist in the cleaner as colloidal particles by the change in reflected light. As the SiO 2 :X 2 O mole ratio increases above 2.0, turbidity increases as some aggregation occurs, effecting the ability to detect extremely low levels of organic and inorganic contaminates. Finally, the cleaning agent exhibits excellent corrosion resistance on metallic materials. Although silicate solutions are reputed to have inherent corrosion resistance characteristics, testing with amphoteric metals indicated otherwise. Specifically, aluminum alloys 5052, 5456, and 6061, all of which are constituent metals of aviation oxygen systems, demonstrated rapid corrosive attack by silicate alkaline solutions. This is corrected by the addition of the inorganic and environmentally safe molybdate and fluoroborate compounds. The corrosion inhibiting characteristics of molybdate compounds and fluoroborate compounds combine to produce a synergistic corrosion inhibitor system greater than the sum of the individual molybdate and fluoroborate compounds.
EXAMPLE II: The aluminum corrosion resistance performance of the oxygen cleaning agent described in EXAMPLE I is as follows: three alloy 5052 aluminum coupons, each having a total surface area of 31 square centimeters were immersed for 24 hours in the oxygen cleaning agent at 76.7° C. The resultant weight loss was between 0.032 and 0.065 milligrams per square centimeter with no visual evidence of corrosion or staining; three alloy 5456 aluminum coupons, each having a total surface area of 38 square centimeters were immersed for 24 hours in the oxygen cleaning agent at 76.7° C. The resultant weight loss was between 0.053 and 0.105 milligrams per square centimeter with no visual evidence of corrosion or staining; and three alloy 6061 aluminum coupons, each having a total surface area of 41 square centimeters were immersed for 24 hours in the oxygen cleaning agent at 76.7° C. The resultant weight loss was 0.000 milligrams per square centimeter with no visual evidence of corrosion or staining.
The preferred method of manufacturing the inorganic aqueous cleaning composition of this invention is as follows: demineralized water is added to an aqueous silicate solution of SiO 2 and X 2 O in a SiO 2 :X 2 O mole ratio in the range of 1.8 to 2.2 of known concentration that is maintained in motion (e.g. by paddle wheel, pump, or other method) to obtain a polysilicate anion concentration of 2 to 18% by weight, wherein X is a member of the group consisting of sodium and potassium. Reagent grade X 2 MoO 4 is then added to obtain a weight concentration in the range of 0.01 to 1.0%, wherein X is a member of the group consisting of sodium and potassium. Reagent grade fluorboric acid (HBF 4 ) is diluted to within the range of from 1:1 to 20:1 with demineralized water and then added to the solution while in motion (by paddle wheel, pump or other method) at a rate no less than 3.8 liters per minute to obtain a pH of 11.5 to 12.0 and a weight concentration in the range of 0.01% to 1.0% of in-situ XBF 4 , wherein X is a member of the group consisting of sodium and potassium.
A centrifugal pump, is then be used to ensure complete blending of the cleaning compound. The minimum blending time when recirculating cleaning compound through the pump is determined as follows:
Minimum blending time=(0.693/W)(V)(5)
where: W=pump flow rate in liters per minute and
V=batch volume in liters.
The novelty of the invention is the method in which the highly concentrated silicated cleaning solution is manufactured without the benefit of any organic additives and the method in which the pH is reduced without resulting in polymerization.
The first step of adding demineralized water to the concentrated silicate solution precludes the pH transition from 7, that of the base demineralized water, up to around 12.4 as the solution reaches the desired silicate concentration. This prevents cycling the silicate solution between polymerization and depolymerization. The addition of water to the concentrated silicate, results in a pH reduction from about 12.7 to 12.4. At no time is the silicate subjected to an unstable environment.
The second step of adding sodium or potassium molybdate allows the solution to reach maximum conductivity prior to the addition of the fluoroboric acid which will partially neutralize the solution causing a drop in both pH and conductivity.
The third step of adding diluted fluoroboric acid, partially neutralizes the solution with the following results: the pH is reduced from about 12.4 to 11.5 to 12.0 for better corrosion resistance and environmental compatibility while forming in-situ sodium or potassium fluoroborate for additional corrosion resistance. This is all accomplished without effecting the concentration of the polysilicate anion which would effect the performance of the cleaning composition. Additionally, this is accomplished with an acid that is both soluble (at the concentrations previously discussed) with the silicate solution and, in situ, is not an environmental hazard.
The fourth step of recirculating the solution through a centrifugal pump for the time specified provides a 97% probability that the solution is completely mixed to ensure meeting the compositional specifications previously stated. The minimum mixing time formula is a variation of a continuous concentration-dilution equation which defines the recirculation half-life (0.693/W)(V) or the time it takes for 50% of the solution to pass from a tank, through a centrifugal pump or equivalent mixer, and back to the tank. The factor 5 relates to five half-lives resulting in 97% of the solution being passed through the centrifugal pump or equivalent mixer and originates from the common equation (11/2 n )(100%). Factors of "n" greater than 5 are economically impractical. Factors of "n" less than 5 result in inadequate mixing.
EXAMPLE III: Cleaning composition according to the specifications previously stated was manufactured according to the invention as follows: 1,357 kilograms of demineralized water per ASTM D1193 Type II was added to 517.6 kilograms of a 40% (26% SiO 2 /14% Na 2 O) sodium silicate solution having a SiO 2 :Na 2 O mole of 1.85. Then 10.4 kilograms 99.9% sodium molybdate was added to the solution. Then 30.9 kilograms of 48 to 50% fluoroboric acid diluted with 154.4 kilograms of demineralized water per ASTM D1193 Type II was added to the solution at a rate of 7.6 liter per minute. The entire solution was then recirculated through a 188 liter per minute centrifugal pump for 35 minutes. A sample of the final solution was subsequently heated to 75° C. After 168 hours, no evidence of precipitation, flocculent or other separation was noted.
EXAMPLE IV: Preparation of the oxygen cleaning agent would be the same as in EXAMPLE III except that potassium would be substituted for sodium.
EXAMPLE V: Cleaning composition according to the specifications previously stated was manufactured not according to the invention as follows: 517.6 kilograms of a 40% (26% SiO 2 /14% Na 2 O) sodium silicate solution having a SiO 2 :Na 2 O mole of 1.85 was added to 1,511.4 kilograms of demineralized water per ASTM D1193 Type II. Then 10.4 kilograms 99.9% sodium molybdate was added to the solution. Then 30.9 kilograms of 48 to 50% fluoroboric acid was added batch wise to the solution. A sample of the final solution was subsequently subjected to 75° C. After 48 hours, complete silicate dissolution occurred. Thus failure to follow the inventive manufacturing method described resulted in a solution useless as a cleaner. | A cleaning composition, method of manufacture and method of cleaning of forse in cleaning equipment including life support equipment employed in the generating, handling, storage and delivery of oxygen-enriched gases and liquids are provided in which the cleaning composition is inorganic, non-flammable, non-toxic, environmentally safe, non-corrosive, and ready to use and which includes an aqueous silicate solution together with fluoroborates and molybdates. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to toys and more particularly to a toy of reassembleable parts capable of performing multiple toy functions.
2. Prior Art
The prior art has provided familiar toys such as erector sets and other building block toys from which various structures may be configured. However, the prior art has not provided such toys with the diverse toy functions and animated features contemplated by the instant invention. Particularly, the prior art has not provided a toy configurable as a race car which may also provide the functions of a vehicle launcher or a spinning top.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an added degree of sophistication to toys configurable from a number of press-fit and snap-fit attachable parts. It is another object of the invention to provide a number of diverse and stimulating toy functions in such a toy. Particularly, it is an object of the invention to provide a toy configurable as a race car, or as a launcher for projectiles, vehicles or a spinning top.
These and other objects and advantages are achieved according to the invention by a number of elements which may be removably assembled into a race car vehicle. One of the elements contains a spring loaded hammer mechanism which may serve to launch a second vehicle or a projectile. Another of the elements is adapted to serve as a launcher for a top which doubles as a vehicle wheel cover.
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in exploded perspective form the toy of the preferred embodiment of the invention with parts arranged to form a vehicle.
FIG. 2 is a top view of a launch mechanism of the preferred embodiment of the invention.
FIG. 3 illustrates a perspective of the preferred embodiment of the invention configured as a projectile launcher.
FIG. 4 illustrates the toy of the preferred embodiment of the invention configured as a toy vehicle launcher.
FIG. 5 is an exploded perspective view of the tank element of the preferred embodiment illustrating structure adapting the tank element as a top launching mechanism.
FIG. 6 is a side view of a release button and a drive element on the top launching mechanisms.
FIG. 7 is a top view of the release button.
FIG. 8 is a plan view of a wheel cover.
FIG. 9 is a partial sectional view of a wheel cover element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is provided to enable any person skilled in the toy industry to make and use the invention and it sets forth the best mode contemplated by the inventor of carrying out this invention. Various modifications, however, will remain readily apparent to those skilled in the above art, since the generic principles of the present invention have been defined herein specifically to provide a relatively economical and easily manufactured combination vehicle and launcher toy assembly.
As illustrated in FIG. 1, various parts of the toy of the preferred embodiment of the invention are attachable to an underframe element 11. These include a wheel-bearing nose member 13, a cockpit cover 15, a tank 17, wheels 19 and a spoiler 21.
The underframe 11, preferably molded integrally of plastic, includes several elements. A channel 12 of rectangular cross-section contains a smaller channel 25 and attaches to two fins or wings 23 and to a tank base 14. The smaller channel 25 is mounted interiorly to the larger channel 12 with its sides parallel to those of the larger channel 12. One end of the smaller channel 25 extends into the tank base 14 via a slot 16 in the base 14. The other end of the smaller channel 25 is closed and bears a tab 49 having a lip 51 formed thereon.
The fins or wings 23 are mounted perpendicularly to the sides of the larger channel 12. Each wing has a circular aperture 33 therein wherein press-fit tabs 32 on the cockpit 15 may be press-fit in order to attach the cockpit 15 to the underframe 11. Each wing 33 also has a rectangular side tab 41 mounted at the front thereof.
The tank base 14 is formed just behind the fins 33. The sides of the tank base 14 rise above the plane of the fins 33 and form a rectangular-rimmed opening 29.
The tank 17 has a rectangular lip 31 formed on its bottom side and a circular aperture 22 formed on its top side. The lip 31 is dimensioned such that the tank 17 may press-fit mount into the rectangular rim of the aperture 29 in the tank base 14. The circular aperture 22 permits press-fit mounting of the spoiler 21 onto the tank 17. The spoiler and tank mounting contributes to the sling-shot racer appearance of the toy.
The wheels 19 rotatably mount on axles 35 formed at the sides of the rectangular opening 29. Each wheel 19 is retained by means of a plug 25 which press-fits on the end of each axle 35. Mounted on each plug 25 is a pin 37 on which a conically shaped wheel cover 39 may be press-fit mounted.
The nose 13, which rotatably mounts first and second wheels 20, slideably mounts onto the underframe 11. Several slots in the nose facilitate this mounting. As seen in FIG. 3, the underside of the nose 13 contains a slot 45 complementary to the smaller channel 25. The nose 13 also has rectangularly shaped apertures 43 at either side thereof. An aperture 47 is formed in the nose 13 to accomodate the tab 49 at the end of the smaller channel 25. To attach the nose member 13, the channel 25 and side tabs 41 are aligned in their proper slots 43, 45 and the nose member 13 is slid onto the channel 25 and the slots 43, 45 until the tab 49 enters the aperture 47 and locks by means of the lip 51.
When the elements shown in FIG. 1 are properly assembled as just described, a toy resembling a slingshot or grand prix race car is formed. As better illustrated in FIG. 2 through FIG. 9, the elements of the preferred embodiment of FIG. 1 may be easily disassembled to form other toys and perform other toy functions. These toys and toy functions will now be explained in greater detail.
FIG. 2 illustrates a launching mechanism formed on the underside of the underframe 11. This device includes a T-shaped hammer 61 which slides in a slot 27 in the small channel 25 and is connected to cock a spring 63 attached at the far end of the channel 25.
A number of cutout portions at one end of the slot 27 enable cocking the hammer 61 and thereafter releasing it. The slot 27 ends in a rigid U-shaped member 65. Attached around the periphery of the U-shaped member 65 is a second U-shaped member 67 having raised ramps 69 and a trigger projection 71 thereon. This second U-shaped member 67 is constructed to be thin and flexible so it may bend in respect to the first U-shaped member 65. The hammer 61 has apertures 72 therein sized to permit entry of the ramps 69.
In operation, the spring 63 is cocked by pulling back the hammer 61. The hammer 61 slides down the slot 27 and proceeds up over the ramps 69 forcing the second U-shaped member 67 down until the back surface of the hammer 61 slides over the ramps 69 such that the hammer 61 is held in position by the engagement of the apertures 72 with the ramps 69. When it is desired to launch, the trigger 71 is depressed removing the abuttment between the back edges 70 of the ramps 69 and the apertures 72, thereby subjecting the hammer 61 to the spring force.
The hammer 61 may be used to perform several launching functions. As FIG. 3 illustrates, the hammer 61 may be used to launch a projectile 73 at a toy target 75. As shown in FIG. 4, the hammer 63 may also be used to launch a vehicle 77 configured from the elements of the preferred embodiment.
In FIG. 4, the nose member 13 serves as the launch vehicle 77 while the underframe 11 serves as the launcher. The rear wheels 19 are retained on the underframe 11 and the underframe 11 is inverted from its position in FIG. 1 such that an angulated launch ramp is formed. The base 60 of the T-shaped hammer 61 is sized to slidably fit into the slot 45 on the underside of the nose member 13. By then mounting the vehicle 77 on the hammer 61 and therafter releasing the hammer 61, the vehicle 77 may be propelled down the launch ramp and across the surface on which the ramp rests.
As further shown in FIG. 4, a mounting member 78 having a press-fit slot 80 and a press-fit plug 82 may also be provided. The press-fit slot permits attachment of the mounting member to the vehicle 77. The plug 82 enables attachment of a toy doll figure 79 to the launch vehicle 77.
As illustrated in FIG. 5 through FIG. 9, the tank member 17 and a wheel cover 39 may be adapted to function as a top, according to the perferred embodiment of the invention. This adaptation will now be discussed in more detail.
As illustrated in FIG. 5, the tank 17 has a hollow interior including a cylindrical opening 79 and three detents 81 spaced 120 degrees apart and extending out from the edges of the tank interior towards the opening 79. A cover 83 is mountable by means of screws (not shown) to the tank 17. The cover 83 has a cylindrical opening 85 concentric with the opening 79 of the tank body 17 and has a ratchet element 87 surrounding the opening 85. The top winding mechansim 89 shown in FIGS. 6, 7 is mounted in the interior of the tank body 17 between the aperture 79 and the cover member 83.
The top winding mechanism 89 includes a release button 91 shown in FIGS. 6 and 7, and a drive element 92 shown in FIG. 6. The release button 91 includes a cap 93 having a cylindrical opening 95 therein. At the base of the cap 93 several projections 97 are formed. These projections 97 interact with the detents 81 in the bottom of the tank body 17 to prevent the cap 93 from rotating when it is in place in the cylindrical opening 79 of the tank body 17. One of the cap projections 97 has a detent 99 depending therefrom.
The drive element 92 includes a first cylinder 101, a cylindrical flange 103 formed at the bottom of the first cylinder 101 and a second cylinder 105 which terminates in a mounting mechanism 107, 110 for the wheel cover 39 shown on FIGS. 8 and 9. The first cylinder 101 of the drive element 92 is slidably and rotatably mountable in the cylindrical opening 95 in the cap 93 of the release button 91. A spring 109 slides over the first cylinder 101 and has a hook 111 which is attached to the detent 99 when the long cylinder 101 is inserted into the cap 93. The flange 103 is of a diameter larger than that of the opening 85 in the tank cover 83 such that the second cylinder 105 and mounting mechanism 107, 110 project through the tank cover opening 87 but are retained in the interior of the tank 17 by the flange 103. When the drive element 92 is mounted in the release button 93 and the hook 111 of the spring 109 is hooked over the detent 99, the drive element 92 may be rotated with respect to the release button 91, which is held stationary by virtue of the detents 81 in the tank housing 17. Such rotation winds the spring 109.
The mounting mechanism of the drive element 92 is configured to releaseably interlock with the hub 113 of the wheel cover 39. In the embodiment illustrated, the mechanism includes an element 107 of rectangular cross-section having a pin 110 mounted at its tip. These two elements 107, 110 fit into complementary apertures 112, 114 in the wheel hub 113.
A cylinder 115, concentric about the hub 113, bears three ramped teeth 117 which cooperate with three flexible projections 119 of the ratchet element 87 on the tank cover 83 to form a ratchet mechanism. This ratchet mechanism functions such that when the wheel hub 113 is inserted into the aperture 85 and mounted on the mounting mechanism 107, 110 the wheel 39 may be rotated in one direction only. That direction is the one wherein the backs 116 of the ramps 117 initially engage the flexible projections 119 and depress them inward. In the opposite direction, where the fronts 118 of the ramps engage the projections 119, no rotation of the wheel 39 is possible.
In operation, the wheel cover 39 is placed onto the mounting mechanism 107, 110 of the drive element 92 and manually rotated to wind-up the spring 109. With the wheel cover 39 in this position, the drive cylinder flange 103 is held a short distance away from the interior rim of the cover aperture 85. The ramp teeth 117 and projections 119 prevent the wheel from rotating in the direction urged by the spring 109. The wheel cover 39 can only be rotated in a direction which imparts additional bias to the spring element 109. When the spring 109 is sufficiently wound, the release button 91 is depressed causing the drive element 92 to move out through the opening 85 and eject the wheel cover 39 from the ratchet mechanism. In this manner, the drive element 92 is allowed to spin until the spring bias is spent. The spinning of the drive element 92 is imparted to the conically shaped wheel cover 39, which subsequently spins off the drive element 92 and performs a familiar spinning top function.
The preferred embodiment of the invention thus provides an action-packed toy, which is in itself a plurality of toys. As may be appreciated, many adaptations and modifications may be made in the preferred embodiment just described without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | A toy including a number of snap and press-fit parts which may be configured as a race car and may be reassembled to form various other toys. In one such toy, the race car body may be disassembled to form a spring-loaded projectile launcher. Other parts may configure a second vehicle launchable by the projectile launcher. In still another variation, a wheelcover is adapted to be launched as a spinning top. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an optical waveguide distribution device having at least one splice cassette and a plurality of couplings.
2. Technical Background
For example, in distribution cabinets for optical cables, distribution devices are used that are known from the product catalog “Accessories for OWG-cable networks, issue 2, page 227, year 2002, Corning Cable Systems GmbH & Co. KG”. The optical, waveguide distribution device shown there comprises a distribution panel which is mounted or stored in a tray-like manner in a frame or a housing, the distribution panel having a front wall, a rear wall, two side walls extending between the front wall and the rear wall, and a base wall. In the region of the front wall of the distribution panel, couplings are positioned which are formed both on an outer side of the front wall and an inner side of the front wall, so that plugs of optical waveguides can be inserted into the couplings starting both from the outer side of the front wall and from the inner side of the front wall. In such an optical waveguide distribution device, it is usual for optical waveguides, which are prefabricated at one end with a plug, to be inserted into the couplings via the plug from the inner side of the of the front wall, free ends of these optical waveguides being placed in at least one splice cassette of the distribution panel. An optical cable with further optical waveguides can be introduced into the distribution device via the rear wall of the distribution panel, it being possible to splice the optical waveguides of the optical cable with the waveguides which are inserted into the couplings of the front wall via plugs from the inner side. Splices formed between these optical waveguides are placed in a splice cassette, which, according to prior art, is connected to the base wall of the distribution panel. If splices are to be formed between optical waveguides that are to be connected to each other in such an optical waveguide distribution device, it has proved to be problematic that the optical waveguides are relatively badly accessible for splicing work, which is especially the case when a plurality of splice cassettes are stacked one above the other in the distribution panel.
SUMMARY OF THE INVENTION
Against this background, the present invention is based on the problem of providing a novel optical waveguide distribution device.
This problem is solved by an optical waveguide distribution device having the features of claim 1 .
According to the invention, the or each splice cassette is removably connected with the distribution panel, the or each splice cassette being able to be placed on the front wall of the distribution panel, and the front wall of the distribution panel also being removably connected to the same in such a manner accommodated that the front wall can be displaced or repositioned relative to the distribution panel together with the or each splice cassette by the front wall and the splices placed in the or each splice cassette.
For the purpose of the present invention, it is suggested to removably connect the or each splice cassette and the front wall to the distribution panel, so that the front wall, together with the or each splice cassette accommodated in the region of the front wall, can be displaced or repositioned relative to the distribution panel. It can thereby be ensured, that the optical waveguides are more easily accessible for splicing work.
Preferably, the front wall of the distribution panel, on which the couplings are positioned, has holding elements on a top edge, in order to accommodate the or each splice cassette.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred developments of the invention follow from the subclaims and the description below. Exemplary embodiments will be explained in more detail using the drawing, in which:
FIG. 1 shows a perspective side view of an optical waveguide distribution device for the purpose of the present invention;
FIG. 2 shows the optical waveguide distribution device according to the invention of FIG. 1 with a splice cassette which has been displaced in comparison with FIG. 1 ; and
FIG. 3 shows the optical waveguide distribution device according to the invention of FIGS. 1 and 2 with a splice cassette which has been displaced in comparison with FIGS. 1 and 2 and a front wall which has also been displaced.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in greater detail below with reference to FIGS. 1 to 3 .
FIGS. 1 to 3 show an optical waveguide distribution device 10 according to the invention comprising a distribution panel 11 , which is mounted in a tray-like manner in a frame or a housing 12 . The distribution panel 11 comprises a front wall 13 , a rear wall 14 , side walls 15 and 16 extending between the front wall 13 and the rear wall 14 , and a base wall 17 . The entire distribution panel 11 can be pulled out of the housing 12 in the manner of a drawer, the guidance of this drawer-like relative movement between the distribution panel 11 and the housing 12 , being served by assigning to the side walls 15 and 16 of the distribution panel 11 guide pins (not illustrated) which engage in guide grooves 18 of the housing 12 , the guide grooves 18 of the housing 12 extending approximately parallel to the side walls 15 and 16 of the distribution panel 11 .
A plurality of couplings 19 are assigned to the front wall 13 of the distribution panel 11 , the couplings 19 being formed both in the region of an outer side 20 of the front wall 13 and in the region of an inner side 21 of the front wall 13 . Plugs of prefabricated optical waveguides can be introduced into the couplings 19 formed in the region of the outer side 20 as well as of the inner side 21 of the front wall 13 , such optical waveguides prefabricated with connectors being referred to as “pigtails” or “patch cords.”
In the exemplary embodiment shown in FIGS. 1 to 3 , plugs of the first optical waveguides, designed as pigtails, are inserted into the couplings 19 positioned in the region of the inner side 21 of the front wall 13 , these first optical waveguides being designed without a plug at an end opposite the connector plugs. An optical cable 22 with a plurality of second optical waveguides can be introduced into such an optical waveguide distribution device 10 via the rear wall 14 , the second optical waveguides of the optical cable 22 being spliced with the free ends of the first optical waveguides, which, at their opposite ends, are inserted into couplings 19 formed on the inner side 21 of the front wall 13 via plugs. Splices formed in this manner are placed in at least one splice cassette 23 of the distribution panel 11 , excess lengths of the second optical waveguides of the optical cable 22 being placed in the region of an excess length store, formed by guiding elements 24 of the distribution panel 11 . In the exemplary embodiment of FIGS. 1 to 3 , only one splice cassette 23 is shown, but the optical waveguide distribution device 10 according to the invention or the distribution panel 11 may also have a plurality of splice cassettes 23 stacked one above the other.
For the purpose of the present invention, it is suggested that the splice cassette 23 is removably connected to the distribution panel 11 , to be precise, in such a manner that the splice cassette 23 can be displaced or repositioned relative to the distribution panel 11 together with the splices placed in the splice cassette 23 . In the exemplary embodiment shown, the splice cassette 23 , or a stack of splice cassettes 23 , is stored on or fixed to a carrier plate 25 , it being possible for the splice cassette 23 together with the carrier plate 25 to be displaced or repositioned relative to the distribution panel 11 . For this purpose, the carrier plate 25 is assigned locking elements 26 , via which the carrier plate 25 and thus the splice cassette 23 is anchored or removably connected in the position illustrated in FIG. 1 to the guiding elements 24 in the region of the base wall 17 of the distribution panel 11 . The locking elements 26 are preferably designed in this case as so-called push/pull locks.
After opening of the locks 26 , the carrier plate 25 , together with the or each splice cassette 23 fixed to the carrier plate 25 , can be repositioned relative to the distribution panel 11 , to be precise in such a manner that the carrier plate 25 and thus the or each splice cassette 23 can be fitted onto the front wall 13 of the distribution panel 11 . For this purpose, the front wall 13 of the distribution panel 11 has holding elements 27 in the region of a top edge; said holding elements 27 interact with the locking elements 26 in order to accommodate the carrier plate 25 in the region of the front wall 13 .
After removing the or each splice cassette 23 from the position shown in FIG. 1 , it therefore serves the purpose of the present invention to move the or each splice cassette into the position shown in FIG. 2 and in so doing placing it in the region of the front wall 13 of the distribution panel 11 . Consequently, the excess lengths of the second optical waveguides of the optical cable 22 are easily or well accessible, said excess lengths being led to or placed in the region of the excess length store formed by the guiding elements 24 .
For the purpose of the present invention, the front wall 13 of the distribution panel 11 is furthermore removably connected to the latter, so that the front wall 13 can be displaced or repositioned relative to the distribution panel 11 . In the exemplary embodiment shown in FIGS. 1 to 3 , the front wall 13 is removably connected to holding sections 29 via locking elements 28 , the holding sections 29 preferably being a component of the side walls 15 and 16 or a component of the base wall 17 . The locking elements 28 , just like the locking elements 26 , are preferably in turn designed as so-called push/pull locks, the front wall 13 , preferably together with the splice cassette 23 (see FIG. 3 ) fitted onto the front wall 13 , can be displaced or repositioned relative to the distribution panel 11 after opening of the locking elements 28 . Consequently, the optical waveguides can be accessed particularly easily for splice work. Due to the combined displacement of the front wall 13 with the or each splice cassette 23 attached to or fitted onto the front wall 13 it is possible to lead the optical waveguides to be connected to a relatively distant splicer, without there being risk of damage to the pigtails with prefabricated plugs.
For the purpose of the present invention, an optical waveguide distribution device 10 is therefore suggested, in which a splice cassette 23 or a stack of splice cassettes 23 can be displaced relative to the distribution panel 11 of the optical waveguide distribution device 10 . The splice cassette 23 or the stack of splice cassettes 23 is accommodated a front wall 13 of the distribution panel 11 , in this case on the front wall 13 to be displaced or repositioned relative to the distribution panel 11 together with the splice cassette 23 or the stack of splice cassettes 23 . In the case of splice cassettes 23 fitted onto the front wall 13 , the first optical waveguides prefabricated with connectors and running between the front wall 13 and the splice cassettes 23 , remain almost completely uninfluenced by repositioning, there only being a need for the second optical waveguides, introduced via the optical cable 22 , to be provided with a corresponding excess length for repositioning or displacement.
LIST OF REFERENCE SYMBOLS
10 Optical waveguide distribution device
11 Distribution panel
12 Housing
13 Front wall
14 Rear wall
15 Side wall
16 Side wall
17 Base wall
18 Guide groove
19 Coupling
20 Outer side
21 Inner side
22 Optical cable
23 Splice cassette
24 Guiding element
25 Carrier plate
26 Locking element
27 Holding element
28 Locking element
29 Holding section | There is disclosed an optical waveguide distribution device having a distribution panel with splice cassettes removably connected thereto. Fiber optic splices are placed within the splice cassettes, so that removal of the splice cassettes allows improved access to the splices. In addition, the distribution panel includes a front wall upon which are positioned a plurality of couplings. The front wall is removably connected to the distribution panel to allow improved access to the couplings. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/461,482, filed Aug. 12, 2009, which claims priority to U.S. Provisional Patent Application No. 61/188,727, filed Aug. 12, 2008.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a location-based recovery device and risk management system for portable computing devices and data.
[0004] 2. Related Art
[0005] With the advent of telecommunications, it has become useful and desirable for enterprises and individuals to employ various forms of sensors and communications devices to monitor the condition and location of certain assets such as portable computing devices. Advances in digital, electronic and wireless communication devices have extended the range and convenience of portable asset monitoring. Global Positioning Satellites (GPS) such as Inmarstat, Iridium, Globalstar, or Msat now increase the accuracy of portable asset location and movement. Such technologies are significant in improving efficiency and economic management of portable assets. Such devices and business practices are well known in the prior art.
[0006] There are approximately a dozen disclosures describing GPS features that relate to portable device theft and recovery that constitutes the known prior art relating to the present invention. The present invention provides novel and useful improvements, methods and processes for reducing economic and property losses related to the theft or loss of portable computing devices which, without limitation, is distinguished from the prior art in the following discussion.
[0007] In U.S. Patent Publication No. 2006/0007039, a method and system are disclosed for expanding law enforcement recovery efforts for missing vehicles using VHF enabled networks and concealed GPS receivers. The present invention application is distinguished in that its hardware elements are novel and unique to the small dimensions of a portable computing device. A further limitation of the prior art is that it substantially provides only passive tracking capabilities. An improvement of this invention over the prior art is the novel enablement of the tracking device to receive and initiate certain limited and useful operations of the stolen or missing computing assets to prevent unauthorized use of its digital content.
[0008] U.S. Patent Publication No. 2004/0198309 discloses a stolen vehicle tracking and recovering method that utilizes cellular telecommunication networks for providing location guidance information to improve vehicle recovery. An improvement of the present invention over the prior art is its use of an implanted GPS device within a portable computing device that communicates directly with a global positioning satellite network and independently of the operating system of the portable computing device.
[0009] In U.S. Patent Publication No. 2003/0005316, the prior art teaches a mobile system that is provided with a theft recovery mechanism comprising a host chipset and a locator subsystem connected to the host chipset that is arranged to determine a current location of the mobile system; and a main storage connected to the host chipset and arranged to store an operating system (OS) and contain an OS-Present application and/or a Pre-OS application configured to enforce security policies during user authentication and determine whether the mobile system may have been stolen or used inappropriately based on the security policies. A novel improvement of the present invention is its use of an implanted autonomous device that coordinates theft and tracking functions separate from an existing computing operating system. This improvement provides a measure of security from programming interference or compromise by software viruses that can attack and compromise mobile device operating systems.
[0010] In U.S. Pat. No. 5,793,283, titled “Pager Vehicle Theft Prevention and Recovery System”, the prior art teaches a theft prevention and recovery system using pager network for vehicles, which transmits a designated electronic alarm signal via free space through an electronic transceiver when a remote alarm activation signal is received. The user instructs the transceiver to transmit a continuous pager signal containing longitudinal and latitudinal coordinates generated by the GPS. The longitudinal and latitudinal coordinates allow the car to be traced and recovered. The present invention is distinguished from this prior art because its mode of operation configures to the unique parameters of a personal computing system, which contains data files. In the event of a loss or theft of the personal computing system, a novel improvement of the present invention is that it can determine and activate procedures on the data files if such data files must be cordoned off, destroyed, encrypted or transmitted to a remote and secure location.
[0011] Other prior art is disclosed in U.S. Patent Publication No. 2007/0180207, which involves secure radio frequency identification (RFID) backup/restore for computing/pervasive devices. This prior art uses an automated RFID based data backup and recovery system for a computing device to invoke logic to initiate physical copying and transmission of digital storage device content to remote storage device. The present invention is distinguished by its separate universal GPS device that is installed in a portable computing device. Further the present invention requires positive activation by the user and can trigger disablement of the host computing device to prevent economic loss related to a potential disclosure breach of proprietary, personal or commercial data.
[0012] In U.S. Patent Publication No. 2006/0033616, titled “Smart Container Gateway”, the prior art comprises a smart container gateway that provides communication with global and local networks, container and cargo security sensors and cargo identification tags. The smart container gateway communicates with one or more networks by means of an integrated structural RF antenna, power generator and radio control subsystem. The present invention is distinguished in that its application requires insertion of a compact and covert device into the interior space of the portable computing device and requires external power from the host device and external activation prior to performing or activating to perform any function.
[0013] In U.S. Patent Publication No. 2005/0017900, titled “Tracking Unit”, the prior art describes a tracking unit for assisting in the recovery of stolen monies or other property includes a housing containing a GPS receiver for receiving GPS signals from overhead satellites, a cellular phone transceiver, a microprocessor, and a battery. Following a theft, the microprocessor activates the cellular phone transceiver to dial the telephone number of a central monitoring station. The present invention is distinguished in that it is directly installed into the theft risk (i.e. the portable computing device) in which it is installed.
[0014] In U.S. Patent Publication No. 2004/0075539, titled “Vehicle Monitoring System”, the prior art discloses “remote theft monitoring for vehicle by sensing vehicle displacement, engine operation and key entry.” When a possible theft condition is determined, the service provider server will generate a message to alert a security agency. The present invention disclosure is distinguished by its use in portable computing devices and its requirement for active external activation by an owner to operate its novel features and benefits.
[0015] In U.S. Pat. No. 6,049,269, titled “Wide Area Wireless System for Access Into Vehicles and Fleets for Control, Security, Messaging, Reporting and Tracking”, the prior art invention uses a paging signal initiated by owner if his or her vehicle is stolen, on-board paging receiver, decoder, controller, alarm and ultimate disablement of vehicle. The present invention is an improvement in its use of a novel software based method that employs an insertable GPS device into portable computing devices. In the present invention, a novel software based method computes a GPS system purchase price related to the savings from economic loss by recovery or by cash compensation in the event of an unrecoverable loss of said portable computing device.
[0016] Notwithstanding the prior art discussed herein, the invention is novel because none of the prior disclosures either alone or in combination are sufficient to disclose the invention set forth in this application. As a result, the present invention offers numerous advantages over the prior art, including, without limitation:
[0017] a) The claimed invention discloses a novel and useful GPS device and antennae system that may be covertly and efficiently installed into a portable computing device.
[0018] b) The invention is a novel means to employ software in the GPS device that may instruct the portable computing device to transmit, alter or destroy data files in the portable computing device to prevent loss of economic value or personal privacy.
[0019] c) The invention is a novel software based method and financial system to acquire and install such a GPS device and software and to provide an insurance product to compensate for loss by the theft of or accidental loss of portable computing devices. From the discussion that follows, it will become apparent that the present invention addresses the deficiencies associated with the prior art while providing numerous additional advantages and benefits not contemplated or possible with prior art constructions.
SUMMARY OF THE INVENTION
[0020] A location-based recovery device and risk management system for portable computing devices and data is disclosed herein. The location-based recovery device and risk management system both protects data stored on portable computing devices and assists in the location and recovery of portable computing devices that have been stolen or otherwise lost. The stored data may be overwritten or encrypted for later decryption when the portable computing device is recovered. In this manner, such data is protected even when the portable computing device is lost.
[0021] Various embodiments of the location-based recovery device and risk management system are disclosed herein. For instance, in one exemplary embodiment, the location-based recovery device and risk management system may be a portable computing device comprising a power source configured to allow operation of the portable computing device without being connected to an electrical outlet, a data storage assembly configured to store one or more data files on the portable computing device, and a wireless communication assembly.
[0022] The wireless communication assembly may be configured to receive one or more wireless signals to determine a geographic location of the portable computing device, receive input indicating the theft or loss of the portable computing device, and transmit the geographic location of the portable computing device after receiving the input indicating the theft or loss of the portable computing device.
[0023] Upon receiving one or more particular wireless transmissions, the data storage assembly modifies the data files utilizing a random binary fill or encryption that is capable of decryption if the portable computing device is recovered. This protects the data files on the portable computing device. It is contemplated that the particular wireless transmissions may only be transmitted by an authorized user of the portable computing device.
[0024] It is noted that the wireless communication assembly may have various configurations. For example, the wireless communication assembly may comprise a GPS device, a cellular data transceiver, a Wi-Fi data transceiver, or various combinations thereof in one or more embodiments.
[0025] In another exemplary embodiment, the location-based recovery device and risk to management system may be a data protection and recovery system for a portable computing device (e.g., a laptop, tablet, or smartphone). Such system may comprise one or more communication devices configured to send one or more transmissions to the portable computing device indicating the theft or loss of the portable computing device, wherein the portable computing device is configured to, upon receipt of one or more particular transmissions, modify data stored thereon utilizing a random binary fill or encryption that is capable of decryption if the portable computing device is recovered. The communication devices will typically also be configured to receive a response from the portable computing device indicating the geographic location of the portable computing device.
[0026] A user interface of the system may query a user whether to activate data file management on the portable computing device. Upon receiving user input activating data file management, the communication devices transmit the particular transmissions thereby causing the portable computing device to modify the data stored thereon utilizing a random binary fill or encryption that is capable of decryption if the portable computing device is recovered. The particular transmissions may be received wirelessly by the portable computing device. It is noted that the communication devices may be further configured to transmit one or more instructions to the portable computing device to decrypt encrypted data store thereon.
[0027] The user interface may be further configured to query the user whether to activate file management comprising the random binary fill or encryption that is capable of decryption if the portable computing device is recovered. In addition, it is contemplated that the user must be an authorized user of the data protection and recovery system in order to utilize the system's capabilities.
[0028] Various methods for data protection and recovery for a portable device are disclosed herein as part of the location-based recovery device and risk management system as well. For instance, in one exemplary embodiment, a method for data protection and recovery for a portable device may comprise providing a data storage device configured to store data on the portable device and to modify the stored data utilizing a random binary fill or encryption that is capable of decryption and data recovery if the portable device is recovered, and wirelessly receiving input indicating the theft or loss of the portable computing device via a signal reception and transmission assembly of the portable computing device. Upon receiving the particular wireless transmissions, a geographic location of the portable computing device is determined and reported to a user via the signal reception and transmission assembly.
[0029] In the method, modification of the stored data utilizing a random binary fill or encryption that is capable of decryption and data recovery if the portable device is recovered is conditioned upon receipt of one or more particular wireless transmissions by the signal reception and transmission assembly.
[0030] It is noted that the method may further comprise installing a GPS device, cellular data transceiver, Wi-Fi data transceiver, or various combinations thereof in the portable device as part of the signal reception and transmission assembly. Similar to above, it is contemplated that the particular wireless transmissions may only be transmitted by an authorized user of the portable device.
[0031] Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
[0033] FIGS. 1A-1C are exemplary schematics illustrating the elements of the invention device in various view planes that demonstrate the composition of electrical and structural elements necessary for installation into a portable computing device.
[0034] FIG. 1A is a frontal plane view of said exemplary device.
[0035] FIG. 1B is a back plane view of said exemplary device.
[0036] FIG. 1C is a side view of said exemplary device.
[0037] FIG. 2 is an exemplary process and software block flow diagram for use of the installed exemplary device of FIGS. 1A-C in the event of theft or loss of the portable computing device to which the device is covertly affixed.
[0038] FIG. 3 is a block diagram illustrating a preferred embodiment of the method and system disclosed by the present invention which respects to, purchase, registration, signal generation, tracking and control of the installed exemplary device of FIGS. 1A-1C .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] In the following description, numerous specific details are set forth in order to provide a more thorough description of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known features have not been described in detail so as not to obscure the invention.
[0040] Due to the growth of the Information Technology (IT) infrastructure and general decrease in costs and sizes of GPS device components, there has been a growing demand for GPS implementation within portable assets, such as portable computing devices. As individuals and enterprises expand the use of portable computing devices such as with laptop, tablet, and handheld computers (e.g., smartphones), there has been an increasing recognition of the vulnerability such devices have for theft or loss and the corresponding increase in economic value and corresponding loss when theft or loss occurs. For example, of the more than 10,000 laptops that go missing every month at Chicago O'Hare Airport, approximately only 22% are ever recovered.
[0041] A problem in the prior art has been an inability to configure and fabricate GPS devices that were compact enough to conveniently install on portable computing devices. A further problem is the inability to configure an embedded antennae configuration with such a compact GPS device that will reliably transmit such signals usable by a GPS tracking network for device recovery in the event of theft or loss. A still further problem has been a lack of means to configure such GPS devices for simple, rapid and covert installation into existing portable computing devices that will be both efficacious yet difficult to detect and disable by thieves. A still further problem in the prior art is the lack of an enabling system to instruct the installed GPS device in a portable computing device to instruct the computing device to transmit, alter or destroy stored data files to prevent economic loss or breach of privacy rights. A still further problem is the lack of a suitable business method and process to price, acquire and install such GPS devices, concurrent with a method to price and provide a risk management financial instrument to compensate a purchaser for potential the risk of loss and impairments occasioned by the irrecoverable or partial recovery of portable computing devices and data therein installed.
[0042] Currently, GPS is a fast-growing field. For instance, cell phones currently have the ability to have GPS on them, as do automobiles, thereby giving GPS products off-the-shelf availability. However, in the present invention, the device's solutions and implementation, and the size of the unit make it unique. In addition, the present invention includes a novel, computationally based recovery replacement program that utilizes a generated insurance service to mitigate the risks and costs associated with theft and loss of portable computing devices.
[0043] Therefore, a first object of the present invention is to disclose a novel and useful GPS device and antennae system that may be covertly and efficiently installed into a portable computing device through the memory slots on the motherboard.
[0044] A second further object of the invention is to disclose a novel means to employ specific software (referred to herein as “Silver Bullet software”) in the GPS device that may independently instruct the portable computing device to transmit, alter or destroy data files in the portable computing device to prevent loss of economic value or personal privacy through the unique coding of the Silver Bullet software application.
[0045] A third further object of the present invention is to disclose a novel computerized and enabled method to acquire and install such a GPS device and software and to provide a computer generated insurance product to compensate for accidental loss or theft of such portable computing devices.
[0046] The present invention is embedded into the portable computing device via an open card slot on the motherboard of said portable computing device, which is respectively illustrated in the diagrams of FIGS. 1A , 1 B, and 1 C. In a preferred embodiment, the device is always powered on, even when the portable computing device is not plugged in. The power drain is minimal due to the fact the device is in “sleep mode” and allows for a SMS message to be sent to the device on demand and therefore locating the portable computing device with accuracy within 5 meters.
[0047] Unlike prior art products that are required to be connected to the Internet, the present invention can be located on demand regardless of whether or not the portable computing device is plugged in or connected to the Internet. A SMS text message is sent to the device and it responds with longitude/latitude parameters of its locations. These parameters are entered into a mapping software system and locate the device and display its location on a map of the area within 5 meters of accuracy.
[0048] In contrast, prior art devices are typically embedded into the systems BIOS and can only be located from internet “hotspots” such as Starbucks coffee, bookstores and other wired locations, etc. This means the portable computing device can only be located from an internet connection in which it is connected therefore no on demand capability exist with the prior art products and, therefore, are less accurate.
[0049] The present invention incorporates other novel features as well. For example, if desired by the owner, a transmitted message to the Silver Bullet software can be sent to and through the present invention to destroy the data contained on the hard drive rendering the portable computing device useless. The Silver Bullet software function will issue a command to the present invention that will activate a binary overwrite command that will fill the entire hard drive with 1's and 0's rendering the portable computing device useless and even unable to boot up since the operating system will also be overwritten. Prior art products do not offer or anticipate this capability.
[0050] Furthermore, in the unlikely event the portable computing device is not recovered within a definite time (e.g., 15 calendar days), the risk management process of the present invention will electronically commence an order, payment and shipment process to replace the portable computing device with a comparable product of like, kind and quality or better. Additionally the risk management process can also electronically provide compensation to the owner for the lost economic value of the data files stored on the unrecovered portable computing device.
[0051] It will be obvious to one skilled in the art that the invention may take numerous forms of device and system configurations that will accommodate a diversity of covert GPS tracking devices, portable computing devices, and electronically implemented, software-based insurance and purchase business systems. What follows is a preferred embodiment of the useful novelties of the present invention. However, for one skilled in the art it will be obvious that the novel features disclosed herein may be employed with equal utility to alternate configurations of the invention elements.
[0052] The disclosed invention is the GPS personal tracking and recovery device used inside of laptops and other types of portable computing devices. In a preferred embodiment with this type of system, a battery or power source is required. If the device is charged using its internal battery it typically has four hours of run time and three days of standby time. However, if the invention device is charged using the laptop power source in which the invention device was installed, that device can operate efficiently using inside power as long as that power is available. In some cases, people will disconnect the power and/or repackage. However, when it becomes time to re-engage power, the invention device will begin transmitting again and has been set on a protocol that allows the user to continue to transmit immediately. If somebody attempts to change the exterior of the portable computing device, the invention's embedded chip will still react.
[0053] Referring now to FIG. 1A , the exemplary invention is shown in frontal plane view. At 100 the flexible antenna for GMS transmission is displayed. At 102 , a GPS antenna is displayed. A telephone modem 104 provides for reception and transmission of software enabled data and instructions between the invention device and a remote invention user. A GPS transmitter 106 enables the invention device to transmit and obtain location signals from a GPS/GSM array. A SIMM card housing and apparatus 108 together with the modem 104 , antennae 102 , 100 and the GPS transmitter 106 are affixed and communicate with a circuit board 110 . In the present embodiment, the circuit board 100 is in signal communication with the computing element of portable computing device through a connector rail 112 . The circuit board 110 has an electric power connection with the portable computing device at 114 .
[0054] Referring now to FIG. 1B is a back plane “through view” of the exemplary invention which was previously referenced in FIG. 1A . The invention illustrated in FIG. 1B maintains the same orientation as FIG. 1A and the observer views the back plane view through the front plane orientation. The conspicuous feature of FIG. 1B is a rechargeable battery element 118 , affixed to the circuit board 110 , which communicates with external recharging power through the battery recharge port at 114 .
[0055] Referring now to FIG. 1C is an alternative side view of the invention device illustrating an alternative positioning of some of the invention device elements. More specifically, the circuit board 110 is shown housing various communication circuit elements 120 within the circuit board 110 itself. The flexible antenna 100 is mechanically affixed to the rechargeable battery 118 . The connector rail 112 and battery recharge port elements are deliberately omitted in the plane view to highlight other invention elements. However, for one skilled in the art such alternate assemblies are well understood and frequently used to minimize overall device size and/or connection compatibility to the portable computing device. Further, flexibility in the invention device element assembly lends itself to covert design in either imitation of other circuit elements or compact size. Either option is novel and useful in preventing invention device tampering or detection.
[0056] For this exemplary application, the invention tracking device will be used inside of a laptop computing device, deriving its power source directly from said computer's battery source as shown at 114 in FIGS. 1A and 1B respectively. The invention device allows the laptop owner to use either a desktop computer, a third party tracking service and/or a cellular phone for immediate tracking capability. Additionally, once the invention device registers the laptop as missing, an owner has the ability to initiate regular monitoring whereby, for example, the installed device can transmit a location, based upon plain sight, every two minutes up to every 24 hours.
[0057] This invention's tracking device is useful because of the fact that there is a high theft and low recovery rate of laptops. An additional novel benefit is that this invention device can be used in almost any type of device which utilizes an AC/DC power source and which can be converted to the 12-volt standard typically required. The usefulness of this device is self-evident with the ability to recover misplaced or stolen products through the ability to have immediate real-time access based upon GPS satellite transmission.
[0058] FIG. 2 is a block diagram indicating an exemplary software enabled process utilizing the tracking device. Such a process starts 200 with physical installation of the device at a step 205 , referenced in FIGS. 1A-C . Concurrently at step 205 , the software components are installed in the invention device and a covert tracker device 225 such as a desktop computer, cellular phone or a telecommunications service provider system. The enabled covert tracking device system remains dormant at a step 210 until activation by a transmitted request from the owner or authorized user to an operational covert tracker device. An activation of the installed device at a step 215 results in a query at a decision step 220 on whether to activate the tracking program routine. A “no” response at decision step 220 returns the installed device to a dormant mode at step 210 . A “yes” at decision step 220 requires manual activation of the software elements to activate tracking operations at a step 225 through transmission and detection of GPS location coordinates at a step 230 . Upon activation, the owner or authorized user is queried as to whether to commence data file management via the installed tracker device at a decision step 235 . A “no” at decision step 235 returns either to the decision step 220 tracker query option or to automated tracking at step 225 that continues periodic detection and transmission of GPS location coordinates. A “yes” at decision step 235 is indicative of a threat that data on the portable computing device is at risk of unauthorized use or unacceptable loss. A “yes” at decision step 235 thus queries the owner or authorized user to encrypt or destroy portable computing device data files at a decision step 240 . If the “destroy” option is authorized, the invention initiates its Silver Bullet software routine to overwrite and destroy portable computing device data files. It will be obvious to one skilled in the art that the Silver Bullet software may also be used to uninstall or disable stored software programs, protocols or operating systems deemed proprietary and a cause of economic loss in the event of loss or imminent unauthorized use of the portable computing device. If the encrypt option is selected at decision step 240 then the owner/authorized user is queried whether to transmit such data files at a decision step 245 . If a “yes” occurs at decision step 245 then the installed tracking device uploads and sends such files to the activation location at a step 250 . If an owner successfully recovers the portable computing device at a decision step 260 , the tracking routine ends and the system is returned to its initial settings of the dormant state at step 210 . If the laptop or data are not recovered within a definite time at decision step 260 , the owner then electronically files an insurance claim at a step 265 , which makes compensation to the owner for loss. Upon replacement of the lost hardware, the user process returns to step 205 for installation and protection of the replacement device.
[0059] Referring now to FIG. 3 , a preferred embodiment of the method of the present invention is shown. A laptop computer owner 360 who will own or owns a portable laptop 330 will procure the covert GPS device 320 in connection with a purchase agreement that incorporates an insurance policy related to a future event involving theft or loss of laptop 330 . The policy will be produced using a novels series of software algorithms that utilize, without limitation, a plurality of data inputs; the cost of GPS device 320 , the cost of installation of GPS device, the cost of monitoring service 340 , the cost of communications from monitoring service to GPS satellite array 310 , the cost of communication of the GPS satellite with covert GPS device 320 , a future time based value of information and data maintained or to be maintained on laptop 330 for which owner 360 will be compensated in the event of theft or loss of laptop. The payments made by laptop owner 360 to insurer 350 may be a lump sum or a series of fixed or variable payments. The covert GPS device 320 will be installed by a certified contractor and will place the covert device into laptop 330 in a manner that makes it difficult to recognize the covert device as other than the normal hardware of laptop. The contractor will also connect the covert device power receptacle to the power system of laptop 330 . The contactor will enable an anti tampering feature of covert GPS device 320 to trigger an alarm or automatic transmission signal as part of the security protection features of the invention. The covert GPS device 320 will be electronically enabled using embedded software algorithms that may also be encrypted to provide security to the owner 360 and an identifier code for monitoring service 340 and GPS satellite array 310 . In the event of a theft or loss of laptop 330 , owner 360 will communicate the event to insurer 350 . Insurer 350 will communicate with service 340 to initiate a tracking algorithm to locate laptop 330 . Alternately, the owner 360 call report will be automatically forwarded to monitoring service 340 . GPS device 320 will receive an enabling transmission from GPS Satellite 310 and commence periodic GPS location emissions using power derived from laptop 330 power source.
[0060] In a further variation of the invention, the monitoring service 340 will manually or automatically transmit to the GPS satellite array 310 an authorization for covert device 320 to initiate a wireless data transmission of files stored on laptop 330 to secure files managed by the monitoring service 340 . These files will be forwarded under secure transmission or recorded on to a suitable data storage medium for physical delivery of such data files stored on laptop 330 to owner 360 . In a still further variation of the invention the instructions regarding data stored on laptop 330 may instruct the laptop to alter or eradicate such stored files.
[0061] In summary and without limitation, the invention is comprised of the following elements:
[0062] A first element consisting of fabricating an installed covert tracking device further comprised of circuit, electronic and power elements as shown in FIGS. 1A , 1 B, and 1 C that is compatible with the portable computing device into which it is installed;
[0063] A second element where said covert tracking device is acquired in conjunction with a software generated insurance policy and tracking system to mitigate the risk of loss of a portable computing device into which said covert tracking device is installed;
[0064] A third element of installing the covert tracking device covertly inside the portable computing device and further attaching it to the power source and/or battery of said portable computing device where said tracking device itself does not rely on any functions from the portable computing device and is stand-alone other than the power source;
[0065] A fourth element where, once the tracking device is installed in the portable computing device, and in the event for whatever reason the portable computing device is misplaced and or stolen, an owner of the lost portable computing device will have the ability to telecommunicate to activate a recovery protocol utilizing the tracking features of the covert tracking device;
[0066] A fifth element where recovery of all portable computing devices using this tracking device invention is based upon real-time GPS locations and, in the event recovery is not immediate, the tracking device itself receives a communication that allows the tracking device to power on and regularly source and transmit GPS location data until actual recovery or determination of an unrecoverable loss of said portable computing device.
[0067] A sixth element where a portable computing device being misplaced or stolen, a certain minimum time must lapse (e.g., 5 days) before it is deemed unrecoverable. If the portable computing device is not recovered within the lapsed period, a risk management underwriter will be obligated, through said insurance policy, to replace the unrecovered portable computing device together with a compensable sum for the economic loss of proprietary data files.
[0068] It will be obvious to one skilled in the art that this invention device, method and process apply to numerous other types of portable computing devices. The immediate invention opportunity appears to be with laptops, as there is apparently a unique and unmet need to mitigate sensitive and valuable data storage and restriction issues in the event of loss or theft of the portable computing device.
[0069] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. In addition, the various features, elements, and embodiments described herein may be claimed or combined in any combination or arrangement. | A device and software utilizing Global Positioning Satellite (GPS) technologies for monitoring and recovering portable computing devices and, a method and system for acquiring such devices, protecting data on such devices, and for compensating owners of devices. A GPS mechanism of the invention provides real time tracking of missing devices that may be coordinated with security agencies to intercept and recover missing computing devices. When a stolen device is unrecoverable, the invention may receive a signal to initiate data recovery where a wireless network is available to recover data for the owner. Alternatively, the GPS mechanism instructs the device to encrypt or destroy stored data files to prevent commercial espionage or privacy violations. The invention discloses a software system and method for computing a purchase price of the GPS mechanism, computing compensation for loss of the device and lost data. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to the general field of pedestrian barriers, and more particularly to the field of barriers used to control and direct groups of people in public places.
[0002] Queue barriers are commonly used to guide and control crowds of people at public events and exhibits. Typical freestanding queue barriers comprise a draped rope or retractable belt stretched between upright tubular stanchions, each mounted on a weighted circular base. For aesthetic reasons, it is often desirable to minimize the diameter of the stanchions and the bulk of the base. The preference for a sleek, unobtrusive look, particularly at artistic exhibits, can dictate the use of slender cords rather than belts between the stanchions.
[0003] While spring-loaded spool mechanisms are suitable for use with retractable belt barriers, a spool for the equivalent length of cord would need to be much wider—requiring an unsightly larger stanchion diameter. For retractable cord barriers, proper cord tension is a critical element, since a sagging cord is a visual distraction, while an excessively taut, unyielding cord can pose a tripping or safety hazard.
[0004] The present invention addresses these requirements by providing a retraction mechanism in which the cord is helically wound around one or more pairs of opposing pulleys. When the cord is extended, one set of pulleys in each pair remains fixed, while the other slides toward it against the resistance of a constant-force spring. In order to achieve the proper balance of cord and spring tension, the optimal stretch factor of the cord is less than 50%, as compared to 100% stretch cord commonly used in other applications. The optimal stretch factor of the cord is selected to achieve the correct balance between the retraction force of the spring, which is constant, and the extension force of the cord, which increases as the cord stretches. The excessive stiffness of 100% stretch cord translates into a large force that must be exerted to extend the cord. That large extension force must be balanced by an equally large refraction force of the spring, thereby requiring a large spring. But the refraction force of a large spring will cause a stanchion to tip over unless its base is heavily weighted. High spring tension will also cause an extended cord to snap back forcefully and hazardously when released. On the other hand, a cord with minimal or no stretch will be unyielding when taut and can become slack and develop an unsightly sag when extended between stanchions.
[0005] There are several U.S. patents directed to spring-biased retraction mechanisms. The systems described in the U.S. patents of Carlson (U.S. Pat. No. 5,117,859), Schwendinger (U.S. Pat. No. 6,338,450) and Bertagna et al. (U.S. Pat. No. 5,421,530) do not employ constant force springs, because there is no need in these applications to maintain a constant tension on the extended hose/cable/cord. Moreover, since the stretch factor of the hose/cable/cord in these applications is negligible, these mechanisms do not need to balance the opposing forces of a spring and a stretched cord, as does the present invention.
[0006] While the phone cord rewinder described in the U.S. patent of Ditzig (U.S. Pat. No. 5,507,446) does utilize a constant-force coiled metal spring as the biasing mechanism between the pulleys, it lacks any means of maintaining a constant taut tension on the extended phone cord, which must have a certain amount of slack to be usable.
[0007] The U.S. patent of Knapp et al. (U.S. Pat. No. 6,143,985) discloses a cable retracting system for modular components, using a pulley system biased by constant-force coiled metal springs. Unlike the Ditzig mechanism, this apparatus is designed to maintain a low constant force on the extended cable sufficient to prevent dangling and entanglement. But the Knapp system is incapable of providing the “straight line” tension required in a queue barrier and cannot be adapted to handle a stretchable cord.
[0008] In short, none of the spring-biased pulley retraction mechanisms disclosed in the prior art address the problem of achieving a constant taut, but yielding, tension in a stretchable cord. Nor can the features of the prior art mechanisms be combined in an obvious way to achieve this functionality of the present invention.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a queue barrier specifically suited for applications, such as museums, which demand an aesthetically pleasing, unobtrusive appearance. In addition to directing the flow of patrons entering an exhibit, these barriers are often used to keep patrons at a safe distance from sensitive art objects. For that reason, barriers that deploy retractable belt or tape restraints between the stanchions are not desirable, because the breadth of the belt or tape interferes with the patrons' view of the protected object. For the same reason, the stanchion itself should have the minimal diameter consistent with its function.
[0010] Although a retractable cord has much less visual impact than a belt or tape, it has a greater bulk when wrapped around a spool than does a belt or tape. Since spring-loaded spools are the standard retraction mechanisms in existing queue barriers, the objective of combining a retractable cord with a slender stanchion is the central technical problem which the present invention addresses.
[0011] The present invention addresses this technical problem by providing, instead of the standard spring-loaded spool retraction mechanism, a spring-biased pulley retraction mechanism acting on a stretchable cord. A constant-force coiled metal spring is used, such that the retraction force on the cord does not increase as the cord is extended—as it would for a helical spring governed by Hooke's Law. The use of a constant-force spring avoids abrupt snap-back of the extended cord when released, as well as the need for excessive pulling force on the cord as it approaches full extension, which tends to cause the stanchion to tip over.
[0012] The present invention achieves a dynamic balance between the constant retraction force of the spring-biased pulley system and the opposing contraction force of the stretched cord as it extends. The elastic cord most commonly used in other applications has a stretch factor of 100% —i.e., it will expand to twice its unstretched length. The contraction force exerted by 100% stretch cord will increase proportionally to its stretch until it reaches full extension. While it's possible to maintain a balance between this contraction force and the retraction force of the spring if the latter force also proportionally increases in accordance with Hooke's Law, the barrier stanchion would tend to tip over at full extension unless its base were heavily weighted to anchor the spring. In combination with a constant-force spring, on the other hand, a balance between the proportionally increasing contraction force of 100% stretch cord and the constant refraction force of the spring cannot be maintained over the entire extension of the cord. Either the spring must be over-sized, in which case the extended cord will be excessively taut, creating a tripping/safety hazard, or the spring must be under-sized, in which case the extended cord will be slack and unsightly and will not retract properly.
[0013] By utilizing a cord with a stretch factor of less then 50%, the present invention achieves a dynamic balance between the contraction force of the cord and the constant retraction force of the spring-biased pulley system. As the cord is extended, it initially stretches until it becomes taut, yet yielding if engaged by a patron. As the cord is further extended, its contraction force and the retraction force of spring-biased pulley system remain in balance, allowing the taut but yielding tension of the cord to be maintained without exerting an excessive tipping force on the stanchion.
[0014] The foregoing summarizes the general design features of the present invention. In the following sections, specific embodiments of the present invention will be described in some detail. These specific embodiments are intended to demonstrate the feasibility of implementing the present invention in accordance with the general design features discussed above. Therefore, the detailed descriptions of these embodiments are offered for illustrative and exemplary purposes only, and they are not intended to limit the scope either of the foregoing summary description or of the claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a front view of an exemplary queue barrier comprising three (3) interconnected stanchions;
[0016] FIG. 2A is a perspective view of a retraction mechanism, comprising two pairs of spring-biased opposing pulleys, according to the preferred embodiment of the present invention;
[0017] FIG. 2B is a front view of a refraction mechanism, comprising two pairs of spring-biased opposing pulleys, according to the preferred embodiment of the present invention;
[0018] FIG. 2C is a rear view of a retraction mechanism, comprising two pairs of spring-biased opposing pulleys, according to the preferred embodiment of the present invention;
[0019] FIG. 3 is an exploded view of a retraction mechanism, comprising two pairs of spring-biased opposing pulleys, according to the preferred embodiment of the present invention;
[0020] FIG. 4 is a front view of a retraction mechanism, comprising two pairs of spring-biased opposing pulleys, with an elastic cord helically winding around each pair of opposing pulleys, according to the preferred embodiment of the present invention;
[0021] FIG. 5A is a detail view of a spring-loaded cord connector in the closed position;
[0022] FIG. 5B is a detail view of a spring-loaded cord connector in the unlocked open position;
[0023] FIG. 5C is a detail view of a spring-loaded cord connector in the locked open position;
[0024] FIG. 6A is a detail view of the closed position of the spring mechanism of the spring-loaded cord connector as depicted in FIG. 5A ;
[0025] FIG. 6B is a detail view of the unlocked open position of the spring mechanism of the spring-loaded cord connector as depicted in FIG. 5B ;
[0026] FIG. 6C is a detail view of the locked open position of the spring mechanism of the spring-loaded cord connector as depicted in FIG. 5C ; and
[0027] FIGS. 7A-7D are views of an exemplary floor socket for the support of one of the stanchions of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Referring to FIG. 1 , an exemplary queue barrier system 10 according to the present invention comprises three (3) tubular stanchions 11 , each supported by a weighted base 12 . Alternately, each of the stanchions can be anchored in a floor socket 13 , of which FIGS. 7A-7D depict an illustrative example.
[0029] In FIG. 1 , a first stanchion 14 is releasably connected to a second stanchion 15 by two retractable elastic cords 17 , which extend from two cord apertures 18 in the first stanchion 14 . A first upper cord 19 extends from a first upper cord aperture 20 of the first stanchion 14 and releasably attaches to a second upper cord connector 26 of the second stanchion 15 . A first lower cord 22 extends from a first lower cord aperture 23 of the first stanchion 14 and releasably attaches to a second lower cord connector 28 of the second stanchion 15 .
[0030] The reason for having both upper and lower cords 17 interconnecting the stanchions 11 is compliance with ADA requirements, with the lower cords serving as an indicator for visually-impaired persons. The upper cords are set at approximate hip-to-waist level for a standing person, while the lower cords are at approximate knee level.
[0031] Referring again to FIG. 1 , the first stanchion 14 is releasably connected to a third stanchion 16 by two retractable elastic cords 17 , which extend from two cord apertures 18 in the third stanchion 16 . A third upper cord 29 extends from a third upper cord aperture 30 of the third stanchion 16 and releasably attaches to a first upper cord connector 21 of the first stanchion 14 . A third lower cord 32 extends from a third lower cord aperture 33 of the third stanchion 16 and releasably attached to a first lower cord connector 24 of the first stanchion 14 .
[0032] It is understood that this illustrative three-stanchion barrier system can be further extended. For example, the second stanchion 15 can be further connected to a fourth stanchion (not shown) by extending upper and lower elastic cords (not shown) from a second upper cord aperture 25 and a second lower cord aperture 27 to corresponding upper and lower cord connectors of the fourth stanchions (not shown). Similarly, the third stanchion 16 can be connected to a fifth stanchion (not shown) by extending upper and lower elastic cords (not shown) from the fifth stanchion to the third upper cord connector 31 and the third lower cord connector 34 , respectively. In this manner, the queue barrier can be indefinitely extended in either direction according to the desired area to be enclosed.
[0033] Although, in the exemplary barrier system 10 depicted in FIG. 1 , the stanchions 11 are arranged in a straight line, it is understood that angular connections between the stanchions 11 are also feasible, and that multiple cord connectors can be located on the stanchions 11 at various angles with respect to the cord apertures 18 .
[0034] FIGS. 2A-2C and FIG. 3 depict an exemplary mechanism 35 within each stanchion 11 which controls the extension and retraction of the elastic cords 17 . The depicted embodiment 35 comprises two pairs of opposing spring-biased pulleys 36 , which are mounted on a pulley frame 37 consisting of two parallel frame rods 38 anchored to the stanchion 11 . An upper pair of pulleys 39 comprises an upper fixed pulley 40 , which is fixedly attached to the upper end of the pulley frame 37 , and an upper movable pulley 41 , which is slidably attached to the midsection of the pulley frame 37 . A constant-force upper coil spring 42 is anchored to the pulley frame 37 immediately below the upper movable pulley 41 , with the free end of the coil 42 attached to the upper movable pulley 41 and restraining its movement toward the upper fixed pulley 40 .
[0035] Similarly, a lower pair of pulleys 43 comprises a lower fixed pulley 44 , which is fixedly attached to the midsection of the pulley frame 37 below the upper coil spring 42 , and a lower movable pulley 45 , which is slidably attached to the lower end of the pulley frame 37 . Optionally, the upper coil spring 42 can be anchored to the pulley frame 37 by the same structure that attaches to the lower fixed pulley 44 to the midsection of the pulley frame 37 . A constant-force lower coil spring 46 is anchored to the pulley frame 37 immediately below the lower movable pulley 45 , with the free end of the coil 46 attached to the lower movable pulley 45 and restraining its movement toward the lower fixed pulley 41 .
[0036] Referring now to FIG. 4 , the upper cord 19 helically winds around the upper pair of pulleys 39 , with its proximal end 47 anchored in the upper fixed pulley 40 , and its distal end 48 extending outward from the upper fixed pulley 40 through the upper cord aperture 20 of the stanchion 11 . When the distal end 48 of the upper cord 19 is pulled away from the stanchion 11 to interconnect it with an adjoining stanchion (as shown in FIG. 1 ), the shortening of the length of the upper cord 19 helically winding around the upper pair of pulleys 39 draws the upper movable pulley 41 toward the upper fixed pulley 40 against the constant retractive force of the upper coil spring 42 .
[0037] As the elastic upper cord 19 is extended, it stretches to its maximum length, which is preferably about 20% greater than its unstretched length. The 20% stretch factor allows the upper coil spring 42 to be moderately sized, so that its retraction force is not so great as to tip the stanchion 11 to which it's anchored or to cause the upper cord to snap back forcefully when released. The size of the upper coil spring 42 is selected so that its constant retractive force balances the contractive force of the upper cord 19 when fully stretched.
[0038] Referring again to FIG. 4 , the lower cord 22 helically winds around the lower pair of pulleys 43 , with its proximal end 49 anchored in the lower fixed pulley 44 , and its distal end 50 extending outward from the lower fixed pulley 44 through the lower cord aperture 23 of the stanchion 11 . When the distal end 50 of the lower cord 22 is pulley away from the stanchion 11 to interconnect it with an adjoining stanchion (as shown in FIG. 1 ), the shortcoming of the length of the lower cord 22 helically winding around the lower pair of pulleys 43 draws the lower movable pulley 45 toward the lower fixed pulley 44 against the constant retractive force of the lower coil spring 46 .
[0039] As the elastic lower cord 22 is extended and stretched to its maximum length, its contractive tension balances the retractive force of the lower coil spring 46 in the same way as described above with reference to the dynamic balance between upper cord 19 and upper coil spring 42 .
[0040] FIGS. 5A-5C and FIGS. 6A-6C depict an optional configuration for accessing the upper cord connector 21 of the stanchions 11 . The top of the stanchion 11 is configured with a spring-loaded liftable access cap 51 , through which the upper cord connector 21 can be accessed with a connecting cord from an adjoining stanchion. As shown in FIGS. 5A and 6A , the access cap 51 is retained in the closed position by a spring mechanism 52 —in this example a helical spring. As the cap 51 is lifted into the open position, depicted in FIG. 5B , the spring 52 is compressed, as shown in FIG. 6B . When the cap 51 is swiveled outward, as shown in FIG. 5C , it locks in the open position against the restoring force of the spring 52 , as depicted in FIG. 6C . With the access cap 51 locked in the open position, the upper cord connector 21 is accessible to a connecting cord extending from another stanchion, as shown in FIG. 5C . Once the connecting cord is in place, the access cap 51 is swiveled inward again, as shown in FIG. 5B , and the spring 52 is able to retract ( FIG. 6B ) and restore the cap 51 to the closed position depicted in FIGS. 5A and 6A .
[0041] Although the preferred embodiment of the present invention has been disclosed for illustrative purposes, those skilled in the art will appreciate that many additions, modifications and substitutions are possible, without departing from the scope and spirit of the present invention as defined by the accompanying claims. | A retractable cord queue barrier system uses a spring-biased pulley refraction mechanism acting on a stretchable cord. A constant-force coiled metal spring is used, such that the retraction force on the cord does not increase as the cord is extended—as it would for a helical spring governed by Hooke's Law. The use of a constant-force spring avoids abrupt snap-back of the extended cord when released, as well as the need for excessive pulling force on the cord as it approaches full extension, which tends to cause the stanchion to tip over. Dynamic balance between the contractive force of the stretchable cord and the retractive force of the constant-force spring achieves a taut but not unyielding tension in the interconnecting cords between stanchions. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to a device for the variable adjustment of the control times of gas exchange valves of an internal combustion engine with a hydraulic phase adjustment device, a camshaft, a volume accumulator, a fastening element constructed separately from the camshaft, and a central screw, wherein the central screw penetrates the phase adjustment device and wherein an end of the central screw contacts an axial side surface of the phase adjustment device and a first thread is constructed on the other end.
BACKGROUND
[0002] In modern internal combustion engines, devices for the variable adjustment of the control times of gas exchange valves are used to be able to vary the phase relation between the crankshaft and camshaft in a defined angle range between a maximum advanced position and a maximum retarded position. The device is integrated in a drive train by means of which torque is transmitted from the crankshaft to the camshaft. This drive train can be realized, for example, as a belt, chain, or gearwheel drive. In addition to the camshaft, the device has a phase adjustment device and a central screw by means of which the phase adjustment device is locked in rotation with the camshaft. The phase adjustment device can be constructed, for example, as an oscillating drive in a vane cell construction with several pressure chambers acting against each other. By adding pressurized medium to a group of pressure chambers while simultaneously discharging pressurized medium from the other group of pressure chambers, the phase relation of the impeller relative to the cell wheel and thus the camshaft relative to the crankshaft can be varied. The pressurized medium flow to and from the pressure chambers is typically regulated by means of a hydraulic proportional directional control valve that can be mounted, for example, within the central screw.
[0003] Such a device is known, for example, from DE 10 2005 060 111 A1. In this embodiment, the central screw is screwed with a solid camshaft, in order to realize the rotationally locked connection between the phase adjustment device and the camshaft.
[0004] From DE 10 2004 026 863 A1, another device is known. In this embodiment, the phase adjustment device is mounted on an installed camshaft that consists of a tube and cams attached to this tube. In this embodiment, the attachment of the phase adjustment device to the camshaft can be realized only with difficulty due to the camshaft constructed as a hollow tube. For this reason, the phase adjustment device is locked in rotation on the camshaft by means of a weld connection.
[0005] Another device is known from DE 102 28 354 A1. In this embodiment, a hollow space that is used as a volume accumulator is provided within the solid camshaft. In operating phases of the internal combustion engine in which sufficient pressurized medium is made available from a pressurized medium pump of the internal combustion engine for operating the phase adjustment device, the volume accumulator fills with pressurized medium. If the demand for pressurized medium of the phase adjustment device increases past the volume flow provided by the pressurized medium pump, the volume accumulator supports the phase adjustment device.
SUMMARY
[0006] The present invention is based on the objective of specifying a device with high response behavior and low manufacturing expense.
[0007] This objective is met according to the invention in that the interior of the camshaft has a hollow space in which the fastening element is mounted fixed in position, wherein a second thread is formed on the fastening element and this second thread interacts with the first thread of the central screw such that a rotationally locked connection between the device and the camshaft is produced and wherein, in the hollow space, a volume accumulator with a housing is arranged, wherein an axial end of the housing contacts a contact surface of the fastening element.
[0008] The device has a hydraulic phase adjustment device, a camshaft, a central screw, and a first fastening element. The phase adjustment device is in driven connection with a crankshaft and is locked in rotation with the camshaft by means of the central screw. For this purpose, the central screw penetrates the phase adjustment device, wherein one end of the central screw, for example, a collar, contacts an axial side surface of the phase adjustment device and a first thread, usually an external thread, is formed on the other end. By pressurizing the phase adjustment device with pressurized medium, a phase of the camshaft can be varied relative to the crankshaft. The camshaft has a hollow space in which the fastening element constructed separately from the camshaft is mounted fixed in position, i.e., it cannot be moved in the axial direction or in the peripheral direction under normal loads. The fastening element can be screwed, for example, with the lateral surface of the hollow space. Also conceivable is a non-positive-fit connection. The fastening element has a second thread, usually an internal thread, in which the central screw is screwed, so that the phase adjustment device is locked in rotation with the camshaft. In addition, the device has a volume accumulator that is arranged in the camshaft. The volume accumulator is filled with pressurized medium in phases in which sufficient pressurized medium is available for operating the phase adjustment device. In phases of the insufficient supply of pressurized medium to the phase adjustment device, the pressurized medium stored in the volume accumulator is provided. The volume accumulator has a housing in which the pressurized medium can be stored. In the interior of the housing, for example, a moveable, spring-loaded piston, a flexible membrane, or a bubble filled with gas can be arranged that are used as force accumulators. Here, it is provided that an axial end of the housing contacts a contact surface, usually an axial side surface, of the fastening element. In addition, the housing could be connected to the fastening element. The fastening element is thus used, on one hand, for producing the rotationally locked connection between the phase adjustment device and the camshaft by means of the central screw, wherein, through the use of the fastening element, this connection method can also be used for relatively thin-walled, installed camshafts. In addition, the fastening element is used for the axial position fixing of the housing of the volume accumulator.
[0009] During the installation of the device, initially the fastening element is positioned and fixed in the hollow space of the camshaft. Then the phase adjustment device is locked in rotation with the camshaft by means of the central screw and the volume accumulator is inserted into the camshaft from the end facing away from the phase adjustment device. Then this end of the camshaft is closed with a second fastening element, wherein the second fastening element forces the volume accumulator against the first fastening element, so that the volume accumulator is fixed in the axial direction.
[0010] In one refinement of the invention, it is proposed for the contact surface to have a conical form in the direction of the housing. In this way, the housing of the volume accumulator is centered during the installation of the second fastening element, so that the housing is automatically oriented coaxial to the axis of rotation of the camshaft. For this purpose, advantageously a conical contact surface is likewise provided on the second fastening element. Through the centering of the housing in the hollow space of the camshaft, a ring gap is produced between the housing and the lateral surface of the hollow space, wherein this gap can be used for supplying lubricant to the camshaft bearing points.
[0011] It can also be provided that the first fastening element or the central screw has a pressurized medium channel that runs in the axial direction and opens on the side of the fastening element turned away from the phase adjustment device into the hollow space, for example, the ring gap. Here, the pressurized medium channel can be constructed, for example, as a borehole within the central screw or on an outer lateral surface of the fastening element. It can also be provided that the pressurized medium channel communicates with the volume accumulator or with a camshaft bearing point.
[0012] Thus the fastening element takes on not only the functions of fastening the phase adjustment device to the camshaft and the volume accumulator to the camshaft, but also forms, in a simple, cost-neutral way, parts of the pressurized medium supply system within the device and adjacent assemblies. This reduces the number of components required and the complexity of the device considerably.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Additional features of the invention can be found in the following description and from the drawings in which an embodiment of the invention is shown in simplified form.
[0014] Shown are:
[0015] FIG. 1 only very schematically, an internal combustion engine,
[0016] FIG. 2 a longitudinal section view through a device according to the invention,
[0017] FIG. 3 an enlarged view of the detail X from FIG. 2 , and
[0018] FIG. 4 a perspective view of a fastening element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] In FIG. 1 , an internal combustion engine 1 is sketched, wherein a piston 3 sitting on a crankshaft 2 is indicated in a cylinder 4 . The crankshaft 2 connects to an intake camshaft 6 or exhaust camshaft 7 in the shown embodiment by means of a traction mechanism drive 5 , wherein a first and a second device 11 can provide for a relative rotation between the crankshaft 2 and the camshafts 6 , 7 . The cams 8 of the camshafts 6 , 7 actuate one or more intake gas exchange valves 9 and one or more exhaust gas exchange valves 10 , respectively. It can also be provided to equip only one of the camshafts 6 , 7 with a device or to provide only one camshaft 6 , 7 that is provided with a device 11 .
[0020] FIG. 2 shows a first embodiment of a device 11 according to the invention in a longitudinal section and cross section, respectively. The device 11 has a phase adjustment device 12 , a camshaft 6 , 7 , a central screw 13 , and a first fastening element 14 . The phase adjustment device 12 is constructed as a hydraulic adjustment drive, wherein this is set in rotation by the crankshaft 2 by means of a traction mechanism or gearwheel drive 5 and is locked in rotation with the camshaft 6 , 7 . By supplying pressurized medium to a group of not-shown pressure chambers of the hydraulic adjustment drive of the phase adjustment device 12 while simultaneously discharging pressurized medium from a second group of similarly not shown pressure chambers, the phase position of the camshaft 6 , 7 can be varied relative to the crankshaft 2 in a defined angle interval. Such phase adjustment devices 12 are known in professional circles and disclosed, for example, in DE 42 18 082 A1 or DE 10 2005 060 111 A1.
[0021] The phase adjustment device 12 is arranged on an axial end of the camshaft 6 , 7 and contacts an axial stop formed on the camshaft 6 , 7 in the axial direction. By means of the central screw 13 , the phase adjustment device 12 is locked in rotation with the camshaft 6 , 7 . For this purpose, the central screw 13 penetrates the phase adjustment device 12 , wherein one end of the central screw 13 is constructed with a collar extending in the radial direction. The collar contacts a side surface of the phase adjustment device 12 turned away from the camshaft 6 , 7 . A first thread 15 is formed on the other end of the central screw 13 .
[0022] The camshaft 6 , 7 is constructed as a hollow shaft and has a hollow space 16 that extends along the entire camshaft 6 , 7 . The first fastening element 14 is arranged within the hollow space 16 and mounted on the camshaft 6 , 7 fixed in position, i.e., it cannot move in the axial and radial directions. In the shown embodiment, this is realized by means of a press-fit connection between an outer lateral surface of the first fastening element 14 and a lateral surface 16 a of the hollow space 16 . The first fastening element 14 has, in a central passage borehole, a second thread 17 in which the first thread 15 of the central screw 13 engages, so that the phase adjustment device 12 is locked in rotation with the camshaft 6 , 7 .
[0023] A volume accumulator 18 is arranged within the hollow space 16 of the camshaft 6 , 7 . The volume accumulator 18 has a housing 19 , a separating element 20 that is constructed as a piston 20 , and a spring element 21 . The housing 19 has an essentially hollow cylindrical form each with an opening 22 on each axial end side, wherein the housing 19 extends inward in the radial direction on its axial ends 23 . The outer diameter of the housing 19 has a smaller construction than the diameter of the hollow space 16 . The piston 20 is constructed as a thin-walled, pot-shaped sheet-metal component and supported so that it can move in the axial direction within the housing 19 . Here, the piston 20 separates the interior of the housing 19 into a storage space 24 and a complementary space 25 .
[0024] The spring element 21 is arranged in the complementary space 25 and is supported, on one side, on the side of the piston 20 turned away from the storage space 24 and, on the other side, on the area of the housing 19 extending inward in the radial direction.
[0025] The axial ends 23 of the housing 19 each contact a conical contact surface 26 ( FIGS. 2 and 3 ). The first conical contact surface 26 is constructed as an inner cone on the side of the first fastening element 14 turned away from the phase adjustment device 12 . The second contact surface 26 is constructed on a second fastening element 27 that is locked in rotation with the camshaft 6 , 7 and is arranged on the end of the camshaft 6 , 7 turned away from the phase adjustment device 12 . Here, the second contact surface 26 is constructed as an outer cone. The volume accumulator 18 is fixed by the contact of the housing 19 on the conical contact surfaces 26 in the hollow space 16 in the axial direction and centered relative to the longitudinal axis of the camshaft 6 , 7 . Because the outer diameter of the essentially hollow cylindrical housing 19 is less than the inner diameter of the lateral surface 16 a of the camshaft 6 , 7 , a ring gap 28 is realized between the housing 19 and the lateral surface 16 a . Thus there is no risk that the housing 19 will be deformed during the positioning in the hollow space 16 due to unevenness on its lateral surface 16 a . This guarantees that the piston 20 does not become jammed within the housing 19 , but instead can move smoothly. This eliminates cost-intensive and time-intensive cutting post processing on the lateral surface 16 a of the camshaft 6 , 7 .
[0026] Starting from the first fastening element 14 , the ring gap 28 extends along the entire camshaft 6 , 7 and covers, in particular, several camshaft bearing points 29 . In the area of the camshaft bearing points 29 , several boreholes 30 are formed on the camshaft 6 , 7 that communicate, on one side, with the ring gap 28 and, on the other side, with each camshaft bearing point 29 . The ring gap 28 is sealed in the axial direction by the second fastening element 27 . The first fastening element 14 has, on its outer lateral surface, first pressurized medium channels 31 in the form of grooves extending in the axial direction ( FIG. 4 ), so that the ring gap 28 communicates with a mounting area 13 a of the hollow space 16 in which the central screw 13 is arranged.
[0027] During the operation of the internal combustion engine 1 , pressurized medium fed by a not-shown pressurized medium pump is fed by means of boreholes 30 constructed on the camshaft 6 , 7 in the area of the first camshaft bearing point 29 a . The pressurized medium is led to the camshaft bearing points 29 via the first pressurized medium channels 31 , the ring gap 28 , and the boreholes 30 . Here, the second fastening element 27 prevents the discharge of pressurized medium on the side of the camshaft 6 , 7 turned away from the phase adjustment device 12 .
[0028] At the same time, the pressurized medium is led via screw openings 32 into the interior of the hollow central screw 13 . Within the central screw 13 , the pressurized medium is led, on one side, via a not shown, hydraulic proportional directional control valve arranged in the interior of the central screw 13 to the phase adjustment device 12 . Such proportional directional control valves are known, for example, from DE 10 2005 052 481 A1. In addition, when sufficient pressurized medium is being supplied to the phase adjustment device 12 , excess pressurized medium is led via a second pressurized medium channel 33 formed in the central screw 13 to the storage space-side opening 22 of the housing 19 of the volume accumulator 18 and is fed to the storage space 24 . Therefore, the piston 20 is moved against the force of the spring element 21 , wherein the volume of the storage space 24 increases at the expense of the volume of the complementary space 25 . If the pressurized medium volume needed by the phase adjustment device 12 exceeds the pressurized medium volume supplied by the pressurized medium pump, the piston 20 is pushed in the opposite direction due to the force exerted on this piston by the spring element 21 and thus the pressurized medium stored in the volume accumulator 18 is fed via the second pressurized medium channel 33 to the phase adjustment device 12 .
[0029] Thus pressurized medium is supplied to the phase adjustment device 12 , the volume accumulator 18 , and the camshaft bearing points 29 via the interior of the camshaft 6 , 7 , wherein no additional components are needed. A separate supply of pressurized medium to the camshaft bearing points 29 is not required.
[0030] The second fastening element 27 has an axial, central passage opening 34 by means of which the complementary space 25 communicates with the interior of the internal combustion engine 1 . Thus, air and pressurized medium can escape from the complementary space 25 .
LIST OF REFERENCE SYMBOLS
[0000]
1 Internal combustion engine
2 Crankshaft
3 Piston
4 Cylinder
5 Traction mechanism drive
6 Intake camshaft
7 Exhaust camshaft
8 Cam
9 Intake gas exchange valve
10 Exhaust gas exchange valve
11 Device
12 Phase adjustment device
13 Central screw
13 a Mounting area
14 First fastening element
15 First thread
16 Hollow space
16 a Lateral surface
17 Second thread
18 Volume accumulator
19 Housing
20 Separating element/piston
21 Spring element
22 Opening
23 Axial end
24 Storage space
25 Complementary space
26 Contact surface
27 Second fastening element
28 Ring gap
29 Camshaft bearing point
29 a First camshaft bearing point
30 Borehole
31 First pressurized medium channel
32 Screw opening
33 Second pressurized medium channel
34 Passage opening | A device ( 11 ) for variable adjustment of the control times of gas change valves ( 9, 10 ) of an internal combustion engine ( 1 ) having a hydraulic phase adjustment apparatus ( 12 ), a camshaft ( 6, 7 ), a volume accumulator ( 18 ), a first fastening element ( 14 ) designed separately to the camshaft ( 6, 7 ) and a central screw ( 13 ), wherein the central screw ( 13 ) extends through the phase adjustment device ( 12 ) and wherein one end of the central screw ( 13 ) contacts an axial side surface of the phase adjustment device ( 12 ) and a first thread ( 15 ) is constructed on the other end. | 5 |
[0001] This is a continuation of prior International Application PCT/DE2006/002101, filed Nov. 29, 2006.
[0002] The invention relates to a method for reducing chatter in a motor vehicle power train that has a combustion engine as drive and a clutch device, wherein a rotating component of the power train is driven by means of the combustion engine and the speed of rotation of the component is detected, and wherein the presence of chatter is detected. The invention also relates to a motor vehicle power train that has a combustion engine as drive, a clutch device and a device for registering the speed of rotation of a rotating component of the power train, wherein the device for detecting the speed of rotation is connected to a control and/or regulating device.
BACKGROUND
[0003] Such a method and such a motor vehicle power train, in which chatter induced during the slippage phase of a clutch itself occurs in the power train, are known from DE 102 44 026 A1. The chatter is caused by a negative friction coefficient gradient of the clutch, which makes the damping in the power train negative. The vibrations are converted by the drive wheels of the motor vehicle into longitudinal vibrations, and are experienced as unpleasant by the vehicle occupants. To reduce the amplitude of the chatter, a transmission brake situated in the power train acts on a rotating component in the vehicle power train in such a way that the rotary motion of this component is continuously or periodically retarded. The transmission brake only makes a limited reduction of the chatter possible, however.
SUMMARY OF THE INVENTION
[0004] An object of the present invention provides a method and a device of the type named at the beginning, which makes effective attenuation of the chatter possible.
[0005] In accordance with an embodiment of the present invention, the invention provides that when chatter occurs, to actively damp the chatter a torque is transmitted to the rotating component by means of an electric motor in such a way that for a chatter component where the speed of the rotating component is decreasing the rotating component is driven by means of the electric motor, and for a chatter component where the speed of the rotating component is increasing the rotating component is retarded by means of the electric motor.
[0006] Thus the torque of the electric motor may be modulated so that the chatter is actively damped. The amplitude of the chatter oscillations may be effectively attenuated in both directions. This method can be used to reduce both chatter that is caused by negative friction coefficient gradients of the clutch and chatter that occurs due to geometric irregularities. In an advantageous manner, in addition to damping the chatter, the electric motor can also be used as a drive motor for the motor vehicle power train, in addition to and/or instead of the combustion engine. The combustion engine can then be dimensioned correspondingly smaller. Compared to a combustion engine without an electric motor, a hybrid drive of this sort may makes a significant reduction in fuel consumption possible, since when coasting the combustion engine is uncoupled from the drive wheels of the motor vehicle power train, and the deceleration energy may be converted by means of the electric motor into electrical energy and may be temporarily stored for example in a rechargeable battery.
[0007] In an expedient embodiment of the invention, the rotating component may be an input shaft of a shift transmission, in particular a parallel shift transmission, where a rotation speed signal for the input shaft may be measured to detect the speed of rotation. The rotation speed signal is preferably measured inductively.
[0008] It is beneficial, when a control signal for the torque of the electric motor is provided, if a signal for a chatter component included in the rotational speed signal is preferably generated through high-pass filtering of the rotation speed signal, if a differential signal is formed from the control signal and the signal for the chatter component, and the torque of the electric motor is set depending on the differential signal. The chatter can then be attenuated even more effectively.
[0009] Here the torque of the electric motor is preferably set in proportion to the amplitude of the differential signal whereby using a parameterizable proportionality factor may be implemented.
[0010] In a preferred embodiment of the invention the mean acceleration of the rotating component is determined, with the control signal being chosen so that the acceleration of the electric motor conforms to the mean acceleration of the rotating component. That makes it unnecessary for the mass of the electric motor to be accelerated by the combustion engine.
[0011] A preferred design of the invention may include the motor vehicle power train having a combustion engine, an electric motor, a clutch device and a parallel shift transmission with a drive part and a first and a second input shaft and that the clutch device has a first clutch to connect the drive part to the first input shaft and a second clutch to connect the drive part to the second input shaft, comprising the following steps:
[0012] the clutches are brought to a disengaged position in which the first input shaft and the second input shaft are separated from the drive part,
[0013] for a drive-off procedure, the parallel shift transmission is set so that the first input shaft 17 a has a drive connection with an output shaft 22 of the parallel shift transmission by way of a first gear, and the second transmission shaft 17 b is connected by way of a second gear,
[0014] the first clutch K 1 is engaged at least far enough so that it can transmit a torque,
[0015] the system detects whether chatter is present,
[0016] if chatter is present, the electric motor 11 is used to transmit a torque to the second input shaft 17 b in such a way that with a chatter component where the speed of the second input shaft 17 b is decreasing, the shaft is driven by means of the electric motor 1 , and with a chatter component where the speed of the second input shaft 17 b is increasing, the shaft is retarded by means of the electric motor 11 ,
[0017] the procedure continues with step d).
During the drive-off procedure the electric motor may thus be connected by way of the second gear and the second transmission shaft to the output shaft of the parallel shift transmission, so that the electric motor can introduce a torque into the output shaft of the parallel shift transmission whose pattern may be chosen so that the chatter may be actively attenuated.
[0019] In a preferred embodiment of the invention, after steps c), d) and/or e) the system checks whether the drive-off process has ended, and steps d), e) and/or f) are carried out only if the drive-off process has not ended. Thus the compensation for chatter may be blocked outside of the drive-off process, in order to avoid unnecessary actuation of the electric motor.
[0020] In regard to the motor vehicle power train, the problem named earlier may be solved by the motor vehicle power train having an electric motor as auxiliary drive, which is connected to the control and/or regulating device through an actuating device, and by the control and/or regulating device being designed so that with a chatter component where the speed of rotation is decreasing the rotating component may be driven by means of the electric motor, and with a chatter component where the speed of rotation of the rotating component is increasing, the rotating component may be retarded by means of the electric motor.
[0021] By means of the electric motor, chatter that occurs at the clutch device can be reduced actively by overlaying a torque that is modulated contrary to the chatter. The hybrid drive made from the combustion engine and the electric motor may also enables fuel-saving operation of the motor vehicle power train.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] An exemplary embodiment of the invention will be explained in greater detail below on the basis of the drawing. The figures show the following:
[0023] FIG. 1 : a schematic partial depiction of a motor vehicle power train having a parallel shift transmission, wherein a first clutch is engaged and a second clutch is disengaged, and
[0024] FIG. 2 : a depiction similar to FIG. 1 , but wherein the first clutch is disengaged and the second clutch is engaged.
DETAILED DESCRIPTION
[0025] A motor vehicle power train shown schematically in FIGS. 1 and 2 has a hybrid drive with a combustion engine 10 in the form of a reciprocating piston engine and an electric motor 11 designed as a starter generator as its drive. The combustion engine 10 has a crankshaft 12 on which reciprocating pistons 13 are mounted through connecting rods; the reciprocating pistons are situated so that they can move away from and toward the crankshaft 12 in cylinders of an engine block in a known manner. On the engine block a cylinder head is provided, which has intake and outlet valves that are actuatable by means of a control device which is not shown in further detail in the drawing. The reciprocating pistons 13 , the cylinder head and the intake and outlet valves delimit combustion chambers, in which a fuel-air mixture can be ignited.
[0026] The crankshaft 12 is drive-connected with a flywheel 14 , which has a ring gear that meshes with two gear wheels 15 a , 15 b that are situated at the circumference of the ring gear and offset from each other. Each of these drives a clutch plate 16 a . A first clutch plate 16 a of a first clutch K 1 is situated axially relative to a first gear wheel 15 a , and a first clutch plate 16 a of a second clutch K 2 is situated axially relative to a second gear wheel 15 b . Assigned to each first clutch plate 16 a is a second clutch plate 16 b . The respective first and second clutch plates 16 a , 16 b that are assigned to each other can be brought into a disengaged and an engaged position. In the disengaged position the first and second clutch plates 16 a , 16 b are at a distance from each other axially, and in the engaged position the clutch plates 16 a , 16 b are in contact with each other and frictionally engaged.
[0027] The second clutch plate 16 b of the first clutch K 1 is drive-connected with a first transmission input shaft 17 a , and the second clutch plate 16 b of the second clutch K 2 is drive-connected with a second transmission input shaft 17 b of a parallel shift transmission. Situated on the transmission input shafts 17 a , 17 b are first transmission gears 18 a , 18 b , which can be connected by means of a shifting apparatus (not shown in further detail in the drawing) in a rotationally fixed connection to the transmission input shaft 17 a , 17 b assigned to them, to change the transmission ratio. Synchronizer rings 19 are provided to synchronize the first transmission gears 18 a , 18 b with the respective transmission input shafts 17 a , 17 b assigned to them. The first transmission gears 18 a situated on the first transmission input shaft 17 a are assigned to reverse gear R and to forward gears 1 , 3 and 5 , and the first transmission gears 18 a situated on the second transmission input shaft 17 b are assigned to forward gears 2 , 4 and 6 .
[0028] The second input shaft 17 b is drive-connected with the rotor of an electric motor 11 , the stator of which is connected to the motor block in a rotationally fixed connection. A winding of the electric motor 11 is connected to a rechargeable battery through an actuating device 20 .
[0029] The first transmission gear wheels 18 a , 18 b mesh with second transmission gear wheels 21 , which are situated on an output shaft 22 of the parallel shift transmission and are rigidly connected to that shaft. The output shaft 22 is drive-connected through a differential to drive wheels (not shown in further detail in the drawing) of the power train. The first transmission gear wheels 18 a , 18 b and the second transmission gear wheels 21 have different diameters.
[0030] To start the combustion engine 10 , the first transmission gear wheels 18 b situated on the second input shaft 17 b are disengaged from the input shaft 17 b . If the first transmission gear wheels 18 b are already disengaged from the second input shaft 17 b , this step can be omitted.
[0031] In addition, the first clutch K 1 is brought to the disengaged position and the second clutch K 2 to the engaged position. If the clutches K 1 , K 2 are already in the indicated position, this step can be omitted. Alternatively, the first clutch K 1 can be brought to the engaged position and the first transmission gear wheels 18 a disengaged from the first input shaft 17 a.
[0032] Then the combustion engine 10 will be driven by means of the electric motor 11 in order to start it. As that occurs, the electric motor 11 transmits a drive torque to the second drive shaft, which is transmitted through the second clutch K 2 to the crankshaft 12 .
[0033] With first clutch K 1 disengaged, the parallel shift transmission is set so that the first transmission shaft 17 a is drive-connected through the first gear with the output shaft 22 of the parallel shift transmission. Furthermore, with second clutch K 2 disengaged, the parallel shift transmission is set so that the second transmission shaft 17 b is connected through the second gear with the output shaft 22 .
[0034] Then the first clutch K 1 is slowly engaged to start the motor vehicle in motion, so that the combustion engine 10 transmits a drive torque to the drive wheels through first clutch K 1 , first input shaft 17 a , a first transmission gear wheel 18 a , a second transmission gear wheel 21 and output shaft 22 . Clutch K 2 continues to be disengaged (see FIG. 1 ).
[0035] At the same time, the system detects whether chatter is present. To that end, for example, a rotational speed signal N Ge for the first input shaft 17 a can be measured, and any vibrating component that may be present can be filtered out of the rotational speed signal N Ge and then compared with a limit.
[0036] If chatter is present, the electric motor 11 is used to transmit a torque to the second input shaft 17 b and from there through the second gear to the output shaft 22 in such a way that with a chatter component where the speed of the first input shaft 17 a is decreasing, the shaft is driven by means of the electric motor 11 , and with a chatter component where the speed of the first input shaft 17 a is increasing, the shaft is retarded by means of the electric motor 11 . To that end, a control signal M control is provided for the torque M e-machine of the electric motor 11 , and a signal is produced for a chatter component included in the rotational speed signal N Ge by filtering the rotational speed signal N Ge . The control signal M control is chosen so that the acceleration of the electric motor 11 conforms to the mean acceleration of the second input shaft 17 b . That makes it unnecessary for the mass of the electric motor 11 to be accelerated by the combustion engine 10 . A differential signal is formed from the control signal and the signal for the chatter component, and the torque of the electric motor 11 is set depending on the differential signal:
[0000] M e-machine =M control −k *( N Ge −N G-filt )
[0037] N Ge-filt is produced here by low-pass filtering the rotational speed signal N Ge . The value k stands for a proportionality factor. The corresponding torque is transmitted through the second gear to the output shaft 22 , and from there through the first gear to the first input shaft 17 a.
[0038] A check is then performed to determine whether the drive-off process has ended. The velocity of the vehicle can be measured to that end and compared to a limit. Instead of the velocity, however, the rotational speed of the first input shaft can also be measured and compared to the limit.
[0039] If the drive-off process has not yet ended, the system checks whether the chatter has subsided. To that end, the vibrating component of the rotational speed signal is newly determined and compared to the limit. If the chatter has not subsided, it continues to be damped by means of the electric motor 11 , while the procedural steps described above are run through again.
[0040] If no chatter is present, the system checks whether the drive-off process has ended. If not, the system again checks whether chatter is present, in order to compensate for it by means of the electric motor 11 if necessary. The system just described can be employed accordingly when starting out in reverse gear R.
[0041] As can be seen from FIG. 2 , it is also possible to start out in second gear. With second clutch K 2 disengaged, the parallel shift transmission is set so that the second transmission shaft 17 b is drive-connected through the second gear with the output shaft 22 of the parallel shift transmission. Furthermore, the first clutch K 1 is disengaged and/or the first gear wheels are disengaged from the first transmission shaft 17 a.
[0042] Then the second clutch K 2 is slowly engaged to start the motor vehicle in motion, so that the combustion engine 10 transmits a drive torque to the drive wheels through second clutch K 2 , second input shaft 17 b , transmission gear wheel 18 b for the second gear, a second transmission gear wheel 21 and output shaft 22 . Clutch K 1 continues to be disengaged (see FIG. 2 ).
[0043] Now the system detects whether chatter is present. To that end a rotational speed signal for the second input shaft 17 b is measured, and any chatter component present is filtered out of the rotational speed signal and then compared to a limit.
[0044] If chatter is present, the electric motor 11 is used to transmit a torque to the second input shaft 17 b and from there through the second gear to the output shaft 22 in such a way that with a chatter component where the speed of the second input shaft 17 b is decreasing, the shaft is driven by means of the electric motor 11 , and with a chatter component where the speed of the second input shaft 17 b is increasing, the shaft is retarded by means of the electric motor 11 . The torque M e-machine of the electric motor 11 is determined according to the equation stated above from the control signal M control , the rotational speed signal N Ge for the second input shaft 17 b and the proportionality factor k. Otherwise the procedural steps set forth for FIG. 1 are utilized accordingly.
[0045] It should also be mentioned that the electric motor 11 can also be situated axially relative to the crankshaft 12 .
REFERENCE LABELS
[0000]
10 combustion engine
11 electric motor
12 crankshaft
13 reciprocating piston
14 flywheel
15 a first gear wheel
15 b second gear wheel
16 a first clutch plate
16 b second clutch plate
17 a first input shaft
17 b second input shaft
18 a first transmission gear wheel
18 b first transmission gear wheel
19 synchronizer ring
20 actuating device
21 second transmission gear wheel
22 output shaft
K 1 first clutch
K 2 second clutch | The invention relates to a method for reducing chatter in automotive drive train which comprises an internal combustion engine as the drive and a clutch device. According to the method, a rotating component of the drive train is driven by means of the internal combustion engine and the speed of the component is detected. Any chatter is also detected. When chatter occurs, an electric motor is used to transmit a torque onto the rotating component in order to actively dampen the chatter. The rotating component is driven by the electric motor for any chatter component at which the speed of the rotating component decreases and the rotating component is slowed down by the electric motor for any chatter component at which the speed of the rotating component increases. | 8 |
BACKGROUND
1. Field Of The Invention
This patent relates to food containers. More particularly, this patent relates to a container for holding milk and cereal in separate compartments until ready for consumption.
2. Description Of The Related Art
It is an axiom that breakfast is the most important meal of the day. However, many persons no longer have the time to sit down and eat a balanced healthy breakfast. The present invention is a milk and cereal container having a removable freeze pack and designed to be filled with milk and cereal, placed in one's briefcase, backpack, purse, lunchbox, etc., and carried until the user is ready to eat. The present invention enables the user to eat a healthy meal of cold milk and crunchy cereal at his or her convenience.
Containers for holding milk and cereal can be found in the prior art. For example, Keck U.S. Pat. No. 4,558,804 describes a carousel type appliance in which milk is held in a lower chamber and cereal is held in an upper carousel. The user rotates the carousel which releases a measured amount of cereal and sips the milk from the lower chamber. Sullivan U.S. Pat. No. 4,625,882 describes a toy-like device in which the milk and cereal are mixed together by dumping the milk from a pivotally supported bucket into a boatlike cereal holder. Davis U.S. Pat. No. 4,986,433 describes a serving piece in which cereal is shovelled down a spout into a bowl in which milk is held.
None of the prior art patents discloses a milk and cereal container which can be easily transported. Furthermore, none discloses a container which keeps milk cold until use. Therefore, there exists a need for a milk and cereal container which holds milk and cereal in separate compartments until ready to be consumed, can be easily transported, and keeps the milk cold until ready to use.
SUMMARY OF THE INVENTION
The present invention is a container for milk and cereal comprising a milk reservoir and a cereal compartment. The milk reservoir is preferably located at one end of the container. At least one freeze pack adjacent to the milk reservoir keeps the milk cold until ready for consumption. The cereal compartment is located at the end of the container opposite the milk reservoir and has an opening and a cover removably secured over the opening. The container comprises at least one valve interposed between the milk reservoir and the cereal compartment which may be opened when the consumer is ready to introduce milk into the cereal compartment. In the preferred embodiment, a spoon compartment adjacent the milk reservoir contains a detachable spoon.
It is an object of the present invention to provide a container which holds milk and cereal in separate compartments until ready to be consumed.
A further object is to provide a container for milk and cereal which can be easily transported.
A still further object is to provide a container for milk and cereal which keeps the milk cold until use.
THE DRAWINGS
FIG. 1 is a top view of the milk and cereal container of the present invention.
FIG. 2 is a cross-sectional view of the milk and cereal container of FIG. 1 taken along line 2--2 of FIG. 1 and shown containing milk and cereal.
FIG. 3 is a right side view of the milk and cereal container of FIG. 1 shown with the spoon compartment lid in place and the detachable spoon shown in phantom line.
FIG. 4 is a front view of the milk and cereal container of FIG. 1.
FIG. 5 is a top view of an alternative embodiment of the milk and cereal container of the present invention, shown without the removable cereal compartment lid and in partial cutaway view to show the integrated freeze packs.
FIG. 6 is a cross-sectional view of the milk and cereal container of FIG. 5 taken along line 6--6 of FIG. 5.
FIG. 7 is a right side view of the milk and cereal container of FIG. 5 shown without the spoon compartment lid to reveal the spoon compartment and detachable spoon.
FIG. 8 is a front view of the milk and cereal container of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Turning to the drawings, there is shown in FIGS. 1 to 4 a milk and cereal container 10 according to the present invention. The container 10 comprises a milk reservoir 12 and a cereal compartment 14. In the preferred embodiment, the milk reservoir 12 is located at one end of the container 10 and the cereal compartment 14 is located at the other end of the container 10. A freeze pack 16 is located adjacent to the milk reservoir 12 is filled with a freezable material to keep the milk cold until ready for consumption. The freeze pack 16 may be removable or may be integrated into the container 10. If a removable freeze pack 16 is used, the freeze pack is held in a freeze pack compartment 17. A freeze pack compartment cap 19 is used to cover the freeze pack compartment opening.
A valve 18 interposed between the milk reservoir 12 and the cereal compartment 14 may be turned to either a closed position for keeping the milk and cereal separate or an open position for introducing the milk into the cereal compartment 14. The valve 18 may be opened and closed by hand.
The milk reservoir 12 has a fill opening 20 located at one end of the container 10. A cap 22 is used to cover the opening 20 after the reservoir 12 is filled with milk. The cap 22 may be a snap-on type cap, screw cap, or other suitable cap. Preferably, the cap 22 is attached to the container 10 by a short, flexible plastic line 24.
The cereal compartment 14 has a lid 26 which may be removed to expose the cereal prior to eating. The lid 26 may be hinged or may snap on or slide on. A snap on lid 26 is shown in FIGS. 2, 3 and 4.
The preferred embodiment comprises a spoon compartment 28 and a spoon 30. The spoon 30 is held in the spoon compartment 28 by a pair of plastic snap-type fasteners 32 for easy removal. A lid 34 may be used to cover the spoon compartment 28.
Preferably, the container 10, freeze pack compartment cap 17, fill cap 22, cereal compartment lid 26 and spoon 30 are formed of plastic to provide durable lightweight use and easy cleaning, although other suitable materials, such as stainless steel, are contemplated.
In the preferred embodiment, all parts of the milk and cereal container 10 except the spoon 30 are permanently attached to the container 10 to minimize the possibility of a lost part.
The present invention is used in the following manner. Prior to use, the freeze pack 16 is stored in a freezer until it reaches a suitable cold temperature. When ready to use, the user simply removes the freeze pack 16 from the freezer, inserts it into the freeze pack compartment 17, pours milk into the milk reservoir 12 and adds cereal to the cereal compartment 14. The user can then carry the container 10 with him or her until ready to eat. To eat, the user removes the cereal compartment lid 26, opens the valve 18 to mix the milk and cereal in the cereal compartment 14, and eats the milk and cereal with the detachable spoon 30. The spoon 30 and container 10 are washable and may be used repeatedly.
FIGS. 5 to 8 disclose an alternative embodiment of the milk and cereal container 110 according to the present invention. In the alternative embodiment, the milk reservoir 112 is located around the perimeter of the container 110 and the cereal compartment 114 is located in the center of the container 110. Freeze packs 116 located adjacent to the milk reservoir 112. The freeze packs 116 are integrated into the container 110.
Valves 118 interposed between the milk reservoir 112 and the cereal compartment 114 may be turned to either a closed position for keeping the milk and cereal separate or an open position for introducing the milk into the cereal compartment 114.
The milk reservoir 112 has a fill opening 120 located at one end of the container 110. A cap 122 is used to cover the opening 120 after the reservoir 112 is filled with milk. The cap 122 is attached to the container 110 by a short, flexible plastic line 124.
The cereal compartment 114 has a lid 126 which may be removed to expose the cereal prior to eating. The lid 126 may be hinged or may snap on or slide on. A snap on lid 126 is shown in FIGS. 6, 7 and 8.
The alternative embodiment also comprises a spoon compartment 128 and a spoon 130. The spoon 130 is held in the spoon compartment 128 by a pair of plastic snap-type fasteners 132 for easy removal.
Other modifications and alternative embodiments of the invention are contemplated which do not depart from the spirit and scope of the invention as defined by the foregoing teachings and appended claims. For example, instead of being located on the front side of the container, the freeze pack cap may be located on top of the container. | A milk and cereal container comprises built-in milk and cereal compartments and an optional detachable spoon. At least one freeze pack adjacent the milk compartment keeps the milk cold until ready for consumption. A valve interposed between the milk and cereal compartments controls the flow of milk into the cereal compartment, and keeps the cereal and milk separate until the user is ready to eat. The container is washable and reusable. | 5 |
BACKGROUND
[0001] For treatment of health problems in the mouth or throat, people have for centuries held in their mouths a composition containing herbal or other medication for topical application. The oldest name for such a composition, derived from Latin and previously from Greek, is “troche”. A modem form of troche is the cough drop, so named because it was formed by “dropping” hot, viscous, sugar-based candy onto a sheet or into a mold where it cools to form the troche. Another modem form of troche is the throat “lozenge”, so named because it was in the shape of a diamond (like on playing cards), which is the meaning of the word “lozenge”. The structural characteristics of these types of troches are determined by their primary structural ingredients which are typically corn syrup or sugars, including sugar alcohols. The troches are relatively hard and are often irritating to tender surfaces such as canker sores. These troches are only mildly adherent to teeth and not significantly adherent to gums, cheeks, or lips.
[0002] To achieve higher concentrations of medication at a particular spot in the mouth than troches can deliver, adherent oral patches have been developed. An oral patch typically includes one or more flexible saliva flow impeding layers that do not dissolve entirely such as invented by Anthony et al. and disclosed in U.S. Pat. No. 5,713,852. Another example of an oral patch is the DentiPatch which has one or more non-soluble thermo-plastic layers and lidocaine, offered for sale by Noven Pharmaceuticals, Inc. As used herein, the word “patch” does not include preparations that move about the mouth rather than resting in one place, such as cough drops, throat lozenges, or other troches, and therefore do not impede local flow of saliva. Nor does it include preparations that do not hold together as a single item when held in the mouth such as preparations of powder, liquid, paste, viscous liquid gel, or a tablet or troche that crumbles into a powder or paste when chewed or placed in saliva.
[0003] The most significant differences between an oral patch as used herein and other forms of medicinal preparations such as troches are that an oral patch is designed to (1) release medication into the mouth over a relatively long period of time, such as 30 minutes or more, (2) be at least mildly adherent and adequately conforming to adhere so that it can be placed in a preferred location and not be dislodged by gravity or gentle movement, (3) restrict local flow of saliva so that the medication can reach high concentrations along side the patch, and (4) remain in the mouth as a single item that will not spread to be in a plurality of locations in the mouth at one time.
[0004] There are many uses for preparations containing a medication to be delivered topically in the mouth. In many treatment situations, it is advantageous to retain the preparation at one location in the mouth rather than allowing it to move in the mouth such as when talking. U.S. Pat. No. 6,139,861 issued to Mark Friedman surveys the known methods for adhering a slowly dissolving medication to a location within the mouth. These methods include two forms of adherent soluble patches, referred to by Friedman as “mucoadhesive erodible tablets”. These tablets are formed using polymers carboxymethylcellulose, hydroxymethylcellulose, polyacrylic acid, and carbopol-934. None of these polymers melts to a liquid at human mouth temperatures.
SUMMARY OR THE INVENTION
[0005] The invention is a soft, adherent oral patch including a hydrophilic polymer that is liquid at human mouth temperatures. The oral patch is made of two primary components.
[0006] The first component is a porous molecular network formed as a unitary solid structure that remains a solid at human mouth temperatures. In preferred embodiments, this network is elasto-plastic (elastic or plastic or a combination thereof), giving it a soft feel in the mouth, in contrast to being crumbly or a paste. The network is preferably hydrophilic so that, even when applied to a wet mucosal surface in the mouth, it will tend to adhere by absorbing moisture from the mucosal surface. Preferably, the network slowly dissolves in saliva so that the patch merely dissipates over time and the patch never has to be removed form the mouth.
[0007] The second component is a hydrophilic polymer that is liquid at human mouth temperatures distributed throughout the pores of the network. Because the polymer is hydrophilic and liquid at human mouth temperatures, it will adhere very well to wet surfaces inside the mouth and is quite soft which provides a soothing feeling to any sensitive tissue such as canker sores. The adherent oral patch will adhere to teeth, gums, cheek, lips, or tongue without the user first drying saliva from the tissue. If the patient merely places the oral patch in his or her mouth and holds it in the desired location for 10 to 40 seconds, it will then adhere to the tissues that it has been touching without movement, even though those tissues are wet. This is far easier for patients to use than requiring that the tissue first be dried with a towel before the adherent oral patch is placed. If the patient wants to use an oral patch in the lip or under the tongue, the oral patch can easily be removed for talking and then easily be replaced without using a towel or a mirror.
[0008] A desired medication is also located within the pores of the network along with the hydrophilic polymer.
[0009] The network component may be comprised of a thermo gel having a melting temperature higher than human mouth temperatures. Preferably, the thermo gel is elasto-plastic, such as formed by a mixture of the hydrogels konjac gum and xanthan gum dissolved in hot water and then cooled to form an elasto-plastic gel. Alternatively, the network may be comprised of a complex carbohydrate, such as cellulose, pectin, maltodextrin, or starch from potato, rice, corn, or wheat. Also, the network may be comprised of a hydrogel with a melting temperature higher than temperatures in the human mouth formed of amino acids, such as peptides.
[0010] In preferred embodiments, the hydrophilic polymer gels to a solid at room temperatures. This allows the oral patch to be removed from the mouth and placed on a smooth surface, such as a plastic bag. Because the hydrophilic polymer then gels, the oral patch again becomes handleable with the fingers to return it to the mouth without being too sticky to handle or leaving a residue on the fingers or on the plastic bag. In one such embodiment, the hydrophilic polymer is protein gelatin rendered from animal tissue, which solidifies at just below mouth temperatures and remains a solid even at clothes pocket temperatures so it will not melt in a pocket.
[0011] In another aspect, the invention is a method for manufacturing an adherent oral patch. In this method, ingredients for forming the porous network, molecules of the hydrophilic polymer, molecules of the medication, and water are mixed together. The mixture is heated to dissolve all ingredients, either before the ingredients are added together or after they are added together, and the mixture is then cooled, thereby causing the ingredients for forming a network to form the porous network as a unitary solid structure having the medication and the hydrophilic polymer within its pores. Before it is cooled, the hot mixture may be deposited into a mold of a suitable shape to form the preferred unitary solid structure. The mold may be formed in powdered starch, as is well known in the candy making industry for forming gumdrops. Alternatively, the mold may be formed of a rigid material such as metal or plastic. If the mold is thin plastic or aluminum, it may also serve as packaging for delivery of the oral patch to the consumer.
BRIEF DESCRIPTION OF THE DRAWING
[0012] [0012]FIG. 1 a shows a side view of a soft, adherent, soluble oral patch.
[0013] [0013]FIG. 1 b shows a top view of the same oral patch.
[0014] [0014]FIG. 2 shows, in representational form, the structure of the solid, porous network, including the pores.
DETAILED DESCRIPTION
[0015] [0015]FIG. 1 shows a preferred shape for the oral patch. It has a feel and texture like gummy candies. It is made with slowly dissolving hydrocolloids so that that it typically lasts in the mouth for at least one to six hours. The patch can be formed in the shape of a tablet or a lozenge or a wafer or any other desired shape. A preferred shape is a thin lentil as shown in FIG. 1 a.
[0016] [0016]FIG. 2 shows, in representational form, the structure of the solid, porous network, including the pores. To practice this invention, a requirement for the network is that it remains a solid, rather than melting, at human mouth temperatures. So that the oral patch will slowly erode, the network should be made of a material with a low to moderate rate of disintegration in warm saliva. If the network does not erode fast enough, medication will be drawn out of the network faster than the network erodes and, although a portion of the oral patch remains in the mouth, it will no longer be doing any good. The hydrophilic polymer that, along with water and medication, fills pores of the network helps to slow the loss of medication from within pores of the network. Being a polymer, its molecules are long and they tend to be entangled by the network. The polymer molecules, in turn, along with the network structure, tend to entangle molecules of the medication. To obtain greater entanglement, molecules of the medication may be weakly chemically bound, such as by cross-linking, to molecules of the hydrophilic polymer or the network or both.
[0017] To understand by analogy how the porous network filled with a polymer that is liquid at mouth temperatures becomes very sticky without disintegrating, imagine a fish net bag filled with linguini Alfredo. When the linguini Alfredo is cold, such as when just removed from a refrigerator, the Alfredo sauce is congealed and the entire structure is not very sticky. Then put it in a microwave oven. The Alfredo sauce melts and becomes quite sticky. By itself, the fishnet bag is not sticky. But, the holes are large enough that strands of linguini covered with sauce will bulge out of the holes. When warm, the entire structure, if thrown against a wall, would probably stick, yet the bag keeps it all together as one piece. The strands of linguini are like the long molecules of a polymer that is liquid at mouth temperatures. Their length keeps them from easily falling out of the fish net bag.
[0018] Many different compositions can be used to form the network. For ease of manufacturing, it is convenient if the network is comprised of a thermo gel having a melting temperature higher than human mouth temperatures. This allows the entire mixture to be a liquid at temperatures far above human mouth temperatures and allows the network to be formed by cooling the mixture such that the thermo gel forms the desired network by a gelation process. The temperature at which the gel forms can be lower than human mouth temperatures, provided the temperature at which it melts again is higher than human mouth temperatures.
[0019] Readily available materials that form such a gel include agar, in various forms, carrageenan, in most of its forms, particularly kappa carrageenan, konjac gum, locust bean gum, and xanthan gum. All of these materials form a thermo gel that is sufficiently elastic or plastic or a combination thereof for the network to feel soft in the human mouth if it is adequately hydrated. If water is dried out of the network, it will become hard and will produce an unattractive feel when placed in contact with sensitive tissues, such as canker sores. To prevent the network from drying out, it may be packaged with a hermetic seal or a non-evaporating plasticizer, such as glycerol (glycerin) may be added. However, the more glycerol is added the less adherent the oral patch will be.
[0020] Synthetic hydrogels may be used for either the network that does not melt at mouth temperatures or the adherent, liquid polymer. Protein-based hydrogels are usually prepared using proteins extracted from natural sources, but they may be synthesized, such as with diblock copolypeptide amphiphiles, as taught by Nowak, et. al, “Rapidly Recovering Hydrogel Scaffolds From Self-Assembling Diblock Copolypeptide Amphiphiles”. Nowak, A. P.; Breedveld, V.; Pakstis, L.; Ozbas, B.; Pine, D. J.; Pochan, D.; Deming, T. J. Nature, 2002, 417, 424-428. The use of synthetic materials allows adjustment of copolymer chain length and composition. Synthetic hydrogels may also be made from polysaccharides and synthetic block copolymers which form thermoreversible gels and allow the solubilisation of hydrophobic medications for controlled release, as taught by Williams, P A, at the Centre for Water Soluble Polymers, North East Wales Institute, Plas Coch, Mold Road, Wrexham, Wales.
[0021] Instead of forming the network with a true hydrogel, the network may be formed with a complex carbohydrate, such as cellulose, pectin, starch, maltodextrin or other polysaccharides. Forming of hydrated network structures out of such materials is well known in the candy making industry for making gummy candies. Or the network may be formed with a combination of a true hydrogel and a complex carbohydrate.
[0022] The most crucial ingredient for the adherent oral patch is a hydrophilic polymer that is liquid at human mouth temperatures located within pores of the network. Gelatin rendered from animal protein, such as from pork skin or cattle hooves or from fish, serves very well as this ingredient. These gelatins are graded according to “bloom strength” which refers to the strength of the gel that is formed. Gelatin with a higher bloom strength is preferred for the adherent oral patch because it also has a higher viscosity in liquid form. The high viscosity in liquid form prevents the gelatin molecules from escaping the network substantially faster than the network erodes, and the high viscosity better retains the medication for slow release. The highest commercially available bloom strength, 250, is preferred.
[0023] The adherent oral patch is suitable for use with all of the medications mentioned in U.S. Pat. No. 6,139,861 issued to Friedman, including steroids, such as a glucocorticoid steroids, and non-steroidal anti-inflammatory drugs such as naproxen sodium, ibuprofen, acetaminophen, and ketoprofen. The medication may also be an antimicobial, such as an anti-fungal for treatment of candida organisms (thrush), such as nystatin, clotrimazole, miconazole, or fluconazole. The medication may be intended for treatment of canker sores (aphthous ulcers), including pharmaceutical antibiotics such as tetracycline, penicillin, or amoxicillin, or other canker sore treatment medications such as deglycyrrhizinated licorice root extract (DGL) or amlexanox.
[0024] If the network is formed of a hydrogel as described above, the oral patches may be manufactured by processes well known in the candy making industry. The process is to form a well-hydrated mixture at temperatures just below the boiling temperature of water so that water does not boil off and yet the hydrogels are fully activated for gelling when the product is cooled. In this process, the network can be formed of a combination of a true hydrogel such as xanthan gum with locust bean gum or with konjac gum and a complex carbohydrate such as cellulose or pectin or starch. For the medication deglycyrrhizinated licorice root extract (DGL), an effective ratio by weight is 56% water, 16% gelatin, 11% DGL, 10% cellulose, 4.8% glycerol, and 2.2% gums such as kappa carrageenan or xanthan gum plus locust bean gum or konjac gum heated to 200 degrees F.
[0025] The hot mixture is poured or squirted into molds. The molds be may open top molds or closed molds. Open top molds may be formed by pressing a plug into powdered starch such as cornstarch or may be formed in a tray for packaging the products such as thermo formed PVC or PET or a cold press laminate of aluminum and PVC with a thin layer of polyamide for strength. Closed molds may be used such as in an injection-molding machine. Because the mixture typically requires about 2 hours to form a strong enough oral patch for de-molding, it is preferable to intermittently move trays of two-part molds, upper and lower, under pump depositer injector nozzles. The nozzles fit into holes in the upper mold located at the center of each oral patch. After de-molding, the upper molds are used again for another batch. The lower molds may be plastic lined, in which case the plastic becomes a part of the final packaging. A suitable size for each oral patch is 0.8 grams poured into the mold.
[0026] If the oral patches are deposited in powdered starch, the starch absorbs some of the excess water and the oral patches are further dried in a drying room before being removed from the starch, packaged in a hermetic seal, and sterilized with gamma radiation or heat and pressure in a retort.
[0027] If the oral patches are deposited in molds formed in a tray, the tray is stored in a drying room until the oral patches lose a suitable amount of moisture. A suitable method of drying in trays is to expose them without convection to room temperature and humidity for 3 days or, with convection, for 24 hours. In the drying process, the oral patches lose about 47% of their weight, so an oral patch that started at 0.8 grams poured into the mold becomes 0.42 grams. The trays are then sealed with a film or foil lid that is adhered by conventional heat-sealing techniques and the entire package is sterilized with gamma radiation or heat and pressure in a retort.
[0028] For most applications, most users prefer that the oral patches be medium dry to dry. With this starting dryness, the oral patches are more adherent and have more integrity so they can be removed for talking or eating and then replaced. The only drawback to this dryness is that the oral patch becomes hard when it dries, giving the oral patch a less soothing feel. It is also less conforming and therefore does not stick well to hard surfaces such as guns and teeth. When the oral patch is placed in contact with delicate tissue, such as a large canker sore, most users prefer that the oral patch be moist and soft. Thus, it is preferable to package the oral patches with a film that allows moisture to pass so moisture can easily be added to or removed from the oral patches without removing them from the packaging. If the packaging film is a barrier to germs, this allows the oral patches to remain sterile and not grow mold even when they are moist. Effective films are cellophane, polystyrene, poybutadiene, polyamide, Tyvek (matted polyethylene threads) and expanded films such as Goretex. Polyamide with a thickness of 0.7 mil to 1.0 mil is effective. Allowing such a package to sit for a day or two with a few drops of water on the package is sufficient to hydrate the oral patch inside. Conversely, allowing the package to sit on a shelf in a dry room for one to three days is sufficient to dry out the oral patch.
[0029] While particular embodiments of the invention have been described above, the scope of the invention should not be limited by the above descriptions but rather limited only by the following claims. | A soft, adherent, soluble oral patch for delivering topical medication in the mouth including a hydrophilic polymer that is liquid at human mouth temperatures. Preferably, the hydrophilic polymer gels to a solid at temperatures just below human mouth temperatures. The structure of the oral patch is formed with a porous network that remains solid at human mouth temperatures and slowly dissolves in saliva. In some embodiments, the network is elasto-plastic and in some cases it is hydrophilic. The hydrophilic polymer is located within pores of the network, along with a desired medication. The oral patch is formed by mixing and hydrating the ingredients, bringing them to a hot temperature just below boiling, and cooling them to form a gel. The hot mixture may be poured into molds and the mold may also serve as packaging for delivery. The packaging may comprise a germ barrier moisture passing film which allows the oral patch to dry out or become re-hydrated without growing mold. | 0 |
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates in general to air conditioning units for controlling environmental conditions within building spaces, including air conditioning units for computer rooms, data centers (server rooms), and other building spaces intended for uses having special environmental control requirements. The disclosure relates in particular to air conditioning units adapted for installation within the building spaces served by the units.
BACKGROUND
[0002] Computer rooms and other building spaces intended for specialized uses often require precise control and regulation of environmental conditions such as temperature and humidity in order to ensure proper operation of equipment (such as but not limited to computers) installed in such building spaces. Cooling requirements for computer rooms are typically much greater and more stringent than for most building spaces due to the need to dissipate heat generated by the computer equipment operating in the computer rooms. Humidity control requirements are typically stringent as well, as excessive moisture in the air in a computer room can cause operational and maintenance problems with the computer equipment.
[0003] Accordingly, computer rooms commonly are provided with specialized air conditioning (A/C) systems for controlling and regulating temperature and humidity. It has been common in the past for computer room A/C systems to be located outside the computer room and even outside the building housing the computer room, due to the physical size of the equipment needed to meet the A/C requirements for the computer room in question. In recent years, however, computer room air conditioning units (or “CRAC units”) have been developed that are sufficiently compact for installation within a computer room without greatly increasing the required floor area or height of the computer room. Examples of such CRAC units include chilled water or DX (direct expansion) A/C units manufactured by the Liebert® Corporation.
[0004] Conventional CRAC units commonly utilize banked (i.e., angularly-oriented) cooling coils specially constructed for use in CRAC unit and arrayed in an A-frame or V-frame configuration within the unit. Airflow typically enters the unit vertically through the top or bottom of the unit and proceeds in a straight, vertical path through the filters and coils. In CRAC units of this type, the air velocity through the filters (also referred to herein as the “face velocity”) is comparatively high, which results in reduced filter performance.
[0005] Another drawback of known CRAC units is that they cannot be readily adapted to use direct evaporative cooling systems using saturated evaporative media pads without increasing the size of the units so much that their use within a computer room becomes unviable or undesirable. Direct evaporative cooling systems using saturated evaporative media pads rely on gravity to allow water sprayed on top of the unit to trickle down, saturating the pad through which the airstream passing through the CRAC unit travels. Some of the water in the evaporative pad evaporates into the airstream, adiabatically cooling it. Water is collected in a sump located beneath the evaporative pad. However, this type of direct evaporative cooling system cannot be used in conventional CRAC units using a conventional vertical airflow pattern, because the evaporative media pads would have to be oriented horizontally, such that water would not be able to drain from the media by gravity into a drain pan. Moreover, the requirement for the evaporative media to be horizontally oriented for use in a CRAC unit having a vertical airflow pattern would increase the size of the unit and the floor area it requires.
[0006] For the foregoing reasons, there is a need for CRAC units characterized by lower face velocities (and therefore better filter performance and efficiency) than conventional CRAC units, without increasing the physical size of the units significantly or at all. In addition, there is a need for CRAC units that can be adapted to use direct evaporative cooling media, without significant effect on the physical size of the units.
BRIEF SUMMARY
[0007] In general terms, the present disclosure teaches an enclosed air conditioning unit comprising a filter section and a cooling section in which the airflow path through the filter section and cooling section is substantially horizontal, with the physical size and configuration of the unit's cabinet or enclosure being essentially the same as (or smaller than) the cabinets for conventional air conditioning units having comparable or lower performance capabilities.
[0008] In a first aspect, the present disclosure teaches an air conditioning unit comprising an enclosure having a first wall, a second wall opposite the first wall, and a primary air intake in an upper region of the enclosure; and an air treatment component assembly mounted within the enclosure so as to define a first chamber between the component assembly and the enclosure's first wall and a second chamber between the component assembly and the enclosure's second wall. Air entering the primary air intake from outside the enclosure will flow, in sequence, downward within the first chamber, horizontally through the component assembly into the second chamber, and downward within the second chamber toward a discharge outlet in a lower region of the enclosure.
[0009] In one particular embodiment in accordance with the above-described first aspect, the air conditioning unit comprises an enclosure (cabinet) having a first wall, a second wall opposite the first wall, and a primary air intake in an upper region of the enclosure; plus an air treatment component assembly including a generally flat filter section and a generally flat cooling section. The filter section and cooling section are installed in parallel juxtaposition, and oriented vertically within the enclosure, so as to define a first chamber between the filter section and the enclosure's first wall, and a second chamber between the cooling section and the enclosure's second wall. Air entering the primary air intake from outside the enclosure will flow, in sequence, downward within the first chamber, horizontally through the filter section and the cooling section into the second chamber, and downward within the second chamber toward a discharge outlet in a lower region of the enclosure. Optionally, the air conditioning unit may include a bypass air intake through which air from outside the unit can flow downward into the second chamber. Embodiments that have a bypass air intake preferably will also have an intake damper for regulating the flow of air into the second chamber.
[0010] In a second aspect, the present disclosure teaches an air conditioning unit comprising an enclosure having a first wall, a second wall opposite the first wall, and a primary air intake in a lower region of the enclosure; and an air treatment component assembly mounted within the enclosure so as to define a first chamber between the component assembly and the enclosure's first wall and a second chamber between the component assembly and the enclosure's second wall. Air entering the primary air intake from outside the enclosure will flow, in sequence, upward within the first chamber, horizontally through the component assembly into the second chamber, and upward within the second chamber toward a discharge outlet in an upper region of the enclosure.
[0011] In one particular embodiment in accordance with the above-described second aspect, the air conditioning unit comprises an enclosure (cabinet) having a first wall, a second wall opposite the first wall, and a primary air intake in a lower region of the enclosure; plus an air treatment component assembly including a generally flat filter section and a generally flat cooling section. The filter section and cooling section are in parallel juxtaposition and oriented vertically within the enclosure, so as to define a first chamber between the filter section and the enclosure's first wall, and a second chamber between the cooling section and the enclosure's second wall. Air entering the primary air intake from outside the enclosure will flow, in sequence, upward within the first chamber, horizontally through the filter section and the cooling section into the second chamber, and upward within the second chamber toward a discharge outlet in an upper region of the enclosure. Optionally, the air conditioning unit may include a bypass air intake through which air from outside the unit can flow upward into the second chamber. Embodiments that have a bypass air intake preferably will also have an intake damper for regulating the flow of air into the second chamber.
[0012] The first and second walls typically will be, respectively, the front and rear walls of the enclosure, such that the first chamber will be adjacent the front wall. In alternative embodiments, however, the first and second walls could be, respectively, the rear and front walls of the enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Exemplary embodiments of CRAC units in accordance with the present disclosure will now be described with reference to the accompanying Figures, in which numerical references denote like parts, and in which:
[0014] FIG. 1 is a schematic vertical cross-section through a prior art CRAC unit.
[0015] FIG. 2 is a longitudinal vertical section through a first embodiment of a CRAC unit in accordance with the present disclosure, incorporating evaporative cooling media and a drift eliminator.
[0016] FIG. 3A is a transverse vertical section through the CRAC unit shown in FIG. 2 .
[0017] FIG. 3B is a transverse vertical section through a variant CRAC unit similar to the embodiment shown in FIG. 3A but with a DX cooling coil added.
[0018] FIG. 4 is an enlarged vertical section through a CRAC unit as shown in FIG. 3A , in which air enters an upper region of the unit and exits from a lower region of the unit.
[0019] FIG. 5 is an enlarged vertical section through a variant embodiment of the CRAC unit shown in FIGS. 3A and 4 , in which air enters a lower region of the unit and exits from a upper region of the unit.
DETAILED DESCRIPTION
[0020] FIG. 1 illustrates a prior art CRAC unit 10 in which airflow (denoted by flow arrows F) enters the top of the unit (either directly from the room in which the unit is installed or, alternatively, via a duct bringing air from outside the room), passes through a filtration section 12 , then through an A-frame banked cooling coil section 14 , and then is discharged into the room at the bottom of the unit by means of supply fans 16 . Drain pans 15 are provided to carry condensation off the coils 14 to a sump (not shown).
[0021] FIGS. 2 and 3A illustrate the general configuration and basic components of one CRAC unit embodiment 100 in accordance with the present disclosure. CRAC unit 100 comprises an enclosure 101 which has a first wall 103 and an opposing second wall 104 , with either or both of walls 103 and 104 having access doors 102 as required for operation and maintenance. Enclosure 101 houses an assembly of air treatment equipment components which in the illustrated embodiment includes a filter section 110 and a cooling section 120 . Filter section 110 and cooling section 120 are each of substantially uniform thickness with generally flat side surfaces, and they mounted within enclosure 101 so as to be substantially parallel and closely adjacent to each other (i.e., in parallel juxtaposition) and oriented vertically within the enclosure 101 between and generally parallel to walls 102 and 103 . In the embodiment shown in FIG. 4 , this arrangement of the air treatment component assembly results in the formation of a first chamber 140 between filter section 115 and first wall 103 , and a second chamber 145 between cooling section 120 and second wall 104 .
[0022] FIG. 3B shows a variant CRAC unit embodiment 150 similar to CRAC unit 100 but with a DX coil 160 added to the air treatment component assembly.
[0023] FIG. 4 illustrates the airflow path through CRAC unit embodiment 100 . The airflow path through CRAC unit 150 would be similar to that shown in FIG. 4 . CRAC units 100 and 150 are “downflow” units in which airflow through the unit is from top to bottom. However, these units can be readily adapted for upflow operation, such as in the variant CRAC unit embodiment 200 shown in FIG. 5 , in which airflow through the unit is from bottom to top.
[0024] In the downflow CRAC unit 100 shown in FIG. 4 , air enters a primary air intake 105 at the top of the unit, with the airflow initially being vertically downward (as denoted by airflow arrow F 1 ) within first chamber 140 , but then is diverted horizontally (as denoted by horizontal airflow arrow F 2 ) through filter section 115 and cooling section 120 . Cooling section 120 may comprise cooling coils and/or evaporative media. The use of direct evaporative cooling in a vertically-oriented CRAC unit is thus made possible by configuring the unit 100 such that the airflow pattern through the unit has a primary horizontal component F 2 as illustrated in FIG. 4 .
[0025] In the embodiment shown in FIG. 4 , in which cooling section 120 includes evaporative media, CRAC unit 100 also incorporates a “drift eliminator” 125 (a term that will be well understood by persons skilled in the art) to remove any water droplets present in the airflow exiting the evaporative media, thus preventing what is known as “water carryover” from the evaporative media into the cooled air discharged from the unit. The airflow F 2 downstream of drift eliminator 125 is diverted vertically downward (as denoted by airflow arrow F 3 ) within second chamber 145 to a lower region of CRAC unit 100 , from which it is discharged into the space to be cooled. As indicated in FIG. 4 , the airflow discharge from CRAC unit 100 could be vertically downward (as denoted by airflow arrow F 4 ), or alternatively horizontal (as denoted by airflow arrow F 5 ) through the front and/or sides of the unit. Supply fans 130 propel the cooled air either directly into the space to be cooled or into connecting ductwork.
[0026] Also as shown in FIG. 4 , CRAC unit 100 may optionally be provided with a bypass air intake 110 controlled by an intake damper 112 to allow a regulated downward flow of incoming air into second chamber 145 (as denoted by airflow arrow F 6 ), bypassing cooling section 120 to allow for cooling capacity modulation, by blending the downward-flowing untreated bypass airflow F 6 into the airflow F 2 exiting cooling section 120 (and drift eliminator 125 , as the case may be). Depending on the properties of the primary incoming airflow F 1 (e.g., temperature and humidity), it may not always be necessary for all supplied air to pass through cooling section 120 of CRAC unit 110 . For example, cooled air exiting cooling section 120 can be blended in suitable proportions with warmer untreated bypass air F 5 to produce an airflow supply to the room at a temperature somewhere between the temperatures of the two airflows being blended.
[0027] The upflow CRAC unit embodiment 200 illustrated in FIG. 5 operates in substantially the same way as downflow CRAC unit embodiment in FIG. 4 except for the direction of airflow and correspondingly necessary modifications. In the illustrated embodiment, CRAC unit 200 comprises an enclosure 201 having first and second walls 203 and 204 (and access doors 202 ) and housing an air treatment component package comprising a filter section 115 , cooling section 120 , and drift eliminator 125 generally as in CRAC unit embodiments 100 and 150 . Similar to CRAC unit 100 shown in FIG. 4 , the arrangement of the air treatment component assembly within enclosure 201 results in the formation of a first chamber 240 between filter section 115 and first wall 203 , and a second chamber 245 between cooling section 120 and second wall 204 .
[0028] A lower portion of enclosure 201 defines an intake plenum 200 having a roof structure 212 defining a primary air intake 215 through which intake air (denoted by airflow arrow F 1 ′) can flow upward into first chamber 240 within enclosure 201 to be horizontally diverted (as denoted by horizontal airflow arrow F 2 ′) through filter section 115 , cooling section 120 , and drift eliminator 125 .
[0029] The airflow F 2 ′ downstream of drift eliminator 125 is diverted vertically upward (as denoted by airflow arrow F 3 ′) within second chamber 245 to an upper region of CRAC unit 200 , from which it is discharged into the space to be cooled by supply fans 130 . As indicated in FIG. 5 , the airflow discharge from CRAC unit 200 could be vertically upward (as denoted by airflow arrow F 4 ′), or alternatively horizontal (as denoted by airflow arrow F 5 ′) through the front and/or sides of the unit.
[0030] Also as shown in FIG. 5 , CRAC unit 200 optionally may be provided with a bypass air intake 220 controlled by an intake damper 222 to allow a regulated upward flow of incoming air into second chamber 245 (as denoted by airflow arrow F 6 ′), bypassing cooling section 120 and flowing upward within second chamber 245 to mix with the airflow F 2 ′ exiting cooling section 120 and drift eliminator 125 .
[0031] The airflow paths through the CRAC units shown in FIGS. 4 and 5 provide enhanced flexibility over prior art CRAC units and facilitate standardization of parts, thus avoiding the need for specialized components such as A-frame or V-frame coils and banked filters as in prior art CRAC units. The horizontal airflow across the internal components of the CRAC unit results in reduces face velocities across those components. Low face velocities increase filtration efficiency, prevent water carryover, reduce static pressure drop through the unit, and increase the cooling effectiveness of the cooling systems in the unit. The horizontal airflow in CRAC units in accordance with the present disclosure also allows for the use of direct evaporative cooling systems within the units using saturated evaporative media pads.
[0032] CRAC units in accordance with the present disclosure can be adapted to use a variety of cooling systems, including but not limited to chilled water, DX refrigeration, and direct evaporative cooling systems. A wide range of airflows and static pressures can be accommodated. The CRAC units and associated control systems can be designed to provide reliable data center climate control while significantly reducing the electrical energy consumption of the computer room or data center's HVAC system.
[0033] CRAC units in accordance with the present disclosure can be manufactured as packaged pieces of equipment, requiring a single-point electrical connection and communications connection as well as one piping connection each for water and drain for easy unit set-up on site. Outdoor air and return air can be mixed remotely via the building's ventilation system and ducted into the CRAC unit.
[0034] In preferred embodiments, CRAC units as disclosed herein are controlled by dedicated, onboard PLCs (programmable logic controllers). Each CRAC unit's onboard controller controls all aspects of the unit's operation, including monitoring internal temperatures, modulating fan speed, and operation of the cooling systems.
[0035] Variants of the disclosed CRAC units can be adapted in accordance with one or more options as listed below with respect to airflow configuration, air conditioning method, control type, and fan type:
Flow Configuration
[0036] Both downflow or upflow configurations are readily adaptable for mounting in rooms with or without raised floor systems, for example:
Downflow units with an air intake in the upper section of the unit (top, front, side, or back), and an air discharge outlet in a lower region of the unit (bottom, front, side, or back). Upflow units with an air intake in the lower section of the unit (bottom, front, side, or back), and an air discharge outlet in a upper region of the unit (top, front, side, or back).
Air Conditioning Method
[0039] One or more air conditioning options can be used in a given CRAC unit, for example;
Direct evaporative cooling—uses adiabatic evaporative cooling to cool the air stream by streaming water down an internal evaporative media pad. All components of the evaporative cooling system are provided integral to the unit. Water cooling—uses water passing through a coil in the CRAC unit to act as a cooling medium. Various cooling sources are possible, including:
Chilled water using the building's chilled water system. Cooling provided by air-cooled or water-cooled chillers. Waterside economizer: water is cooled using an outdoor drycooler or indirect evaporative cooler; this can be used independently or in conjunction with a water-cooled chiller. Seawater, river water, irrigation water, or water from other natural sources can be passed through a coil to provide cooling.
DX cooling—uses a refrigeration-based direct expansion (DX) coil to cool the airstream, with a rooftop condensing unit to provide heat rejection. Heating—for applications requiring specific dehumidification reheat, a heating coil can be provided to warm the airstream; heating coils may be of hot water or electric element types.
CRAG Unit Control
[0047] CRAC units in accordance with the present disclosure can use a variety of different control options, preferably including an onboard PLC controller capable of handling all unit functions, and optionally including any of the following:
Full stand-alone unit control—all CRAC unit control is carried out by the onboard controller. Units can modulate remote dampers, control fan speed, choose modes of cooling, modulate valves, control pumps, etc. Remote automatic control—some high-level unit control is handled by a remote building management system (BMS) or by a dedicated central control system for the CRAC units. Modes of cooling and overall enable/disable functions are controlled by the external controller, as well as operating setpoints. Full CRAC unit information can be sent to the remote controller, and the remote controller is capable of controlling any part of the unit as may be desired. Constant/variable air volume—supply fans can be speed-controlled for variable-volume systems. For constant air volume operation, the speed controller is set to a constant value at the time of CRAC unit start-up. Sensors—various sensors can be provided with the CRAC unit for various control aspects. Examples of sensors include temperature, humidity, smoke detection, and water detection. Miscellaneous control options—other modes of operation such as control of external devices such as duct-mixing dampers and remote pumps, etc.
Fan Types
[0053] CRAC units in accordance with the present disclosure can be adapted to accommodate a variety of different required airflows and system static pressures according to the type of fans selected. For compactness of size and pressure-handling capabilities, the preferable fan type is an airfoil-blade backwards-inclined plenum fan. However, other types of fans such as forward and backward curved centrifugal scroll fans could also be used.
[0054] It will be readily appreciated by those skilled in the art that various modifications to embodiments in accordance with the present disclosure may be devised without departing from the scope and teaching of the present teachings, including modifications which may use equivalent structures or materials hereafter conceived or developed. It is to be especially understood that the scope of the claims appended hereto should not be limited by any particular embodiments described and illustrated herein, but should be given the broadest interpretation consistent with the description as a whole. It is also to be understood that the substitution of a variant of a claimed element or feature, without any substantial resultant change in functionality, will not constitute a departure from the scope of the disclosure.
[0055] In this patent document, any form of the word “comprise” is intended to be understood in its non-limiting sense to mean that any item following such word is included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one such element is present, unless the context clearly requires that there be one and only one such element. Any use of any form of any term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements in question, but may also extend to indirect interaction between the elements such as through secondary or intermediary structure.
[0056] Relational terms such as “vertical”, “horizontal”, and “parallel”, are not intended to denote or require absolute mathematical or geometrical precision. Accordingly, such terms are to be understood as denoting or requiring substantial precision only (e.g., “substantially vertical” or “generally vertical”) unless the context clearly requires otherwise. Any use of any form of the term “typical” is to be interpreted in the sense of representative of common usage or practice, and is not to be interpreted as implying essentiality or invariability. | An enclosed air conditioning unit includes a filter section and a cooling section through which intake air passes before being discharged into a space within a building. The orientation of the filter section and cooling section is substantially vertical, and the airflow path through the filter section and the cooling section is substantially horizontal, resulting in reduced face velocities across these components, thereby increasing filtration efficiency and cooling effectiveness, while allowing the physical size and configuration of the air conditioning unit's enclosure to be the same as or smaller than the enclosures for conventional air conditioning units having comparable or lower performance. | 7 |
BACKGROUND OF THE INVENTION
The present invention is directed to a servicing arrangement for a conveyor belt cleaner, and in particular to a servicing arrangement which enables a conveyor belt cleaner to be selectively removed or installed from a location exterior to the housing in which the conveyor belt cleaner is located.
Conveyor belt cleaners are often used at the discharge end of a conveyor to remove any conveyed material which adheres to the conveyor belt. The scraping blades of a belt cleaner wear down during use and require periodical replacement in order to maintain belt cleaning efficiency. Conveyor belt cleaners are typically mounted to opposing walls of a housing which forms part of a conveyor chute. When maintenance on a conveyor belt cleaner is required, such as the replacement of scraper blades, the conveyor is typically shutdown thereby stopping rotation of the belt to allow maintenance personnel to enter the chute housing for access to the belt cleaner. Although the conveyor is shutdown, maintenance personnel are still exposed to the potential danger of falling downwardly through the conveyor chute.
There has been a need expressed to be able to perform maintenance on conveyor belt cleaners, including the replacement of scraper blades, while the conveyor belt is in operation. This need is particularly felt by plants that operate continuous processes wherein the shutdown of a conveyor stops operation of the process. As belt cleaning efficiency is becoming more and more a necessity for the efficient operation of a process, and as the use of highly abrasive bulk solids in processes is requiring more frequent maintenance to conveyor belt cleaners to maintain cleaning efficiency, shutting down conveyors to perform conveyor belt maintenance is becoming problematic. While there is a need to be able to perform maintenance on conveyor belt cleaners while the conveyor remains in operation, performing maintenance service on a conveyor belt cleaner from within a chute housing while the conveyor remains in operation is dangerous as the maintenance personnel are exposed to the rotating belt, moving idler rollers and other components of the conveyor, the material discharged from the conveyor, and the downward opening of the conveyor chute. In addition, while the conveyor is operating, conveyor belt cleaners are subject to the potential for "pull through" of the scraper blades by the conveyor belt.
A belt cleaner mounting arrangement having slidably removable scraper blades is described in U.S. Pat. No. 4,249,650, which is assigned to the applicant Martin Engineering Company. The mounting arrangement includes an elongate support member which is rotatably mounted at each end in respective bearing assemblies. A plurality of sleeve members connected one to the other are slidably carried on the support member, but are prevented from rotating with respect to the support member. A scraper blade is mounted to each sleeve member. A flexible cable extends through the hollow center of the support member and is attached to the outwardly located sleeve members. The sleeve members and scraper blades are removed from the support member by disassembling one of the bearing members and pulling on the cable to slide the sleeve members off of the support member. The support member of the conveyor belt cleaner remains located within the conveyor housing during removal of the sleeve members and scraper blades.
A conveyor belt cleaner also having slidably removable scraper blades is described in U.S. Pat. No. 4,953,689, which is also assigned to Martin Engineering Company. The belt cleaner includes an elongate support member which is adapted to be rotatably mounted in bearing members at each respective end thereof. A plastic sleeve is mounted over the support member. The sleeve is slidable longitudinally with respect to the support member, but is connected to the support member to prevent sliding movement during use. The sleeve is also prevented from rotating with respect to the support member. The sleeve includes an elongate track in which scraper blades are slidably mounted. A cable extending through the scraper blades is pulled to slide the scraper blades along the track and off of the sleeve. The sleeve and the support member remain located within the conveyor housing during removal of the scraper blades.
Neither of the arrangements disclosed in these two patents provide a guide member which guides and supports the support member and scraper blades of a conveyor belt cleaner after the support member is disengaged from its bearing members to allow the removal thereof from the conveyor housing, and which guides and supports the support member and scraper blades as the support member is installed within the conveyor housing until the support member is rotatably mounted at each end in its bearing members.
The present invention provides a servicing arrangement for a conveyor belt cleaner which allows the conveyor belt cleaner scraper blades and support member to be removed and replaced by maintenance personnel from the exterior of the conveyor housing while the conveyor remains in operation thereby reducing or eliminating the potential for injury to maintenance personnel during conveyor belt cleaner maintenance.
SUMMARY OF THE INVENTION
A servicing arrangement is provided for supporting and guiding a conveyor belt cleaner having one or more scraper blades mounted to a support member as the conveyor belt cleaner is removed from, or mounted to, a support structure. The servicing arrangement includes an elongate mandrel guide member having a first end and a second end. The second end of the mandrel member is adapted to be attached to a support such as a side wall of a conveyor chute housing. The first end of the mandrel member is preferably located adjacent an aperture located in an opposing side wall of the conveyor chute housing. A support member having a bore extending therethrough is adapted to be rotatably positioned over the mandrel member to cover the mandrel member and prevent the deposit of conveyed material thereon. The support member is selectively slidable along the axis of the mandrel member and relatively rotatable with respect thereto such that the support member is selectively removable or selectively positionable on the mandrel member through the aperture in the side wall of the housing. The support member is adapted to receive and support a conveyor belt cleaner blade such that when the support member is positioned over the mandrel member in operative position and the cleaner blades are mounted on the support member, rotation of the support member relative to the mandrel member is effective to position the cleaner blade or blades relative to the conveyor belt.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a tensioning device shown attached to the servicing arrangement of the present invention and to the exterior surface of a side wall of a conveyor chute housing.
FIG. 2 is a perspective view of the second end of the servicing arrangement shown attached to the exterior surface of a second side wall of the conveyor chute housing.
FIG. 3 is a perspective view similar to FIG. 1 but with the tensioning device removed to show the first end of the mandrel member.
FIG. 4 is an elevational view of the servicing arrangement shown installed in a conveyor chute housing and with a tensioning device and a conveyor belt cleaner attached thereto.
FIG. 5 is an exploded view showing the servicing arrangement installed in a conveyor chute housing and the tensioning device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As best shown in FIG. 4, the servicing arrangement 10 of the present invention is adapted to be attached at one end to a fixed support such as a conveyor chute housing 12 and is adapted to support and guide a conveyor belt cleaner 14 for use in cleaning the belt (not shown) of a conveyor. The chute housing 12 includes a first side wall 16 having an external surface 18 and an internal surface 20 and an opposing second side wall 22 having an external surface 24 and an internal surface 26. The second side wall 22 is spaced apart from the first side wall 16 and is generally parallel thereto. As best shown in FIG. 3, the first side wall 16 includes an aperture 28. The aperture 28 is shown in FIG. 3 as being generally L-shaped, but may be configured in various other shapes as desired including circular, rectangular, or an inverted T-shape. The second side wall 22 includes an aperture 30 as best shown in FIG. 4 which is generally circular, but which may be formed in various other configurations and shapes as desired. The chute housing 12 defines a chamber 32 located between the first side wall 16 and the second side wall 22. The conveyor belt cleaner 14 includes one or more scraper blades 34 adapted for scraping engagement with a conveyor belt. The conveyor belt cleaner 14 may be of the type as described in U.S. Pat. Nos. 4,598,823, 4,643,293, or 4,953,689 which are assigned to Martin Engineering Company, the applicant herein, or various other types of conveyor belt cleaners as desired.
The servicing arrangement 10 includes an elongate mandrel member 40 having a first end 42, a second end 44 and a longitudinal axis 46. The mandrel member 40 includes an outer surface 48 which is generally circular or cylindrical, but which may be formed in other shapes as desired. The mandrel member 40 may be a solid shape such as a rod or bar, or a hollow shape such as a tube.
The servicing arrangement 10 also includes a mounting member 50 as best shown in FIG. 2. The mounting member 50 includes a first plate element 52 and a second plate element 54 spaced apart from and generally parallel to the first plate element 52. The first plate element 52 is attached to the second plate element 54 by ribs 56A-B which are spaced apart from one another and which extend generally perpendicular to the first plate element 52. The second end 44 of the mandrel member 40 is attached to and retained by the first plate element 52. The first plate element 52 may include an aperture 58 adapted to receive the second end 44 of the mandrel member 40 whereupon the second end 44 is welded to the first plate element 52. Alternatively, the second end 44 may abut and be welded to the interior surface 60 of the first plate element 52 or the second end 44 may be threadably attached to the first plate element 52. The second end 44 of the mandrel member 40 is thereby rigidly attached to the first plate element 52 such that the mandrel member 40 extends in a cantilevered manner from the first plate element 52. However, the second end 44 may be attached to the first plate element 52 in various other manners such that the second end 44 is rotatably attached to the first plate element 52 for selective rotation about the axis 46, is pivotally attached to the first plate element 52, or is slidably attached to the first plate element 52 such that the mandrel member 40 may slide generally linearly and vertically upwardly or downwardly.
The second plate element 54 includes a generally circular aperture 62 through which the mandrel member 40 extends. The aperture 62 has a diameter which is larger than the diameter of the mandrel member 40. The mandrel member 40 extends substantially concentrically through the aperture 62. The second plate element 54 also includes a plurality of apertures adapted to receive fasteners 64 for attaching the second plate element 54 of the mounting member 50 to the external surface 24 of the second side wall 22 of the chute housing 12. Alternatively, the second plate element 54 and ribs 56A-B may be eliminated and the first plate element 52 may be attached directly to the second side wall 22. When the second end 44 of the mandrel member 40 is attached to the second side wall 22 of the chute housing 12, the first end 42 of the mandrel member 40 preferably extends a short distance through the aperture 28 in the first side wall 16 such that access to the first end 42 is provided to an operator or maintenance personnel without entering the chamber 32 of the chute housing 12.
The servicing arrangement 10 also includes a tubular support member 70 having a first end 72 and a second end 74. The support member 70 includes a bore 76 extending between the first end 72 and second end 74. The support member 70 includes an outer surface 78 which is generally circular or cylindrical, but which may be rectangular or other shapes as desired. As best shown in FIG. 4, one or more mounting plates 80 may be attached to the outer surface 78 of the support member 70 which are adapted to removably retain the scraper blades 34. Alternatively, a sleeve member (not shown) such as described in U.S. Pat. No. 4,953,689 may be slidably mounted over the support member 70 to removably retain the scraper blades 34. The bore 76 of the support member 70 is larger in diameter than the outside diameter of the mandrel member 40. Depending upon the particular arrangement, the fit could vary between a precision fit with a few thousandths of an inch clearance to a relatively loose fit. The support member 70 is adapted to be rotatably positioned over the mandrel member 40 for selective rotation about the axis 46 with respect to the mandrel member 40 and is adapted to be slidable along the mandrel member 40 generally parallel to the axis 46. The outer diameter of the support member 70 is adapted to fit closely within the aperture 62 of the mounting member 50. The second end 74 of the support member 70 extends through the aperture 62 of the mounting member 50 and is thereby rotatably mounted to and supported by the mounting member 50. Alternatively, the second end 74 of the support member 70 may fit closely within the aperture 30 of the housing 12 such that the second end 74 is rotatably mounted and supported by the second sidewall 22 of the housing 12 or a bearing member attached thereto.
As best shown in FIG. 3, the servicing arrangement 10 also includes a cover plate 82. The cover plate 82 includes a generally circular aperture 84 and a plurality of apertures 86 which are adapted to receive fasteners 87. The cover plate 82 also includes an aperture 88 adapted to receive a hasp 89 which is attached to the external surface 18 of the first side wall 16. The cover plate 82 is adapted to be fastened to the exterior surface 18 of the first side wall 16 by the fasteners 87 with the first end 42 of the mandrel member 40 extending generally concentrically through the aperture 84. The cover plate 82 is adapted to cover the aperture 28 in the first side wall 16 except for the area left open by the aperture 84. If desired the cover plate 82 may be additionally secured to the first side wall 16 by a padlock attached to the hasp 89 to prevent unauthorized removal of the cover plate 82.
A tensioning device 90 may be used in connection with the servicing arrangement 10 to provide selective rotation of the support member 70 and conveyor belt cleaner 14 about the axis 46. A preferred tensioning device is disclosed in U.S. Pat. No. 5,385,507, which is assigned to the applicant Martin Engineering Company and which is incorporated herein by reference. Other types of tensioning devices may also be used with the servicing arrangement 10, however, the tensioning device must protect the operator from scraper blades being pulled through by the moving belt if service work is done while the belt is in operation. The tensioning device 90 includes an adapter member 92 having a bore 94 which is adapted to receive the first end 72 of the support member 70. The adapter 92 is selectively connected to the first end 72 of the support member 70 by fastener means such as a set screw 96. The adapter member 92 is selectively attached to a driven hub 98. The driven hub 98 is attached to a drive hub 100 by a resilient torsion coupling member such as a torsion tube 102. The drive hub 100 is selectively rotatably attached to a housing 104. As best shown in FIGS. 1 and 4, the housing 104 of the tensioning device 90 is mounted to a fixed support such as the first side wall 16 of the chute housing 12 by the fasteners 87. The first end 72 of the support member 70 is thereby rotatably mounted to a fixed support by the tensioning device 90.
In operation, the mounting member 50 is attached to the exterior surface 24 of the second side wall 22 of the chute housing 12 such that the mandrel member 40 extends through the aperture 30 in the first side wall 12 and such that the first end 42 of the mandrel member 40 extends a short distance through the aperture 28 in the opposing first side wall 16. The support member 70, having the scraper blades 34 of the conveyor belt cleaner 14 attached thereto and having the adapter member 92 of the tensioning device 90 attached to the first end 72, is slidably placed onto the mandrel member 40. The second end 74 of the support member 70 is slid over the first end 42 of the mandrel member 40 such that the first end 42 is inserted into the bore 76 at the second end 74 of the support member 70. The support member 70 is slid longitudinally along the mandrel member 40 generally parallel to the axis 46 such that the support member 70 and the conveyor belt cleaner 14 pass through the aperture 28 in the first side wall 16. The support member 70 is slid along and guided by the mandrel member 40 until the second end 74 of the support member 70 passes through the aperture 30 in the second side wall 22, through the aperture 62 in the second plate element 54 and abuts the interior surface 60 of the first plate element 52. The support member 70 is adapted to fit closely within the aperture 62 of the second plate element 54 to substantially seal the aperture 62 thereby preventing dust within the chamber 32 from escaping through the aperture 62. When the support member 70 is fully inserted over the mandrel member 40, the first end 72 of the support member 70 is located at the first side wall 16 such that the adapter member 92 of the tensioning device 90 is located at least in part outside of the chamber 32 of the chute housing 12. The cover plate 82 is placed adjacent the external surface 18 of the first side wall 16 with the fasteners 87 extending through the apertures 86. The driven hub 98 of the tensioning device 90 is coupled to the adapter member 92 and the housing 104 is attached to the first side wall 16 by the fasteners 87. The conveyor belt cleaner 14 may then be rotated about the axis 46 and about the mandrel member 40 into scraping engagement with the conveyor belt by the tensioning device 90 with the desired amount of force. The installation or mounting of the support member 70 and conveyor belt cleaner 14 within the chamber 32 of the chute housing 12 is accomplished by maintenance personnel operating entirely outside of the chute housing 12 and without entering the chamber 32 while the conveyor belt remains in operation. Once the support member 70 and belt cleaner 14 are installed, the mandrel member 40 is not necessary to the operation or support of the belt cleaner 14 as the support member 70 is mounted by the tensioning device 90 and mounting member 50 to the housing 12. The servicing arrangement 10 is installed and may be removed when desired from the exterior of the housing 12.
The support member 70 and the conveyor belt cleaner 14 may similarly be removed from the mandrel member 40 and the chamber 32 in a reverse manner by maintenance personnel operating entirely outside of the chute housing 12 while the conveyor belt remains in operation as the maintenance personnel do not enter the chamber 32. The tensioning force applied by the tensioning device 90 to the scraper blades 34 is initially released. The tensioning device 90 is then removed from the first side wall 16 and uncoupled from the adapter member 92. The support member 70 and belt cleaner 14 are rotated, by manually grasping the adapter member 92 and first end 72 of the support member 70, to rotate the scraper blades 34 away from the conveyor belt to avoid any contact therewith. The cover plate 82 is then removed. The support member 70 and the attached conveyor belt cleaner 14 may then be slid along the mandrel member 40 through the aperture 28 in the first sidewall 16 and off the first end 42 of the mandrel member 40 to remove the support member 70 and conveyor belt cleaner 14 from the mandrel member 40 and the chamber 32, all from the outside of the chute housing 12.
Various features of the invention have been particularly shown and described in connection with the illustrated embodiment of the invention, however, it must be understood that these particular arrangements merely illustrate, and that the invention is to be given its fullest interpretation within the terms of the appended claims. | A servicing arrangement is provided for a conveyor belt cleaner. The servicing arrangement includes an elongate mandrel member having a first end and second end. The second end of the mandrel member is adapted to be attached to a support such that the mandrel member is retained by the support in a cantilevered manner. A support member is adapted to be positioned over the mandrel member by sliding the support member over the first end of the mandrel member. The support member is selectively slidable along the mandrel member to selectively remove or selectively mount the support member on the mandrel member. The support member is adapted to receive and support a conveyor belt cleaner. An operator can easily remove the conveyor belt cleaner from the mandrel member for service or replacement of the conveyor belt cleaner from the outside of a conveyor housing during conveyor operation when a suitably designed tensioner with a release mechanism is used to protect the operator from cleaner blade pull through. | 1 |
This is a Division of application Ser. No. 08/847,493, filed Apr. 25, 1997, now U.S. Pat. No. 6,224,952 which is a division of Ser. No. 08/016,240, filed Feb. 11, 1993, now U.S. Pat. No. 6,207,281, which is a Division of Ser. No. 07/660,949, filed on Feb. 26, 1991, now U.S. Pat. No. 5,190,824,which is a continuation-in-part of Ser. No. 07/318,541, filed Mar. 3, 1989, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an electrostatic erasing abrasion-proof coating and method for forming the same.
Abrasion-proof coatings are formed over surfaces which has a tendency to take scratches due to external rubbing actions. The surface of glass plates which may be used for transmitting light therethrough is a typical example of such a surface. Contact image sensor, which have been recently developed, are suitable for use in compact facsimile machines, copying machines or the like. The image sensor makes direct contact with an original and scans the surface of the original by moving relative to this.
An example of the contact image sensor is illustrated in FIG. 1 . The sensor comprises a glass substrate 1 , a photosensitive semiconductor device 2 , a transparent protective layer 3 , an adhesive layer 4 , an ITO film 5 and a glass pane 6 . An original bearing an image to be sensed is placed in contact with the external surface of the glass pane 6 . The ITO film, which is a transparent conductive film, is grounded for the purpose of canceling out electrostatic charges collected on the contact surface of the pane 6 due to rubbing action between the original 9 and the glass pane 6 . In case of treatment of usual papers, the size of scratches may be of the order of 1 micron meter or less so that the performance of the sensor is not substantially deteriorated by the scratches. However, if a staple is held to a paper to be telefaxed, the paper may give scratches of substantial size which degrade the quality of the transmission. Furthermore, the use of the ITO film for canceling out static electricity increases the size and the production cost of the device.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an excellent abrasion-proof coatings and methods for forming the same which produce no static electricity on the coating even when rubbing action takes place thereon.
In order to accomplish the above and other objects, it is proposed to coat a surface with carbon films in different deposition conditions in order that the external surface of the coating has a higher degree of hardness for providing an abrasion-proof surface and that the carbon coating includes an inner layer whose resistivity is comparatively low (conducting) to extinguish the influence of static electricity. This structure can be realized by inverting the polarity of the pair of electrodes, between which direct or high frequency electric energy is supplied, an object to be coated being mounted on one of the electrodes. When the electrode supporting the object is supplied with high frequency energy (that is to say, the electrode functions as the cathode), the hardness of carbon material becomes high. On the other hand, when the electrode supporting the object is grounded (i.e., the electrode functions as an anode), the hardness becomes low but the conductivity thereof becomes high. By letting the surface be a cathode, carbon material being deposited is eliminated due to bombardment of positive ions such as hydrogen ions, where the elimination rate of soft carbon material is higher than that of hard carbon material.
According to a preferred embodiment of the present invention, the energy band gap of carbon product for forming the external abrasion-proof surface of the coating is not lower than 1.0 eV, preferably 1.5 to 5.5 eV: the Vickers hardness is not lower than 500 Kg/mm 2 , preferably not lower than 2000 Kg/mm 2 , ideally not lower than 6500 Kg/mm 2 , at the external surface of carbon coatings: the resistivity ranges from 10 10 to 10 15 ohm centimeter: and the thermal conductivity of the product is not lower than 2.5 W/cm deg, preferably 4.0 to 6.0 W/cm deg. When used for thermal heads or contact image sensor which are frequently subjected to rubbing action, the smooth, hard and static erasing surface of the carbon coating is very suitable. The carbon coating includes an inner layer region having a low resistivity. The Vickers hardness and the resistivity of the inner layer region are not higher than 1000 Kg/mm 2 , preferably 500 to 700 Kg/mm 2 , and not higher than 10 12 ohm centimeter, preferably 1×10 2 to 1×10 6 ohm centimeter. The inner layer region has lower Vickers hardness and higher conductivity than the external surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view showing a prior art contact image sensor.
FIG. 2 is a schematic diagram showing a CVD apparatus for depositing carbon material in accordance with the present invention.
FIG. 3 is a graphical diagram showing the Vickers hardness and the resistivity of carbon films which have been deposited on an electrode functioning as a cathode.
FIG. 4 is a graphical diagram showing the Vickers hardness and the resistivity of carbon films which have been deposited on an electrode functioning as an anode.
FIG. 5 is a schematic diagram of a carbon coating in accordance with the present invention.
FIGS. 6 (A), 6 (B), 7 (A), 7 (B), 8 (A), and 8 (B) are graphical diagrams showing the variations of the hardness and the resistivity of carbon films through the depth thereof in accordance with the present invention.
FIG. 9 is a cross sectional view showing an image sensor given a carbon coating in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 2, there is shown a plasma CVD apparatus for depositing carbon material on a surface in accordance with the teaching of the present invention. The surface to be coated may, for example, be made of semiconductor, glass, metal, ceramics, organic resins, magnetic substance, and so forth.
The apparatus comprises a reaction chamber 18 defining a reaction space 30 therein, first and second electrodes 21 and 22 , a high frequency electric power source 23 for supplying electric power between the electrodes 21 and 22 through a matching transformer 24 , a DC bias source 15 connected in series between the electrodes 21 and 22 , a gas feeding system 11 consisting of four passages 12 to 15 each of which is provided with a flow meter 17 and a valve 16 , a microwave energy supply 11 , a nozzle 19 through which gas excited by the microwave energy supply 20 is introduced into the reaction space 30 , and an exhaust system 26 including a pressure control valve 27 , a turbomolecular pump 28 and a rotary pump 29 . The electrodes are designed such that (the area of the first electrode 21 )/(the area of the second electrode 22 )<1. A pair of switching means 31 and 32 is provided for inverting the polarities of the electrodes 21 and 22 . In a first position of the switching means, the electrode is grounded while the other electrode 21 is supplied with high frequency electric energy from the power source 23 . In the other second position, the electrode 21 is grounded while the electrode 22 is supplied with high frequency electric energy from the power source 23 . An object having the surface to be coated is mounted on the electrode 21 .
In operation of this apparatus, a carrier gas of hydrogen is introduced to the reaction space 30 from the gas feeding passage 12 as well as a reactive gas of a hydrocarbon such as methane or ethylene from the gas feeding passage 13 . The gas introduction rates of hydrogen and the hydrocarbon are 3:1 to 1:3, preferably 1:1. In addition to this, a V-Group dopant gas such as NH 3 or PH 3 , or a III-Group dopant gas may be inputted to the reaction space 30 through the gas feeding passage 14 or 15 in order to form impurity semiconductors. Pre-excitation may be effected by the microwave energy supply 10 . The pressure in the reaction space is maintained within the range between 0.001 to 10 Torr, preferably 0.01 to 0.5 Torr. High frequency electric energy at a frequency not lower than 1 GHz, e.g. 2.45 GHz, is applied to the reactive gas at 0.1 to 5 kilo Watt for breaking C—H bonds. When the frequency is selected to be 0.1 to 50 MHz, C═C bonds can be broken and transformed to —C—C— bonds. By virtue of this reaction, carbon atoms are deposited atoms in the form of a structure in which the diamond structure occurs at least locally.
A bias voltage of, for example, −200 to 600 V is set at the DC bias source 15 . The effective bias voltage level is substantially −400 to +400 V when a self bias level in this case of −200 V is spontaneously applied between the electrodes 21 and 22 with the bias voltage level of the source 15 being zero.
Generally, the high frequency input power is chosen between 10 Watt and 5 kilo Watt, preferably between 50 Watt and 1 kilo Watt. This input power corresponds to 0.03 to 3 Watt/cm 2 in terms of plasma energy. The substrate temperature is maintained in a range of +250 to −100° C. by means of a temperature control means (not shown). When diamond deposition is desired, the substrate temperature has to be elevated further.
FIG. 3 shows the resistivity and the Vickers hardness of films deposited on a surface, to which high frequency electric energy was applied through the electrode 21 at various power levels. As can be seen from the figure, a harder film was deposited by inputting higher power energy. FIG. 4 shows the resistivity and the Vickers hardness of films deposited on a surface which was grounded. Comparing FIG. 4 with FIG. 3, it will be apparent that the resistivity of carbon films formed at the anode side (on the grounded electrode) becomes lower than that in the cathode side (supplied with high frequency energy).
In accordance with the teaching of the present invention, a surface is coated with a carbon coating while the deposition condition is changed in order that the hardness of the carbon initially or intermediately deposited on the substrate is relatively low, but the deposition condition is changed such that hardness of the carbon finally deposited becomes very high in order to provide a hard external abrasion-proof surface. This procedure can be carried out in two ways. As seen from FIG. 6 (A), the hardness may be changed in steps by stepwise change of the deposition condition in accordance with the above description. Alternatively, as seen from FIG. 6 (B), the hardness may be changed continuously from the inner surface to the external surface of the carbon coating.
The hardness or resistivity of the carbon coating can be changed, rather than monotonically, in order that an intermediate region of the coating is conductive and sandwiched by hard carbon regions. FIG. 5 illustrates such a case including three carbon film regions. The lower and top films 41 and 43 are deposited to have a high degree of hardness while the intermediate film 42 is deposited to have low resistivity. This example can be realized in two ways as illustrated in FIG. 7 (stepwise change) and FIG. 8 (continuous change). The lower hard film 41 is semi-insulating so that it protects the surface to be coated electrically and mechanically. Further the lower hard film has a function as a blocking layer to prevent impurity from entering into the intermediate film 42 and also a function of improving adhesivity to the substrate and the electrical property. The intermediate region 42 has conductivity and functions as a Buffer layer to alleviate distortion generated by mechanical stress.
Experiment 1:
A carbon coating was deposited on a transparent polyimide film 35 as shown in FIG. 9 . An amorphous silicon photosensitive semiconductor device 34 was formed on a glass substrate 33 in a conventional manner as well as the polyimide film 35 . A first carbon film 36 of 0.6 micron meter thickness was formed on the polyimide film 35 under deposition conditions that the structure was placed on the electrode (cathode) supplied with high frequency energy of 260 W, the introduction rate of carbide gas such as methane, ethylene, or ethane diluted by hydrogen (e.g. methane:hydrogen=1:1) was 100 SCCM, the pressure of the reactive gas was 0.03 Torr, and the deposition time was 60 minutes. The hardness and the resistivity were measured to be 1000 Kg/mm 2 and 1×10 12 ohm centimeter. A second carbon film 37 of 0.5 micron meter thickness was formed on the first film 36 under deposition conditions that the electrode supporting the structure was grounded (as an anode), the input high frequency energy was 300 W, the introduction rate of carbide gas such as methane, ethylene, or ethane diluted by hydrogen (e.g. methane:hydrogen=1:1) was 100 SCCM, the pressure of the reactive gas was 0.03 Torr, and the deposition time was 40 minutes. The hardness and the resistivity were measured to be 600 Kg/mm 2 and 1×10 10 ohm centimeter. Finally, a third carbon film 38 was deposited in the same deposition conditions as the first film 36 . The first film may be dispensed with.
Experiment 2:
This was carried out in accordance with the diagram shown in FIGS. 8 (A) and 8 (B) rather than FIGS. 7 (A) and 7 (B). That is, the resistivity and the hardness were continuously decreased and increased along with the decrease and the increase of input energy. Carbon deposition was started under the deposition conditions that the structure was placed on the electrode (cathode) supplied with high frequency energy of 300 W, the introduction rate of carbide gas such as methane, ethylene, or ethane diluted by hydrogen (e.g. methane:hydrogen=1:1) was 100 SCCM, and the pressure of the reactive gas was 0.03 Torr. The input high frequency energy was gradually decreased from 300 W to 200 W at 0.5 to 2.5 W/min. The hardness and the resistivity were decreased, along with the decrease of the input energy, from 1000 Kg/mm 2 to 500 Kg/mm 2 and from 1×10 12 ohm centimeter to not lower than 1×10 8 ohm centimeter respectively. The total thickness of this carbon coating was 0.2 micron meter. After the positions of the switch 31 and 32 were reversed (i.e. the electrode 21 was grounded as an anode), carbon deposition was resumed while the input power was decreased from 300 W to 200 W and subsequently increased from 200 W to 300 W at 0.5 to 2.5 W/min. The hardness and the resistivity were changed along with the change of the input energy, that is, the hardness was decreased from 500 Kg/mm 2 to 300 Kg/mm 2 and subsequently increased from 300 Kg/mm 2 to Kg/mmg/mm 2 and the resistivity was decreased and then increased within the range between 1×10 12 ohm centimeter and 1×10 8 ohm centimeter. However, the resistivity of this intermediate layer should be lower than that of the underlying hard carbon coating as illustrated in FIGS. 8 (A) and 8 (B). The total thickness of this carbon coating was 0.4 to 1 micron meter. After the positions of the switch 31 and 32 were reversed again in the initial positions (i.e. the electrode 21 was supplied with high frequency energy as a cathode), carbon deposition was resumed while the input power was increased from 200 W to 300 W at 0.5 to 2.5 W/min. The hardness and the resistivity were increased, along with the input energy, from 500 Kg/mm 2 to 2000 Kg/mm 2 and from not lower than 1×10 8 ohm centimeter to 1×10 12 ohm centimeter. However, the resistivity of this upper carbon film should be higher than that of the intermediate layer. The total thickness of this carbon coating was 0.3 to 0.7 micron meter.
Experiment 3:
A first carbon film of 0.6 micron meter thickness was formed on the polyimide film under deposition conditions that the structure was placed on the electrode (cathode) supplied with high frequency energy of 260 W, the introduction rate of carbide gas such as methane, ethylene, or ethane diluted by hydrogen (e.g. methane:hydrogen=1:1) was 100 SCCM, the pressure of the reactive gas was 0.03 Torr, and the deposition time was 60 minutes. The hardness and the resistivity were measured to be 1000 Kg/mm 2 and 1×10 12 ohm centimeter. A second carbon film of 0.5 micron meter thickness was formed on the first film under deposition conditions that the electrode supporting the structure was grounded (as an anode), the input high frequency energy was 300 W, the introduction rate of carbide gas such as methane, ethylene, or ethane diluted by hydrogen was 100 SCCM, the pressure of the reactive gas was 0.03 Torr, and the deposition time was 40 minutes. The hardness and the resistivity were measured to be 600 Kg/mm 2 and 1×10 10 ohm centimeter. On the second film, a third external film was deposited at an input energy of 80 W for 50 min., at 150 W for 50 min. and at 300 W for 40 min. sequentially. Then the third film was formed, having its resistivities of 5×10 10 , 2×10 12 , and 1×10 14 ohm centimeter across its thickness of 1.7 micron meters.
Experiment 4:
A first carbon film of 0.6 micron meter thickness was formed on the polyimide film under deposition conditions that the structure was placed on the electrode (cathode) supplied with high frequency energy of 260 W, the introduction rate of carbide gas such as methane, ethylene, or ethane diluted by hydrogen (e.g. methane:hydrogen=1:1) was 100 SCCM, the pressure of the reactive gas was 0.03 Torr, and the deposition time was 60 minutes. The hardness and the resistivity were measured to be 1000 Kg/mm 2 and 1×10 12 ohm centimeter. After the positions of the switch 31 and 32 were reversed (i.e. the electrode 21 was grounded as an anode), a second carbon film was formed while the input power was decreased from 300 W to 200 W and subsequently increased from 200 W to 300 W at 0.5 to 2.5 W/min. The hardness and the resistivity were changed along with the change of the input energy, that is, the hardness was decreased from 500 Kg/mm 2 to 300 Kg/mm 2 and subsequently increased from 300 Kg/mm 2 to 500 Kg/mm 2 and the resistivity was decreased and then increased within the range between 1×10 12 ohm centimeter and 1×10 8 ohm centimeter. However, the resistivity of this second carbon film should be lower than that of the first carbon film. The total thickness of this carbon coating was 0.4 to 1 micron meter. On the second film, a third external film was deposited at an input energy of 80 W for 50 min., at 150 W for 50 min. and at 300 W for 40 min. sequentially. Then the third film was formed, having its resistivities of 5×10 10 , 2×10 12 , and 1×10 14 ohm centimeter across its thickness of 1.7 micron meters.
Experiment 5:
First and third carbon films were deposited in diamond structure. The deposition conditions required to deposited carbon crystals (diamond) were 700 to 900° C. (substrate temperature), 1.0 to 5 KW (input high frequency energy), 12 hours (deposition time) and CH 4 /H 2 =0.1 to 4 (reactive gas), 3 to 80 Torr (pressure). The thickness of the first and third films were 0.6 micron meter respectively. The Vickers hardness was measured to be 10,000 Kg/mm 2 . The resistivity was 1×10 15 ohm centimeter. After the first film deposition, a second carbon film (i.e. intermediate film) of 0.5 micron meter thickness was formed on the first film under deposition conditions that the electrode supporting the structure was grounded (as an anode), the input high frequency energy was 300 W, the introduction rate of methane diluted by hydrogen was 100 SCCM, the pressure of the reactive gas was 0.03 Torr, and the deposition time was 40 minutes. The hardness and the resistivity were measured to be 600 Kg/mm 2 and 1×10 10 ohm centimeter. Subsequently, the third film was formed under the above deposition conditions.
While a description has been made for several embodiments, the present invention should be limited only by the appended claims and should not be limited by the particular examples, and there may be caused to artisan some modifications and variation according to the invention. For example, it has been proved effective to add hydrogen, a halogen, boron, nitrogen, phosphorus or the like into the carbon coating. Preferably, the proportion of hydrogen or a halogen is not higher than 25 atomic % and the proportion of the other additives are not higher than 5%. Also, though the experiments were carried out for depositing carbon coatings on semiconductor substrates, the carbon coatings can be deposited on a substrate made of an organic resin such as PET (polyethylenetelephtalene), PES, PMMA, teflon, epoxy and polyimides, metallic meshes, papers, glass, metals, ceramics, parts for magnetic heads, magnetic discs, and others.
The types of carbon coatings deposited in accordance with the present invention includes amorphous, polycrystals (comprising diamond powders), and diamond films. In the case of a dual film, lower and upper films may be, respectively, amorphous and amorphous (having different hardnesses), amorphous and polycrystals, polycrystals and polycrystals, or polycrystals and a diamond film. | An abrasion-proof and static-erasing coating is formed on the contact surface of a contact image sensor. The coating comprises a first film having a high hardness and a low conductivity, a second film formed on the first film and having a low hardness and a high conductivity, and a third film having a high hardness and a high resistivity providing an abrasion-proof insulating external surface. | 8 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to a process for producing a cement clinker having a content of coal ash as a source of calcium in the feedstock introduced into the cement kiln; more especially the invention is concerned with such a process in which the coal ash is derived predominantly from lignite and sub-bituminous coal sources. The fly ash component of this type of coal ash is referred to as Class C.
2. Description of the Prior Art
In a cement plant, cement clinker is created at elevated temperatures in a cement kiln from cement clinker raw ingredients which travel through the kiln from a feed end to a discharge end, while passing through different processing zones at elevated temperature. These processing zones include a calcining and a clinkering or burning zone.
Cement clinker comprises various cement compounds formed from the raw ingredients, for example dicalcium silicate, tricalcium silicate, tricalcium aluminate and tetracalcium aluminoferrite. Formation of these cement compounds requires sources of calcium, silicon, aluminium hand iron in the raw ingredients fed to the cement kiln.
The cement clinker raw ingredients include a source of calcium carbonate, usually limestone, as a source of calcium for the cement compounds of the cement clinker. The calcium carbonate is thermally decomposed to lime and carbon dioxide in the calcining zone. The carbon dioxide emissions represent a pollution problem as they exit from the kiln, the significance of which has heightened with geopolitical concerns surrounding the Kyoto Accord.
Coal ash is derived from the burning of lignite, bituminous and sub-bituminous coal in power plants; the fly ash is recovered from the exhaust gases of the coal burning plants, and bottom ash is recovered from the bottom of the boiler as a granular coal ash.
Coal ash including class C fly ash has been blended or interground with cement clinker, because of its pozzolanic nature, to produce blended cements or has been used as a pozzolanic admixture in concrete, but has not previously been considered as a source of calcium in the production of cement clinker. Moreover fly ash is formed as very fine particles and is normally utilized in that form, with a minimum of processing. The fine particles can present a handling problem. Bottom ash which can also be used as a source of calcium does not have this problem because of its larger particle sizes.
Fly ash is produced in huge tonnages and while uses have been developed for fly ash, the enormous quantities produced still present a disposal problem.
SUMMARY OF THE INVENTION
It is an object of this invention to employ coal ash as a source of calcium in cement clinker production.
It is a particular object of this invention to employ a coal ash derived predominantly from lignite and sub-bituminous coal as a source of calcium in cement clinker manufacture.
It is a further object of his invention to provide such processes with reduced emissions of carbon dioxide per unit weight of cement clinker produced.
In accordance with the invention there is provided in a method of cement clinker manufacture in which a clinker feed material containing a source of calcium carbonate is fed into a feed end of a cement kiln, the feed material is heat processed in the kiln to produce cement clinker with emission of carbon dioxide from thermal decomposition of the source of calcium carbonate and discharge of the carbon dioxide from the kiln, and cement clinker is discharged from a discharge end of the kiln, the improvement wherein a coal ash derived from burning pulverized lignite or sub-bituminous coal is included in the feed material in said kiln to replace a portion of said source of calcium carbonate in the formation of said cement clinker, with a lowering of the emission of carbon dioxide in said kiln, per unit weight of cement clinker produced.
In another aspect of the invention there is provided a method of producing cement clinker with reduced emission of carbon dioxide from a change of cement clinker raw ingredients comprising:
i)providing a rotary cement kiln having a feed end and a discharge end;
ii) establishing predetermined levels of at least calcium, silicon and aluminium for a cement clinker, based on a raw ingredient feed material comprising a source of calcium carbonate, a source of silicon and a source of aluminium,
iii) providing a raw ingredient feed material formulation comprising said sources, in which a portion of said source of calcium carbonate is replaced by a coal ash derived from lignite or sub-bituminous coal while maintaining said predetermined level of calcium;
iv) feeding said formulation into said kiln,
v) exposing said formulation to elevated temperatures in said kiln, while feeding said ingredients from said feed end towards said discharge end, to calcine said source of calcium carbonate with formation of calcium oxide and liberation of carbon dioxide, and chemically combine and integrate said calcium oxide with said sources of silicon and aluminium, and said coal ash, as a cement clinker, and
vi) discharging said cement clinker from said discharge end, whereby carbon dioxide emissions are reduced in proportion to the replacement of said source of calcium carbonate by said coal ash.
BRIEF DESCRIPTION OF THE DRAWING
Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawing, in which:
FIG. 1 is a simplified schematic illustration of a kiln assembly including a kiln and a cooler.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
i) Coal Ash
The coal ash as employed in this invention refers to the residue produced in coal burning furnaces from burning pulverized anthracite or lignite, or bituminous or sub-bituminous coal. Such coal ash includes fly ash which is the finely divided coal ash carried from the furnace by exhaust or flue gases; and bottom ash which collects at the base of the furnace as agglomerates.
The coal ash employed in the invention is, more especially, one having a significant content of calcium, particularly a Class C fly ash; or bottom ash similarly having a significant calcium content such as results from burning lignite or sub-bituminous coals in coal burning boilers or furnaces.
The Class C fly ashes referred to above are defined by CSA Standard A23.5 and ASTM C618, both incorporated herein by reference.
The coal ash may typically contain 10 to 40%, more usually 10 to 35%, of calcium determined as calcium oxide. For the purposes of this invention, since the fly ash is being employed as a source of calcium, coal ash of high calcium content especially 20 to 40%, more especially 30 to 40% are preferred, but based on wide availability coal ash having a calcium content of 25 to 35% will more generally be employed.
Coal ashes also have significant contents of silicon, aluminium and iron which are all important elements in cement clinker formation. Typical contents determined as their oxides are silicon 30 to 40%, aluminium 15 to 25% and iron 3 to 8%.
All percentages herein are by weight unless otherwise indicated. It will be understood and readily recognized by persons in the art that calcium, silicon, aluminium and iron are not present as elements in the fly ash or even, necessarily as oxides of the elements, however the weight % of such elements is conveniently and traditionally expressed as oxides whether the elements are actually present as oxides or otherwise.
Typically a majority of the fly ash, at least about 80%, by weight, comprises particles of less than 45 microns.
Bottom ash typically is recovered from the base of the furnace as granules of which 70%, by weight, have a size in the range of 100 microns to 8 cm. It has similar chemistry to the fly ash being from the same coal source and occurs in lesser amounts than the fly ash, typically 10-20% of the coal ash produced.
ii) Process
The process is further described by reference to the embodiment in which the coal ash is a Class C fly ash.
The fly ash is suitably introduced to the feed inlet of the cement kiln so that all or a majority of the fly ash travels with the other cement clinker raw ingredients towards the discharge outlet of the kiln, and is not entrained by exhaust and combustion gases travelling within the cement kiln. In order to achieve this the fly ash may be premixed in its fine particle form, with the other raw ingredients, before being introduced into the kiln. The fly ash may also be fed independently to the cement kiln feed inlet, and in such case the fine fly ash particles may conveniently be agglomerated to larger particles, prior to introduction to the kiln. The fly ash may also be introduced independently into the kiln downstream of the feed inlet but upstream of the zone of the kiln in which clinker formation occurs. Thus the fly ash may be introduced to the kiln in the drying zone or the calcining zone.
In particular the fly ash is introduced to the kiln at a zone upstream of a zone in which heat processing to form cement clinker occurs, and more especially is a zone in which the calcium oxide chemically combines and integrates with the sources of silicon and aluminium to form cement clinker.
One property of Class C fly ash, not present in ashes from bituminous coals, F ashes, is their self cementing properties created by some of the compounds that also occur in cement.
Such agglomeration may be carried out in a conventional agglomerator for fine particle materials, but also to take advantage of the self hardening by adding water to layers of the fly ash and allowing the layers to solidify due to hydraulic behaviour to rock-like layers which may then be crushed to a convenient particle size for handling, for example in the size ranges for sand , gravel and cobbles.
To this end agglomerated fly ash particles in which at least 80% by weight, have a particle size of 0.1 mm to 6 inches, especially 5 mm to 70 mm are convenient for handling in the process of the invention.
Introducing the fly ash in a non-air entrainable state, for example in a water damp or moistened state, is another means of minimizing loss of the fly ash into the emission gases generated in the cement kiln. In this case the damp or moistened fly ash is subjected to drying as it travels with the clinker raw ingredients, and the fly ash is either entrapped in pockets between adjacent clinker ingredient particles or has chemically integrated or combined with the raw ingredient sufficiently downstream in the kiln that it is not entrained by the gases generated in the kiln.
Furthermore since the inclusion of the fly ash as a source of calcium lowers the requirement for calcium carbonate with a consequent lowering of the emissions, especially carbon dioxide, the likelihood of entrainment of fly ash particles by such gas emission reduction is also lowered.
Bottom ash being coarse, it can be introduced into the raw limestone circuit and through the primary grinding mills or as required, introduced at mid kiln through openings/scoops in the kiln shell
In particular the coal ash is introduced to the feed inlet or mid kiln if preferred of the kiln for the clinker raw ingredients, such that the coal ash is conveyed with the other clinker raw ingredients towards the discharge outlet, and the coal ash is exposed to a temperature and residence time effective for melting of the coal ash and chemical integration and combination with the other ingredients to form the cement clinker. Since the main elements of a coal ash are calcium, silicon, aluminium, iron and oxygen, the main components of cement clinker are all found in the coal ash but with the additional benefit that the coal ash is previously formed at high temperature and thus does not have thermal decomposition products.
Since the calcium carbonate addition to the kiln, as the prime source of calcium, can be lowered in proportion to the employment of coal ash as a source of the calcium, emissions of carbon dioxide in the kiln can be lowered proportionately.
The final proportions require analysis of the balance of each component, calcium, silicon, alumina and iron, all contributed by the coal ash, and all the other raw materials used by the cement plant to meet the intended class of cement clinker, Types 1,2,3,4,5 and special cements listed in ASTM.
Various delivery means may be employed for introducing the coal ash to the kiln or to the clinker raw ingredients for premixing, and the design and location of suitable delivery means in the upstream of the feed inlet of the kiln is well within the skill of persons in the art. For example, when fly ash is selected, a damp or moistened fly ash may be introduced by a reclaim screw auger, the fly ash could also be pneumatically delivered to the feed inlet and, for example might be pneumatically injected into the interior of the clinker raw ingredients for enhanced commingling with the clinker raw ingredients. Introduction into the interior of the raw ingredients also minimizes possible loss of the fly ash by entrainment in gases generated in the kiln.
Fly ash is commercially available and normally employed in a dry state, in which it is a fine powder. As such it is more difficult to successfully introduce fly ash into the kiln, and retain it with the clinker raw ingredients for combination and integration therewith in the kiln. One would have losses of the fine powder by entrainment in gases flowing in the kiln. Bottom ash would behave differently because of its coarser particles.
The coal ash is suitably introduced to the clinker raw ingredients or directly at the feed inlet of the kiln in an amount to provide 5 to 45%, typically 10 to 30%, by weight, of the calcium content of the cement clinker being produced.
iii) Chemical Processing
In a typical cement clinker production site the raw ingredients for clinker production are assessed prior to introduction into the kiln and proportioned to produce a cement clinker with contents of calcium, silicon, aluminium, iron and other metals in predetermined amounts or ranges, so as to provide a cement clinker for producing a cement of a certain desired class, such as one having early strength during setting, or high ultimate strength.
In accordance with preferred embodiments of the invention, the content of calcium carbonate as a source of calcium, in the clinker raw ingredients is lowered or reduced according to the calcium provided by the coal ash. In this way the balance of calcium desired in the cement clinker is maintained. The reduction in the amount of the source of calcium carbonate, for example limestone, results in a lowering or reduction in the amount of carbon dioxide generated in the kiln per unit weight of cement clinker produced.
The amount of other ingredients in the cement clinker raw ingredients may also be conveniently adjusted in accordance with the desired amounts or ranges for the other elements in the cement clinker, based on the content of these elements in the coal ash, and the amount of fly ash employed as replacement for the source of calcium carbonate.
Brief Description of the Drawing
Further features and advantages of the present invention will become apparent form the following detailed description, taken in combination with the appended drawing, in which:
FIG. 1 is a simplified schematic illustration of a kiln assembly including a kiln and a cooler.
Detailed Description of Preferred Embodiment of the Invention with Reference to the Drawing
With further reference to FIG. 1, a kiln assembly 10 includes a feed inlet 12 , a rotary kiln 14 and a cooler 16 .
The kiln 14 is mounted for rotation relative to feed inlet 12 and cooler 16 .
Rotary kiln 14 has a drying zone 20 for use in a wet process, a calcining zone 22 , a burning zone 24 and an initial cooling zone 26 .
Rotary kiln 14 extends between a feed port 18 and a clinker outlet 28 .
A burner assembly 30 mounted externally of kiln 14 has a burner nozzle 32 mounted in a firing hood 38 which nozzle 32 extends through outlet 28 into kiln 14 . A flame 36 is developed at nozzle 32 .
Cooler 16 has an entry port 42 which communicates with clinker outlet 28 of kiln 14 , and an exit port 44 . A cooler grate 40 is mounted in cooler 16 and air jets 46 disposed below cooler grate 40 feed jets of cooling air upwardly through cooler grate 40 and a bed 52 of clinker supported on cooler grate 40 .
Cooler 16 has an air discharge 48 .
Cooler grate 40 comprises a plurality of plates in side-by-side relationship. Some of the plates have openings therethrough to allow passage of the cooling air. Some plates are fixed and other are mounted to oscillate, back and forth. The movement of the oscillating plates agitates the clinker.
The cooler grate 40 is inclined downwardly from the entry port 42 to exit port 44 . The bed 52 of clinker is advanced towards exit port 44 by the oscillation of some of the plates, in conjunction with the inclination and the build-up of clinker introduced into cooler 16 from kiln 14 .
In operation raw cement clinker ingredients 50 which include a coal ash, in particulate form, are fed through inlet 12 and feed port 18 into kiln 14 , where they first enter drying zone 20 . The kiln 14 rotates slowly, and is inclined downwardly from port 18 to outlet 28 . With the rotation of kiln 14 , the ingredients advance slowly and sequentially through drying zone 20 , calcining zone 22 and burning zone 24 , into which a flame extends from burner nozzle 32 .As a variation, the coal ash may be fed through mid kiln access ports or scoops.
In drying zone 20 the temperature typically ranges from 300° C. to 800° C. In calcining zone 22 the temperature typically ranges from 825° C. to 1000° C. and in burning zone 24 the temperature is typically 1400° C. to 1425° C.
Clinker formation is completed in burning zone 24 .
Hot clinker produced in kiln 14 is discharged, through clinker outlet 28 and enters cooler 16 at entry port 42 where it falls onto the cooler grate 40 which advances the hot clinker towards exit port 44 . The hot clinker falling onto cooler grate 40 forms a bed 52 of clinker particles which typically has a thickness or depth of 6 to 24 inches.
Air is injected under pressure through air jets 46 located below cooler grate 40 , the air permeates through plates in the cooler grate 40 and the bed 52 , the clinker being progressively cooled by the air from jets 46 as it advances towards exit port 44 . The cooler 16 is typically operated under low pressure or partial vacuum and the air permeating upwardly through bed 52 flows either along the path indicated by the arrows A into kiln 14 or along the path indicated by the arrows B exiting from the downstream end of the cooler. The path of travel of the bed 52 is indicated by the arrow C.
EXAMPLE
i) Trials
Different formulations of clinker feed ingredients are summarized below in the Table, to demonstrate the variation of contribution of Ca, Al, Si and Fe to the resulting clinker, that can be achieved by replacement of different amounts of limestone (calcium carbonate) by different amounts of coal ash, in accordance with the invention.
SiO 2 %
Al 2 O 3 %
Fe 2 O 3 %
CaO %
% used
MIX 1
Limestone 1
12
2.8
1.5
43
46
Limestone 2
5
0.9
0.5
52
43
Ash
42
21
5.6
11
6
Iron
56
0.7
sand
73
4
mix chemistry
14
3.2
1.7
43
clinker
22
5
2.7
66
chemistry
C2S
14.5
C3S
63
C3A
8.8
C4AF
8.22
MIX 2
Limestone 1
12
2.8
1.5
43
45
Limestone 2
5
0.9
0.5
52
42
Ash
35
21
5.6
17
11
Iron
56
0.7
sand
73
4
mix chemistry
13.5
3.9
1.5
43.1
clinker
21
6
2.4
66.6
chemistry
C2S
12.2
C3S
63
C3A
12
C4AF
7.16
MIX 3
Limestone
6.7
0.4
0.7
51
81
Ash
46
17
8
19
18
sand
90
1
mix chemistry
14.7
3.5
2
44
clinker
22
5.2
3.1
66.2
chemistry
C2S
15
C3S
63
C3A
8.5
C4AF
9.3
Minor oxides are not accounted for in the in the final chemistries summarized in the Table. | A method of cement clinker manufacture comprises feeding a clinker feed material containing a source of calcium carbonate into a feed end of a cement kiln, the feed material is heat processed in the kiln to produce cement clinker with emission of carbon dioxide from thermal decomposition of said source of calcium carbonate and discharge of the carbon dioxide from the kiln, and cement clinker is discharged from a discharge end of the kiln; a coal ash derived from burning pulverized lignite or sub-bituminous coal is included in the feed material fed into the feed end to replace a portion of the source of calcium carbonate, and provides a source of calcium as well as other components notably silicon and aluminum, in the formation of the cement clinker, with a lowering of the emission of carbon dioxide in the kiln, per unit weight of cement clinker produced. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for re-executing a process on a computer system for fault correction wherein said process includes a number of activities which are executed by said computer system according to a workflow graph, wherein each of said activities requires for its execution at least one work item from another one of said activities, and wherein each of said activities creates at least one work item to be used by another one of said activities.
2. Description of the Related Art
In the technical area of data processing many application processes are described by workflow graphs. Such a directed workflow graph represents a network of activities which are linked e.g., by control flow connectors. The control flow connectors in the workflow graph are so directed as to sequence the execution of activities in consistency with the direction of the graph. Each individual activity uses work items as an input and delivers work items as an output. These work items have to be in a well defined state when an activity is started or ended. The activities as such in most cases need a user for their execution. Typical activities in the area of software development are e.g., the design of a software module or the coding of such a software module.
Such workflow graphs can be executed by so-called workflow manager programs, e.g., by the "IBM® FLOWMARK™" product "IBM is a registered trademark of International Business Machines Corporation and FLOWMARK is a trademark of International Business Machines Corporation."
During the execution of the above mentioned activities, e.g. during the design of a software module, sometimes the situation occurs that one of the work items delivered by the executed activity is found to be incorrect at some point in time later in the process. At this later point in time the faulty activity delivering the faulty work item has already been completed and process has been continued. Therefore, it is possible that the faulty activity causes a number of other activities to be incorrect due to a faulty input.
When the faultiness of an activity has been detected by the user its correction requires not only the correction of the faulty activity but also the correction of all other activities which were caused to be incorrect due to the faulty work item delivered by the faulty activity. As a consequence, the correction requires the re-execution of parts of the already executed workflow graph until all faulty activities and all faulty work items are repaired. Until now, such re-execution is done manually by the user.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a method for re-executing a workflow graph automatically.
The invention solves this object by a method as described above with the further steps of: a) identifying by a user one of said activities to be faulty and correcting it, b) evaluating by said computer system those ones of said activities which are influenced by said faulty activity with the help of said at least one work item created by said faulty activity, c) executing by said computer system said corrected faulty activity and said evaluated activities according to said workflow graph.
More detailed, the invention solves this object by a method as described above with the further steps of: a) on detection of a fault halting any further activity execution in the workflow graph and identifying by a user the first of said activities to be faulty, having delivered a faulty work item and correcting said faulty activity so that said faulty work item is delivered in a corrected form from said corrected activity, b) evaluating by said computer system those ones of said activities which are influenced by said faulty activity by the cause of said at least one work item created by said first faulty activity, c) executing by said computer system said evaluated activities, in the cases needed with the involvement of a user according to the sequences of said evaluated activities according to said direction of said workflow graph, d) resuming said halted execution of said workflow graph when all said evaluated activities have executed as said in step c).
The invention provides an advantageous method in which the computer system evaluates and controls the re-execution of the faulty activities automatically. The user does not have to evaluate which activities are faulty and which ones therefore have to be re-executed. In addition the user does not have to control such re-execution with regard to the sequence and/or the completeness. All this is done automatically by the computer system with the help of the work items. The computer system evaluates the work items which are delivered by the faulty activity. Then the computer system evaluates which other activities are influenced by these work items directly or indirectly. Finally, the computer system re-executes all those activities which have such influenced work items as an input. Again, the user does not have to need not select these work items or activities; work item's or activities are done by the computer system automatically, involving the user only in those cases where he is needed for executing said evaluated activities.
In an embodiment of the invention the evaluating step b) comprises the steps of: b1) evaluating by said computer system those ones of said activities which require for their execution said at least one work item created by said faulty activity, b2) evaluating by said computer system those ones of said work items which are created by said activities found in the preceding step, b3) evaluating by said computer system those ones of said activities which require for their execution said ones of said work items found in the preceding step, b4) repeating step b2) and step b3) until all activities are found which are influenced by said faulty activity.
More detailed, the evaluating step b) comprises the steps of b1) evaluating by said computer system those ones of said activities which succeed said first faulty activity and which require, for their execution said at least one faulty work item created by said first faulty activity, b2) evaluating by said computer system those ones of said work items which are created by said activities found in the preceding step, b3) evaluating by said computer system those ones of said activities which require for their execution said ones of said work items found in the preceding step, b4) repeating steps b2) and steps b3) until all activities are found which are influenced by said first faulty activity and had already been executed before said halting of execution of activities in the workflow graph.
This embodiment provides an advantageous method to evaluate all those activities which are influenced directly or indirectly by the work items of the faulty activity. The user need not evaluate these work items or activities; work item's or activities area evaluated by the computer system automatically, involving said user only in these cases where he is needed for executing said first faulty activity and said evaluated activities.
In another embodiment of the invention a version number is assigned to each one of said activities and the executing step c) further comprises the step of: assigning a new version number to said corrected faulty activity and said evaluated activities for distinguishing said corrected faulty activity and said evaluated activities from the respective corresponding activities executed formerly.
This embodiment provides an advantageous method to distinguish the faulty activities from the corrected activities. Such distinction is extendable to a number of successive versions when e.g., a "corrected" activity is found to be incorrect at a later point in time and therefore has to be re-executed a second time.
Furthermore, an advantageous computer system is provided for carrying out the above mentioned inventive methods. Such computer system comprises a memory, wherein said activities and said work items are stored in said memory, and wherein said work items are assigned to said activities, respectively. Additionally, said version numbers are stored in said memory, wherein said version numbers are assigned to said activities, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the invention will be evident from the following description of an embodiment of the invention which is represented in the drawings.
FIG. 1 provides a list of possible activities of a workflow graph;
FIG. 2 shows the relationship between activities and work items in a schematic representation;
FIG. 3 provides a list of possible work items;
FIG. 4 provides a list of possible incarnations of the work items;
FIGS. 5A and 5B shows the relationship between work items and incarnations in a schematic representation;
FIG. 6 shows a workflow graph with a number of activities; and
FIGS. 7(A,B) shows a table of activities with the accompanying work items and incarnations as it is stored in a memory of a computer system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The workflow graph shown in FIG. 6 includes a number of activities which are linked by control flow connectors. This workflow graph defines a process wherein the activities of the workflow graph are executed by a user. After the execution of any of the activities, the process is continued according to the respective control flow connector in the workflow graph.
The process which is represented by the workflow graph of FIG. 6 represents the development of a piece of software and includes the development of three different software modules in parallel. The entire process will be described in further detail after the following description of FIGS. 1 to 5b.
FIG. 1 shows a list of possible activities with respective activity types. An activity with an activity type NAME MODULES enables the user to create a number of different module names which may be assigned to succeeding activities. An activity with an activity type BUNDLE SPLIT enables the user to split one process path in a number of different process paths. All these split process paths are distinguished from another by the different module names. An activity with an activity type BUNDLE JOIN enables the user to join together a number of different process paths into one process path. An activity with an activity type DESIGN MODULE enables the user to create the design of a software module according to given requirements. An activity with an activity type CODE MODULE enables the user to program the designed software module, i.e., to create the source code for the designed software module. An activity with an activity type COMPILE MODULE enables the user to compile the programmed software module, i.e., to create the object code of the programmed source code. An activity with an activity type LINK MODULES enables the user to link together the different compiled software modules, i.e., to create the linked object code of the different software modules. An activity with an activity type CLOSE DEVELOPMENT enables the user to finish the development of a piece of software.
FIG. 2 shows the relationship between activities and work items. Any of the above mentioned activities is actually done by the user. To start any of these activities, at least one work item is required as an input. For example, the activity with the activity type CODE MODULE needs the design of the respective software module to be programmed as an input, or the activity with the activity type LINK MODULES needs the object code of a number of different software modules as an input. After the execution of any of these activities, at least one work item is created as an output. For example, the activity with the activity type DESIGN MODULE creates the design of the respective software module as an output, or the activity with the activity type COMPILE MODULE creates the object code of the respective software module as an output.
Any of the activities may only be started as soon as all required work items are available, i.e., as soon as all those activities are finished which create work items for the respective activity to be started. As well, any of the activities may only be finished as soon as all output work items relating to the respective activity are created.
FIG. 3 shows a list of possible work items. A work item with a work item type MODULE relates to the different modules of the entire piece of software, i.e., describes the function of a respective module of the piece of software. A work item with a work item type PROGRAM relates to the result of the software development, i.e., describes the programmed piece of software.
FIG. 4 shows a list of possible incarnations for work items with respective incarnation types and possible states of incarnations. A work item has its own name, but it is only represented by its set of incarnations. A work item may possess several incarnations at the same time, as defined by the incarnation types for a work item type. Each incarnation of a specific work item may be in one of several incarnation states. All incarnations of a work item, or more precisely all instances of incarnation types for one instance of a work item type have the same work item name. An incarnation of type FUNCTIONS of a work item of type PROGRAM with the assumed name "P" contains the requirements for the discrete functions to be implemented in a set of modules. Incarnations of type MOD -- DES, with assumed names "A" , "B" , and "C" contain the design for the named work items. An incarnation of type MOD -- CODE contains for each incarnation of type MOD -- DES the corresponding source code. An incarnation of type MOD -- OBJ contains the object code as obtained from compiling the source code of the corresponding incarnation of type MOD -- CODE. An incarnation of type LOAD -- PROG of a work item of type PROGRAM contains the result of linking all incarnations of type MOD -- OBJ for all work items of type MODULE. Any incarnation of a work item can be in any of a set of permitted states. An incarnation state NAMED represents that the work item and its first incarnation has been named. An incarnation state COMPL represents that an incarnation is completed. An incarnation type APPR represents that the incarnation is approved.
FIG. 5A shows the relationship between work items and their incarnations. An incarnation of type MOD -- CODE of a work item of the type MODULE is the input for a certain activity. As already mentioned, a work item is changed by the activity, by creating a new incarnation of type MOD -- OBJ for the same work item. The activity has used the incarnation MOD -- CODE of the work item to create the incarnation MOD -- OBJ for the work item.
FIG. 5B shows the relationship between incarnations of work items and the states of these incarnations. A work item incarnation with the state NAMED is input to a certain activity. The activity changes the state of that incarnation to COMPL, with the consequence that the work item continues to have an incarnation of type MOD -- DES, but due to the execution of the activity now with a state changed from NAMED to COMPL.
As already described, FIG. 6 shows a workflow graph with a number of activities which are linked by control flow connectors. Such a workflow graph has the object to organize the work of one or more people. For example, if a software module has to be developed by one or more engineers, the workflow graph organizes the process of development. The workflow graph does not create any code of the software module. Such code is developed within the several activities of the workflow graph by the engineers.
At the beginning of the development of a PROGRAM named "P", an activity NAME -- MODULES, using as input the incarnation of type FUNCTIONS of the work item "P" of type program, creates three work items of type MODULE, with the names "A", "B", and "C". These modules represent the development of three different pieces of software that are then linked together to become the incarnation LOAD -- PROG of the work item of type PROGRAM, named "P". For that purpose, an activity BUNDLE -- SPLIT creates three parallel threads of activities in the workflow graph for the development of each of the modules "A", "B", and "C". For each of these modules in the three parallel threads of the workflow graph, activities are provided for designing, coding and compiling the respective pieces of software. For the module "B", these activities are DESIGN -- MODULE/B, CODE -- MODULE/B, and COMPILE -- MODULE/B. Then the incarnations of type MOD -- OBJ of these modules "A", "B", and "C" are taken together again with the help of the activity BUNDLE -- JOIN that combines the three parallel threads into one successor thread, where the three pieces of software are linked by an activity LINK -- MODULES/P and at the end the development of the program "P" is closed by the activity CLOSE -- DEVELOPMENT/P.
FIG. 7 shows a table of activities with the accompanying work items and incarnations as it is stored in a memory of a computer system.
A comparison shows that all activities of FIG. 6 are also listed in FIG. 7. Additionally, FIG. 7 includes further information concerning the work item incarnations which are input to each activity and which are output from each activity. A work item incarnation which is input to an activity is indicated with an "I" and a work item incarnation being output is indicated with an "O".
As an example, the activity "CODE -- MODULE/B" has as an input the incarnation "MOD--DES" with the state "COMPL" of the work item named "B" of type MODULE, and as output the incarnation "MOD -- CODE" with the state "COMPL" of the same module.
In another example, the activity "LINK -- MODULES" has three input incarnations of type "MOD -- OBJ" from the three work items of type "MODULE" named "A", "B", and "C", and one output incarnation of type "LOAD -- PROG" of a work item of type "PROGRAM" named "P".
In a first column indicated with a "V" for "version number", every activity is provided with such a version number. In particular in the three parallel control paths, the version numbers are created in a kind of hierarchical manner to show the dependency of each activity from the respective previous activity.
A second column indicated with "F" for "faulty" and "X" for "error found by user" provides the following information. Let's assume that the output of the activity "CODE MODULE/B" is faulty. This means that the design of the software module "B" which was made by e.g., an engineer is not correct. Usually, it is not possible to find such an error at once. Instead, such errors are found later e.g., after the linkage of the whole software package. In any case, the error has to be found by a person and this person has then to indicate this error in the table of FIG. 7. This is shown by the "X" in FIG. 7 which indicates the relevant output work item incarnation which was found to be faulty, i.e., the work item incarnation "MODULE/B/INC:MOD -- DES".
The "X" in the second column has the consequence that the computer system automatically searches for all activities which have the faulty work item incarnation, or any faulty incarnations derived from the first faulty incarnation as an input. In FIG. 7, this is the activity "CODE -- MODULE/B", which has the faulty work item incarnation "MODULE/B/INC:MOD -- DES" as input and creates the faulty work item incarnation "MODULE/B/INC:MOD -- CODE" as output. The computer system indicates these input work item incarnations as well as output work item incarnations of the relevant activities with an "F" for being faulty.
Then the computer system repeats the similar procedure for all output work item incarnations which have now been indicated with an "F". This means that the computer system automatically searches for all activities which have faulty work item incarnations as an input. Again, the computer system indicates these input work item incarnations as well as all output work item incarnations of the relevant activities with an "F" for being faulty.
This procedure is repeated by the computer system until all activities are found which are influenced directly or indirectly by the activity which was found to be faulty by a person and which was indicated with a "X". At the end, all these influenced faulty activities are indicated with a "F".
In a next step, the computer system automatically re-executes all faulty activities. This is done by providing a "R" for "re-execution" in a third column of FIG. 7. The "R" has the consequence that all these activities have to be re-executed. In FIG. 7, the activities "DESIGN MODULE/B", "CODE MODULE/B", "COMPILE MODULE/B", "BUNDLE JOIN", "LINK MODULES/P" and "CLOSE DEVELOPMENT/P" have to be re-executed. The re-execution itself is done in the same way as the previous execution of the activities, i.e., an engineer develops the design of the module "B" under the activity "DESIGN MODULE/B", then an engineer develops the code for the designed software module under the activity "CODE MODULE/B", and so on. For this re-execution, the computer system is only the organizer so that all developments are made according the workflow graph of FIG. 6. However, the computer system is not the one who creates the design of the module or its code.
After the re-execution of the relevant activities, the computer system automatically provides an new version number to these re-executed activities. This is shown in another column in FIG. 7 which is indicated again with "V" for "version number". The new version numbers are different from the previous version numbers so that the computer system is able to distinguish the faulty activities from the re-executed activities.
It is possible that, after the re-executions, a person finds another faulty activity. This might be a re-executed activity or one of the other non-re-executed activities. If so, the computer system runs the same procedure as described by always using the latest, i.e., youngest version. All faulty activities are indicated with a "F" and a "R" again and are re-executed. Of course, it is possible that a re-executed activity is re-executed another time. Then, the computer system provides a new version number for the re-executed activities for distinguishing purposes. This process may be repeated as often as it is necessary whereby the table according to FIG. 7 in the memory of the computer system always provides the actual state of the software development as well as its history. | A method for re-executing a process on a computer system is described wherein said process includes a number of activities which are executed by said computer system according to a workflow graph. Each of said activities requires for its execution at least one work item incarnation from another one of said activities, and each of said activities creates at least one work item incarnation to be used by another one of said activities. The method comprises the steps of a) identifying by a user one of said activities to be faulty and correcting it, b) evaluating by said computer system those ones of said activities which are influenced by said faulty activity with the help of said at least one work item incarnation created by said faulty activity, and c) executing by said computer system said corrected faulty activity and said evaluated activities according to said workflow graph. The described method has the advantage that all activities being incorrect due to the faulty activity are re-executed automatically by the computer system. | 6 |
This is a division of application Ser. No. 417,140, filed Nov. 19, 1973 and now U.S. Pat. No. 3,884,436.
FIELD OF THE INVENTION
The invention relates to a cold gas pressure system incorporated into a conventional ejection seat system for freeing an aircraft pilot from his survival kit and parachute canopy hindering his escape from an aircraft in a ground emergency. Particular novel features of the invented system include cold gas driven releasable latches and tension release gas line connectors. Other features of the invented system relate to a fail-safe actuator which separates the gas source from the remaining release system when the pilot utilizes the ejection seat to escape from his aircraft.
DESCRIPTION OF THE PRIOR ART
Sophisticated aircraft are equipped with ejection seat systems which enable a pilot to escape from the aircraft. In a typical ejection seat system, a parachute canopy package is secured to the seat behind the pilot. A survival kit is usually disposed in the seat of the system upon which the pilot sits. The pilot enteres the cockpit of his aircraft wearing a parachute harness which he connects to the riser straps of the packed parachute and to straps of the survival kit. The pilot then secures himself in the seat with a shoulder harness, a lap belt and leg or garter straps.
Upon a ground emergency it is essential that the pilot be able to escape from the aircraft as quickly as possible. Accordingly, typical ejection seat systems are equipped with emergency ground egress release mechanisms which free the pilot from the shoulder harness, lap belt and leg restraint straps upon pulling a single lever. However, the pilot must execute separate maneuvers to separate himself from the parachute canopy and from the survival kit. Such separate maneuvers are deliberately required so as to prevent the pilot from inadvertently releasing himself from the parachute and survival kit when he ejects from the aircraft.
However, in an emergency situation on the ground with existing ejection seat systems, the pilot, after freeing himself from the ejection seat, must either attempt egress from the aircraft with his parachute and survival kit or free himself from the parachute and survival kit and then attempt egress from the aircraft.
Various release systems exist which expedite a pilot's egress from aircraft on the ground. For example, a gas-actuated release system is described in U.S. Pat. No. 3,658,281 issued to Mr. John A. Gaylord in which a pilot releases himself from his parachute harness by puncturing a high-pressure gas canister mounted on the harness which then simultaneously disconnects all the strap connectors holding the harness together. The gas canister is punctured by a single manual maneuver. Another approach is examplified by the single point parachute harness release mechanism described in U.S. Pat. No. 3,692,262 also issued to Mr. John. A. Gaylord wherein all the straps of the harness are secured by a single releasable locking mechanism located at the pilot's waist.
Summarizing, existing strap release systems in ejection seats require a pilot to manually operate a minimum of two or three release mechanisms to free himself from the seat and encumbrances hindering his egress from the aircraft on the ground. In emergency ground situations where the pilot is dazed, injured or simply confused and forgetful, the time delay required for executing two or more manual maneuvers in order to escape from the aircraft can prove fatal.
In addition, if a pilot utilizes a typical ejection seat system to escape from his aircraft, he must be automatically separated from that system together with his parachute and survival kit after a short delay. Accordingly, the number of mechanical connections between the ejection seat system and the pilot, parachute or survival kit are kept to an absolute minimum because of the possibility of failure of one of the connections to release, thus tying the massive ejection seat system to the pilot after ejection. In such instances, the pilot would fall to his death inasmuch as his parachute could not support both him and the ejection seat safely.
SUMMARY OF THE INVENTION
A gas-actuated release system is incorporated into a conventional ejection seat system of an aircraft for releasing a pilot from straps connecting him to his parachute and survival kit. The release system is energized by the pilot manually operating an existing emergency ground egress release mechanism which also frees him from other devices restraining him in the ejection seat. Thus, by a single manual maneuver, a pilot can free himself from all straps and encumbrances which would hinder or slow his escape from the aircraft in case of a ground emergency.
The described gas-actuated release system includes a positive interlock mechanism which frees and ejects the gas source from the system when the pilot energizes the ejection seat mechanism for escape from the aircraft. Thus, the pilot is positively prevented from inadvertently freeing himself from his parachute and survival gear when he utilizes the ejection seat to escape from the aircraft.
Latching devices of the invented release system secure the parachute and the survival package to the parachute harness worn by the pilot and disengage responsive to gas pressure. Gas pressure is supplied by a cartridge mounted in a piercing mechanism on the body of the ejection seat. The latching devices are connected to the ejection seat by flexible high pressure conduits equipped with tension release connectors.
In particular, the tension release connectors of the invented gas-actuated release system are designed to pull apart absent gas pressurization. Thus, the described connectors enable the ejection seat to fall free of, or separate from, the pilot, together with his parachute and survival kit after ejection from the aircraft. The connectors also include means for positive locking action upon gas pressurization thus preventing inadvertant depressurization of the gas release system when it is activated.
DESCRIPTION OF THE FIGURES
FIG. 1 is a partially cutaway prespective view of a Martin-Baker* ejection seat system, showing the location of the gas-actuated latches, the flexible gas lines and the tension release gas line connectors.
FIGS. 2 and 2ashow a rear view of the ejection seat showing the location of the gas lines and the piercing-decoupling interlock device of the gas-actuated release system.
FIG. 3 is a perspective view of the connection between the decoupling interlock system and the ejection release system of the ejection seat.
FIGS. 4a through f show the details of the canister piercing-decoupling interlock mechanism of the gas-actuated release system.
FIGS. 5a through c show the details of the gas-energized releasable latch for securing the survival kit to the parachute harness of the pilot.
FIGS. 6a through f show the details of the gas-energized releasable latching mechanisms between the parachute pack and the parachute harness.
FIGS. 7a, b, c & d show the details of the tension release gas line connectors.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the conventional ejection seat system 11 is shown. A parachute pack 12 is mounted on the back of the ejection seat 11 above the back cushion 13 behind the head of the pilot if he were sitting in the seat II. A survival pack 14 is disposed in the seat of the system II. Gas-energized releasable latches 16 are secured to riser straps 17 to the parachute pack 12. Gas-energized releasable latches 18 mounted on the survival package 14 secure straps 19 which are adapted to be connected to a parachute harness worn by a pilot. Flexible gas lines 21 connect between the latches 16 and 18 and a gas source mounted on the back of the seat system 11. Tension release gas line connectors 22 are incorporated into the flexible gas lines 21.
To eject from the aircraft, the pilot pulls either the face curtain ejection balls 23 above his head or the seat ejection bail 24 located in the center of the seat between his legs. To release himself from all straps connecting him to the ejection seat system 11, the parachute pack 12 and the survival pack 14, the pilot pulls the emergency ground egress release handle 26 upwards. As shown in FIG. 1, the strap release lever 26 is located on the right arm of the ejection seat system II proximate the pilot's right hand if he were sitting in the system.
DETAILED DESCRIPTION OF THE CANISTER PIERCING-DECOUPLING DEVICE
Referring now to FIGS. 2 and 2a showing the rear perspective view of the ejection seat II and the canister piercing-decoupling interlock device 27, the piercing mechanism 28 of the device 27 is operated by a mechanical linkage (not shown) operatively connected to the release lever 26 by conventional mechanical means including a rocking shaft 29. In particular, pulling the release lever up causes the lever 31 on the side structure of the ejection seat system II to rotate clockwise pushing a bar 32 into the piercing mechanism 28 of the interlock device 27 to pierce the membrane of the canister 33 containing a high pressure gas. The details of the piercing mechanism are described below.
After the canister 33 is pierced, high pressure gas flows into rigid gas lines 30 mounted on the structure of the ejection seat system to the flexible gas lines 21. As shown in FIG. 2, the flexible gas lines 21 are disconnected from the lines going to the releasable latches at the tension release gas line connectors 22.
The interlock mechanism of the device 27 comprises a retainer clip 34 which is adapted to be pulled free of the device 27 whereupon a spring ejects the gas canister 33 from the device 27 (described below in greater detail). A cable 36 is connected between the retainer clip 34 and a pulley 37 rigidly mounted on a shaft 38.
In more detail, referring to FIG. 3, the cable 36 is secured by conventional means to the pulley 37 which is rigidly mounted on the shaft 38. The shaft 38 rotates counterclockwise when the pilot pulls either the face curtain ejection bail 23 or the seat ejection bail 24. Accordingly, when the face curtain or seat ejection bails, 23 and 24 respectively, are pulled, the cable 36 pulls the retainer clip 34 out of the interlock mechanism of the device 27 and the gas canister 33 is ejected therefrom. Thus it is impossible for the pilot to inadvertently energize the gas-actuated release system when he ejects from his aircraft in the air. However, if the ejection seat system II fails to operate after the pilot has pulled the ejection balls 23 and 24, the pilot can still pull the emergency ground egress release handle 26 to free himself from straps confining him to the ejection seat system II without freeing himself from his parachute and survival kit, thus leaving him free to attempt to escape from his aircraft by other maneuvers.
Referring now to FIGS. 4a, b & c, the canister piercing-decoupling interlock device 27 comprises a housing having a rectangular slot 41 for receiving the bar 32 and a hollow cylindrical housing 42 perpendicularly disposed with respect to the slot 41 for receiving a gas canister pack. A canister piercing plunger 44 is received in a cylindrical port 46 communicating between the slot 41 and the cylindrical housing 42. The cylindrical port 46 is coaxially aligned with the cylindrical housing 42. The canister piercing plunger includes an annular slot for receiving an O-ring for making a hermetic seal between the plunger 44 and the walls of the cylindrical port 46. The O-ring 47 also serves to hold the plunger 44 in a non-piercing position (see FIG. 4b).
Referring to FIGS. 4b and c, the head of the plunger 44 is rounded and projects outward from the cylindrical port 46 into the slot 41. The bar 32 has a recess 48 for receiving the rounded head of the plunger 44 (see FIG. 4c). The shoulder 49 of the recess is perpendicular with respect to the axis of the bar 32 to prevent the bar from sliding longitudinally into slot 41 in a direction indicated by the arrow 70. The other shoulder 51 of of the recess 48 is inclined with respect to the axis of the bar 32 such that when the bar is pushed in a direction indicated by the arrow 52 by the mechanical linkage 29 (see FIG. 2), the plunger 44 is driven into the cylindrical port 46 and pierces the gas canister 33. The end of the bar 32 is also cutaway beyond the inclined shoulder 51 which allows gas pressure to force the plunger 44 back out into the slot 41.
Referring now to FIG. 4a, the gas canister pack 43 includes a cylindrical cup 53 with a port 54 drilled coaxially through its bottom. The port 54 is threaded for receiving a conventional high pressure gas canister 33. A conventional seal 56 is disposed between a shoulder within the port and the neck of the canister 33. The cylindrical cup 53 includes an annular slot 57 around its outside surface proximate to the closed end for receiving an O-ring seal 58 and an annular shoulder 59 at its open end of a slightly greater diameter than its outer diameter.
The gas canister pack is adapted to be inserted into the hollow housing 52. The O-ring seal 58 makes a hermetic seal between the inner walls of the housing 42 and the outer walls of the cup 53. The inner wall of the hollow cylindrical housing 42 is relieved proximate its open end to a diameter slightly greater than that of the annular shoulder 57 to provide an annular shoulder 61 within the hollow housing 42. A spring 60 is compressed between the annular shoulder 50 at the open end of the cup 53 and the annular shoulder 61 within the housing 42.
Referring to FIGS. 4d and 4e, two slots 62 are cut through the wall of the open end for receiving the prongs 63 of the retainer clip 34 (see FIG. 4c). The ends of the prongs 63 of the retainer clip 34 are adapted to clip onto a ring 65 mounted around the gas canister 33 with a slight compressive force such that the clip will not vibrate out of the slot 62. As shown in FIG. 4d, the annular shoulder 59 of the gas canister pack 43 engages the inner edge of the prongs 63 and the outer edge of the prongs 63 engage the wall of the cylindrical housing 42. Thus, the retainer clip 34 secures the gas canister pack 43 within the hollow cylindrical housing 42 of the canister piercing-decoupling interlock device 27.
The piercing mechanism of the device 27 operates in the following fasion: the pilot pulls the strap release lever 26 causing the mechanical linkage 29 to drive the bar 32 in a direction indicated by the arrow 52. The inclined shoulder 51 of the bar drives the canister piercing plunger 44 into the cylindrical port 46 piercing the diaphram on the gas canister bottle 33. The gas pressure in the canister drives the piercing plunger back out into the slot 41 and gas floods the remainder of the release system via the port 50.
The interlock mechanism of the device 27 operates in the following fashion: the pilot pulls the bail, 23 or 24, for ejecting from the aircraft, rotating the shaft 38 to pull the retainer clip 34 out of the device 27, whereupon the spring 60 compressed between the annular shoulder 59 of the gas canister pack and the annular shoulder 61 of the housing 42 ejects the gas canister pack out the open end of the housing 42. With the high pressure gas canister removed from the device 27, there is no possibility of pressurizing the remainder of the gas-actuated release system.
DESCRIPTION OF THE GAS-ENERGIZED RELEASABLE LATCH SECURING THE SURVIVAL KIT
Referring now to FIGS. 5a, b & c, the gas-energized releasable latch securing the survival pack 14 to the parachute harness worn by a pilot comprises a female member 66 attached to the survival package 14 and a male member 67 adapted to be secured to a strap connected to the parachute harness. In more detail, in the exploded view shown in FIG. 5a, the female member 66 comprises a solid housing 68 having a cylindrical horizontal passage way 69. One end of the passageway is threaded for receiving a conventional gas line connector 71. The other end of the passageway has an annular slot for receiving a conventional circular retaining clip 72. A locking plunger 73 disposed in the horizontal passageway 69 includes a solid cylindrical locking section 74 connected to a piston section 76 by a bar 77. A spring 78 is compressed between the circular retaining clip 72 and the cylindrical locking section 74 of the locking plunger 73 such that the piston section 76 of the plunger 73 is pushed against the gas line connector 71 (see FIG. 5b). The housing 68 includes a rectangular passageway 79 perpendicularly intersecting the cylindrical passageway 69. The rectangular passageway is adapted to receive the male member of the latch.
In particular, the male member of the latch 67 comprises a conventional rectangular bail 81 for securing a webbing strap having a rectangular latching member 82 extending perpendicularly outward therefrom. The latching member 82 has a cylindrical recess 83 proximate its extending end which has the same radial dimension as the cylindrical passageway 69 of the female member 66 such that when the latching member 82 is inserted into the rectangular passageway 79 of the female member 66, the horizontal cylindrical passageway 69 is unimpeded.
As shown in FIGS. 5b & 5c, when the described latching mechanism is locked, the latch member 82 of the male member 67 is inserted into the rectangular passageway 79 of the female member 66. The locking plunger 73 is inserted into the cylindrical passageway 69 such that its locking section is disposed at the intersection of the latching member 82 and the passageway 69, thus locking the male and female members together. The piston section 76 of the locking plunger 73 includes an annular slot 80 for receiving an O-ring 75. The O-ring makes a hermetic seal between the cylindrical walls of the passageway 69 and the piston section 76.
When the latch is energized with gas, the pressure drive the locking plunger 73 against the spring 78 moving the locking section 74 of the plunger 73 out of engagement with the latching member 82 of the male member 67. The small diameter bar 77 between the locking section and piston section of the plunger 73 is designed such that it will not engage the latching member 82. Thus, the male member will pull free of the female member.
DETAILED DESCRIPTION OF THE GAS-ENERGIZED RELEASABLE LATCH SECURING THE PARACHUTE PACK
Referring now to FIGS. 6a through f, the latch 16 securing the riser strap 17 to the parachute pack 12 to the pilot's parachute pack comprises a solid rectangular member 84 having a cylindrical passageway 86 along its central longitudinal axis. The rectangular member 84 includes 2 integral extending flanges 85 having coaxial cylindrical holes therethrough. A webbing pin 89 is received by the cylindrical holes 88 for securing the riser strap 17.
One end of the cylindrical passageway 86 is adapted to receive a conventional gas line connector elbow 91. The other end of the passageway 86 has an annular slot 92 for receiving a conventional circular retaining clip 93. A locking plunger 94 is disposed in the passageway 86. The plunger 94 includes a cylindrical locking section 96 fitting within the passageway 86 connected to a piston section 97 by a small diameter bar 98. The piston section 97 of the plunger 94 has an annular slot 99 for receiving an O-ring 101 seal for making a hermetic seal between the piston and the walls of the passageway 86. A spring 102 is disposed between the retaining clip 93 and the end of the locking section 96 of the plunger 94.
The rectangular bar 84 of the latch also has a rectangular passageway 103 which perpendicularly intersects the cylindrical passageway 86. The rectangular passageway 103 is adapted to receive a rectangular latching section 104.
In more detail, the latching section 104 comprises the male prong 106 of a conventional parachute release device having a rectangular shank 107 extending from their base. The rectangular shank 107 has a cylindrical recess 108 perpendicular to its axis.
When the described latch is locked, the rectangular shank 107 of the latching section 104 is inserted into the rectangular passageway 103 through the rectangular structural member 84 such that the recess 108 coincides with the passageway 86. The locking plunger 94 is inserted into the passageway 86 such that the cylindrical locking section 96 of the plunger 94 engages the recess 108 of the latching section 104 thus preventing the latching section from being pulled free of the rectangular bar 84. The spring 102 holds the locking plunger 94 in the locking position as described above.
When the described latch is energized with pressurized gas, the locking plunger 94 is driven against the spring 102 bringing the locking section 96 up to the plunger out of engagement with the recess 108 at the end of the shank 107 of the latching section 104, thus allowing the latching section to be pulled free of the rectangular bar 84.
DESCRIPTION OF TENSION RELEASE GAS LINE CONNECTORS
Referring now to FIGS. 7a, b & c, the tension release gas line connector 109 comprises 3 coaxial cylindrical elements fitted together. The elements starting from the outside are: a cylindrical sleeve III, a receiving cylinder 112 and a probe element 113. The sleeve cylinder III has an inwardly extending annular shoulder 114 at one end and an annular slot 116 cut into the inside wall of the sleeve III proximate the annular slot 116. The cylindrical receiving element 112 is coaxially fitted within the sleeve III, and is connected by a tubular element 119 to the flexible hose from the releasable latches securing the survival kit and parachute. The configuration of the inside wall of the cylindrical receiving element is described with respect to FIG. 7a from left to right. First, there is an annular pocket 120 of relatively long longitudinal width, then an annular slot 21 for receiving an O-ring seal 122, and an annular groove 123.
The probe element 113 is inserted coaxially into the cylindrical receiving element 112. The O-ring 122 makes a hermetic seal between the inside wall of the receiving element 112 and the outside surface of the probe element 113. One end of the probe element 113 is adapted to be connected to a flexible gas line from the ejection seat system II. The free end of the probe element 113 has a plurality of holes 124 which communicate from the inside volume of the probe element to the annular pocket 120 when inserted into the receiving cylinder 112. Two annular slots 126 are cut into the inside wall of the probe element 113 on either side of the holes 124 for receiving O-ring seals 127. The probe element 113 has a second row of holes 128 which come into registry with the annular recess 123 of the cylindrical receiving element 112 when the probe is inserted into the coupling. Steel locking balls 129 are disposed in the holes 128. The probe further includes an annular groove 131 around the outside surface of the probe between the holes 128 and the connected end of the probe 113.
As shown in FIG. 7a, a retaining sleeve 132 having an annular shoulder 133 with an outer diameter equal to the outer diameter of the cylindrical receiving element 112 and an inner diameter slightly greater than the outer diameter of the probe element 112 abutts against the end of the cylindrical receiving element 112 and is held in that abutting relationship by a spring 134 compressed between the circular retaining clip 117 and the extending annular shoulder 113 of the sleeve. A row of holes 136 are cut perpendicularly through the shoulder 133 of the retaining sleeve 132 for receiving steel release balls 137. The diameter of the release balls 137 is greater than the thickness of the cylindrical receiving element 112. Accordingly, when the probe element 113 is inserted into the cylindrical receiving unit 112 the release balls are received in the annular recess 131 around the outside surface of the probe.
A locking plunger 138 having a small diameter section 139 and a large diameter section 141 is disposed within the probe element 113 such that the locking balls 129 disposed in the holes 128 rest on the small diameter section 139 of the plunger. An annular pocket 142 is cut around the outside surface of the plunger 138. A central passageway 143 is drilled along the longitudinal axis of the plunger and a port 144 is drilled from the annular pocket 142 to the passageway such that a gas can flow through the plunger into the pocket. The plunger 138 also has an annular slot 146 cut into its outside surface for receiving an O-ring seal 147. The O-ring makes a hermetic seal between the plunger and the inner surface of the probe element 113. The upstream end of the locking plunger comprises a plurality of extending fingers 148 having a raised section 149 at their ends. The raised sections 149 at the ends of the fingers 148 are received in an annular groove 151 cut into the inside wall of the probe element 113. The annular grooves 151 have an abrupt shoulder on the upstream side and an inclined shoulder on the downstream side of the groove. The inner wall of the probe element also includes a second annular groove 152 downstream from the groove 151.
The end of the tubular element 119 connected to the cylindrical receiving element 112 includes a solid stop 153 having a cylindrical recess for receiving the small diameter section 139 of the locking plunger 138. A plurality of ports 155 are cut through the wall of the tubular element so that gas can communicate from the annular pocket 120 into the passageway of the tubular element 119.
The described tension release gas line connector has 3 functional modes: (1) the unlatched or disconnect mode shown in FIG. 7b; (2) the tension release or breakaway mode shown in FIG. 7c; and, (3) gas communicating mode shown in FIG. 7d. The functional modes of the described connector are described in the above order.
To unlatch or disconnect the tension release gas line connector 109, the annular sleeve is moved in the direction of the arrow 110 compressing the spring 133 until the annular recess 115 comes into registry with the release balls 137 contained in the holes 136 between the abutting ends of the cylindrical receiving element 112 and the retaining sleeve 132, whereupon the probe element is pulled in the direction of the arrow 135, causing the release balls to push into the recess 118. It should be noted that in the unlatching or disconnect mode, that the cylindrical receiving element 112 and the retaining sleeve remain stationery with respect to each other. To recouple the connector the procedure is simply repeated bringing the annular recess 115 into registry with the release balls 137 and then inserting the probe element 113.
The tension release or breakaway functional mode of the described connector can be described as follows: the sleeve III and the cylindrical receiving element move together in the direction of the arrow 110. Simultaneously, the probe element moves in the direction of the arrow 135. The release balls 137 restrained by the inside surface wall of the sleeve III and the annular recess 131 on the outside surface of the probe 113 move with the retaining sleeve 132 until the balls 137 come into registry with the annular recess 115 and the sleeve whereupon the balls move outward and the probe pulls free of the connector.
In the gas communicating functional mode (FIG. 7d) of the connector, gas pressure drives the locking plunger 138 downstream in the direction of the arrow 110 such that the large diameter section of the plunger 141 drives the locking balls 129, disposed in the holes 128, upward into the annular recess 123 on the inside wall of the cylindrical receiving element 112, thus locking the probe and receiving element together. The stop 153 at the end of the tubular element 118 stops the plunger 134 such that its annular pocket 142 is between the two O-ring seals 127. Gas flows through the connector via the central passageway 143 through the plunger 138 out the port 144 into the annular pocket 120 through the ports 155 into the central passage of the tubular element connected to the flexible tubing going to the releasable latches. The annular groove 151 prevents the locking plunger 138 from sliding upstream in the connector prior to pressurization. Upon pressurization, the raised sections 149 of the locking fingers 148 are received in the annular groove 152 to lock the plunger in a gas communicating position. | A gas-actuated release system is incorporated into a conventional ejection seat of an aircraft for freeing a pilot from his survival gear which could hinder his escape from the aircraft in a ground emergency. The system includes fail-safe features which prevent its operation when the pilot ejects from the aircraft via the ejection seat system. Flexible gas lines between the survival gear and the ejection seat are equipped with tension release connectors which pull apart upon separation of the pilot and survival gear from the ejection seat after ejection from the aircraft. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 60/772185 filed Feb. 10, 2006, the disclosure of which is hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Grant Nos. R01HL59249 and R01HL69509 awarded by the National Institutes of Health.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field
[0004] The present invention generally relates to mammalian tissue repair and regeneration, and to cellular therapy and tissue engineering, for treatment of degenerative diseases such as atherosclerosis and heart failure. More particularly, the invention relates to the use of statins and isoprenoid pathway inhibitors in cellular therapy and tissue engineering, especially for protecting stem cells and myocytes against inflammatory injury and apoptosis, prolonging stem cell survival, and promoting their differentiation into myogenic cell lineages.
[0005] 2. Description of Related Art
[0000] Inflammatory Response in Injured Tissue
[0006] Transplantation or mobilization of stem cells with growth factors has been emerging as a potentially novel therapy for regenerative medicine. However, one of the major challenges to successful stem cell therapy is the difficulty of stem cell survival and differentiation in the harsh microenvironment of diseased tissues or organs, such as infarcted or ischemic hearts with inflammation (1). Tissues in response to inflammatory stimulation can release radicals such as nitric oxide (NO), a gaseous signaling molecule that plays an important role in regulation of myocardial metabolism and function (2). Through NO synthases (NOS), cardiovascular cells can transiently synthesize large quantities of NO which, in turn, regulate the heart contractility (3). Exposure to NO at high levels may cause dysfunction of mitochondria (4,5), and trigger apoptosis (6). Pro-inflammatory cytokines, such as interleukin-1 (IL-1) and tumor necrosis factor-α (TNF-α), can induce expression of inducible NOS (iNOS) that generates larger quantities of NO, resulting in cardiac cell degeneration and apoptosis (7,8). The cytokine-induced expression of iNOS can occur in both ischemic and nonischemic heart failure, septic cardiomyopathy, cardiac allograft rejection, and myocarditis. Suppression of the cytokine-inducible, NO-synthesizing enzyme may reduce generation of cytotoxic reactive nitrogen radicals, leading to increased survival of grafted or pre-existing stem cells in the diseased hearts with inflammation.
[0000] Cholesterol Synthetic Pathway.
[0007] 3-hydroxy-3-methyl glutaryl coenzyme A (HMG CoA)-reductase acts as the rate-limiting enzyme for endogenous cholesterol synthesis. The HMG-CoA reductase inhibitors, statins or vastatins, are widely used cholesterol-lowering medicines for both primary and secondary prevention of atherosclerosis or coronary heart disease. Statins can effectively diminish endogenous cholesterol synthesis and reduce the plasma LDL cholesterol levels in patients with hypercholesterolemia (9,10). It has been reported that treatment with statins benefits the coronary endothelium and contributes to plaque stabilization in patients with coronary artery disease (42). In addition, improved clinical outcomes after coronary stent implantation in patients undergoing statin therapy have been demonstrated (43). Those effects can be achieved either by anti-apoptotic mechanisms or by promoting endogenous repair mechanisms with accelerated re-endothelialization of damaged vessel tissues involving the mobilization and incorporation of bone marrow-derived endothelial progenitor cells (44). Other beneficial effects of statins on cardiac tissue and function have also been reported, which could be explained by the anti-apoptotic and prodifferentiating effects of statins on progenitor cells. Indeed, recent studies using animal models of myocardial ischemia or infarction (17,18,45) and human clinical trials (18,46) suggest the clinical relevance of HMG-CoA reductase inhibitors as potential therapeutic agents for the treatment of patients with myocardial infarction and heart failure. It has been previously demonstrated that treatment with statins may confer cardioprotection in isolated perfused hearts during ischemia-reperfusion, which is in part due to a reduction in myocyte apoptosis (17). Very recently, it has been shown that statin treatment protects embryonic myocyte progenitors against the cytotoxicity caused by cytokine-induced high output of nitric oxide (NO) production induced by inflammatory cytokines (45). The anti-inflammatory effect of statins has been documented in diseased cardiovascular tissues (47). The effects of statins on restoration of vascular functions and the promotion of endogenous repair by bone marrow-derived stem/progenitor cell recruitment have been also reported (44,39).
[0008] The molecular basis for the many diversified bioactivities of statins is not completely understood. Increasing evidence indicates that certain pharmacological effects of statins occur independently of cholesterol. Indeed, the mevalonate pathway can produce certain by-products or intermediates, in addition to cholesterol, that are essential for late fetal and early neonatal tissue development, namely isoprenoid compounds (48,49). Research has suggested that HMG-CoA reductase inhibitors may seriously alter the cholesterol homeostasis in the brain and therefore influence the normal growth, development, and survival of neurons (50). A caution has been raised about the adverse side-effects of long-term statin therapies on the central nervous system (51,52). However, other investigations have pointed to the potential benefits of statin treatment to increase survival and differentiation of oligodendrocyte progenitors in an animal model of multiple sclerosis (50) and to induce neuroglial differentiation of bone marrow-derived human mesenchymal stem cells (53). Moreover, statins have been shown to induce osteoblast differentiation of embryonic stem cells (ESCs) (54,55) and bone marrow-derived stem cells but not stem cell proliferation (56).
[0009] Recent studies suggest that by blocking the mevalonate pathway, statins exert pleiotropic effects on vascular cell function that may not be related directly to cholesterol synthesis (11,12). Accumulating evidence indicates the involvement of the intermediates or by-products, e.g. isopranoids, from the mevalonate-cholesterol synthesis pathway in regulation of intracellular signal transduction and activation of transcriptional factors critical for inflammatory proteins and iNOS gene expression in heart failure (13). However, there are controversial reports on the statin regulation of iNOS expression in different cell types. For instance, Pahan et al. (14,15) showed that lovastatin inhibits iNOS and cytokine expression in rat macrophages, astrocytes, and microglia via reducing Ras farnesylation and inactivating NF-κB inactivation. By contrast, Hattori et al. (16) reported that statins augment cytokine-mediated induction of NO synthesis in vascular smooth muscle cells through altering synthesis of tetrahydrobiopterin (BH4), a key co-factor for iNOS, with little influence on NF-κB activities. Recent work have shown that statin treatment may confer cardioprotection in the isolated-perfused hearts during ischemia-reperfusion, which is in part due to a reduction in myocyte apoptosis (17).
[0000] Synthesis of Non-Sterol Isoprenoids and Protein Prenylation.
[0010] The HMG-CoA reductase inhibitors statins are potent inhibitors of cholesterol biosynthesis. However, the overall clinical benefits observed with statin therapy appear to be greater than what might be expected from changes in the lipid profile alone, suggesting that the beneficial effects of statins may extend beyond their effects on serum cholesterol levels. Inhibition of HMG-CoA reductase by statins may exert pleiotropic effects on cellular signaling and cellular functions involved in inflammation. Statin-sensitive signaling molecules include Rho guanosine triphosphatases (GTPases), mitogen-activated protein kinases, and Akt (61); statin-sensitive cellular functions include adhesion, chemotaxis, and release of superoxide anion (O 2 − ) and cytokines. It is generally believed that the majority of the observed anti-inflammatory effect of inhibition of HMG-CoA by statins can be attributed to the reduction in the cellular levels of isoprenoids and the prenylation of signaling proteins (e.g., Rho GTPases) (62-66). Rapidly accumulating evidence indicates that statins exert regulatory effects on cellular signaling via inhibiting protein prenylation by depleting the cellular pool of isoprenoids (e.g., geranylgeranyl-pyrophosphate) downstream of mevalonic acid (the product of HMG CoA reductase), as various effects of statins on cellular signaling and functions can be blocked by co-incubation of cells with mevalonic acid or isoprenoids. One of the genes whose expression is regulation by the protein prenylation-associated signaling is nitric oxide synthase (NOS) (62), an enzyme catalyzes conversation of L-arginine to L-cirtrulline and nitric oxide, a gaseous signaling molecule. Protein prenylation mediated by isoprenoids from the mevalonate pathway has impacts on expression of at least two isoforms of NOS, eNOS (61,62,67) and iNOS (68,45), through regulation of the gene promoter activities.
[0000] Cholesterol Synthesis Essentialfor Embryonic Development.
[0011] Cholesterol synthesis and metabolism appear to be essential for normal embryonic development (69,70). Target knockout of the HMG-CoA reductase gene is lethal (71). The embryos homozygous for the Hmgcr mutant allele can be recovered at the blastocyst stage, but not at E8.5, indicating that HMG-CoA reductase is crucial for early development of the mouse embryo. Supplementing the dams with mevalonate partially rescues the lethal phenotype. The importance of cholesterol for embryonic development is also evidenced by the finding that the distal inhibitors of cholesterol synthesis are highly teratogenic in animals (72-74). These inhibitors of cholesterol synthesis include AY 9944 and BM 15766 that inhibit 7-dehydrocholesterol reductase, and triparanol that inhibits Δ 24 -dehydrocholesterol reductase. Both the enzymes catalyze the last step of cholesterol synthesis. Treatment with these inhibitors caused holoprosencephalic brain anomalies, a severe genetic defect seen in patients with Smith-Lemli-Opitz syndrome (75,76,86), which is a recessive autosomal genetic disease characterized by malformations (microcephaly, corpus callosum agenesis, holoprosencephaly, and mental retardation), male pseudohermaphroditism, finger anomalies, and failure to thrive. The human genetic disease is another example of the genetic impact of cholesterol deficiency on embryonic development. Patients with this genetic disorder typically have a deficit in 7-dehydrocholesterol reductase, a severe hypocholesterolemia and an accumulation of precursors: 7-dehydrocholesterol, 8-dehydrocholesterol, and oxidized derivatives. The presence of 7-dehydrocholesterol in the serum of patients is pathognomonic. Administration of high concentrations of cholesterol can effectively improve the patient's clinical outcome. In the past few years, several distinct inherited disorders (77,78) have been linked to different enzyme defects in the cholesterol biosynthetic pathway, in addition to SLOS. Patients afflicted with these disorders are characterized by multiple morphogenic and congenital anomalies including internal organ, skeletal and/or skin abnormalities. By the finding of abnormally increased levels of intermediate metabolites, patients may be treated with normal products or transduced with normal genes that correct the disease-causing mutations in genes encoding the implicated enzymes.
[0000] Statins and Statin-Like Compounds
[0012] The term “statins” refers to a group of functionally and structurally similar compounds that inhibit the enzyme 3-hydroxy-3-methylglutaryl coenzyme A (HMG-CoA) reductase. Statins have a lactone structure or open lactone structure, as it known. Known statins include cerivastatin, marketed as Baycol® by Bayer (See U.S. Pat. Nos. 5,006,530 and 5,177,080), lovastatin, marketed as Mevacor® by Merck (See U.S. Pat. No. 4,963,538), simvastatin, marketed as Zocar®, pravastatin, marketed as Pravachol®, atorvastatin, marketed as Lipotor® by Warner-Lambert (See U.S. Pat. No. 5,273,995), fluvastatin, marketed as Lescol® (See U.S. Pat. No. 4,739,073), and rosuvastatin, marketed as Crestor® (See, e.g., WO 02/41895). Another statin is NK-104 developed by NEGMA (87). Additional compounds of similar structure and/or which inhibit enzymes of the isoprenoid/steroid pathway, such as HMG-CoA reductase, are termed “statin-like” compounds. The ability of a compound to inhibit these enzymes can be determined by standard assays well known in the art, and as described below.
[0000] Statin's Effect on Stem Cell Function
[0013] The HMG-CoA reductase inhibitor statins are the most widely described drugs that can effectively lower blood cholesterol levels, and prevent atherosclerosis and atherosclerosis-associated coronary heart disease. However, there has been a debate on whether statins exert teratogenic effects on embryonic development. Early reports (79-82) suggest that certain forms of statins may cause abnormalities in embryogenesis, including mevinolinic acid, Compactin and lovastatin. However, compared to the distal inhibitors of cholesterol synthesis, the statin effect is relatively minor. In fact, recent work on adult stem cells indicates that treatment with statins increases the number of circulating adult stem cells in patients with atherosclerosis. The statin-mediated HMG-CoA reductase inhibition has a biphasic dose-dependent effect on angiogenesis in a manner independent of cholesterol synthesis and associated with alterations in endothelial apoptosis and growth signaling. The non-sterol isoprenoid geranylgeranyl pyrophosphate may partially reverse the statin's effect, suggesting the involvement of geranylated proteins.
[0014] Statins also enhance new bone formation in vitro and in rodents. This effect is associated with increased expression of the bone morphogenetic protein (BMP) gene in bone-forming stem cells. Lovastatin and simvastatin can increase bone formation when injected subcutaneously over the calvaria of mice and increased cancellous bone volume when orally administered to rats (88). Thus, in appropriate doses, statins may have therapeutic applications for the treatment of osteoporosis. The mechanism by which statins induces BMP expression is unclear. There is evidence that lovastatin stimulates rapid activation of Ras, which associates with and activates PI 3 kinase in plasma membrane which in turn regulates Akt and Erk1/2 to induce BMP-2 expression for osteoblast differentiation (89). Interestingly, BMP expression is also closely associated with cardiac myogenesis. In 1997, Schultheiss T M, et al. (90) demonstrated that bone morphogenetic protein (BMP) signaling plays a central role in the induction of cardiac myogenesis in the chick embryo. At the time when chick precardiac cells become committed to the cardiac muscle lineage, they are in contact with tissues expressing BMP-2, BMP-4, and BMP-7. Application of BMP-2-soaked beads in vivo elicits ectopic expression of the cardiac transcription factors CNkx-2.5 and GATA-4. Furthermore, administration of soluble BMP-2 or BMP-4 to explant cultures induces full cardiac differentiation in stage 5 to 7 anterior medial mesoderm, a tissue that is normally not cardiogenic. The competence to undergo cardiogenesis in response to BMPs is restricted to mesoderm located in the anterior regions of gastrula- to neurula-stage embryos. The secreted protein noggin, which binds to BMPs and antagonizes BMP activity, completely inhibits differentiation of the precardiac mesoderm, indicating that BMP activity is required for myocardial differentiation in this tissue. Together, these data imply that a cardiogenic field exists in the anterior mesoderm and that localized expression of BMPs selects which cells within this field enter the cardiac myocyte lineage. Because statins and isoprenoid pathway inhibitors activate the BMP genes, they may exert effects on stem cells by promoting osteogenesis and myogenesis
SUMMARY OF THE INVENTION
[0015] In accordance with certain embodiments of the present invention, a method is provided for enhancing survival and differentiation of stem cells and cells of myogenic lineage derived from the stem cells, when the cells are exposed to an inflammatory or apoptotic stimulus. This method includes culturing stem cells in vitro in a medium containing a statin, to produce statin-pretreated cells with enhanced resistance to inflammatory or apoptotic stimuli. In some embodiments, the statin-pretreated cells are allowed to differentiate in the presence of the statin, to produce statin-pretreated cells of myogenic lineage.
[0016] In some embodiments, the method further includes exposing the pretreated stem cells, or the statin-pretreated cells of myogenic lineage, to an inflammatory or apoptotic stimulus. In some embodiments, the statin-pretreated cells are exposed to the inflammatory or apoptotic stimulus in vitro, such as when testing a candidate statin or another compound for modulation of the above-described protective effect. For example, the method may include exposing the statin-pretreated cells to the inflammatory or apoptotic stimulus in vitro, and then determining whether survival and differentiation of statin-pretreated stem cells is enhanced compared to non-statin-pretreated stem cells, or statin-pretreated cells of myogenic lineage derived from the stem cells, which are likewise exposed to the stimulus.
[0017] In some embodiments, the statin is a statin or statin-like compound that inhibits HMG-CoA reductase. Such inhibitory compounds include, but are not limited to, atorvastatin, cerivastatin, fluvastatin, lovastatin, mevastatin, pitavastatin, rosuvastatin, simvistatin and ezetimibe and combinations of those.
[0018] In some embodiments, the statin pre-treated cells are either embryonic stem cells or adult stem cells residing in adult tissues, and in some embodiments, the cells of myogenic lineage comprise differentiated or undifferentiated cardiac or vascular myoblasts. For example, the statin pre-treated cells may be embryonic cardiac myoblasts or embryonic vascular myoblasts.
[0019] In some embodiments, an above-described method further includes transplanting into a diseased tissue or organ the statin pretreated stem cells, or statin-pretreated cells of myogenic lineage derived from the stem cells, in a medium comprising the statin or one or more isoprenoid pathway inhibitor. A diseased tissue or organ may be, for example, an ischemic or infarcted tissue or organ. In some embodiments, the statin and the isoprenoid pathway inhibitor(s) are both included in the medium.
[0020] In some embodiments, exposing the statin-pretreated cells to the inflammatory or apoptotic stimulus occurs in vivo, after implanting or transfusing into a host the statin-pretreated stem cells or the statin-pretreated cells of myogenic lineage derived from the stem cells. In certain embodiments, a statin is administered to the host prior to, or after, implantation or transfusion of the pretreated cells. The statin may be administered orally, intravenously or locally.
[0021] In some embodiments, the cells are cultured in the medium containing a statin for up to 24 hours, to produce the statin-pretreated cells. In certain embodiments, the medium contains the statin in a concentration of about 1 to 10 μg/mL. In some embodiments, an above-described method also includes exposing the statin-pretreated cells to at least one statin or at least one isoprenoid pathway inhibitor in vitro. In some embodiments, an above-described method includes locally administering the statin- or isoprenoid pathway inhibitor-pretreated cells in vivo.
[0022] Also provided in accordance with the present invention is a method of protecting implanted embryonic stem cells, or cells of myogenic lineage derived from the stem cells, from the cytotoxic effects of inflammatory or apoptotic stimuli. Such stimuli may occur when the tissue is exposed to one or more inflammatory or apoptotic agent, such as oxidized low density lipoprotein (oxLDL), oxysterols, cytokines and Fas ligand, for example. This method includes transplanting into a vascular or cardiac tissue of a mammal a plurality of in vitro statin-pretreated embryonic stem cells, or statin-pretreated cells of myogenic lineage derived from such stem cells, whereupon apoptosis in the transplanted statin-pretreated cells is inhibited. In some embodiments, prior to being transplanted, the stem cells are uncommitted and are capable of differentiating into cells having a vascular or cardiac myocyte phenotype when transplanted into the cardiac or vascular tissue. In some embodiments, the stem cells are autologous or allogenic to the mammal. In some embodiments, the vascular or cardiac tissue is in a mammal with heart failure or a myocardial infarction or at least one atherosclerotic lesion, such as an aneurism or is an unstable plaque caused by hyperlipidemia, for example.
[0023] In some embodiments of the aforesaid methods, the inhibition of apoptosis deters apoptotic cell death of the transplanted stem cells or myocytes.
[0024] In some embodiments, an above-described method includes contacting the statin-pretreated cells with a non-steroidal isoprenoid to modulate the effect of the statin. In some embodiments, a method may further include administering clusterin to the tissue. This could be done separately or with administration of at least one isoprenoid pathway inhibitor, to enhance protection of the statin-pretreated embryonic stem cells, or statin-pretreated cells of myogenic lineage derived from the stem cells, from cytotoxic effects of inflammatory or apoptotic stimuli.
[0025] In some embodiments, an aforesaid method comprises, prior to transplanting into a mammalian tissue, treating stem cells in a medium containing at least one statin, at least one bone morphogenic protein and clusterin, to promote myogenic differentiation of the stem cells. These and other features, advantages and embodiments will be apparent with reference to the following detailed description, drawings and claims.
BRIEF SUMMARY OF THE DRAWINGS
[0026] FIG. 1 is a graph showing that simvastatin treatment reduces iNOS mRNA levels in TNF-α- and IL-1α-stimulated cardiac myoblasts. Reverse transcription-PCR for iNOS mRNA and 18S rRNA was performed using total RNA isolated from H9c2 cardiac myoblasts exposed to simvastatin (10 −8 to 10 −5 mol/L) in the presence of TNF-α (20 ng/mL) (closed squares) or IL-1α (20 ng/mL) (closed roots) for 24 h. PCR products were semi-quantified by densitometry after electrophoresis on agarose gels stained with ethidium bromide. The steady state level of iNOS mRNA was normalized to the level of the 18S rRNA against unstimulated controls. Data show mean ±S.D. from triplicate experiments.
[0027] FIG. 2 is a group of immunoblots and bar graphs showing that simvastatin reduces iNOS protein expression in TNF-α- or IL-1α-stimulated cardiac myoblasts. Immunoblotting with anti-iNOS antibody was conducted with total proteins extracted from H9c2 cells exposed to simvastatin (10 −8 to 10 −5 mol/L) in the presence of IL-1α (20 ng/mL) (Panels A and C) or TNF-α (20 ng/mL) (Panels B and D) for 24 h. Protein bands probed by antibody are quantified by densitometry (Panels C and D). Data represent the mean ±S.D. from three separate experiments. *, P<0.05.
[0028] FIG. 3 is a graph showing the time course of nitrite production in cardiac myoblasts treated with IL-1α alone or in combination with simvastatin or L-mevalonate. The logarithmic regression curves show the time-dependent nitrite production in H9c2 cardiac myoblasts exposed to IL-1α (20 ng/mL) in the presence (closed squares) and absence (closed roots) of simvastatin (10 −6 mol/L), or pretreated with simvastatin in combination with L-mevalonate (10 −4 mol/L, closed triangles) for 30 min prior to the addition of IL-1α. Data represent the means ±S.D. from three separate experiments. *, p<0.05
[0029] FIG. 4 is a group of immunoblots and bar graphs showing that L-mevalonate blocks the simvastatin inhibitory effect on TNF-α- and IL-1α-induced iNOS protein expression in cardiac myoblasts. Immunoblotting with anti-iNOS antibody using total proteins extracted from H9c2 cardiac myoblasts treated with simvastatin (10 −8 to 10 −5 mol/L) alone or in combination with L-mevalonate (10 −4 mol/L) for 30 min prior to the addition of IL-1α (20 ng/mL, Panels A and C) or TNF-α (20 ng/mL, Panels B and D). Immunoreactive iNOS bands were quantified by densitometry. Data represent the mean ±S.D. from three separate experiments. *, P<0.05.
[0030] FIG. 5 is an immunoblot and bar graphs showing that GGPP attenuates the simvastatin inhibitory effect on IL-1α-induced iNOS expression and nitrite production in cardiac myoblasts. Panels A and B. Immunoblotting with anti-iNOS antibody was conducted with total proteins extracted from H9c2 cells treated with increasing concentrations of simvastatin (10 −8 to 10 −6 mol/L) alone or in combination with geranylgeranylpyrophosphate (GGPP, 10 −6 mol/L) for 30 min, followed by stimulation with IL-1α (20 ng/mL) for 24 h. Immunoreactive iNOS bands were quantified by densitometry. Data represent means ±S.D. from three separate experiments. Panel C. Nitrite concentrations were determined by Griess reaction in the media of H9c2 cells under the same treatment shown in panels A and B. Data show means ±S.D. from three experiments. *, p<0.05.
[0031] FIG. 6 is a groups of bar graphs showing that Rho-associated kinase mediates simvastatin suppressive effect on iNOS expression in IL-1α-stimulated cardiac myoblasts. Panel A. Immunoblotting with anti-iNOS antibody in H9c2 cardiac myoblasts pretreated with Y-27632 (10 −6 to 10 −5 mol/L) alone or in combination with 10 −6 mol/L simvastatin for 30 min, followed by the addition of IL-1α (20 ng/mL) for 24 h. Immunoreactive iNOS bands were quantified by densitometry. Each bar represents the mean ±S.D. from three separate experiments. *, p<0.05. Panel B. Nitrite production was determined by Griess reaction with the media of H9c2 cell cultures treated under the same conditions shown in panel A. Each bar represents the mean ±S.D. from five separate experiments. *, p<0.05. Panel C. Rho kinase assays for assessing substrate protein phosphorylation. After treatment with cytokine and simvastatin or Y-27632, cells were lyzed, centrifuged, and resulting supernatants collected for enzymatic assays. The Rho Kinase-mediated protein phosphorylation was quantified by spectrophotometry at 450 nm. Data were presented as means ±S.D. (n=5). *, p<0.05; **, p<0.01
[0032] FIG. 7 is an autoradiogram and a group of immunoblots and bar graphs showing that simvastatin inactivates NF-κB and prevents its p65/RelA subunit from nuclear translocation in cytokine-stimulated cardiac myoblasts. Panel A. Electrophoretic mobility gel shift assay was performed by mixing 32 P-oligonucleotide coding for the consensus sequence of NF-κB binding promoter with the nuclear proteins from H9c2 cells preincubated with 10 −6 mol/L simvastatin for 8, 18 or 24 h, followed by incubation with 20 ng/mL IL-1α for 15 min. Specificity of the NF-κB-DNA complex formation was determined by competition with unlabeled, cold oligonucleotide and by supershift with anti-NF-κB antibody. The autoradiogram is a representative of three separate gel shift experiments for NF-κB. Panels B-G. Immunoblotting with antibody against p65/RelA subunit of NF-κB in the total cellular (Panels B and C) or nuclear proteins (Panels D and G) extracted from H9c2 cells stimulated with IL-1α after 24 h preincubation with simvastatin 10 −6 mol/L in the presence or absence of L-mevalonate and Y-27632 (Panel C). Immunoreactive p65 bands were quantified by densitometry (Panels E, F and G). Data represent the means ±S.D. from three separate experiments. *, P<0.05.
[0033] FIG. 8 is an immunoblot and bar graph showing that simvastatin elevates the phosphorylated IκBα intracellular pool without subsequent degradation in IL-1α stimulated cardiac myoblasts. Immunoblotting with antibody against ser32 phosphorylated IκBα in total proteins extracted from IL-1α-induced H9c2 cells after 24 h preincubation with simvastatin (10 −8 -10 −6 mol/L) (Panel A). Immunoreactive bands were quantified by densitometry (Panel B). Each bar represents the means ±S.D. from three separate experiments. *, p<0.05.
[0034] FIG. 9 is a schematic presentation of the signal transduction pathways by which statins regulate iNOS expression in embryonic cardiac myoblasts.
[0035] FIG. 10 is a group of photomicrographs of undifferentiated and differentiated human embryonic stem cells (hESCs). a, hESCs undifferentiated; b, embryoid body (EB) at day 26, arrow showing beating myogenic colonies; c, microvascular structure in EBs. D, a high power view of a tubing structure in EB. (Arrows).
[0036] FIG. 11 is a series of graphs showing edge-motion detection of mESC-derived contractile myogenic cells untreated (upper) or treated with isoproterenol (10 ng/ml) in the absence (middle) or presence (lower) of propanolol (25 ng/ml).
[0037] FIG. 12 is an immunoblot and bar graph showing immunoblotting for ubiquitinated proteins in murine and human ESC. A, immunoblotting for ubiquitin (upper panel) and b-actin (lower). B, relative abundance of ubiquitin-proteins in murine and human ESC.
[0038] FIG. 13 is a pair of photomicrographs showing hESC-derived EB after treatment with MG132 for 2 days. a, untreated and b, treated.
[0039] FIG. 14 is a pair of HPLC radiochromatograms of [ 3 H]-7-ketocholesterol and [ 3 H]-cholesterol in human 293 embryonic kidney cells transfected with apolipoprotein-J. a, cellular lipids; and b, medial lipids. The cells were incubated with [ 3 H]-7-ketocholesterol (0.5 uCi/ml) for 24 hrs. Lipids were extracted and analyzed by HPLC in both cells and media. Upper panel, cell lipids; Lower, media.
[0040] FIG. 15 is a graph showing TUNEL staining of mouse peritoneal macrophages. Macrophages loaded with acLDL were treated with CP-113,818 (▪), CP-113,818 plus U18666A (♦), or U18666A in medium containing 0.2% BSA (□). After treatment the cells were fixed and nuclear DNA fragments were labeled using a fluorescent TUNEL assay.
[0041] FIG. 16 is a graph showing statin Inhibition of iNOS expression in Embryonic Cardiac Myoblasts Exposed to Proinflammatory Cytokines for 24 hrs.
[0042] FIG. 17 is shows A, Western Blot for iNOS in embryonic cardiac myoblasts stimulated with IL-1α (20 ng/ML) in the presence or absence of simvastatin or simvastatin +/− geranylageranyl pyrophosphate (GGPP, 10 −6 mol/L) for 24 hrs. A, Western blot with anti-iNOS and B, shows the densitometry of iNOS protein bands. N=3, mean ±SD.
[0043] FIG. 18 shows gel shift assays for the NF-kB activity. Nuclear proteins were extracted from cytokine-treated and untreated cardiac myoblasts in the presence or absence of simvastatin, and mixed with 32 P-NF-kB consensus or control double strand oligos. Protein-oligo complexes were detected by autoradiogram following electrophoresis.
[0044] FIG. 19 is a Western blot for phosphorylated IκBα in IL-1 stimulated cardiac myoblasts in the presence or absence of simvastatin. Upper panel shows densitometry of protein bands. N=3, mean ±SD.*, p<0.05.
[0045] FIG. 20 is a Western blot for cardiac sarcomeric α-actinin in simvastatin-treated murine ESCs. Total proteins extracted from simvastatin-treated murine ESCs. Western blot was conducted with anti-α-actinin and densitometry performed for semiquantitation of the protein levels, normalized by β-tubulin bands. N=4, mean ±SD; *, p<0.05.
[0046] FIG. 21 is a bar graph showing the development of beating myocytes in simvastatin (10 −6 mol/L)-treated and untreated murine ESCs in the presence or absence of L-mevalonate (10 −5 mol/L) for 8 days. Phase-contrast microscopy was used to quantify the region with beating myocytes.
[0047] FIG. 22 are bar graphs showing that simvastatin treatment enhances cardiac differentiation of murine embryonic stem cells. Embryoid bodies (EBs) in the hanging-drop cultures of ESCs were plated in duplicate in 6-well plates with 10 EBs per well and then treated with simvastatin with or without mevalonate. At day 12, the number of contracting EB outgrowths (Panel A) and extension of beating area (Panel B) were detrmined by morphometry. The results were plotted as percentages of the total EBs counted in each well and shown as the mean ±SD for each of the 3 separate experiments. *, P<0.05 vs untreated control; #, P<0.05 vs simvastatin-treated control.
[0048] FIG. 23 are immunoblots showing that simvastatin treatment enhances the expression of the cardiac-specific proteins α-actinin and myocardin A but not endothelial protein Tie-2 in murine embryonic stem cells. Immunoblot analysis of proteins from EBs treated with or without Simvastatin, was carried out with antibodies against cardiac-specific proteins, such as sarcomeric α-actinin (Panels A and D) and myocardin A (Panels B and E), as well as endothelial-specific proteins such as Tie-2 (Panels C and F). β-Tubulin staining of stripped blots was used as a control. Intensity of immunoreactive protein bands was assessed by densitometry (Panels D-F). *, P<0.05 vs untreated cells.
[0049] FIG. 24 is a series of immunoblots showing expression of Bad, Bcl-x L , and PCNA in embryonic myoblasts treated with or without simvastatin in the presence or absence of IL-1α. Expression of Bad (BD Biosciences, San Jose, Calif.), Bcl-x L (BD Biosciences), and PCNA (BD Biosciences) in H9C2 embryonic myoblasts stimulated with IL-1 in the presence or absence of simvastatin, was analyzed by immunoblotting with monoclonal antibodies against Bad (Panel A, upper), Bcl-x L (Panel B, upper), and PCNA (Panel C, upper). Quantitation of protein bands was achieved by densitometry (Panels D, E and F, bottom). β-Tubulin staining of stripped blots was used as a control. Data show the mean ±SD for each of the 3 separate experiments. #, P<0.05 vs untreated cells; *, P<0.05 vs IL-1-treated cells; **, P<0.05 vs IL-1+simvastatin-treated cells. PCNA, proliferating cell nuclear antigen; IL-1, interleukin-1-α; iNOS, inducible nitric oxide synthase; MnSOD, manganese superoxide dismutase.
[0050] FIG. 25 is an immunoblot assay showing the expression of iNOS and MnSOD in murine embryonic stem cells treated with or without Simvastatin. Expression of iNOS (Panels A and C) and MnSOD (Panels B and D) in murine ESCs in the presence or absence of simvastatin was analyzed by immunoblotting. Quantitation of protein bands was achieved by densitometry (panels C and D). β-Tubulin staining of stripped blots was used as a control. Data show the mean ±SD for each of the 3 separate experiments. #, P<0.05 vs untreated cells.
[0051] FIG. 26 is a group of photomicrographs showing that simvastatin prevents IL-1-induced apoptosis in H9c2 embryonic myoblasts. The cells were exposed with IL-1αSimvastatin for 24 hours and then stained with two fluorochromes: acridine orange and ethidium bromide. Living (green fluorescence) and apoptotic (red fluorescence) cells were identified and counted with an Olympus fluorescence microscope connected to a computer imaging station. A, untreated; B, IL-1; C-E, IL-1+simvastatin at different concentrations; F, IL-1+simvastatin+mevalonate 10 −4 mol/l. Sim, simvastatin; Mev, mevalonate; IL-1, interleukin-1α.
DETAILED DESCRIPTION
[0052] It is now proposed that at least some statins and isoprenoid pathway inhibitors can be advantageously used to influence cardiovascular stem cell and/or myocyte survival, proliferation and differentiation. Despite the recent knowledge that statin treatment may confer cardioprotection in isolated perfused hearts during ischemia-reperfusion, the molecular mechanism underlying the statin protective effect is unknown. Because stem cells participate in post-ischemic heart repair, it was of interest to determine whether statin treatment inhibits cytokine-induced expression of iNOS in premature, undifferentiated cardiac myoblasts. In this study, a cell culture system was employed to determine whether inhibition of HMG-CoA reductase by simvastatin alters expression of iNOS in embryonic, undifferentiated cardiac myoblasts exposed to proinflammatory cytokines. The resulting data showed that simvastatin treatment significantly reduced expression of iNOS in cardiac myoblasts stimulated with cytokines. The statin inhibitory effect might occur through a mechanism in which isoprenoids, an intermediate or similar by-products from cholesterol synthesis, regulate activation of several key intracellular signalling proteins, such as Rho A kinase and NF-κB. Taken together, this data strongly supports the notion that statins have regulatory effects on iNOS expression by undifferentiated myoblasts during the development of cardiac failure and inflammation. The present investigation also included determining whether a statin (e.g., simvastatin), at therapeutic doses, would affect embryonic stem cell (ESC) myogenic differentiation and resistance to apoptosis. The impact of endogenous cholesterol depletion by inhibition of HMG-CoA reductase was also determined. It was found that simvastatin, at therapeutic doses, promotes ESC myogenic differentiation and increased their resistance to apoptosis.
[0000] Materials and Methods
[0053] Materials. Human recombinant interleukin(IL)-1α and tumor necrosis factor(TNF)-α were from R&D Systems Inc. (Minneapolis, Minn.), L-mevalonate was obtained from Sigma, geranylgeranylpyrophosphate (GGPP) and farnesylpyrophosphate (FPP) were from Biomol Research Laboratories Inc. (Plymouth, Pa.), Rho inhibitor Y-27632 was from Calbiochem (S. Diego, Calif.). Simvastatin obtained from Merk Sharp & Dohme (Rome, Italy) was activated to its active form by alkaline hydrolysis before use. Briefly, 4 mg of simvastatin prodrug were dissolved in 8 mL of NaOH 0.1 N/NaCl 0.154 mol/L solution, and then incubated at 50° C. for 2 h. The pH was brought to 7.0 by HCl. The final concentration of the stock solution adjusted to 4 mg/mL and stored at −20° C. (45).
[0054] Cell cultures. H9c2 cells purchased from American Type Culture Collection (ATCC, Rockville, Md.) are spontaneously immortalized ventricular myoblasts from the rat embryo, with preservation of several electrical and biochemical characteristics found in adult cardiomyocytes. They were cultured in DMEM medium (ATCC) supplemented with 10% heat-inactivated fetal bovine serum (FBS) in 95% air and 5% CO 2 at 37° C. At subconfluence (70-80%), H9c2 myoblasts cultured at petri dishes or 24-well plates were pre-exposed to simvastatin and then stimulated with the proinflammatory cytokine, IL-1-α or TNFα, in the presence or absence of isoprenoids, the intermediates or by-product from cholesterol synthesis, or mevalonate (10 −4 mol/L) (45). After certain time intervals, 100 μL/well culture media were collected for determination of nitrite production.
[0055] The murine ESC (mESC) line CCE was obtained from American Type Culture Collection (ATCC, Rockville, Md.). Murine ESCs were cultured without feeder cells in Dulbecco's modified Eagle's medium supplemented with 10 % ESC-qualified Fetal Bovine Serum (FBS) (Stem Cell Technologies, Vancouver, Va.), pyruvate (Stem Cell Technologies, stock solution diluted 1:100), 2 mM L-glutamine, nonessential amino acids (Stem Cell Technologies, stock solution diluted 1:100), 100 IU/mL penicillin, 0.1 mg/mL streptomycin, and leukemia inhibitory factor (LIF) (Stem Cell Technologies). To induce differentiation, EBs were formed from undifferentiated mESCs in hanging drops of 400 cells in 20 μL of medium without LIF. After 5 days in suspension, EBs were plated on gelatin-coated dishes and cultured in cardiomyocyte-differentiation medium (Iscove's modified Eagle's medium, supplemented with 15% FBS, 2 mM L-glutamine, 5×10 −5 M β-mercaptoethanol, nonessential aminoacids, 100 IU/mL penicillin, 0.1 mg/mL streptomycin).
[0056] Statin Treatment. At plating on day zero, EBs were treated with simvastatin (10 −1 -10 −6 mol/L), which blocks HMG-CoA reductase in the presence or absence of mevalonate (10 −4 mol/L). The inhibition of endogenous cholesterol synthesis was the mechanism used for analyzing the effect of endogenous cholesterol depletion on EB differentiation. By days 8 through 12 after plating, spontaneously contracting cell clusters could be observed within the EB outgrowths. Culture media from both simvastatin-treated and untreated cells were changed each day after day 3.
[0057] The rat embryonic myogenic cell line H9c2 was commercially obtained from ATCC and maintained in Dulbecco's modified Eagle's medium (GIBCO) supplemented with 10% FBS at 37° C. in 95% air and 5% CO 2 . At subconfluence (70%-80%), H9c2 myoblasts cultured in petri dishes or 24-well plates were pre-exposed to simvastatin (10 −8 -10 −6 mol/L) and then stimulated with the proinflammatory cytokine IL-1-α (20 ng/mL) for 24 hours in the presence or absence of mevalonate (10 −4 mol/L) (45).
[0058] Assay for NO Production. The activity of iNOS was determined in the culture medium by assaying nitrites, taken as an index of NO production, using the Griess reagent (1% sulphanilic acid and 0.1% N-[1-naphtyl] ethylenediamine-HCl in 5% phosphoric acid) as reported previously (4,18,19). Equal volumes of medium and Griess reagent were mixed, and the purple products quantified spectrophotometrically at 550 nm. Nitrite concentrations were determined from a linear standard curve constructed with known concentrations of sodium nitrite (0 to 40 μmol/L nitrite).
[0059] Immunoblotting. Total proteins were isolated from rat cardiac myoblasts (H9c2 cells) or embryonic stem cells in an ice-cold lysis buffer containing 10 mmol/L Tris (tris(hydroxymethyl)aminomethane) (pH 7.4), 1% sodium dodecyl sulfate (SDS) and 1× protease inhibitor (1 mmol/L sodium orthovanadate). Proteins (15 μg/lane) were separated under the reducing conditions (125 mM Tris pH 6.8, 4% SDS, 10% glycerol, 0.006% bromophenol blue, 2% β-mercaptoethanol) by electrophoresis onto 5-10% SDS-polyacrylamide gel and electro-blotted to nitrocellulose membranes (Osmonics, Westborough, Mass.). The membranes were reversibly stained with Ponceau red (Sigma) to verify equal protein loading and/or transfer. After blocking in Tris-buffered saline (0.2 M Tris and 8% NaCl) containing 5% non-fat powdered milk and 0.1% Tween 20 for 1 hour at room temperature, the membranes were incubated overnight at 4° C. with following primary antibodies to (a) iNOS (Transduction Laboratories, Lexington, Ky.; BD Biosciences); (b) NF-κB p65/rel (Santa Cruz Biotechnologies, Santa Cruz, Calif.); (c) ser 32 -phosphorylated inhibitor IκBα (Santa Cruz); (d) Bad (BD Biosciences, San Jose, Calif.); (e) Bcl-x L (BD Biosciences); (f) proliferating cell nuclear antigen (PCNA; BC Biosciences); (g) ryanodine receptor (Santa Cruze Biotechnology, Inc., Santa Cruz, Calif.); (h) α-sarcomeric actinin (Sigma); (i) myocardin A (developed by immunizing rabbits with a synthetic myocardin A peptide); (j) Tie-2 (Santa Cruz); (k) manganese superoxide dismutase (Santa Cruz); and (1) β-tubulin (Sigma). The blots were incubated with horseradish peroxidase-coupled secondary antibodies, washed and developed by using a SuperSignal West Pico Chemiluminescent Substrate Kit (Pierce, Rockford, Ill.). Intensity of each immunoreactive protein band was quantified by densitometric analysis. Cytokine-stimulated RAW 264.7 cells (Transduction Laboratories, Lexington, Ky.) were used as positive controls.
[0060] RNA isolation and RT-PCR. Total cellular RNA was isolated by a single extraction using an acid guanidinium thiocyanate-phenol-chloroform method with modification as reported elsewhere (17). Semi-quantitative multiplex reverse-transcription polymerase chain reaction (RT-PCR) was performed with a set of specific primers for iNOS. As the “house-keeping” controls, the 18S rRNA was also analysed by RT-PCR. The PCR products were visualized and quantified using a computerized densitometric system (BioRad Gel Doc 1000, Milan, Italy).
[0061] Electrophoretic mobility gel shift assay. Nuclear proteins were extracted from stimulated or unstimulated H9c2 cells. Cells were harvested and homogenized with an Ultra-Turrax T25-tissue homogenizer (Janke and Kunkel) in a low salt solution (0.6% Nonidet P-40 [NP-40], 150 mM NaCl, 10 mM HEPES pH 7.9, 1 mM EDTA, 0.5 mM phenylmethylsulfonyl fluoride [PMSF]), and centrifuged for 30 sec at 2000 rpm. The supernatant was incubated for 5 min on ice and then centrifuged for 5 min at 5000 rpm. The nuclei were resuspended in a high salt solution (25% glycerol, 20 mM HEPES Ph 7.9, 420 mM NaCl, 1.2 mM MgCl 2 , 0.2 mM EDTA, 0.5 mM DTT, 0.5 mM PMSF, 2 mM benzamidine, 5 g/mL of each aprotinin, leupeptin and pepstatin). Protein concentrations were determined by Mio-Rad Laboratories Protein Assay (Bio-Rad Laboratories Inc, Hercules, Calif., USA). Double-stranded synthetic oligonucleotides NFκB motif (5′-AGT TGA GGG GAC TTT CCC AGG C-3′ and 5′-CCT GGG AAA GTC CCC TCA ACT-3′) was labeled with [γ- 32 P]-ATP. Binding reactions containing 10 μg of crude nuclear extract were performed using the electrophoretic mobility gel shift assay core system (Promega, Madison Wis.) according to the manufacturer's protocol. For supershift experiments, mouse monoclonal anti-NF-κB antibody (1-2 μg) was added into the reaction.
[0062] Rho kinase assay. Cell pellets were homogenized in lysis buffer (50 mM NaCl, 50 mmol/L Tris-Hcl pH 8.0, 0.1% Triton X-100, 0.5 mM EDTA, 1 mM EGTA, 1 μg/ml pepstatin, 1 μg/ml leupeptin, 2 mM NaF, 2 mM sodium orthovanadate, 5 mM β-mercaptoethanol). After the cell lysates were centrifuged at 30.000 g for 30 minutes, supernatants were collected and incubated (100 μl/well) in 96-well plates pre-coated with a substrate corresponding to the myosin-binding subunit of myosin phosphatase, which contains a threonin residue selectively phosphorylated by Rho-kinase. Plates were incubated with HRP conjugated antibody specific for phosphorylated proteins, and then incubated with the HRP-substrate yielding colored products, which were subsequently quantified by spectrophotomerty at 450 nm. Purified Rho kinase was used as the positive controls and the cell lysates from the cultures treated with the Rho kinase inhibitor Y27632 as the negative controls.
[0063] Assays for Apoptosis. Analysis of apoptotic cells was performed by fluorescent microscopy with fluorochromes acridine orange and ethidium bromide (Sigma), as described previously (19). Apoptotic cells were discernible by their condensed, fragmented nuclei stained with both fluorochromes and were counted under a fluorescence microscope (Olympus, Center Valley, Pa.) connected to a computer imaging analysis station.
[0064] Nitrite Assays. Nitrite, a stable end-product of nitric oxide, was measured by using Griess reagent (1% sulphanilic acid and 0.1% N-[1-naphtyl] ethylenediamine-HCl in 5% phosphoric acid). Equal volumes of medium and Griess reagent were mixed, and the resulting purple product quantified by spectrophotometric assay at 550 nm. Nitrite concentrations were calculated from a linear standard curve constructed with known concentrations of sodium nitrite (0-14 μmol/L nitrite) (19).
[0065] Statistical Analysis. Two-group comparisons were performed by the Student's t-test for unpaired values. Comparisons of means of multiple groups were performed by analysis of variance (ANOVA), and the existence of individual differences, in case of significant F values at ANOVA, tested by Scheffé's multiple contrasts.
[0066] Transplantation of stem cells. In an animal model, statin-pretreated stem cells or myocytes are transplanted into a heart with or without infarction, using any suitable technique that is known in the art. It can then be determined whether the statin-pretreated stem cells or myocytes differentiate and/or survive better in an environment with inflammatory stimuli. For comparison, non-statin-pretreated stem cells or myocytes are similarly transplanted into a heart with or without infarction.
[0067] Echocardiography and ECG and Patch-clamp studies. After transplantation of the stem cells, morphological and functional changes are monitored using echocardiography using any suitable method which is known in the art, such as those described in U.S. patent application Ser. No. 11/252,260, the disclosure of which is hereby incorporated herein by reference. For example, in an animal model, 2D and M-Mode echocardiography may be performed after transplantation, e.g., at one, two, and four weeks. Electrophysiological changes are important features of cardiac dysfunction during myocardial infarction or ischemic heart failure. To characterize the electrophysiological alterations in the infarcted heart with statin-pretreated stem cell transplantation, any suitable methods may be used. Two such approaches are (1) in vivo study with electrocardiogram (ECG), and (2) in vitro study with the patch-clamp technique to measure ion channel functions.
[0000] Experimental Procedures
[0000] 1. Simvastatin Inhibits iNOS Expression and Nitrite Production in Cardiac Myoblasts Induced by Proinflammatory Cytokines.
[0068] Exposure to IL-1α (20 ng/mL) or TNF-α (20 ng/mL) significantly increased the levels of iNOS mRNA in H9c2 cardiac myoblasts ( FIG. 1 ), when compared those in normal, untreated H9c2 cells. In order to determine whether statins affect iNOS expression in embryonic cardiac cells, simvastatin was added into the cell cultures simultaneously with the cytokines. It was observed that in a concentration-dependent fashion, simvastatin markedly diminished expression of iNOS mRNA in H9c2 cells stimulated with the proinflammatory cytokines ( FIG. 1 ). Under the same concentrations, both IL-1α and TNF-α stimulated cells showed a similar response to simvastatin in terms of iNOS mRNA expression. In the presence of simvastatin, IL-1α treated cells showed a dose-dependent decline in iNOS mRNA to the same or similar degrees as that in TNF-α treated cells ( FIG. 1 ). Thus, simvastatin reduced steady-state levels of iNOS mRNA in H9c2 cardiac myoblasts stimulated with the proinflammatory cytokines.
[0069] Further analysis of iNOS protein expression by immunoblotting with antibodies against iNOS confirmed the presence of high levels of iNOS expression in H9c2 cardiac myoblasts stimulated with IL-1α and TNF-α. Intense protein bands immunoreactive to anti-iNOS antibody corresponding to a molecular mass of 130 KDa were detected in the cytokine-stimulated H9c2 cells (FIGS. 2 A-B). At the same concentrations, both the proinflammatory cytokines exerted stimulatory effects on iNOS protein expression in the cells. Interestingly, consistent to its effect on iNOS mRNA expression, simvastatin (10 −8 -10 −5 mol/L) reduced expression of iNOS protein in H9c2 cells stimulated with IL-1α ( FIGS. 2A and C) as well as TNF-α ( FIGS. 2B and D). Thus, treatment with simvastatin inhibited expression of both iNOS mRNA and protein in cardiac myoblasts induced by proinflammatory cytokines.
[0070] In order to further verify the statin inhibitory effect on iNOS gene expression, the accumulation of nitrite, a stable NO end-product reflecting the NOS activities, in the cultures treated with or without IL-1α and simvastatin was examined. Under the baseline condition without cytokine stimulation, H9c2 cells generated nitrite at the rates of approximately 0.8 μmol/10 5 cells/24 h ( FIG. 3 ). Stimulation with IL-1α (20 ng/mL) markedly increased nitrite production. The rates of nitrite production were more than 3.5 μmol/10 5 cells/24 h in the cytokine-stimulated cells for the period of incubation from 24 to 48 h (p<0.05). Simvastatin (up to 10 −6 mol/L) significantly diminished the cytokine-induced nitrite production in H9c2 cells ( FIG. 3 ). The range of simvastatin concentrations leading to inhibition of nitrite production in cytokine-stimulated cells is comparable to the plasma levels of the drug in patients treated (20). Thus, at the pharmacological doses, simvastatin markedly reduced production of nitrite by H9c2 cells stimulated with the pro-inflammatory cytokines.
[0000] 2. L-Mevalonate Mediates the Simvastatin Inhibitory Effect on iNOS Expression in Cardiac Myoblasts.
[0071] Generated by HMG CoA reductase, L-mevalonate serves as a key intermediate of cholesterol synthesis from acetyl-CoA. In order to determine whether the statin inhibition of iNOS gene expression occurred through blocking the HMG CoA reductase activity or reduction in L-mevalonate synthesis, exogenous L-mevalonate was added into the cultures of H9c2 cells with IL-1α (20 ng/mL) in the presence or absence of simvastatin (10 −6 mol/L). It was observed that addition of L-mevalonate in excess amounts significantly increased the nitrite concentrations in the cultures of H9c2 cells exposed to a combination of IL-1α and simvastatin ( FIG. 3 ). Examination of iNOS protein by immunoblotting revealed that L-mevalonate diminished the inhibitory effect of simvastatin by increasing iNOS protein expression in H9c2 cells treated with simvastatin plus IL-1α ( FIGS. 4A and C) or TNF-α ( FIGS. 4B and D). In the absence of simvastatin, L-mevalonate had no or little effect on cytokine-induced iNOS expression in H9c2 cells ( FIG. 4 ), suggesting that L-mevalonate selectively blocked the simvastatin inhibitory effect on cytokine induction of iNOS in cardiac myoblasts. Because there was no major difference in induction of iNOS expression between IL-1α and TNF-α treated cells, the following experiments with simvastatin were mainly performed on the cells stimulated with IL-1α.
[0000] 3. The Isoprenoid Intermediate GGPP, but not FPP, Blocks Simvastatin Inhibitory Effect on iNOS Expression.
[0072] In addition to L-mevalonate, several downstream intermediates or by-products from the cholesterol biosynthetic pathway (21) may contribute to the inhibitory effect of simvastatin on expression of iNOS protein and activities. To exhaust the endogenous intermediates and by-products from cholesterol synthesis, H9c2 cells were pretreated with simvastatin (10 −8 to 10 −7 mol/L) up to 24 h, and then stimulated the cells with IL-1α (20 ng/mL) in the presence or absence of the isoprenoid intermediates, such as GGPP and FPP. Immunoblotting showed that addition of GGPP (10 −7 to 10 −5 mol/L) reversed the simvastatin-mediated suppression of the cytokine-induced expression of iNOS protein ( FIG. 5A -B) and nitrite production ( FIG. 5C ) at almost the same levels to those in the L-mevalonate treated cells. In contrast, however, treatment with FPP at the same concentrations as GGPP did not alter nitrite accumulation in the cells pretreated with simvastatin and then IL-1α ( FIG. 5C ). These results suggested that GGPP but not FPP directly appeared to reverse the statin-induced inhibition of iNOS expression in the cardiac myoblasts stimulated with IL-1α.
[0000] 4. Rho Kinase Contributes to Statin Inhibitory Effect on iNOS Expression in Cardiac Myoblasts Treated with IL-1α.
[0073] The Rho family of small GTP-binding proteins consists of three subfamilies, Rho, Rac and Cdc42, which play important roles in signal transduction and cell cycle regulation (22,23). The intermediate derivative of L-mevalonate, GGPP, acts as a lipid attachment to the Rho proteins, while FPP mainly targets Ras. Therefore, it was investigated whether the Rho kinase mediates the simvastatin effect on iNOS expression. The Rho kinase inhibitor Y-27632 (24) specifically inactivates p160ROCK, a key subunit of this kinase, known to regulate NO synthesis (11). It was tested whether Y-27632 affects iNOS expression in IL-1 treated H9c2 cells. It was observed that inhibition of Rho kinase with Y-27632 (10 −6 to 10 −5 mol/L) did not alter cytokine-induced iNOS protein expression in H9c2 cells ( FIG. 6A ). However, the Rho kinase inhibitor almost abolished the inhibitory effect of simvastatin on iNOS protein expression ( FIG. 6A ). Assessment of nitrite production indicated that Y-27632 dose-dependently increased the iNOS activity in the cytokine-treated H9c2 cells, suggesting the involvement of post-translational modification by Rho kinase in regulation of iNOS activities. Interestingly, in the presence of Y-27632, simvastatin treatment reduced neither NOS protein expression ( FIG. 6A ) nor nitrite accumulation ( FIG. 6B ). The reversal of the statin-induced nitrite reduction by Y-27632 occurred to the same extents as seen in the cells treated with L-mevalonate ( FIG. 6B ). To further confirm that Rho kinase A participates in the statin suppression of iNOS expression, the Rho kinase A bioactivities in H9c2 cells treated with both IL-1α and simvastatin was testedf by using enzymatic assays. It was found that simvastatin dose-dependently reduced Rho mediated protein phosphorylation ( FIG. 6C ), although the inhibitory effect appeared less striking than that of Y-27632. Thus, Rho kinase activation might be involved in the downstream events for simvastatin inhibition of iNOS expression.
[0000] 5. Simvastatin Inactivates NF-κB through Elevation of Intracellular IκB in Cardiac Myoblasts Stimulated with Cytokines.
[0074] The nuclear transcription factor NF-κB binds to the iNOS gene promoter critical for iNOS gene transcription (25). The effect of simvastatin on IL-1α-induced activation of NF-κB in H9c2 cells was tested by using the gel-shift assay with a 32 P-end-labelled NF-κB oligonucleotide. The nuclear proteins extracted from serum-starved H9c2 cells showed a stronger NF-κB activity after stimulation by IL-1α for 15 min ( FIG. 7A ). The specificity of the NF-κB DNA-protein complex formation was verified by competition with unlabelled, cold oligonucleotides and by addition of anti-NF-κB antibody which led to the bands for the NF-κB-DNA complexes super-shifted ( FIG. 7A ). In addition, there was no significant binding with the oligonucleotide probe alone or by omitting protein substrate or using the nuclear protein extract from the unstimulated H9c2 cells. In the subsequent experiments, the cells were treated with 1 μM of simvastatin before IL-1α stimulation. A time-dependent decline in NF-κB-DNA binding was found ( FIG. 7A , lane 7 to 10). Simvastatin treatment for 24 hours markedly inhibited IL-1α-induced activation of NF-κB ( FIG. 7A , lane 11) (P<0.001 vs IL-1α-stimulated cells). Inclusion of antibody to NF-κB in the binding reactions resulted in a further reduction in the IL-1α-induced mobility of the complex ( FIG. 7A , lane 12).
[0075] The reduction in the nuclear NF-κB activity did not appear to be due to overall inhibition of expression of this transcription factor by the statin, as immunoblotting analysis of total cellular NF-κB levels showed no significant difference between simvastatin-treated or untreated cells with cytokine stimulation ( FIGS. 7B and C). The potential mechanism underlying the simvastatin inhibitory effect on NF-κB activation was delineated by performing immunoblotting analysis on the same nuclear protein extracts from IL-1α-stimulated H9c2 cells with an antibody specific for the p65 subunit of NF-κB. A time-dependent decrease in the p65 NF-κB protein nuclear translocation with pretreatment with simvastatin ( FIGS. 7D and F) was observed. The statin-suppressed NF-κB nuclear translocation was clearly related to the HMG CoA reductase activity since addition of L-mevalonate could elevate the nuclear p65/rel protein levels in the statin-treated, cytokine-stimulated cells ( FIGS. 7E and G). In addition, the Rho kinase inhibitor Y-27632 showed no major effect on the nuclear NF-κB translocation. Although Y-27632 (10 −4 mol/L) reversed the statin inhibitory effect on iNOS activities, this Rho kinase inhibitor did not influence the nuclear p65 translocation as there was no difference in the nuclear p65 concentration between the cells treated with and without Y-27632 in the presence of IL-1α ( FIGS. 7E and G). These observations suggest a discrepancy between L-mevalonate and the Rho inhibitor in regulating the statin modulation of iNOS expression and activation in the cytokine-stimulated cells.
[0000] 6. Simvastatin Increases the Phosphorylated IκBα in the Cytosol without Subsequent Degradation.
[0076] Under the physiological conditions, NF-κB is sequestered as an inactive form in the cytosol through non-covalent interactions with inhibitory proteins, such as IκBα, β and ε. Each IκB isoform contains, in its N-terminal region, a pair of serine residues. In the case of IκBα, these serine residues (amino acids 32 and 36) become phosphorylated by a serine-specific kinase following stimulation. Phosphorylation does not disassociate IκBα from NF-κB but renders IκBα a substrate for ubiquitination and then degradation by the 26S proteasome. In order to provide further insight into the regulatory role of simvastatin, by immunoblotting with a specific antibody to IκBα, the IL-1α-induced degradation of IκBα phosphorylated at Ser −32 was examined in the presence or absence of simvastatin. After 15 minutes treatment with 20 ng/mL IL-1α, a decrease in the cellular content of Ser 32 -phosphorylated IκBα in H9c2 cells was detected ( FIG. 8 ). However, pretreatment with simvastatin (10 −8 to 10 −6 mol/L) reversed the IL-1α induced decline in the levels of Ser 32 -phosphorylated IκBα in a dose-dependent manner ( FIG. 8 ). The highest levels of the phosphorylated IκBα were detected in H9c2 cells exposed to the statin at 10 −7 mol/L for 24 h ( FIG. 8 ). The increased accumulation of phosphorylated IκBα in the simvastatin-treated cells implicates a prolonged lifespan or a lower rate of degradation of phosphorylated IκB protein that inactivates NF-κB.
[0000] 7. hESC Growth and Differentiation.
[0077] hESC grown in DMEM media with 10% fetal bovin serum and a group of growth factors were induced to differentiate in a hang-drop 3D cell culture system. hESCs from two (H1 or H9) lines were cultured with a mouse fetal fibroblast feeder layer. After forming EBs in the hanging-drop 3D system they were replated in 12-well plates. Cardiovascular phenotypic development was observed in many of the EBs, in which the colonies with beating myocytes developed spontaneously ( FIG. 10 ). Surrounding the beating colonies, the cells developed a blood vessel-like structure ( FIG. 10 ). Using the edge-motion detection technique, a single beating myogenic cell within the developing EBs was recorded. This provides a functional marker showing the differentiational potential in cardiomyogenesis. Expression of β-adrenergic receptors in the developing EBs was evaluated by incubating with the agonist isoproterenol at 10 ng/ml and/or antagonist propanolol at 25 ng/ml. mESC-derived EBs with beating myocytes responded to isoproterenol by marked increased contraction in both frequency and ampltitute ( FIG. 11 ). Addition of propanolol almost abolished the isoproterenol stimulatory effect, suggesting that the stimulatory effect occurred via β-receptor.
[0000] 8. Protein Ubiquitination in hESC and mESC
[0078] Cholesterol is essential for cellular membrane structure, metabolism and function. Cholesterol depletion is lethal to embryogenesis in animals. Cholesterol synthesis is highly regulated by protein phosphorylation and ubiquitination and by sterol-sensitive, SREBP-mediated transcriptional regulation. Several enzymes involved in cholesterol synthesis and metabolism are regulated by the ubiquitin-proteasome system, including HMG-CoA reductase and SREBPs, which are key proteins for cholesterol synthesis. Proteins were extracted from undifferentiated (day 0) murine and human ESCs as well as differentiated (day 10-40). Immunoblotting with anti-ubiquitin antibodies (BD-Bioscience) revealed weaker bands of ubiquitinated proteins in both murine and human ESC at day 0 than those of differentiated murine (day 10) and human (day 40) ESC ( FIG. 12 ). Control loading with anti-b-actin antibody displayed no difference in the β-actin band intensity between the two pairs of cell groups. Thus, protein ubiquitination is more active in undifferentiated ESCs than that in the differentiated ones. The mevalonate pathway leading to cholesterol synthesis also generates non-sterol isoprenoids that have profound biological impacts on various cellular functions, including protein prenylation important for cross-membrane signal transduction and transcriptional regulation.
[0000] 9. Impact of Protein Ubiquitination on EB Formation
[0079] To determine whether protein ubiquitination has any impact on EB formation, hESCs were cultured in hanging-drops with the proteasomal inhibitor MG132 at 100 nm, and then plated in regular culture for 1-2 days. The untreated hESC-derived EB appeared more compact and firmly connected, while the treated EB spread out and surrounded by differentiated cells ( FIG. 13 ). Hence, MG-132 inhibition helped the cell differentiation, suggesting the involvement of ubiquitination in the stem cell differentiation.
[0000] 10. Conversion of 7-Ketocholesterol to Cholesterol in Human HEK 293 Embryonic Kidney Cells with Overexpression of Apolipoprotein-J (apoJ).
[0080] Several embryonic cell lines were recently established with overexpression of apolipoprotein-J, also known as clusterin. Incubation of the cells with radioactive [ 3 H]-7-ketocholesterol (0.5 μci/ml) for 24 hrs led to increased radioactivity in the cells significantly, indicating the uptake of this sterol ( FIG. 14 ). High performance liquid chromatography (HPLC) was performed to separate the cellular and medial lipids, and the radioactivity was measured in the cell lipid extract as well as in culture media. as expected, [ 3 H]-7-ketocholesterol was found in the cells and media at the elution time of about 9 min. Interestingly, free [ 3 H]-cholesterol eluted at nearly 20 min was also detected in the cells but this signal was almost undetectable in the media ( FIG. 14 ). This suggests that the embryonic cells with apoJ overexpression had converted an active metabolism which might convert 7-ketocholesterol into cholesterol.
[0000] 11. Inhibition of Cholesterol Esterization by ACAT Induces Apoptosis Associated with Cholesterol Transport.
[0081] It was tested whether cholesterol accumulation can induce apoptosis in cells treated with the acyl coenzyme-A:cholesterol acyltransferase (ACAT) inhibitor CP-113,818. In situ labeling of DNA fragments were analyzed in murine macrophages treated with the inhibitors using the TUNEL technique. An increase in the number of TUNEL positive cells as a function of the length of incubation of the acLDL-preloaded cells with the ACAT inhibitor CP-113,818 was observed ( FIG. 15 ). However, when treated simultaneously with the hydrophobic amine U18666A, an intracellular cholesterol transport inhibitor and CP-113,818, the number of TUNEL positive cells appearing over time was greatly reduced. U18666A alone had no effect on the number of cells bearing this marker of apoptosis when compared to untreated controls. These TUNEL positive cells showed nuclear morphology typical of apoptosis, including nuclear chromatin condensation and fragmentation. Few TUNEL positive cells were detected in untreated control and in cultures treated with CP-113,818 plus U18666A for 24 h. Thus, inhibition of cholesterol transport with U18666A blocked the apoptotic effect of the ACAT inhibitor.
[0000] 12. The HMG-CoA Reductase Inhibitor Statin Inhibits iNOS Expression in Embryonic Cardiac Myoblasts Induced by Proinflammatory Cytokines.
[0082] In order to determine whether statins affect iNOS expression in embryonic cardiac cells, simvastatin was added into the cell cultures simultaneously with the cytokines. It was observed that in a concentration-dependent fashion, simvastatin markedly diminished expression of iNOS mRNA in H9c2 cells stimulated with the proinflammatory cytokines ( FIG. 16 ). Under the same concentrations, both IL-1α and TNF-α stimulated cells showed a similar response to simvastatin in terms of iNOS mRNA expression. In the presence of simvastatin, IL-1α treated cells showed a dose-dependent decline in iNOS mRNA to the same or similar degrees as that in TNF-α treated cells. Thus, simvastatin reduced steady-state levels of iNOS mRNA in H9c2 cardiac myoblasts stimulated with the proinflammatory cytokines.
[0000] 13. The Isoprenoid Intermediate GGPP Blocks Simvastatin Inhibitory Effect on iNOS Expression.
[0083] In addition to L-mevalonate, several downstream intermediates or by-products from the cholesterol biosynthetic pathway may contribute to the inhibitory effect of simvastatin on expression of iNOS protein and activities. H9c2 cells were pretreated with simvastatin (10 −8 to 10 −7 mol/L) up to 24 h, and then stimulated the cells with IL-1α (20 ng/mL) in the presence or absence of the isoprenoid intermediates, such as GGPP and FPP. Immunoblotting showed that addition of GGPP (10 −7 to 10 −5 mol/L) reversed the simvastatin-mediated suppression of the cytokine-induced expression of iNOS protein (FIGS. 17 A-B) at almost the same levels to those in the L-mevalonate treated cells. In contrast, however, treatment with FPP at the same concentrations as GGPP did not alter nitrite accumulation in the cells pretreated with simvastatin and then IL-1α (not shown). These results suggested that GGPP but not FPP appeared to directly reverse the statin-induced inhibition of iNOS expression in the cardiac myoblasts stimulated with IL-1α.
[0000] 14. Simvastatin Inactivates NF-κB in Cardiac Myoblasts Stimulated with Cytokines.
[0084] The nuclear transcription factor NF-κB binds to the iNOS gene promoter critical for iNOS gene transcription. The effect of simvastatin on IL-1α-induced activation of NF-κB in H9c2 cells was examined by using the gel-shift assay with a 32 P-end-labelled NF-κB oligonucleotide. The nuclear proteins extracted from serum-starved H9c2 cells showed a stronger NF-κB activity after stimulation by IL-1α for 15 min ( FIG. 18 .). The specificity of the NF-κB DNA-protein complex formation was verified by competition with unlabelled, cold oligonucleotides and by addition of anti-NF-κB antibody which super-shifted the bands of NF-κB-DNA complexes ( FIG. 18 .). In addition, there was no significant binding with the oligonucleotide probe alone or by omitting protein substrate or using the nuclear protein extract from the unstimulated H9c2 cells. In the subsequent experiments, the cells were treated with 1 μM of simvastatin before IL-1α stimulation. A time-dependent decline in NF-κB-DNA binding was found ( FIG. 18 , lane 7 to 10). Simvastatin treatment for 24 hours markedly inhibited IL-1α-induced activation of NF-κB ( FIG. 18 , lane 11) (P<0.001 vs IL-1α-stimulated cells). Inclusion of antibody directed against NF-κB in the binding reactions resulted in a further reduction in the IL-1α-induced mobility of the complex ( FIG. 18 , lane 12). The reduction in the nuclear NF-κB activity did not appear to be due to overall inhibition of expression of this transcription factor by the statin, as immunoblotting analysis of total cellular NF-κB levels showed no significant difference between simvastatin-treated or untreated cells with cytokine stimulation.
[0000] 15. Simvastatin Increases the Phosphorylated IκBα in the Cytosol.
[0085] Under the physiological conditions, NF-κB is sequestered as an inactive form in the cytosol through non-covalent interactions with inhibitory proteins, such as IκBα, β and ε. Each IκB isoform contains, in its N-terminal region, a pair of serine residues. In the case of IκBα, these serine residues (amino acids 32 and 36) become phosphorylated by a serine-specific kinase following stimulation. Phosphorylation does not disassociate IκBα from NF-κB but renders IκBα a substrate for ubiquitination and then degradation by the 26S proteasome. In order to provide further insight into the regulatory role of simvastatin, by immunoblotting with a specific antibody to IκB, the IL-1α-induced degradation of IκBα phosphorylated at Ser 32 in the presence or absence of simvastatin was observed. After 15 minutes treatment with 20 ng/mL IL-1α, a decrease in the cellular content of Ser 32 -phosphorylated IκBα in H9c2 cells was observed. However, in the cytokine-stimulated cells, pretreatment of with simvastatin (10 −8 to 10 −6 mol/L) increased the levels of Ser 32 -phosphorylated IκBα in a dose-dependent manner ( FIG. 19 ). The highest levels of the phosphorylated IκBα were detected in H9c2 cells exposed to the statin at 10 −7 mol/L for 24 h ( FIG. 19 ). The increased accumulation of phosphorylated IκBα in the simvastatin-treated cells implicates a prolonged lifespan or a lower rate of degradation of phosphorylated IκB protein that inactivates NF-κB.
[0000] 16. Simvastatin Promotes Cardiomyogenic Differentiation of Embryonic Stem Cells
[0086] It was tested whether statin treatment has any impact on myogenesis in embryonic stem cells. Western blot was conducted in simvastatin-treated and untreated murine embryonic stem cells with monoclonal antibodies against cardiac sarcomeric α-actinin. Stem cells were cultured in a hanging drop system for 4 days and then transferred to petric dishes for further development. A dose-dependent increase in cardiac myogenesis was found, evidenced by increased expression of cardiac sarcomeric α-actinin ( FIG. 20 ) and appearance of contractile myocytes ( FIG. 21 ). The induction of beating myocytes in the statin-treated ESCs could be partially blocked by L-mevalonate.
[0000] 17. Potential Applications for Non-Sterol Isoprenoid Intermediates
[0087] Cholesterol synthesis generates non-sterol isoprenoid intermediates as by-products, which can promote protein prenylation as well as signal transduction potentially important for stem cell growth, survival and differentiation as well as atherosclerosis and inflammation (62-64,83,84). Abnormal synthesis and metabolism of cholesterol may cause certain severe pathological conditions. For instance, hypercholesterolemia is a causitive risk factor for atherosclerosis (85), a chronic arterial disease with life-threatening complications, namely myocardial and cerebral infarctions, which is the leading cause of death in the United States, while hypocholesterolemia characterizes the Smith-Lemli-Opitz syndrome (SLOS) (75,76,85), a recessive autosomal genetic disease characterized by a deficit in cholesterol production with a series of malformations (microcephaly, corpus callosum agenesis, holoprosencephaly, and mental retardation), male pseudohermaphroditism, finger anomalies, and failure to thrive.
[0088] Little is known, however, about the potential role of cholesterol biosynthesis and metabolism in regulation of hESC function, and the hESC pluripotency in growth, survival and differentiation. It is proposed that hESCs undergo active cholesterol synthesis and metabolism, and that regulation of the production of cholesterol and its derivatives plays a critical role for the maintenance of hESC pluripotency in proliferation, survival and differentiation under both physiological or pathophysiological conditions. At least some of the existing cholesterol-lowering drug statins may have potentially beneficial effects on hESCs, apart from their customery use. Millions of patients are taking one of the statin drugs now for prevention and treatment of atherosclerosis, but the biosafety of this HMG-CoA reductase inhibitor is still a concern among health providers and patients. In this regard, hESCs provide a highly valuable model for testing the effect of statins on human embryonic development. Because the isoprenoids prenylate a number of membrane-bound or receptor-associated proteins important for cell signal transduction, it is now proposed for the first time that one or more non-sterol isoprenoid intermediate of cholesterol synthesis or mevanolate/isoprenoid pathway inhibitors will be potentially useful as a therapeutic drug, and can be used in combination with stem cell therapy. The intermediate compounds geranylgeranyl pyrophosphate (PPGG) and geranyl pyrophosphate (PGG), for example, are expected to modulate apoptosis in stem cells, myoblasts and other cells by isoprenoid-mediated signaling transduction. Potential applications include protective effects for stem cells, and treatment of a variety of degenerative diseases, wound healing and cancer treatment. It is expected that further analysis of prenylated membrane proteins and cell signaling in hESCs will demonstrate the feasibility of this approach to development of this type of new, non-sterol therapeutic compounds.
[0000] 18. Effects of Simvastatin on Cardiomyocyte Differentiation
[0089] Spontaneous cardiac differentiation of mouse embryonic stem cells (mESCs) was assessed in vitro as the presence of rhythmically beating embryonic blastocyst (EB) outgrowth. To determine the effects of cholesterol depletion on differentiation by blocking the HMG-CoA reductase activity with statin, some cultures were supplemented with simvastatin (10 −8 -10 −6 mol/L) after plating the EBs from the hanging drops (day zero). Thereafter, EB outgrowths were counted periodically under the inverted microscope equipped with a digital video camera, to determine whether or not they contained beating foci at different time points (days 3, 5, 7, 10, 12, and 14). At approximately day 7, contracting areas began to appear. There was no major difference in the size and beating foci between the simvastatin-treated and untreated EBs, indicating that the statin treatment did not prevent EB formation and early myogenesis. At day 12, simvastatin exposure increased the percentage of beating EB outgrowths (42±0.1%) compared to that of the untreated control EBs (18±0.1%) ( FIG. 22A ). Concomitant with the increased number of beating EBs, the size of the beating area for simvastatin-treated EBs increased 2-fold (evaluated at day 12) compared to that of untreated control EBs, a significant augmentation (p<0.05) ( FIG. 22B ).
[0090] To determine whether the statin induction of contracting EBs occurred by blocking the HMG-CoA reductase activity or inhibiting L-mevalonate synthesis (a key intermediate of cholesterol synthesis from acetyl-CoA), exogenous L-mevalonate was added into the cultures of EBs in the presence or absence of 10 −6 mol/L simvastatin. It was observed that adding excess L-mevalonate significantly decreased the incidence of beating foci in the EBs exposed to simvastatin—without any cytotoxicity ( FIG. 22A ). However, in the absence of simvastatin, L-mevalonate had no or little effect on contracting EBs ( FIG. 22A ), suggesting that L-mevalonate selectively blocked the simvastatin stimulatory effect on cardiac differentiation. All analyzed EB outgrowths showed a similar developmental pattern with contracting cells first appearing at the periphery of EB outgrowths.
[0091] To establish the phenotypic characteristics of EB outgrowths, expression of cardiac-specific proteins was assessed by immunoblotting with antibodies against sarcomeric α-actinin and myocardin A, a key regulator of cardiac myogenesis (57). By day 12, in a dose-dependent fashion, simvastatin treatment increased expression of both sarcomeric α-actinin ( FIGS. 23A and C) and myocardin A ( FIGS. 23B and D), while the statin had little impact (not shown) on expression of Tie-2, an endothelian cell-specific protein potentially important for vascular tissue formation (58).
[0092] Under the same cell culture conditions specific for cardiomyocyte differentiation, untreated EBs showed modest expression of sarcomeric α-actinin, and myocardin A ( FIG. 23A, 23B ). Thus, treatment with simvastatin appeared to enhance expression of cardiac-specific proteins in a concentration-dependent manner. The range of simvastatin concentrations leading to induction of cardiac differentiation is comparable to the drug plasma levels in patients treated with the statin (20).
[0000] 19. Effects of Simvastatin on Apoptosis of Embryonic Myoblasts Induced by IL-1
[0093] It was previously demonstrated that simvastatin treatment can attenuate iNOS expression and NO synthesis in cytokine-stimulated embryonic cardiac myoblasts (45). Because the high output of NO production is pro-apoptotic, it was hypothesized whether simvastatin can increase the resistance of myogenic cells against apoptosis induced by IL-1, a proinflammatory cytokine. The committed H9C2 embryonic myoblasts were pretreated with simvastatin (10 −7 -10 −6 mol/L), and then IL-1 (20 ng/mL) was added into the cultures to trigger apoptosis. The proapoptotic protein Bad and anti-apoptotic protein Bcl-x L (59,60) wwere analyzed by immunoblotting. In the cells without statin treatment, IL-1 reduced expression of the anti-apoptotic protein Bcl-x L but had no significant effects on Bad expression ( FIGS. 24A and 24B ). Adding simvastatin (10 −7 -10 −6 mol/L) significantly diminished the IL-1 inhibitory effects. The simvastatin effect appeared to be mediated by the mevalonate pathway because adding L-mevalonate reversed the statin effect ( FIG. 24B ). The proliferating cell nuclear antigen was also down-regulated by IL-1 treatment, which could be partially blocked by adding simvastatin under a mechanism controlled by mevalonate ( FIG. 24C ). Treatment with simvastatin significantly diminished expression of iNOS ( FIG. 25A ) and MnSOD ( FIG. 25B ).
[0094] Furthermore, it was examined whether simvastatin exerts protective effects against apoptosis induced with IL-1 by staining with the fluorochromes acridine orange and ethidium bromide in H9c2 embryonic myoblasts. In untreated cells, low rates (less than 5%) of apoptosis occurred spontaneously ( FIG. 26 , Panel A). However, exposure to the cytokine for a prolonged period of time led to increased apoptosis ( FIG. 5 , Panel B). Incubation with IL-1 (20 ng/mL) for 48 to 72 hours induced significant elevation of cell death by 2- to 3-fold (p<0.05). Interestingly, in agreement with a previous finding (45), simvastatin significantly increased cell viability and reduced numbers of apoptotic cells in the cultures with IL-1 ( FIG. 26 , Panels C-E). The simvastatin cytoprotective effect was diminished by L-mevalonate ( FIG. 26 , Panel F).
[0095] Thus, simvastatin may not only induce myogenic differentiation but also protect differentiated cardiac cells and premature embryonic cardiomyoblasts against cytokine-induced apoptosis. Simvastatin is a representative statin with biological activities shared by other statins, such as atorvastatin, cerivastatin, fluvastatin, lovastatin, mevastatin, pitavastatin, rosuvastatin, and ezetimibe, which are expected to provide effects similar to those described above.
[0000] Discussion
[0096] The embryonic H9c2 cardiac myoblast model has been used widely to study cardiac stem cell development and differentiation. Highly resembling premature cardiac myogenic cells, H9c2 cells show well-characterized cardiac properties in electrophysiology as well as in cellular receptor and signal transduction (26,27). It is notable that the embryonic H9c2 cardiac myoblasts can constitutively express iNOS as well as eNOS at low levels under the normal cell culture. The constitutively expressed, moderate NOS activities may reflect the role of NO in intracellular signalling of undifferentiated, premature myoblasts. Bloch et al. (28,29) have reported that both iNOS and eNOS exist in E9.5 rat and murine embryos, correlated with high expression of soluble guanylylcyclase as well as a high cyclic GMP content. The NO production mediated by the NOS isoforms present constitutively in the cardiac myogenic cells contributes to cardiomyogenesis, since continuous incubation of EBs with the NOS inhibitors results in a pronounced differentiation arrest in the premature cardiomyocytes, and coapplication of NO-donors reverses the inhibitory effect.
[0097] However, the high-output, persistent NO production via overexpression of iNOS induced by proinflammatory cytokines may have deteriorating effects on cardiac cells (8,13). In this study, it was shown that the H9c2 premature cardiac cell line is sensitive to stimulation of proinflammatory cytokines such as IL-1α and TNFα. The high levels of iNOS expression and NO production in this premature, delicate myocyte progenitor suggests a vulnerability of cardiac stem cells to the proinflammatory environment of the hearts with acute infarction or ischemic injury. Because the high output of NO production causes cardiac cell dysfunction and even apoptotic cell death, inhibition of iNOS expression may have benefit impacts on the stem cell survival and differentiation. Increased resistance to proinflammatory or pro-apoptotic insults may represent a key factor that leads to a successful cardiac stem cell therapy. Current data from the in vitro studies provide clear evidence that the cholesterol-lowering drugs, statins, can regulate iNOS expression. The statin regulatory effect on iNOS expression appears through specific inhibition of HMG CoA reductase, reversibly blocked by excess amounts of L-mevalonate. The statin effect seems however independent of the statin-mediated reduction in cholesterol synthesis because addition of exogenous cholesterol does not prevent the statin effect. The concentrations for simvastatin achieving its inhibitory effect are as low as 10 −8 mol/L. The dosage of 10 −8 -10 −6 mol/L is close to the range of the expected plasma levels of simvastatin in clinical application (20). This suggests that statins, at the current therapeutic dosages, may block iNOS expression during inflammation.
[0098] In this study, the mechanism by which statins regulate iNOS expression was demonstrated, showing that simvastatin acts multilaterally at different phases of iNOS expression, and on the levels of mRNA, protein and enzymatic activities. Recently, the isoprenoid intermediates, including GGPP and FPP, have been implicated in contributing to the statin regulatory effects on expression of NOS expression. This is largely due to the fact that addition of GGPP significantly can diminish the statin-inhibitory effect. It has been previously demonstrated that, in addition to reducing hepatic cholesterol biosynthesis by inhibiting HMG CoA reductase, statins may display biological activities associated with depletion of L-mevalonate as well as biologically active isoprenoid intermediates. Some of the isoprenoids (e.g., GGPP) play an important role in the covalent attachment to cell membranes, subcellular localization, and intracellular trafficking of membrane-associated proteins, including regulating endothelial cell function (30). In this study it was observed that the addition of GGPP, but not FPP, prevented the inhibitory effect of simvastatin on cytokine-induced iNOS expression and activity, indicating that the inhibition of post-translational geranylgeranylation, but not of farnesylation, can be related to the inhibitory effect of simvastatin on cytokine-induced iNOS expression in the premature myoblasts.
[0099] The Rho proteins (23) are a group of small GTP-binding molecules involved in the control of NOS protein expression and turnover in cardiovascular cells (11,31,32). The members of the Rho family including RhoA, RhoB, Rac and Cdc42 proteins are normally geranylgeranylated, whereas Ras proteins are predominantly farnesylated. Current data from the studies with the Rho kinase inhibitor point to the involvement of Rho proteins in simvastatin-associated iNOS inhibition in premature cardiac myoblasts. Rho kinase activation has been implicated to reduce iNOS activities. In this study, it was found that inhibition of Rho kinase with Y-27632 enhances NO production in cytokine-stimulated H9c2 cells. Furthermore, with enzymatic assays, it was demonstrated that the statin treatment can reduce the Rho kinase activity as well. This finding is consistent with previous reports that lipid-soluble statins (e.g., lovastatin, simvastatin, and atorvastatin) inhibit the Rho kinase activity (33). However, from the data generated in this study, the simvastatin treatment did not appear to cause superinduction but suppression of iNOS expression by IL-1 in H9c2 cells, unlike the previous study conducted in vascular smooth muscle cells (33). The different statin effects between the embryonic cardiac myoblasts and mature smooth muscle cells may reflect the fact that different signal transduction pathways may operate in different types of cells.
[0100] Pretreatment with lovastatin, an inhibitor of protein prenylation, resulted in superinduction of iNOS. This superinduction can be reversed by geranylgeraniol, but not by farnesol, suggesting that inhibition of geranylgeranylation, not farnesylation, is responsible for enhanced iNOS expression. The results demonstrate that a farnesylated protein(s) mediates IL-1beta induction of iNOS, whereas a geranylgeranylated protein(s) represses this induction. Also, by modulating Ras farnesyl protein transferase, lovastatin blocks LPS-induced iNOS expression in rat primary astrocytes in a manner reversible by L-mevalonate and farnesylpyrophosphate (14). However, on the contrary, treatment with cerivastatin and fluvastatin was recently reported to enhance cytokine induction of NO synthesis in rat vascular smooth muscle cells (16). An increase in IL-1β-induced nitrite production and apoptosis in adult cardiac myocytes may occur after treatment with very high concentrations (10 −5 and 10 −4 mol/L) of fluvastatin through inhibition of Rho-associated kinase (34,35). In addition, there have been reports showing that statin treatment may induce apoptosis of vascular cells (35-37). However, in the present system, no appreciable cell death via apoptosis was observed in the statin-treated cardiac myoblasts, regardless of the presence or absence of the proinflammatory cytokines. Recent studies (38,39) have also demonstrated that statin treatment can increase numbers of circulating endothelial cell progenitors, suggesting that statins are cytoprotective rather than cytotoxic to the undifferentiated, embryonic stem cells.
[0101] The cytokine induction of iNOS expression involves multiple transcription factors, in particular the nuclear factor NF-κB. Upon activation by cytokines (e.g., IL-1 and TNF-α, NF-κB translocates from the cytosolic compartment to the nucleus, where it binds to the iNOS gene promotor, and ultimately triggers iNOS gene transcription. This process is mediated by kinase-mediated protein phosphorylation and requires disassociation between NF-κB and its native inhibitor IκB. One of the statins, mevastatin, has been reported to inactivate NF-κB and reduce NF-κB-dependent expression of the endothelial adhesion proteins, VCAM and E-selectin (40). Consistently, the data from the current study clearly shows that simvastatin treatment can reduce NF-κB nuclear translocation and elevate the cytosolic content of phosphorylated IκBα. Rho associated kinases (ROCK) have been reported to mediate the regulatory effect of statins on iNOS expression in airway epithelial cells (41). ROCK may control the iNOS gene promoter activities via NF-κB, however, the ROCK inhibitor Y-27632 shows different effects from those of statins in terms of iNOS gene activation. Thus, it is likely that statins may regulate cytokine-induced iNOS expression through different signal pathways which involve both Y-27632-sensitive and insensitive signalling as well as the NF-κ-B and IκBα interaction ( FIG. 9 ).
[0102] At the present time, there is still a dispute in this field as to whether NO protects or damages the myocardium during inflammation or whether statin suppression of iNOS expression is beneficial or harmful to the heart (2). It has been recently established that simvastatin reduces reperfusion injury in the isolated-perfused working rat heart by preventing eNOS from inactivation and by suppressing ischemia-related iNOS induction, which correlates with a reduction in cardiomyocyte apoptosis (17). The current finding that simvastatin decreases cytokine-induced iNOS expression in cultured premature cardiac myoblasts illustrates a causal relationship between increased NO and depressed cardiac contractility in heart failure. Further clarification of the mechanism underlying the statin effect on NO production and survival of cardiac stem cells may provide valuable information that will help in designing therapies for patients with myocardial infarction or ischemic heart failure.
[0103] While the preferred embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is only limited by the claims, that scope including all equivalents of the subject matter of the claims. The disclosures of all patents, patent applications and publications cited herein are hereby incorporated herein by reference to the extent that they describe materials, methods or other details supplementary to those set forth herein.
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Schultheiss T M, et al. 1997 Genes Dev, February 15; 11(4):451-62 | A method of enhancing survival and differentiation of stem cells, and cells of myogenic lineage derived from said stem cells, when the cells are exposed to an inflammatory or apoptotic stimulus comprises culturing stem cells in vitro in a medium containing a statin, to produce statin-pretreated cells with enhanced resistance to inflammatory or apoptotic stimuli. Additionally, the statin-pretreated cells may be caused or allowed to differentiate into statin-pretreated cells of myogenic lineage (e.g., cells having a vascular or cardiac myocyte phenotype). The resulting inflammation- and apoptosis resistant cells may then be used for cell therapy, as in treating an ischemic or infarcted vessel or heart. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a Continuation of Ser. No. 11/066,448 filed on Feb. 28, 2005, which is a Continuation of Ser. No. 10/933,267 filed on Sep. 3, 2004, now issued as U.S. Pat. No. 6,974,212, which is a Continuation of Ser. No. 10/636,249 filed on Aug. 8, 2003, now issued as U.S. Pat. No. 6,796,651, which is a Divisional of 09/575,182 filed on May 23, 2000, now issued as U.S. Pat. No. 6,924,907, all of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a compact printer system able to print full-color, business card size documents from a device about the size of a pen. The system includes various hot-connectable modules that provide a range of functions. In particular the invention relates to a compact color printer that provides a print function for the compact printer system.
[0003] Reference may be had to co-pending applications claiming priority from Australian Provisional Patent Application number PQ0560 dated 25 May 1999. The co-pending applications describe related modules and methods for implementing the compact printer system. The co-pending applications are as follows:
Docket USSN No. Title 6,712,452 PP02 Modular Compact Printer System 6,416,160 PP03 Nozzle Capping Mechanism 6,238,043 PP04 Ink Cartridge for Compact Printer System 6,958,826 PP07 Controller for Printer Module 6,812,972 PP08 Camera Module for Compact Printer System 09/575,157 PP09 Image Processor for Camera Module 6,553,459 PP10 Memory Module for Compact Printer System 6,967,741 PP11 Effects Module for Compact Printer System 6,956,669 PP12 Effects Processor for Effects Module 6,903,766 PP13 Timer Module for Compact Printer System 6,804,026 PP15 Color Conversion Method for Compact Printer System 09/575,120 PP16 Method and Apparatus of Dithering 6,975,429 PP17 Method and Apparatus of Image Conversion
BACKGROUND OF THE INVENTION
[0004] Microelectronic manufacturing techniques have led to the miniaturization of numerous devices. Mobile phones, personal digital assistant devices, and digital cameras are very common examples of the miniaturization trend.
[0005] One device that has not seen the advantage of microelectronic manufacturing techniques is the printer. Commercially available printers are large compared to many of the devices they could support. For instance, it is impractical to carry a color printer for the purpose of instantly printing photographs taken with known compact digital cameras.
[0006] A compact printhead has been described in co-pending United States Patent Applications filed simultaneously to the present application and hereby incorporated by cross reference:
USSN Docket No. Title 7,018,016 MJ62 Fluidic seal for an ink jet nozzle assembly 6,428,133 IJ52 Ink jet printhead having a moving nozzle with an externally arranged actuator 6,526,658 IJM52 Method of manufacture of an ink jet printhead having a moving nozzle with an externally arranged actuator 6,328,417 MJ63 Ink jet printhead nozzle array 6,390,591 MJ58 Nozzle guard for an ink jet printhead
SUMMARY OF THE INVENTION
[0007] According to one aspect of the invention, there is provided a printing assembly comprising:
[0008] a printing subassembly having a printhead and at least one first roller adjacent to the printhead; and
[0009] an ink cartridge including a housing, the housing defining at least one ink reservoir, and at least one second roller mounted to the housing, the second roller being arranged to cooperate with the first roller to draw print media past the printhead.
[0010] According to another aspect of the invention, there is provided a printer module for a compact printer system comprising:
[0000] an elongate body;
[0000] a stationary printhead housed within the body,
[0000] means for moving a printable media past the stationary printhead;
[0000] an ink reservoir within the body and communicating with the printhead;
[0000] means within the body for storing an image to be printed by the printhead; and
[0000] means for transferring the image to the printhead;
[0000] the printhead printing the image on substantially the full width of the printable media in a single pass.
[0011] According to one embodiment of the present invention there is provided an ink cartridge for an inkjet printer comprising a housing defining at least one ink reservoir and at least one second roller mounted to the housing.
[0012] Further features of the invention will be evident from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order to assist with describing preferred embodiments of the invention, reference will be made to the following figures in which:
[0014] FIG. 1 is a printer module;
[0015] FIG. 2 is a camera module;
[0016] FIG. 3 is a memory module;
[0017] FIG. 4 is a communication module;
[0018] FIG. 5 is a flash module;
[0019] FIG. 6 is a timer module;
[0020] FIG. 7 is a laser module;
[0021] FIG. 8 is an effects module;
[0022] FIG. 9 is a characters module;
[0023] FIG. 10 is an adaptor module;
[0024] FIG. 11 is a pen module;
[0025] FIG. 12 is a dispenser module;
[0026] FIG. 13 is a first compact printer configuration;
[0027] FIG. 14 is a second compact printer configuration;
[0028] FIG. 15 is a third compact printer configuration;
[0029] FIG. 16 is a fourth compact printer configuration;
[0030] FIG. 17 is an exploded view of the Printer Module of FIG. 1 ;
[0031] FIG. 18 is a top view of the Printer Module with ink cartridge removed;
[0032] FIG. 19 is a cross-sectional view through AA in FIG. 18 ; and
[0033] FIG. 20 is a block circuit diagram of a controller for the printer module.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Referring to FIGS. 1 to 12 , there are shown various modules that together form a compact printer system. Individual modules can be attached and detached from the compact printer configuration to allow a user-definable solution to business-card sized printing. Images can also be transferred from one compact printer to another without the use of a secondary computer system. Modules have a minimal user-interface to allow straightforward interaction.
[0035] A compact printer system configuration consists of a number of compact printer modules connected together. Each compact printer module has a function that contributes to the overall functionality of the particular compact printer configuration. Each compact printer module is typically shaped like part of a pen, physically connecting with other compact printer modules to form the complete pen-shaped device. The length of the compact printer device depends on the number and type of compact printer modules connected. The functionality of a compact printer configuration depends on the compact printer modules in the given configuration.
[0036] The compact printer modules connect both physically and logically. The physical connection allows modules to be connected in any order, and the logical connection is taken care of by the compact printer Serial Bus—a bus that provides power, allows the modules to self configure and provides for the transfer of data.
[0037] In terms of physical connection, most compact printer modules consist of a central body, a male connector at one end, and a female connector at the other. Since most modules have both a male and female connector, the modules can typically be connected in any order. Certain modules only have a male or a female connector, but this is determined by the function of the module. Adaptor modules allow these single-connector modules to be connected at either end of a given compact printer configuration.
[0038] A four wire physical connection between all the compact printer modules provides the logical connection between them in the form of the compact printer Serial Bus. The compact printer Serial Bus provides power to each module, and provides the means by which data is transferred between modules. Importantly, the compact printer Serial Bus and accompanying protocol provides the means by which the compact printer system auto-configures, reducing the user-interface burden on the end-user.
[0039] Compact printer modules can be grouped into three types:
[0040] image processing modules including a Printer Module ( FIG. 1 ), a Camera Module ( FIG. 2 ), and a Memory Module ( FIG. 3 ). Image processing modules are primarily what sets the compact printer system apart from other pen-like devices. Image processing modules capture, print, store or manipulate photographic images;
[0041] housekeeping modules including an Adapter Module ( FIG. 10 ), an Effects Module ( FIG. 8 ), a Communications Module ( FIG. 4 ), and a Timer Module ( FIG. 6 ). Housekeeping modules provide services to other modules or extended functionality to other modules; and isolated modules including a Pen Module ( FIG. 11 ) and a Laser Module ( FIG. 7 ). Isolated modules are those that attach to the compact printer system but are completely independent of any other module. They do not necessarily require power, and may even provide their own power. Isolated Modules are defined because the functionality they provide is typically incorporated into other pen-like devices.
[0042] Although housekeeping modules and isolated modules are useful components in a compact printer system, they are extras in a system dedicated to image processing and photographic manipulation. Life size (1:1) illustrations of the compact printer modules are shown in FIGS. 1 to 12 , and example configurations produced by connecting various modules together are shown in FIGS. 13 to 16 .
[0043] FIG. 1 shows a printer module that incorporates a compact printhead described in Co-pending United States Patent Applications listed in the Background section of this application, incorporated herewith by reference, and referred to herewith as a Memjet printhead. The Memjet printhead is a drop-on-demand 1600 dpi inkjet printer that produces bi-level dots in up to 4 colors to produce a printed page of a particular width. Since the printhead prints dots at 1600 dpi, each dot is approximately 22.5 μm in diameter, and spaced 15.875 μm apart. Because the printing is bi-level, the input image should be dithered or error-diffused for best results. Typically a Memjet printhead for a particular application is page-width. This enables the printhead to be stationary and allows the paper to move past the printhead. A Memjet printhead is composed of a number of identical ½ inch Memjet segments.
[0044] The printer module 10 comprises a body 11 housing the Memjet printhead. Power is supplied by a three volt battery housed in battery compartment 12 . The printhead is activated to commence printing when a business card (or similar sized printable media) is inserted into slot 13 . Male connector 14 and female connector 15 facilitate connection of other modules to the printer module 10 .
[0045] FIG. 2 shows a camera module 20 . The camera module provides a point-and-shoot camera component to the compact printer system as a means of capturing images. The camera module comprises a body 21 having a female connector 22 . A lens 23 directs an image to an image sensor and specialized image processing chip within the camera 24 . A conventional view finder 25 is provided as well as a lens cap 26 . An image is captured when the Take button 27 is pushed. Captured images are transferred to the Printer Module 10 for subsequent printing, manipulation, or storage. The Camera Module also contains a self-timer mode similar to that found on regular cameras.
[0046] FIG. 3 shows a Memory Module 30 comprising a body 31 , LCD 32 , IN button 33 , OUT button 34 and SELECT button 35 . The Memory Module 30 is a standard module used for storing photographic images captured by the Camera 20 . The memory module stores 48 images, each of which can be accessed either at full resolution or at thumbnail resolution. Full resolution provides read and write access to individual images, and thumbnail resolution provides read access to 16 images at once in thumbnail form.
[0047] The Memory Module 30 attaches to other modules via a female connector 36 or male connector 37 . The male and female connectors allow the module to be connected at either end of a configuration. Power is provided from the Printer Module 10 via the Serial Bus.
[0048] A Communications Module 40 is shown in FIG. 4 . The communications module 40 consists of a connector 41 and a cable 42 that terminates in an appropriate connector for a computer port, such as a USB port, RS232 serial port or parallel port. The Communications Module 40 allows the compact printer system to be connected to a computer. When so connected, images can be transferred between the computer and the various modules of the compact printer system. The communications module allows captured images to be downloaded to the computer, and new images for printing to be uploaded into the printer module 10 .
[0049] A Flash Module 50 is shown in FIG. 5 . The Flash Module 50 is used to generate a flash with flash cell 51 when taking photographs with the Camera Module 20 . The Flash Module attaches to other modules via female connector 52 and male connector 53 . It contains its own power source. The Flash Module is automatically selected by the Camera Module when required. A simple switch allows the Flash Module to be explicitly turned off to maximize battery life.
[0050] FIG. 6 shows a Timer Module 60 that is used to automate the taking of multiple photos with the Camera Module 20 , each photo separated by a specific time interval. The captured photos are stored in Memory Module 30 . Any flash requirements are handled by the Camera Module 20 , and can therefore be ignored by the Timer Module. The Timer Module 60 consists of a body 61 housing a LCD 62 , START/STOP button 63 and UNITS button 64 . A SELECT button 65 allows the user to select time units and the number of units are set by UNITS button 64 . The Timer Module 60 includes a male connector 66 and female connector 67 . The Timer Module takes its power from the Printer Module 10 via the Serial Bus.
[0051] A Laser Module 70 is shown in FIG. 7 . The Laser Module 70 consists of a body 71 containing a conventional laser pointer operated by button 72 . As the Laser Module is a terminal module it only has one connector, which in the example is a male connector 73 . The Laser Module is an isolated module, in that it does not perform any image capture, storage, or processing. It exists as a functional addition to the compact printer system. It is provided because laser pointer services are typically incorporated into other pen-like devices. The Laser Module contains its own power supply and does not appear as a device on the Serial Bus.
[0052] The Effects Module shown in FIG. 8 is an image processing module. It allows a user to select a number of effects and applies them to the current image stored in the Printer Module 10 . The effects include borders, clip-art, captions, warps, color changes, and painting styles. The Effects Module comprises a body 81 housing custom electronics and a LCD 82 . A CHOOSE button 83 allows a user to choose between a number of different types of effects. A SELECT button 84 allows the user to select one effect from the number of effects of the chosen type. Pressing the APPLY button 85 applies the effect to image stored in the Printer Module 10 . The Effects Module obtains power from the Serial Bus. Male connector 86 and female connector 87 allow the Effects Module to be connected to other compact printer system modules.
[0053] FIG. 9 shows a Character Module 90 that is a special type of Effects Module (described above) that only contains character clip-art effects of a given topic or genre. Examples include The Simpsons®, Star Wars®, Batman®, and Dilbert® as well as company specific modules for McDonalds® etc. As such it is an image processing module. It consists of a body 91 housing custom electronics and a LCD 92 . SELECT button 93 allows the user to choose the effect that is to be applied with APPLY button 94 . The Character Module obtains power from the Serial Bus through male connector 95 and female connector 96 .
[0054] The Adaptor Module 100 , shown in FIG. 10 , is a female/female connector that allows connection between two modules that terminate in male connectors. A male/male connector (not shown) allows connection between two modules that terminate in female connectors. The Adaptor Module is a housekeeping module, in that it facilitates the use of other modules, and does not perform any specific processing of its own.
[0055] All “through” modules have a male connector at one end, and a female connector at the other end. The modules can therefore be chained together, with each module connected at either end of the chain. However some modules, such as the Laser Module 70 , are terminating modules, and therefore have either a male or female connector only. Such single-connector modules can only be connected at one end of the chain. If two such modules are to be connected at the one time, an Adaptor Module 100 is required.
[0056] FIG. 11 shows a Pen Module 110 which is a pen in a module form. It is an isolated module in that it attaches to the compact printer system but is completely independent of any other module. It does not consume or require any power. The Pen Module is defined because it is a convenient extension of a pen shaped, pen sized device. It may also come with a cap 111 . The cap may be used to keep terminating connectors clean in the case where the chain ends with a connector rather than a terminating module.
[0057] To assist with accurately feeding a business card sized print media into slot 13 of the printer module 10 , a dispenser module 120 is provided as shown in FIG. 12 . The dispenser module 120 comprises a body 121 that holds a store of business card sized print media. A Printer Module 10 locates into socket 122 on the dispenser module 120 . When correctly aligned, a card dispensed from the dispenser module by slider 123 enters slot 13 and is printed.
[0058] In the sense that a minimum configuration compact printer system must be able to print out photos, a minimum compact printer configuration contains at least a Printer Module 10 . The Printer Module holds a single photographic image that can be printed out via its. Memjet printer. It also contains the 3V battery required to power the compact printer system.
[0059] In this minimum configuration, the user is only able to print out photos. Each time a user inserts a business card 130 into the slot in the Printer Module, the image in the Printer Module is printed onto the card. The same image is printed each time a business card is inserted into the printer. In this minimum configuration there is no way for a user to change the image that is printed. The dispenser module 120 can be used to feed cards 130 into the Printer Module with a minimum of fuss, as shown in FIG. 13 .
[0060] By connecting a Camera Module 20 to the minimum configuration compact printer system the user now has an instant printing digital camera in a pen, as shown in FIG. 14 . The Camera Module 20 provides the mechanism for capturing images and the Printer Module 10 provides the mechanism for printing them out. The battery in the Printer Module provides power for both the camera and the printer.
[0061] When the user presses the “Take” button 27 on the Camera Module 20 , the image is captured by the camera 24 and transferred to the Printer Module 10 . Each time a business card is inserted into the printer the captured image is printed out. If the user presses “Take” on the Camera Module again, the old image in the Printer Module is replaced by the new image.
[0062] If the Camera Module is subsequently detached from the compact printer system, the captured image remains in the Printer Module, and can be printed out as many times as desired. The Camera Module is simply there to capture images to be placed in the Printer Module.
[0063] FIG. 15 shows a further configuration in which a Memory Module 30 is connected to the configuration of FIG. 14 . In the embodiment of FIG. 15 , the user has the ability to transfer images between the Printer Module 10 and a storage area contained in the Memory Module 30 . The user selects the image number on the Memory Module, and then either sends that image to the Printer Module (replacing whatever image was already stored there), or brings the current image from the Printer Module to the specified image number in the Memory Module. The Memory Module also provides a way of sending sets of thumbnail images to the Printer Module.
[0064] Multiple Memory Modules can be included in a given system, extending the number of images that can be stored. A given Memory Module can be disconnected from one compact printer system and connected to another for subsequent image printing.
[0065] With the Camera Module 20 attached to a Memory Module/Printer Module compact printer system, as shown in FIG. 15 , the user can “Take” an image with the Camera Module, then transfer it to the specified image number in the Memory Module. The captured images can then be printed out in any order.
[0066] By connecting a Communications Module 40 to the minimum configuration compact printer system, the user gains the ability to transfer images between a PC and the compact printer system. FIG. 16 shows the configuration of FIG. 15 with the addition of a Communications Module 40 . The Communications Module makes the Printer Module 10 and any Memory Modules 30 visible to an external computer system. This allows the download or uploading of images. The communications module also allows computer control of any connected compact printer modules, such as the Camera Module 20 .
[0067] In the general case, the Printer Module holds the “current” image, and the other modules function with respect to this central repository of the current image. The Printer Module is therefore the central location for image interchange in the compact printer system, and the Printer Module provides a service to other modules as specified by user interaction.
[0068] A given module may act as an image source. It therefore has the ability to transfer an image to the Printer Module. A different module may act as an image store. It therefore has the ability to read the image from the Printer Module. Some modules act as both image store and image source. These modules can both read images from and write images to the Printer Module's current image.
[0069] The standard image type has a single conceptual definition. The image definition is derived from the physical attributes of the printhead used in the Printer Module. The printhead is 2 inches wide and prints at 1600 dpi in cyan, magenta and yellow bi-level dots. Consequently a printed image from the compact printer system is 3200 bi-level dots wide.
[0070] The compact printer system prints on business card sized pages (85 mm×55 mm). Since the printhead is 2 inches wide, the business cards are printed such that 1 line of dots is 2 inches. 2 inches is 50.8 mm, leaving a 2 mm edge on a standard business-card sized page. The length of the image is derived from the same card size with a 2 mm edge. Consequently the printed image length is 81 mm, which equals 5100 1600 dpi dots. The printed area of a page is therefore 81 mm×51 mm, or 5100×3200 dots.
[0071] To obtain an integral contone to bi-level ratio a contone resolution of 267 ppi (pixels per inch) is chosen. This yields a contone CMY page size of 850×534, and a contone to bi-level ratio of 1:6 in each dimension. This ratio of 1:6 provides no perceived loss of quality since the output image is bi-level.
[0072] The printhead prints dots in cyan, magenta, and yellow ink. The final output to the printed page must therefore be in the gamut of the printhead and take the attributes of the inks into account. It would at first seem reasonable to use the CMY color space to represent images.
[0073] However, the printer's CMY color space does not have a linear response. This is definitely true of pigmented inks, and partially true for dye-based inks. The individual color profile of a particular device (input and output) can vary considerably. Image capture devices (such as digital cameras) typically work in RGB (red green blue) color space, and each sensor will have its own color response characteristics.
[0074] Consequently, to allow for accurate conversion, as well as to allow for future image sensors, inks, and printers, the CIE L*a*b* color model [CIE, 1986, CIE 15.2 Colorimetry: Technical Report (2 nd Edition), Commission Internationale De l'Eclairage] is used for the compact printer system. L*a*b* is well defined, perceptually linear, and is a superset of other traditional color spaces (such as CMY, RGB, and HSV).
[0075] The Printer Module must therefore be capable of converting L*a*b* images to the particular peculiarities of its CMY color space. However, since the compact printer system allows for connectivity to PCs, it is quite reasonable to also allow highly accurate color matching between screen and printer to be performed on the PC. However the printer driver or PC program must output L*a*b*.
[0076] Each pixel of a compact printer image is therefore represented by 24 bits: 8 bits each of L*, a*, and b*. The total image size is therefore 1,361,700 bytes (850×534×3).
[0077] Each image processing module is able to access the image stored in the Printer Module. The access is either to read the image from the Printer Module, or to write a new image to the Printer Module.
[0078] The communications protocol for image access to the Printer Module provides a choice of internal image organization. Images can be accessed either as 850×534 or as 534×850. They can also be accessed in interleaved or planar format. When accessed as interleaved, each pixel in the image is read or written as 24 bits: 8 bits each of L*, a*, b*. When accessed as planar, each of the color planes can be read or written independently. The entire image of L* pixels, a* pixels or b* pixels can be read or written at a time.
[0079] Detailed views of the Printer Module 10 are shown in FIGS. 17, 18 and 19 . The Printer Module 10 is the central module in the compact printer system. It contains a 2-inch Memjet printhead 16 , a Cyan/Magenta/Yellow ink cartridge 17 , the current image stored in flash memory on the printhead, and a power source in the form of a 3V battery 12 a in the battery compartment 12 . With regards to processing, the Printer Module 10 contains a controller chip (or chips) 101 that controls printing of the stored image in high quality.
[0080] The Printer Module 10 can be used as a stand-alone printer of a single image (such as business cards), or can be used in conjunction with other modules to print a variety of images.
[0081] Looking in detail at FIG. 17 , the body 11 of the printer module is in three parts being a lid 11 a , base 11 b and chassis 11 c . Printhead 16 with filter 16 a fits into the chassis 11 c . Powered rollers 18 a are driven by motor and gearbox 103 . Neutral rollers 18 b fit into ink cartridge 17 and guide a card past the printhead 16 . Springs 18 c ( FIG. 19 ) urge the neutral rollers 18 b towards the powered rollers 18 a . The ink cartridge 17 is located beyond the rollers 18 so that the card passes between the printhead 16 and the ink cartridge 17 . Ink inlets 105 provide communication between the ink cartridge 17 and the printhead 16 . Micro-moulded channels 106 in the chassis 11 c distribute the ink from the ink inlets 105 to the length of the printhead 16 .
[0082] Serial bus 104 provides power and data between the printer module 10 and other modules connected to male connector 14 and female connector 15 . The serial bus 104 picks up power from the battery 12 a and signals from the controller 101 . Looking at FIG. 19 , to print an image, a user simply inserts a business card into the input slot 13 of the Printer Module. Sensor 102 detects the insertion and a small motor 103 a and gearbox 103 b activates rollers 18 to carry the card through the module. A tab film 107 provides signal connection from the sensor 102 to the controller 101 and hence to the motor and gearbox 103 . A wedge 108 holds the tab film 107 in place to make a signal connection.
[0083] The printed card is ejected from the output slot 13 a of the module over a time period of 1 second. There is no on/off switch—the act of inserting the card is the effective “on” switch for the duration of a print.
[0084] To reduce the chance of ink drying in the printhead 16 a capping mechanism 19 is provided to cap the ink nozzles in the printhead. The capping mechanism 19 comprises a capping arm 191 supporting a blotter 192 with adjacent elastomeric seals 193 . A clutch 194 is operatively associated with one of the powered rollers 18 a to move the capping arm 191 out of the path of the card for printing.
[0085] The volume of ink present in an ink cartridge is 450 ml (2 mm×3 mm×75 mm), enough to produce 450 million dots of a given color. The exact number of images that can be printed before replacement will depend on the color composition of those images. 450 ml represents:
25 full black cards (black requires all three colors to be used) 50 full sized photos at 50% CMY coverage 111 typical photo/text cards at 22.5% CMY coverage 166 cards of black (CMY) text at 15% coverage
[0090] A QA chip in the ink cartridge keeps track of how much ink has been used. Sensors in the ink cartridge provide signals to the QA chip that are transferred to the controller 101 via contacts 109 . If there is insufficient ink of any color to print a given image, the card will pass through the printer module, but nothing will be printed.
[0091] It is a simple matter to replace the old ink cartridge 17 by sliding latch 171 , removing lid 11 a , unclipping the old cartridge and clipping on a new one.
[0092] A schematic of a suitable controller 101 is shown in FIG. 20 . The controller may be embodied in a single application specific integrated circuit or in a number of discrete elements. The controller 101 includes a simple micro-controller CPU core 201 with associated program ROM 202 and program RAM 203 . The CPU 201 communicates with the other units within the controller via memory-mapped I/O supported by a Memory Decoder 204 . The Decoder 204 translates data addresses into internal controller register accesses over the internal low speed bus 205 , and therefore allows for memory mapped I/O of controller registers. The bus 205 includes address lines 205 a and data or control lines 205 b.
[0093] An optional Serial Bus interface 206 , is connected to the internal chip low-speed bus 205 and connects to the Serial Bus for communication with other modules. A parallel interface 207 provides communication to the motor and gearbox 103 in the printer module 10 . It can also receive signals from buttons, such as a paper sensor 102 .
[0094] There are two optional low-speed serial interfaces 208 , 209 connected to the internal low-speed bus 205 . A first interface 208 connects to the QA chip 220 in the ink cartridge of the printer module 10 . The second interface connects to a QA chip 221 on the print module 10 . The reason for having two interfaces is to connect to both the on-module QA Chip 221 and to the ink cartridge QA Chip 220 using separate lines to improve security. If only a single line is used, a clone ink cartridge manufacturer could usurp the authentication mechanism and provide a non-proprietary cartridge.
[0095] The total amount of memory required for the interleaved linear CMY/L*a*b* image is 1,361,700 bytes (approximately 1.3 MB). The image is written to Image Storage Memory 211 by the Image Access Unit 212 , and read by both the Image Access Unit 212 and the Printhead Interface (PHI) 210 . The CPU does not have direct random access to this image memory. It must access the image pixels via the Image Access Unit 212 . The Printhead Interface 210 is the means by which the controller loads the printhead 16 with the dots to be printed, and controls the actual dot printing process.
[0096] The controller 101 may also include a clock phase-locked loop 213 that provides timing signals to the controller. The clock 213 draws a base signal from crystal oscillator 214 . Some CPU include a clock so the clock and crystal would not be required.
[0097] A standard JTAG (Joint Test Action Group) Interface 215 is included in the controller for testing purposes. Due to the complexity of the controller, a variety of testing techniques are required, including BIST (Built In Self Test) and functional block isolation. An overhead of 10% in chip area is assumed for overall chip testing circuitry.
[0098] The battery used to power the compact printer system is a CR1/3N cell. The battery contains enough power to print 133 photos. The characteristics of the battery are listed in the following table.
Parameter Value Type Designation CR1/3N Voltage (V) 3 Electrochemical System Lithium Typical Capacity (mAh) 170 Height (mm) 10.80 Diameter (mm) 11.60 Weight (g) 3.00
[0099] Throughout the specification the aim has been to describe the preferred embodiments of the invention without limiting the invention to any one embodiment or specific collection of features. Persons skilled in the relevant art may realize variations from the specific embodiments that will nonetheless fall within the scope of the invention. | A modular camera assembly includes a camera module. The camera module includes a camera, and a first body which supports the camera and terminates in a first connector opposite the camera. The camera includes a view finder, a lens, and a movable protective cover which can be moved to cover the view finder and lens. The camera further includes an image sensor which can capture an image through the lens that is viewed with the view finder. A printer module includes an elongate second body which terminates in a second connector. The second connector can connect with the first connector so that the bodies together form a barrel of substantially uniform diameter. The second body defines a pair of longitudinally extending and opposite slots. The second body houses a printer which can print the captured image on a sheet of print media which passes through the slots. | 6 |
FIELD OF THE INVENTION
This invention relates to composite color-plus-clear coatings and methods, especially compositions for the clearcoat of such coatings.
BACKGROUND OF THE INVENTION
Color-plus-clear composite coatings are widely utilized in the coatings art. They are particularly desirable where exceptional gloss, depth of color, distinctness of image, or special metallic effects are desired. The automotive industry has made extensive use of color-plus-clear composite coatings for automotive body panels. Such coatings, however, require an extremely high degree of clarity in the clearcoat to achieve the desired visual effect. As such, the clearcoat of a color-plus-clear composite coating is especially susceptible to a phenomenon known as environmental etch. Environmental etch manifests itself as spots or marks on or in the clear finish of the coating that often cannot be rubbed out.
It is often difficult to predict the degree of resistance to environmental etch that a clearcoat will exhibit. Many coating compositions known for their durability and/or weatherability when used in exterior paints, such as high-solids enamels, do not provide the desired level of resistance to environmental etch when used as the clearcoat of a color-plus-clear composite coating.
Many compositions have been proposed for use as the clearcoat of a color-plus-clear composite coating, such as polyurethanes, acid-epoxy systems and the like. However, many prior art systems suffer from disadvantages such as coatability problems, compatibility problems with the pigmented basecoat, solubility problems. Moreover, very few one-pack coating compositions have been found that provide satisfactory resistance to environmental etch, especially in the demanding environment of automotive coatings. Thus, there exists a continuing need for curable coating compositions that provide satisfactory resistance to environmental etch when used as the clearcoat of a color-plus-clear component coating.
SUMMARY OF THE INVENTION
It has now been discovered that carbamate-functional acrylic polymers can be used in the clearcoat composition of a color-plus-clear composite coating. Thus, according to the present invention, there is provided a method of applying a color-plus-clear composite coating comprising the steps of applying a colored coating composition to a substrate, and applying a clear coating composition over the colored coating composition, wherein the clear coating composition is a curable coating composition comprising:
(a) a first component comprising a polymer backbone having appended thereto at least one carbamate functional group, and
(b) a second component comprising a compound having a plurality of functional groups that are reactive with said carbamate group.
The composite coating, when cured, provides a hard but flexible, durable, attractive clearcoat finish that is highly resistant to environmental etch. The clearcoat composition can be effectively applied as a one-pack system without the necessity of mixing reactive materials just prior to application as in a two-pack system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polymer component (a) used in the composition of the invention can be prepared in a variety of ways. One way to prepare such polymers is to prepare an acrylic monomer having a carbamate functionality in the ester portion of the monomer. Such monomers are well-known in the art and are described, for example in U.S. Pat. Nos. 3,479,328, 3,674,838, 4,126,747, 4,279,833, and 4,340,497, the disclosures of which are incorporated herein by reference. One method of synthesis involves reaction of a hydroxy ester with urea to form the carbamyloxy carboxylate (i.e., carbamate-modified acrylic). Another method of synthesis reacts an α,β-unsaturated acid ester with a hydroxy carbamate ester to form the carbamyloxy carboxylate. Yet another technique involves formation of a hydroxyalkyl carbamate by reacting a primary or secondary amine or diamine with a cyclic carbonate such as ethylene carbonate. The hydroxyl group on the hydroxyalkyl carbamate is then esterified by reaction with acrylic or methacrylic acid to form the monomer. Other methods of preparing carbamate-modified acrylic monomers are described in the art, and can be utilized as well. The acrylic monomer can then be polymerized along with other ethylenically-unsaturated monomers, if desired, by techniques well-known in the art.
An alternative route for preparing the polymer (a) used in the composition of the invention is to react an already-formed polymer such as an acrylic polymer with another component to form a carbamate-functional group appended to the polymer backbone, as described in U.S. Pat. No. 4,758,632, the disclosure of which is incorporated herein by reference. One technique for preparing polymers useful as component (a) involves thermally decomposing urea (to give off ammonio and HNCO) in the presence of a hydroxy-functional acrylic polymer to form a carbamate-functional acrylic polymer. Another technique involves reacting the hydroxyl group of a hydroxyalkyl carbamate with the isocyanate group of an isocyanate-functional acrylic or vinyl monomer to form the carbamate-functional acrylic. Isocyanate-functional acrylics are known in the art and are described, for example in U.S. Pat. No. 4,301,257, the disclosure of which is incorporated herein by reference. Isocyanate vinyl monomers are well-known in the art and include unsaturated m-tetramethyl xylene isocyanate (sold by American Cyanamid as TMI®). Yet another technique is to react the cyclic carbonate group on a cyclic carbonate-functional acrylic with ammonia in order to form the carbamate-functional acrylic. Cyclic carbonate-functional acrylic polymers are known in the art and are described, for example, in U.S. Pat. No. 2,979,514, the disclosure of which is incorporated herein by reference. A more difficult, but feasible way of preparing the polymer would be to trans-esterify an acrylate polymer with a hydroxyalkyl carbamate.
The polymer (a) will generally have a molecular weight of 2000-20,000, and preferably from 4000-6000. Molecular weight can be determined by the GPC method using a polystyrene standard. The carbamate content of the polymer, on a molecular weight per equivalent of carbamate functionality, will generally be between 200 and 1500, and preferably between 300 and 350. The glass transition temperature, T g , of components (a) and (b) can be adjusted to achieve a cured coating having the T g for the particular application involved. The average T g of unreacted components (a) and (b) should be between 10° C. and 80° C., with the individual T g 's being adjusted to achieve optimum performance.
The polymer component (a) can be represented by the randomly repeating units according to the following formula: ##STR1##
In the above formula, R 1 represents H or CH 3 . R2 represents H, alkyl, preferably of 1 to 6 carbon atoms, or cycloalkyl, preferably up to 6 ring carbon atoms. It is to be understood that the terms alkyl and cycloalkyl are to include substituted alkyl and cycloalkyl, such as halogen-substituted alkyl or cycloalkyl. Substituents that will have an adverse impact on the properties of the cured material, however, are to be avoided. For example, ether linkages are thought to be susceptible to hydrolysis, and should be avoided in locations that would place the ether linkage in the crosslink matrix. The values x and y represent weight percentages, with x being 10 to 90% and preferably 40 to 60%, and y being 90 to 10% and preferably 60 to 40%.
In the formula, A represents repeat units derived from one or more ethylenically unsaturated monomers. Such monomers for copolymerization with acrylic monomers are known in the art. They include alkyl esters of acrylic or methacrylic acid, e.g., ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, butyl methacrylate, isodecyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl acrylate, and the like; and vinyl monomers such as unsaturated m-tetramethyl xylene isocyanate (sold by American Cyanamid as TMI®), styrene, vinyl toluene and the like.
L represents a divalent linking group, preferably an aliphatic of 1 to 8 carbon atoms, cycloaliphatic, or aromatic linking group of 6 to 10 carbon atoms. Examples of L include ##STR2## --(CH 2 )--, --(CH 2 ) 2 --, --(CH 2 ) 4 --, and the like, In one preferred embodiment, --L-- is represented by --COO--L'-- where L' is a divalent linking group, Thus, in a preferred embodiment of the invention, the polymer component (a) is represented by randomly repeating units according to the following formula: ##STR3##
In this formula, R 1 , R 2 , A, x, and y are as defined above. L' may be a divalent aliphatic linking group, preferably of 1 to 8 carbon atoms, e.g., --(CH 2 )--, --(CH 2 ) 2 --, --(CH 2 ) 4 --, and the like, or a divalent cycloaliphatic linking group, preferably up to 8 carbon atoms, e.g., cyclohexyl, and the like. However, other divalent linking groups can be used, depending on the technique used to prepare the polymer. For example, if a hydroxyalkyl carbamate is adducted onto an isocyanate-functional acrylic polymer, the linking group L' would include an --NHCOO-urethane linkage as a residue of the isocyanate group.
The composition of the invention is cured by a reaction of the carbamate-functional polymer component (a) with a component (b) that is a compound having a plurality of functional groups that are reactive with the carbamate groups on component (a). Such reactive groups include active methylol or methylalkoxy groups on aminoplast crosslinking agents or on other compounds such as phenol/formaldehyde adducts, isocyanate groups, siloxane groups, cyclic carbonate groups, and anhydride groups. Examples of (b) compounds include melamine formaldehyde resin (including monomeric or polymeric melamine resin and partially or fully alkylated melamine resin), urea resins (e.g., methylol ureas such as urea formaldehyde resin, alkoxy ureas such as butylated urea formaldehyde resin), polyanhydrides (e.g., polysuccinic anhydride), and polysiloxanes (e.g., trimethoxy siloxane). Aminoplast resin such as melamine formaldehyde resin or urea formaldehyde resin are especially preferred. Even more preferred are aminoplast resins where one or more of the amino nitrogens is substituted with a carbamate group for use in a process with a curing temperature below 150° C., as described in the concurrently-filed U.S. patent application entitled "Carbamate-Defunctionalized Aminoplast Curing for Polymer Compositions" in the names of John W. Rehfuss and Donald L. St. Aubin.
A solvent may optionally be utilized in the clearcoat composition used in the practice of the present invention. Although the composition used according to the present invention may be utilized, for example, in the form of substantially solid powder, or a dispersion, it is often desirable that the composition is in a substantially liquid state, which can be accomplished with the use of a solvent. This solvent should act as a solvent with respect to both the carbamate-functional polymer (a) as well as the component (b). In general, depending on the solubility characteristics of components (a) and (b), the solvent can be any organic solvent and/or water. In one preferred embodiment, the solvent is a polar organic solvent. More preferably, the solvent is a polar aliphatic solvents or polar aromatic solvents. Still more preferably, the solvent is a ketone, ester, acetate, aprotic amide, aprotic sulfoxide, or aprotic amine. Examples of useful solvents include methyl ethyl ketone, methyl isobutyl ketone, m-amyl acetate, ethylene glycol butyl ether-acetate, propylene glycol monomethyl ether acetate, xylene, N-methylpyrrolidone, or blends of aromatic hydrocarbons. In another preferred embodiment, the solvent is water or a mixture of water with small amounts of aqueous co-solvents.
The clearcoat composition used in the practice of the invention may include a catalyst to enhance the cure reaction. For example, when aminoplast compounds, especially monomeric melamines, are used as component (b), a strong acid catalyst may be utilized to enhance the cure reaction. Such catalysts are well-known in the art and include, for example, p-toluenesulfonic acid, dinonylnaphthalene disulfonic acid, dodecylbenzenesulfonic acid, phenyl acid phosphate, monobutyl maleate, butyl phosphate, and hydroxy phosphate ester. Other catalysts that may be useful in the composition of the invention include Lewis acids, zinc salts, and tin salts.
In a preferred embodiment of the invention, the solvent is present in the clearcoat composition in an amount of from about 0.01 weight percent to about 99 weight percent, preferably from about 10 weight percent to about 60 weight percent, and more preferably from about 30 weight percent to about 50 weight percent.
Coating compositions can be coated on the article by any of a number of techniques well-known in the art. These include, for example, spray coating, dip coating, roll coating, curtain coating, and the like. For automotive body panels, spray coating is preferred.
Pigmented basecoat compositions for such composite coatings are well-known in the art, and do not require explanation in detail herein. Polymers known in the art to be useful in basecoat compositions include acrylics, vinyls, polyurethanes, polycarbonates, polyesters, alkyds, and polysiloxanes. Preferred polymers include acrylics and polyurethanes. In one preferred embodiment of the invention, the basecoat composition also utilizes a carbamate-functional acrylic polymer. Basecoat polymers are preferably crosslinkable, and thus comprise one or more type of cross-linkable functional groups. Such groups include, for example, hydroxy, isocyanate, amine, epoxy, acrylate, vinyl, silane, and acetoacetate groups. These groups may be masked or blocked in such a way so that they are unblocked and available for the cross-linking reaction under the desired curing conditions, generally elevated temperatures. Useful cross-linkable functional groups include hydroxy, epoxy, acid, anhydride, silane, and acetoacetate groups. Preferred cross-linkable functional groups include hydroxy functional groups and amino functional groups.
Basecoat polymers may be self-cross-linkable, or may require a separate cross-linking agent that is reactive with the functional groups of the polymer. When the polymer comprises hydroxy functional groups, for example, the cross-linking agent may be an aminoplast resin, isocyanate and blocked isocyanates (including isocyanurates), and acid or anhydride functional cross-linking agents.
After an article is coated with the above-described layers, the composition is subjected to conditions so as to cure the coating layers. Although various methods of curing may be used, heat-curing is preferred. Generally, heat curing is effected by exposing the coated article to elevated temperatures provided primarily by radiative heat sources. Curing temperatures will vary depending on the particular blocking groups used in the cross-linking agents, however they generally range between 93° C. and 177° C., and are preferably between 121° C. and 141° C. The curing time will vary depending on the particular components used, and physical parameters such as the thickness of the layers, however, typical curing times range from 15 to 60 minutes.
The invention is further described in the following examples.
PREPARATION 1--CARBAMATE-FUNCTIONAL ACRYLIC
A three-necked 5-1 round bottom flask was fitted with an agitator at the center neck and a thermal couple at one of the side necks to monitor the reaction temperature. A nitrogen purge line was also fed through this neck. The second side neck was fitted with a Claissen adaptor and water cooled condenser.
198 g Urethane-grade mixed aromatics solvent (Solvesso® 100) and 225 g urethane-grade toluene were charged to the flask. The mixture was agitated and heated to reflux with a nitrogen purge. As the mixture reached reflux temperature, 127° C., the nitrogen purge was discontinued.
923 g TMI® (unsaturated m-tetramethyl xylene isocyanate, American Cyanamid), 692 g ethyl hexyl acrylate and 269 g of a 50% solution of t-butyl peracetate in odorless mineral spirits were charged to a separate container. This mixture was pumped to the refluxing solvents over a period of 3.5 hour. At the conclusion of this first feed, a second addition of 27 g of the t-butyl peracetate solution and 27 g urethane grade mixed aromatics were charged over 30 minutes. 8.2 g Urethane-grade mixed aromatics was flushed through the pump and into the reaction mixture after the second initiator feed. The reaction mixture was then held at reflux, 135° C. for one hour.
After this hold period, the batch was cooled to 70° C. 1.1 g Dibutyltin dilaurate was charged and mixed into the batch for five minutes. At this point, 565 g hydroxypropyl carbamate was charged to the reaction mixture over 30 minutes. The batch was then slowly heated to 100° C. and held at this temperature until isocyanate functionality had disappeared as determined by infrared spectroscopy or titration. Upon the disappearance of the isocyanate, 852 g monobutyl ether of ethylene glycol was charged to the vessel and allowed to homogenize. The heat to the reaction was turned off and the carbamate functional acrylic was removed from the vessel.
PREPARATION 2--CARBAMATE-MODIFIED MELAMINE
A three-necked 5-1 round-bottomed flask was fitted with a vacuum sealed agitator at the center neck and a thermocouple at a side neck to monitor the reaction temperature. The second side neck as temporarily fitted with a water cooled condensor. Vacuum was applied through a collecting vessel and supercooled condensor via this side neck of the reaction flask.
1708 g Hexamethoxylated monomeric melamine and 1044 g butyl carbamate were charged to the flask. The mixture was homogenized with agitation while heating slowly to 60° C. As the mixture reached 60° C., 1.2 g dodecylbenzyl sulfonic acid was charged to the vessel. The condensor was removed and the flask fitted to the vacuum set-up. The mixture was heated to 100° C. at a rate of 1° C./min. When the mixture reached 70° C., 15-20" vacuum was applied. The methanol was collected as it condensed in the supercooled condensor. A stoichiometric amount of methanol, 279 g, was removed in 2.5 hours at 25" vacuum and 100° C. After this amount was removed, the heat and vacuum were discontinued. The vessel was charge with 433 g xylene, homogenized, and carbamate-modified melamine separated from the mixture.
EXAMPLE 1
A clear coating composition was prepared by combining the following materials:
665 g carbamated acrylic (Preparation 1)
167 g carbamated melamine (Preparation 2)
345 g butyl acetate
44 g Exxate® 800 (methyl octoate isomers)
19 g Tinuvin® 384B
6 g Tinuvin® 123
12 g 25% active oxizolidine blocked dodecylbenzyl sulfonic acid
The coating composition was sprayed over steel panels that had been previously sprayed with an acrylic pigmented basecoat and flashed. Viscosity was adjusted to 30 seconds with butyl acetate. The panels were baked 10 minutes at 82° C. and 20 minutes at 132° C.
Film builds: basecoat 15 μm
clearcoat 51 μm
Tukon hardness 13.5
MEK rubs 200, slight scoring
The panel of Example 1 was subjected to 16 weeks of severe weathering conditions in Jacksonville, Fla., and exhibited significantly reduced environmental etch versus comparison panels coated having clearcoats of hydroxyl-functional acrylic polymer cross-linked with melamine.
EXAMPLE 2
A clear coating composition was prepared by combining the following materials:
184 g carbamated acrylic (Preparation 1)
60 g hexamethoxylated monomeric melamine
130 g butyl acetate
14 g butyl cellosolve acetate
6 g Tinuvin® 384B
1.9 g Tinuvin® 123
3.8 g 25% active oxizolidine blocked dodecylbenzyl sulfonic acid
The coating composition was sprayed over steel panels that had been previously sprayed with an acrylic pigmented basecoat and flashed. Viscosity was adjusted to 20 seconds with butyl acetate. The panels were baked 10 minutes at 82° C. and 20 minutes at 132° C.
Film builds: basecoat 15 μm
clearcoat 58 μm
The panel of Example 2 was subjected to 16 weeks of severe weathering conditions in Jacksonville, Fla., and exhibited significantly reduced environmental etch versus comparison panels coated having clearcoats of hydroxyl-functional acrylic polymer cross-linked with melamine.
PREPARATION 3--CARBAMATE-FUNCTIONAL ACRYLIC
A three-necked 5-1 round bottom flask was fitted with an agitator at the center neck and a thermal couple to monitor the reaction temperature at one of the side necks. A nitrogen purge/sparge line was also fed through this neck. The second side neck was fitted with a Claissen adaptor and water-cooled condenser.
235 g Xylene and 356 g amyl acetate were charged to the flask. The mixture was agitated and heated to reflux with a nitrogen purge. As the mixture reached reflux, 143° C., the nitrogen purge was discontinued. 301 g Styrene, 196 g ethylhexyl acrylate, 337 g ethylhexyl methacrylate 445 g hydroxyethyl methacrylate, 226 g cyclohexyl methacrylate, 123 g of a 50% solution of t-butyl peracetate in odorless mineral spirits, and 116 g xylene were charged to a separate container. This mixture was pumped to the refluxing solvent over a period of four hours. At the conclusion of this feed, 35 g xylene was added through the pump and into the reaction mixture. The reaction mixture was held at reflux, 140° C., for one hour.
The mixture was cooled to 120° C. and charged with 205 g urea. The temperature dropped as the urea dissolved. The reaction mixture was slowly heated to 150° C. and held for the remainder of the synthesis.
The vessel was then charged with 2 g of King Industry catalyst Nacure® XP-348 (metal carbalate). At this point, the reaction was sparged with nitrogen to facilitate the evacuation of ammonia formed from the thermal decomposition of the urea.
Incremental additions of the catalyst (0.5 g) were added once an hour. The reaction was monitored for the disappearance of hydroxyl by titration. When no hydroxyl was detected by titration, the nitrogen sparge and heat were cut, and 560 g methyl isobutyl ketone was added to the mixture. The mixture was homogenized, followed by separation of the polymer.
EXAMPLE 3
A coating composition was formed by blending 50 g of the carbamate-functional acrylic from Preparation 3, 7.7 g hexamethoxylated monomeric melamine, and 0.6 g oxizolidine-blocked dodecylbenzyl sulfonic acid. The composition was coated onto a glass plate, followed by vacuum drawdown to form an 200 μm-thick layer. The cured coating was baked at 132° C. for 30 minutes. The coating passed a test of 200 MEK rubs.
The invention has been described in detail with reference to preferred embodiments thereof. It should be understood, however, that variations and modifications can be made within the spirit and scope of the invention. | A method of producing an article with a color-plus-clear composite coating is described. The method comprises the steps of applying a colored coating composition to a substrate, and applying a clear coating composition over the colored coating composition, wherein the clear coating composition is a curable coating composition comprising:
(a) a first component comprising a polymer backbone having appended thereto at least one carbamate functional group, and
(b) a second component comprising a compound having a plurality of functional groups that are reactive with said carbamate group. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Non-Provisional Patent Application Ser. No. 12/474,917, filed on May 29, 2009, which claims priority from Provisional U.S. Patent Application Ser. No. 61/152,061; filed Feb. 12, 2009, entitled HYBRID MARINE POWER TRAIN SYSTEM the entirety each of which is expressly incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to marine powertrains and more specifically to a device for transmitting power from hybrid prime movers to one or more propulsion devices on a marine vehicle.
[0004] 2. Discussion of the Related Art
[0005] In light of numerous environmental concerns, hybrid electric-combustion vehicles that can be powered with electrical power instead of relying solely on internal combustion engines are being used to reduce pollution, primarily in the form of reduced exhaust emissions and noise, and to improve overall fuel efficiency. As a result, such hybrid vehicles are becoming increasingly popular. To date, the most prevalent commercialized examples of this trend are found in the automobile industry.
[0006] Some efforts have been made to utilize electric power and hybrid drive technologies in marine vehicles. However, the most prevalent marine examples have been implemented in custom hybrid electric-combustion systems only in the largest of marine vessels, but none of these marine vehicles incorporate a power device that allows for controlled application of either or both power sources, the electric motor and the combustion engine, while not significantly impacting propulsive efficiency.
[0007] Because the current marine powertrains fail to provide a solution to the problems of noise, air pollution, low fuel efficiency, and reliability, a green solution was desired that would create less environmental pollution in the form of decreased noise and exhaust emission, and realize the advantages of a secondary prime mover in terms of speed and stealth while not sacrificing improved propulsive and fuel efficiency. What is needed then is a hybrid power device for a marine vehicle that is flexible and efficient—one that allows the user to rely solely on an electric motor in certain circumstances, solely on a combustion engine in other circumstances, or on both prime movers in other circumstances, while not impacting speed and propulsive efficiency.
SUMMARY OF THE INVENTION
[0008] The present invention provides a device for transmitting power from two hybrid power sources to at least one or more propulsion devices such surface propeller drives, conventional propeller installations, water jets, outdrives, pod drives, and the like.
[0009] According to one aspect of the invention, a propulsion system for a marine vehicle includes an electric motor having a first power transmitting element in communication with a power transmitting device whereby a first torque is transmitted to a first input of the power transmitting device. In addition, the system includes a combustion engine having a second power transmitting element in communication with the power transmitting device whereby a second torque is transmitted to a second input of the power transmitting device. At least one propulsor having a power input element is also provided, wherein a torque applied to the power input element generates a propulsive force to move the marine craft. The power transmitting device further includes at least one output in communication with the at least one propulsor's power input element, and a power transmitting assembly configured such that 1) when the first torque or the second torque is applied at any given time, there is a substantially corresponding torque of the output in communication with the at least one propulsor's power input element; and 2) when the first torque applied to the first input and the second torque applied to the second input is at substantially the same revolutions per minute, a substantially corresponding revolutions per minute of the output in communication with the at least one propulsor's power input element occurs.
[0010] In another aspect of this embodiment, a propulsor thruster configured for optimum efficiency when running at full power with both the first torque applied to the first input and the second torque applied to the second input at substantially the same revolutions per minute.
[0011] According to another aspect of this embodiment, an RPM equalizing device configured to control the power transmission from the first power transmitting element of the electric motor and from the second power transmitting element of the combustion engine such that the first input and second input are rotated at substantially the same revolutions per minute.
[0012] In a further aspect of this embodiment, an automatic mode selection element is configured to control the application of power from the electric motor and the combustion engine such that either power source can be used independently or in combination.
[0013] In yet another aspect of this embodiment, the electric motor is configured to be run over a range of power outputs that includes a power output that causes a revolutions per minute of the first input that is substantially the same revolutions per minute of the second input whereby the electric motor may be a booster.
[0014] According to another aspect of this embodiment, the power transmitting device is a gear box further including a gear box housing fixed with respect to a transom of a marine vehicle. The gear box also includes a power transmitting assembly including a gear train mounted within the gear box housing, the gear train accepting power from the first input and the second input and substantially halving the power into the two power transmitting device.
[0015] According to another embodiment, a method of propelling a marine vessel includes operating prime movers, wherein one prime mover is an electric motor and one prime mover is a combustion engine. The method further includes accepting power created by either or both prime movers into a gear train housed in a gear box, and outputting the power as either one or two power components. Next, the method includes accepting the one or two power components into corresponding one or two clutch assemblies, and selectively transmitting the one or two power components through the clutch assemblies and to corresponding one or two propulsors operably connected thereto thereby propelling a marine vehicle.
[0016] Being able to use an electric motor as a sole prime mover allows boats and other marine vehicles to reduce pollution from exhaust emissions and to reduce noise when at or near marinas, or other mooring locations, as may be required by waterway regulations.
[0017] It is further noted that in various jurisdictions, anti-idling rules and regulations are being proposed and implemented for boats and other watercraft. Some jurisdictions are proposing and implementing rules and regulations that prohibit the use of internal combustion engines, or establish maximum horsepower ratings for internal combustion engines, for certain portions of the waterways in these jurisdictions.
[0018] In addition marine vehicles, especially those involved in military maneuvers, may need to run as quietly as possible to avoid detection. Being able to power the marine vehicle quietly with just an electric motor in a so-called stealth mode may help avoid detection by enemy forces, thus saving lives and equipment.
[0019] Marine vehicles may also be required to operate at lower speeds to avoid generating wakes when traversing a no-wake designated portion of a waterway. Importantly, electric motors are not only quieter and cleaner than combustion engines, but they are more fuel efficient than combustion engines at lower speeds.
[0020] Alternatively, being able to use the combustion engine as the sole prime mover allows for the usage of an alternative fuel source and alternative prime mover in the event of the failure of the electric motor or the loss of electric power such as when the batteries are discharged. This redundancy allows the vehicle to be more reliable, and to continue its voyage even after the loss of either prime mover or its associated fuel. In addition, the combustion engine may recharge the discharged batteries by generating electricity when turning the electric motor.
[0021] Finally, being able to use both prime movers, the combustion engine and the electric motor, can allow for increased maximum speed, which is especially important for pursuit or evasion for military marine craft, government agency marine vehicles, and the like. In addition, using both prime movers may allow a planing marine craft to overcome a high resistance hump in achieving planing condition, which neither the electric motor nor the combustion engine on its own can overcome.
[0022] These, and other aspects and objects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which:
[0024] FIG. 1 is a side elevation view with a cutaway section of the aft portion of a marine vehicle showing a hybrid power device in accordance with a preferred embodiment;
[0025] FIG. 2 is a top elevation view with a cutaway section of the aft portion of a marine vehicle showing a hybrid power device in accordance with a preferred embodiment including two propulsors (i.e., surface drives);
[0026] FIG. 3 is an isometric schematic representation of a hybrid power device in accordance with a preferred embodiment including two propulsors (i.e., propellers);
[0027] FIG. 3A is an isometric schematic representation of a hybrid power device in accordance with a preferred embodiment including two propulsors (i.e., propellers) and a control system;
[0028] FIG. 4 is a schematic representation of a gear train of the gearbox of the hybrid power device of FIGS. 2 and 3 ;
[0029] FIG. 5 is a schematic representation of a gear train of the gearbox of the hybrid power device of FIG. 1 ;
[0030] FIG. 6 is a rear elevation, schematic representation of a marine vessel incorporating two hybrid power devices with each gearbox driving two propulsors (i.e., pairs of counter-rotating propellers);
[0031] FIG. 7 is a family of plots showing RPM versus propeller blade diameter for several values of motor horsepower; and
[0032] FIG. 8 is a family of plots showing marine craft speed (knots) versus RPM for several values of propeller diameter size.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] With reference now to the drawings, and particularly to FIG. 1 , there is shown a cutaway side view of an aft portion of a marine vessel 12 that has a transom 14 and includes the hybrid power device 10 of a preferred embodiment having a single power output 30 .
[0034] The hybrid power device 10 utilizes two prime movers, an electric motor 16 and a combustion engine 18 that may be a diesel or gasoline powered engine. A transmission 20 is operably connected to prime mover 18 , behind or downstream of prime mover 18 . Transmission 20 is preferably an MGX-series transmission (QuickShift® transmission) or an MG-series transmission, available from Twin Disc, Inc. headquartered in Racine, Wis. and in one preferred embodiment is a 2-speed transmission.
[0035] Prime movers combustion engine 18 and transmission 20 are connected to a gearbox 22 , for example by way of a transmission output shaft 24 . In addition, prime mover electric motor 16 is connected to gearbox 22 , for example by way of a transmission output shaft 26 . Power transmitting device, for example gear box 22 converts power that is delivered from prime movers 16 , 18 into one or more power components. In this illustrative embodiment there is a single power component output via power output shaft 30 for drive assembly 28 . The drive assembly 28 is preferably a marine surface drive, for example an ARNESON™ surface drive available from Twin Disc, Inc., noting that other drives, including submerged-type drives, water jets, and so forth are also contemplated and well within the scope of the invention.
[0036] Referring now to FIG. 2 , there is shown cutaway top view of an aft portion of a marine vessel 12 that has a transom 14 and includes another embodiment of a hybrid power device 40 of the current invention having two power outputs 44 , 48 .
[0037] The hybrid power device 40 utilizes two prime movers, an electric motor 16 and a combustion engine 18 that may be a diesel, a turbine, or gasoline powered engine. A transmission 20 is operably connected to the prime mover 18 , behind or downstream of the prime mover 18 . Transmission 20 is preferably an MGX-series transmission (QuickShift® transmission) or an MG-series transmission, available from Twin Disc, Inc. headquartered in Racine, Wis. and in one preferred embodiment is a 2-speed transmission.
[0038] Prime mover combustion engine 18 is connected to transmission 20 via output 25 , and transmission 20 is connected to a power splitting gearbox 42 , for example by way of a transmission output shaft 24 . In addition, prime mover electric motor 16 is connected to a power splitting gearbox 42 , for example by way of an output shaft 26 . Power splitting gearbox 42 converts power that is delivered from either or both prime movers 16 , 18 into two output power components via power output shaft 44 for drive assembly 46 and power output shaft 48 for drive assembly 50 . The drive assemblies 46 , 50 are preferably marine surface drives, for example ARNESON™ surface drives available from Twin Disc, Inc., noting that other drives, including submerged-type drives, water jets, and so forth are also contemplated and well within the scope of the invention.
[0039] Referring now to FIGS. 2 and 3 , hybrid power device 40 with power splitting gearbox 42 provides an interface between the marine vessel 12 and the drive assemblies 46 , 50 while inputting power from the prime movers 16 , 18 and dividing and distributing the power (or components thereof) to the pair of drive assemblies 46 , 50 . In this regard, hybrid power device 40 allows a marine vessel 12 with a pair of prime movers 16 , 18 to utilize a pair of counter-rotating propellers 52 , 54 ( FIG. 3 ).
[0040] Still referring to FIGS. 2 and 3 , in one embodiment, prime mover 16 may be a two-hundred fifty horsepower electric motor, and prime mover 18 may be a diesel combustion engine with substantially the same horsepower, and the power transmitting device 42 may be a 1-to-1 ratio power splitting gear box such as that disclosed in U.S. Ser. No. 12/478,329, filed on Jun. 4, 2009, and expressly incorporated by reference herein, although other ratios are contemplated, for example, 2-to-1 to accommodate a combustion engine with a high RPM. The electric motor 16 may have its own gear box 45 for reducing the RPMs of its output shaft 26 (as shown in FIG. 3 ), for example by a 2-to-1 or a 3-to-1 ratio, or it may connect directly to the gear box 42 (as shown in FIG. 2 ). As well, the combustion engine 18 may have its own gear box 20 .
[0041] Either or both prime movers 16 , 18 can be activated to turn corresponding outputs 26 , 24 . With either prime mover 16 , 18 activated the speed of the marine vehicle may be, for example, thirty-six knots. With both prime movers 16 , 18 activated the speed of the marine vehicle may be, for example, fifty knots. With both prime movers activated the electric motor 16 may run as a booster to the combustion engine 18 in which case combustion engine gear box 20 may be a 2-speed gearbox, for example, with 1500 RPM maximum output in one speed in order to accommodate the higher RPM of the combustion engine with respect to the electric motor. Also, with both prime movers 16 , 18 activated, the hybrid power device may be designed so that both prime movers contribute substantially equally to the power input to power transmitting gear box 42 , or a control system may equalize power inputs into the gear box 42 as described below (similarly, for the power input to power transmitting device 22 in the embodiment of FIG. 1 ).
[0042] Referring more specifically to FIG. 3 , either prime mover 16 , 18 may transmit its power to drives 46 , 50 by mechanically engaging the power transmission path with a clutch, for example, clutches 51 , 53 for transmission of torque to drives 46 , 50 respectively. Alternatively, one or more clutches may control the transmission of power from the prime mover 16 , 18 into the gear box 42 or the gear box 10 (not shown). In addition, each prime mover 16 , 18 has a power source: a battery pack for electric motor 16 and a fuel tank for combustion engine 18 (not shown).
[0043] Turning now to FIG. 3A , a control system 15 , by monitoring various electric motor 16 and combustion engine 18 signals such as output speed, output power, output load, and the like may provide flexible control of hybrid power device 10 . The electric motor 16 and combustion engine 18 may be controlled either independently or in combination to achieve a desired result, for example, substantially equal power distribution between prime movers 16 , 18 , optimal power, speed, and/or fuel efficiency. The control system 15 may monitor and/or control the prime movers 16 , 18 with control interface device ECUs (engine control units) 29 , 31 . Control and status signals may be transmitted and received by the main control unit 23 via wired connections shown as harnessing 27 (alternatively, via wireless connections not shown). The control system 15 may also have user interface 33 that provides control and status for the user which may be separate or integrated with the main control unit 23 .
[0044] Continuing with FIG. 3A , control system 15 may manage the on-the-fly engagement or disengagement of either prime mover 16 , 18 to optimize the desired result using disconnect devices 19 , 21 , respectively. Either or both of the prime movers 16 , 18 may be physically disconnectable from gear box 42 via various means. For example, either or both disconnect devices could be a clutch. Again, control of the power connections to shafts 26 , 24 may be desirable to reduce drag, while only using one prime mover, or may aid in the control system's ability to seamlessly manage on-the-fly connections/disconnections of either prime mover. This may allow an emergency “limp-home” mode in the case of a failed prime mover. Also, control system 15 may manage disconnect devices 19 , 21 to achieve other desired results; for example, to optimize speed or efficiency, allow for manual control in select situations, and so forth.
[0045] Control system 15 may consist of a microprocessor based ECU capable of monitoring various sensors, directly or indirectly with a bus and then communicating with both prime mover ECUs 29 , 31 to achieve desired responses, and controlling the disconnect device, are via, for example, associated harnessing 27 . Sensors may include speed, temperature, pressure, etc. as required to obtain data to achieve the desired results.
[0046] Referring now to FIGS. 2-4 , power splitting gearbox 42 at least partially contains a gear train 70 or other various components of the power splitting gearbox 42 . The gearbox housing 100 may mechanically attach and provide an interfacing structure between the drive assemblies 46 , 50 and the transom 14 . This is because the gearbox housing 100 may attach to the transom 14 , and the final drive assemblies 46 , 50 attach to the gearbox housing 100 . Since gearbox housing 100 connects the final drive assemblies 46 , 50 to the transom 14 , it also distributes the application of propulsive forces delivered through the final drive assemblies 46 , 50 as well as the weight of the power splitting gearbox 42 and drive assemblies 46 , 50 to the transom 14 .
[0047] Now referring to FIG. 4 , but also to FIGS. 2 and 3 , gear train 70 mechanically splits power received through inputs 24 , 26 for delivery through outputs 44 , 48 which may drive a drive assembly 46 , 50 . Gear train 70 includes multiple gears 60 that intermesh with each other and therefore rotate simultaneously. Gears 60 preferably have helically cut teeth and are radially aligned with each other so that every other gear 60 of gear train 70 rotates in the same direction, while gears 60 that are immediately adjacent each other rotate in opposing directions. Since adjacent, radially engaging gears rotate in opposite directions, intuitively, gears 60 that are spaced from each other by two intermediate gears (or a number of gears that is a multiple of two) will rotate in opposing directions. Correspondingly, the gear train 70 can input power into any one of gears 60 in gear train 70 and achieve counter-rotation of outputs 44 , 48 , by delivering power through gears 60 that are spaced from each other by two intermediate gears 60 (or a number of gears that is a multiple of two). Thus, contra-rotating outputs could be alternatively connected to the center of gears 55 , 57 , though not preferred.
[0048] It is contemplated that inputs 24 , 26 and outputs 44 , 48 need not be separate and distinct components, apart from gears 60 , but rather can be integrated with individual ones of the gears 60 . For example, input 24 can be a splined inner circumferential surface of one of the gears 60 that receives a splined end of output shaft 44 . Likewise, outputs 44 , 48 can be splined inner circumferential surfaces of ones of the gears 60 that accept and drive splined ends of output shafts 44 , 48 connected to drive assemblies 46 , 50 .
[0049] Now referring to FIG. 5 , but also to FIG. 1 , gear train 70 mechanically transmits power received through inputs 24 , 26 for delivery through outputs 30 which may drive a drive assembly 28 . The gear train 70 includes multiple gears 60 that intermesh with each other and therefore rotate simultaneously. Gears 60 preferably have helically cut teeth and are radially aligned with each other so that every other gear 60 of the gear train 70 rotates in the same direction, while gears 60 that are immediately adjacent each other rotate in opposing directions. Although shown with inputs connected to the outermost gears in FIG. 5 , the gear train 70 can input power into any one of the gears 60 in the gear train 70 . Similarly, gear train 70 may deliver output from the center gear 70 to output shaft 30 as shown, or any of the other gears.
[0050] It is contemplated that inputs 24 , 26 and output 30 need not be separate and distinct components, apart from the gears 60 , but rather can be integrated with individual ones of the gears 60 . For example, input 24 can be a splined inner circumferential surface of one of the gears 60 that receives a splined end of input shaft 24 . Likewise, output 30 can be splined inner circumferential surfaces of ones of the gears 60 that accept and drive splined ends of output shafts 30 connected to drive assembly 28 .
[0051] Turning now to FIG. 6 , by using a pair of hybrid power devices 40 each having a power splitting gearbox 42 , a marine vessel 12 that has two pairs of prime movers 16 , 18 and 17 , 19 can utilize two pairs of counter-rotating propellers 52 , 54 and 53 , 55 , whereby four total propellers, including a pair of counter-rotating propellers at each of the starboard and port sides of the transom 14 , are incorporated into the marine vessel 12 .
[0052] Referring next to FIGS. 7 and 8 and also to FIG. 3 , an example demonstrating the dual and single prime mover engagement at two speeds is described showing the correspondence in optimally efficient propulsor geometry. Turning to FIG. 7 in particular, in an embodiment in which a single prime mover 16 or 18 of about 250 HP is engaged and the output of the prime mover is configured to rotate at substantially 1500 RPM, the optimally efficient propeller diameter can be determined utilizing FIG. 7 as follows: 1) locate the 1500 RPM point 112 on the vertical axis and the corresponding 1500 RPM horizontal line 114 , 2) locate or approximate the intercept of the horsepower (HP) curve with the 1500 RPM horizontal line 114 , and 3) read the propeller diameter in inches from the corresponding intercept on the horizontal axis 118 . For example, with the given prime mover of 250 HP, there is no corresponding HP curve, so locate the closest curves that are greater than and less than 250 HP. So, using FIG. 7 locate the 200 HP curve 120 and the 300 HP curve 122 . Follow the curves 120 , 122 through their intercept points with the 1500 RPM horizontal line 114 , points A and B. Because 250 HP is approximately midway, bisect the line between points A and B and draw a vertical line 124 from that point to intercept the horizontal axis 118 at point C. Finally, read the optimum propeller diameter from the horizontal axis point C, which in this case is approximately 23.75 inches. Thus, either 250 HP prime mover running at 1500 RPM is optimized for that rotational speed with a propeller having a diameter of about twenty-four inches.
[0053] Referring now more specifically to FIG. 8 , determining the speed of the marine vehicle can be performed given the propeller diameter and the horsepower. For example, with a twenty-four inch diameter propeller 1) select the corresponding twenty-four inch curve 132 , 2) locate the 1500 RPM on the horizontal axis 134 , 3) draw a vertical line 136 through the intercept of the twenty-four inch curve 132 (shown as point D), 4) draw a horizontal line 138 from the intercept D to the vertical axis showing knots 140 , and 5) read the speed of the corresponding craft as thirty knots 142 .
[0054] Similarly, when running the vessel with both prime movers 16 , 18 engaged the power amounts to substantially 500 HP. Referring again to FIG. 7 , the propulsor blade has a vertical line indicating its diameter 124 . The intercept of the 500 HP curve 143 with the diameter 124 is at point E. Drawing a vertical line from point E to the vertical axis 146 indicates that the propulsor blade diameter of about twenty-four inches with 500 HP will yield about 1900 RPM. Referring again to FIG. 8 to compute speed, 1900 RPM is located on the horizontal axis and a vertical line 146 is drawn to intercept with the twenty-four inch curve at point F. Speed is determined by drawing a horizontal line from the intercept to the vertical axis 148 and determining the speed in knots of about 38. The propulsor blade diameter of twenty-four inches is optimally efficient for 250 hp and 500 hp operation at speeds of about 30 and 38 knots respectively (corresponding to 1500 and 1900 RPM).
[0055] Referring again to FIG. 3 , in another embodiment wherein both prime movers 16 , 18 contribute substantially equally, the combustion engine 18 and electric motor 16 may be geared to rotate, for example, at 1500 RPM into gear box 42 . Propulsive efficiency to achieve fifty knots for a ten ton marine vehicle would be substantially 0.69 when driving propellers 52 , 54 , which would require that propellers be sized at about 23.5 inches by forty-two inches. Importantly, the same propeller sizing is optimally efficient with either prime mover engaged at a full speed of thirty-six knots for example. More importantly, by providing substantially equivalent power from prime movers 16 , 18 there is a optimum propulsor output sizing (for either propellers or water jets) that is the same for maximum single prime mover speed and maximum dual prime mover speed.
[0056] Still referring to FIG. 3 , note that the combustion engine prime mover 18 may have a gearbox having a low and high gear 20 , whereas the electric prime mover 16 may have no gearbox due to its substantially flat power curve. In one embodiment, the combustion engine 18 may be providing an output of about 1500 RPM into gear box 20 having a gear ratio of 1:1.25 that increases the RPMs of the gearbox output 24 to about 1500 RPM. This may yield a speed of thirty-six knots with either and only one of the two prime movers 16 , 18 engaged. The 23.524×42 inch propeller sizing (i.e., a 23.524 inch diameter blade with a 42 inch pitch) remains optimum with a 0.69 efficiency.
[0057] The 23.5×42 sizing works out to a 4% slip at fifty knots and 16% slip at thirty-six knots. This 12% slip difference is in keeping with propulsion norms for both surface and submerged propellers, lower speed, higher slip. The fact that the propeller efficiency is 0.69 in both cases comes from proprietary tunnel test data for surface propellers.
[0058] The power device 10 need not be limited to the embodiments described above, but may include other embodiments. The scope of some of these changes is discussed above. The scope of others will become apparent from the appended claims.
[0059] Regardless, it is noted that many changes and modifications may be made to the present invention without departing from the spirit thereof. The scope of some of these changes is discussed above. The scope of others will become apparent from the appended statements of invention. | A hybrid power device for a marine vehicle is provided that has two hybrid prime movers, an electric motor and a combustion engine, that distribute power, for example torque, to a single or dual propulsor, such as surface drives with propellers. The prime movers can apply power singly or in unison, but maintain substantially optimum propulsive efficiency in all cases. The power outputs of the prime movers are in communication with a power transmitting device such as a gear box that may combine the power outputs to drive a single propulsor, or may have a power-splitting embodiment driving dual propulsors. In addition, multiple hybrid power devices may be deployed in other embodiments. | 1 |
TECHNICAL FIELD
This disclosure relates generally to a semiconductor device and method of manufacture and, more particularly, relates to a multiple-patterned semiconductor device.
BACKGROUND
The semiconductor industry is producing more and more capable components with smaller and smaller feature sizes. Due to the increased demand for highly integrated semiconductor devices, advanced techniques of fabricating more semiconductor devices in a smaller die area have become strongly relied upon. The production of such semiconductor devices reveals new design and manufacturing challenges to be addressed in order to maintain or improve semiconductor device performance.
As the device density of semiconductors increases, the conductor line width and spacing within the semiconductor devices decreases. Multiple-pattern lithography represents a class of technologies developed for photolithography to enhance the feature density of semiconductor devices. Double-patterning, a subset of multiple-patterning, may be used as early as the 45 nm node in the semiconductor industry and may be the primary technique for the 32 nm node and beyond. Double-patterning employs multiple masks and photolithographic steps to create a particular level of a semiconductor device. With benefits such as tighter pitches and narrower wires, double-patterning alters relationships between variables related to semiconductor device wiring and wire quality to sustain performance.
SUMMARY
In an embodiment, this disclosure relates to a multiple-patterned semiconductor device. The semiconductor device may include one or more layers. A particular level of the semiconductor device may include signal tracks defined by different masks and exposures. The signal tracks may have a quality characteristic. The semiconductor device may include repeater banks. The repeater banks may repower signals. The semiconductor device may achieve a timing tolerance standard.
In an embodiment, this disclosure relates to a method of manufacture for a multiple-patterned semiconductor device. The method of manufacture includes defining portions of layers. Photomasks having signal track patterns may be used to define the portions of the layers. The method may include determining a quality characteristic of the signal track patterns. The method may include selecting a photomask for etching vias. The method may achieve a signal travel path within a timing tolerance standard.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view showing double-patterned signal tracks carrying wires, connectors, and repeater banks pursuant to the disclosure;
FIG. 1B is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure;
FIG. 1C is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure;
FIG. 2 is a perspective view showing double-patterned signal tracks carrying wires, connectors, and repeater banks pursuant to the disclosure;
FIG. 3 is a perspective view showing double-patterned signal tracks carrying wires, connectors, and repeater banks pursuant to the disclosure;
FIG. 4A is a cross-sectional view of a semiconductor device pre-exposure to a first mask and pre-exposure to a second mask pursuant to the disclosure;
FIG. 4B is a cross-sectional view of a semiconductor device post-exposure to the first mask and pre-exposure to the second mask pursuant to the disclosure;
FIG. 4C is a cross-sectional view of a semiconductor device post-exposure to both the first mask and to the second mask pursuant to the disclosure;
FIG. 4D is a cross-sectional view of a semiconductor device post-development pursuant to the disclosure;
FIG. 5A is a perspective view showing double-patterned signal tracks carrying wires, connectors, and repeater banks pursuant to the disclosure;
FIG. 5B is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure;
FIG. 5C is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure;
FIG. 5D is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure;
FIG. 6 is a flow chart showing an operation to choose via masks in accordance with an embodiment; and
FIG. 7 is a flow chart showing an operation to choose via masks in accordance with an embodiment.
DETAILED DESCRIPTION
As conductor line width and pitch geometries decrease, the use of double-patterning on a particular level may increase in order to achieve the required conductor dimensions while still using existing state of the art lithographic exposure equipment. A benefit of double-patterning includes the ability to form tight conductor pitches; however, double-patterning may introduce other variables related to timing and noise into the semiconductor process. Double-patterns alter relationships between adjacent wires in both width and spacing. Adjacent wire channels may be defined in separate lithography steps. Distinctions between adjacent wires may arise due to lithographic exposure variations and registration or placement errors of one exposure relative to another. The need to design for non-optimal wires restricts semiconductor design variables, such as signal repeater spacing, which may affect semiconductor die size.
Single level patterning enables straightforward characterization of parameters with signal delay implications such as wire width, height, and spacing variations. A product of a resistance value (R) of a wire and a capacitance value (C) of the wire forms an RC time constant for the wire (note this is an approximation since the R and the C are distributed along the wire length). Historically, a decrease in wire width or thickness brings about a resistance increase and a corresponding capacitance decrease. The C decrease approximately offsets the R increase in the RC time constant. Such capacitance decrease occurs in part due to a reduction in lateral capacitance because the space between wires increases as wire width decreases. Similarly, an increase in wire width or thickness brings about a resistance decrease approximately offset in the RC time constant by a corresponding capacitance increase. Such a capacitance increase occurs in part due to a rise in lateral capacitance because the space between wires decreases as wire width increases. Thus, in conventional, single-patterned wires the RC time constant remains within appropriate limits of tolerance.
Double-patterning prompts a different nature of lateral capacitance relative to single level patterning. In double-patterning, the width of adjacent wires is rather independent, i.e., track poorly. Wire widths may not track well between adjacent wires created using separate exposures. Relatively narrow wires may be next to or between relatively wide wires. Double-patterning creates varying lateral capacitance between adjacent wires effectively separate from wire resistance variations. The resistance value (R) and the capacitance value (C) may fail to counterbalance each other across process variations. For example, a highly resistive wire may have high R and high C. Thus, the RC time constant between adjacent wires may vary significantly. Wires of one pattern of a double-pattern may carry a signal faster than wires of the other pattern. This may cause signals to reach their respective destinations at different times. Early analysis of a particular 14-15 nm technology indicates a potential doubling of worst case lateral capacitance between adjacent wires, doubling of coupled noise, and increased total wire C by as much as 50%. Such variations may require a solution to mitigate these effects. Potential solutions include repeaters more frequently placed or wires separated more. Such solutions may increase semiconductor die size. Increasing semiconductor die size may be discouraged and may negatively impact the ability to use such a semiconductor device in some systems. Using signal tracks from more than one pattern to carry a signal may achieve desirable results related to signal timing.
Given significant variations in a wire RC time constant, designing for a high RC time constant on both “A wires” and “B wires” may involve close signal repeater spacing. As only either the “A wires” or the “B wires” may be at the RC time constant limit of tolerance, mitigating the one a higher RC time constant by reducing signal repeater spacing may suffice. This may reduce the excess margin required for spacing all signal repeaters at the high RC time constant wire driven limit. As the logic content of a die increases, on-chip communication requirements tend to grow exponentially in both the width of buses between die elements and the speed at which the buses must run. Reducing signal repeater spacing impacts designs by limiting the maximum sized unit that can be placed between repeater bays, which may complicate large block timing closure and increase die size. Maximizing signal repeater spacing may benefit semiconductor die size.
A semiconductor device may include a layer which may conduct a signal. Such a signal conductor layer may be multiple-patterned. In an embodiment, the layer may be double-patterned. Photolithography steps may involve separate masks including a first mask and a second mask. Adjacent wire channels may be defined with such separate masks in separate lithography steps. A first pattern with a wire channel may carry an “A wire” and a second pattern with a wire channel may carry a “B wire.” Wiring channels may alternate in layout for “A wires” and “B wires.” Thus, an “A wire” may exist between “B wires” and a “B wire” may exist between “A wires.”
A repeater may transfer a signal from a first signal track to a second signal track. As such, the repeater may transfer the signal from an “A wire” to a “B wire” or from a “B wire” to an “A wire.” The signal may be transferred multiple times in traveling from an origin to a destination. Signal paths may carry signals in part on fast wires and in part on slow wires. Signal paths may be transferred using vias and a higher level metal. Signal paths may criss-cross. Other possibilities for transferring signals are considered.
The repeater may repower the signal. The signal may be repowered multiple times in traveling from the origin to the destination. Two signals traveling from origins on “A wires” and “B wires” may each reach destinations to achieve a timing tolerance standard. The timing tolerance standard may include a difference from an amount of time for a first signal path and a second signal path to carry a signal a distance from the origin to the destination. The amount of time may be the expected time for the signal path to carry the signal the distance. The difference may be statistical or deterministic. The difference may be statistical when a signal path carries a signal on an equal number of “A wires” and “B wires.” The difference may be deterministic when a signal path carries a signal on an unequal number of “A wires” and “B wires,” such as embodiments where a signal path carries a signal on one more “A wire” or on one more “B wire.” In embodiments, at least one signal path may transfer or criss-cross without repowering. Other expected times and differences are considered.
Advanced semiconductor process technologies may utilize a dual damascene technique. With this technique, a metal trace may be defined before an underlying via to an underlying plane. The signal tracks may have a quality characteristic. Examples of the quality characteristic may be a size value, a width, an RC time constant value, or a time for a signal to travel a distance. A first quality characteristic may be considered substantially equal to a second quality characteristic if the values are within five percent of one another.
The width of the metal troughs for “A wires” and “B wires” may be measured. The width of the metal trough for an “A wire” may be the first quality characteristic and the width of the metal trough for a “B wire” may be the second quality characteristic. The measurement may occur before etching the metal troughs. The measurement may occur before etching the underlying vias. The connections below said metal wire may be modified by selecting one of various via level design reticles. Allowing a potential via in either of two or more locations that could connect to either of two or more potential signal repeaters may mitigate the effects of the high RC time constant, slower wire. In this case, the slower wire drives more closely spaced repeaters.
FIG. 1A is a perspective view showing double-patterned signal tracks carrying wires, connectors, and repeater banks pursuant to the disclosure. Illustration 100 depicts a semiconductor device according to an embodiment. In FIG. 1A , for example, signal tracks carrying “A wires” 101 (shown relatively wide) may be faster than signal tracks carrying “B wires” 102 (shown relatively narrow). The “A wires” 101 may have a shorter RC time constant than the “B wires” 102 . A signal track carrying an “A wire” 101 and signal track carrying a “B wire” 102 may be distanced by a signal track separation space 105 .
A repeater may exist with multiple repeater banks. A repeater bank may be synonymous with a repowering block. Each repeater bank may have a measurable area, FET width, transistor threshold voltage, and buffer strength. A first repeater bank 111 and a second repeater bank 112 may be distanced by a repeater bank separation space 115 . The repeater banks may each have an insulation 130 , a gate 131 or 132 , and source-drain areas 133 , 135 or 134 , 136 . In an embodiment, the first repeater bank 111 and the second repeater bank 112 may have equivalent areas, FET widths, transistor threshold voltages, and buffer strengths.
Vias may serve to connect wires and repeater banks. A first via input 121 may exist to join a previous wire segment to the first repeater bank 111 . A second via input 122 may exist to join a previous wire segment to the second repeater bank 112 . A first via output 123 may exist to join the first repeater bank 111 to a next wire segment. A second via output 124 may exist to join the second repeater bank 112 to a next wire segment. In an embodiment, the inputs 121 , 122 and the outputs 123 , 124 of the repeater banks 111 , 112 may be alternated by one signal track. In other embodiments, inputs such as 121 , 122 and outputs such as 123 , 124 may be arranged an odd number of signal tracks apart. Other possibilities are considered with other embodiments.
FIG. 1B is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure. In FIG. 1B , for example, signal tracks carrying “A wires” 101 may be faster than signal tracks carrying “B wires” 102 . The “A wires” 101 may have a shorter RC time constant than the “B wires” 102 . The wires may be in segments shown in FIG. 1B as 101 A, 101 B, 101 C, 101 D, 101 E for “A wires” and 102 A, 102 B, 102 C, 102 D, 102 E for “B wires.”
A signal track carrying a wire may have a signal path transferred to another signal track carrying a wire at each repeater bank. In an embodiment, the signal path may be alternated by one signal track. The signal path may alternate between “A wires” 101 and “B wires” 102 , transferring at repeater banks. In other embodiments, the signal path on “A wires” 101 and “B wires” 102 may be staggered in different ways such as an arrangement where signal paths include signal tracks where the transfer of a signal is to a signal track an odd number away. As in FIG. 1B , the effect is that signal paths carrying signals may weave back and forth between “A wires” 101 and “B wires” 102 , repowering at repeater banks along the way.
As depicted in FIG. 1B , the signal path of example signal 141 may originate on an “A wire” 101 A, transfer using repeater bank 141 AB to a “B wire” 102 B, transfer using repeater bank 141 BC to an “A wire” 101 C, transfer using repeater bank 141 CD to a “B wire” 102 D, and transfer using repeater bank 141 DE to an “A wire” 101 E where signal 141 ultimately reaches its destination. Similarly, the signal path of example signal 142 may originate on a “B wire” 102 A, transfer using repeater bank 142 AB to an “A wire” 101 B, transfer using repeater bank 142 BC to a “B wire” 102 C, transfer using repeater bank 142 CD to an “A wire” 101 D, and transfer using repeater bank 142 DE to a “B wire” 102 E where signal 142 ultimately reaches its destination.
Two signal paths, each carrying a signal, traveling on an equal number of “A wires” 101 and “B wires” 102 may result in the signals traveling the same distance in a nearly equivalent amount of time as each other. A signal traversing in an alternating fashion between “A wires” 101 and “B wires” 102 may arrive at the destination at a time nearly equivalent to a signal traversing in an alternating fashion between “B wires” 102 and “A wires” 101 . As in illustration 140 , signals 141 and 142 will reach their destinations at nearly the same time, having traveled on fast wires 101 and slow wires 102 the same distances (plus or minus the length of one wire segment). Such signal travel may occur without excessively stressing a high RC wire.
FIG. 1C is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure. In FIG. 1C , for example, signal tracks carrying “A wires” 101 may be faster than signal tracks carrying “B wires” 102 . The “A wires” 101 may have a shorter RC time constant than the “B wires” 102 . The wires may be in segments shown in illustration 170 as 101 A, 101 B, 101 C, 101 D, 101 E for “A wires” and 102 A, 102 B, 102 C, 102 D, 102 E for “B wires.”
A signal track carrying a wire may have a signal path transferred to another signal track carrying a wire at each repeater bank. In an embodiment, the signal path may be alternated by one signal track. The signal path may alternate between “A wires” 101 and “B wires” 102 , transferring at repeater banks. In other embodiments, the signal path on “A wires” 101 and “B wires” 102 may be staggered in different ways such as an arrangement where signal paths include signal tracks where the transfer of a signal is to a signal track an odd number away. As in FIG. 1C , the effect is that signal paths carrying signals may weave back and forth between “A wires” 101 and “B wires” 102 , repowering at repeater banks along the way.
As depicted in FIG. 1C , the signal path of example signal 171 may originate on an “A wire” 101 A, transfer using repeater bank 171 AB to a “B wire” 102 B, transfer using repeater bank 171 BC to an “A wire” 101 C, transfer using repeater bank 171 CD to a “B wire” 102 D, and transfer using repeater bank 171 DE to an “A wire” 101 E where signal 171 ultimately reaches its destination. Similarly, the signal path of example signal 172 may originate on a “B wire” 102 A, transfer using repeater bank 172 AB to an “A wire” 101 B, transfer using repeater bank 172 BC to a “B wire” 102 C, transfer using repeater bank 172 CD to an “A wire” 101 D, and transfer using repeater bank 172 DE to a “B wire” 102 E where signal 172 ultimately reaches its destination.
Two signal paths, each carrying a signal, traveling on an equal number of “A wires” 101 and “B wires” 102 may result in the signals traveling the same distance in a nearly equivalent amount of time as each other. A signal traversing in an alternating fashion between “A wires” 101 and “B wires” 102 may arrive at the destination at a time nearly equivalent to a signal traversing in an alternating fashion between “B wires” 102 and “A wires” 101 . As in FIG. 1C , signals 171 and 172 will reach their destinations at nearly the same time, having traveled on fast wires 101 and slow wires 102 the same distances (plus or minus the length of one wire segment). Such signal travel may occur without excessively stressing a high RC wire.
The magnitude of the RC time constant may correlate to the magnitude of delay with a changing wire length. Signal delay on a signal path may correlate to the square of the wire length needed for the signal to traverse a distance. Reducing repeater spacing may reduce the wire component of the RC time constant by the square of the ratio of the reduced repeater spacing and the original repeater spacing. The wire may extend the distance of the original repeater spacing. The capacitance component may fail to experience a reduction. Allowing the higher RC wires to be more closely spaced than the better quality wires nets a larger average spacing between repeaters. As discussed above, a larger average spacing between repeaters may benefit the die size and permit more design variables. Such spacing may positively impact the semiconductor device as a whole.
FIG. 2 is a perspective view showing double-patterned signal tracks carrying wires, connectors, and repeater banks pursuant to the disclosure. Illustration 200 depicts a semiconductor device according to an embodiment. Aspects of the embodiment depicted in FIG. 2 are similar or the same as depicted in illustration 100 . In illustration 200 , for example, signal tracks carrying “B wires” 202 may be faster than signal tracks carrying “A wires” 201 . The “B wires” 202 may have a shorter RC time constant than the “A wires” 201 .
Vias may serve to connect wires and repeater banks. A first via input 221 may exist to join a previous wire segment to the first repeater bank 111 . A second via input 222 may exist to join a previous wire segment to the second repeater bank 112 . A first via output 223 may exist to join the first repeater bank 111 to a next wire segment. A second via output 224 may exist to join the second repeater bank 112 to a next wire segment. In an embodiment, the inputs 221 , 222 and the outputs 223 , 224 of the repeater banks 111 , 112 may be alternated by one signal track. In other embodiments, inputs such as 221 , 222 and outputs such as 223 , 224 may be arranged an odd number of signal tracks apart. Other possibilities are considered with other embodiments.
FIG. 3 is a perspective view showing double-patterned signal tracks carrying wires, connectors, and repeater banks pursuant to the disclosure. Illustration 300 depicts a semiconductor device according to an embodiment. Aspects of the embodiment depicted in illustration 300 may be similar or the same as depicted in illustrations 100 , 200 . In illustration 300 , for example, signal tracks carrying “A wires” 301 may be equivalent in speed to signal tracks carrying “B wires” 302 . The “A wires” 301 may be equivalent in RC to the “B wires” 302 .
Vias may serve to connect wires and repeater banks. A first via input 321 may exist to join a previous wire segment to the first repeater bank 111 . A second via input 322 may exist to join a previous wire segment to the second repeater bank 112 . A first via output 323 may exist to join the first repeater bank 111 to a next wire segment. A second via output 324 may exist to join the second repeater bank 112 to a next wire segment. In an embodiment, the inputs 321 , 322 and the outputs 323 , 324 of the repeater banks 111 , 112 may be alternated by one signal track. In other embodiments, inputs such as 321 , 322 and outputs such as 323 , 324 may be arranged an odd number of signal tracks apart. If the wires are equivalent in RC, illustrations such as 100 , 200 may also succeed and the connections may be discretionary. Other possibilities are considered with other embodiments.
Connections may be made at a different pattern design levels or layers according to embodiments. Transfer of signals may occur between multiple layers. Repowering may occur in this context as well. A signal may transfer from a signal track on a first signal conductor layer to a signal track on a second signal conductor layer using vias and higher level metals or other techniques. The transfer may occur in a similar fashion as shown in illustrations 100 , 140 , 170 , 200 , 300 . As such, the signal may be transferred multiple times in traveling from an origin to a destination. Such back and forth between signal tracks carrying slow wires and fast wires may occur across the semiconductor device between multiple layers. Other configurations and possibilities are considered with other embodiments.
FIG. 4A is a cross-sectional view of a semiconductor device pre-exposure to a first mask and pre-exposure to a second mask pursuant to the disclosure. To form a semiconductor device, an interlayer insulating film 402 may be formed on a semiconductor substrate 401 in which various components are to be formed. A photoresist 403 may then be coated on the interlayer insulating film 402 . Advanced semiconductor process technologies may utilize a dual damascene technique. With this technique, the metal trace may be defined before the underlying via to the underlying plane. A first mask 411 may be used to define a first signal track set and a second mask 422 may be used to define a second signal track set.
FIG. 4B is a cross-sectional view of a semiconductor device post-exposure to the first mask and pre-exposure to the second mask pursuant to the disclosure. The first mask 411 may define the first signal track set on the photoresist 403 through exposure. A photoresist 413 post-exposure to the first mask may have the first signal track set defined.
FIG. 4C is a cross-sectional view of a semiconductor device post-exposure to both the first mask and to the second mask pursuant to the disclosure. The second mask 422 may define the second signal track set on the photoresist 413 through exposure. A photoresist 423 post-exposure to the second mask may have the second signal track set defined.
FIG. 4D is a cross-sectional view of a semiconductor device post-development pursuant to the disclosure. A photoresist 433 post-development may have both the first signal track set and the second signal track set ready to be measured. The width of the metal troughs for “A wires” and “B wires” may be measured on the photoresist 433 . The measurement may occur after the photoresist has been developed and processed. Processing may include removing portions of the photoresist that were exposed. The measurement may occur before etching the metal troughs. The measurement may occur before etching the underlying vias. Via locations may be decided before etching. The dominate variable of the variation in trough width may be due to the exposure. In FIG. 4D , for example, channels developed for “A wires” with a first width 441 may be faster than channels developed for “B wires” with a second width 442 because the first width 411 may be greater than the second width 412 . In some embodiments, after etching the metal troughs, measurement may occur again before etching the underlying vias.
FIG. 5A is a perspective view showing double-patterned signal tracks carrying wires, connectors, and repeater banks pursuant to the disclosure. Aspects of the semiconductor device depicted in illustration 500 may be similar or the same as depicted in illustrations 100 , 140 , 170 , 200 , 300 , 400 . In illustration 500 , for example, signal tracks carrying “A wires” 101 may be faster than signal tracks carrying “B wires” 102 . The “A wires” 101 may have a shorter RC time constant than the “B wires” 102 . A first repeater bank 511 and a second repeater bank 512 may be distanced by a repeater bank separation space 515 . The repeater bank separation space 515 may be as small as possible. For example, the repeater bank separation space 115 in illustrations 100 , 140 , 170 , 200 , 300 , 400 may be 30 microns whereas the repeater bank separation space 515 in illustration 500 may be 1 micron.
A buffer strength may indicate the ability of a repeater to boost a signal over a distance from an origin to a destination. The buffer strength of a strong repeater bank may be fifty percent stronger than a weak repeater bank. In an embodiment, the first repeater bank 511 and the second repeater bank 512 may have different buffer strengths. A greater buffer strength may successfully drive a signal over a length of a particular wire in a specified time. In illustration 500 , the buffer strength of the first repeater bank 511 connected to a signal track carrying a fast wire 101 may be weaker than the buffer strength of the second repeater bank 512 connected to a signal track carrying a slow wire 102 .
In an embodiment, the different buffer strengths of the first repeater bank 511 and the second repeater bank 512 may result from making FET widths different or establishing different transistor threshold voltages for each repeater bank. The width of a repeater bank connected to a signal track with a slow wire may be larger relative to a FET width of a repeater bank connected to a signal track with a fast wire. A threshold voltage is the voltage at which there are sufficient electrons in to make a low resistance conducting path. Reducing a transistor threshold voltage of a repeater bank may increase the buffer strength of the bank. The transistor threshold voltage of a repeater bank connected to a signal track with a slow wire may be reduced relative to that of a repeater bank connected to a signal track with a fast wire. As depicted in illustration 500 , repeater bank 512 may have a wider FET width or a reduced transistor threshold voltage relative to that of repeater bank 511 . Thus, the buffer strength of the repeater bank 511 connected to a signal track with a fast wire 101 may be weaker than the buffer strength of the repeater bank 512 connected to a signal track with a slow wire 102 .
In an embodiment, the different buffer strengths of the first repeater bank 511 and the second repeater bank 512 may result from establishing different areas for each repeater bank. The area may be directly proportional to a quantity of repeater finger connectors, hence affecting the buffer strength. Reducing the area of a repeater bank may decrease the buffer strength of the repeater bank. Enlarging the area of a repeater bank may increase the buffer strength of the repeater bank. Reducing the area of a first repeater bank may offset enlarging the area of second repeater bank. The total area of the two repeater banks as whole may change insubstantially in modifying the area of each repeater bank individually. The area of the first repeater bank 511 connected to a signal track with a fast wire 101 may be reduced relative to that of the second repeater bank 512 connected to a signal track with a fast wire 102 . In an embodiment, the first repeater bank 511 may have fewer repeater finger connectors than the second repeater bank 512 . Thus, the buffer strength of the repeater bank 511 connected to a signal track with a fast wire 101 may be weaker than the buffer strength of the repeater bank 512 connected to a signal track with a slow wire 102 .
FIG. 5B is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure. Aspects of the semiconductor device depicted in FIG. 5B may be similar or the same as depicted in FIGS. 1A-5A . In FIG. 5B , for example, signal tracks carrying “A wires” 101 may be faster than signal tracks carrying “B wires” 102 . The “A wires” 101 may have a shorter RC time constant than the “B wires” 102 . The wires may be in segments shown in FIG. 5B as 101 A, 101 B, 101 C, 101 D, 101 E for “A wires” and 102 A, 102 B, 102 C, 102 D, 102 E for “B wires.” The segment lengths may be of a substantially equal length. A substantially equal length may be a length of a first segment within ten percent of a length of a second segment. Selected vias 546 for a weaker repeater bank 541 AB and selected vias 547 for a stronger repeater bank 542 AB are shown in FIG. 5B . The vias 546 , 547 may be chosen to connect signal tracks of a given RC time constant with repeater banks of a given strength. The needed strength or weakness selection and appropriate via connection may be done based on determination, by measurement, of trench widths. The trench will be filled with metal to make an “A wire” or a “B wire.”
A signal track carrying a wire may have a signal path transferred to another signal track carrying a wire at each repeater bank. In an embodiment, the signal path may be alternated by two signal tracks. The signal path may alternate between different “A wires” 101 or different “B wires” 102 , transferring at repeater banks. In other embodiments, the signal path on “A wires” 101 and “B wires” 102 may be staggered in different ways such as an arrangement where signal paths include signal tracks where the transfer of a signal is to a signal track an even number away. As in FIG. 5B , the effect is that signal paths carrying signals may weave back and forth between different “A wires” 101 or different “B wires” 102 , repowering at repeater banks along the way.
In an embodiment, the repeater banks may have different buffer strengths. The different buffer strength may result from establishing different FET widths or transistor threshold voltages for each repeater bank. FIG. 5B depicts signal 541 traveling on “A wires” and signal 542 traveling on “B wires.” The signal may repower at repeater banks along the way. Repeater banks 541 AB, 541 BC, 541 CD, and 541 DE may be weaker repeater banks connected to signal tracks with fast wires 101 and repeater banks 542 AB, 542 BC, 542 CD, and 542 DE may be stronger repeater banks connected to signal tracks with slow wires 102 . The FET widths of repeater banks connected to signal tracks with slow wires 102 may be larger relative to that of repeater banks connected to signal tracks with fast wires 101 . Alternatively, the transistor threshold voltage of repeater banks connected to signal tracks with slow wires 102 may be reduced relative to that of repeater banks connected to signal tracks with fast wires 101 . In such embodiment, a signal traveling on “A wires” 101 may arrive at the final destination at a time statistically equivalent to a signal traveling on “B wires” 102 .
As depicted in FIG. 5B , the signal path of example signal 541 may originate on an “A wire” 101 A, transfer using weaker repeater bank 541 AB to an “A wire” 101 B, transfer using weaker repeater bank 541 BC to an “A wire” 101 C, transfer using weaker repeater bank 541 CD to an “A wire” 101 D, and transfer using weaker repeater bank 541 DE to an “A wire” 101 E where signal 541 ultimately reaches its destination. Similarly, the signal path of example signal 542 may originate on a “B wire” 102 A, transfer using stronger repeater bank 542 AB to a “B wire” 102 B, transfer using stronger repeater bank 542 BC to a “B wire” 102 C, transfer using stronger repeater bank 542 CD to a “B wire” 102 D, and transfer using stronger repeater bank 542 DE to a “B wire” 102 E where signal 542 ultimately reaches its destination.
FIG. 5C is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure. Aspects of the semiconductor device depicted in FIG. 5C may be similar or the same as depicted in FIGS. 1A-5B . FIG. 5B and FIG. 5C may differ only by repeater bank areas. In FIG. 5C , for example, signal tracks carrying “A wires” 101 may be faster than signal tracks carrying “B wires” 102 . The “A wires” 101 may have a shorter RC time constant than the “B wires” 102 . The wires may be in segments shown in FIG. 5C as 101 A, 101 B, 101 C, 101 D, 101 E for “A wires” and 102 A, 102 B, 102 C, 102 D, 102 E for “B wires.” The segment lengths may be of a substantially equal length. A substantially equal length may be a length of a first segment within ten percent of a length of a second segment. Selected vias 576 for a weaker repeater bank 571 AB and selected vias 577 for a stronger repeater bank 572 AB are shown in FIG. 5B . The vias 576 , 577 may be chosen to connect signal tracks of a given RC time constant with repeater banks of a given strength. The needed strength or weakness selection and appropriate via connection may be done based on determination, by measurement, of trench widths. The trench will be filled with metal to make an “A wire” or a “B wire.”
A signal track carrying a wire may have a signal path transferred to another signal track carrying a wire at each repeater bank. In an embodiment, the signal path may be alternated by two signal tracks. The signal path may alternate between different “A wires” 101 or different “B wires” 102 , transferring at repeater banks. In other embodiments, the signal path on “A wires” 101 and “B wires” 102 may be staggered in different ways such as an arrangement where signal paths include signal tracks where the transfer of a signal is to a signal track an even number away. As in FIG. 5C , the effect is that signal paths carrying signals may weave back and forth between different “A wires” 101 or different “B wires” 102 , repowering at repeater banks along the way.
In an embodiment, the repeater banks may have different buffer strengths. The different buffer strength may result from establishing different areas for each repeater bank. FIG. 5C depicts signal 571 traveling on “A wires” and signal 572 traveling on “B wires.” The signal may repower at repeater banks along the way. Repeater banks 571 AB, 571 BC, 571 CD, and 571 DE may be weaker repeater banks connected to signal tracks with fast wires 101 and repeater banks 572 AB, 572 BC, 572 CD, and 572 DE may be stronger repeater banks connected to signal tracks with slow wires 102 . The area of repeater banks connected to signal tracks with slow wires 102 may be greater than that of repeater banks connected to signal tracks with fast wires 101 . In such embodiment, a signal traveling on “A wires” 101 may arrive at the final destination at a time statistically equivalent to a signal traveling on “B wires” 102 .
As depicted in FIG. 5C , the signal path of example signal 571 may originate on an “A wire” 101 A, transfer using weaker repeater bank 571 AB to an “A wire” 101 B, transfer using weaker repeater bank 571 BC to an “A wire” 101 C, transfer using weaker repeater bank 571 CD to an “A wire” 101 D, and transfer using weaker repeater bank 571 DE to an “A wire” 101 E where signal 571 ultimately reaches its destination. Similarly, the signal path of example signal 572 may originate on a “B wire” 102 A, transfer using stronger repeater bank 572 AB to a “B wire” 102 B, transfer using stronger repeater bank 572 BC to a “B wire” 102 C, transfer using stronger repeater bank 572 CD to a “B wire” 102 D, and transfer using stronger repeater bank 572 DE to a “B wire” 102 E where signal 572 ultimately reaches its destination.
FIG. 5D is a planar view showing both an example signal path on wires that a signal may travel on double-patterned signal tracks and the relative location of repeater banks according to an embodiment of the disclosure. Aspects of the semiconductor device depicted in FIG. 5D may be similar or the same as depicted in FIGS. 1A-5C . FIG. In FIG. 5C , for example, signal tracks carrying “A wires” 101 may be substantially equal in speed to signal tracks carrying “B wires” 102 . The “A wires” 101 may have a substantially equal RC time constant compared to the “B wires” 102 . The wires may be in segments shown in FIG. 5D as 101 A, 101 B, 101 C, 101 D, 101 E for “A wires” and 102 A, 102 B, 102 C, 102 D, 102 E for “B wires.” The segment lengths may be of a substantially equal length. A substantially equal length may be a length of a first segment within ten percent of a length of a second segment. Selected vias 596 for a stronger repeater bank 591 AB and selected vias 597 for a weaker repeater bank 592 AB are shown in FIG. 5D . The vias 596 , 597 may be chosen to connect signal tracks of a given RC time constant with repeater banks of a given strength. The needed strength or weakness selection and appropriate via connection may be done based on determination, by measurement, of trench or trough widths. The trench or trough will be filled with metal to make an “A wire” or a “B wire.”
A signal track carrying a wire may have a signal path transferred to another signal track carrying a wire at each repeater bank. The signal path may alternate between different “A wires” 101 or different “B wires” 102 , transferring at repeater banks. In other embodiments, the signal path on “A wires” 101 and “B wires” 102 may be staggered in different ways. As in FIG. 5D , the effect is that signal paths carrying signals may weave back and forth between different “A wires” 101 or different “B wires” 102 , repowering at repeater banks along the way. In an embodiment, the repeater banks may have different buffer strengths with signals able to repower at repeater banks along the way. Repeater banks 591 AB, 591 BC, 591 CD, and 591 DE may be stronger repeater banks and repeater banks 592 AB, 592 BC, 592 CD, and 592 DE may be weaker repeater banks. In such embodiment, signal 591 may arrive at the final destination at a time statistically equivalent to signal 592 .
As depicted in FIG. 5D , the signal path of example signal 591 may originate on an “A wire” 101 A, transfer using stronger repeater bank 591 AB to an “A wire” 101 B, transfer using weaker repeater bank 592 BC to an “A wire” 101 C, transfer using stronger repeater bank 591 CD to an “A wire” 101 D, and transfer using weaker repeater bank 592 DE to an “A wire” 101 E where signal 591 ultimately reaches its destination. Similarly, the signal path of example signal 592 may originate on a “B wire” 102 A, transfer using weaker repeater bank 592 AB to a “B wire” 102 B, transfer using stronger repeater bank 591 BC to a “B wire” 102 C, transfer using weaker repeater bank 592 CD to a “B wire” 102 D, and transfer using stronger repeater bank 591 DE to a “B wire” 102 E where signal 592 ultimately reaches its destination.
Two signal paths, each carrying a signal, traveling on “A wires” 101 and “B wires” 102 with stronger and weaker repeater banks may result in the signals traveling the same distance in a nearly equivalent amount of time as each other. FIG. 5B , FIG. 5C , and FIG. 5D show first signals 541 , 571 , 591 and second signals 542 , 572 , 592 may arrive at the destination at a nearly equivalent time. Such signal travel may occur without excessively stressing a high RC wire.
Aspects of the semiconductor device as depicted in FIGS. 1A-5D may include other characteristics according to other embodiments. Connections may be made at a different pattern design levels or layers according to embodiments. Signal paths may include multiple layers. Repowering may occur on multiple layers in this context as well. A signal may transfer from a signal track on a first signal conductor layer to a signal track on a second signal conductor layer using vias and higher level metals or other techniques. The transfer may occur in a similar fashion as shown in the illustrations. As such, the signal may be transferred multiple times in traveling from an origin to a destination. Such back and forth between signal tracks may occur across the semiconductor device between multiple layers. Other configurations and possibilities are considered with other embodiments.
FIG. 6 is a flow chart showing an operation to choose via masks in accordance with an embodiment. Wire channels or tracings for wire channels created by masks for “A wires” and “B wires” may be measured as in block 610 . A measurement in block 610 may include measuring the width of a trench or trough. Trench, trough, and channel may be synonymous. The measurement in block 610 may be performed before a via etch. The measurement in block 610 may be performed before via or metal depositions. Measurements from block 610 may be used to compare channels created by masks for “A wires” and “B wires” in block 620 . The largest measurement from block 610 of the width of a trench or trough may be considered faster in decision block 620 . The smallest measurement from block 610 of the width of a trench or trough may be considered slower in decision block 620 . Thus, a channel with a larger width may be faster than a channel with a smaller width.
In an embodiment, a via mask may be chosen based on a comparison of channels. Via etching may occur in accordance with embodiments as described in FIGS. 1A-5D . If channels for “A wires” are larger than channels for “B wires” then an “A faster than B” via mask may be used as in block 631 . Through use of an “A faster than B” via mask, vias may be etched in accordance with semiconductor device wiring 100 as in block 641 . If channels for “B wires” are larger than channels for “A wires” then a “B faster than A” via mask may be used as in block 632 . Through use of a “B faster than A” via mask, vias may be etched in accordance with semiconductor device wiring 200 as in block 642 . If channels for “A wires” are equal to channels for “B wires” then an “A equals B” via mask may be used as in block 633 . Through use of an “A equals B” via mask, vias may be etched in accordance with semiconductor device wiring 300 as in block 643 .
FIG. 7 is a flow chart showing an operation to choose via masks in accordance with an embodiment. Operation 700 is similar to operation 600 . Operation 700 may differ from operation 600 after decision block 620 . Via masks as in blocks 731 , 732 , 733 may differ from via masks of blocks 631 , 632 , 633 of operation 600 . Via etching may occur in accordance with a semiconductor device wiring utilizing buffers of different strengths as in blocks 741 , 742 , 743 similar to illustration 500 .
If channels for “A wires” are larger than channels for “B wires” then an “A faster than B” via mask may be used as in block 731 . Through use of an “A faster than B” via mask, vias may be etched in accordance with illustration 500 as in block 741 . Vias may connect the faster “A wires” to weaker buffers and the slower “B wires” to stronger buffers as described in block 741 . If channels for “B wires” are larger than channels for “A wires” then a “B faster than A” via mask may be used as in block 732 . Through use of a “B faster than A” via mask, vias may be etched with similar methodology to illustration 500 as in block 742 . Vias may connect the faster “B wires” to weaker buffers and the slower “B wires” to stronger buffers as described in block 741 . If channels for “A wires” are equal to channels for “B wires” then an “A equals B” via mask may be used as in block 733 . Through use of an “A equals B” via mask, vias may be etched with similar methodology to illustration 300 . Vias may alternate connecting wires with buffers of different strengths as in block 743 so that the signals reach the final destination at the same time. Other embodiments and variations on embodiments are contemplated. | A multiple-patterned semiconductor device and a method of manufacture are provided. The semiconductor device includes one or more layers with signal tracks. The signal tracks have a quality characteristic. The semiconductor device also includes repeater banks to repower signals. The method of manufacture includes defining portions of layers with photomasks having signal track patterns, determining a quality characteristic of the signal track patterns, and selecting a photomask for etching vias. | 7 |
FIELD OF THE INVENTION
The present invention relates to a holder for wires, and more particularly, to a holder for fiber optic wires.
BACKGROUND OF THE INVENTION
Various holders, clips and other devices have been used in the prior art for retaining wires, cables and other articles. Generally speaking, these prior art devices are not readily adapted for holding fiber optic wires. These fiber optic wires are very thin (basically the diameter of a human hair) and may, for example, run into and out of an epoxy-filled electronic module which is potted and baked. These modules are precision relatively-expensive components. The fiber optic wires emanating therefrom are not readily manipulated into a bundle; as a result, the present commercial practice is to hold these fiber optic wires together with tape (such as “SCOTCH” tape or masking tape) or “VELCRO” fasteners or whatever is readily available to the installer or assembly line worker.
To the best of my knowledge and belief, nothing is readily available on the open market or in the prior art for holding these fiber optic wires together; and this is a distinct disadvantage and deficiency in the art.
BRIEF SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to alleviate the disadvantages and deficiencies of the prior art by providing a holder for fiber optic wires which is efficient, relatively low cost, and easy and convenient to use.
In accordance with the teachings of the present invention, a first embodiment thereof is herein illustrated and described, which comprises a unitary molded member having a first portion provided with a recess formed therein, the recess having at least one radially-extending pocket formed therein. A second portion of the unitary molded member has at least one radially-extending protrusion formed thereon, and a substantially-flexible intermediate strap portion connects the first and second portions, respectively, of the unitary molded member. Accordingly, the intermediate strap portion of the unitary molded member may be folded back upon itself to form a loop for retaining the plurality of fiber optic wires therein and transversely thereof In this manner, the second portion of the unitary molded member may be received within the recess formed in the first portion thereof, and the protrusion on the second portion may be received in the pocket on the first portion, such that the second portion is releasably locked to the first portion of the unitary molded member.
Preferably, the recess in the first portion of the unitary molded member comprises a semi-circular recess.
In a preferred embodiment, the semi-circular recess in the first portion of the unitary molded member has a pair of circumferentially-spaced pockets for receiving a respective pair of circumferentially-spaced protrusions on the second portion of the unitary molded member.
Additionally, the first portion of the unitary molded member terminates in a substantially-flat external face provided with an integral protruding flange, thereby facilitating a manual manipulation of the unitary molded member.
Preferably, the unitary molded member is molded from a conductive silicone material.
A second embodiment of the present invention comprises a unitary molded member including a substantially-cylindrical first portion having a bore formed therein and further having a cut-out sector communicating with the bore. This cut-out sector has at least one inwardly-projecting protrusion adjacent to the bore in the first portion of the unitary molded member. The unitary molded member further has a second portion having a substantially trapezoidal cross-section complementary to the cut-out sector in the first portion of the unitary molded member. The second portion of the unitary molded member further has at least one outwardly-projecting protrusion formed thereon. A flexible intermediate portion joins the first and second portions of the unitary molded member. In this manner, the second portion of the unitary molded member may be folded into the first portion of the unitary molded member, such that the second portion is received in the cut-out sector in the first portion, and such that the outwardly-projecting protrusion on the second portion snaps over the inwardly-projecting protrusion on the first portion. As a result, the unitary molded member has a releasably-locked position, and the plurality of fiber optic wires are retained within the bore of the unitary molded member, transversely thereof, in the releasably-locked position of the unitary molded member.
In a preferred embodiment, the cut-out sector of the unitary molded member has a pair of opposed inwardly-projecting protrusions cooperating with a pair of opposed outwardly-projecting protrusions formed on the second portion of the unitary molded member.
Preferably, the intermediate portion of the unitary molded member comprises a “living” hinge.
Like the first embodiment of the present invention, the second embodiment is also molded from a conductive silicone material.
These and other objects of the present invention will become apparent from a reading of the following specification taken in conjunction with the enclosed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of one embodiment of the unitary molded member of the present invention, the unitary molded member retaining a plurality of fiber optic wires emanating from an electronic module (the latter forming no part of the present invention and hence being shown schematically).
FIG. 2 is an end view of the unitary molded member of FIG. 1, drawn to an enlarged scale, and showing the fiber optic wires being retained in the loop formed when the unitary molded member is folded back upon itself.
FIG. 3 is a cross-sectional view of the unitary molded member, taken along the lines 3 — 3 of FIG. 1, and drawn to a substantially enlarged scale.
FIG. 4 is a side elevational view of the unitary molded member of FIG. 1 in its unfolded (“natural”) shape.
FIG. 5 is a further side elevational view of the unitary molded member of FIG. 4, but showing the flexible intermediate strap portion of the unitary molded member being partially folded back upon itself (for retaining the fiber optic wires within the loop being formed).
FIG. 6 is a perspective view of the unitary molded member of FIG. 1, part of which is broken away and sectioned to show the conductive silicone material.
FIG. 7 is a side elevational view of a second embodiment of the unitary molded member of the present invention, this second embodiment being shown in its unfolded (“natural”) shape.
FIG. 8 is a further side elevational view of the unitary molded member of FIG. 7, showing the unitary molded member in the process of being folded back upon itself.
FIG. 9 is a still further side elevational view of the unitary molded member of FIGS. 7 and 8, but showing the unitary molded member in its releasably-locked position.
FIG. 10 is an enlarged portion of FIG. 9, showing the fiber optic wires (in cross-section) being retained within the unitary molded member, transversely thereof.
FIG. 11 is a perspective view of the unitary molded member of FIG. 7, with part broken away and sectioned to show its conductive silicone material.
FIG. 12 is a pictorial view, showing how the present invention (in this instance, the second embodiment of the invention) may be used to retain the cables of a laptop computer, it being understood that the holder is substantially enlarged in scale.
FIG. 13 is a further pictorial view, showing the application of the teachings of the present invention to the cables of a personal computer (PC).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a first embodiment of the holder of the present invention comprises a unitary molded member 10 retaining a plurality of fiber optic wires 11 connected to an electronic module 12 .
With further reference to FIGS. 2-5, the unitary molded member 10 has a first portion 13 , a second portion 14 , and an intermediate strap portion 15 joining the first and second portions 13 and 14 , respectively. The first portion 13 has a substantially semi-circular (semi-cylindrical) recess 16 provided with a pair of circumferentially-spaced pockets 17 and 18 , respectively. The second portion 14 of the unitary molded member 10 is substantially circular (that is, cylindrical) and has a pair of circumferentially-spaced protrusions 19 and 20 , respectively cooperating with the pockets 17 and 18 , respectively, in the recess 16 of the first portion 13 , thereby releasably locking the first portion 13 to the second portion 14 of the unitary molded member 10 .
In this locked position of the unitary molded member 10 , the intermediate strap portion 15 forms a loop 21 (see FIGS. 2 and 3) for retaining the fiber optic wires 11 . As shown in FIG. 3, the fiber optic wires 11 (in this instance) are provided with respective jackets 22 .
With reference again to FIG. 3 and with further reference to FIG. 6, the unitary molded member 10 is preferably molded from a conductive silicone material for improved anti-static performance which is desirable in the fiber optic industry.
The first portion 13 of the unitary molded member 10 has a substantially flat face 23 provided with an extending flange 24 . The flange 24 facilitates manual manipulation of the unitary molded member 10 .
It will be understood that the unitary molded member 10 is wrapped around the fiber optic wires 11 transversely thereof; that is, the fiber optic wires 11 may be laid on the intermediate strap portion 15 , and then the unitary molded member 10 is folded back upon itself (forming the loop 21 ) and is then “snapped” into place in its releasably locked position, thereby “trapping” the fiber optic wires 11 in the loop 21 . Conversely, the unitary molded member 10 may be unfolded by manually pulling it apart (or by using a suitable tool, if necessary) so that the loop 21 is unfolded and the fiber optic wires 11 are released.
Since the unitary molded member 10 is molded from a material which is somewhat flexible or pliable, the unitary molded member 10 will become somewhat distorted in its releasably locked position. This is shown more clearly in FIG. 2 .
The second portion 14 of the unitary molded member 10 may have a bore 14 A to make the second portion more flexible and hence facilitate the “snap fit” of the second portion 14 into the first portion 13 of the unitary molded member 10 .
With reference to FIGS. 7-11, a second embodiment of the present invention comprises a unitary molded members 10 ′ having a first portion 25 which is generally cylindrical and has a bore 26 communicating with a cut-out sector portion 27 . The unitary molded member 10 ′ has a second portion 28 which, preferably, is generally trapezoidal in cross-section and is complementary to the cut-out sector 27 ; and the unitary molded member 10 ′ further has an intermediate “living” hinge portion 29 connecting the first and second portions 25 and 28 , respectively.
The first portion 25 of the unitary molded member 10 ′ has (at least one) and preferably a pair of inwardly-projecting protrusions (or “bumps”) 30 and 31 , respectively, between the bore 26 and the cut-out portion 27 . The second portion 28 of the unitary molded member 10 ′, in turn, has at least one and preferably a pair of outwardly-projecting protrusions (or “bumps”) 32 and 33 , respectively, which cooperate with the inwardly-projecting protrusions 30 and 31 , respectively, on the first portion 25 of the unitary molded member 10 ′. When the second portion 28 is folded into the first portion 25 (see FIGS. 8 and 9) the protrusions 32 and 33 on the second portion 28 ride over the respective protrusions 30 and 31 on the first portion 25 ; and the second portion 28 is thus “snapped” into the first portion 25 of the unitary molded member 10 ′. This is the removably locked position of the unitary molded member 10 ′ as shown in FIGS. 9 and 10. The unitary molded member 10 ′ is relatively flexible and thus may be somewhat distorted as the protrusions 32 and 33 slide over and crimp or deform the protrusions 30 and 31 , respectively.
With reference again to FIG. 10, the fiber optic wires 11 ′ are retained in the bore 26 of the first portion 25 of the unitary molded member 10 ′, transversely thereof. In this embodiment, the fiber optic wires 11 ′ may be of the non-jacketed type.
With reference to FIG. 11, the unitary molded member 10 ′ (like the unitary molded member 10 ) is also preferably molded from a conductive silicone material.
The inherent utility and advantages of the present invention are applicable to other environments (other than fiber optic wires) and the unitary molded members 10 and 10 ′, respectively, may be scaled up (or down) in size for various product applications.
Accordingly, in FIG. 12, several unitary molded members 10 ″ (a scaled-up version of the cylindrical unitary molded member 10 ′ of FIGS. 7 and 8) may be used to neatly retain the cables 34 of a laptop computer 35 ; and in FIG. 13, several cylindrical unitary molded members 10 ″ may be used to neatly retain the cables 36 of a personal computer (PC) 37 . Other uses may be made of the unitary molded members of the present invention.
Obviously, many modifications may be made without departing from the basic spirit of the present invention. Accordingly, it will be appreciated by those skilled in the art that within the scope of the appended claims, the invention may be practiced other than has been specifically described herein. | A unitary member is molded (preferably from a conductive silicone material) to form a holder or clip for retaining fiber optic wires. Two embodiments are disclosed. | 6 |
TECHNICAL FIELD
The present invention relates to a system and method for automatically determining and then delivering, based on the weight of an animal and type of medicine, an amount of medicine optimal for the animal.
BACKGROUND INFORMATION
The regular and accurate administration of medicine to animals such as hogs and cattle is critical to the physical health of the animals, the resulting quality of the food products the animals deliver, and the sense of confidence the consumer has in the wholesomeness of those food products. These concerns are equally prevalent in both the cattle and hog industries, so it will be understood and appreciated that the following references to cattle, made for illustrative simplicity, are equally applicable to hogs and all other food animals.
In cattle, vast numbers of different, complex medicinal regimens have been developed and implemented in an effort to generate healthier animals that produce a safe, higher quality and quantity of beef. Because slaughtered beef is valued, in significant part, on its quality characteristics, and because the premium paid for high quality beef is high, those raising cattle for profit remain in search of the optimum medical regimen. Furthermore, pharmaceutical companies almost blindly spend billions of dollars developing individual medicines without the opportunity or resources to conduct a large-scale, extended length individual animal-based field tests. Compounding the problem is the fact that current systems and methods of record keeping among cattle ranchers and pork producers fail to provide the kind and volume of high quantity, high integrity information about the effects of various medicines on individual animals that would alert pharmaceutical developers of the most likely avenues for future successful drug development. Additionally, the growing concerns by consumers over the residual effects of the application of these medical treatments (as they relate to food safety) are not satisfied by any present method or system for medical treatment tracking or accounting.
The life of a head of cattle, from calf to slaughter, is in the range of one to two years (the period is less for hogs). Even in this relatively short period of time, the numbers of medical treatments a particular animal may receive are numerous. Additionally, the numbers of head of cattle a cattleman must raise to be profitable is generally large. Even if a cattleman endeavors to be diligent in the recordation of medicines given to individual cattle in his herd, the logistics of keeping such records make the task nearly impossible. First, animals as big as cattle are generally unappreciative of being stuck with the rather large needles typically used to inject medicines. Outweighed by a factor of three, four or five, the cattleman faces a battle just to deliver the injection. In addition to the physical struggle of man vs. animal, the conditions in many feedlots can be brutally inhospitable, especially in colder months and in the less temperate regions where cattle are typically raised. Finally, many cattle operations operate on tight profit margins, making the cost of additional labor for recording and maintaining recorded data (which may or may not have a positive effect on the price of the end product) prohibitive. Given these impediments, it is nearly impossible for a cattleman to simultaneously and accurately record information relevant to medicines and the animals the medicines are given to.
Numerous advances in the medicine delivery systems have helped cattlemen gain increased control over the historically chaotic task of administering medicines to animals. Notably, U.S. Pat. No. 5,961,494, which is specifically incorporated herein by reference, the inventor of which is also the inventor herein, discloses a marking syringe which, when actuated, simultaneously injects medicine into an animal and places a mark on the skin of the animal in proximity to the location of the injection. This marking syringe (known commercially as the “VAC-MARC®”) cleverly reduces what was formerly a clumsy, two-step injecting and marking process into one step—the actuation of the syringe. Nonetheless, a cattleman using the marking syringe taught by the '494 patent and desiring to maintain records of injections would still have to somehow identify the animal and then manually record the fact that that particular animal had been injected.
Beyond the logistics of injecting and marking an animal, proper identification and dosage of the animal is also important. In this regard, the leading system is described in pending U.S. patent application Ser. No. 09/477,262 (specifically incorporated herein by reference and previously filed by the inventor herein), which teaches the principals of the commercially available VAC-TRAC™ system, available through AgEcom Corp. of Marietta, Ga., 1-800-793-1671. The VAC-TRAC™ system successfully and innovatively incorporates automatic recordation of animal injection information with animal identification information. Unfortunately, however, even the state-of-the-art VAC-TRAC™ system is unable to deliver, in real-time, different dosages of medicines to different animals based on automatically determining the weight of the animal and automatically adjusting the dosage accordingly.
Accordingly, there is a need for a system and method in which information relating to the administration of medicines to animals can be automatically accessed and implemented in the process of delivery of the medicines to the animals, then recorded for access and review after delivery. There is a further need for a system and method of combining and coordinating these automatic features with the automatic recordation of animal identification data. A still further need exists for a system and method for accomplishing the aforementioned needs and reliably and automatically recording the resulting information in a location and format in which it can be later used in the improved development of animal food products such as beef.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a system and method for automatically controlling the quantitative delivery of, and then recording the occurrence of the administration of medicines to animals. An intelligent syringe receives and automatically implements an instruction relating to a preferred quantity of medicine to be delivered to a specific animal, based on the measured weight of the animal. Upon actuation of the intelligent syringe, a first signal containing information relating to the actuation of the intelligent syringe, and the resulting injection of the animal is transmitted to a data repository.
An EID/RFID is attached to the animal to provide a tamper-resistant electronic identification of the animal, and a receiver is utilized for receiving the first signal from the intelligent syringe and the electronic identification of the animal. Thereafter, a computer database maintains the information contained in the first signal for selective access and analysis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an exemplary embodiment of the present invention in an exemplary operating environment.
FIG. 2 depicts an exemplary embodiment of a transmitting syringe in accordance with an exemplary embodiment of the present invention.
FIG. 3 is a flow diagram detailing exemplary steps in performing the method of the present invention.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 depicts an exemplary embodiment of the present invention in an exemplary operating environment.
More specifically, the system and method for variable dosage medicine delivery 5 (hereinafter referred to as the “System”) features logistical and procedural devices by which a cattleman 10 can operate out of a farm office 20 in a particular remote injection area 30 to automatically deliver variable dosage injections to animals such as an animal 40 and, importantly, automatically record data (also referred to as “information”) relating to the injections.
In operation, the cattleman 10 begins operation of the System 5 by entering identification data such as personal identification information into a personal computer (“PC”) 25 in or near his farm office 20 . Depending on the desires of the system administrators, different levels and types of information may be required of the cattleman 10 before the cattleman 10 is authorized for further use of the System 5 . Determination as to authorization may be made by comparison of information requested of the cattleman 10 to information maintained in a database such as the access database 28 . Information contained in the access database 28 relating to authorization criteria for cattlemen could originate from any of a wide variety of sources such as a system administrator, drug manufacturer, or the like.
As far as the specifics of authorization are concerned, it may be sufficient for the cattleman 10 to enter an indicator of his personal identity, such that verification as to his training relating to the System 5 can be verified. It is understood that a substantial aspect of the value of information derived from operation of the System 5 is the guarantee that the information is devoid of errors which may originate with operation by untrained or improperly trained cattlemen. Verification that a particular cattleman has training sufficient to operate the system properly and, therefore, produce reliable data is considered valuable.
Beyond verification that a particular cattleman is properly trained for operation of the System 5 , it may also be desirable to require the cattleman 10 to enter into the system, for authorization, the specific medical regimen about to be applied by the cattleman 10 to the animal 40 . Clearly, if the cattleman 10 is not authorized, by virtue of a lack of training or certification, to deliver a particular medical regimen, the System 5 has no authority to prevent such delivery. However, because of the cattleman's lack of training or certification, introduction of medical delivery information derived from the activities of an untrained cattleman into the body of data produced by the present invention may have a diminishing effect on the otherwise robust data body. In such a situation, the System 5 would simply not record data relating to medicines delivered by an improperly trained or certified cattleman. Furthermore, it will be understood and appreciated that other discriminators, above and beyond the identity and training of a particular cattleman, may be used to determine whether or not information relating to an instant medical delivery is to be introduced into the body of data.
If the cattleman 10 is authorized to use the System 5 and, additionally, meets any other criteria or discriminators put in place by the system administrator, the system is primed by application of electrical power to necessary subsystems and components, such as those in the injection arena 30 .
In preparation for an injection session, the cattleman 10 accesses and prepares for use a syringe such as intelligent syringe 50 . The intelligent syringe 50 , described with greater specificity during the later description of FIG. 2, is a syringe having the ability to receive information relating to a particular optimal dosage amount, then simultaneously deliver a dosage-controlled injection and a marking ink spot to the animal 40 , then transmit information relating to the delivery of the injection to a data collector for collection and eventual dissemination.
In a preferred embodiment of the present invention, the intelligent syringe 50 is connected to a medicine reservoir 52 via a medicine conduit 54 . It is foreseen that many medical administrations will be of such a small amount, by volume, that the cattleman 10 can retain the medicine reservoir 52 on an arm, leg, or in a backpack-type retention device, for ease of mobility about the injection arena. The medicine conduit 54 is a flexible, tubular member securely interconnected between the intelligent syringe 50 and the medicine reservoir 52 . As is well known to those skilled in the administration of medicines to animals, all medicine delivery components must comport with relevant health and safety regulations, especially in view of the highly toxic nature of many such medicines. In preparation for commencement of animal injections, the cattleman 10 may also place a personal data device (“PDD”) 56 such as a Palm Pilot®-type product on his person for recording injection information as will be described momentarily. It will also be understood that the spirit and scope of the present invention specifically contemplates transmitting syringes which, themselves, carry a sufficient amount of medicine to accomplish a desirable number of injections, without requiring either a detached medicine reservoir 52 or a medicine conduit 54 .
Now that the System 5 is activated by registration of an authorized user such as the cattleman 10 administering a medical regimen he is authorized to administer, and the necessary medicine delivery components 50 , 52 and 54 are in place, an animal 40 is moved into the injection arena 30 .
The robustness of the information ultimately derived from the System 5 relies, in significant part, on the reliable linkage between a particular animal such as animal 40 and the injection data derived from delivery of an injection to the animal 40 . Toward such end, a reliable animal identification device such as a bolus 45 is attached to the animal 40 . As is well known to those familiar with animal identification techniques, the bolus 45 is typically a passive magnetic device which can be deposited in the rumen (stomach) of the animal by swallowing, attached to the ear or other extremity of the animal by an attachment means, or placed under the skin of the animal in an anticipatable location.
Generally, the passive bolus 45 of the present invention emits a detectable electrical signal upon stimulation by a stimulus signal. The electrical signal is unique to the particular animal to which the bolus 45 is attached, and accurate detection of the signal provides an equally accurate identification of the animal.
In an embodiment of the present invention, transmission of a stimulus signal 60 by a stimulus signal transmitter 62 excites the bolus 45 to generate a responsive identification signal 64 . A signal receiver 66 is located in sufficient proximity to the animal 40 (optimally within the injection arena 30 ) so as to detect the identification signal 64 . In an optional embodiment, the signal receiver 66 is integral to the intelligent syringe 50 . After detection of the identification signal 64 , the signal receiver delivers the electrical characteristics of the identification signal 64 to the processor 70 via processor link 68 .
As the cattleman 10 delivers the injection to the animal 40 by actuating the intelligent syringe 50 , an ink mark is placed on the animal 40 in close proximity to the location of the injection and, importantly, an injection signal 58 is transmitted from the intelligent syringe 50 to the signal detector 66 for delivery to the processor 70 via processor link 68 . After delivery of both an information signal 58 and an identification signal 64 to the processor 70 , the information may be linked and transmitted via a communications link 72 to a records database 80 .
In another embodiment of the present invention, actuation of the intelligent syringe 50 generates an injection signal 58 ′ to be received by the PDD 56 for short term or temporary storage. The PDD may also, in such an embodiment, be equipped with a signal receiver analogous in functionality to the previously described signal detector 66 . In this embodiment, following an injection session, the cattleman 10 may take the PDD 56 back to the personal computer 25 in the farm office 20 and download data relating to particular animals and their respective injections via dataport 26 . The dataport 26 may be a disk drive, CD-ROM, hotsync cradle for a Palm Pilot®-type device, or any other such mechanism by which information may be relayed from the PDD 56 to the dataport 26 . Following delivery of the downloaded data from the PDD 56 via the dataport 26 to the personal computer 25 , the data may be periodically or instantaneously delivered to the processor 70 or a central server for all such devices via a communication link 27 .
In yet another embodiment of the present invention, transmission of the stimulus signal 60 by the stimulus signal transmitter 62 may be triggered by a triggering event. In other words, absent a triggering event, no stimulus signal is sent, the bolus is not stimulated to transmit a responsive identification signal 64 , and no data relating to a related injection is recorded.
Although many such triggering events are contemplated by various embodiments of the present invention, a representative triggering event is movement of the animal 40 onto a scale 47 or by passing through or otherwise activating a stationary reader designed to detect and monitor the presence of the animal 40 in the desired location. As the animal 40 moves onto the scale 47 , the processor 70 controlling the stimulus signal transmitter 62 may allow transmission of the stimulus signal 60 . Absent the presence of the animal 40 on the scale 47 , no stimulus signal 60 is sent and the animal 40 is not identified. Optionally, the processor 70 may continue to monitor the scale 47 to verify that there is not a significant fluctuation in the weight indicated by the scale. Namely, the processor may be programmed to detect a first animal departing the scale 47 and a second animal moving onto the scale 47 , in the event that no injection information was recorded for the first animal. If such a change is detected, the processor simply directs storage of the identification signal relating to the first animal in a segregated data file, followed by transmission of a new stimulus signal 60 to detect the identity of the second animal. Such an arrangement further assures parties interested in data integrity that the System 5 was not somehow “sidestepped.”
The preferred embodiment of the present invention contemplates the weighing of the animal 40 on the scale 47 as the triggering event. In this embodiment, not only does the triggering event enable the system 5 to effect the delivery of medicine and subsequent verifiable recording of the event, but the actual weight of the animal 40 is relayed to the processor 70 via datalink 48 . When the processor 70 receives the weight of the animal 40 via datalink 48 , it directs transmission by the transmitter 62 of a dosage signal 61 which directs injection of a specific, predetermined amount of medicine or vaccine, depending on the size of the animal 40 and other factors.
By determining the amount of medicine to be given to an animal such as animal 40 as a factor of the weight of the animal, dosage amounts are far more accurate than a standardized dosage amount given to all animals. It is well known to those in the industry that the weight of animals in any particular operation may vary by as much as 200%. Nonetheless, by giving all of those animals the same dosage, for the sake of simplicity, many animals will be overmedicated and many animals will be undermedicated. Either way, the outcome is not optimal. Animals do not receive the most effective dosage, ranchers may spend more than necessary for medications, and the consumer ultimately receives a product with either increased medicine residue or, alternately, increased undesirable pathogens relating to insufficient medication. By implementation of this embodiment of the present invention, animals receive only the amount of medicine determined to be optimal for their individual weight.
The determination as to what amount of medicine is optimal for a particular weight is most likely and most effectively made by the pharmaceutical company that manufactures the medicine. There are a wide variety of methods by which this information can be accessed by the processor 70 , all of which are well known to those skilled in the art. One example might be a pharmaceutical company providing a rancher with a compact disk or floppy disk containing the matrix for determining optimal dosage amounts for particular weights. The information would be loaded into the system 5 via the PC 25 , database 90 , or directly to the processor 70 . Regardless, when the cattleman prepares to deliver a particular medical regimen, he indicates such in the manner previously described. Thereafter the weight of the animal 40 corresponds to the dosage information and transmission of a dosage signal 61 is accomplished.
Following transmission of the dosage signal 61 and completion of the dosage-controlled injection of the animal 40 , information relating to the identity and injection of an animal 40 may be transmitted directly to a satellite 69 via microwave or other suitable satellite uplink signal 67 . The exact source of transmission of the satellite uplink signal 67 is not critical . . . it may originate from a capable transmitter within the intelligent syringe 50 , from the PDD 56 , or from an intermediate local booster transmitter (not shown), which intermediate local booster transmitter simply takes lower power signals transmitted by the intelligent syringe 50 and/or the PDD 56 and packets the data for transmission by developing appropriate propagation characteristics.
After receipt of the information relating to the identity and injection of the animal 40 by the satellite 69 , the information may be routed to a ground-based receiver 68 ′ for delivery to a processor 70 in a well known manner.
Periodically, the information gathered in accordance with the above specified system and information relating to dosages delivered are transmitted from the processor 70 to a records database 80 for storage and access by authorized users. Control over access to the records database 80 is maintained by a gatekeeper 85 . Gatekeepers such as gatekeeper 85 are well known in the data management industry and simply require an individual desiring access beyond the gatekeeper to provide a key, PIN, code word, or other information so that passage beyond the gatekeeper can be limited to those authorized such passage.
In one embodiment, the gatekeeper 85 is linked by a communications link 87 to a subscriber database 90 within a main office 92 . The main office 92 may receive information subscription inquiries from parties desiring to be authorized parties, such as breeders 94 , pharmaceutical companies 96 and banks 98 . If the terms established by principals within the main office 92 are agreeable to such potential authorized parties, and if such potential authorized parties satisfy the agreed upon terms, information specific to the newly authorized party is entered into the subscription database 90 . When such newly authorized party, such as a pharmaceutical company 96 , for instance, attempts to access the records database 80 , the gatekeeper 85 inquires as to the authority of the pharmaceutical company 96 to gain access by checking the subscriber database 90 . If the pharmaceutical company 96 is an authorized subscriber, the gateway 85 permits communicative interconnection to the records database 80 . Had the pharmaceutical company 96 not been determined to be an authorized user, the gateway 85 would have denied access.
Referring now to FIG. 2, an exemplary embodiment of the intelligent syringe 50 in accordance with an exemplary embodiment of the present invention is shown. More particularly, the intelligent syringe 50 of the preferred embodiment comprises, generally, a syringe handle 104 operatively connected to a medicine syringe 150 and an optional ink dispenser 170 . The syringe handle 104 comprises a first syringe handle 110 pivotally connected to a second syringe handle 130 . The first syringe handle 110 is elongated, having a first end 111 and a second end 113 . An ink dispenser interface 117 is located generally adjacent to the socket 115 on the handle 110 . The handle 110 has a pivot hole in its second end 113 .
The second syringe handle 130 of the intelligent syringe 50 is also elongated and has a first end 131 and a second end 133 . The first end 131 of the second syringe handle 130 may securely receive a hook 190 for storage of the marking syringe 105 between uses. The second syringe handle 130 is configured to function as a finger grip for the user. The second end 133 of the second syringe handle 130 is sized to slidably straddle the second end 113 of the first handle 110 and has a pivot hole through its thickness. The second handle 130 includes an integral medicine syringe collar 132 and an integral ink dispenser collar 134 .
During assembly, the second end 133 of the second syringe handle 130 is positioned over the second end 113 of the first syringe handle 110 such that the pivot holes in the ends 113 , 133 are axially aligned. Thereafter, a pivot pin 120 is inserted through the aligned holes and appropriately secured therein in any number of ways, including deforming distal ends of the pivot pin 120 so that the diameter of the pivot pin 120 is larger at the points of deformation than the diameter of the pivot pin receiving holes, thereby preventing withdrawal of the pivot pin 120 through the pivot receiving holes. After the pivot pin 120 is properly positioned and secured, the second syringe handle 130 rotates about the axis of the pivot pin 120 in a plane defined by the second syringe handle 130 and the first syringe handle 110 . In use, the first and second handles 110 , 130 are initially in a spread position. The user can then grip the first and second handles 110 , 130 and squeeze them into a closed position as the handles 110 , 130 pivot about the pin 120 .
The medicine syringe 150 is mounted between the handles 110 , 130 by means of the medicine syringe collar 132 on the second syringe handle 130 and the socket 115 on the first syringe handle 110 . The medicine syringe 150 comprises a medicine syringe head 152 with a ball 153 , an extendible medicine syringe shaft 151 , a medicine syringe biasing spring 168 , a medicine syringe plunger 160 , a medicine syringe dosage chamber 161 , a medicine syringe needle fastener 162 , and a needle 164 . In order to connect the medicine syringe 150 to the handle 104 , the dosage chamber 161 is threaded into the handle collar 132 of the handle 130 , and the medicine syringe head 152 is connected to the handle 110 by engaging the ball 153 of the head 152 into the socket 115 of the handle 110 in a well known manner.
The head 152 is hollow and further comprises a medicine syringe nipple 156 and a transmitting syringe stop flange 158 . The medicine syringe nipple 156 may be integral to the hollow medicine syringe head 152 and is sized to securely receive a syringe vaccine hose (not shown). Vaccine is delivered to the hollow interior cavity of the head 152 via the vaccine hose which is connected to a vaccine source (not shown). The medicine syringe stop flange 158 extends laterally about the periphery of the medicine syringe head 152 .
The extendible medicine syringe shaft 151 interconnects the syringe head 152 and the plunger 160 . The shaft 151 has an interior axial conduit (not shown) which communicates at one end with the interior cavity of the head 152 and at the other end with an interior axial conduit (not shown) through the plunger 160 . The syringe shaft 151 extends through a medicine syringe collar 132 of the second syringe handle 130 and into the vaccine dosage chamber 161 . In order to vary the amount of the dosage, the shaft 151 has a vaccine dosage adjust valve 166 . The dosage adjust valve 166 comprises a collar that engages the plunger 160 on one end and is threaded onto the syringe shaft 151 .
In the preferred embodiment of the present invention, in which a dosage signal 61 is transmitted to the intelligent syringe 50 and the intelligent syringe 50 automatically varies the dosge amount depending on the size of the animal 40 (and possibly other factors, as well), a controller 198 is functionally connected to the dosage adjust valve 166 . More particularly, the controller 198 comprises a receiver 199 for receiving the dosage signal 61 from the transmitter 62 . The controller 198 possesses the requisite intelligence (by way of internal microprocessor) to convert the dosage signal 61 into an action command for the dosage adjust valve 166 . Thereafter, the controller 198 automatically adjusts the dosage adjust valve 166 to provide the proper dosage to the animal 40 via simple mechanical linkage such as that which is well known in the art.
It is envisioned that the dosage receiver 199 and the controller 198 will eventually be powered by a power source such as power source 188 , illustrated as positioned within the intelligent syringe 50 . Presently, to achieve proper standards of performance, and considering the shortcomings of battery technology, the controller 198 and dosage receiver 199 may be powered by an external power source (not shown).
After automatic adjustment of the dosage adjust valve 166 , and actuation of the intelligent syringe 50 , the medicine syringe plunger 160 slides within the vaccine dosage chamber 161 . An O-ring 163 creates a liquid tight seal between the periphery of the plunger 160 and the interior wall of the dosage chamber 161 . The plunger 160 has a check valve (not shown) within its interior axial conduit that allows liquid to pass only in the direction toward the needle end of the syringe 150 .
The medicine dosage chamber 161 is formed of a translucent or transparent material and is secured at its first end to the medicine syringe collar 132 . The medicine dosage chamber 161 may be scored with incremental graduations to assist a user in dosage measurements. At its second end, the medicine dosage chamber 161 removably receives a syringe needle fastener 162 . The syringe needle fastener 162 is fitted to capture a needle 164 . A check valve (not shown) is fitted within the syringe needle fastener 162 to allow liquid flow only out of the needle 164 .
A syringe biasing spring 168 is disposed around the medicine syringe shaft 151 between the medicine syringe stop flange 158 and the vaccine dosage adjust valve 166 . The biasing spring 168 is a compression spring which serves to return the syringe handles 110 , 130 to their initial spread position after being squeezed closed by the user.
When the handles 110 , 130 are squeezed together, the plunger 160 moves within the dosage chamber 161 . The movement of the plunger 160 closes the check valve within the plunger 160 to force vaccine in the dosage chamber 161 through the check valve within the needle fastener 162 and out through the needle 164 . When the handles 110 , 130 are released by the user, the check valve within the needle fastener 162 closes to preclude fluid or air being drawn into the dosage chamber 161 through the needle 164 . Simultaneously, the check valve within the plunger 160 opens to that vaccine is drawn into the dosage chamber 161 through the nipple 156 , the hollow head 152 , the conduit within the shaft 151 , and the conduit within the plunger 160 . By turning the dosage adjust valve 166 , the length of the shaft 151 is changed. Changing the length of the shaft 151 changes the length of the plunger stroke, and the amount of medicine delivered through the needle 164 is correspondingly changed.
The optional ink dispenser 170 comprises a self contained storage unit 189 . The self contained storage unit 189 may take any number of forms well known to those skilled in the art of marking substance apparatus, including, but not limited to, a canister, a jar, a tube, or the like. Further, the specific form of self contained storage unit 189 is dependent upon the type of ink being utilized. For instance, a pressurized canister maybe used to store ink which is suspended in, or in the form of, a compressed gas. Alternatively, a structure such as that used to store household caulk may be used to store liquid ink.
To support and retain the self contained storage unit 189 , the second handle 130 may further comprise an integral retention cage 144 extending from the ink dispenser collar 134 . The retention cage 144 may take any number of forms well known to those skilled in the art of mechanical design. It will be appreciated that the form of the retention cage 144 is dependent upon the physical characteristics of the self contained storage unit 189 being used.
The self contained storage unit 189 may comprise a pressurized canister 191 , the ink dispenser interface 117 having a contact point 118 , a retention cage 144 having a body 145 , a valve actuator 146 , a tip opening 147 , and a can detent 148 . The pressurized canister 191 may contain ink in the form of an aerosol, a non-aerosol compressed gas, or the like. The pressurized canister may be mounted to the second handle 130 my means of the collar 134 and the retention cage 144 . The pressurized canister 191 comprises a canister body 192 having a bottom surface 193 , a valve trigger (not shown), and an ink discharge orifice 182 . In order to install the pressurized canister 191 into the handle 104 , the canister body is inserted into the handle collar 134 of the second syringe handle 130 and maneuvered into the retention cage 144 until the can detent 148 makes contact with the bottom surface 193 of the canister 191 , thereby securely capturing the pressurized canister 191 within the retention cage 144 .
After secure capture of the pressurized canister 191 within the retention cage 144 , the ink discharge orifice 182 extends through the tip opening 147 , and the valve trigger is positioned in contact with, or adjacent to, the valve actuator 146 . When fully inserted, the retention cage 144 assures that the bottom of the pressurized canister 191 is aligned with the radial path of rotation of the ink dispenser contact point 118 on the second syringe handle 130 , as defined by rotation of the second handle 130 about the pin 120 .
Importantly, it is specifically contemplated that the intelligent syringe could be pneumatic in design. More specifically, the syringe may be powered by a source of compressed air or liquid so that when the user activates a trigger, the functions previously described as effected by squeezing the handles together are accomplished.
Central to the preferred functionality of the intelligent syringe 50 is the transmitter circuitry integral to the intelligent syringe 50 . In an exemplary embodiment, the transmitter circuitry comprises a transmit trigger 184 , a transmitter 186 , and a power source 188 . As depicted in FIG. 2, the transmit trigger 184 may be positioned within the handle 110 proximal to the ink dispenser contact point 117 . The transmit trigger 184 supports a transmit sensor 185 positioned such that actuation of the intelligent syringe 50 by squeezing handles 110 , 130 places the transmit sensor 185 in contact with the pressurized canister 191 . The transmit trigger, powered by a power source 188 such as a battery, detects contact between the transmit sensor 185 and the pressurized canister 191 and relays an appropriate signal to the transmitter 186 . As previously described with reference to FIG. 1, the specific characteristics of the transmitter 186 will vary depending on the particular embodiment of the present invention being practiced, but in all cases, the transmitter is of sufficient signal strength and signal complexity to transmit, at a minimum, the injection event to a receiver.
Optionally, the intelligent syringe 50 may include a flow meter in communication with the medicine syringe 150 for detecting the amount of medicine delivered in any given actuation. In such an optional embodiment, the transmitter 150 must be of a type to be able to transmit such data to a designated receiver. Similarly, it is within the spirit and scope of the present invention that the medicine syringe 150 is capable of transmitting and facilitating the recording of the time and date on which medical treatments were given, as well as specifics of the particular treatment, such as the manufacturer of the medicine, the batch number and the date of manufacture.
Turning now to FIG. 3, a flow diagram detailing exemplary steps in performing the method of the present invention is shown. The method begins at step 200 and, at step 205 the system is “powered on” by a cattleman 10 , another operator, or remote device. After being powered on, the system 5 requests input of a user ID at step 210 . As previously described, the user ID may be input via PC 25 .
At decision block 215 , a comparison is done between the user ID entered at step 210 and a list of authorized users maintained in a database such as access database 28 . If the user ID entered does not correspond to a user ID maintained in the access database 28 , the method of the present invention ends at step 280 . If, on the other hand, the user is deemed to be an authorized user, an injection session begins at step 220 . Depending on specific system configuration and requirements, session initiation such as that referenced in step 220 may include turning on the trigger device such as scale 47 and waiting for an appropriate trigger signal, as previously discussed. Additionally, before animals may be injected in accordance with the method of the present invention, an intelligent syringe 50 must be connected to a medicine reservoir 52 as shown in step 225 .
After the set-up steps are complete, the system remains in a “standby” state anticipating a trigger event. If, after a predetermined, prolonged period of time, no trigger event has occurred, the method ends at step 280 , per decision block 230 . If a trigger event does occur, two things happen substantially simultaneously. First, the head of cattle causing the trigger event is identified in accordance with the particular capabilities of the system of the present invention at step 240 . Second, the animal is weighed at step 232 . After being weighed, the weight of the animal is transmitted to the processor or other computation cell as previously described with reference to FIG. 1 . At the computation cell, a dosage calculation is made at step 236 to determine what particular dosage of medicine should be given an animal of the weight measured. After completion of the dosage calculation at step 236 , the dosage is transmitted to the intelligent syringe at step 238 .
If, after occurrence of a trigger event, weighing and calculation of dosage for the animal and identification of the animal, but before transmission of data, the trigger event is interrupted (step 245 ), the method returns to step 230 and awaits another trigger event. If there is no trigger event interrupt, the cattleman 10 actuates the intelligent syringe 50 and delivers the desired injection at step 250 . Data relating to the injection is transmitted from the intelligent syringe 50 in step 255 and, at decision block 260 , a determination is made as to whether the data was received by the receiver 66 . If no data was received, the method of the present invention returns to step 230 and awaits a trigger event. If the data is received, the data is associated with the specific identity of the animal 40 which caused the trigger event and resulting trigger signal at step 265 .
Thereafter, the present invention awaits the arrival of another head. If, as depicted in decision block 270 , another head is detected, the system is monitored for occurrence of a trigger event at decision block 230 . From decision block 230 , the process continues until when, after a predetermined, prolonged period of time, no additional animals are detected, the method ends at step 280 .
It will be understood and appreciated that the spirit and scope of the present invention is not limited to the particular embodiments referenced and discussed herein, but to the claims appended hereto. | A system and method for automatically controlling the quantitative delivery of, and then recording the occurrence of the administration of medicines to animals is disclosed and claimed. An intelligent syringe receives and automatically implements an instruction relating to a preferred quantity of medicine to be delivered to a specific animal, based on the measured weight of the animal. Upon actuation of the intelligent syringe, a first signal containing information relating to the actuation of the intelligent syringe, and the resulting injection of the animal is transmitted to a data repository.
An EID is attached to the animal to provide a tamper-resistant electronic identification of the animal, and a receiver is utilized for receiving the first signal from the intelligent syringe and the electronic identification of the animal. Thereafter, a computer database maintains the information contained in the first signal for selective access and analysis. | 0 |
This application is a continuation division of application Ser. No. 07/713,370 filed Jun. 12, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to bakery foods containing dietary fibers.
2. Description of Prior Art
Recent years, it has been made clear that deficiency of dietary fibers is closely related to certain diseases such as cancer, heart disease, cerebral apoplexy, diabetes each ranking high in the causes of death in western countries as well as in Japan, and to diseases such as constipation, varicocele, cholelithiasis. Under such circumstances, various kinds of foods containing dietary fibers have come to be sold on the market in conjunction with the recent change in eating habits. Representative ones among the mentioned foods containing dietary fibers are soft drinks, desserts, teas, starch noodle (glass noodle), soybean curd (tofu), etc. It is, however, hard to take in quantitatively a required amount of dietary fibers from such foods in the eating habits today, and therefore it is desired to prepare daily foods so as to contain quantitatively required amount of dietary fibers. It may be generally said that bakery foods such as bread is certainly suitable to be employed as one of the mentioned dietary fiber foods, but various disadvantages come out when adding the dietary fibers to the bakery foods mainly from the viewpoint of quality.
The dietary fibers are roughly classified into water-soluble dietary fibers and insoluble ones. Cellulose, lignin, hemicellulose A and C, chitin, collagen, etc. belong to the latter. The former is further divided into high molecular materials such as pectin, guar gum, devils-tongue mannan, sodium alginate, carrageenan, agar, carboxymethylcellulose, etc. and low viscosity materials such as indigestible dextrin, polydextrose, etc.
When adding some insoluble dietary fibers to a bakery food such as bread, one who eats the food feels rough to his tongue due to the insolubility, resulting in an undesirable taste. On the other hand, this disadvantage of feeling rough to one's tongue is certainly overcome in the case of water-soluble dietary fibers, but in the group high molecular materials being one of such water-soluble dietary fibers, viscosity is high and water absorption coefficient of "dough" is increased. Accordingly, when adding a high molecular material over 3%, extensibility of dough is reduced thereby causing a difficulty in formation of dough. As a result, it becomes unavoidable to add more water for overcoming such difficulty, which, in turn, brings about a taste different from familiar one, and moreover there arises another problem of increasing water activity and accelerating deterioration (i.e., life of the food).
In the case of adding low viscosity materials, although there is no problem like the addition of high molecular materials, volume of the product obtained is reduced eventually resulting in a disadvantage of tastelessness.
It is expected that dietary fibers perform various useful physiological functions such as reduction of cholesterol, saving the insulin secretion, acceleration of bowels evacuation, saving of harmful objects, etc. and are now occupying a position of 6th nutritive substance. However, due to the change of the eating habit in recent years, amount of dietary fibers taken in from the daily meals has been actually reduced, and hence it is desirable to have meals containing more dietary fibers from the viewpoint of preventive medicine.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a bakery food containing sufficient dietary fibers which is delicious and enables to take in dietary fibers without fail through the daily meals.
In order to accomplish the foregoing object, there is provided in accordance with the invention a method for preparing a bakery food comprising the steps of kneading wheat flour, baking the Kneaded wheat flour after fermentation thereof; wherein indigestible dextrin is added in the mentioned step of kneading, thereby a bakery food containing dietary fibers superior in both taste and quality being achieved. It is preferable that the indigestible dextrin is added during a process of main kneading according to sponge and dough method.
The term "bakery food(s)" used herein means products obtained through the processes of kneading, fermentation and baking of wheat flour employed as main material, and includes various kinds of bread, pizza, yeast doughnut. The "bakery food(s)" includes the mentioned products whose material is partially of some grain flour other than wheat flour such as rice flour, corn flour, buckwheat flour, rye flour, etc. The mentioned baking process includes frying with oil wheat flour employed as main material in known bakery foods. This is, hard wheat flour or semi-hard wheat flour is employed in the invention.
The indigestible dextrin employed in the invention can be produced by several methods as disclosed in Japanese Patent Publication (unexamined) No. 2-100695, Japanese Patent Application No. 63-299308 or Japanese Patent Application No. 63-307194. In effect, any indigestible dextrin can be adopted as far as it is essentially made from pyrodextrin.
More specifically, essential parts of the methods disclosed in the mentioned Japanese Patent Application No. 63-299308 are as follows: (1) a method of preparing dextrin containing dietary fibers comprising the steps of dissolving pyrodextrin into water, and hydrolyzing a solution of pyrodextrin with α-amylase; (2) a method of preparing dextrin containing dietary fibers according to the mentioned item (1), wherein hydrogen is added after the hydrolysis with α-amylase; (3) a method for preparing dextrin containing dietary fibers according to the mentioned item (2), wherein the solution of pyrodextrin is treated with transglucosidase and/or α-amylase after the hydrolysis of α-amylase and before the hydrogenation; and (4) a method for preparing dexitrin containing dietary fibers according to the mentioned item (1) or (3), wherein starch alone or starch mixed with at least one of monosaccharide and oligosaccharide is roasted by conventional method. Preferred embodiments are illustratively described in detail in the specification of the Japanese Patent Application No. 63-299308.
Essential parts of the method disclosed in the mentioned Japanese Patent Application No. 63-307194 are as follows: (1) a method for preparing dextrin containing dietary fibers comprising the steps of hydrolyzing pyrodextrin with α-amylase, hydrolyzing the same with glucoamylase, preparing a highly pure dextrin solution by filtering, decolorization and deionization, separating dietary fiber component by means of a chromatography through strongly acidic cation exchange resin, thereby extracting dietary fibers; (2) a method according to the item (1), wherein the pyrodextrin is hydrolyzed with transglucosidase after the hydrolysis with glucoamylase and before the steps of filtering, decolorizing and deionization; and (3) a method according to the mentioned item (1), wherein hydrogen is added to the dextrin containing dietary fibers prepared by the mentioned method (1) or (2). Preferred embodiments are likewise described in detail in the specification of the Japanese Patent Application No. 63-307194.
The present invention relates essentially to such bakery foods as produced through the processes of kneading, fermentation and baking, and more particularly to a production process of bread. Production process of bread is classified into so-called "straight dough method" and "sponge and dough method" each being carried out according to known process. It is, however, generally said that the latter is more preferable than the former in view of both taste and quality.
In both straight dough and sponge and dough methods, indigestible dextrin is added in the kneading process. To be more specific, in the kneading process of straight dough method, indigestible dextrin is preferably added at the point of time when dough has been formed by about 50 to 80%. In the case of sponge and dough method, indigestible dextrin is preferably added at the point when dough has been formed by about 40 to 70%. If the addition of indigestible dextrin is carried out at any point of time other than the mentioned point, not only volume will be insufficient but also taste will be poor. In this respect, the addition timing of indigestible dextrin shows an extent of formation of dough as compared with the state of formation at the time of completing the kneading process, and guideline can established in such a manner as to know an approximate value of the formation degree of a dough in the form of a ratio with respect to a sum obtained by multiplying a coefficient of kneading speed by a kneading time, said coefficient of kneading speed being classified into low speed 1, middle speed 1.5 and high speed 2. However, this guideline may be different depending upon the type of kneading machine, and therefore such guideline should be appropriately established according to individual type of kneading machine.
It is preferable that addition amount of indigestible dextrin is 1 to 15% by weight, more preferably, 3 to 10% by weight with respect to total amount of material flour in case that wheat flour is totally or partially replaced by other grain flour. If the addition amount is over 15% by weight, taste and volume are both apt to be inferior. On the other hand, if the addition amount is less than 1%, both taste and quality remain unchanged as compared with the conventional foods containing poor dietary fibers, which does not comply with the objective of the invention.
As mentioned above, a bakery food containing dietary fibers, which is superior in the aspect of both taste and quality, is now achieved in accordance with the invention by adding indigestible dextrin essentially made from pyrodextrin in the conventional production process of bakery food, preferably at a very limited point of time therein.
Generally, various additives are added to bakery foods for various purposes, other than secondary materials such as yeast, yeast food, sugar, salt, skin milk powder, oils and fats. For example, emulsifying agents such as glycerine fatty acid ester, sucrose fatty acid ester etc., succharides such as maltose, sorbitol, starch syrup, etc., polysaccharides such as gellangum, carrageenan, etc., condense milk, egg, vital gluten, flavours, colorant, preservatives, expanding agent are these additives, and they can be appropriately added according to the requirement. It is also preferable to add small amount of dietary fibers other than indigestible dextrin within the restriction of not affecting the quality.
Other objects and advantages of the invention will become apparent in the course of following description.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Described hereinafter are embodiments in accordance with the present invention. Bakery foods obtained were evaluated through sensory test by 10 panelers and specific volume was determined by substitution method. Results of the sensory test were classified into appearance, crumb and taste each being subject to five-step evaluation, and every aspect of controls (i.e., comparative examples to which no dietary fibers were added) were evaluated as getting 0 (i.e., no mark), based on which relative evaluation was carried out.
Following table shows a result of such relative evaluation in the form of average value of total points.
______________________________________ Fairly Fairly good Good Average Bad bad______________________________________Appearance 2 1 0 -1 -2Crumb 2 1 0 -1 -2Taste 2 1 0 -1 -2Total point of 6 3 0 -3 -6evaluation______________________________________
Check-points in the evaluation
Appearance: color of baked crust thickness and softness of dough, proportion and symmetry;
Crumb: color of crumb, bubbles formed on sliced surface, thickness of cell walls between bubbles
Taste :odor, taste and flavor
EXAMPLE 1 AND COMPARATIVE EXAMPLES 1 TO 2
Breads were produced according to normal process of sponge and dough method on the following blending and kneading conditions. 6 parts by weight of Pine Fiber (produced by Matsutani Chemical Industries Co., Ltd.) were added in the following steps. Table 1 shows evaluation of the breads thus obtained. Breads of comparative examples were produced on the kneading condition of adding no indigestible dextrin in the main kneading (1).
______________________________________[Blending]Sponge mixinghard wheat flour 70 parts by weightyeast 2.2 parts by weightyeast food 0.1 parts by weightwater 40 parts by weightDough mixinghard wheat flour 30 parts by weightsugar 6 parts by weightsalt 2 parts by weightskim milk powder 2 parts by weightshortening 5 parts by weightyeast 0.2 parts by weightwater 24 parts by weight[kneading]Sponge mixing 3 min at low speed 1 min at high speedDough (1) 3 min at low speed 3 min at high speedkneading ⊚ 2 min at low speed 4 min at high speed (2) 3 min at low speed 4.5 min at high speed ⊚ 2 min at lowspeed 2.5 min at high speed[Addition timing of indigestible dextrin]Example Addition in ⊚ of At the point when about1A Dough kneading (1) 47% of dough was formedExample Addition in ⊚ of At the point when about1B Dough kneading (2) 63% of dough was formedComparative Addition to wheatExample 1 flour of sponge mixingComparative Addition to wheat At the point whenExample 2 flour in dough formation degree of mixing dough was 0______________________________________
TABLE 1______________________________________ Specific volume Total point______________________________________Control 4.80 0Example 1A 4.68 2.5Example 1B 4.83 2.8Comparative 4.10 -3.5Example 1Comparative 3.92 -3.9Example 2______________________________________
The mentioned Pine Fiber were produced by the method disclosed in Example 1 of the Japanese Patent Application 63-29908 (Japanese Patent Publication (unexamined) No. 2-145169).
EXAMPLE 2 AND COMPARATIVE EXAMPLE 3 to 4
Breads were produced on the same production conditions as the foregoing Example 1 with the exception of changing addition amount of indigestible dextrin (Pine Fiber). Table 2 shows addition amounts of indigestible dextrin and evaluation of the breads.
TABLE 2______________________________________ Addition amounts of indigestible Specific Total dextrin volume point______________________________________Control 0% 4.80 0Comparative 2% 4.77 -0.3Example 3Example 2A 4% 4.62 1.7Example 2B 8% 4.72 2.6Example 2C 13% 4.58 1.0Comparative 17% 4.33 -1.9Example 4______________________________________
EXAMPLE 3 AND COMPARATIVE EXAMPLE 5
Breads were produced according to normal process of straight dough method on the following blending and kneading conditions. 5 parts by weight of indigestible dextrin were added in the following steps. Table 3 shows evaluation of the breads obtained. In the control, no indigestible dextrin was added but following the kneading condition (1).
______________________________________[Blending]hard wheat flour 100 parts by weightsugar 4 parts by weightsalt 2 parts by weightshortening 3 parts by weightyeast 2 parts by weightyeast food 0.1 parts by weightskim milk powder 1 parts by weightwater 65 parts by weight[Kneading](1) 4 min at low speed 2 min at high speed⊚3 min at low speed 3 min at middle speed1 min at high speed 1 min at middle speed(2) 4 min at low speed 2 min at high speed3 min at middle speed ⊚ 3 min at low speed1 min at high speed 1 min at middle speed[Addition process of indigestible dextrin]Example 3 Addition in ⊚ of At the point when about dough mixing (2) 66% of dough was formedComparative Mixed with wheat At the point when forma-Example 5 flour as material tion degree of dough was 0______________________________________
TABLE 3______________________________________ Specific volume Total point______________________________________Control 4.70 0Example 3 4.58 1.5Comparative 3.63 -4.7Example 5______________________________________
EXAMPLE 4
Breads were produced according to normal process of sponge and dough method on the following blending and kneading conditions. 7 parts by weight of indigestible dextrin prepared according to the method disclosed in the Japanese Patent Publication (unexamined) No. 2-100695 was added in the steps ⊚ of the following kneading conditions. Table 4 shows evaluation as compared with the control to which no indigestible dextrin was
______________________________________[Blending]Sponge mixinghard wheat flour 70 parts by weightyeast 2.5 parts by weightyeast food 0.1 parts by weightwater 40 parts by weightDough mixinghard wheat flour 30 parts by weightsugar 5 parts by weightsalt 2 parts by weightshortening 4 parts by weightmargarine 4 parts by weightskim milk powder 2 parts by weightegg 7 parts by weightyeast 0.2 parts by weightwater 18 parts by weight[Kneading]Sponge mixing:3 min at low speed; 1 min at high speed;Dough mixing:(1) 3 min at low speed; 2 min at middle speed;2 min at high speed; ⊚ 2 min at low speed;2 min at middle speed; 1 min at high speed;______________________________________
EXAMPLE 5
Breads were produced in the same manner as Example 4 with the exception that 5.5 parts by weight of following indigestible dextrin was added. Table 4 shows evaluation thereof.
[Indigestible dextrin employed in Example 5]
10 kgs of pyrodextrin ("Arabix #7" produced by Matsutani Chemical Industries) were dissolved into 20 kgs of water with pH adjusted to 5.5, then 0.2% by weight of a-amylase ("Klaistase KD" produced by Daiwa Chemical) was added to the solution for reaction at 85 ° C. for one hour. Thereafter reaction with amylase was stopped while keeping the solution temperature at 120° C. for 15 minutes, then the temperature was decreased to 55° C. with pH adjusted to 4.5, and 0.1% by weight of glucoamylase (Gluczyme NL 4.2 by Amano Seiyaku) was added for saccharification for 36 hours. At this point, pH was adjusted to 3.5 and reaction with glucoamylase was stopped. Then, the solution was refined with the use of activated charcoal and ion exchange resins, and concentrated to obtain 1.5 kg of 50% solution. This solution was composed of 51.2% glucose, 2.2% dissaccharide, 3.9% trisaccharide, and 42.8% tetrasaccharide and higher oligosaccharides. 100 ml of this solution was put to pass through a column filled with alkali metal type strongly acidic cation exchange resin XFS-43279.00 (produced by Dow Chemical Japan) at SV=0.25, then water was put to pass therethrough, whereby a high molecular weight dextrin was extracted. Saccharide component of this dextrin was composed of 4.4% glucose, 1.2% disaccharide, 1.7% trisaccharide and 92.1% tetrasaccharide and higher oligosaccharides, and it was recognized through a quantitative analysis by Prosky AOAC method that content of the dietary fiber was 83.9%.
TABLE 4______________________________________ Specific volume Total point______________________________________Control 4.73 0Example 4 4.71 2.5Example 5 4.66 2.2______________________________________ | A method for producing a bakery food comprising the steps of kneading a wheat flour, baking the kneaded wheat flour after fermentation, the method being characterized by adding indigestible dextrin in the step of kneading. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/DE2003/003898, filed Nov. 25, 2003 and claims the benefit thereof. The International Application claims the benefits of German application No. 10255159.6 filed Nov. 26, 2002, both applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a method for the automatic configuration of communication relationships between communication units situated in a packet-oriented communications network.
SUMMARY OF THE INVENTION
[0003] In the interests of optimizing current communications networks, in particular broadband subscriber access networks (also called access networks), a large number of subscribers are to be guaranteed low-cost access to both narrowband and broadband services—e.g. video-on-demand. In the course of this optimization, the technological and economical cost of implementing network devices that can be situated in current communications networks may be reduced by using technologies that have not been specifically developed for broadband subscriber access networks, but for mass markets (e.g. personal computers). An example of such a widespread and correspondingly further developed technology is the “Ethernet”, which has been standardized according to IEEE standard 802.3 and which provides a frame-oriented or packet-oriented and connectionless transmission method. In network devices that can be situated in current communications networks, such as—for example—multiplex devices, it is known for data cells, for example those configured according to asynchronous transfer mode (ATM)—also called ATM cells—as well as time-slot-oriented information (e.g. TDM or PCM structures, Pulse Code Modulation) to be switched, via an Ethernet situated locally in the network device, between remote subscriber line modules situated in the network device and at least one central unit or module having central functions. The Ethernet may be used both as a “wiring” or “backplane” in a card rack for bridging short distances, and as a comprehensive communications network for bridging larger distances.
[0004] In the transition from traditional, circuit-switching or time-slot-oriented communications networks to packet-oriented communications networks, particularly on communications networks according to IEEE standard 802.3, the change in transmission method also entails changes in the addressing and configuration of the system components involved. The following system structure is frequently used in current communications networks:
a central module—hereinafter also called a central communication device—with a plurality of assigned communication units providing Ethernet interfaces, for example—hereinafter also called transformer modules—which are connected via a central switching device—e.g. Ethernet switch—to a packet-oriented communications network—e.g. Ethernet, a plurality of remote modules—hereinafter also called remote communication devices—each of which likewise incorporates at least one communication unit providing an Ethernet interface—a transformer module—in which at least one communication unit is connected via a switching device—in this case an Ethernet switch—to the communications network, and—via said communications network—to the central communication device.
[0007] In the system structure described above, the object is to facilitate a functional startup of the arrangement or system—i.e. to boot it up—in such a way that a logical point-to-point connection is set up between communication units or transformer modules assigned in each case to a remote module and to the central module.
[0008] A conventional solution option consists in setting up the individual configuration of the respective point-to-point connections via the communications network by means of local management consoles that can be connected to the communication devices. However, in a system covering a large geographical area, with many remote communication devices, this cannot be done by network operators due to the increased cost. The alternative option of having a fixed configuration is likewise not possible, since the assignment is to be effected dynamically.
[0009] The object of the invention is to improve the configuration of communication relationships between central and remote communication devices situated in a communications network, such that no interaction with a central management system is necessary. This object is achieved by the claims.
[0010] In the inventive method, communication relationships are configured between communication units situated in a packet-oriented communications network, assigned to at least one remote and one central communication device, and in each case having communications-network-specific address information. The main aspect of the method according to the invention consists in that a data packet comprising the respective address information of the communication unit is generated by at least one remote communication device or by at least one communication unit that is assigned to said device and is transmitted to the central communication device via the communications network. Said central communication device identifies the address information contained in the incoming data packet, selects at least one communication unit assigned to the central communication device, and assigns the identified address information to the selected communication unit. Furthermore, said central communication device—or at least one selected communication unit—generates at least one data packet which comprises the respective address information of the selected communication unit, and transmits said data packet to the remote communication device via the communications network. The communication relationship between the addressed communication units is configured via the communications network with the aid of the address information transmitted to the central and remote communication device.
[0011] The main advantage of the inventive method consists in that no management system (central or remote) is required for the setting up or configuration of communication relationships between communication units—e.g. interface units or transformer modules—situated in a communications network. The inventive method can therefore be used during the initialization of a communications network, e.g.—a system booting, as no communication with a central management system is possible during this period.
[0012] Only after these communication relationships have been set up according to the inventive method is it possible, for example, for the management system to communicate via the communications network via the communication relationships that have been set up. The inventive method makes it possible, at the earliest possible stage during system initialization, for the communication units or modules involved in a communication relationship that is to be set up, to be notified of the respective reciprocal communications-network-specific address information—also called MAC addresses—at runtime, thus facilitating a random assignment for the point-to-point connections.
[0013] The packet-oriented communications network is advantageously configured according to the IEEE standard 802.3. Such communications networks that are based on Ethernet technology are designed for the mass market in local networks (LANs) and are therefore low-cost. With the aid of Ethernet technology, therefore, internally situated communications networks can be used, for example locally in a network device, as cost—effective wiring of—for example—central and remote modules (“backplane”).
[0014] Other advantageous embodiments of the inventive method and a communication arrangement for implementing the inventive method are described in the dependent claims.
[0015] The inventive method is described in greater detail below with the help of two drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a communication arrangement, situated in a communications network, for implementing the inventive method, and
[0017] FIG. 2 shows an alternative development version of the communication arrangement shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0018] FIG. 1 is a block circuit diagram showing a network device NE that is situated in a subscriber access network or access network ACCESS and configured as a multiplex device, and in which the respective subscribers—not shown—are connected to a higher-level communications network OKN—for example an ISDN communications network—via a plurality of remote modules DBG . . . k situated in the network device NE and via a plurality of subscriber accesses TA or subscriber access lines. An “internal”, packet-oriented communications network EN—hereinafter also called “Ethernet”—which is configured according to IEEE standard 802.3, and via which the respective remote modules DBG 1 . . . k—hereinafter also called remote communication devices—are connected to a central module ZBG—hereinafter also called a central communication device—is situated in the network device NE. The remote communication devices DBG 1 . . . k and the central communication device ZBG each have a switching device SW—hereinafter called the Ethernet switch—which has been adapted to the transmission technology of the communications network EN, whereby said communications devices DBG 1 . . . k, ZBG are connected to the packet-oriented communications network EN via a connection port of the Ethernet switch SW and a connection AD, AZ of the respective communication device DBG 1 . . . k, ZBG, said connection being provided for this purpose.
[0019] In this exemplary embodiment, each remote communication device DBG 1 . . . k has a communication unit KE represented by a transformer module KE. Each transformer module KE implementing the subscriber access incorporates transformation functions for the transition between—for example—time-slot-oriented transmission technology that is implemented on the subscriber access line, and packet-oriented transmission technology—in this case TCM/Ethernet—that is implemented in the communications network. Each transformer module KE is connected to the Ethernet switch SW assigned in the remote communication device DBG 1 . . . k. It should be noted that each remote communication device DBG 1 . . . k may comprise a plurality of such transformer modules or communication units KE.
[0020] It should also be noted, in the event that only one communication unit KE is assigned to the remote communication device DBG 1 . . . k, that the remote communication device DBG 1 . . . k and the assigned communication unit may be logically combined, in other words may be regarded as an identical or logically related unit.
[0021] Furthermore, a plurality of transformer modules or communication units KE, which are each connected to the Ethernet switch SW situated in the central module ZBG, are likewise situated in the central communication device ZBG. All communication units KE have their own address information mac 1 _ 1 . . . k_n, macz 1 . . . 1 —also called a MAC address (Medium Access Control)—which uniquely identifies the respective communication unit KE in the packet-oriented communications network EN. Each communication device DBG 1 . . . k, ZBG that is connected to the packet-oriented communications network EN has a control device STE, which is connected to the components of the respective communication device—and therefore to the respective transformer modules KE and the Ethernet switch SW. The transformer modules KE situated in the central communication device ZBG each have a connection AL, via which the respective transformer modules KE are connected to the higher-level communications network OKN that is configured—in this exemplary embodiment—according to the ISDN transmission method, via corresponding outputs UL in the central communication device ZBG.
[0022] According to an alternative development version illustrated in FIG. 2 , the outputs AL of the transformer modules KE situated in the central communication device ZBG are taken back to corresponding ports AP′ of the Ethernet switch SW situated in the central module ZBG, said Ethernet switch SW being connected to the higher-level communications network OKN via further ports AP″. The corresponding configuration transmits information between the transformer modules (KE) and the higher-level communications network (OKN) via the Ethernet switch SW and its connections AP′, AP″ respectively.
[0023] When the arrangement illustrated in the block circuit diagram is started up, communication relationships or logical point-to-point connections, via which the payload information is transmitted following successful startup, are to be set up between the communication units KE situated in the remote and central communication devices.
[0024] The sequence of the inventive method is described in greater detail below:
1. In one development version of the inventive method, a freely selectable MAC address iadr—hereinafter also called the initialization address—is defined as being known to all control units STE situated in the respective remote and central communication devices DBG 1 . . . k, ZBG. The time of initialization of the communication arrangement illustrated in the block circuit diagram, also called the system start-up or boot, is considered below. After the initialization of the system or of the communication arrangement, all communication devices DBG 1 . . . k, ZBG connected to the packet-oriented communications network EN behave passively. For the exemplary embodiment, it may also be assumed that—during the system initialization—a communication relationship or logical point-to-point connection kb (many such connections are signified in the block circuit diagram by a dotted double-ended arrow) is to be set up between the transformer module KE situated in the first communication device DBG 1 and a transformer module KE situated in the central communication device ZBG. 2. The control device STE situated in the first remote communication device DGB 1 configures the initialization address iadr as a (temporary) destination MAC address in the communication unit KE assigned to said device. This initialization address iadr is also configured in the assigned Ethernet switch in such a way that the connection port AP that implements the connection to the communications network EN is selected on the network side by said initialization address iadr. Furthermore, all units situated in the communications network EN, such as—for example—switches, are configured by presetting them so that the data packets or Ethernet frames having the initialization address iadr are switched toward the central communication device. 3. The control unit STE situated in the central communication device ZBG configures the initialization address iadr in the relevant Ethernet switch SW as pertaining to precisely one respective output port AP assigned to precisely one transformer module KE, so that a unique switching decision can be made immediately without “flooding” or “learning”. Two development versions are possible according to this exemplary embodiment: firstly, an incoming data packet or Ethernet frame that has the initialization address iadr as the destination address is switched via the transformer module KE and via an interface to the control unit STE, said interface being provided for this purpose, as indicated in the block circuit diagram by the route L 1 , L 2 . In the other version, an Ethernet frame having the initialization address iadr is switched via an interface of the Ethernet switch SW—said interface being specially provided for this purpose—directly to the control unit STE—as indicated in the block circuit diagram by the route L 3 . 4. After the initialization according to step 2, the transformer module KE in the first remote communication device DBG 1 starts to transmit special data packets or Ethernet frames—illustrated schematically in the block circuit diagram by a data packet fr_z—cyclically to the initialization address iadr. These Ethernet frames fr_z may, for example, be configured such that they differ somehow from a normal payload and can therefore be clearly identified as a “handshake”. This may be achieved, for example, by setting a specific value of the “Ethernet type field” defined in the Ethernet standard. Unlike the values already provided or reserved in the standard, this value may be freely selected. Furthermore, the MAC address—in this case mac 1 _ 1 —of the transformer module KE is inserted in the generated Ethernet frames fr_z as the “originating address”. 5. The Ethernet switch SW situated in the first remote communication device DGB 1 forwards the data packet fr_z thus generated to the Ethernet EN via the connection port AP, since this switching decision is clear as a result of step 2. 6. The data packet fr_z switched to the central module ZBG via the communications network EN is received by the Ethernet switch SW situated in the central communication device ZBG, whereby the originating address mac 1 _ 1 contained in the received data packet fr_z is identified or “learnt” and a unique switching decision is likewise made by the Ethernet switch SW on the basis of the configuration described in step 3. The received data packet is forwarded to the control device STE of the central communication device ZBG via one of the configured connection ports AP, either via the illustrated route L 1 , L 2 or via the alternative route L 3 , depending on the version selected. 7. The control device STE situated in the central communication device ZBG extracts from the received data packet or Ethernet frame fr_z the originating MAC address (in this case mac 1 _ 1 ) contained in it, and selects a transformer module KE that is currently unassigned and available in the central communication device ZBG. For this exemplary embodiment it must be assumed that the transformer module KE with the corresponding MAC address macz 1 is selected. The control device STE implements the extracted originating MAC address (mac 1 _ 1 ) in the selected transformer module KE (macz 1 ) as the destination for the transmit direction of the point-to-point connection to be set up. The control device STE also determines the MAC address of the selected transformer module (in this case macz 1 ), which in turn must be communicated to the first remote communication device DBG 1 as the (ultimate) destination. 8. The control device STE situated in the central communication device ZBG generates (for example via the route L 3 illustrated in the block circuit diagram) an equally “special” Ethernet frame as the response to the Ethernet frame emitted by the remote communication device DBG 1 . The destination of this special Ethernet frame or data packet schematically illustrated in the block circuit diagram by a data packet fr_d—is the first remote communication device DBG 1 , or the communication unit or transformer module KE (mac 1 _ 1 ) assigned to said remote communication device DBG 1 —i.e. the MAC address mac 1 _ 1 that has just been learnt is inserted in the generated Ethernet frame fr_d as destination information. Furthermore, the originating MAC address of the transformer module (in this case macz 1 ) selected in step 7 is inserted in the special Ethernet frame fr_d as the originating address. All Ethernet switches SW affected have learnt the MAC address of the transformer module KE assigned to the first remote communication device DBG 1 and are able to make a unique switching decision for the return route. 9. The Ethernet switch SW situated in the first remote communication device DBG 1 extracts from this received data packet or response Ethernet frame fr_d in a similar way to step 3. In this way the control device STE can extract the originating MAC address contained in the Ethernet frame and configure it as the ultimate destination of the point-to-point connection kb to be set up or configured in the transformer module KE assigned to it. 10. The transformer module KE situated in the first remote communication device DGB 1 stops the cyclical emission of Ethernet frames fr_z according to step 4, so that the transportation of the actual payload via the communication device kb, that was set up with the aid of the inventive method, may now commence.
[0035] According to an alternative development version of the communication arrangement illustrated in the block circuit diagram, the respective remote communication devices DBG 1 . . . k can each be connected to the central communication device ZBG via a connection line implementing the communications network EN, said connection line VL being indicated in the block circuit diagram by a dotted line. All data packets emitted by the remote communication devices DBG 1 . . . k are automatically switched or routed to the central communication device ZBG via these connection lines VL. It should be noted that the random MAC address or initialization address iadr previously provided for the inventive method is not required in an arrangement of this type, since all data packets are switched or transmitted to the central communication device ZBG from the remote communication devices DBG 1 . . . k via the connection lines without switching decisions, and therefore the initialization address is not required as destination information or routing information for the Ethernet frames. In this development version, therefore, only the MAC addresses of the respective transformer modules KE that represent the end points of the point-to-point connections to be set up—i.e. mac 1 _ 1 . . . k_n, macz 1 . . . 1 —are inserted and transmitted in the described way. The non-use of routing information in Ethernet frames would not, however, conform to the standard (e.g. as per IEEE 802.3), which means that the inventive method could not be implemented with standard-compliant components. A proprietary adaptation—which is associated with higher cost—would be required, while it is nevertheless possible, in this development version, to dispense with any type of management (central or remote).
[0036] The inventive method enables a system configuration to be configured and booted up dynamically without the involvement of a central management system. The method described in greater detail in the exemplary embodiment uses only resources that comply with the Ethernet standard and manages without broadcasts, which—for reasons of clear data separation—is regarded as unsuitable, particularly in the context of communications networks being operated by different network operators. With the exception of the development version described above, the inventive method requires a unique MAC address or initialization address, which is fixed yet freely selectable, in order to configure an essentially unlimited quantity of point-to-point connections. | In the inventive configuration of a communication relationship, a data packet comprising the respective address information of the communication unit is generated by at least one remote communication device or by at least one communication unit that is assigned to said device and is transmitted to a central communication device via a communication network. Said central communication device selects an assigned communication unit and generates a data packet, which comprises the respective address information of the selected communication unit, said data packet being transmitted to the remote communication device. The communication relationship between the addressed communication units is configured with the aid of the transmitted or exchanged address information via the communications network. The inventive method can be advantageously used during the initialization of a communications network, e.g. a booting of the system, as no communication with a management system (central or remote) is possible during this period. | 7 |
This applications is a continuation of application Ser. No. 08/477,677, filed Jun. 7,1995, now abandoned.
TECHNICAL FIELD
The invention relates generally to the field of formulation of proteins useful for attenuating inflammation and coagulation. More specifically, the invention relates to the formulation of Tissue Factor Pathway Inhibitor (TFPI) to achieve concentrations of TFPI useful for administration to patients.
BACKGROUND
TFPI inhibits she coagulation cascade in at least two ways: preventing formation of factor VIIa/tissue factor complex and by binding to the active site of factor Xa. The primary sequence of TFPI, deduced from cDNA sequence, indicates that the protein contains three Kunitz-type enzyme inhibitor domains. The first of these domains is required for the inhibition of the factor VIIa/tissue factor complex. The second Kunitz-type domain is needed for the inhibition of factor Xa. The function of the third Kunitz-type domain is unknown. TFPI has no known enzymatic activity and is thought to inhibit its protease targets in a stoichiometric manner; namely, binding of one TFPI Kunitz-type domain to the active site of one protease molecule. The carboxy-terminal end of TFPI is believed to have a role in cell surface localization via heparin binding and by interaction with phospholipid. TFPI is also known as Lipoprotein Associated Coagulation Inhibitor (LACI), Tissue Factor Inhibitor (TFI), and Extrinsic Pathway Inhibitor (EPI).
Mature TFPI is 276 amino acids in length with a negatively charged amino terminal end and a positively charged carboxy-terminal end. TFPI contains 18 cysteine residues and forms 9 disulphide bridges when correctly folded. The primary sequence also contains three Asn-X-Ser/Thr N-linked glycosylation consensus sites, the asparagine residues located at positions 145, 195 and 256. The carbohydrate component of mature TFPI is approximately 30% of the mass of the protein. However, data from proteolytic mapping and mass spectral data imply that the carbohydrate moieties are heterogeneous. TFPI is also found to be phosphorylated at the serine residue in position 2 of the protein to varying degrees. The phosphorylation does not appear to affect TFPI function.
TFPI has been isolated from human plasma and from human tissue culture cells including HepG2, Chang liver and SK hepatoma cells. Recombinant TFPI has been expressed in mouse C127 cells, baby hamster kidney cells, Chinese hamster ovary cells and human SK hepatoma cells. Recombinant TFPI from the mouse C127 cells has been shown in animal models to inhibit tissue-factor induced coagulation.
A non-glycosylated form of recombinant TFPI has been produced and isolated from Escherichia coli (E. coli) cells as disclosed in U.S. Pat. No. 5,212,091. This form of TFPI has been shown to be active in the inhibition of bovine factor Xa and in the inhibition of human tissue factor-induced coagulation in plasma. Methods have also been disclosed for purification of TFPI from yeast cell culture medium, such as in Petersen et al, J.Biol.Chem. 18:13344-13351 (1993).
Recently, another protein with a high degree of structural identity to TFPI has been identified. Sprecher et al, Proc. Nat. Acad. Sci., USA 91:3353-3357 (1994). The predicted secondary structure of this protein, called TFPI-2, is virtually identical to TFPI with 3 Kunitz-type domains, 9 cysteine-cysteine linkages, an acidic amino terminus and a basic carboxy-terminal tail. The three Kunitz-type domains of TFPI-2 exhibit 43%, 35% and 53% primary sequence identity with TFPI Kunitz-type domains 1, 2, and 3, respectively. Recombinant TFPI-2 strongly inhibits the amidolytic activity of factor VIIa/tissue factor. By contrast, TFPI-2 is a weak inhibitor of factor Xa amidolytic activity.
TFPI has been shown to prevent mortality in a lethal Escherichia coli (E. coli) septic shock baboon model. Creasey et al, J. Clin. Invest. 91:2850-2860 (1993). Administration of TFPI at 6 mg/kg body weight shortly after infusion of a lethal dose of E. coli resulted in survival in all five TFPI-treated animals with significant improvement in quality of life compared with a mean survival time for the five control animals of 39.9 hours. The administration of TFPI also resulted in significant attenuation of the coagulation response, of various measures of cell injury and significant reduction in pathology normally observed in E. coli sepsis target organs, including kidneys, adrenal glands, and lungs.
Due to its clot-inhibiting properties, TFPI may also be used to prevent thrombosis during microvascular surgery. For example, U.S. Pat. No. 5,276,015 discloses the use of TFPI in a method for reducing thrombogenicity of microvascular anastomoses wherein TFPI is administered at the site of the microvascular anastomoses contemporaneously with microvascular reconstruction.
TFPI is a hydrophobic protein and as such, has very limited solubility in aqueous solutions. This limited solubility has made the preparation of pharmaceutically acceptable formulations of TFPI difficult to manufacture, especially for clinical indications which may benefit from administration of high doses of TFPI. Thus, a need exists in the art for pharmaceutically acceptable compositions containing concentrations of TFPI which can be administered to patients in acceptable amounts.
SUMMARY OF THE INVENTION
The invention relates to pharmaceutically acceptable compositions wherein TFPI is present in a concentration of more than 0.2 mg/mL solubilizing agents. The solubilizing agents may be acetate ion, sodium chloride, citrate ion, isocitrate ion, glycine, glutamate, succinate ion, histidine, imidazole and sodium dodecyl sulfate (SDS). In some compositions, TFPI may be present in concentrations of more than 1 mg/mL and more than 10 mg/mL. The composition may also have one or more secondary solubilizers. The secondary solubilizer or solubilizers may be polyethylene glycol (PEG), sucrose, mannitol, or sorbitol. Finally, the composition may also contain sodium phosphate at a concentration greater than 20 mM.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the solubility of TFPI at different pH conditions. About 10 mg/mL TFPI in 2M urea was dialyzed against 20 mM acetate, phosphate, citrate, glycine, L-glutamate and succinate in 150 mM NaCl. The concentration of remaining soluble TFPI after dialysis was measured by UV absorbance after filtering out the precipitates through 0.22 μm filter units.
FIG. 2 shows the solubility of TFPI as a function of concentration of citrate in the presence of 10 mM Na phosphate at pH 7. TFPI solubility increases with increasing concentration of citrate.
FIG. 3 shows the solubility of TFPI as a function of concentration of NaCl. TFPI solubility increases with increasing salt concentration, indicating salt promotes solubility of TFPI.
FIG. 4 shows effect of pH on the stability of TFPI prepared in 10 mM Na phosphate, 150 mM NaCl and 0.005% (w/v) polysorbate-80. Stability samples containing 150 μg/mL TFPI were incubated at 40° C. for 20 days. Kinetic rate constant for the remaining soluble TFPI was analyzed by following decrease of the main peak on cation exchange chromatograms.
FIG. 5A shows the percentage of remaining soluble TFPI measured by cation exchange HPLC and FIG. 5B remaining active TFPI by prothrombin time assay as a function of phosphate concentration. The formulation contains 150 μg/mL TFPI prepared in 150 nM NaCl and 0.005% (w/v) POLYSORBATE-80 (sorethytan) at pH 7 with varying concentrations of phosphate.
FIG. 6 shows loss of soluble TFPI at 40° C. measured by both cation-exchange HPLC (triangle) and prothrombin time assay (circle) for 0.5 mg/mL TFPI formulated in 10 mM Na citrate, pH 6 and 150 mM NaCl.
FIG. 7 shows loss of soluble TFPI at 40° C. measured by both cation-exchange HPLC (open symbol) and prothrombin time assay (closed symbol) for 0.5 mg/mL TFPI formulated in 10 mM Na phosphate, pH 6 and either 150 mM NaCl (triangle) or 500 mM NaCl (circle).
FIG. 8 shows loss of soluble TFPI at 40° C. measured by both cation-exchange HPLC (open symbol) and prothrombin time assay (closed symbol) for 0.5 mg/mL TFPI formulated in 10 mM Na acetate and pH 5.5 containing 150 mM NaCl (triangle) or 8% (w/v) sucrose (square) or 4.5% mannitol (circle).
FIG. 9 shows two non-reducing SDS gels for TFPI formulation samples at pH 4 to 9 stored at 40° C. for 0 and 20 days.
BRIEF DESCRIPTION OF THE INVENTION
It has now been found that solubility of TFPI is strongly dependent on pH and, surprisingly, that polyanions such as citrate, isocitrate, and sulfate have profound solubilizing effects on TFPI. This finding is surprising in light of the hydrophobic nature of TFPI and the hydrophilic character of these counterions. Thus, citrate, isocitrate, sulfate as well as other solubilizers described hereinbelow can be used to produce pharmaceutically acceptable compositions having TFPI concentrations sufficient for administration to patients. It has also been shown that other organic molecules can act as secondary solubilizers. These secondary solubilizers include PEG, sucrose, mannitol, and sorbitol.
Further, it has been shown that aggregation of TFPI appears to be the major degradation route at neutral and basic pH conditions and that fragmentation occurs at acidic pH conditions.
DETAILED DESCRIPTION OF THE INVENTION
A. Definitions
As used herein, "TFPI" refers to mature Tissue Factor Pathway Inhibitor. As noted above, TFPI is also known in the art as Lipoprotein Associated Coagulation Inhibitor (LACI), Extrinsic Pathway Inhibitor (EPI) and Tissue Factor Inhibitor (TFI). Muteins of TFPI which retain the biological activity of TFPI are encompassed in this definition. Further, TFPI which has been slightly modified for production in bacterial cells is encompassed in the definition as well. For example, a TFPI analog has an alanine residue at the amino-terminal end of the TFPI polypeptide has been produced in Escherichia coli. See U.S. Pat. No. 5,212,091.
As used herein, "pharmaceutically acceptable composition" refers to a composition that does not negate or reduce the biological activity of formulated TFPI, and that does not have any adverse biological effects when formulated TFPI is administered to a patient.
As used herein, "patient" encompasses human and veterinary patients.
As used herein, the term "solubilizer" refers to salts, ions, carbohydrates, amino acids and other organic molecules which, when present in solution, increase the solubility of TFPI above 0.2 mg/mL. Solubilizers may also raise the concentrations of TFPI above 1 mg/mL and above 10 mg/mL. It should be noted that solubilizers may act as stabilizing agents. Stabilizing agents preserve the unit activity of TFPI in storage and may act by preventing formation of aggregates, or by preventing degradation of the TFPI molecule (e.g. by acid catalyzed reactions).
As used herein, the term "secondary solubilizers" refers to organic salts, ions, carbohydrates, amino acids and other organic molecules which, when present in solution with a solubilizer, further increase the solubility of TFPI. Secondary solubilizers may have other effects as well. For example, secondary stabilizers may be useful in adjusting tonicity (e.g. to isotonicity).
B. General Methods
TFPI may be prepared by recombinant methods as disclosed in U.S. Pat. No. 5,212,091, the disclosure of which is herein incorporated by reference. Briefly, TFPI is expressed in Escherichia coli cells and the inclusion bodies containing TFPI are isolated from the rest of the cellular material. The inclusion bodies are subjected to sulfitolysis, purified using ion exchange chromatography, refolded by disulfide interchange reaction and the refolded, active TLPI purified by cation exchange chromatography. TFPI may also be produced in yeast as disclosed in co-pending U.S. Ser. No. 08/286,530.
TFPI activity may be tested by the prothrombin time assay (PTT assays). Bioactivity of TFPI was measured by the prothrombin clotting time using a model RA4 Coag-A-Mate from Organon Teknika Corporation (Oklahoma City, Okla.). TFPI samples were first diluted to 9 to 24 ug/mL with a TBSA buffer (50 mM Tris, 100 mM NaCl, 1 mg/mL BSA, pH 7.5). Then 10 uL of Varify 1 (pooled normal plasma from Organon Teknika Corp.) was mixed with 90 uL of diluted TFPI samples in a sample tray and warmed to 37° C. in the instrument. Finally Simplastin Excel (Thromboplastin from Organon Teknika Corp.) was added to start the clotting. The time delay in clotting due to anticoagulant activity of TFPI was measured and converted into TFPI concentration in the measured samples by comparison to a TFPI standard curve.
The amount of soluble TFPI may also be quantified by measuring the area of the main peak on a cation exchange chromatogram. HPLC analysis of TFPI samples was performed using a Waters 626 LC system (Waters Corporation, Milford, Mass.) equipped with a Water 717 plus heater/cooler autosampler. Data acquisition was processed by a Turbochrom system from Perkin-Elmer.
The cation exchange (IEX) method used a Pharmacia Mono S HR 5/5 glass column. The column was equilibrated in 80% buffer A (20 mM sodium acetate trihydrate:acetonitrile solution (70:30 v/v) at pH 5.4) and 20% buffer B (20 mM sodium acetate trihydrate-1.0 M ammonium chloride:acetonitrile solution (70:30 v/v) at pH 5.4). After a sample was injected, a gradient was applied to elute the TFPI at a flow rate of 0.7 mL/min from 20% buffer B to 85% buffer B in 21 minutes. Eluting TFPI species were detected by absorbance at 214 nm. The main peak (monomer TFPI) was found to elute at about 18 minutes. Loss of soluble TFPI was quantified by integrating remaining peak area of the main peak.
Al reagents are U.S.P. or A.C.S. grade. Suppliers include J. T. Baker and Sigma Co. (St. Louis, Mo.).
C. EXAMPLES
Example 1
About 10 mg/mL TFPI in 2M urea was dialyzed against one of the following: 20 mM acetate, 20 mM phosphate, 20 mM citrate, 20 mM glycine, 20 mM L-glutamate or 20 mM succinate in 150 mM NaCl as described above. 6-10 mg/mL TFPI bulk stock was loaded into Spec/Por 7 dialysis tubings (MW cutoff 3,500). Dialysis was carried out either at 4° C. or ambient temperature. Three changes of buffer at a protein solution to buffer ratio: 1 to 50-100, were made during course of dialysis over 12 to 24 hr time period. After dialysis, TFPI solution was filtered by Costar 0.22 micron filter units to separate precipitated TFPI from soluble TFPI. The solubility of TFPI was then measured by UV/Vis absorbance assuming an absorptivity 0.68 (mg/mL) -1 cm -1 at 278 nm. The solutions were prepared at various pH levels by titration with HCl or NaOH.
After completion of dialysis, the precipitates were filtered through 0.22 μm filter units. The concentration of remaining soluble TFPI after dialysis was measured by UV absorbance. FIG. 1 shows the results of these experiments. Solubility of TFPI increased greatly in solutions containing 20 mM acetate, 20 mM phosphate, 20 mM L-glutamate and 20 mM succinate at pH levels below 7 and particularly at or below pH 4.5. Solubility of TFPI was also substantially increased in solutions containing 20 mM glycine above pH 10. FIG. 2 shows the solubility of TFPI as a function of concentration of citrate ion in the presence of 10 mM Na phosphate at pH 7. TFPI solubility increases with increasing concentration of citrate. FIG. 3 shows the solubility of TFPI as a function of concentration of NaCl at pH 7.0. TFPI solubility increases with increasing salt concentration, indicating salt promotes solubility of TFPI.
The solubility of TFPI was studied using a number of different solubilizers and secondary solubilizers. Table 1 shows solubility of TFPI in varying buffer solutions measured by UV absorbance after dialyzing 6 to 10 mg/mL TFPI into these buffer solutions.
TABLE 1______________________________________ SolubilityContent pH c (mg/ml) uv______________________________________Salt Effect10 mM Na.sub.3 PO.sub.4 7 0.2110 mM Na.sub.3 PO.sub.4, 150 mM NaCl 7 0.7220 mM Na.sub.3 PO.sub.4, 150 mM NaCl 7 0.8520 mM Na.sub.3 PO.sub.4, 0.5 M NaCl 7 6.7120 mM Na.sub.3 PO.sub.4, 1 M NaCl 7 8.24pH effect20 mM NaOAc, 150 mM NaCl 3 10.2720 mM NaOAc, 150 mM NaCl 3.5 10.2520 mM NaOAc, 150 mM NaCl 4 7.5420 mM NaOAc, 1S0 mM NaCl 4.5 1.7520 mM NaOAc, 150 mM NaCl 5 1.1520 mM NaOAc, 150 mM NaCl 5.5 0.8520 mM Na.sub.3 PO.sub.4, 150 mM NaCl 5.5 0.8920 mM Na.sub.3 PO.sub.4, 150 mM NaCl 6 0.7820 mM Na.sub.3 PO.sub.4, 150 mM NaCl 6.5 0.7920 mM Na.sub.3 PO.sub.4, 150 mM NaCl 7 0.8520 mM Na.sub.3 PO.sub.4, 150 mM NaCl 7.5 0.8220 mM Na.sub.3 PO.sub.4, 150 mM NaCl 8 0.8620 mM NaCitrate, 150 mM NaCl 4 2.1720 mM NaCitrate, 150 mM NaCl 4.5 1.1920 mM NaCitrate, 150 mM NaCl 5 1.120 mM NaCitrate, 150 mM NaCl 5.5 1.8420 mM NaCitrate, 150 mM NaCl 6 2.0920 mM NaCitrate, 150 mM NaCl 6.5 2.1220 mM NaCitrate, 150 mM NaCl 7 1.9220 mM Glycine, 150 mM NaCl 9 0.3220 mM Glycine, 150 mM NaCl 10 0.920 mM Glycine, 150 mM NaCl 11 13.9420 mM L-Glutamate, 150 mM NaCl 4 9.0720 mM L-Glutamate, 150 mM NaCl 5 1.2120 mM Succinate, 150 mM NaCl 4 8.6220 mM Succinate, 150 mM NaCl 5 1.2120 mM Succinate, 150 mM NaCl 6 1.07Citrate10 mM Na.sub.3 PO.sub.4, 20 mM NaCitrate 7 1.1610 mM Na.sub.3 PO.sub.4, 50 mM NaCiirate 7 5.8110 mM Na.sub.3 PO.sub.4, 100 mM NaCitrate 7 12.710 mM Na.sub.3 PO.sub.4, 200 mM NaCitrate 7 15.910 mM Na.sub.3 PO.sub.4, 300 mM NaCitrate 7 8.36Mg2+, Ca2+ and polyphosphate10 mM Na.sub.3 PO.sub.4, 150 mM NaCl, 1 mM MgCl2 7 0.6610 mM Na.sub.3 PO.sub.4, 150 mM NaCl, 10 mM MgCl2 7 1.0210 mM Na.sub.3 PO.sub.4, 150 mM NaCl, 0.1 mM CaCl2 7 0.6710 mM Na.sub.3 PO.sub.4, 150 mM NaCl, 1 mM CaCl2 7 0.7110 mM Na.sub.3 PO.sub.4, 150 mM NaCl, 10 mM triphosphate 7 3.6410 mM Na.sub.3 PO.sub.4, 5% PEG-400 7 0.0710 mM Na.sub.3 PO.sub.4, 10 mM EDTA 7 0.3610 mM Na.sub.3 PO.sub.4, 100 mM Na2SO4 7 5.0810 mM Na.sub.3 PO.sub.4, 100 mM L-aspartic acid 7 0.410 mM Na.sub.3 PO.sub.4, 100 mM Succinic acid 7 2.3310 mM Na.sub.3 PO.sub.4, 100 mM Tartaric acid 7 2.5620 mM Na.sub.3 PO.sub.4, 100 mM Maleic acid 7 0.1120 mM Na.sub.3 PO.sub.4, 100 mM Malic acid 7 1.8710 mM Na.sub.3 PO.sub.4, 100 mM L-glutamic acid 7 010 mM Na.sub.3 PO.sub.4, 150 mM NaCl 7 0.2510 mM Na.sub.3 PO.sub.4, 100 mM isocitrate 7 10.83NaOAc, NaPO4 and NaCl10 mM NaOAc, 150 mM NaCl 4.5 1.7610 mM NaOAc 4.5 4.8910 mM NaOAc 5.5 4.9510 mM NaOAc 6.5 5.110 mM NaOAc 7 5.8710 mM Na.sub.3 PO.sub.4, 150 mM NaCl 4.5 0.1410 mM Na.sub.3 PO.sub.4 4.5 4.9710 mM Na.sub.3 PO.sub.4 5.5 0.7910 mM Na.sub.3 PO.sub.4 6.5 0.09110 mM Na.sub.3 PO.sub.4 7 0.9450 mM NaOAc 5 5.245 mM NaOAc 5.5 4.5910 mM NaOAc 5.5 5.0520 mM NaOAc 5.5 5.0450 mM NaOAc 5.5 5.71100 mM NaOAc 5.5 1.4200 mM NaOAc 5.5 1.325 mM NaOAc, 5 mM NaCl 5.5 4.855 mM NaOAc, 10 mM NaCl 5.5 5.045 mM NaOAc, 50 mM NaCl 5.5 0.565 mM NaOAc, 100 mM NaCl 5.5 0.435 mM NaOAc, 200 mM NaCl 5.5 0.85 mM NaOAc 4.5 7.2710 mM NaOAc 4.5 6.520 mM NaOAc 4.5 8.3250 mM NaOAc 4.5 9.175 mM NaOAc 5.5 8.9810 mM NaOAc 5.5 8.0820 mM NaOAc 5.5 8.9950 mM NaOAc 5.5 2.925 mM NaOAc, 150 mM NaCl 4.5 2.610 mM NaOAc, 150 mM NaCl 4.5 2.5920 mM NaOAc, 150 mM NaCl 4.5 2.5550 mM NaOAc, 150 mM NaCl 4.5 2.15 mM NaOAc, 150 mM NaCl 5.5 0.6510 mM NaOAc, 150 mM NaCl 5.5 0.6920 mM NaOAc, 150 mM NaCl 5.5 0.7450 mM NaOAc, 150 mM NaCl 5.5 0.91Hydrophobic chain length10 mM Na.sub.3 PO.sub.4, 50 mM Formic acid 4 0.1210 mM Na.sub.3 PO.sub.4, 50 mM Acetic acid 7 0.1610 mM Na.sub.3 PO.sub.4, 50 mM Propanoic acid 7 0.1610 mM Na.sub.3 PO.sub.4, 50 mM Butanoic acid 7 0.1310 mM Na.sub.3 PO.sub.4, 50 mM Pentanoic acid 7 0.1410 mM Na.sub.3 PO.sub.4, 50 mM Hexanoic acid 7 0.11Others20 mM NaOAc, 3% Mannitol, 2% Sucrose, 4 19.95% PEG-40020 mM Na Citrate, 3% Mannitol, 2% Sucrose, 6.5 0.725% PEG-40020 mM Na Citrate, 150 mM NaCl, 5% PEG-400 6.5 2.1820 mM NaOAc, 150 mM NaCl, 5% PEG-400 4 19.820 mM Na Citrate, 130 mM NaCl, 1% Glycine, 0.25% 6.5 1.485% PEG-40020 mM Na Citrate, 130 mM NaCl, 1% Glycine, 0.25% 6.5 1.32"TWEEN-80 (surface active agent)"5 mM NaAcetate 5.5 8.95 mM NaAcetate, 8% Sucrose 5.5 115 mM NaAcetate, 0.01% 5.5 75 mM NaAcetate, 8% Sucrose, 0.01 % Polysorbate-80 5.5 1210 mM NaAcetate 5.5 7.610 mM NaAcetate, 8% Sucrose 5.5 1010 mM NaAcetate, 8% Sucrose, 0.01% Polysorbate-80 5.5 12.15 mM NaAcetate, 5% Sorbitol 5.5 7.85 mM NaAcetate, 4.5% Mannitol 5.5 9.25 mM Histidine 6 5.55 mM Histidine 6.5 15 mM NaCitrate 5.5 0.15 mM NaCitrate 6 0.15 mM NaCitrate 6.5 0.15 mM NaSuccinate 5.5 0.65 mM NaSuccinate 6 0.35 mM NaSuccinate 6.5 0.210 mM Imidazole 6.5 2.5, 10.810 mM Imidazole 7 0.810 mM Imidazole, 8% Sucrose 6.5 12.25 mM NaAcetate 6 8.210 mM Imidazole, 5 mM NaAcetate 6.5 12.810 mM NaCitrate 6 0.2100 mM NaCitrate 6 8.1100 mM NaCitrate 7 9.310 mM Naphosphate, 260 mM Na2SO4 6 9.110 mM NaPhosphate, 100 mM NaCitrate 8 8.810 mM NaCitrate, 1% L-glutamic acid 6 4.610 mM NaCitrate, 2% L-lysine 6 1.110 mM NaCitrate, 0.5% L-aspartic acid 6 0.410 mM NaCitrate, 0.1% Phosphate glass 7 5.910 mM Tris, 100 mM NaCitrate 8 8.510 mM NaCitrate, 1 M Glycine 6 0.310 mM NaCitrate, 300 mM Glycine 6 0.310 mM NaCitrate, 280 mM Glycerol 6 0.310 mM NaCitrate, 0.5 M (NH4)2SO4 6 8.310 mM NaCitrate, 120 mM (NH4)2SO4 6 8.810 mM NaCitrate, 260 mM Na2SO4 6 9.410 mM Na.sub.3 PO.sub.4, 0.1% Phosphate glass 7 15.810 mM NaCitrate, 0.1% SDS 6 11.210 mM NaCitrate, 0.02% SDS 6 7.810 mM NaAcetate, 8% PEG-400 5.5 13.710 mM NaAcetate, 150 mM NaCl, 8% PEG-400 5.5 0.610 mM NaAcetate, 8% PEG-400 6 16.210 mM NaCitrate, 8% PEG-400 6 0.2______________________________________
Example 2
The stability of TFPI stored at various pH conditions was tested. TFPI was prepared by dialysis as above in 10 mM Na phosphate, 150 mM NaCl and 0.005% (w/v) POLYSORBATE-80. Stability samples containing 150 μg/mL TFPI were incubated at 40° C. for 20 days. Kinetic rate constant for the remaining soluble TFPI was analyzed by following decrease of the main peak on cation exchange chromatograms. As can be seen in FIG. 4, the decay rate constant increases at pH above 6.0, indicates more aggregation at higher pH conditions.
TFPI was also formulated at a concentration of 150 μg/mL in 150 mM NaCl and 0.005% (w/v) POLYSORBATE-80 at pH 7 with varying concentrations of phosphate. FIG. 5A shows the percentage of remaining soluble TFPI measured by the cation exchange HPLC. Increasing concentrations of phosphate ion in solution resulted in higher levels of soluble TFPI remaining after incubation at 40° C. Higher levels of phosphate ion also resulted in higher levels of active TFPI as assayed by the prothrombin time assay. These results are shown in FIG. 5B.
Stability of TFPI at a concentration of 0.5 mg/mL and formulated in 10 mM Na citrate, pH 6 and 150 mM NaCl was also tested at 40° C. over a 40 day period. As seen in FIG. 6, cation-exchange HPLC (triangle) shows the presence of soluble TFPI at levels greater than 60% initial, even after the 40 day incubation. In like manner, the prothrombin time assay (circle) shows the presence of active TFPI at levels greater than 60% initial, even after the 40 day incubation.
FIG. 7 shows loss of soluble TFPI at 40° C. measured by both cation-exchange HPLC (open symbol) and prothrombin time assay (closed symbol) for 0.5 mg/mL TFPI formulated in 10 mM Na phosphate, pH 6 and either 150 mM NaCl (triangle) or 500 mM NaCl (circle).
FIG. 8 shows loss of soluble TFPI at 40° C. measured by both cation-exchange HPLC (open symbol) and prothrombin time assay (closed symbol) for 0.5 mg/mL TFPI formulated in 10 mM Na acetate and pH 5.5 containing 150 mM NaCl (triangle) or 8% (w/v) sucrose (square) or 4.5% (w/v) mannitol (circle).
FIG. 9 shows two non-reducing SDS gels for TFPI formulation samples in 10 mM NaPO 4 , 150 mM NaCl, and 0.005% POLYSORBATE-80 at pH 4 to pH 9 stored at 40° C. for 0 days (lower) and 20 days (upper). No loss on TFPI is seen at 0 days. However, at 20 days cleavage fragments of TFPI may be seen at the lower pH range (i.e. pH 4 and pH 5). Without being bound to a particular theory, it is believed that these fragments may result from an acid catalyzed reaction.
Finally, Table 2 shows the half-life of remaining soluble TFPI at 40° C. for various formulations. 0.5 mg/mL TFPI was formulated in these formulation conditions and incubated at 40° C. Samples were withdrawn at predetermined time intervals and loss of soluble and active TFPI were examined by the IEX-HPLC and the PT assay. Half-life for remaining soluble TFPI was then calculated by performing a single exponential fitting to the IEX-HPLC and PT assay results.
TABLE 2______________________________________ t1/2 (day) at 40° C.0.5 mg/ml TFPI formulated in: IEX-HPLC PT assay______________________________________10 mM Na Acetate, 150 mM NaCl, pH 5.5 10.8 17.210 mM Na Citrate, 150 mM NaCl, pH 5.5 12.2 24.410 mM Na Acetate, 8% (w/v) Sucrose, pH 5.5 43.2 42.210 mM Na Acetate, 4.5% Mannitol, pH 5.5 47.7 46.610 mM Na Succinate, 150 mM NaCl, pH 6.0 7.8 11.010 mM Na Citrate, 150 mM NaCl, pH 6.0 13.0 18.810 mM Na Phosphate, 150 mM NaCl, pH 6.0 7.8 11.210 mM Na Phosphate, 500mM NaCl, pH 6.0 52.2 68.910 mM Na Citrate, 150 mM NaCl, pH 6.5 10.0 14.8______________________________________ | Compositions are described that are suitable for formulating TFPI. The compositions allow preparation of pharmaceutically acceptable compositions of TFPI at concentrations above 0.2 mg/mL and above 10 mg/mL. | 8 |
RELATED APPLICATION
[0001] This application claims priority from co-pending provisional application Ser. No. 61/171,968, which was filed on 23 Apr. 2009, and which is incorporated herein by reference in its entirety.
STATEMENT OF GOVERNMENT RIGHTS
[0002] Development of the present invention was supported, at least in part, by a grant from the U.S. Government. Accordingly, the Government may have certain rights in the invention, as specified by law.
FIELD OF THE INVENTION
[0003] The present invention relates to the field of tissue engineering and, more particularly, to a system and method of extending the in vitro useful life of a culture of muscle cells.
BACKGROUND OF THE INVENTION
[0004] Skeletal muscle differentiation and maturation is a complex process involving the synergy of different growth factors and hormones interacting over a broad time period [1-11]. The differentiation process is further complicated by neuronal innervation, where neuron to muscle cell signaling can regulate myosin heavy chain (MHC) gene expression and acetylcholine receptor clustering [12-18]. Consequently, understanding of the role of the growth factors, hormones and cellular interactions in skeletal muscle differentiation would be a key step in generating physiologically relevant tissue engineering constructs, developing advanced strategies for regenerative medicine and integrating functional skeletal muscle with bio-hybrid MEMS devices for non-invasive interrogation in high-throughput screening technologies.
[0005] In order for skeletal muscle myotubes developed in vitro to be useful in tissue engineering applications, they must exhibit as many of the functional characteristics of in vivo skeletal muscle fibers as possible. During muscle fiber development in vivo, several critical structural changes occur that indicate functional maturation of the extrafusal myotubes. These changes include sarcomere organization, clustering and colocalization of ryanodine (RyR) and dihydropyridine (DHPR) receptors and MHC class switching [19-23]. Each of these structural changes reflects the physiological maturation of the skeletal muscle and is critical for consistent muscular contraction. For example, organization of the contractile proteins myosin and actin into sarcomeric units gives skeletal muscle myotubes organized and structured contraction, a property lacking in smooth muscle. The organization of sarcomeres in skeletal muscle gives rise to anisotropic and isotropic bands of proteins (A and I bands) and gives skeletal muscle a striated appearance. The clustering and colocalization of RyR and DHPR is indicative of transverse tubule (T-tubule) biogenesis and excitation contraction coupling. This developmental step structurally links electrical excitation to the internal contractile system by providing close apposition of DHPR located in the T-tubule and RyR located in the sarcoplasmic reticulum. Finally, a properly functioning skeletal muscle must express the appropriate MHC proteins required for the task it must perform. For example, different muscle fibers express different MHC proteins depending on the rate of contraction and force generation required by the work to be done. Consequently, skeletal muscle fibers change their MHC expression profiles to best meet the requirements of the body as it matures. Without these modifications, an in vitro model of skeletal muscle maturation cannot achieve full physiological relevance.
[0006] One approach for identifying the role of specific growth factors and hormones in muscle differentiation is to develop an in vitro model system consisting of a serum-free medium supplemented with the factors of interest. Such a model provides the opportunity to evaluate the role of each factor individually or in combination with others known or believed to be important in skeletal muscle development. For example, the concentration and/or temporal application of medium components in order to influence the maturation of extrafusal fiber or intrafusal fiber subtypes could be easily investigated.
[0007] Employing a non-biological growth substrate such as trimethoxy-silylpropyl-diethylenetriamine (DETA) provides an additional measure of control. DETA is a silane molecule that forms a covalently bonded monolayer on glass coverslips, resulting in a uniform, non-hydrophilic surface for cell growth. The use of DETA surfaces is advantageous from a tissue engineering perspective because it can be covalently linked to virtually any hydroxolated surface, it is amenable to patterning using standard photolithography and it promotes long-term cell survival because it is non-digestible by matrix metalloproteinases secreted by the cells [24, 25].
[0008] Previously, studies have demonstrated the usefulness of the DETA silane substrate for in vitro culture systems. Interesting features of the DETA silane are that its molecular geometry does not allow for an ordered nanolayer and may partially mimic the three dimensional features of an extracellular matrix, which may be responsible for robust growth of different cell types on this synthetic substrate [24-31]. Additionally, DETA's non-biological nature supports the analysis of ECM proteins secreted by the cell in response to different in vitro conditions.
[0009] We earlier developed a defined system that promoted differentiation of different skeletal muscle phenotypes and resulted in the formation of contractile myotubes. This resulted in short-term survival of the myotubes [25, 28]. We also have developed a novel bio-hybrid technology to integrate functional myotubes with cantilever based bio-MEMS devices for the study of muscle physiology, neuromuscular junction formation and bio-robotics applications for use in a model of the stretch reflex arc [32]. More recently, using our defined model system, we have achieved a significant breakthrough by creating mechanosensitive intrafusal myotubes in vitro [33]. The intrafusal fibers differentiated upon addition of neuregulin 1-□-1 to serum-free medium in our defined system. Intrafusal fibers are the myotubes present in the muscle spindle which functions as the sensory receptor of the stretch reflex circuit [16] and combined with extrafusile fibers represent the primary component necessary to reproduce functional muscle function in vitro.
[0010] This system has been utilized as a model for different developmental and functional applications, however, further improvements are necessary to enhance the physiological relevance of the skeletal muscle myotubes [32, 33]. Specifically, in order to create a working model of the stretch reflex arc, myotubes are needed that more accurately represent extrafusal fibers in vivo. A more advanced developmental system for skeletal muscle would have applications in basic science research and tissue engineering. In this study, we have demonstrated sarcomere assembly, the development of the excitation-contraction coupling apparatus and myosin heavy chain (MHC) class switching.
[0011] The results disclosed herein suggest we have discovered a group of biomolecules that act together as a molecular switch promoting the transition from embryonic to neonatal MHC expression as well as other structural adaptations resulting in the maturation of skeletal muscle in vitro. The discovery of these biomolecular switches will be a powerful tool in regenerative medicine and tissue engineering applications such as skeletal muscle tissue grafts. It should also be useful in higher content high-throughput screening technology.
SUMMARY OF THE INVENTION
[0012] With the foregoing in mind, the present invention advantageously provides a method of culturing mammalian muscle cells. The method of the invention includes preparing one or more carriers coated with a covalently bonded monolayer of trimethoxy-silylpropyl-diethylenetriamine (DETA). This is followed by verifying DETA monolayer formation by one or more associated optical parameters. The method continues by suspending isolated fetal rat skeletal muscle cells in serum-free medium according to medium composition 1, as set forth below in further detail, then plating the suspended cells onto the prepared carriers at a predetermined density. The method then calls for leaving the carriers undisturbed while the plated cells adhere to the DETA monolayer and covering the carriers with a mixture of medium composition 1 and medium composition 2, both as described below. Finally, the method ends by incubating the carriers.
[0013] In the method, the one or more carriers typically comprise glass cover slips. Those of skill in the art should understand that verifying is accomplished by an optical contact angle goniometer in the present invention, which may also include verifying by X-ray photoelectron spectroscopy (XPS). In the method, verifying may be accomplished by both an optical contact angle goniometer and by XPS.
[0014] Our current cantilever system is designed for force measurements of contracting muscle cells and uses laser optics as a readout system [136]. Alternatively, piezoresistive and piezoelectric approaches are the most widely applied techniques for measuring stress applied on microcantilevers [137] and could be easily adapted to the present invention by those of ordinary skill in the art. The advantage is that the mechanical device and the read our electronics can be implemented in the same integrated circuit. Replacing the optical readout with piezoelements will reduce the size and complexity of our current cantilever system.
[0015] Those skilled in the art will know that piezoelectricity is the ability of certain materials (crystals and certain ceramics) to generate an electric potential in response to applied mechanical stress [132]. The piezoelectric effect is used in various sensors to measure stresses or geometrical deformations in various mechanical devices. The reverse piezoelectric effect turns piezoelectric materials into actuators, when an external voltage is applied to the crystal [133]. Piezoelectric materials are e.g. quartz, bone, sodium tungstate, zinc oxide, or lead zirconate titanate (PZT) [134]. A similar effect is the piezoresistive phenomenon. When subjected to mechanical stress, these materials change their resistivity [135].
[0016] Culture aspects of the method include wherein plating the muscle cells is at a density of approximately from 700 to 1000 cells/mm2. Then, leaving the carriers undisturbed continues for approximately one hour and incubating is effected under physiologic conditions and may best be accomplished at approximately 37° C. in an air atmosphere with about 5% CO 2 and 85% humidity. The culture is then covered with a mixture of approximately equal volumes of medium composition 1 and medium composition 2. Preferably, an initial complete change of the medium covering the carriers is accomplished by substituting NBactiv4 medium during incubation. Moreover, after the initial complete change of medium, changing every three days more than half of the medium covering the carriers is preferred and it is most preferred changing every three days approximately three quarters of the medium covering the carriers.
[0017] Another embodiment of the present invention includes a method of culturing mammalian muscle cells which comprises allowing mammalian fetal muscle cells suspended in medium according to composition 1to adhere to a monolayer of covalently bonded DETA formed on an underlying carrier surface and incubating the adhered cells covered in a mixture of approximately equal volumes of medium composition 1 and medium composition 2.
[0018] In the methods of the invention, the mammalian fetal muscle cells may comprise fetal rat cells and the underlying carrier surface may comprise a glass cover slip. Incubating is preferably under physiological conditions, typically at approximately 37° C. in an atmosphere of air with about 5% CO 2 and 85% humidity.
[0019] In the alternate embodiment of the invention, the method includes changing the covering medium to NBactiv4, preferably after approximately four days of incubation. Thereafter, the method calls for changing every three days more than half of the medium covering the carriers and preferably about three quarters of the medium covering the carriers.
[0020] Also part of the invention is a new cell culture medium composition which includes NBactiv4, an antibiotic-antimycotic composition, cholesterol, human TNF-alpha, PDGF BB, vasoactive intestinal peptides, insulin-like growth factor 1, NAP, r-Apolipoprotein E2, purified mouse Laminin, beta amyloid, human tenascin-C protein, rr-Sonic hedgehog Shh N-terminal, and rr-Agrin C terminal. This medium composition may be amplified with G5 supplement, VEGF, acidic fibroblast growth factor, heparin sulphate, LIF, rat plasma Vitronectin, CNTF, GNDF, NT-3, NT-4, BDNF and CT-1.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Some of the features, advantages, and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, presented for solely for exemplary purposes and not with intent to limit the invention thereto, and in which:
[0022] FIG. 1 . is a schematic diagram of a culture protocol according to an embodiment of the present invention;
[0023] FIG. 2 A, B, C and D provide phase pictures of 50 day old myotubes in culture; red arrows showing characteristic striations in most of the myotubes; scale bar equals 75 μm;
[0024] FIG. 3 shows myotubes stained with antibodies against embryonic myosin heavy chain (F 1.652) proteins at day 50; scale bar is 75 μm; A) panel showing phase+fluorescence picture of the myotubes; B) another view of panel A but observed only under fluorescence; white arrows showing the striations; C) panel showing image of myotubes under phase+fluorescence illumination; D) shows panel C observed only under fluorescence illumination; E) panel showing phase+fluorescence picture of the myotubes (white arrow indicating the striations); F) panel E observed only in fluorescence light (white arrow indicating the striations); G) panel showing phase+fluorescence picture of the myotubes (white arrow indicating the striations); H) panel G observed only under fluorescence light (white arrow indicating the striations);
[0025] FIG. 4 shows myotubes immunostained with neonatal myosin heavy chain (N3.36) and alpha-bungarotoxin at day 50; scale bar is 75 μm; A) is a phase picture of 2 myotubes indicated by white arrows; B) both the myotubes shown in phase (panel A) have acetylcholine receptor clustering indicated by alpha-bungarotoxin staining; C) only one myotube out of the two seen in panel A stained for N3.36; D) double stained image of panel A with alpha-bungarotoxin and N3.36; E) phase image of 6 myotubes indicated by white arrows; F) all the myotubes shown in phase (panel E) have acetylcholine receptor clustering shown by alpha-bungarotoxin staining; G) none of the myotubes in panel E stained for N3.36; H) I) and J) show differential staining of the myotubes with N3.36; K) L) and M) showing differential staining of the myotubes with N3.36;
[0026] FIG. 5 illustrates ryanodine receptor and DHPR receptor clustering in 30 days old skeletal muscle culture (scale bar 75 μm); A) phase and fluorescent-labeled picture of the myotubes; B) merged fluorescence picture of the ryanodine receptor (green) and DHPR receptor (red) clustering on the myotubes shown in panel A; C) ryanodine receptor (green) on the myotubes shown in panel A; D) DHPR receptors on the myotubes shown in panel A; E) phase and fluorescent-labeled picture of the myotubes; F) merged fluorescent picture of the ryanodine receptor (green) and DHPR receptor (red) clustering on the myotubes (panel E); G) ryanodine receptor (green) on the myotubes (panel E); H) DHPR receptors on the myotubes (panel E); I) phase and fluorescent-labeled picture of the myotubes; J) K) and L) show merged fluorescence pictures of the ryanodine receptor (green) and DHPR receptor (red) clustering on the myotubes (panel I) at three different planes (white arrows indicate the striations and the receptor clustering);
[0027] FIG. 6 shows ryanodine receptor and DHPR receptor clustering in 100 days old skeletal muscle culture (scale bar: 75 μm); A) shows phase and fluorescent-labeled picture of the myotubes; B) is a merged fluorescence picture of the ryanodine receptor (green) and DHPR receptor (Red) clustering on the myotubes (panel A); C) shows ryanodine receptor (green) on the myotubes (panel A); D) shows DHPR receptors on the myotubes (panel A); E and F show views of the same panels at different planes showing the merged fluorescent picture of the ryanodine receptor (green) and DHPR receptor (red) clustering on the myotubes;
[0028] FIG. 7 depicts patch clamp electrophysiology of the myotubes, wherein A shows representative voltage clamp trace obtained after patching a 48 days old myotube in culture; B shows representative current clamp trace of the same myotube for which voltage clamp trace had been obtained (inset showing the picture of patched myotubes).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. Any publications, patent applications, patents, or other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including any definitions, will control. In addition, the materials, methods and examples given are illustrative in nature only and not intended to be limiting. Accordingly, this invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these illustrated embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
Materials and Methods
Surface Modification and Characterization
[0030] Glass coverslips (Thomas Scientific 6661F52, 22×22 mm No. 1) were cleaned using an O 2 plasma cleaner (Harrick PDC-32G) for 20 minutes at 100 mTorr. The DETA (United Chemical Technologies Inc. T2910KG) films were formed by the reaction of the cleaned glass surface with a 0.1% (v/v) mixture of the organosilane in freshly distilled toluene (Fisher T2904). The DETA coated coverslips were then heated to approximately QQ 100° C., rinsed with toluene, reheated to approximately 100° C., and then oven dried [28]. Surfaces were characterized by contact angle measurements using an optical contact angle goniometer (KSV Instruments, Cam 200) and by X-ray photoelectron spectroscopy (XPS) (Kratos Axis 165). XPS survey scans, as well as high-resolution N1s and C1s scans utilizing monochromatic Al Kα excitation were obtained [28].
Skeletal Muscle Culture and Serum Free Medium
[0031] The skeletal muscle was dissected from the thighs of the hind limbs of fetal rats (17-18 days old). The tissue was collected in a sterile 15 mL centrifuge tube containing 1 mL of phosphate-buffered saline (calcium- and magnesium-free) (Gibco 14200075). The tissue was enzymatically dissociated using 2 mL of 0.05% of trypsin-EDTA (Gibco 25300054) solution for 30 minutes in a 37□ C water bath at 50 rpm. After 30 minutes the trypsin solution was removed and 4 mL of Hibernate E+10% fetal bovine serum (Gibco 16000044) was added to terminate the trypsin reaction. The tissue was then mechanically triturated with the supernatant being transferred to a 15 mL centrifuge tube. The same process was repeated two times by adding 2 mL of L15+10% FBS each time. The 6 mL cell suspension obtained after mechanical trituration was suspended on a 2 mL, 4% BSA (Sigma A3059) (prepared in L15 medium) cushion and centrifuged at 300 g for 10 minutes at 4° C. The pellet obtained was washed 5 times with L15 medium then resuspended in 10 mL of L15 and plated in 100 mm uncoated dishes for 30 minutes. The non-attached cells were removed and then centrifuged on a 4% BSA cushion [28]. The pellet was resuspended in serum-free medium according to the protocol illustrated in FIG. 1 and plated on the coverslips at a density of 700-1000 cells/mm 2 . The serum-free medium containing different growth factors and hormones was added to the culture dish after one hour. The final medium was prepared by mixing medium one (Table 1) and medium two (Table 2) in a 1:1 v/v ratio. FIG. 1 indicates the flowchart of the culture protocol. Tables 1 and 2 indicated the growth factor and hormone supplement compositions of medium one and medium two. The cells were maintained in a 5% CO 2 incubator (relative humidity 85%). The full medium was replaced after four days with NBactiv4 medium according to the protocol in FIG. 1 [34]. Thereafter three-fourth of the medium was changed every three days with NBactiv4.
Immunocytochemistry of Skeletal Muscle Myotubes
[0032] Coverslips were prepared for immunocytochemical analysis as previously described. Briefly, coverslips were rinsed with PBS, fixed in −20□ C methanol for 5-7 min, washed in PBS, incubated in PBS supplemented with 1% BSA and 0.05% saponin (permeabilization solution) for 10 minutes, and blocked for 2 h with 10% goat serum and 1% BSA. Cells were incubated overnight with primary antibodies against embryonic myosin heavy chain (F1.652) (dilution>1:5), neonatal myosin heavy chain (N3.36) (1:5) (Developmental Studies Hybridoma Bank), ryanodine receptor (AB9078, Millipore) (1:500) and dihydropyridine binding complex (α1-Subunit) (MAB 4270, Millipore) (1:500) diluted in the blocking solution. Cells were washed with PBS and incubated with the appropriate secondary antibodies for two hours in PBS. After two hours the coverslips were rinsed with PBS and mounted on glass slides and evaluated using confocal microscopy [25, 28, 31].
AChR Labeling of Myotubes
[0033] AChRs were labeled as described previously by incubating cultures with 5×10-8 M of α-bungarotoxin, Alexa Fluor® 488 conjugate (B-13422; Invitrogen) for 1.5 h at 37° C. [12, 31]. Following incubation in α-bungarotoxin, the cultures were fixed as above for subsequent staining with embryonic myosin heavy chain (F1.652) antibodies.
Patch Clamp Electrophysiology of the Myotubes
[0034] Whole-cell patch clamp recordings were performed in a recording chamber located on the stage of a Zeiss Axioscope 2FS Plus upright microscope as described previously [25, 33]. The chamber was continuously perfused (2 ml/min) with the extracellular solution (Leibovitz medium, 35° C.). Patch pipettes were prepared from borosilicate glass (BF150-86-10; Sutter, Novato, Calif.) with a Sutter P97 pipette puller and filled with intracellular solution (K-gluconate 140 mM, EGTA 1 mM, MgCl 2 2 mM, Na 2 ATP 2 mM, phosphocreatine 5 mM, phosphocreatine kinase 2.4 mM, Hepes 10 mM; pH=7.2). The resistance of the electrodes was 6-8MΩ. Voltage clamp and current clamp experiments were performed with a Multiclamp 700A amplifier (Axon Laboratories, Union City, Calif.). Signals were filtered at 2 kHz and digitized at 20 kHz with an Axon Digidata 1322A interface. Data recording and analysis were done with pClamp 8 software (Axon Laboratories). Membrane potentials were corrected by subtraction of a 15 mV tip potential, which was calculated using Axon's pClamp 8 program. Sodium and potassium currents were measured in voltage clamp mode using voltage steps from a −85 mV holding potential. Action potentials were evoked with 1 second depolarizing current injections from a -85 mV holding potential [25, 28].
Results
DETA Surface Modification and Characterization
[0035] Static contact angle and XPS analysis was used for the validation of the surface modifications and for monitoring the quality of the surfaces. Stable contact angles (40.64±2.9/mean±SD) throughout the study indicated high reproducibility and quality of the DETA surfaces and were similar to previously published results [24, 25, 28, 29, 31]. Based on the ratio of the N (401 and 399 eV) and the Si 2p3/2 peaks, XPS measurements indicated that a reaction-site limited monolayer of DETA was formed on the coverslips [35].
Development of the Serum Free Medium Formulation and Culture Timeline for Long-Term Survival and Maturation of Myotubes
[0036] The serum free medium composition was developed empirically. The final medium is derived from two different medium compositions described in Tables 1 and 2. Table 1 constitutes the same medium composition used previously for a motoneuron-muscle co-culture and adult spinal cord neurons culture [26, 27, 30, 31]. Table 2 is composed of twelve additional factors that had been shown to promote skeletal muscle maturation and neuromuscular junction formation separately. The final medium was prepared by mixing these two media in a 1:1 v/v ratio. After first 4 days of culture the whole medium was replaced with NBactiv4 medium [34]. Thereafter, every three days three-fourth medium was changed with NBactiv4. The culture technique has been illustrated in the flowchart ( FIG. 1 ).
[0037] Using this new medium formulation and timeline, myotubes were successfully cultured for more than 50 days. FIG. 2 indicates 50 days old myotubes in culture. As the myotubes aged and grew they began to form the characteristic anisotropic (A band) and isotropic (I band) banding pattern observed with in vivo muscle fibers [22, 23]. This banding pattern is caused by differential light diffraction due to the organization of myofibril proteins forming sarcomeres within the myotubes [22, 23]. The arrowheads in the images ( FIG. 2A-D ) indicate myotubes where sarcomeric organization has occurred and is visualized by the appearance of A and I bands.
Myotube Expression of Fetal Myosin Heavy Chain
[0038] The myotubes formed were evaluated for the expression of fetal MHC to establish a baseline as comparison to our previous results [28]. In FIG. 3 , the myotubes phenotypes formed at approximately day 50 in vitro are shown. The myotubes ranged from having clustered nuclei ( FIG. 3A-D ) to having diffuse nuclear organization ( FIG. 3E-H ). The arrowheads in the images indicate the characteristic striations.
Differential Expression of Neonatal MHC Protein in the Myotubes
[0039] In order to determine if the myotubes were maturing in a physiologically relevant way as they aged in vitro, the expression of neonatal MHC protein was evaluated. After approximately 50 days in vitro 25% of the myotubes expressed neonatal MHC ( FIG. 4A-M ). Additionally, the myotubes were stained for clustering of acetylcholine receptors (AChR) using alpha bungarotoxin (FIG. 5 B,F). This clustering of the AChR receptors, induced by the motoneuron protein agrin in vivo, are locations on the myotube where neuromuscular junction formation occurs.
Formation of the Excitation—Contraction Coupling Apparatus
[0040] The presence of ryanodine (RyR) receptor and dihydropyridine (DHPR) receptor clusters, as well as their colocalization in vivo, represents the development of excitation-contraction coupling apparatus in skeletal muscle myotubes [19, 21-23]. The clustering of both RyR and DHPR receptors was observed on the myotubes after 30 days in culture ( FIG. 5A-D ). The clustering and colocalization of the RyR+DHPR clusters was observed with different myotube morphologies ( FIG. 5E-L ). This functional adaptation illustrated that the medium formulation facilitated not only the structural maturation but also the functional maturation of myotubes in this in vitro system. The clustering of the RyR+DHPR receptors was also observed in the 70 day old myotubes, indicating that the older myotubes maintained their functional integrity ( FIG. 6A-F ).
Myotube Electrophysiology
[0041] The myotubes contracted spontaneously in the culture and the contractions began generally by day four and continued throughout the life of the culture. Most of the myotubes expressed functional voltage gated sodium, potassium and calcium ion channels as reported previously [28]. The voltage clamp electrophysiology of the myotubes indicated the inward and outward currents that demonstrate functional sodium and potassium channels ( FIG. 7A ). The current clamp study indicated the single action potential fired by the myotubes ( FIG. 7B ).
Discussion
[0042] Herein we have documented the development of a system for long-term in vitro functional, skeletal muscle culture. This system was developed in response to a need for more physiologically relevant skeletal muscle myotubes for functional in vitro systems. For our specific research, they were needed for a realistic model of the stretch reflex arc development and to be integrated with bio-MEMS cantilevers for screening applications. The results indicate we achieved three significant structural modifications within the myotubes, causing both the developmental profile and functionality of the fibers to better mimic in vivo physiology. It is believed that this skeletal muscle maturation resulted from modifications to the cell culture technique, a new medium formulation and the use of NBactiv4 as the maintenance medium.
[0043] The presently described serum-free medium supplemented with growth factors was developed to support the survival, proliferation and fusion of fetal rat myoblasts into contractile myotubes. The rationale for selecting the growth factors was based on the distribution of their cognate receptors in the developing myotubes in rat fetus [1-11]. Tables 1 and 2 reference the literature where these individual growth factors, hormones and neurotransmitters were observed to support muscle and neuromuscular junction development. The composition in Table 1 is the formulation used for a previously published medium used for motoneuron-muscle co-culture and adult spinal cord neuron culture [26, 27, 30, 31]. Table 2 lists the twelve additional factors we have identified in muscle development and neuromuscular junction formation. The use of NBactiv4 for the maintenance of the cells provided unexpected results in that it significantly improved the survival of the skeletal muscle derived myotubes despite the original development of NBactiv4 for the long-term maintenance and synaptic connectivity of fetal hippocampal neurons in vitro [34].
[0044] We observed a ratio of 25% neonatal to 75% embryonic MHC expression of the myotubes, which contrasts with the previous study in which MHC expression was strictly embryonic. We believe that the myotubes matured in this culture system because the long-term survival provided adequate time for the myotubes to respond to the additional growth factors, which activated the necessary signaling pathways to achieve MHC class switching [20]. This suggests that a different growth factor profile could be utilized to activate alternative signaling pathways and drive myotube differentiation down other pathways. For example, the effects of adding steroid hormones like testosterone to the system could be critically examined.
[0045] The colocalization of RyR and DHPR clusters in the myotubes indicated the formation of excitation-contraction coupling apparatus and was another indicator of functional maturation in the fibers. Excitation-contraction coupling is the signaling process in muscle by which membrane depolarization causes a rapid elevation of the cytosolic Ca 2+ generating contractile force [36]. The close proximity of the DHPR and RyR complexes occurs at specialized junctions established between the transverse tubule and sarcoplasmic reticulum (SR) membranes in skeletal muscle myotubes [37]. At these junctions, T-tubule depolarization is coupled to Ca 2+ release from the SR resulting in muscle contraction [38-40]. This structural adaptation represents a significant functional change due to the fact that excitation-contraction coupling is required for successful extrafusal muscle fiber development as well as neuromuscular junction formation [19, 21-23]. This improved model provides the potential to study excitation-contraction coupling in a defined system as well as myotonic and myasthenic diseases.
Conclusion
[0046] The development of sarcomeric structures, the excitation-contraction coupling apparatus and MHC class switching in the skeletal muscle myotubes is a result of the improvements to the model system documented in this research. This improved system along with the new findings support the goal of creating physiologically relevant tissue engineered muscle constructs and puts within reach the goal of functional skeletal muscle grafts. Furthermore, we believe this serum-free culture system will be a powerful tool in developing advanced strategies for regenerative medicine in muscular dystrophies, stretch reflex arc development and integrating skeletal muscle with bio-hybrid prosthetic devices.
[0047] Accordingly, in the drawings and specification there have been disclosed typical preferred embodiments of the invention and although specific terms may have been employed, the terms are used in a descriptive sense only and not for purposes of limitation. The invention has been described in considerable detail with specific reference to these illustrated embodiments. It will be apparent, however, that various modifications and changes can be made within the spirit and scope of the invention as described in the foregoing specification and as defined in the appended claims.
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[0000]
TABLE 1
Medium Composition 1
S.
Cata-
Refer-
No
Component
Amount
logue #
Source
ences
1.
Neurobasal
500
ml
10888
Gibco/
[41]
Invitrogen
2.
Antibiotic-
5
ml
15240-062
Gibco/
Antimycotic
Invitrogen
3.
G5 Supplement
5
ml
17503-012
Gibco/
[42-51]
(100X)
Invitrogen
4.
VEGF 165 r Human
10
μg
P2654
Gibco/
[52-55]
Invitrogen
5.
Acidic FGF
12.5
μg
13241-013
Gibco/
[42, 49,
Invitrogen
51, 56-61]
6.
Heparin Sulfate
50
μg
D9809
Sigma
[42, 49,
51, 56-61]
7.
LIF
10
μg
L5158
Sigma
[62-70]
8.
Vitronectin
50
μg
V0132
Sigma
[71, 72]
(Rat Plasma)
9.
CNTF
20
μg
CRC 401B
Cell
[73-77]
Sciences
10.
NT-3
10
μg
CRN 500B
Cell
[15]
Sciences
11.
NT-4
10
μg
CRN 501B
Cell
[78, 79]
Sciences
12.
GDNF
10
μg
CRG 400B
Cell
[80-84]
Sciences
13.
BDNF
10
μg
CRB 600B
Cell
[79, 85,
Sciences
86]
14.
CT-1
10
μg
CRC 700B
Cell
[87-95]
Sciences
[0000]
TABLE 2
Medium Composition 2
Refer-
No
Component(s)
Amount
Catalog
Source
ences
1
Neurobasal
500
ml
10888
Invitrogen/
[41]
Gibco
2
Antibiotic-
5
ml
15240-
Invitrogen/
antimycotic
062
Gibco
3
Cholesterol
5
ml
12531
Invitrogen/
[96]
(250X)
Gibco
4
TNF-alpha,
10
μg
T6674
Sigma-
[97-99]
human
Aldrich
5
PDGF BB
50
μg
P4056
Sigma-
[62, 100-
Aldrich
103]
6
Vasoactive
250
μg
V6130
Sigma-
[104]
intestinal
Aldrich
peptide
(VIP)
7
Insulin-like
25
μg
I2656
Sigma-
[68, 69, 98]
growth
Aldrich
factor 1
8
NAP
1
mg
61170
AnaSpec,
[105, 106]
Inc.
9
r-
50
μg
P2002
Panvera,
[107]
Apolipoprotein
Madison, WI
E2
10
Laminin,
2
mg
08-125
Millipore
[108-114]
mouse
purified
11
Beta amyloid
1
mg
AG966
Millipore
[115-117]
(1-40)
12
Human
100
μg
CC065
Millipore
[118]
Tenascin-
C protein
13
rr-Sonic
50
μg
1314-SH
R&D
[7, 119-129]
hedgehog,
Systems
Shh
N-terminal
14
rr-Agrin
50
μg
550-AG-
R&D
[130, 131]
(C terminal)
100
Systems | The invention provides a nutrient medium composition and associated methods for lengthening the useful life of a culture of muscle cells. Disclosed is a method of culturing mammalian muscle cells, including preparing one or more carriers coated with a covalently bonded monolayer of trimethoxy-silylpropyl-diethylenetriamine (DETA); verifying DETA monolayer formation by one or more associated optical parameters; suspending isolated fetal rat skeletal muscle cells in serum-free medium according to medium composition 1; plating the suspended cells onto the prepared carriers at a predetermined density; leaving the carriers undisturbed for cells to adhere to the DETA monolayer; covering the carriers with a mixture of medium 1 and medium 2; and incubating. A cell nutrient medium composition includes Neurobasal, an antibiotic-antimycotic composition, cholesterol, human TNF-alpha, PDGF BB, vasoactive intestinal peptides, insulin-like growth factor 1, NAP, r-Apolipoprotein E2, purified mouse Laminin, beta amyloid, human tenascin-C protein, rr-Sonic hedgehog Shh N-terminal, and rr-Agrin C terminal. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates generally to apparatus for selectively contacting peripheral surface regions of a porous panel workpiece with a fluid medium, and relates particularly, but not exclusively, to such apparatus for impregnating panels of pressed particle composition with a supplementary binder.
Pressed particle composition panels, variously referred to also "chipboards", "pressboards", "composition boards", and "particle boards", are used for various structural purposes in place of wood or other structural materials. Typically they are made by wetting particulates such as wood chips with a binder and then similtaneously pressing the mixture of particles and binder into the desired shape and curing the binder.
Because the binder is both costly and rather heavy as compared to the particles, a minimum amount of the binder is used. This leaves the edges or peripheral regions of the board somewhat fragile. This is a disadvantage in that the peripheral regions are most likely to be used for fastening, and therefor must be rugged.
One way to reinforce the edges of the board is to impregnate them with supplementary binder material. Such an approach is described, for instance, in the Swiss Pat. No. 577,378. However, heretofore this type of impregnation has not been developed into a sufficiently high speed process to be commercially viable on a large scale.
SUMMARY OF THE INVENTION
The novel apparatus in accordance with the present invention includes means for automating and speeding certain steps involved in the impregnation of panel peripheral regions, so that high speed production can be better served.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a partially sectioned, front elevational view of an apparatus in accordance with a first preferred embodiment of the present invention and shown in a first stage of its operation;
FIG. 2 is a partially sectioned, front elevational view of the apparatus of FIG. 1 in a second stage of its operation;
FIG. 3 is a partially sectioned, front elevational view of an apparatus in accordance with a second preferred embodiment of the present invention and shown in a first stage of its operation;
FIG. 4 is a partially sectioned, front elevational view showing an embodiment which differs slightly from the apparatus of FIG. 3 and depicting a second stage of its operation;
FIG. 5 is a partially sectioned, side elevational view of an apparatus in accordance with a third preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE I
FIGS. 1 and 2 show an apparatus in accordance with a first embodiment of the present invention. The apparatus is for impregnating the peripheral regions or edge portion of a porous panel member with a supplementary binder to provide structural reinforcement of the edge of the panel. The FIGS. 1 and 2 have like reference numerals for the elements of the apparatus and show the apparatus in two different stages of operation.
Referring now to FIGS. 1 and 2, the apparatus includes fixed support means in the form of a substrate base 6 secured on a frame 4 by means of members 5 and a bottom gasket frame 7 to support a panel 1 for treatment. Frame 7 is provided with a resilient support gasket 8, e.g. of rubber, so that a sealed chamber 9 forms between a panel 1 resting thereon under pressure, and the base 6.
The panel 1 consists essentially of porous material and is formed with a pair of generally planar opposed surfaces with edge portions extending thereabout to define the periphery of the panel 1.
A pivoting frame 11 is mounted to pivot through approximately 90° by means of a pivot drive 12 on a frame 10 disposed adjacent the frame 4. A transport cover 13 forming movable cover means operates is to fit against the panel 1 and is resiliently suspended from the frame 11 by means of bolts 14 and springs 15. A top gasket frame 16 is secured to the cover 13 and is also provided with a resilient support gasket 17 so that a sealed chamber 18 forms between the cover 13 and the panel 1, a vacuum being produced in chamber 18 by means of a suction line 19 and a vacuum pump (not shown).
In the example illustrated, the pivoting drive 12 consists of a hydraulically or pneumatically operated cylinder 20, which by means of a piston rod 22 engages a lever 21 rigidly secured to frame 11, and is controllable by a solenoid valve 23.
A lifting table 24, preferably a scissors-lift table, is disposed inside the frame 4 and the bath 2 for the agent 3 - e.g. a resin or adhesive - is secured thereon.
FIG. 1 shows the bath 2 in the bottom starting position while FIG. 2 shows the top position, the fluid binding agent 3 surrounding the panel 1 for treatment. A limit switch 25 disposed on the frame 4 indicates the corresponding position of the bath 2. An outflow conduit 26 containing a shut-off valve 27 connects bath 2 to a lower-level empty tank 28 into which the agent 3 can be discharged.
Laterally of the apparatus discribed above is a frame 29 in which tank 30 of consolidating or cleaning agent available directly from the trade can be inserted, the tank 30 being disposed at a level such that a free flow is possible to the bath 2 even when the latter is in the top position (FIG. 2), by means of a flexible pipe 31 containing a control valve 32 - e.g. a solenoid valve -- which is operatively connected by a plug-in line 34 to a level indicator 33 - e.g. a level sensor -- disposed on the bath 2. Pipe 31 with control valve 32 can be connected by means of the union 35 to the tank 30 containing the liquid required at any time.
Alternatively, the tank 30 may be equipped with a control valve and a pipe 31 in which case only the plug-in line 34 is connected to the control valve 32 disposed on the tank 30 containing the required liquid.
The embodiment described above operates as follows:
Cover 13 is open, i.e., it is brought into a substantially vertical charging position by means of the pivoting frame 11 and pivoting drive 12, so that the bottom frame 7 is freely accessible. A manipulator (not shown in detail) disposed adjacent frame 4 places a panel 1 for treatment on frame 7 of base 6. Cover 13 is brought into the operative position shown in FIGS. 1 and 2 by means of pivoting drive 12 by actuation of the cylinder, the panel 1 being clamped under pressure between the two frames 7 and 16, the two sealed chambers 9 and 18 being formed. Bath 2 is then raised from bottom position (see FIG. 1) by means of lift table 24 and retained in that position when reaching limit switch 25 (see FIG. 2). In this position the level of the consolidating agent 3 is checked by means of the level indicator 33. If the required level is not available, control valve 32 is actuated and agent is fed from tank 30 to bath 2 until a corresponding control signal again closes control valve 32. If a level sensor 33 and solenoid valve 32 are used, this is effected by a simple electric control circuit.
If the required level is already available, or when it is reached by the above-described control process, a vacuum is generated in the chambers 18 and 19 and inside the panel 1 of porous material by means of the line 19 and a pump. Since the edge parts 36 of the panel 1 are maintained in an exposed condition, agent 3 surrounding the panel 1 penetrates into the edge parts 36 of the panel 1 because of the external atmospheric pressure and gives the edge portions the required strength after setting, such as is required for example for fixing parts by means of screws. The depth of penetration depends on the amount of vacuum and its duration and can readily be controlled by a time relay. After the required time has expired, the vacuum is discontinued and the lift table 24 containing the bath 2 is lowered. Advantageously, during cyclic operation bath 2 is lowered only until the level of agent at least reaches the bottom frame 7, and this can be effected by the control system, e.g. by level sensor disposed on the member 5 or by another limit switch disposed on the frame 4.
The cover 13 is then opened, the panel 1 is removed by means of the manipulator, another working cycle starting by insertion of a new panel 1. The cycle may be controlled, for example, fully automatically by means of an electrical sequential control system.
By means of the bath 2 disposed on the table 24 it is thus possible cyclically quickly to lift and lower the level of the liquid 3, and the change of level must correspond at least to the thickness of the panel 1 for treatment.
For cleaning purposes or at the end of the operation the bath 2 is completely lowered by means of the table 24. For cleaning purposes, the valve 27 is opened so that the agent 3 in the bath 2 flows through the line 26 into the empty tank 28. By changing the plug-in line 34 to a control valve 32 disposed on a tank 30 containing cleaning agent, the bath 2 can be raised and then filled with cleaning agent by the filling operation already described, so that the apparatus is cleaned by one or more circulations of the cleaning agent.
EXAMPLE II
FIGS. 3 and 4 show another preferred embodiment of the invention by an apparatus in which the binding agent is cyclically conveyed from a hyperbaric pressure reservoir tank into the fixed bath by means of a gaseous medium, e.g. compressed air.
Referring now to FIG. 3 a bath 2' is fixed on a frame 4', the bath 2' having a semi-circular depression 50 along the periphery at the bottom. The bottom frame 7 is secured in sealing-tight relationship to a raised central portion or base 51 of the bath 2' and is provided with an elastic support 8. The panel 1 for treatment is placed on the frame 7 as already described in connection with FIGS. 1 and 2 and clamped by the pivotable cover 13. The complete pivoting system with the cover and the vacuum production system comprises the same parts as already described in connection with FIGS. 1 and 2. Beneath the frame 4' and under the base 51 of the bath 2' is a pressure tank 52 directly connected to the bath 2' (see FIG. 3) by means of a number of large section feed tube pipes 53. A line 56 connects pressure tank 52 to two reservoirs 57 and 58 for example, one containing consolidating agent and the other cleaning agent. A control valve 60 and a manual shut-off valve 64 and 64' are provided at the outlet of each reservoir. Alternatively, just one control valve 60 - e.g. a solenoid valve - may be disposed in line 56 between tank 52 and valves 64. Opening of one of the valves 64 and 64' enables the liquid required at any time to be conducted to the pressure tank 52. The shut-off valve 27 in line 56 provides general discharge facilities for the various liquids. A level indicator 59, e.g. a level sensor, disposed on the pressure tank is operatively connected to the or each control valve 60, e.g. by means of a lead in the case of electrically controllable units.
Pressure tank 52 is connected by line 54 to a pressure generator 55 for actuation by means of a gaseous medium, preferably compressed air. Line 54 is connected to a compressed air system or directly to a compressor, line 54 containing a throttle valve 65 and a control valve 61. A controllable drain valve 63 is disposed on the cover of pressure tank 52, valve 63 and control valve 61 being operatively connected to one or more level indicators 33' disposed on bath 2'.
In an alternative embodiment shown in FIG. 4, the pressure generator is a radial fan 55' directly connected to the pressure tank 52 via line 54'. A large section control valve 62, e.g. a solenoid valve, is disposed on pressure tank 52 and is connected to a large-section distributor line 53' from which a number of lines 53 lead to bath 2'. A discharge control valve 63' is also disposed on the cover of the pressure tank and is operatively connected, together with control valve 62, to the level indicators 33' disposed at different levels on the bath 2'.
The alternative embodiment shown in FIG. 3 operates as follows:
Manual shut-off valves 64 on reservoir 57 for the binding agent 3 is opened, and then with the control valve 60 on reservoir 57 open and the discharge control valve 63 open, agent 3 flows into the pressure tank 52 until level indicator 59 delivers a signal and closes control valve 60 and discharge control valve 63 so that the inflow is interrupted. With cover 13 open, a panel 1 is placed on frame 7 of empty bath 2' as already described in connection with FIGS. 1 and 2 and clamped as in the first alternative embodiment by the cover being closed. Control valve 61 is then opened to allow compressed air to pass from compressor 55 through line 54 and throttle valve 65 to pressure tank 52, agent 3 being forced into bath 2' via lines 53. The filling time for bath 2' can be adjusted by means of throttle valve 65. After the agent 3 has reached the top level indicator 33', this level is maintained by a control process with alternate closing and opening of control valve 61 and discharge control valve 63, until the agent has penetrated the panel 1 sufficiently deeplly after the vacuum has built up, as already described in connection with FIGS. 1 and 2.
After the vacuum has ceased, the discharge control valve 63 is completely opened and control valve 61 is closed, so that agent 3 flows back from bath 2' to pressure tank 52. During the change of panels 1 for a new operating cycle which takes place as already described, the level in the pressure tank 52 is checked by level indicator 59 and, if necessary, made up by opening of control valve 60.
To obtain short filling times for bath 2', it is advantageous for not all the agent 3 to be returned to the pressure tank 52. Instead, a level adjusted to beneath the panel 1 for treatment is maintained in the bath 2' during the discharging and charging time by means of an air pressure set to a somewhat lower value in line 54, and for this purpose a second level indicator 33' must be disposed at a corresponding height of the bath 2'.
For cleaning purposes when work is completed, the binding agent is first discharged from the pressure tank 52 by opening the shut-off valve 27 with the manual shut-off valve 64 being closed on tank 57. Valve 64' is then opened to connect the apparatus to the cleaning agent tank 58, and cleaning is carried out as already described by circulating the cleaning agent.
In the alternative embodiment shown in FIG. 4, the pressure tank 52 continuously receives air pressure during the working time, e.g. by means of a radial fan 55'. To bring agent 3 into bath 2' valve 63' is closed, the liquid being forced into bath 2' by the air pressure with the control valve 62 open, until the top level is reached so that a signal from the top level indicator 33' closes control valve 62 and the level is maintained. On completion of the process the discharge control valve 63' and the control valve 62 is opened until the level is beneath the panel 1 and a second level indicator 33' disposed at this level transmits the signal to close the two valves 62 and 63'.
If the consolidation process and the change of boards takes a relatively long time, the radial fan 55' can also be switched off for energy economy. At the end of operations, the stock of agent 3 in the pressure tank 52 can be returned to the reservoir 57 with the discharge control valve 63' and the control valve 62 closed and the control valve 60 open. With the operating procedure described here, it is also possible for the apparatus according to FIG. 4 to be cleaned by means of cleaning agent in the reservoir 58.
To intensify the return and flow of binding agent from bath 2' to pressure tank 52, a vacuum can advantageously be rendered operative at pressure tank 52 although not shown in detail in FIGS. 3 and 4. Rapid change of level of the binding agent liquid level is also possible with the apparatus described in connection with these Figures.
Automatic operation is also possible in the exemplified embodiments according to FIGS. 3 and 4, for example by means of an electrical sequential control system.
EXAMPLE III
FIG. 5 shows another embodiment of apparatus for vacuum-impregnation of boards 1 in cross-section, the apparatus being shown in the charging position on the left of the centre-line 68 and in the working position on the right thereof.
A frame 4' bears a fixed bath 22" provided with a depression 67 at each of at least the two long sides. The bottom frame 7 is secured directly to the base 51 of the bath 2" and is provided with an elastic support 8. Above the bath 2" is a lifting system 70 which is adapted to raise and lower a cover 13 vertically in the horizontal position. Cover 13 is resiliently suspended from a frame 71 by means of bolts 14 and springs 15. Spindles 72 are secured to the frame 71 and cooperate with nuts 74 rotatable on a member 73. The nuts provided with sprocket wheel 75 are simultaneously driven via a chain drive 77 by means of a motor 76 disposed on member 73. The latter is borne on the frame 4' or on the foundation by means of supports (not shown). As already described in connection with FIGS. 1 and 2, the top frame 16 with the elastic support 8 and suction line 19 is secured to the cover 13.
Above the bath 2" outside the lifting zone of the cover 13 is disposed a frame top part 78 on which reversing pulleys 79 are secured. A line 80 leads to the reversing pulleys 79 via pulleys 81 from a line drum 82 disposed on the frame 4'. A displacement member 69 is disposed at each end of the line. The displacement members 69 are lowerable into the depressions 67 of the bath 2" by means of the cable drum 82 which is adapted to be driven by a geared motor 83 and a chain drive 84, the top and bottom positions of the displacement members being signalled directly by limit switches (not shown) or indirectly via level sensors, to the control system.
The embodiment described above operates as follows:
The cover 13 is in the top charging position and the displacement member 69 is also in the top position so that the liquid 3 is within the depressions 67 (see left-hand section of FIG. 5). A panel 1 for treatment is then placed on the frame 7 inside the bath 2", e.g. by means of a manipulator. Cover 13 is brought down vertically into the operative position by means of the lifting system 70 by the drive of the spindles 72, the board being clamped under pressure between the two frames 7 and 16. The displacement members 69 are then lowered into the depressions 67 of the bath 2" by means of the cable drum 82 so that the level of the consolidating liquid 3 rises to above the top edge of the board (see FIG. 5, on right). Penetration of the liquid 3 by means of a vacuum is again as described in connection with FIGS. 1 and 2. On completion of this process, the displacement member 69 is lifted to lower the level of the liquid again and the cover 13 is brought into the top charging position by means of the lifting system 70, and the panel 1 is removed. The liquid used up can be replenished by means of apparatus as described in connection with FIGS. 1 and 2. The entire operation can be effected fully automatically by means of an electrical sequential control system. Cleaning of the apparatus can again be as in the first embodiment.
The use of manipulators for charging the apparatus with workpieces is ensured by constructing the apparatus with fixed supporting surfaces for the panel or board under treatment and with a pivotable or lowerable cover, so that fully automatic operation is possible and the apparatus can be incorporated in a production line for the production of chipboards for example. The alternative embodiments with the lowerable bath and lowerable displacement members, and those with the pressure tank, ensure short cycle times with low operating and investment costs as a result of rapid supply and discharge of the consolidating agent to the panel or board, and compact construction is also ensured. The apparatus can also be rapidly cleaned at low cost. | The apparatus includes a horizontal receiving substrate having a resilient gasket extending over the top surface in a closed figure and spaced from the edge of the substrate. A movable cover member including an inverted shallow chamber is provided with a matching resilient gasket on the underside. Vacuum means are connected to the cover. Means are provided for moving the transport cover and substrate into opposing positions so that a porous panel is clamped with between the cover and the substrate gaskets to seal off the major surface portions of the top and bottom faces of the panel while leaving a peripheral region, including the edge, exposed. A tank containing a fluid medium is arranged to move up and around the substrate so that the fluid medium in the tank contacts the surface of the peripheral region of the panel to achieve impregnation. A vacuum is drawn on the cover chamber so that the fluid medium is drawn into the peripheral regions of the panel. Also disclosed is an arrangement with a tank surrounding the perimeter of the substrate and having a means for changing the level of fluid medium in the tank. The level can be changed by inserting a displacement member into the fluid medium or by forcing the fluid medium into the tank from a hyperbaric reservoir chamber. | 1 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an apparatus for controlling the dispensing of medical gases, particularly for assisting respiration.
[0002] The administration of medical gases, specifically oxygen, is customary for the treatment of certain disorders, mainly affecting the respiratory system.
[0003] The patient breathes through a dispenser that is connected to a centralized or local oxygen supply unit; the dispenser is normally a nasal cannula, through which the patient can receive the oxygen according to two different criteria: dispensing with continuous supply and dispensing on demand. In the first solution, the dispenser supplies oxygen continuously, regardless of the respiratory act that the patient is performing at that moment. In the second solution, a valve is inserted in the gas flow ducts, and when overpressure occurs in the cannula due to patient expiration, the emission of oxygen is interrupted, resuming when the pressure decreases again as a consequence of inspiration.
[0004] The risk, for acute patients who must be constantly connected to the dispenser, is that as a consequence of involuntary movements the cannula can shift or escape from the nose, therefore interrupting the administration of oxygen to the patient. The same problem occurs if the gas supply duct through which the oxygen flows to the dispenser undergoes mechanical deformations, preventing the free flow of the gas toward the patient.
SUMMARY OF THE INVENTION
[0005] The aim of the present invention is to obviate the cited shortcomings and meet the mentioned requirements, by providing an apparatus for controlling the dispensing of medical gases, particularly for assisting respiration, that obviates the interruption of the service provided by the dispenser if such dispenser exits from the nostrils or if the gas feed ducts are blocked.
[0006] An object of the present invention is to provide a structure that is simple, relatively easy to provide in practice, safe in use, effective in operation, and relatively low in cost.
[0007] This aim and this object, which will become better apparent hereinafter are achieved by the present apparatus for controlling the dispensing of medical gases, particularly for assisting respiration, comprising a centralized or local unit for supplying medical gas, which is connected hermetically by way of a tube to a dispenser of said gas to which the patient is connected, characterized in that along said tube there is a detector for detecting the correct respiration of the patient which has at least one pressure sensor adapted to detect the cyclic increases in pressure inside said dispenser caused by patient expirations, in that said sensor conveys its output signals, of the binary type, to said detector, which is adapted to compare the periodicity of said signals with a reference physiological periodicity, an alarm indicator being controlled by said detector and being activated if said periodicity has not occurred due to obstruction of the tube or extraction of the dispenser.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Further features and advantages of the invention will become better apparent from the detailed description of a preferred but not exclusive embodiment of an apparatus for controlling the dispensing of medical gases, particularly for assisting respiration, according to the invention, illustrated by way of non-limitative example in the accompanying drawings, wherein:
[0009] [0009]FIG. 1 is a view of a control apparatus according to the invention applied to a dispenser of the nasal cannula type;
[0010] [0010]FIG. 2 is a functional block diagram of the components of the control apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] With reference to the figures, the reference numeral 1 generally designates a device for assisted respiration that is provided with the apparatus for controlling the dispensing of medical gases, particularly for assisting respiration, according to the invention.
[0012] The reference numeral 2 designates a local unit for supplying medical gas, in the illustrated case a bottle that contains said gas, on the top of which an end of a tube 3 is connected at the outflow control valves. The dispenser, which in the particular case is a nasal cannula 4 , is fixed to the opposite end of the tube 3 , maintaining the continuity of the internal free cross-section for the passage of the gas; the cannula 4 , during use, is arranged so that its two tubular tips 4 a and 4 b , arranged at the opposite end with respect to the end for fixing to the tube 3 , are inserted in the nostrils of the patient 9 . In its central section, the tube 3 is provided with the pressure sensor 5 : the tube 3 leads to the sensor by means of an inlet duct 6 a and exits from it, after being sampled, through the outlet duct 6 b . The sensor 5 is connected electrically to the detector 7 , for detecting correct respiration of a patient, which drives the alarm indicator 8 .
[0013] The detector 7 is constituted by a signal conversion unit 11 and by a timer 13 .
[0014] The signal conversion unit 11 is suitable to detect the rising and falling fronts of the signal 10 provided by the sensor 5 and to emit, at each one of said fronts, a peak pulse as an output signal 12 .
[0015] The timer 13 behaves like a conventional timer in which, once the time to be counted has been set and once it has been activated, the input signal is the signal emitted by the unit 11 , i.e., the signal 12 . The set time depends on a certain reference physiological periodicity, which is typical of respiratory acts and can be deduced from medical treatises. The count is reset at each pulse received from the unit 11 .
[0016] When the timer 13 is able to perform the entire count, it emits an output signal, which reaches the alarm indicator 8 .
[0017] The alarm indicator 8 can be of the acoustic type, such as a buzzer or bell, or of the visual type, such as a flashing light or luminous sign, or can be controlled by a computer suitable for monitoring, on the screen of which the message indicating the anomaly is displayed.
[0018] The indicator 8 can be arranged either in the same room in which the patient is located, reporting the occurred anomaly to said patient, or in a manned room, which is distant with respect to the room in which the patient is located, such as the paramedic reception room in the case of hospitals, ensuring timely intervention if a signal occurs.
[0019] Operation of the invention is as follows: once the patient 9 has been arranged so that the cannula 4 is inserted in his nostrils, pressure variations occur inside the sensor 5 according to the cycle of respiratory acts.
[0020] Both when the medical gas dispensing system is of the continuous-supply type and when it is of the on-demand type, the overpressures and negative pressures caused by respirations can be detected if the sensor 5 is set quantitatively for the intended specific purpose.
[0021] Upon inspiration, the sensor 5 detects a reduction in the pressure inside the tube 3 and therefore outputs the value that corresponds to the low level B of the binary logic in use.
[0022] When the patient 9 breathes out, the sensor 5 detects an increase in the pressure inside the tube 3 and emits a signal that corresponds to the high level A of the binary logic in use.
[0023] The succession of respiratory acts therefore entails that the output signal 10 of the sensor 5 is, in regular operating conditions, a square wave 10 a.
[0024] The succession of rising or falling fronts of the level of the signal 10 is converted by the unit 11 into a series of peak pulses 12 , each pulse occurring at each front.
[0025] The time between each peak and the next, in the case of regular operation, is such that the timer 13 is reset at every count before it can reach the end.
[0026] The preset time counted by the timer 13 must in fact be such as to allow to skip a few respiratory acts, for example because the patient 9 is talking and is breathing through his mouth, without activating the alarm indicator 8 . The low level B also corresponds to the case in which the patient 9 intentionally or unintentionally removes the cannula 4 or if expiration does not occur after inspiration, as indicated by the signal 10 b.
[0027] In this case, the absence of state change fronts in the signal 10 also entails that the outlet 12 of the unit 11 , starting from the moment when the problem occurs, is also zero, and therefore there is no succession of pulses. Therefore, since the timer 13 is not reset by said pulses, it can continue the count, activating the alarm indicator 8 when the count ends.
[0028] Likewise, in the case of an obstructed cannula 4 a certain overpressure is kept constant inside the tube 3 . Said overpressure is detected by the sensor 5 , which keeps its output 10 c at the high level A indefinitely, until the obstruction is eliminated.
[0029] Persistence of the signal 10 at the high value A entails the absence of state change fronts and therefore the absence of pulses downstream of the unit 11 in the signal 12 . In this case also, the timer 13 can complete the count and activate the alarm indicator 8 .
[0030] If an oxygen-dependent patient unintentionally removes the dispensing nasal cannula, he is warned locally by the alarm indicator; the advantage of this use is the fact that the cannula generally slides out unintentionally during sleep. If the control apparatus is not present, the patient might wake up and realize that the cannula has slid out only as a consequence of the onset of the symptoms caused by lack of oxygenation; the presence of the control apparatus according to the invention entails that the patient is woken up shortly after the cannula has slid out, thus avoiding the sickness caused by hypoxia.
[0031] The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims.
[0032] It has thus been shown that the invention achieves the proposed aim and objects.
[0033] For example, if an on-demand dispensing system is used, it is possible to activate a second sensor, which upon inspiration is activated regularly, resetting the timer every time. If no inspiration occurs within the preset time, the alarm is tripped.
[0034] All the details may further be replaced with other technically equivalent ones.
[0035] In practice, the materials used, as well as the shapes and the dimensions, may be any according to requirements without thereby abandoning the scope of protection of the appended claims.
[0036] The disclosures in Italian Patent Application No. BO2002A000310 from which this application claims priority are incorporated herein by reference. | An apparatus for controlling dispensing of medical gases, comprising a unit for supplying medical gas, connected hermetically by way of a tube to a gas dispenser connected to a patient, a detector located along the tube for detecting correct respiration of the patient with at least one pressure sensor that detects cyclic pressure increases inside the dispenser caused by patient expirations, binary output signals being conveyed by the sensor to the detector which compares periodicity of the signals with a reference physiological periodicity, and an alarm indicator controlled by the detector and activated if the periodicity does not occur. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to commonly-assigned copending U.S. patent application Ser. No. ______, filed concurrently herewith, entitled “INK STICKS WITH CORNER GUIDES,” by Brent R. Jones et al., commonly-assigned copending U.S. patent application Ser. No. ______, filed concurrently herewith, entitled “PHASE CHANGE INK STICKS WITH KEYING SYSTEM INDEPENDENT FROM SUPPORT AND GUIDANCE”, by Brent R. Jones, and commonly-assigned copending U.S. patent application Ser. No. ______, filed concurrently herewith, entitled “ONE-WAY PHASE CHANGE INK STICK COMPATIBILITY KEYING”, by Brent R. Jones et al., the disclosures of which are all incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates generally to ink printers, the ink sticks used in such ink printers, and the devices and methods used to provide ink to such printers.
BACKGROUND
[0003] Solid ink or phase change ink printers conventionally receive ink in a solid form, as pellets or ink sticks. The solid ink pellets or ink sticks are placed in a feed chute and a feed mechanism delivers the solid ink to a heater assembly. Solid ink sticks are either gravity fed or urged by a spring through the feed chute toward a melt plate in the heater assembly. The melt plate melts the solid ink impinging on the plate into a liquid that is delivered to a print head for jetting onto a recording medium. Ink sticks for phase change ink printers have historically included bottom and side keying surfaces by which corresponding chutes and feed mechanisms (i.e., “ink loaders”) of the printers guide or coax the ink sticks into optimal feed/melt positions. In horizontal or near horizontal ink loaders, gravity influences the ink stick positions as the ink sticks lean against chute walls or special side-rails. Special guides have even been incorporated into the bottoms of some ink sticks to facilitate their movement over corresponding bottom-rails of some horizontal feed ink loaders. Such guides, coupled with gravity, have typically worked reasonably well to properly position and orient the ink sticks for feeding to the heater plates. In such situations, the sides of the keying features have typically included the ink surfaces contacting the guides. Such guide and key integration has undesirably limited the keying features in that insertion exclusivity has not been the only function that the keying features have been relied upon to provide. In many cases, size, placement, and configuration of keying features has been as much a function of guidance requirements as keying considerations. Keying for insertion is typically intended to allow differentiation between colors and different product models, which can include marketing programs such as contractual or retail pricing of the ink, thus aside from guiding and support functions, the keying offers opportunity to exclude inappropriate colors or models of ink from being inserted in a given ink loader.
[0004] Meanwhile, conventional keying and guide features have been even less effective in vertical ink loaders as the ink sticks have been somewhat position/orientation influenced but in most cases have not been sufficiently constrained to properly feed to the heat plates. Some vertical ink loader guidance systems have even allowed their ink sticks to misalign to extents that they have rotated and jammed. Consequently, most phase change ink printers accommodating multiple ink sticks of each of various colors and incorporating heat plates have used horizontal rather than vertical ink loader systems.
[0005] Keying features for use in many horizontal ink loader systems have been focused on a two vector interface with the ink loader: one surface for insertion and another for feed, with the former surface typically transverse to the latter. In addition to relying on gravity, such sticks are typically made more complex in shape due to color and product series (model or model range) key features running in one direction and guidance elements or surfaces running in another. The large amount of stick geography devoted to color keying in historical ink stick designs has undesirably limited the flexibility and extensibility in product series key features. As with the ink loaders, making design changes to the complex shapes of such ink sticks can introduce undesirable risks of ink stick failure from stress fracturing and variations in cooling deformation, can undesirably increase tooling cost/complexity, and/or can undesirably increase product development times.
[0006] Thus, guidance in the afore-noted cases has relied primarily on combinations of ink stick surfaces including keying surfaces not designed or intended solely for guidance. Another shortcoming of conventional loaders is that insertion keying, including model or series keying, changes from product to product to ensure marketing, operational parameter, or formulation differentiation. Parts internal to the loader, such as push blocks, change in addition to the external key plates. As a result of the historical lack of uniformity in keying schemes and the integration of guidance and keying systems, each new phase change ink printer model has typically needed a new loader configuration, which has undesirably increased ink delivery costs and product development times.
[0007] Orienting an ink loader vertically could potentially improve usability and lower cost. A vertical loader could provide the benefit of using gravity as the primary force to move or feed the ink stick. While guides in horizontal loaders typically emphasize load bearing support, such load bearing would not be required by a vertical loader. However, as noted above, conventional ink shapes are not compatible with vertical loading. Conventional ink shapes are also not compatible with an insertion direction that is in-line with or parallel to the feed direction. Ink sticks used in loaders with independent insertion and feed directions, irrespective of loader orientation or ink feed to gravity, suffer from a lack of simplified extensibility in creating independence between color, model, support, guidance and feed keying. For a more detailed description of a vertically oriented ink loader, see U.S. patent application Ser. No. ______, entitled “______”, U.S. patent application Ser. No. ______, entitled “______”, U.S. patent application Ser. No. ______, entitled “______” and U.S. patent application Ser. No. ______, entitled “______”, all of which are filed concurrently herewith, the entire disclosures of which are expressly incorporated by reference herein.
[0008] Thus, there is a need for phase change ink printer ink sticks having independent guidance and keying features such that the flexibility and extensibility of the keying features may be better optimized, and there is a further need for ink sticks having keying features that can be compatible with parallel insertion and feed to facilitate vertical loading or alternative loaders with feed orientation that may range from horizontal to vertical whether or not insertion is in the feed direction.
SUMMARY
[0009] For insertion into a phase change ink jet printer having first, second, third, and fourth ink feed channels that have first, second, third, and fourth channel positions, a set of ink sticks that includes a first ink stick having a first key feature at a first position on an ink stick corresponding to the position of the first feed channel, a second ink stick having a second key feature at a second position on the ink stick corresponding to the position of the second feed channel, a third ink stick having a third key feature at a third position on the ink stick corresponding to the position of the third feed channel, and a fourth ink stick having a fourth key feature at a fourth position on the ink stick corresponding to the position of the fourth feed channel. In examples the position of each ink stick key feature relative to the remainder of the ink stick corresponds progressively to the position of the feed channel relative to the remainder of the printer.
[0010] In accordance with another aspect of the described apparatus and method, a set of ink sticks were inserted into a phase change ink jet printer having a plurality of feed channels, includes a plurality of ink sticks, in which each of the ink sticks is adapted to be inserted in an insertion direction into one of the feed channels of the phase change ink jet printer. Each ink stick has a keyed surface substantially aligned with the insertion direction. Each of the keyed surfaces has a key feature having a position relative to the keyed surface, and the position of the key feature relative to the keyed surface corresponds to the progressive position of the feed channel relative to an aspect of the printer.
[0011] In accordance with a further apparatus of the invention, an ink delivery system for a phase change ink jet printer includes a plurality of ink feed channels for receiving solid ink sticks inserted in an insertion direction, and a plurality of ink sticks, each adapted for insertion in the insertion direction into one of the feed channels of the printer. Each of the ink sticks has a key element positioned on the ink stick in a progressive position to correspond to the relative progressive position of the feed channel for which the ink stick is adapted.
[0012] In accordance with a method described, inserting an ink stick into a delivery system of a phase change ink jet printer includes orienting the ink stick with a keyed surface facing a first direction, identifying the position of the key feature relative to the remainder of the keyed surface, identifying an ink feed channel of the feed system having a position in the ink delivery system corresponding to the position of the key feature relative to the remainder of the keyed surface, and inserting the ink stick into the identified ink feed channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of an exemplary phase change ink printer.
[0014] FIG. 2 is a partial top perspective view of the rear section of the phase change ink printer of FIG. 1 with its ink access cover open.
[0015] FIG. 3 is a side sectional view of a feed channel of the solid ink feed system of the phase change ink printer taken along lines 3 - 3 of FIG. 2 .
[0016] FIG. 4 is a perspective view of the phase change ink printer of FIG. 1 with its ink access cover open showing an alternate ink loader configuration.
[0017] FIG. 5 is a side sectional view of a feed channel of the solid ink feed system of the phase change ink printer of FIG. 4 .
[0018] FIG. 6 is a perspective view of one embodiment of a solid ink stick.
[0019] FIG. 7 is a top view of the solid ink stick of FIG. 6 .
[0020] FIG. 8 is a sectional view of a feed channel showing corner guide members and the ink stick of FIG. 7 with complementary corner guide elements.
[0021] FIG. 9 is a top view of an alternate ink stick configuration with inset corner guide elements.
[0022] FIG. 10 is a sectional view of a feed channel showing alternative corner guide members and the ink stick of FIG. 9 with complementary corner guide elements.
[0023] FIG. 11 is a top view of an embodiment of a solid ink stick with a corner guide having an orientation feature.
[0024] FIG. 12 is diagrammatical illustration of a multi-color set of ink sticks with progressive color key element, series keying and corresponding key plate.
[0025] FIG. 13 is diagrammatical illustration of an embodiment of parallel progressive color keying.
[0026] FIG. 14 is diagrammatical illustration of an embodiment of perpendicular progressive color keying.
[0027] FIG. 15 is a diagrammatical illustration of an embodiment of one way series compatibility keying for two platforms.
[0028] FIG. 16 is another diagrammatical illustration of an embodiment of one way series compatibility keying for two platforms.
[0029] FIG. 17 is a diagrammatical illustration of yet another embodiment of one way series compatibility keying for three platforms.
[0030] FIG. 18 is a diagrammatical illustration of yet another embodiment of one way series compatibility keying for two platforms.
DETAILED DESCRIPTION
[0031] FIG. 1 is a perspective view of an exemplary phase change ink printer 10 . Printer 10 includes an outer housing having a top surface 12 and side surfaces 14 . A user interface display, such as a front panel display screen 16 , displays information concerning the status of the printer, and user instructions. Buttons 18 or other control elements for controlling operation of the printer are adjacent the user interface window, or may be at other locations on the printer. An ink jet printing mechanism (not shown) is contained inside the housing. The printer includes an access cover 20 that opens (see FIG. 2 ) to provide the user access to an ink feed system (see FIG. 3 ) contained under the top surface of the printer housing that delivers ink to the printing mechanism.
[0032] FIG. 2 is a partial top/front perspective view of the phase change ink printer 10 with its ink access cover 20 open. As seen in FIG. 2 , opening the ink access cover 20 reveals a key plate 26 having keyed openings 24 . Each keyed opening 24 A, 24 B, 24 C, 24 D provides access to an insertion end of one of several individual feed channels 28 A, 28 B, 28 C, 28 D of the solid ink feed system (see FIG. 3 ). A color printer typically uses four colors of ink (black, cyan, magenta, and yellow). Each color corresponds to one of the feed channels. In the illustrated embodiment, the key plate has four keyed openings 24 A, 24 B, 24 C, and 24 D. Each keyed opening 24 A, 24 B, 24 C, 24 D of the key plate 26 has a unique shape. The ink sticks 30 of the color for that feed channel have a shape corresponding to the shape of the keyed opening 24 A, 24 B, 24 C, 24 D. For example, the lateral sides of the key plate openings and the lateral sides of the ink sticks may have corresponding shapes. The keyed openings and corresponding ink stick shapes are designed to ensure that only ink sticks of the proper color are inserted into each ink stick feed channel.
[0033] Referring to FIG. 3 , each feed channel, such as representative feed channel 28 A is a vertically oriented feed channel designed to deliver ink sticks 30 of a particular color to a corresponding melt plate 32 . The vertical orientation of the ink loader simplifies the ink loader by eliminating the need for complex mechanisms designed to urge an ink stick along a horizontally oriented feed channel, where support friction inhibits movement. The vertical orientation may be any orientation that is sufficiently vertical so that gravity provides the primary motive force to feed the ink sticks along the feed channel and to hold the ink sticks against the melt plate 32 as they are melted.
[0034] The feed channel receives ink sticks inserted in an insertion direction L at the insertion end through keyed opening 24 A. In the embodiment of FIGS. 2 and 3 , the insertion and feed directions L, F are substantially parallel. Thus, the key plate 26 and keyed openings 24 A-D are oriented substantially perpendicular to the insertion and feed directions to provide access to the feed channels such that ink sticks are inserted in the feed direction F of the feed channel. In an alternative embodiment as shown in FIGS. 4 and 5 , the insertion direction L may be different from the feed direction F. For example, as in the embodiment of FIGS. 4 and 5 , the key plate 26 and keyed openings 24 A-D may be oriented substantially perpendicular to the insertion direction L and substantially parallel to the feed direction F of the feed channel such that ink sticks may be inserted in the insertion direction L and then moved along the feed channel in the feed direction F.
[0035] Referring now to FIGS. 3 and 5 , the feed channel has sufficient longitudinal length that multiple ink sticks may be inserted into the feed channel. Each feed channel delivers ink sticks along the longitudinal length or feed direction F of the channel to the corresponding melt plate 32 at the melt end of the feed channel. The melt end of the feed channel is adjacent the melt plate 32 . The melt plate 32 melts the solid ink stick into a liquid form. The melted ink typically drips or flows through a gap 33 between the melt end of the feed channel and the melt plate, and into a liquid ink reservoir (not shown).
[0036] An exemplary solid ink stick 30 for use in the feed system is illustrated in FIGS. 6 and 7 . The ink stick is formed of a three dimensional ink stick body. A substantially cubic ink stick body is illustrated in FIG. 6 . The ink stick body illustrated has a bottom, represented by a general bottom surface 52 , and a top, represented by a general top surface 54 . The top and bottom surfaces are shown substantially parallel one another. The ink stick body also has a plurality of side extremities, such as side surfaces 55 , 56 , 61 , 62 . The side surfaces 55 , 56 are substantially parallel one another, and are substantially perpendicular to the top and bottom surfaces 52 , 54 . The side surfaces 61 , 62 are also substantially parallel one another, and substantially perpendicular to the top and bottom surfaces, and to the lateral side surfaces.
[0037] The respective surfaces of the ink stick body need not be substantially flat, nor need they be substantially parallel or perpendicular to one another. Other shapes of the side and end surfaces are also possible, including curved surfaces. The aspect ratios of the ink stick length to height to width could be substantially different. Some ink sticks may be quite long relative to their width, as example. The ink stick can be generally elongated lengthwise, widthwise or even in height or be altered in form in other ways. The lateral side surfaces can also be segmented or stepped, so that one portion of the ink stick body is narrower than another. Nevertheless, the present descriptions should aid the reader in visualizing, even though the surfaces may have three dimensional topographies, or be angled with respect to one another. The ink stick body may be formed by pour molding, injection molding, compression molding, or other known techniques.
[0038] The ink stick 30 includes side surfaces 55 , 56 , 61 , 62 that are oriented substantially parallel to the feed direction F of the feed channel 28 . The bottom surface 52 is a leading end surface which is intended to contact the melt plate of a feed channel first, and the top surface 54 is a trailing end surface. In one embodiment, the ink stick 30 includes corner guide elements 80 for interacting with guide members 104 (See FIG. 8 ) of a feed channel to maintain the orientation and alignment of the ink stick in the feed channel as gravity feeds the ink stick along the feed channel. This interaction of the corner guide elements 80 limit the movement of the ink stick 30 in the feed channel in directions that are perpendicular to the feed direction F. Limiting the relative movement of the ink sticks in directions other than the feed direction prevents rotational movement and skewing of the ink stick which may cause jams and/or improper alignment with the melt plate. Additionally, the use of guides at the extreme corners of an ink stick ensures that the larger surface/perimeter areas of the general sides of an ink stick have room to incorporate an extensible range of color and series keying features. Corner guide elements will be described as extending along the corner edge from the leading face to the trailing face of an ink stick and this description is intended to include non straight line topography and full or partial and segmented lengths of any length which can be intermediate or extending outward from the front and rear faces.
[0039] In one embodiment, the corner guide elements 80 comprise protrusions that extend at least partially along the corner edges of the ink stick parallel to the feed direction. In the embodiment of FIGS. 6 and 7 , there is shown a corner guide element 80 at each corner, although corner guide elements 80 may be used at one, two or three corners. When using only two guide elements, they would ideally be positioned at opposite diagonal corners of the ink stick, though they could be on opposite sides so the term opposite corner is intended to encompass both relationships. Thus, contact between the ink stick 30 and feed channel 28 may be controlled and distributed more evenly thereby permitting low damping friction forces and reducing the effects of dimension intolerances between the feed channel and ink stick. Therefore, the ink stick body does not become skewed with respect to the feed channel. With the ink stick properly aligned with the feed channel, the ink stick meets the melt plate 32 with the intended attitude and alignment. Proper alignment between the ink stick and the melt plate enhances even melting of the ink stick. Even melting reduces the formation of unmelted slivers at the trailing end of each ink stick. Such unmelted slivers may slip through the gap 33 between the melt plate and the end of the feed channel. Such slivers may interfere with the proper functioning of certain portions of the printer or be introduced into different color reservoirs causing color mixing.
[0040] FIG. 8 shows a cross sectional view of the vertical feed channel 28 of FIGS. 3 and 5 . As mentioned above, in a vertical or somewhat vertical loader, gravity may be relied upon to provide the force for moving the ink stick along the channel from the insertion end to the melt end. A gravity ink feed system may be augmented with a further nudging means, such as vibration, small abrupt motion, air blast or any other reasonable means to ensure feed reliability in view of variable exposure or environments (off angle product orientation, dropping the product during relocation, elevated temperatures, damaged ink sticks and the like). References to gravity feed therefore include the possibility of such augmentation but in these cases gravity is the primary motive force and under optimal conditions is all that is necessary to feed the ink. The feed channel includes guide members 104 for constraining movement to the feed direction by interacting with the guide elements 80 of an ink stick 30 . In the embodiment of FIG. 8 , the feed channel guide members comprise corner protrusions that extend the length of the feed channel substantially parallel to the feed direction F. A pair of guide members 104 is provided for each corner guide element 80 of the ink stick 30 . Each pair of guide rails or members 104 for each corner guide element 80 define a space that is substantially complementary to the corner guide element 80 . The complementary shape of the space formed by the corner guide members 104 of the feed channel allow the corner guide elements 80 of the ink stick body to slidingly engage the feed channel guide members 40 of the ink stick feed channel 28 to allow the passage of the ink stick 30 along the feed channel while limiting lateral and rotational movement of the ink stick. The corner guide members 104 of the feed channel may be formed integrally as part of the feed channel body. Many other ink loader guide shapes are contemplated, such as “V” rails, arced, contoured or segmented rails and so forth.
[0041] Although the corner guide elements 80 of an ink stick have been described as protrusions, other forms of corner guide elements are contemplated. For instance, as shown in FIG. 9 , corner guide elements 80 ′ may comprise an inset portion that extends along the corners of an ink stick 30 ′. The shape, placement and number of guide elements would be matched with complementary guide rails or members in the ink loader. FIG. 10 also shows an embodiment of a feed channel for guiding ink sticks having guide members 104 ′ extending from the corners of the feed channel to slidingly engage the inset corner guides in order to maintain the alignment of the ink stick in the feed channel. Still other forms of ink stick corner guides are also envisioned, such as truncated or flattened surfaces that interface with complementary guide features in the loader. A single, predominantly corner positioned (may be asymmetrical) guide element with a shape that is conducive to adequately restraining excess off axis free play of the ink shape is contemplated, though it may not be optimal, it offers an alternative that may be a desirable option.
[0042] The corner guide elements 80 may be mutually independent from any keying features that may be incorporated in the ink stick. For example, the corner guide elements may be unchanging and present on ink sticks intended for printers across multiple platforms and models. The guide shapes used may be accommodated in all keyed openings of ink loaders for the different printers. The use of corner guide elements that are the same across the various platforms enables the feed system to be substantially the same on all units. Independent color and series keying (explained in more detail below) allows the modification or omission of the keying elements without affecting the basic loader configuration. A modification in the keying scheme of the ink sticks requires a change in the key plate configuration to accommodate the keying scheme and not a change to the parts internal to the ink loader, such as feed channel configuration. Due to size or fabrication limitations with some ink sticks, it may be desirable to have a side color or model keying feature extend fully or partially into a corner guide feature. In this case both features could exist and function independently but happen to be adjacent one another.
[0043] To prevent erroneous ink insertion when the corner guides and/or key element patterns (size and position) are symmetrical, the ink stick may include an orientation feature 84 as shown in FIG. 11 . The orientation feature 84 illustrated comprises a modified corner guide element of the ink stick. A corner guide element may be modified in any suitable manner to facilitate proper insertion of the ink stick into the correct feed channel. For instance, in the embodiment of FIG. 11 , the orientation feature 84 comprises a corner guide element having a greater width than the other corner guide elements 80 . The key plate includes a complementary shaped portion that allows the insertion of the unique corner guide element so that the ink stick is oriented correctly prior to insertion. Thus, the orientation feature provides further mechanisms for prohibiting incorrect insertion of the ink stick 30 into a feed channel. Those skilled in the art will identify numerous other modifications and configurations of the corner guide elements to facilitate proper orientation of the ink stick for insertion. For example, the orientation feature can be provided by the relative positioning of the color and/or series key elements 70 . Two corner guide elements on corners of opposite sides but not diagonally opposed can also be used to provide orientation and can be configured to do so with or without assistance from features used for keying. With respect to insertion keying, the ink loader or feed system keyed opening may be in a plate or may be incorporated into other elements of the ink loader, such as the channel or chute walls or one or more inserts that separately or in conjunction with the channel or other structure, make up a keyed opening. It is to be understood that a separate plate is not necessary and may not be present. Ink may be inserted into a loader body or receiving area transverse to the feed direction but the actual channel insertion keying may occur after the ink placement as the ink enters the feed channel. Orientation keying, such as truncating one side of one end, can be employed to prevent insertion of the ink into the receiving area unless it is in an orientation complementary to passage of the ink stick through the insertion keying en route to the feed channel. If a nominally incorrect ink stick were placed in this fashion, it would not proceed through the keyed opening and so could be retrieved so a correct stick could be inserted. Additional feed keying may be employed at any point in the feed channel beyond this feed direction insertion keyed opening. Feed key effectiveness in blocking inappropriate ink sticks is a nominal function, that is, undersize sticks may fit through.
[0044] The ink stick may include keying elements 88 for interacting with the keyed openings 24 A, 24 B, 24 C, 24 D of the key plate 26 to ensure that only ink sticks intended for a specific feed channel are inserted into the feed channel. The key elements 88 comprise a feature of a particular predetermined size, shape, and location on the outer perimeter of the ink stick body that extend at least partially the length of a side surface generally parallel to the insertion direction L of an ink loader. In the particular example illustrated in which the insertion direction L and feed direction F are substantially parallel, the ink stick key element 88 comprises a protrusion or ridge that extends from the top to bottom surface of the ink stick substantially parallel to the feed direction F of the ink loader. Key elements, however, may comprise inset features as well, such as, for example, recesses and notches. The key element 88 is shaped and positioned to match a complimentary key 90 formed in the perimeter of the keyed opening 24 in the key plate.
[0045] Each color for a printer may have a unique arrangement of one or more key elements in the outer perimeter of the ink stick to form a unique cross-sectional shape for that particular color ink stick. The combination of the keyed openings 24 in the key plate 26 and the keyed shapes of the ink sticks 30 (formed by the key elements 70 ) insure that only ink sticks of the proper color are inserted into each feed channel. A set of ink sticks is formed of an ink stick of each color, with a unique key arrangement for ink sticks of each color. In one embodiment, key elements 88 for differentiating between colors of an ink stick may be placed on a single side of each ink stick of a multi-color set of ink sticks. The positioning of the key elements along a perimeter segment of an ink stick may progressively correspond to the progressive position of the keyed opening (and associated feed channel) relative to the other keyed openings in the ink loader mechanism.
[0046] Referring to FIG. 12 , there is shown an embodiment of the progressive keying scheme implemented in a set of ink sticks intended for the ink loader of FIGS. 2 and 3 in which the insertion direction L and feed directions are substantially parallel. In this embodiment, the progressive orientation of the key elements 88 A-D is parallel to the orientation of the feed channels. Thus, the ink stick 30 A intended for the first feed channel 28 A includes a key element 88 A that is positioned the farthest to the left with respect to the other key elements 88 B-D of the ink sticks 30 B-D. The ink stick 30 B intended for the second feed channel 28 B includes a key element 88 B that is positioned the second farthest to the left, etc. FIG. 13 shows an embodiment of the progressive keying scheme for the ink loader of FIGS. 4 and 5 . In this embodiment, the insertion direction L is different than the feed direction F. The key elements comprise inset grooves that extend along the top surface 54 substantially parallel to the insertion direction L. Similar to the embodiment of FIG. 12 , the ink stick 30 A intended for the first feed channel 28 A includes a key element 88 A that is positioned the farthest to the left with respect to the other key elements 88 B-D of the ink sticks 30 B-D. The ink stick 30 B intended for the second feed channel 28 B includes a key element 88 B that is positioned the second farthest to the left, etc.
[0047] Although the key elements 88 A-D are shown as being on a perimeter segment that is substantially parallel to the orientation of the feed channels, the progressive keying scheme of FIG. 10 may be implemented on any side of the ink stick that is substantially aligned with insertion direction L. For example, FIG. 14 shows an embodiment of the progressive keying scheme in which the keying elements have a perpendicular progressive orientation. In the perpendicular progressive orientation, the keying elements may be sequentially positioned along a perimeter segment or surface that is oriented substantially perpendicularly to the left to right orientation of the feed channels. For instance, as shown in FIG. 14 , the keying elements are sequentially positioned along a side surface with each sequential position of the keying elements 88 corresponding to the sequential left to right positioning of the feed channels. The perpendicular progressive orientation may be useful in situations in which the perimeter segments of an ink stick that are parallel to the orientation of the feed channels are narrow, thereby precluding a practical implementation of the progressive keying scheme shown in FIGS. 12 and 13 .
[0048] The single side placement of the keying elements 88 as well as sequential positioning of the key elements has the added benefit of promoting user familiarity with the keying scheme to further ensure that an ink stick is loaded in the proper feed channel. For instance, a printer operator can associate an ink stick with a particular feed channel of the printer by correlating the position of the key element with the correspondingly positioned keyed opening in the key plate.
[0049] In a manner similar to the color keying scheme, one or more series key elements 94 may be incorporated to provide series differentiation in order to ensure that only ink sticks intended for a particular printer are able to be inserted in the printer as shown in FIG. 12 . Thus, a set of ink sticks intended for a particular printer may have one or more key elements 94 formed in the same position on each ink stick of the set as shown in FIG. 12 . A set of ink sticks intended for a different printer may have one or more key elements formed in a particular position on each ink stick of the set that is the same position for each ink stick of the set but at a different position than ink sticks intended for other printers. In embodiments incorporating common side color keying, ink sticks may have up to three sides for incorporating series keying elements, thus, allowing for a wide range of differentiation between printer platforms and models. Additionally, the color key elements 88 and the series key elements 94 may be mutually independent in that the color key elements may be changed or omitted without affecting the configuration or operation of the series key elements and the series key elements may be changed or omitted without affecting the configuration or operation of the color key elements. Thus, ink sticks that are the same color but intended for different printers may have the same color key configuration but different series key configurations. Conversely, ink sticks that are intended for the same printer but are different colors may have the same series key configuration but different color key configurations.
[0050] In another embodiment, the series keying scheme may include “one way” or compatibility keying features in order to accommodate progressive product differentiation. For example, world markets with various marketing approaches, pricing, color table preferences, etc. have created a situation where multiple ink types or formulations may exist in the market simultaneously. Thus, ink sticks may appear to be substantially the same but, in fact, may be intended for different phase change printing systems due to factors such as, for example, date or location of manufacture; geographic variation including chemical or color composition based on regulations or traditions or special market requirements, such as “sold” ink vs. contractual ink supply, North American pricing vs. low cost markets, European color die loading vs. Asian color die loading, etc. A series keying scheme including compatibility keying may be implemented to ensure that ink stick configurations that are intended to be used with one or more phase change ink platforms, based on marketing approaches, ink formulations, geographic regulations, etc., are used only with those platforms. As an example, an ink formulation for one printer series may be compatible with a second printer series, but ink formulated specifically for the second printer series may not be compatible with the first printer series. Similarly, ink sticks intended for North American markets may be compatible with all printing platforms while ink sticks intended for low cost markets may not be compatible with North American printing platforms. This flexibility in one way keying accommodation allows for the intended multiple product use of some ink while appropriately preventing unintended alternate model use, such as convenience of accepting higher market price ink in a later model while preventing the lower market price ink of the later model from fitting into an earlier model. One way or compatibility keying configurations are defined by same color ink stick shapes that are very similar but differ to the extent that corresponding key plate insertion openings can be somewhat different so that alternate but similar shapes may be admitted or selectively excluded based on the size or configuration difference providing the compatibility keying. Though one way keying is facilitated by opportunities with corner guide ink stick configurations and single side color keying, the concept is intended to be extensible to any ink stick form and any ink loader configuration or orientation relative to gravity. One way or compatibility keying is not used for admitting or excluding different colors but rather same color sticks that would be used in different models or model variations.
[0051] Compatibility keying may be incorporated by varying a characteristic of the series key and accommodating the variation of the series key in the keyed openings of respective key plates. Ink stick shapes, including guide features and key elements, may otherwise be identical except for this variation in the series key. Take, for example, the case of two platform differentiation in which ink sticks for a first platform may be used with a second platform, but ink sticks for the second platform may not be used with the first platform. As shown in FIG. 15 , a first series key feature 94 E may be included on both types of ink sticks 30 E, 30 F that is of the same size, shape and location. A second series key 94 F is included on ink stick 30 F that is not included on ink stick 30 E. Referring to the corresponding keyed openings 24 E, 24 F, the series key 94 F has been accommodated in key plate 24 F by incorporating a complementary keyed shape 94 F in opening 24 F such that both ink sticks 30 E and 30 F may be inserted through the keyed opening 24 F. Conversely, ink stick 30 F may not be inserted through the keyed opening 24 E because it does not include a complementary shape 98 F for accommodating the second key feature 94 F of ink stick 30 F. In the embodiment of FIG. 15 and other example figures, the key features comprise protrusions although any suitable feature may be utilized including inset features.
[0052] In another embodiment, compatibility keying may be incorporated by varying a geometric characteristic of a series key element such as, for example, in the case of a protruding element, a width of the element. The more restricted ink sticks may have a wider or larger key feature, and less restricted ink sticks may have a smaller similarly shaped feature or one that would be enveloped by the larger in the same location. The passage of ink sticks through a keyed opening of the key plate may be controlled by varying the size of a complementary shape in the keyed opening of the key plate. For example, as shown in FIG. 16 , ink sticks 30 G and 30 H include a key feature 94 in the same location On each ink stick. The key feature 94 H on ink stick 30 H is wider than the key feature 94 G on ink stick 30 G. Referring now to the corresponding key plates 26 of FIG. 16 , key plate 26 G includes a keyed opening 24 G including a narrow shape 98 G that is configured to allow the passage of ink stick 30 G but not ink stick 30 H. Key plate 26 H includes a keyed opening 24 H including a wide shape 98 H that is configured to allow the passage of both ink sticks 30 G and 30 H. The configuration of an ink stick keying feature and the corresponding key feature in a key plate may have a dimension that is greater than these elements in a second configuration such that the first and second configuration ink stick fits through the key plate opening of the first configuration but only the second ink stick configuration fits through the key plate opening of the second configuration. Since the key feature can be an inset or a protrusion, the reference to a greater dimension defines one element of the ink stick dimension influencing the key feature so that when that dimension is greater, accomplishes the one way exclusion. As example, the greater dimension could apply to the width of the key feature itself in a protruding key configuration or an area adjacent to the key feature in an inset key configuration, the latter resulting in a narrower inset key width.
[0053] Compatibility keying may be incorporated by varying the number of key features and/or varying a geometric characteristic of the key features or varying one or more dimensions of the ink stick or any combination. In addition, in embodiments in which color keying is incorporated on a single side of the ink stick, up to three sides may be used to incorporate compatibility keying. By varying the number and/or characteristics of key features compatibility keying may be extended beyond two platform differentiation. Therefore, many combinations of one way compatibility keying are possible across a wide range of acceptance and exclusion sets. Other dimensional variations can be employed to accomplish one way keying, as example, the length dimension of an ink stick perpendicular to insertion where two sticks might be identical except for a small but exclusionary increase in the length of stick two relative to stick one. As shown in FIG. 18 , for instance, the ink stick 30 M and ink stick 30 N are substantially similarly shaped except the dimension X of ink stick 30 M is smaller than the dimension X′ of ink stick 30 N. Thus, ink stick 30 M may be inserted through the keyed openings 24 M and 24 N. Ink stick 30 N may be inserted through keyed opening 24 N, but, due to the larger dimension X′, ink stick 30 is excluded from insertion through opening 24 M.
[0054] FIG. 17 is a diagrammatical illustration of an embodiment of a compatibility keying scheme for three platform differentiating incorporating geometric and number variations in the series compatibility keying. As can be seen, ink sticks 30 J, 30 K and 30 L may be inserted into key plate 26 L. Ink sticks 30 J and 30 K may be inserted into key plate 26 K, and only ink stick 30 J may be inserted into key plate 26 J. It can be appreciated that by varying the number, placement, shape of key features formed on up to three sides of an ink stick, the possible combinations of compatibility keying configurations is extensive.
[0055] The exemplary embodiments of the series and compatibility keying schemes depicted in FIGS. 15 and 17 are shown as incorporated into embodiments of ink sticks intended for the ink loader of FIGS. 2 and 3 in which the insertion direction L and feed directions F are substantially parallel. Thus, the keying features are shown as extending longitudinally along a surface of the ink stick in a direction parallel to the insertion and feed directions. These schemes, however, may be implemented in a similar manner for the ink loader of FIGS. 4 and 5 in which the insertion directions and feed directions are different as long as the keying features extend along a surface of the ink stick in a direction that is generally the same as the insertion direction of the ink loader.
[0056] Those skilled in the art will recognize that numerous modifications can be made to the specific implementations described above. It should be appreciated that the various male-female implementations of the various key features may be suitably reversed. Additionally, those skilled in the art will recognize that the guide elements located at the ink stick corners, intermediate the corners or in the bottom surface of the ink stick body, and guide rails or members in complementary locations may have numerous shapes other than the particular shapes illustrated. In addition, numerous other configurations of the feed channel, key plate, and other components of the ink feed system can be constructed. Therefore, the following claims are not to be limited to the specific embodiments illustrated and described above. The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others. | A set of ink sticks includes multiple ink sticks, each adapted to be inserted in an insertion direction into one of the feed channels of a phase change ink jet printer. Each ink stick has a keyed surface substantially aligned with the insertion direction, and each of the keyed surfaces has a key feature having a position relative to the keyed surface that corresponds to the position of the feed channel relative to an aspect of the printer. A method of inserting an ink stick into the delivery system of a phase change ink jet printer includes orienting the ink stick with a keyed surface facing a particular direction and identifying the position of the key feature relative to the remainder of the keyed surface. An ink feed channel of the feed system having a coinciding position in the ink delivery system is identified, and the ink stick is inserted into the identified ink feed channel. | 1 |
TECHNICAL FIELD
[0001] This invention relates to a terminal mounting structure for a window pane comprising a terminal for electric connection in contact with a conductive part provided on a glass surface of the window pane, and fixed to the glass surface through a resin material attached to the glass surface.
BACKGROUND OF THE INVENTION
[0002] A terminal mounting structure for a window pane is need, for example, when attaching a terminal for electric connection to a glass surface of a rear window pane of an automobile to arrange a defogging heating wire or an antenna wire on the window pane.
[0003] Conventionally, with this type of terminal mounting structure, it has been common practice to solder a terminal to a conductive part provided on the glass surface. However, when soldering is carried out in a defective manner, there is a possibility of internal stress remaining in the terminal and causing a strength reduction of the terminal. Further, since the terminal is bare, a cover is required under certain circumstances.
[0004] A proposal has been made to place a terminal in contact with a conductive part, attach a case formed of a synthetic resin to the conductive part by using double-sided tape, and insert a pressurizing piece consisting of a spring material between the case and terminal to press resiliently the terminal on the conductive part (see Japanese Unexamined Patent Publication H10-40977, for example).
[0005] It has also been proposed to mount a terminal inside a case, place the case on a glass surface with the terminal contacting a conductive part, inserts these elements into a forming die, injects a resin, and fix the case to the glass surface with an injection product formed by the injection molding (see Japanese Utility Model Publication H6-35722, for example).
[0006] However, the conventional structure described in Japanese Unexamined Patent Publication H10-40977 requires the case in addition to the terminal, and the case needs to be constructed of a base and a lid. Further, it is necessary to assemble the terminal, pressurizing piece and so on in a predetermined way in the case. Thus, this structure has a drawback that workability is poor and cost is high because of an increase in the number of parts, and complicated assembly operation.
[0007] Similarly, the conventional structure described in Japanese Utility Model Publication H6-35722 also has a drawback that, since it is necessary to perform the injection molding after mounting the terminal as desired in a predetermined part inside the case, cost is increased by the complicated assembly operation and increased manufacturing steps.
OBJECT AND SUMMARY OF THE INVENTION
[0008] The present invention overcomes the drawbacks of the prior art, and its object is to provide a terminal mounting structure for a window pane, which can reliably attach a terminal to a glass surface of the window pane using minimal numbers of parts and manufacturing steps.
[0009] In accordance with an embodiment of the present invention, a terminal mounting structure for a window pane comprises a terminal for electric connection, which is in contact with a conductive part provided on a glass surface of the window pane. The terminal mounting structure is fixed to the glass surface through a resin material attached to the glass surface. The terminal is formed of a spring material and comprises deformation allowance regions formed on back surfaces of contact portions of the terminal, which is in contact with the conductive part for allowing elastic deformation of the terminal. The resin material surrounds at least the contact portions and the deformation allowance regions of the terminal.
[0010] In accordance with an embodiment of the present invention, the terminal for electric connection is formed of a spring material and comprises deformation allowance regions formed on back surfaces of contact portions of the terminal, which is in contact with the conductive part for allowing elastic deformation of the terminal. The resin material surrounds the terminal and the deformation allowance regions. Therefore, only required components of the terminal mounting structure of the present invention are the terminal formed of a spring material and a device for forming the deformation allowance regions, e.g., elastically deformable block-like elements.
[0011] The elastically deformable block-like elements can be arranged on the back surfaces of the terminal. The terminal and deformation allowance regions can be surrounded by injection molding of a resin. As a result, the terminal of the present invention can be reliably attached to the glass surface using minimal numbers of parts and manufacturing steps, thereby achieving a cost reduction.
[0012] In accordance with an embodiment of the present invention, a terminal mounting structure for a window pane comprises a terminal for electric connection, which is in contact with a conductive part provided on a glass surface of the window pane. The terminal mounting structure is fixed to the glass surface through a resin material attached to the glass surface. The terminal has elastic elements arranged on back surfaces of contact portions of the terminal, which is in contact with the conductive part for pressing, with elastic force, the terminal on the conductive part. The resin material surrounds at least the contact portions and the elastic elements of the terminal.
[0013] In accordance with an embodiment of the present invention, the terminal for electric connection has elastic elements arranged on back surfaces of contact portions of the terminal, which is in contact with the conductive part for pressing, with elastic force, the terminal on the conductive part. The resin material surrounds the terminal and the elastic elements. Thus, only required components of the present invention are the terminal and elastic elements. The elastic elements can be arranged on the back surfaces of the terminal, and the terminal and elastic elements can be surrounded by injection molding of a resin. This construction can achieve a cost reduction using minimal numbers of parts and manufacturing steps.
[0014] In accordance with an embodiment of the present invention, a terminal mounting structure for a window pane comprises a terminal for electric connection, which is in contact with a conductive part provided on a glass surface of the window pane. The terminal mounting structure is fixed to the glass surface through a resin material attached to the glass surface. The terminal has contact portions, which is in contact with the conductive part and is formed of conductive rubber. The resin material surrounds at least the contact portions of the terminal.
[0015] In accordance with an embodiment of the present invention, the terminal for electric connection has contact portions, which is in contact with the conductive part and formed of conductive rubber. The terminal is surrounded by the resin material. Thus, only part of the terminal can be formed of conductive rubber and the injection molding of a resin surrounds the terminal. This construction can achieve a cost reduction by further reducing the number of parts.
[0016] Various other objects, advantages and features of the present invention will become readily apparent from the ensuing detailed description, and the novel features will be particularly pointed out in the appended clams.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The following detailed description, given by way of example, and not intended to limit the present invention solely thereto, will best be understood in conjunction with the accompanying drawings in which:
[0018] FIG. 1 is a sectional view of a terminal mounting structure in accordance with an exemplary embodiment of the present invention;
[0019] FIG. 2 is a perspective view of the terminal mounting structure of FIG. 1 in accordance with an exemplary embodiment of the present invention;
[0020] FIG. 3 is an explanatory view showing a manufacturing process of the terminal mounting structure in accordance with an exemplary embodiment of the present invention;
[0021] FIG. 4 is a sectional view showing the manufacture process of the terminal mounting structure of FIG. 3 in accordance with an exemplary embodiment of the present invention;
[0022] FIG. 5 is a sectional view of a terminal mounting structure in accordance with an exemplary embodiment of the present invention;
[0023] FIG. 6 is a sectional view of a terminal mounting structure in accordance with an exemplary embodiment of the present invention; and
[0024] FIG. 7 is a front view of a rear window pane of an automobile.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0025] A terminal mounting structure for a window pane in accordance with embodiments of the present invention will be described with reference to the drawings. Same reference numerals will be used to identify similar or same elements or elements having similar functions. The components already described will be affixed with the same reference numerals and will not be particularly described again to avoid unnecessary repetition.
[0026] Turning now to FIG. 7 , in accordance with an exemplary embodiment of the present invention, the terminal mounting structure serves for fixing each terminal 2 to a glass surface 1 a , to provide an electric connection to defogging and deicing heating wires or antenna wires arranged on a rear window pane 1 of an automobile. In the case of defogging heating wires 3 , the terminals 2 are mounted in contact with the power supply portions 4 a of the busbars 4 (acting as conductive parts) provided on the glass surface 1 a.
[0027] In accordance with an exemplary embodiment of the present invention, as shown in FIGS. 1 and 2 , each terminal 2 comprises or is formed of a metal spring material with terminal tips 2 a in contact with the busbar 4 , which is bent to a U-shape.
[0028] In U-shaped hollow sections of the terminal tips 2 a , deformation allowance regions 5 for allowing elastic deformation of the terminal tips 2 a are formed on back surfaces of the portions in contact with the busbar 4 . Specifically, these deformation allowance regions 5 are formed of soft or elastic members for allowing the portions of the terminal tips 2 a in contact with the busbar 4 to make elastic deformation toward and away from the busbar 4 , preferably away from the busbar 4 . For example, the members forming the deformation allowance regions 5 can be elastic elements 6 made of a foamed resin such as styrene foam. The elastic elements 6 acting as the deformation allowance regions 5 are arranged in the U-shaped hollow sections of the terminal tips 2 a . A resin material 7 surrounds the terminal tips 2 a and elastic elements 6 . The resin material 7 is bonded to the busbar 4 through an adhesive member 8 disposed around the terminal tips 2 a . in this way, each terminal 2 is mounted on the glass surface 1 a.
[0029] In accordance with an exemplary embodiment of the present invention, a method of manufacturing the terminal mounting structure will now be described herein. As shown in FIG. 3 ( a ), the window pane 1 comprising busbars 4 is placed on a base 9 formed of an elastic material, such as hard rubber. The adhesive member 8 is formed beforehand on a required portion (i.e. a portion where the resin material is to be applied) of each busbar 4 . For example, the adhesive member 8 is formed by applying a nylon-based adhesive to the busbar 4 with a felt and allowing the adhesive to dry.
[0030] The elastic elements 6 are then placed in the U-shaped hollow sections of the terminal tips 2 a and the terminal 2 is placed in a cavity 11 of an injection molding die 10 . As shown in FIG. 3 ( b ), the die 10 is placed on the busbar 4 , preferably with a buffer member 12 formed of fluoro-resin film interposed between the die 10 and busbar 4 .
[0031] A melted resin 7 a , e.g. a thermoplastic resin such as vinyl chloride, polypropylene or polyester, is then injected into the cavity 11 of the die 10 from an injection molding machine 13 .
[0032] The enlarged view of the 10 is shown in FIG. 4 , which is in communication with the cavity 11 required to be filled completely with the resin 7 a and comprises an incomplete filling cavity 11 a not required to be filled completely with the resin 7 a . This enables the injection to be carried out under a low pressure in the order of 34.32 MPa (350 kgf/cm 2 ), preferably not exceeding 19.61 MPa (200 kgf/cm 2 ).
[0033] Subsequently, when the injected resin 7 a has cooled and solidified, as shown in FIG. 3 ( c ), the resin material 7 surrounds and attaches the terminal tips 2 a and elastic elements 6 of the terminal 2 . Consequently, the deformation allowance regions 5 are formed on the back surfaces of the portions of the terminal tips 2 a in contact with the busbar 4 .
[0034] In accordance with an exemplary embodiment of the present invention, bags containing a gas such as air in a sealed state, for example, can be used in place of the elastic elements 6 . Such bags can form the deformation allowance regions 5 .
[0035] In accordance with an exemplary embodiment of the present invention, each terminal 2 is formed of a metal plate other than the spring material, i.e. formed of a soft conductive material. As shown in FIG. 5 , the terminal tips 2 a bent to the U-shape comprises block-like elastic elements 14 formed of rubber, for example, and arranged on the back surfaces of the portions in contact with the busbar 4 . The elastic elements 14 press the terminal tips 2 a on the busbar 4 with elastic force.
[0036] As discussed herein, the resin materials 7 formed by injection of the melted resin 7 a surrounds and mounts. However, the terminal 2 can be formed of a metal spring material, and the terminal tips 2 a can be pressed on the busbar 4 by the elastic force of the terminal 2 itself as well as the elastic force of the elastic elements 14 .
[0037] As shown in FIG. 6 , in accordance with an exemplary embodiment of the present invention, each terminal 2 has a contact portion 2 b formed of conductive rubber for contacting the busbar 4 . The other portions are formed of an ordinary metal plate. The resin material 7 formed by injection of the melted resin 7 a surrounds and attaches the contact portion 2 b , i.e. the portion 2 b formed of conductive rubber for contacting the busbar 4 . Not only the contact portion 2 b for contacting the busbar 4 but the entire terminal 2 can be formed of conductive rubber.
[0038] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described herein. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | A terminal mounting structure for a window pane for reliable attaching a terminal to a glass surface of the window pane using minimal numbers of parts and manufacturing steps. The terminal mounting structure for a window pane has a terminal for electric connection, which is in contact with a conductive part provided on a glass surface of the window pane. The terminal mounting structure is fixed to the glass surface through a resin material attached to the glass surface. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to air induction systems for the combustion air of internal combustion engines. In particular, the present invention relates to air induction systems providing an integral mass airflow sensor, to measure the amount of air flowing through an air cleaner system.
BACKGROUND OF THE INVENTION
It is well known to provide an air cleaner for purifying raw air before mixing the raw air with fuel for combustion in an internal combustion engine. Such known air cleaners are typically used in automobiles. In operation, such known air cleaners provide for the intake of raw air, the purification of the raw air and the routing of the purified air to a cylinder of an internal combustion engine. In fuel injected engines, this flow rate of combustion air is monitored by a mass airflow sensor disposed someplace in the combustion airflow path. These mass airflow sensors are typically calibrated before installation and are inserted into tubes, housings or conduits that communicate with the combustion airflow path. One problem with these sensors is that they are quite sensitive to alignment and orientation. Furthermore, they are easily damaged during replacement and testing. It would be beneficial, therefore, to provide a mass airflow sensor that is coupled to a readily removable conduit that will protect the sensor elements and also more readily permit sensor testing. Since air cleaners are often provided with readily removable conduits to permit the replacement of air filter elements, it would also be advantageous to dispose of the mass airflow sensor in such a conduit associated with the air cleaner.
SUMMARY OF THE PRESENT INVENTION
The air cleaner and mass airflow rate sensing system includes a housing providing an inlet and a filter at least partially disposed in the housing. The system also includes a conduit adjacent the housing and providing a flange and an outlet. The system also includes a compressible seal disposed between the filter and the flange. The system also includes a locking mechanism adapted to selectively secure the conduit to the housing such that the seal may be compressed between the conduit and the filter. The system also includes mass airflow sensor mounted to the conduit.
The present invention further relates to an air induction and mass airflow rate sensing assembly at least partially disposed in a housing of an air cleaner system for purifying air. The housing provides an inlet and the air cleaner system provides a filter at least partially disposed within the housing, a compressible seal and a locking mechanism. The air induction assembly includes a conduit having a first end and adapted for placement at least partially within the housing and the filter such that a second end extends at least partially from the housing. The air induction assembly also includes a flange extending about the circumference of the conduit. The air induction assembly also includes a mass airflow sensor mounted to the conduit. The seal is disposed between the filter and the flange and the locking mechanism is configured to selectively secure the conduit to the housing.
The present invention further relates to an air cleaning and flow rate measuring system. The system includes a filter element for filtering air. The air cleaner system also includes a housing for supporting the filter element and surrounding the filter element. The system also includes an inlet for introducing air into the housing and into the filter element. The system also includes a conduit providing a flange and an outlet and being disposed adjacent to the filter element. The system also includes a seal for inhibiting the leakage of air from the filter element and disposed between the filter element and the housing. The system also includes a locking means for securing the conduit to the seal and to the housing. The system also includes a mass airflow rate sensor mounted to the conduit. Air enters the housing through the inlet, the air is purified by the filter element, and the air exits the housing through the outlet.
It is an object of this invention to provide an air induction assembly that is capable of rapid replacement. It is also an object of this invention to provide a sensor assembly that is easily accessible and capable of rapid testing or calibration. It is a further object of this invention to provide a sensor that readily interfaces with an air filter. Other objects, features and advantages of the invention will become apparent to those skilled in the art upon review of the following FIGURES, the detailed description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially fragmentary exploded perspective view of an air cleaner system in accordance with a preferred embodiment of the present invention;
FIG. 2 is a fragmentary exploded perspective view of the air cleaner system of FIG. 1;
FIG. 3 is a perspective view of an air induction system according to a preferred embodiment of the present invention;
FIG. 4 is a top plan view of the air induction system of FIG. 3; and
FIG. 5 is a side elevation view of the air induction system of FIG. 3 .
Before explaining in detail at least one preferred embodiment of the invention, it is to be understood that the subject matter recited in the claims is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or shown in the FIGURES. The subject matter recited in the claims is capable of other embodiments or being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, an air cleaner system 10 for purifying raw air is shown according to a preferred embodiment of the present invention. System 10 includes an air induction assembly 60 coupled to a replaceable filter assembly 140 , which is contained within a housing 12 . In the operation of system 10 , raw air is drawn from the exterior of housing 12 into a conduit (shown as a snorkel 18 ). The raw air is directed through filter assembly 140 , is purified, and the resulting purified air is directed to an outlet 66 of air induction assembly 60 . An arrow 188 shows the general directional flow of the air through air cleaner system 10 .
Referring to FIG. 3, air induction assembly 60 is shown according to a preferred embodiment of the present invention. Air induction assembly 60 defines an airflow path for the purified air as indicated by arrow 188 . Air induction assembly 60 includes a conduit (shown as tube 62 ) having an inlet 64 and outlet 66 . Inlet 64 of tube 62 is positioned within the interior of housing 12 . Outlet 66 of tube 62 extends from the exterior of housing 12 . A fastener (shown as a capture clamp 162 ) secures a conduit (shown as a hose 160 ) to outlet 66 of tube 62 . Hose 160 has an interior diameter 186 greater than an exterior diameter 180 of outlet 66 . Hose 160 directs the purified air from outlet 66 to other engine systems (not shown) for processing (e.g., to a carburetor for the mixing of the purified air with fuel, and the eventual placement of the resulting mixture in the cylinder of an internal combustion engine).
Referring to FIGS. 3 through 5, a mass airflow rate sensor assembly (shown as assembly 100 ) is mounted to the exterior of tube 62 . Assembly 100 is positioned between an inward ridge 82 and an outward ridge 80 of tube 62 . Assembly 100 includes an upper housing 112 secured to a lower housing 114 that encapsulate a mass airflow rate sensor 116 and a temperature sensor 118 . Upper housing 112 and lower housing 114 may serve to protect sensor 116 and temperature sensor 118 from environmental factors (e.g., debris, water, heat, vibration, physical manipulation, damage during shipping, etc.). A detector (not shown) capable of monitoring environmental variables (e.g., combustion air speed, air temperature, air density, air moisture, etc.) extends from lower housing 114 into the interior of tube 62 . An electrical conductor (shown as a wire 120 ) connects assembly 100 to an engine system (not shown) such as a computer. According to any preferred or alternative embodiments as shown in FIGS. 1 through 3, assembly 100 may be integrally mounted to tube 62 and may be provided as a complete unit pre-calibrated to known variables related to tube 62 (such as engine size, air temperature, the geometry of tube 62 , the distance between the periphery of tube 62 and the detector, etc.).
Referring to FIG. 2, a generally circular-shaped air filter element (shown as a canister 142 ) of filter assembly 140 is positioned within the interior of housing 12 and supported by a cradle 26 . Canister 142 includes an air receiving surface (shown as an outer wall 150 ) and an air emitting surface (shown as an inner wall 152 ). In the operation of system 10 , raw air enters canister 142 through outer wall 150 and is directed through a filter media 156 (such as pretreated, pleated corrugated paper). During the purification of the raw air, impurities (e.g., debris, particulates, gasses, dirt, pollution, etc.) may be entrapped in filter media 156 . The purified air exits filter media 156 through inner wall 152 of canister 142 . A covering (shown as an end cap 148 ) circumscribes and surrounds the bottom of canister 142 . End cap 148 promotes the entry of raw air through outer wall 150 by covering or blocking the lower portion of canister 142 . Filter assembly 140 also includes a generally “V”-shaped flexible, compressible seal 154 mounted to the upper portion canister 142 . Seal 154 extends radially around an aperture 158 of canister 142 . A fastener (not shown), such as an adhesive or glue, may secure seal 154 to canister 142 , and may secure a left end 144 of filter media 156 to a right end 134 of filter media 156 . Alternatively, seal 154 may be integrally molded to canister 142 .
When system 10 is in a fully assembled condition (as shown in FIG. 1 ), canister 142 is positioned within housing 12 , and inlet 64 of tube 62 is positioned within canister 142 . An outer diameter 190 of inlet 64 is less than a diameter 182 of an aperture 158 of canister 142 . A diameter 184 of an aperture 52 of an upper shell 14 of housing 12 is greater than an outer diameter 192 of end cap 148 , and outer diameter 190 of inlet 64 is less than diameter 182 of aperture 158 of canister 142 . (See FIG. 2.)
A flange 68 integrally mounted to tube 62 extends about the periphery of tube 62 . A housing connector system 40 of upper shell 14 secures filter assembly 140 to a conduit connector system 70 of flange 68 . Housing connector system 40 and conduit connector system 70 may serve to compress seal 154 and form a closure or connection between filter assembly 140 and air induction assembly 60 such that air is inhibited from bypassing canister 142 . Housing connector system 40 includes outwardly extending protrusions (shown as fingers 42 ) and inwardly extending indentations (shown as fingers 44 ) spaced generally evenly about the periphery of aperture 52 of upper shell 14 . Conduit connector system 70 includes reciprocal outwardly extending protrusions (shown as fingers 72 ) and inwardly extending indentations (shown as fingers 74 ) spaced generally evenly about the periphery of flange 68 of tube 62 . Conduit connector system 70 also includes a cover 76 positioned over fingers 74 (see FIG. 4 ). To create the effective closure or connection between filter assembly 140 and air induction assembly 60 , a compressive force is applied to air induction assembly 60 to compress seal 154 between a seal engaging surface 78 of flange 68 and canister 142 . Fingers 72 of conduit connector system 70 are aligned with and inserted into fingers 44 of housing connector system 40 . Tube 62 is rotated relative to upper shell 14 (or vice versa) such that fingers 72 of conduit connector system 70 are positioned below fingers 42 of housing connector system 40 (i.e., the fingers of the housing connector system and the conduit connector system are rotated until they are intertwined and interconnected) and cover 76 is positioned over fingers 44 of housing connector system 40 . The compression of seal 154 and the interconnection of the fingers 42 and fingers 72 maintain such compressive force.
A locking system 90 inhibits further rotation of tube 62 relative to upper shell 14 (such rotation may cause a disconnection between fingers 42 of housing connector system 40 and fingers 72 of conduit connector system 70 ). Locking system 90 includes a ramp 46 mounted to the exterior of upper shell 14 and positioned adjacent to the periphery of aperture 52 . Ramp 46 includes an inclined surface 48 and a vertical surface 50 , which is orthogonal to fingers 42 of upper shell 14 . To secure locking system 90 in a closed position, tube 62 is rotated relative to upper shell 14 (or vice versa) such that a glide 92 mounted to flange 68 slides over inclined surface 48 of ramp 46 . Tube 62 is rotated until a catch 94 of glide 92 passes beyond vertical surface 50 of ramp 46 . Further rotation of glide 92 is inhibited by a vertically extending protrusion (shown as a stop 54 ), which is positioned orthogonal to fingers 42 of shell 14 . Thus, when locking system 90 is in the closed position, glide 92 is secured between vertical surface 50 of ramp 46 and stop 54 . To release locking system 90 from the closed position to an opened position, a force is exerted on a stem 96 of glide 92 to lift stem 96 above both vertical surface 50 and stop 54 such that tube 62 may be further rotated. Upon such further rotation of tube 62 , fingers 42 of housing connector system 40 and fingers 72 of conduit connector system 70 become nonaligned and disconnected such that the closure or seal between seal engaging surface 78 of flange 68 and canister 142 is broken. According to an alternative embodiment as shown in FIGS. 3 and 4, locking system 90 may include reinforcing tabs 98 to secure flange 68 to glide 92 .
Referring to FIG. 2, housing 12 includes upper shell 14 mounted to a lower shell 16 . Upper shell 14 includes a cavity (shown as a reservoir 194 ) and aperture 52 for receiving filter assembly 140 in reservoir 194 . A downward sealing surface 20 engages an upward sealing surface 22 of lower shell 16 . Lower shell 16 includes a cavity (shown as a reservoir 196 ) for the housing or encapsulation of filter assembly 140 . A support structure (shown as cradle 26 ) provides support to canister 142 . Cradle 26 includes a radial support (shown as a flange 28 ) and a transverse support (shown as a flange 30 ). A generally “U”-shaped indent 32 of flange 30 provides a surface upon which outer wall 150 of canister 142 may rest. A generally “V”-shaped indent 38 of flange 28 (having a bottom leg 34 and a side leg 36 ) provides a surface upon which the lower portion of canister 142 may rest, such that bottom leg 34 supports end cap 148 of canister 142 and side leg 36 supports outer wall 150 of canister 142 . According to other alternative embodiments as shown in FIGS. 1 and 2, upper shell 14 may include apertures (not shown), which provide a convenient mounting point for mounting elements such as an air or fluid shock mounting (shown as a grommet 164 ). According to any preferred or alternative embodiment, the exterior of the upper shell may include surface textures to provide additional support to the housing and to assist in the channeling of elements (e.g., air, water, debris, etc.) across the housing.
According to a particularly preferred embodiment, the air cleaner system is used to purify raw air before the raw air is routed to an automotive or vehicular engine. The upper shell and the lower shell of the air cleaner system are preferably constructed of plastic that are vibration welded together at about 120 hertz. The hose mounted to the air induction assembly is preferably made of polyvinylchloride (PVC). The filter element is preferably constructed of paper folded in a zigzag configuration. The end cap is preferably constructed of aluminum metal and encapsulated in urethane. The seal is preferably generally “V”-shaped and constructed of urethane rubber. The accessory is preferably a mass airflow sensor, which measures the amount of raw air purified by the air cleaner, that is pre-calibrated to the geometry of the air induction assembly (e.g., by running a known airflow through the conduit and accounting for various environmental factors such as air speed, air temperature, the diameter of the conduit, the type of engine associated with the air induction assembly, etc.).
It should be noted that the use of the term “conduit” is not meant as a term of limitation, insofar as any valve, hose, tube or like structure providing a channel or passageway through which air may flow is intended to be included in the term. It should also be noted that the use of the term “directed” is not meant as a term of limitation, insofar as any routing or leading of raw or purified air into, through and out of the air cleaner system is intended to be included in the term. It should also be noted that the use of the term “engine system” is not meant as a term of limitation, insofar as any “engine” or like machine for using fuel to produce motion or accompanying accessory (e.g., catalytic convert, carburetor, cylinder, fuel injection system, computer system, fan, etc.) is intended to be included in the term.
While a preferred embodiment of the invention is as described above, there are several substitutions that may be made without departing from the beneficial features of the above-described invention such as variations in sizes, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, or use of materials. For example, the mounting of the upper shell and the lower shell of the housing may be replaced with such well known substitutions as an interlocking tab and slot arrangement (which would have the added benefit of permitting the upper shell to be removed entirely from the lower shell), the hinging of the upper shell to the lower shell (which would permit the shells to be pivotally opened and closed), or other suitable fastening devices (such as welding, ultrasonic welding, vibration welding, glue, screws, rivets, clamps or other conventional methods) or the housing may be provided as a single piece. The aperture in the upper shell may be provided in either or both of the shells.
According to other alternative embodiments associated with the filter assembly, the filter element may be disposable. The filter material may be constructed of a porous material (e.g., cardboard, corrugated paper, carbon block, etc.) or a natural or synthetic fibrous material (e.g., spun polyethylene, glass wool, microbial filter, etc.). The effective closure or seal between the air induction assembly and the housing may be formed by any known connection system (such as a bayonet connector system, a threaded connection, a clamp, etc.) and may be maintained by any locking mechanism (e.g., a detent, a tumbler lock, a tacky adhesive, etc.). The seal may be mounted to the upper shell, fixed to a rigid or semi-rigid framework that also extends about the periphery of the filter element, or detached from both the upper shell and the filter element. The seal may be positioned between the filter and the air induction assembly or between the air induction assembly and the housing. The inlet of the air induction assembly may be positioned in close proximity to the filter element or a space may be provided between the inlet of the air induction assembly and the filter element. Likewise, the filter element may be positioned in close proximity to the periphery of the aperture of the upper shell or a space may be provided between the filter element and the periphery of the aperture of the upper shell. The base of the lower shell may support the bottom portion of the filter element.
According to other alternative embodiments associated with the air induction assembly, the air induction assembly may be disposable or selectively removable from the filter assembly. A screen of geometric cells (e.g., hexagonal cells) may cover the conduit or a flow straighter may be provided within the conduit to inhibit the formation of undesirable airflow (e.g., eddies) around the detector. A vapor management valve may be provided in the flow path of the air induction assembly. The accessory may be permanently or removably mounted to the air induction assembly. Such mounting of the accessory may be integral (such as by the use of potting compounds or adhesives) or removable (such as by known fastening devices). The accessory and the detector may be mounted at any position on the conduit or may be positioned either upstream or downstream from the airflow path through the conduit.
Thus, it should be apparent that there has been provided in accordance with the present invention an air cleaner system that fully satisfies the objectives and advantages set forth above. Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred embodiments without departing from the spirit of the invention as expressed in the appended claims. | A combined air cleaning and flow rate sensing system for the combustion air of an internal combustion engine is disclosed. The system includes a housing providing an inlet and a filter at least partially disposed in the housing. The air cleaner system also includes a conduit adjacent the housing and providing a flange and an outlet. The air cleaner system also includes a compressible seal disposed between the filter and the flange. The air cleaner system also includes a locking mechanism adapted to selectively secure the conduit to the housing such that the seal may be compressed between the conduit and the filter. The air cleaner system also includes an accessory mounted to the conduit. The air entering the inlet exits through the outlet. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to a method of degumming jute fibres, in particular, relates to a method of degumming jute fibres with complex enzyme.
BACKGROUND
[0002] Bast fabrics have gained more and more popularity with people, due to better moisture absorption & breathing, low electrostatic susceptibility, and the antibacterial strength of bast fibres. For making the bast fabrics, the materials adopted can mainly be linen fibre, and ramie fibre, or the fibre combination of said fibres with other fibres, such as cotton fibres, wool fibres, chemical fibres, silk fibres after being blended spun. Linen or ramie is expensive, and this is also the reason why the bast-fabric clothing has not been applied widely. However, Jute, which is cheaper than linen and ramie, has better hygroscopicity and drapability than linen and ramie, and also has great antibiotic ability. Therefore, jute has huge potentiality and application value in clothing making industry. As the content of lignin within jute is relatively high, which is several times as much as that within linen, it is not effective to degum jute fibres and remove the lignin from jute by using the existing degumming technology. And this greatly restrains the application of jute in making clothing. <The Effect of Enzyme Treatment on Jute fibres> published in Journal of Tianjin Industrial University volume 24 of August 2005 introduces the effect of cellulose, hemicellulase, ligninase and pectin depolymerise used in processing the jute fibres, but this article only introduces the method of processing jute fibres using single one of above mentioned enzymes. Although, there are some paragraphs in which the methods of complex enzyme treatment are mentioned, it only refers to the complex enzyme obtained via mixing laccase and cellulose enzyme or mixing hemicellulase enzyme and cellulose enzyme. However, it is testified in practice that it is not effective to remove lignin from jute fibres using the degumming method published in this article. Chinese Patent publication No CN 1232691C introduces a method of degumming jute using complex enzyme. In the method, pectinase and laccase are used to produce a complex enzyme for degumming jute fibres, and the degummed jute fibres, after blended spun or interlaced with other fibres such as cotton fibres and chemical fibres, can generally meet the requirements for clothing materials. However, the effect of removing lignin from jute fibres in such prior art, is still not good enough, as the removal rate is only about 76%. The content of lignin remaining in the jute fibres is still very high. Further more the intensity and the breaking elongation ratio of the jute fibres obtained are still not good enough. Therefore, there is a need of blended spinning or interlacing jute fibres with other fibres such as cotton fibres, and chemical fibres, when making the clothing materials. However, the quality of clothing materials made through blended spinning or interlacing jute fibres with other fibres such as cotton fibres, and chemical fibres still needs to be improved.
BRIEF DESCRIPTION OF INVENTION
[0003] The present invention introduces the first method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
[0004] In the first method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
[0005] a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres ranges from 12:1 to 40:1;
[0006] b. adjusting the PH value of said complex enzyme water solution to more than 5.5, but no more than 6.5, and adjusting the temperature of said complex enzyme water solution to 35° C.-65° C., then keeping said complex enzyme water solution with such temperature value for 20-120 minutes;
[0007] c. adjusting the PH value of said complex enzyme water solution to 7.5-9.5, and adjusting the temperature of said complex enzyme water solution to 40° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 20-120 minutes;
[0008] d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
[0009] The first method, wherein said jute fibres are accumulation stored before the step d.
[0010] The first method, wherein the duration of accumulation storing said jute fibres ranges from 6 to 24 hours.
[0011] The first method, wherein the enzyme deactivation of jute fibres in the step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
[0012] The first method, wherein the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
[0013] The first method, wherein the weight proportion of said complex enzyme and jute fibres ranges from 0.5:100 to 5:100.
[0014] The first method, wherein the temperature of said hot water is above 75°; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
[0015] The first method, wherein said jute fibres is pre-processed before the step a.
[0016] The first method, wherein the pre-processing of said jute fibres is either through one of the means of water bath, acid bath, and soaking with hydrogen Peroxide, or through the combination of at least two of the three means.
[0017] The first method, wherein the temperature of water bath ranges from 30° C. to 65° C.; said acid is sulphuric acid or acetic acid.
[0018] The present invention introduces the second method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
[0019] In the second method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
[0020] a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres ranges from 12:1 to 40:1;
[0021] b. adjusting the PH value of said complex enzyme water solution to 5.0-5.5, and adjusting the temperature of said complex enzyme water solution to above 35° C., but below 55° C., then keeping said complex enzyme water solution with such temperature value for 20-120 minutes;
[0022] c. adjusting the PH value of said complex enzyme water solution to 7.5-9.5, and adjusting the temperature of said complex enzyme water solution to 40° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 20-120 minutes;
[0023] d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
[0024] The second method, wherein said jute fibres are accumulation stored before the step d.
[0025] The second method, wherein the duration for accumulation storing said jute fibres ranges from 6 to 24 hours.
[0026] The second method, wherein the enzyme deactivation of jute fibres in the step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
[0027] The second method, wherein the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
[0028] The second method, wherein the weight proportion of said complex enzyme and jute fibres ranges from 0.5:100 to 5:100.
[0029] The second method, wherein the temperature of said hot water is above 75° C.; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
[0030] The second method, wherein said jute fibres is pre-processed before the step a.
[0031] The second method, wherein pre-processing said jute fibres is either through one of the means of water bath, acid bath, and soaking with Hydrogen Peroxide, or through at least two of the three means.
[0032] The second method, wherein the temperature of water bath ranges from 30° C. to 100° C.; said acid is sulphuric acid or acetic acid.
[0033] The present invention introduces the third method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
[0034] In the third method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
[0035] a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres is equal to or larger than 12:1, but smaller than 15:1;
[0036] b. adjusting the PH value of said complex enzyme water solution to 5.0-5.5, and adjusting the temperature of said complex enzyme water solution to 55°-600°, then keeping said complex enzyme water solution with such temperature value for 25-50 minutes;
[0037] c. adjusting the PH value of said complex enzyme water solution to 7.5-8.0, and adjusting the temperature of said complex enzyme water solution to 60° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 25-50 minutes;
[0038] d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
[0039] The third method, wherein said jute fibres are accumulation stored before the step d.
[0040] The third method, wherein the duration of accumulation storing said jute fibres ranges from 6 to 24 hours.
[0041] The third method, wherein the enzyme deactivation of jute fibres in the step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
[0042] The third method, wherein the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
[0043] The third method, wherein the weight proportion of said complex enzyme and jute fibres ranges from 0.5:100 to 5:100.
[0044] The third method, wherein the temperature of said hot water is above 75°; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
[0045] The third method, wherein said jute fibres is pre-processed before the step a.
[0046] The third method, wherein the pre-processing of said jute fibres is either through one of the means of water bath, acid bath, and soaking with hydrogen Peroxide, or through the combination of at least two of the three means.
[0047] The third method, wherein the temperature of water bath ranges from 30° C. to 100° C.; said acid is sulphuric acid or acetic acid.
[0048] The present invention introduces the fourth method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
[0049] In the fourth method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
[0050] a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres is larger than 15:1, but no more than 40:1;
[0051] b. adjusting the PH value of said complex enzyme water solution to 5.0-5.5, and adjusting the temperature of said complex enzyme water solution to 55° C.-60° C., then keeping said complex enzyme water solution with such temperature value for 25-50 minutes;
[0052] c. adjusting the PH value of said complex enzyme water solution to 7.5-8.0, and adjusting the temperature of said complex enzyme water solution to 60° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 25-50 minutes;
[0053] d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
[0054] The fourth method, wherein said jute fibres are accumulation stored before step d.
[0055] The fourth method, wherein the duration for accumulation storing said jute fibres ranges from 6 to 24 hours.
[0056] The fourth method, wherein the enzyme deactivation of jute fibres in step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
[0057] The fourth method, wherein that the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
[0058] The fourth method, wherein the weight proportion of said complex enzyme and jute fibres ranges from 0.5:100 to 5:100.
[0059] The fourth method, wherein that the temperature of said hot water is above 75° C.; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
[0060] The fourth method, wherein that said jute fibres is pre-processed before the step a.
[0061] The fourth method, wherein that pre-processing said jute fibres is either through one of the means of water bath, acid bath, and soaking with Hydrogen Peroxide, or through the combination of at least two of the three means.
[0062] The fourth method, wherein that the temperature of water bath ranges from 30° C. to 100° C.; said acid is sulphuric acid or acetic acid.
[0063] The present invention introduces the fifth method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
[0064] In the fifth method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
[0065] a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres is 15:1, and the weight proportion of said complex enzyme and jute fibres is equal to or larger than 0.5:100, but smaller than 1:100;
[0066] b. adjusting the PH value of said complex enzyme water solution to 5.0-5.5, and adjusting the temperature of said complex enzyme water solution to 55°-60°, then keeping said complex enzyme water solution with such temperature value for 25-50 minutes;
[0067] c. adjusting the PH value of said complex enzyme water solution to 7.5-8.0, and adjusting the temperature of said complex enzyme water solution to 60° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 25-50 minutes;
[0068] d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
[0069] The fifth method, wherein said jute fibres are accumulation stored before the step d.
[0070] The fifth method, wherein the duration of accumulation storing said jute fibres ranges from 6 to 24 hours.
[0071] The fifth method, wherein the enzyme deactivation of jute fibres in the step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
[0072] The fifth method, wherein the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
[0073] The fifth method, wherein the temperature of said hot water is above 75°; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
[0074] The fifth method, wherein said jute fibres is pre-processed before the step a.
[0075] The fifth method, wherein the pre-processing of said jute fibres is either through one of the means of water bath, acid bath, and soaking with hydrogen Peroxide, or through the combination of at least two of the three means.
[0076] The fifth method, wherein the temperature of water bath ranges from 30° C. to 100° C.; said acid is sulphuric acid or acetic acid.
[0077] In comparison with the prior art, the present invention has several advantages as follows:
(1) It is effective to remove pectinase and laccase from jute fibres through accumulation storing the jute fibre before conducting enzyme deactivation of said jute fibres via washing the jute fibres with hot water or adjusting its PH value, wherein the removal rate of pectinase from the jute fibres reaches about 90%, even up to 96% as its highest value; the removal rate of lignin from the jute fibres reaches about 78%, even up to 86% as its highest value. The jute fibres degummed through abovementioned method will have high spinnability. (2) The process parameters that match with each other are used in treatment of degumming jute fibres with complex enzyme. Via adjusting the PH value of enzyme water solution to more than 5.5 (pectinase is in its highest activity when the PH value is within 4.5-5.0, and the activity of pectinase declines gradually along with the rise of PH value from 5.0), or choose a relatively low holding temperature (lower than 55° C.) while the jute fibres are in the PH value interval in which the jute fibres are in its high activity, select a suitable liquor ratio (laccase is in its highest activity, when the liquor ratio is 15, and its activity declines along with the rise or decline of the liquor ratio), or reducing the use of complex enzyme and adjusting the other process parameters used, so as to ensure the effectiveness of removing lignin from jute fibres, and to further ensure that the jute fibres with high intensity and good breaking elongation ratio can be obtained through the method of degumming of this invention (there can be a rise of the intensity which is more than 2 times as much as it was before, reaching 6-9 dN/tex, and a rise of the breaking elongation ratio which is 1.5 times as much as it was before, reaching about 5-8%), thereby making the length of jute fibres match the its fineness, so as to improving the spinnability; (3) Pre-processing jute fibres before being degummed can swell the jute fibres, so as to better reduce the interacting force among the single fibres, facilitate the contact between enzyme water solution and jute fibres, and remove the pectin and lignin from the jute fibres.
DETAILED DESCRIPTION OF INVENTION
Example 1
[0081] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 65° C., and the holding time is 2 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.1 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 35° C. and keeping the solution with such temperature value for 20 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating up the solution to 70° C., and keeping the solution with such temperature value for 20 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0082] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 2
[0083] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, while the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° C. and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 40 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.0 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 50° C. and keeping the solution with such temperature value for 120 minutes; after that, adjusting the PH value of the heated solution to 9.5 with sodium bicarbonate, heating up the solution to 55° C., and keeping the solution with such temperature value for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0084] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 3
[0085] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath, while the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.5 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 55° C. and keeping the solution with such temperature value for 40 minutes; after that, adjusting the PH value of the heated solution to 8.5 with sodium bicarbonate, heating up the solution to 50° C., and keeping the solution with such temperature value for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0086] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 4
[0087] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 30 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.2 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 40° C. and keeping the solution with such temperature value for 50 minutes; after that, adjusting the PH value of the heated solution to 9.0 with sodium bicarbonate, heating up the solution to 60° C., and keeping the solution with such temperature value for 90 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0088] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 5
[0089] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 60° C., and the holding time is 3 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 3:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 20 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.3 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 45° C. and keeping the solution with such temperature value for 60 minutes; after that, adjusting the PH value of the heated solution to 8.5 with sodium bicarbonate, heating up the solution to 40° C., and keeping the solution with such temperature value for 70 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 3.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0090] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 6
[0091] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 4:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 16 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.4 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 50° C. and keeping the solution with such temperature value for 70 minutes; after that, adjusting the PH value of the heated solution to 9.0 with sodium bicarbonate, heating up the solution to 45° C., and keeping the solution with such temperature value for 80 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
[0092] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 7
[0093] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.7 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 60° C. and keeping the solution with such temperature value for 80 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating up the solution to 65° C., and keeping the solution with such temperature value for 100 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0094] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 8
[0095] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.8 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 65° C. and keeping the solution with such temperature value for 90 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution with such temperature value for 110 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0096] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 9
[0097] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 16 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.6 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 45° C. and keeping the solution with such temperature value for 100 minutes; after that, adjusting the PH value of the heated solution to 9.3 with sodium bicarbonate, heating the solution to 55° C., and keeping the solution with such temperature value for 120 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.5 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0098] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 10
[0099] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 65° C., and the holding time is 2 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.3 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 35° C. and keeping the solution with such temperature value for 20 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution with such temperature value for 20 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0100] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 11
[0101] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, while the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 40 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 54° C. and keeping the solution with such temperature value for 120 minutes; after that, adjusting the PH value of the heated solution to 9.5 with sodium bicarbonate, heating the solution to 55° C., and keeping the solution with such temperature value for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0102] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 12
[0103] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through acid bath, while the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 20 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 45° C. and keeping the solution with such temperature value for 40 minutes; after that, adjusting the PH value of the heated solution to 8.5 with sodium bicarbonate, heating the solution to 50° C., and keeping the solution with such temperature value for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0104] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 13
[0105] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 30 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 50° C. and keeping the solution with such temperature value for 50 minutes; after that, adjusting the PH value of the heated solution to 9.0 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution with such temperature value for 90 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0106] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 14
[0107] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 100°, and the holding time is half an hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 3:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 52° C. and keeping the solution with such temperature value for 60 minutes; after that, adjusting the PH value of the heated solution to 8.5 with sodium bicarbonate, heating the solution to 45° C., and keeping the solution with such temperature value for 70 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
[0108] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 15
[0109] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 4:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 53° C. and keeping the solution with such temperature value for 70 minutes; after that, adjusting the PH value of the heated solution to 9.0 with sodium bicarbonate, heating the solution to 40° C., and keeping the solution with such temperature value for 80 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 3.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
[0110] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 16
[0111] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.1 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 50° C. and keeping the solution with such temperature value for 80 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution with such temperature value for 100 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0112] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 17
[0113] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 35° C. and keeping the solution with such temperature value for 90 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution with such temperature value for 110 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0114] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 18
[0115] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 16 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 52° C. and keeping the solution with such temperature value for 100 minutes; after that, adjusting the PH value of the heated solution to 9.3 with sodium bicarbonate, heating the solution to 55° C., and keeping the solution with such temperature value for 120 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.5 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0116] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 19
[0117] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram, and pre-processing the jute fibres via water bath, wherein the temperature of the water is 65° C., and the holding time is 2 hour; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution with such temperature value for 25 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution with such temperature value for 25 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0118] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 20
[0119] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, while the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution with such temperature value for 50 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution with such temperature value for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0120] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 21
[0121] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through acid bath, while the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 40 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0122] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 22
[0123] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.3 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0124] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 23
[0125] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 100°, and the holding time is half an hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 3:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 7.7 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
[0126] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 24
[0127] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 4:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 45 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 35 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.5 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
[0128] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 25
[0129] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.2 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 57° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the temperature of which is 3.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0130] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 26
[0131] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 35 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0132] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 27
[0133] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 56° C. and keeping the solution at such temperature for 30 minutes; after that, adjusting the PH value of the heated solution to 7.6 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
[0134] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 28
[0135] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 65°, and the holding time is 2 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 16 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 25 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 25 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
[0136] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 29
[0137] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, wherein the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 40 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1. Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 30
[0138] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through acid bath, wherein the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 35 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 40 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0139] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 31
[0140] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 30 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.3 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0141] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 32
[0142] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath at the temperature of 100°, and the holding time is half an hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 3:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 25 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 30 minutes; after that, adjusting the PH value of the heated solution to 7.7 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0143] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 33
[0144] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 4:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 20 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 45 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0145] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 34
[0146] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 35 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.2 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 57° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 35 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0147] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 35
[0148] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 17 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0149] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 36
[0150] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 18 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 56° C. and keeping the solution at such temperature for 25 minutes; after that, adjusting the PH value of the heated solution to 7.6 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.0 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0151] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 37
[0152] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 65 °, and the holding time is 2 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.8:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 25 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 25 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
[0153] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 38
[0154] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, wherein the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 0.9:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1. Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 39
[0155] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath, wherein the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 0.6:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 40 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0156] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 40
[0157] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 0.6:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.3 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0158] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 41
[0159] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath at the temperature of 100°, and the holding time is half an hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 30 minutes; after that, adjusting the PH value of the heated solution to 7.7 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 3.0; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0160] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 42
[0161] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 0.6:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 45 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0162] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 43
[0163] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 0.9:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.2 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 57° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 35 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0164] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 44
[0165] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 0.8:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0166] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
Example 45
[0167] An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 0.7:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 56° C. and keeping the solution at such temperature for 25 minutes; after that, adjusting the PH value of the heated solution to 7.6 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.5 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
[0168] Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
[0169] The pectinase (Bioprep) and the laccase (Denilite) mentioned in above examples are produced by the a Danish company called Novozymes. Table 1 illustrates the removal rates of pectinase and lignin from jute fibres of the different examples.
[0170] While this invention has been described as having several preferred embodiments, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from this present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
[0000]
TABLE 1
Examples
1
2
3
4
5
6
7
8
9
Removal rate of pectinase
86%
96%
90%
92%
95%
96%
92%
91%
89%
Removal rate of lignin
79%
79%
80%
80%
84%
86%
82%
81%
78%
Examples
10
11
12
13
14
15
16
17
18
Removal rate of pectinase
86%
96%
90%
91%
95%
96%
91%
91%
89%
Removal rate of lignin
79%
80%
80%
82%
84%
86%
82%
81%
78%
Examples
19
20
21
22
23
24
25
26
27
Removal rate of pectinase
88%
94%
90%
91%
95%
96%
91%
90%
89%
Removal rate of lignin
79%
80%
79%
80%
84%
86%
82%
81%
78%
Examples
28
29
30
31
32
33
34
35
36
Removal rate of pectinase
88%
96%
88%
91%
95%
96%
91%
90%
89%
Removal rate of lignin
79%
80%
79%
80%
84%
86%
82%
81%
78%
Examples
37
38
39
40
41
42
43
44
45
Removal rate of pectinase
87%
91%
89%
91%
94%
92%
90%
91%
88%
Removal rate of lignin
82%
78%
79%
79%
82%
85%
81%
80%
81% | A method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of: a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres ranges from 12:1 to 40:1; b. adjusting the PH value of said complex enzyme water solution to more than 5.0, but no more than 6.5, and adjusting the temperature of said complex enzyme water solution to 35° C.-65° C., then keeping said complex enzyme water solution with such temperature value for 20-120 minutes; c. adjusting the PH value of said complex enzyme water solution to 7.5-9.5, and adjusting the temperature of said complex enzyme water solution to 40° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 20-120 minutes; d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a Continuation in Part of pending U.S. patent application Ser. No. 12/824,857 filed on Jun. 28, 2010 entitled “Heat Exchange Module for Cogeneration Systems and Related Method of Use,” which in turn is a Continuation in Part of pending U.S. patent application Ser. No. 12/760,256 filed on Apr. 14, 2010 entitled “High Efficiency Cogeneration System and Related Method of Use,” the contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
This invention is directed toward an integrated backup electrical generator and heating system designed allow continual use of the heating system in the absence of an external source of electricity, the system sharing fuel and electrical inputs and sharing exhaust output so to facilitate ease of installation.
BACKGROUND OF THE INVENTION
Cogeneration represents a relatively new concept in the field of generating electricity. Traditionally, electricity has been created by centralized facilities—typically through burning a fossil fuel like coal—which is then transported through an electrical grid to individual residential and commercial facilities.
Within the past several years, cogeneration systems have been developed to essentially reduce both need and reliance on these electrical grids. More specifically, cogeneration systems typically employ a heat engine (typically an internal combustion engine) or a power station located in proximity to the residential or commercial facilities it serves so to simultaneously generate both electricity and useful heat. Most cogeneration systems utilize a centralized reservoir of fossil fuel to create electricity, heat running water and air, and in some instances even provide energy back into the grid for credit.
Recently, there have been several forms of cogeneration systems developed for use in residential homes and smaller commercial facilities. These systems have been dubbed “mini-cogeneration” systems due to their modest size and performance. Another common name associated with these systems is a distributed energy resource (“DER”) system.
Regardless of the moniker, these systems produce usually less than 5 kW of power. Instead of burning fuel to merely heat space or water, some of the energy is converted to electricity in addition to heat. This electricity can be used within the home or business, and if permitted by municipal grid management entities may be sold back to the municipal electricity grid. A recent study by the Claverton Energy Research Group found that such a cogeneration system offered the most cost effective means of reducing CO 2 emissions—even compared to use of photovoltaic devices for the production of energy.
Apart from the energy conservation associated with mini-cogeneration systems, the technology also offers additional logistical benefits. Such cogeneration systems often offer more reliable energy solutions to residential dwellings in rural areas wherein it is difficult access the electrical grid. Alternatively, these systems offer more stable energy supplies in areas often affected by natural disasters such as hurricanes, tornadoes and earthquakes—where the downing of power lines will often lead to large periods with a lack of energy.
While there exists multiple benefits for micro-cogeneration systems, they currently possess several drawbacks. First, current cogeneration systems still create a certain degree of byproduct from the burning of fossil fuels that must be released into the atmosphere. This creates a secondary safety issue as there is a risk that unless this toxic byproduct is sufficiently vented that it could cause a build up of carbon monoxide within the residence. Second, most of the heat engines used in micro-cogeneration systems are not highly efficient, resulting in the waste of expensive fossil fuels. Finally, many cogeneration systems fail to adequately harvest all much of the heat byproduct created from the heat engines, which could be used to heat air and water to be used throughout a facility.
Under normal conditions, residential heating systems require the use of electricity. Even when the main source of combustion is a fossil fuel, such as oil, natural gas, or propane there is almost always a need for electricity to at least power an air blower motor, power water pumps in a boiler unit, or to provide power to a transformer and igniter in a steam unit.
In the case of a power failure during the winter months, homes and homeowners can potentially be in a considerable amount of danger. Water pipes can freeze in only a few hours in the absence of an internal heat source. Additionally, the temperature within the home can rapidly fall to dangerously low levels, placing homeowners in peril.
Portable gasoline generators—normally for the purpose of providing power to lights and appliances during a power outage—are not typically equipped or installed to provide power to heat-providing sources.
Additionally, in warmer months, tropical storms, lightning, power blackouts due to overloaded power grids, and other phenomenon cause residences to lose electrical power. The loss of television, fan, lights, refrigerators, and other appliances is an inconvenience, if not dangerous. During widespread losses in electricity, pumping gasoline for use in a generator is difficult for most gas pumps rely on electric power to operate.
Most natural gas sources operate during loss of electrical power. Installing a natural gas or propane automatic generator, which is wired to a home's breaker or fuse panel, could prevent all the above mentioned problems. Such installations however require extremely expensive equipment, the installation of gas pipes, new electrical connections, and in most applications are extremely expensive upgrades.
Air-cooled fossil fuel generators produce a substantial amount of heat and exhaust under normal operation, yet are designed to operate outdoors where there is sufficient air available for cooling and exhaust discharge. Attempting to operate a generator within a confined environment is met with a significant amount of mechanical challenges, including cooling and discharging heat and exhaust gasses in a safe manner.
Accordingly, there is a need in the field for a highly efficient electricity generation system wherein an indoor generator is easily and cost effectively integrated with an existing furnace or boiler to provide seamless backup power to a facility and provide a means for a fuel-powered heating system to operate. Such a system should comprise a scheme for extracting generator exhaust gasses in a safe and efficient manner that is additionally cost effective to implement. Finally, such improved system should preferably be compact, self-contained and easy to use.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an integrated electrical generator and heating system comprising a heating apparatus for the purpose of providing heat to an interior space that comprises a fuel burner that produces heat, a heat exchanger that is heated by the burner, a draft inducer to promote an influx of combustion air and exhausting of exhaust gas created by the burner, and a flue in communication with the draft inducer. The flue defines the path for the heating apparatus exhaust gas to escape from the system. The flue is made from a material chosen from the group comprising one or more of the following materials: polyvinyl chloride, metal, vitreous enamel, transite, and other materials known in the art. The heater fuel input line is in communication with the burner to provide fuel to the burner. The heating apparatus is at least one of a furnace, boiler, and electric element heater, and provides heat through intermediary fluid movement, the fluids chosen from the group consisting of air, steam, and water.
The integrated electrical generator and heating system also comprises a fuel-powered electrical generator including an electrical input, a first electrical output, a generator fuel input line, an air intake conduit, and an exhaust conduit. The generator accepts electrical service from an electrical power grid through the electrical input. The generator delivers electricity to the heating apparatus through the first electrical output. The generator accepts the air required for combustion through the intake conduit, and exhausts combustion exhaust gases through the exhaust conduit, wherein the exhaust conduit of the generator communicates with the flue of the heating apparatus.
The generator utilizes a fuel to generate electricity chosen from the group comprising natural gas, liquefied petroleum gas, fuel oil, coal, and wood. The generator generates at least one of 120 VAC single-phase power, 240 VAC single-phase power, 240 VAC three-phase power, and 480 VAC three-phase power.
The integrated electrical generator and heating system additionally comprises at least one normally closed relay that communicates electrical service from the power grid to the first electrical output when the generator is powered off. The relay communicates electricity generated by the generator to the first electrical output when the generator is powered on. An electrical exhaust gas relay is activated by the generator when the generator is generating power and signals the exhaust gas relay to signal the draft inducer to activate so that the draft inducer can generate a vacuum to evacuate at least one of generator exhaust gas and heating apparatus exhaust gas from the system.
Additionally, a second electrical output communicates with at least one electrical power receptacle, and at least one normally closed relay communicates electrical service from the power grid to the second electrical output when the generator is powered off. The relay communicates electricity generated by the generator to the second electrical output when the generator is powered on. The exhaust conduit of the generator communicates with the flue of the heating apparatus using a Y-pipe.
A housing encases the generator that has an emergency leak conduit in communication with the exhaust conduit of the generator and at least one intake port on the housing. Also at least one fan is proximate the leak conduit port, the fan being activated when the generator is powered on to create a negative pressure within the housing causing air external to the housing to enter into the housing through the intake port.
A pressure switch communicates with the heating apparatus proximate the flue and also communicates with the generator, wherein the pressure switch detects a negative pressure induced by the draft inducer and disables the generator when the draft inducer is not functional.
The fuel to power the heating apparatus is of the same type of fuel to power the generator, and the heater fuel input line communicates with the generator fuel input line and both the heating apparatus and generator share a common source of fuel.
A heat exchange module for employing usable heat created by a cogeneration system coupled to a generator is also contemplated in this disclosure. This cogeneration system is coupled to a generator and comprises a heating apparatus for the purpose of providing heat to an interior space. The heating apparatus comprises a fuel burner that produces heat, a heat exchanger that is heated by the burner, a draft inducer to promote an influx of combustion air and exhausting of exhaust gas created by the burner, and a flue in communication with the draft inducer. The flue is a path for the heating apparatus exhaust gas to escape from the system, and a heater fuel input line in communication with the burner to provide fuel to the burner.
Additionally, this embodiment of the invention comprises a fuel-powered electrical generator including an electrical input, a first electrical output, a generator fuel input line, an air intake conduit, and an exhaust conduit. The generator accepts electrical service from an electrical power grid through the electrical input, and the generator delivers electricity to the heating apparatus through the first electrical output. The generator accepts air required for combustion through the intake conduit and exhausts combustion exhaust gas through the exhaust conduit. At least one normally closed relay communicates electrical service from the power grid to the first electrical output when the generator is powered off, and the relay communicates electricity generated by the generator to the first electrical output when the generator is powered on. An electrical exhaust gas relay is activated by the generator when the generator is generating power, and signals the draft inducer to activate. The draft inducer generates a vacuum that evacuates at least one of generator exhaust gas and heating apparatus exhaust gas from the system. A second heat exchanger having a collection chamber and at least one heat exchange conduit captures the generator's exhaust gas for the purpose of heating at least one heat exchange conduit. The heat exchange conduit contains water that is heated by the heat exchange conduit. The heated water in the heat exchange conduit is used as water for at least one of a water heater and a radiant heating system. It should be noted that all of the embodiments of the integrated electrical generator and heating system described above are applicable as embodiments of the heat exchange module for employing usable heat created by a cogeneration system coupled to a generator.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is made to the following detailed description, taken in connection with the accompanying drawings illustrating various embodiments of the present invention, in which:
FIG. 1 is a schematic illustrating the overall positioning of the cogeneration system in light of the electricity grid;
FIG. 2 is a diagram illustrating placement of the cogeneration system and various connections with the existing furnace, air-conditioning and air handlers;
FIG. 3 illustrates the primary components of the cogeneration system including the catalytic converter and cooling manifolds;
FIG. 4 is a schematic illustrating the various components of the control system, which includes a battery;
FIG. 5 is a schematic that illustrates the components of the first cooling manifold;
FIG. 6 illustrates the components of the heat exchange module;
FIG. 7 is a schematic illustrating the module controller;
FIG. 8 is a schematic illustrating the integrated electrical generator and heating system; and
FIG. 9 is a schematic illustrating a heat exchange module for employing usable heat created by a cogeneration system coupled to a generator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternate embodiments.
Positioning and Location of Cogeneration System
FIG. 1 and FIG. 2 both illustrate, by way of example, one positioning and location of the preferred cogeneration system 500 . FIG. 1 provides a general illustration of a conventional centralized power generation system. Here, a central power plant 100 generates electricity for disbursement to a plurality of various residential and commercial facilities 300 throughout a distinct geographic area. Such central power plant 100 can create electricity through an energy source 430 , such as conventional burning of fossil fuels (typically coal) through nuclear energy or harnessing geothermal energy.
Positioned between the central power plant 100 and the residential or commercial facility 300 is the electric grid 200 . This electric grid 200 consists of various transformers, power stations and power lines that transport electricity from the central power plant 100 . This electricity is then supplied to residential or commercial facilities 300 for use.
When a residential or commercial facility employs the invention, it must also include various components to properly service the overall apparatus. This includes a fuel source 400 that supplies a sufficient amount and quantity of energy to the cogeneration system 500 . Such fuel source 400 may include, but is certainly not limited to, a reservoir 410 of fossil fuels, such as petroleum, oil, propane, butane, ethanol, natural gas, liquid natural gas (LNG) or fuel oil. Alternatively, the fuel source 400 may alternatively be a fuel line 420 such as a natural gas or propane line supplied by a municipality. Regardless, either fuel source 400 must supply sufficient energy to power the cogeneration system 500 —which in turn can create electricity and usable heat for the furnace 600 and other appliances.
FIG. 1 also illustrates how the cogeneration system 500 can supply energy back to the electricity grid 200 for credits. This occurs when the cogeneration system 500 supplies a greater level of energy than required by the facility 300 . While FIG. 1 shows the placement of the cogeneration system in light of the electric grid 200 , FIG. 2 shows the interconnectivity within the residential facility 300 itself. As illustrated, an energy source 430 stored within a reservoir 410 (or fed by a fuel line 420 ) is supplied to the cogeneration system 500 . Spending of this energy source 430 within the cogeneration system 500 creates two forms of energy: electricity 601 and usable heat 602 . The electricity 601 can provide energy to the residential facility 300 , as well as power both the furnace 610 and the air-conditioning unit 620 . Alternatively, the furnace 610 can be supplied energy directly from the reservoir 410 .
In addition, usable heat 602 created by the cogeneration system 500 can be used to heat air from a return air handler 630 prior to being introduced into the furnace 610 for heating. By doing so, the system essentially pre-heats the incoming cooler air prior to being warmed by the furnace 610 , which in turn requires less energy (and results in less strain on the furnace 610 ). This is one of many forms of energy conservation contemplated by the invention.
Once heated air leaves the furnace 610 , it is positioned within a supply air handler 640 to be circulated throughout the residential facility 300 . Alternatively, when cooler air is desired, the convention contemplates having the air conditioning unit 620 supply cooler air to the supply air handler 640 . As such, the apparatus taught by the invention requires interplay and interconnectivity between the cogeneration system 500 , the furnace 610 , the air conditioning unit 620 and both air handlers 630 and 640 to ensure efficient cooling and heating of air circulated throughout the home.
The Cogeneration System
FIG. 3 illustrates, by way of example, the components that make up the cogeneration system 500 . As shown, the primary components of the apparatus include a reservoir 410 capable of housing an energy source 430 (which can be a fossil fuel), a regulator system 504 , a modified combustion engine 520 (hereinafter referred to simply as a “modified engine”), a catalytic converter 530 , and two cooling manifolds 540 and 550 which help treat the various hot gasses 603 which form as byproduct from the modified engine 520 . Other additional or substitute components will be recognized and understood by those of ordinary skill in the art after having the benefit of the foregoing disclosure.
As illustrated in FIGS. 2 and 3 , the first component of the cogeneration system 500 is the fuel source 400 , which can be a reservoir 410 (or alternatively a fuel line 420 ). The reservoir 410 is of a size and dimension to provide a sufficient amount and quantity of an energy source 430 to fuel the cogeneration system 500 for a defined period of time preferably thirty days. Moreover, the reservoir 410 is designed to maintain a variety of fossil fuels including petroleum, natural gas, propane, methane, ethanol, biofuel, fuel oil or any similar and related fuel known and used to create energy via combustion. The reservoir 410 is typically housed outside of the residential facility 300 for safety and aesthetics.
Regardless of the type, the energy source 430 is drawn out of the reservoir 410 and treated for injection into the modified engine 520 through a regulator system 504 . This regulator system 504 ensures that the energy source 430 is fed to the modified engine 520 at a specific pressure and flow rate—regardless of the outside temperature, pressure or weather conditions. Because the cogeneration system 500 will be employed in a variety of conditions from low lying areas to the mountains, in tropical climates to arctic regions, the regulator system 504 must be self-regulating, robust and capable of handling large swings in weather conditions.
As illustrated in FIG. 3 , the regulator system 504 includes four primary components: two fuel valves 505 and 506 , a fuel pump 507 and a pressure regulator 510 . Other related and additional components will be recognized and understood by those of ordinary skill in the art upon review of the foregoing. The energy source 430 is drawn from the reservoir through the fuel pump 507 for transport into the modified engine 520 .
Positioned between the reservoir 410 and fuel pump 507 are a plurality of fuel valves 505 and 506 . More specifically, there is a first fuel valve 505 and second fuel valve 506 —which function to help regulate the flow and velocity of the energy source 430 . The underlying purpose of both fuel valves 505 and 506 is to ensure redundancy in case one valve malfunctions, becomes clogged or becomes inoperable.
A pressure regulator 510 is positioned after the fuel pump 507 to ensure the proper pressure of the energy source 430 prior to entry into the modified engine 520 . The energy source 430 travels throughout both fuel valves 505 and 506 , the fuel pump 507 and the pressure regulator 510 through a sixteen gauge shell, two inch fire rated insulation acoustic lined conduit 508 which includes a sixteen gauge interior body with powder coating.
Once the pressure of the power source 430 stabilizes through use of the pressure regulator 510 , the fuel then enters the modified engine 520 . As illustrated with reference to FIG. 6 , the modified engine 520 can act as a regular combustion engine to burn the power source 430 , which in turn drives one or more pistons 521 to turn a shaft 522 that rotates an alternator 523 to create electricity.
With reference to FIG. 6 , byproducts of the modified engine 520 include usable heat 602 , as well as hot gases 603 . These hot gases 603 include, but are not necessarily limited to, HC, CO, CO 2 , NO x , SO x and trace particulates (C9PM0). When leaving the modified engine 520 , these hot gasses 603 have a pressure between 80 to 100 psi and a temperature between 800 to 1200 degrees Fahrenheit. These high pressure and temperature hot gasses 603 are then transported into the catalytic converter 530 for treatment.
The modified engine 520 illustrated in both FIG. 3 and FIG. 6 ensures delivery of usable electricity to not only the residential facility 300 but also the electricity grid 200 . As shown in FIG. 3 , this is achieved through combination of a vibration mount 524 and a harmonic distort alternator 525 —both of which are attached to the modified engine 520 . The vibration mount 524 is positioned below the modified engine 520 through a plurality of stabilizing legs.
The function and purpose of the vibration mount 524 is to ensure that the modified engine 520 is not only secure but also that it does not create a distinct frequency—through the turning of the various pistons 521 , shaft 522 , and alternator 523 (shown in greater detail in FIG. 6 )—to risk degrading the quality of usable electricity flowing from the cogeneration system 500 . This is because the electricity grid 200 requires a very specific and regulated electricity supply.
The uniform feed of electricity to both the facility 300 and electricity grid 200 is further aided by the harmonic distort alternator 525 . As shown in FIG. 3 , the harmonic distort alternator 525 is positioned directly on the modified engine 520 and prior to both the residential facility 300 and electricity grid 200 . This harmonic distort alternator 525 regulates the amplification and voltage of electricity. In addition, a subsequent electricity filter 527 can be used to provide a final regulation of the electricity. A more detailed description of this system is offered in FIG. 6 described in greater detail below.
FIG. 3 also illustrates the placement, positioning and utility of the catalytic converter 530 . The catalytic converter 530 functions to help ensure the proper treatment of the hot gases 603 created by combustion within the modified engine 520 —in order to reduce levels of toxic byproducts being released into the atmosphere.
Overall efficiency of the catalytic converter 530 is based upon two primary chemical properties: (a) selection of the correct platinum based catalytic material, and (b) regulation of the proper temperature and pressure of the hot gases 603 when entering the catalytic converter 530 . More specifically, the invention contemplates feeding the various hot gases 603 into the catalytic converter 530 at between 800 to 1000 degrees Fahrenheit and at a pressure ranging between 80 to 100 psi. The preferred catalytic material is a combination of palladium and platinum. More specifically, the preferred catalyst contemplated by the invention includes 5-30% palladium and 70-95% platinum by weight. However, other percentages are contemplated by the invention. Based upon the invention, the catalytic converter 530 is 99.99% efficient in converting the various hot gases 603 into non-toxic treated byproduct 604 .
Hot gases 603 treated by the catalytic converter 530 are then transported into one or more cooling manifolds 540 and 550 . As shown in both FIGS. 3 and 5 , each cooling manifold 540 includes a series of heat exchangers tasked with cooling the various hot gases 603 to essentially ambient temperature. Within each manifold, cooling water 543 is supplied from an external water supply line 542 (usually the same as used by the facility 300 ) in a first conduit 544 . This first conduit 544 encapsulates a second conduit 545 in which hot gases 603 flow through the manifold 540 . Based upon the temperature gradient created between both conduits 544 and 545 , the hot gases 603 are cooled while the cooling water 543 is warmed.
As shown in greater detail in FIG. 3 , once the hot gases 603 are cooled, they leave the cooling manifold 530 and enter into a liquid separator 560 . At this point, the hot gases 630 are at or near ambient temperature. Moreover, much of the hot gases 603 have been filtered for either removal into the atmosphere or recycled for re-treatment in the catalytic converter 520 . Such hot gases 603 —which are mostly light by-products—are filtered by the liquid separator 560 . The liquid separator 560 creates a sufficient vacuum within the remaining hot gases 603 to remove these light-weight byproducts 604 for eventual off-gassing.
As shown in FIG. 3 , it is preferred that there be at least two cooling manifolds 540 and 550 to separate and bring the hot gases 603 to ambient temperature: a first cooling manifold 540 and second cooling manifold 550 . As shown, the second cooling manifold 550 feeds into a second liquid separator 565 —which functions the same as the first liquid separator 560 . There are two contemplated designs for the invention. First, the first cooling manifold 540 can feed into a second cooling manifold 550 to create an “in series” design. Alternatively, both cooling manifolds 540 and 540 can work in parallel—such that they both receive hot gases 603 from the catalytic converter 530 to be cooled and separated by both liquid separators 560 and 565 also in parallel.
Materials drawn from both liquid separators 560 and 565 are then placed in a separator loop 570 . This loop 570 functions to circulate the various cooled by-products and allow off gassing through a vent 590 . The vent 590 may be aided by a fan 580 .
Control and Storage of Generated Electricity
FIG. 4 illustrates, by way of example, one manner in which electricity created by the cogeneration system 500 is controlled, stored and sold back to the electricity grid 200 . As shown and described in greater detail above, electricity is generated in the modified engine 520 through combustion of an energy source 430 . This electricity is sent to the harmonic distort alternator 525 to ensure the current matches the consistency of electricity found in the electricity grid 200 .
In the embodiment shown in FIG. 4 , electricity leaves the distort alternator 525 and flows into the control panel 650 . The control panel 650 includes several components to filter and regulate the incoming electricity. First, the control panel 650 includes a regulator 651 that helps purify the current of the electricity coming from the modified engine 520 . Second, the control panel 650 includes a filter 652 that normalizes any noise or distortion remaining within the current.
Filtered and regulated electricity can then be directed to two receptacles: either a battery 660 (which alternatively can be an inverter) for later use or directly to the facility 300 . As shown in FIG. 4 , the cogeneration system 500 can include a battery 660 capable of storing electricity for later use by the facility 300 . Attached to the battery is an automatic transfer switch 670 . The switch 670 functions to gauge energy needs of the residential facility 300 . If the home needs or anticipates greater energy use, the switch 670 ensures that electricity is drawn from the battery for use by the facility 300 .
As further shown in FIG. 4 , electricity can flow either from the control panel 650 or the battery 660 into the breaker panel 680 of the facility 300 . The breaker panel 680 allows various appliances throughout the residential facility 300 to be supplied with electricity from the cogeneration system 500 . Excess energy not needed by the breaker panel 680 to supply the energy needs of the facility 300 is then transported to the electricity grid 200 . Prior to transport to the electricity grid 200 , it is preferable that current flows through a meter 690 to measure the credits appropriate for the residential facility 300 to receive from the public utility.
The Cooling Manifolds
FIG. 5 illustrates, by way of example, the first cooling manifold 540 . The preferred first cooling manifold 540 functions essentially as a heat exchanger to necessarily cool the various hot gases 603 , generated from the modified engine 520 , which have been treated by the catalytic converter 530 . Based upon treatment, the combination of platinum and palladium within the catalytic converter 530 , resulting in 99.99% conversion of these various hot gases 603 into inert and safe treated byproduct 604 . The remaining non-treated hot gases 603 and treated byproduct 604 are then separated and filtered through the first cooling manifold 540 (in combination with the first liquid separator 560 ) through a temperature gradient effectuated by interaction with cooling water.
As illustrated in FIG. 5 , the first cooling manifold 540 includes, but is not necessarily limited to, a collection chamber 541 , a water supply line 542 , cooling water 543 , a first conduit 544 , a second conduit 545 , a third conduit 546 , a plurality of connecting elbows 552 and a condensate drain 553 . While FIG. 5 denotes six portions of the first conduit 544 in parallel relation to one another, the invention contemplates up to twenty-one such portions to ensure effective treatment and separation of the various hot gasses 603 and treated byproduct 604 . Moreover, while FIG. 5 shows the various parts and functionality of the first cooling manifold 540 , it is understood that these are the same primary components also found in the second cooling manifold 550 .
As further shown in FIG. 5 , hot gases 603 and treated byproduct 604 flow from the catalytic converter 530 into the collection chamber 541 of the first cooling manifold 540 . This collection chamber 541 allows both hot gases 603 and treated byproduct 604 to be positioned for cooling via the heat exchanger 547 created within the first cooling manifold 540 .
Positioned parallel to the collection chamber 541 is a heat exchanger 547 that consists of a plurality of conduits 544 — 546 in which the actual heat exchange takes place. The first conduit 544 is larger in both length and diameter in comparison to the second conduit 545 and the third conduit 546 . Moreover, it is preferable that the first conduit 544 is of a sufficient size and dimension to encapsulate and fit over both the second conduit 545 and the third conduit 546 .
The first conduit 544 includes a water intake 548 and a corresponding water discharge 549 . Connected to the first conduit 544 through the water intake 548 is a water supply line 542 . The water supply line 542 provides cooling water 543 to the first cooling manifold 540 —typically from the municipal water supply available in the facility 300 —which is at ambient temperature. However, the cooling water 543 can alternatively be any liquid capable of heat exchange. Thus, this water supply line 542 helps fill the first conduit 544 with cooling water 543 to help in the heat exchange process.
Positioned within the first conduit 544 of the heat exchanger 547 is the second conduit 545 . Both hot gases 603 and treated byproduct 604 enter the second conduit 545 through the chamber collection 541 . Heat exchange occurs when the warmer second conduit 545 is cooled by the surrounding cooling water 543 positioned within the first conduit 544 . This heat exchange can cause portions of the gaseous treated byproduct 604 to liquefy—causing separation with the hot gases 603 .
Warmed cooling water 543 is then removed and repositioned through an outlet 549 in the first conduit 544 , which in turn feeds a second heat exchanger 547 positioned directly below the first heat exchanger 547 . This removed warmed cooling water 543 then flows into the inlet 548 of the second heat exchanger to fill another first conduit 544 . This process of removing, repositioning and re-feeding cooling water 543 can continue throughout as many heat exchangers 547 as necessary to effectuate appropriate separation.
After use within the various heat exchangers 547 positioned within the cooling manifold 540 , the cooling water 543 is then removed and emptied into a heat exchange module 800 (described in greater detail below). Upon leaving the cooling manifold 540 , the cooling water 543 is typically well above ambient temperature and is typically above 140 degrees Fahrenheit. Such cooling water 543 constitutes useful heat that can be used for a variety of various applications including, but certainly not limited to, assisting in heating water for use and consumption throughout the home or commercial facility.
Positioned within the second conduit 545 of each heat exchanger 547 is a third conduit 546 . The third conduit 546 functions primarily to collect the various cooled and now liquefied treated byproduct 604 . Positioned on the bottom of each third conduit 546 are perforations sufficient to collect liquid by product 604 cooled within the second conduit 545 . Positioned at the distal end of the third conduit 546 is a connecting elbow 552 . Positioned outside of both the first conduit 544 and second conduit 545 , the connecting elbow 552 further effectuates liquefaction and condensing of the byproduct 604 (via air cooling) and then transports this liquid to the first liquid separator 560 .
As further shown in FIG. 5 , the distal end of each third conduit 546 contains a connecting elbow 552 , which horizontally feeds into a centralized condensate drain 553 . This condensate drain 553 functions to house and maintain all of the liquid treated byproduct 604 from the various third conduits 546 of each heat exchanger 547 . This resulting byproduct 604 can then be removed from the cogeneration system 500 through a disposal—which can be part of residential facilities 300 regular sewer or septic lines (or alternatively can be vented).
Likewise, cooled hot gases 603 (which remain in the second conduit 544 ) are then transported to the next heat exchanger for additional cooling. This continues until the hot gases 603 reach near ambient temperature. This also helps ensure any treated byproduct 604 is properly separated for placement in the condensate drain 553 . Any remaining hot gases 603 may be recycled back from the first cooling manifold 540 into the catalytic converter 530 . Alternatively, these hot gases 603 may be additionally treated and cooled in a second cooling manifold 550 .
Preferably, the liquid treated byproduct 604 is passed through the first liquid separator 560 shown in both FIG. 3 and FIG. 5 . This liquid separator 560 includes a partial vacuum that can draw any additional undesirable light gases out of the treated byproduct 604 . These gases 605 can either be retreated in the catalytic converter 540 via a recycle stream or alternatively vented from the cogeneration system 500 to a passageway outside of the residential facility 300 . Once these gases 605 are extracted through the partial vacuum, the remaining treated byproduct 604 can be drained through the residential facility's 300 septic or sewer system.
The Heat Exchange Module
The invention is further directed to a heat exchange module 800 (hereinafter the “module 800 ”). FIG. 6 provides, by way of example, one embodiment of the module 800 . As shown and illustrated, the module 800 includes six primary components (a) a first inlet 810 for injecting cooling water 543 (or any other similar cooling fluid), (b) a second inlet 820 for introducing the cold water supply 825 (typically from a municipal source), (c) contact coils 830 which function to effectuate heat exchange, (d) the insulated housing 840 which positions and maintains the contact coils 830 , (e) the first outlet 850 for removing the cooling fluid 543 , and (f) the second outlet 860 for removing the treated water supply 825 .
As illustrated in FIG. 6 , the central component of the module 800 is the insulated housing 840 . The insulated housing 840 is hard, resilient, non-corrosive and watertight. Moreover, the insulated housing 840 includes an inner shell 841 , which has a top side 842 , a corresponding bottom side 843 , and a cylindrical middle portion 844 . The cylindrical middle portion 844 is located between both sides 842 and 843 and preferably includes multi-layers of insulate 845 .
The insulate 845 includes a first insulate layer 846 , a second insulate layer 847 and a third insulate layer 848 . These three layers of insulate 845 are positioned outside the inner shell 841 which helps effectuate heat transfer, as well as maintain an above ambient temperature environment within the insulated housing 840 . Moreover, the inner shell 841 is made of a lightweight and durable material such as a ceramic, composite, glass or metal. More specifically, the inner shell 841 can be of uni-body construction and formed from aluminum.
Positioned on the top side 842 of the inner shell 841 is the first inlet 810 . The first inlet 810 functions to inject cooling water 543 from either cooling manifold ( 540 or 550 ) into the module 800 . The first inlet 810 connects to a vertical injector 811 which introduces the now warmed cooling water 543 into the bottom of the inner shell 841 . Upon residing within the inner shell 841 for a pre-specified period of time, the cooling water 543 can be removed from the insulated housing 840 through the first outlet 850 . The cooling water 543 —now cooled through contact with the cold water supply 825 —can return to either cooling manifold ( 540 or 550 ) to help further effectuate heat exchange with the hot gases 603 .
As further shown and illustrated in FIG. 6 , the top end 841 of the insulated housing 840 also includes the second inlet 820 . The second inlet 820 functions to introduce the cold water supply 825 into the module 800 . This cold water supply 825 is typically from a municipal authority (such as a city water line) or well. More specifically, the second inlet 820 flows into a plurality of contact coils 830 positioned within the inner shell 841 . While the contact coils 830 can take many a shape and form, they are preferably curved in a manner that maximizes their overall surface area—which allows greater thermal contact between the warmer cooling water 543 and the cold water supply 825 . Upon treatment within the contact coils 830 , the now warmed water supply 825 is removed from the module 800 and transported to a tankless water heater 900 .
Prior to entry in the tankless water heater 900 , the now warmed water supply 825 is well above ambient temperature. Accordingly, the heating of this warmed water supply 825 requires less energy within the tankless water heater 900 in order to supply warm water to various parts of the home or commercial facility (in comparison with traditional tankless water heaters 900 which receive water directly from a municipal source). Moreover, this efficiency is no longer dependent upon the temperature of the water supply 825 provided by a municipal authority (or outside well)—or based upon the outside weather conditions. Put another way, implementation of the module 800 allows use of the tankless water heater 900 in any geographic location—regardless of whether the home or commercial facility is in a warm weather climate.
One issue presented by the module 800 is the risk of pressure differentials. Because the cooling water 543 (positioned within the inner shell 841 ) transitions from hot to cold (upon heat exchange with the municipal or well based water supply 825 ) such cooling water 543 can have thermal expansion. Accordingly, the invention contemplates a pressure relief valve 880 positioned on the top side 542 to exhaust and remove any necessary excess cooling water 543 created through heat exchange. An emergency drain pan 881 can be positioned below the bottom side 842 of the insulated housing 840 to collect such excess cooling water 543 . Alternatively, fluid received from the pressure relief valve 880 can be returned to either manifold 540 or 550 .
FIG. 6 further shows how usable heat—provided in the form of heated cooling water 543 —can be used to effectuate heat exchange with other components of the cogeneration system 100 , such as the air and heating systems. One secondary heat exchange contemplated by the module 800 includes pre-heating air prior to introduction into the furnace of the home or commercial facility. This can be accomplished through a secondary air exchanger 890 .
As shown and illustrated in FIG. 6 , the secondary air exchanger 890 first includes an exchange feed 891 which draws heated cooling water 543 from the insulated housing 540 . Preferably, this exchange feed 891 is located and positioned on the top side 542 of the inner shell 541 . The exchange feed 891 then transports the heated water supply 825 into an air exchanger 890 . The purpose and functionality of the air exchanger 890 is to allow the heated water supply 825 to heat up (warm) an incoming air feed 896 prior to entry into the furnace. This can be accomplished by either a misting system 897 or a series of micro-coils 898 (or combination of both). Upon heat exchange, the heated water supply is collected and then either (a) fed back into the module 800 through a return feed 899 or (b) alternatively recycled back to either cooling manifold ( 540 or 550 ) to be rewarmed and then returned to the module 800 .
The Module Controller
In addition, FIG. 7 shows how a controller 950 can be connected to the module 800 , as well as its components 960 (i.e., the air exchanger 890 , the first inlet 810 and the first outlet 850 ). The controller 950 functions to regulate and time introduction and removal of cooling water 543 throughout these components to optimize efficiency of the system. In one embodiment contemplated by the invention, the controller 950 can measure the internal temperature of the inner shell 841 and gauge whether to draw warmed cooling water 543 from the cooling manifolds ( 540 or 550 ) or stagnant cooling water 543 through the first outlet 550 .
Alternatively, the controller 950 can order removal of cooling water 543 from the insulated housing 840 for purposes of introduction into the air exchanger 890 (based upon communication with the furnace). Similarly, once cooling water 543 is removed for use in the air exchanger 890 , the controller 950 can determine if there is sufficient fluid within the inner shell 841 and draw more cooling water 543 from one or more manifolds ( 540 and 550 ). This helps to ensure not only that there is no stagnation of the cooling water 543 within the insulated housing 540 , but also that the temperature of such cooling water 543 can effectively make thermal contact with (and warm) the cooling coils 830 .
Overview of the Heater and Electrical Generator System
Referring initially to FIG. 8 , this embodiment of the invention describes an integrated heating/electrical generation system 1000 comprising an electrical generator 1002 , preferably situated indoors, which is integrated with a heating apparatus 1004 . In a preferred embodiment the heating apparatus 1004 is a furnace. In another embodiment, the heating apparatus 1004 is a boiler. The heating apparatus 1004 shares a common exhaust gas exit 1006 with the generator 1002 .
The Heating Apparatus
FIG. 8 illustrates the flow of electricity, air, and exhaust of the system 1000 , as well as illustrating the system's 1000 major components. The generator 1002 , in a preferred embodiment, is a 3 kW electrical generator comprising a natural gas fuel source 1008 , the fuel source reaching the generator by a fuel input line 1009 . In alternate embodiments, the fuel source 1008 is at least one of propane, fuel oil, and liquefied petroleum gas. The generator 1002 serves the purpose of providing electricity to the heating apparatus 1004 through a first electrical output 1010 and to electrical outlets 1012 through a second electrical output 1014 .
The generator 1002 is of a type well-known in the art, wherein a fuel-powered engine (not shown) actuates an alternator (not shown) to generate alternating current (AC) power. A control panel (not shown), also well known in the art, on the generator indicates the status of the generator 1002 utilizing at least an AC voltmeter, run timer, and circuit breakers. The control panel also comprises electrical outputs 1010 , 1014 and an auto idler circuit for automatically reducing engine RPM in the absence of an electrical load.
Still referring to FIG. 8 , the generator 1002 receives an electrical input 1016 from a local electrical service 1018 , such that would typically be found in a facility or a commercial site. This local electrical service 1018 is a junction that receives electricity from a municipal power grid 1020 . The electrical input 1016 passes to a relay 1022 in communication with the generator and the electrical outputs 1010 , 1014 . The relay 1022 is normally closed, so electricity into the relay 1022 passes directly through the relay to the electrical outputs 1010 , 1014 , thus an external electrical source, such as the municipal power grid 1020 is ultimately responsible for providing power to the heating apparatus 1004 and the electrical outlets 1012 . In the case of a loss of electrical service 1018 , electricity generated by the generator 1002 is provided to the relay 1022 , wherein the power of the generator causes the relay 1022 to actuate so that the electricity generated by the generator is routed to the electrical outputs 1010 , 1014 . In a preferred embodiment, the relay 1022 actuates automatically upon generator 1002 power input, the generator 1002 automatically sensing a loss of electrical input 1016 and starting the generator 1002 engine.
In this embodiment, unlike a traditional portable or standby generators, an appliance connected directly to the generator 1002 operates under normal conditions even when the generator 1002 is powered off. The same holds true for items plugged into the outlets 1012 , as these too maintain electrical current in the absence of generator 1002 power. This improvement allows for the convenience of an automatic transfer switch without the need for an automatic transfer switch, and is accomplished utilizing at least one series of normally closed relays 1022 which allow electrical current to travel through the relay 1022 to the heating apparatus 1004 and electrical outlets 1012 . No energy is required to keep the relay 1022 contact in the closed position, since the relay 1022 is normally closed in a non-energized state. Therefore even upon failure of the relay 1022 , electrical outlets 1012 and the heating apparatus 1004 still receive electricity. In the event of a power failure, the generator 1002 automatically powers on due to an engine start relay circuit (not shown), wherein the engine start relay is normally open when the generator receives electricity from the local electrical service 1018 , but upon loss of electricity closes and causes the engine to start. When the generator 1002 is generating electricity, the relay 1022 is placed in an open state that connects electrical connections 1010 , 1014 to the generator 1002 effectuating a transfer of electricity source from the local electrical service 1018 to that of the generator 1002 .
The generator 1002 comprises an air intake conduit 1033 that provides air to the generator's 1002 engine. There is also an exhaust conduit 1024 in communication with the engine so that combustion gasses have a route to exit from the generator 1002 .
In a preferred embodiment, the generator 1002 is enclosed by a housing 1036 . The purpose of the housing 1036 is to provide for a more visually streamlined installation, and also to contain any exhaust gasses that inadvertently escape from the generator 1002 . The housing 1036 comprises an emergency leak conduit 1038 in communication with the exhaust conduit 1024 for the purpose of scavenging exhaust gasses from within the housing 1036 . To provide fresh air to the housing 1036 , an intake port 1040 provides a path into the inside of the housing 1036 and the fresh air is used as a vehicle to aid in the exhaust of the gasses that may inadvertently escape from the generator 1002 . To maintain a negative pressure to evacuate the housing 1036 , a fan 1042 is in communication with the leak conduit 1038 . The fan 1042 is activated when the generator is powered on by an electrical connection 1044 that provides power to the fan 1042 , the connection being mediated by the relay 1022 . The fan 1042 , when powered on, creates a negative pressure within the housing 1036 , which causes air external to the housing 1036 to enter into the housing 1036 through the intake port 1040 and then exits, along with scavenged exhaust gasses, the housing 1036 through the leak conduit 1038 . When the generator 1002 is off, no power is provided to the fan 1042 , for the relay is in the normally closed position. Should exhaust gas leakage occur, the leaked gas could not escape the cabinet, and would instead be drawn into the flue 1032 . In a preferred embodiment, an alarm 1033 communicating with both a carbon monoxide sensor 1035 and a shut-down circuit on the generator 1002 prevents the generator 1002 from operating when exhaust gasses are detected by the carbon monoxide sensor 1035 and also provides an audible signal.
The generator 1002 generates power that is appropriate for the installation wherein the generator resides. For residential applications, the generator generates electricity that is compatible with the requirements of a household. In the United States, this would typically be 120 VAC single-phase power and 240 VAC single-phase power. In industrial settings, the generator generates at least one of single-phase and three-phase power ranging from 110 VAC to 480 VAC.
The Heating Apparatus
With continuing reference to FIG. 8 , the system 1000 comprises a heating apparatus 1004 for the purpose of providing heat to an interior space. In a preferred embodiment, the heating apparatus 1004 is a natural gas furnace, such furnace types being well known in the art. In another embodiment, the heating apparatus 1004 is a boiler. In yet a different embodiment, the heating apparatus 1004 is an electric element heater. The heating apparatus 1004 , in the case of a natural gas furnace, comprises a burner 1026 for burning natural gas to heat a heat exchanger 1028 . The heating apparatus 1004 provides heat to an interior space utilizing intermediary fluid movement of a heat exchanger 1028 , the heat exchanger 1028 utilizing at least one of air, steam, and water to mediate heating. The heating apparatus 1004 utilizes a combustible fuel to generate a flame in the burner 1026 that heats the heat exchanger 1028 , the fuel being at least one of natural gas, liquefied petroleum gas, fuel oil, coal, and wood. In a preferred embodiment, the fuel is delivered from the fuel source 1008 through the fuel input line 1009 to the burner 1026 .
To ensure an adequate influx of air for combustion from the air source 1030 , the heating apparatus 1004 comprises a draft inducer 1034 . The draft inducer 1034 is a device well known in the art comprising an electric fan to create a positive draft that aids in the proper exhaust of combustion gasses. The draft inducer 1034 is in communication with the flue 1032 , and is proximate the burner 1026 . In a preferred embodiment, the draft inducer 1034 promotes exhaust of combustion gasses and also promotes the influx of air from an air source 1030 for combustion.
The burner 1026 of the heating apparatus 1004 requires a source of air 1030 that provides the air required for the combustion process. Additionally, a flue 1032 is in communication with the burner 1026 that allows the heating apparatus 1004 to exhaust combustion gasses from the heating apparatus 1004 through the exhaust gas exit 1006 of the system 1000 . The flue 1032 is a conduit constructed of heat-resistant material that provides a point where exhaust gasses may be safely disbursed, which is typically to a point outside the structure being heated. The flue 1032 is constructed from polyvinyl chloride (PVC), metal, vitreous enamel, or transite.
Heating Apparatus and Generator Interaction
With continuing reference to FIG. 8 , the generator 1002 is installed in close proximity with the heating apparatus 1004 , since both of these units 1002 , 1004 utilize common electrical service 1016 , fuel source 1008 , and exhaust gas exit 1006 .
The flue 1032 of the heating apparatus 1004 is in communication with the exhaust conduit 1024 of the generator 1002 at a Y-junction 1046 . Therefore, the heating apparatus 1004 shares a common exhaust gas exit 1006 with the generator 1002 . The emergency leak conduit 1038 in communication with the exhaust conduit 1024 is therefore also in communication with the common exhaust gas exit 1006 . In a preferred embodiment, the flue 1032 , exhaust conduit 1024 , and the Y-junction 1046 are made of polyvinyl chloride pipe.
The power for the electrical outlets 1012 and the heating apparatus 1004 are relayed through a relay 1022 associated with the generator 1002 , thus a single input source of electrical service 1018 powers the electrical outlets 1012 wherein the generator 1002 is installed and provides power to the heating apparatus 1004 . When electrical service 1018 is not provided, the same electrical connections 1010 , 1014 are utilized for electricity delivery to electrical outlets 1012 and the heating apparatus 1004 , yet the generator 1002 provides the electricity in that case.
When the generator 1002 is powered on, electricity is provided by the generator 1002 to actuate an exhaust gas relay 1047 , which provides power to the draft inducer 1034 . The draft inducer 1034 is activated to expel the generator's exhaust through the common exhaust gas exit 1006 even if the furnace is not producing heat. The draft inducer 1034 also induces the evacuation of the generator's 1002 housing 1036 . In one embodiment, the draft inducer 1034 is installed before the burner 1026 , and in another embodiment, the draft inducer 1034 is installed after the junction of the Y-pipe 1046 .
A pressure switch 1048 communicates with the heating apparatus proximate the flue 1032 , the draft inducer 1034 , and also communicates electrically with the generator 1002 . In a preferred embodiment, the pressure switch 1048 is a diaphragm type switch well known in the art wherein the switch monitors the relative pressure within the flue 1032 compared to the ambient pressure, detecting when the draft inducer 1034 is functioning. If the draft inducer 1034 is not functioning, the pressure switch 1048 detects the lack of a lower pressure in the flue 1032 and sends an electrical signal to the generator 1002 , disabling the generator 1002 for safety purposes.
The fuel source 1008 in a preferred embodiment of the invention is shared, so that a common fuel line 1009 is utilized by both the generator 1002 and the heating apparatus 1004 .
FIG. 8 exemplifies that the generator 1002 shares electrical service 1018 , fuel source 1008 , and an exhaust gas exit 1006 , so the installation of a generator to work in conjunction with a home's existing heating apparatus is a relatively simple installation. Specifically, the generator 1002 utilizes the existing furnace or boiler's induction system (collectively 1030 , 1034 , 1032 , 1006 ) to form a vacuum to extract the emissions from the generator 1002 . The generator communicates with the heating apparatus exhaust gas relay 1047 which controls and energizes the heating system's induction fan to evacuate both generator 1002 and heating apparatus 1004 exhaust gases to the outdoors. The generator's 1002 exhaust conduit 1024 contacts the heating apparatus 1004 flue 1032 and this is accomplished using a Y-fitting 1046 that is easily integrated into an existing flue 1032 installation. The pressure switch 1048 may be installed in the system at the same time as the Y-fitting 1046 . By sharing existing fuel and exhaust lines, this installation scheme drastically reduces labor and material cost. This indoor generator 1002 system 1000 also reduces or eliminates the chances of harmful escaping emissions.
FIG. 9 illustrates how the generator 1002 can be incorporated into the cogeneration system 500 ( FIGS. 1 , 2 ) described herein. In this embodiment, the generator 1002 provides power for a facility 300 and the electrical grid 1020 , yet the generator's exhaust is fed into a catalytic converter 530 and cooling manifolds 540 , 550 as part of the cogeneration system 500 scheme. The generator 1002 is in communication with a heating apparatus 1004 and shares a common fuel source 1008 and electrical service 1018 with the heating apparatus 1004 . The primary difference the configuration of the generator 1002 in this embodiment of the invention illustrated in FIG. 9 , as compared to the combination generator/heating apparatus system 1000 illustrated by FIG. 8 , is that the exhaust from the generator is not merely exhausted, but rather harnessed in at least one cooling manifold 540 , 550 .
Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. | The invention is directed to a combination heater and electrical generator designed to allow continual use of the heating system in the absence of an external source of electricity. The system shares fuel and electrical inputs and also shares exhaust outputs so to facilitate ease of use installation as well as affording a small installation footprint. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to automatic guided vehicles (AGVs) and, more particularly, to an AGV system having interfacing computer sub-systems for controlling guidance, pick-up and delivery, traffic control and internal AGV monitoring.
In the field of material handling, most commonly in a warehouse environment, many articles must be stored in inventory and, an indefinite time later, retrieved for use. The larger the warehouse facility, the greater the number of objects that can be stored.
Moreover, large warehouse facilities require a great amount of geographical space. Not only are modern warehouses spread over a great amount of distance, but their height allows a many objects to be stacked for storage one above the other. Each object location or bin can be identified along three axes: X, Y and Z. Thus, a warehouse location for any specified particular object can be uniquely identified.
When the warehouse is large, it becomes burdensome to move material from one part of it (e.g., the port of entry) to another part thereof (e.g., a storage bin). Moreover, certain warehouses house large objects, weighing many pounds or even tons. The combination of large objects to be stored in a warehouse and great distances between pickup and delivery (P & D) stands is ideal for assigning tasks to automatic guided vehicles. As used herein, the term "assignment" indicates an address of a P & D stand for a pickup operation or for a deliver operation.
It has been found that guided vehicles moving over a buried inductive cable can perform many of the functions that humans perform without the requirement of lighting, heating, ventilation and air conditioning that would normally be required for a pleasant human work environment. Moreover, AGVs can be relied upon to operate continuously 24 hours per day. This advantage of performance over human laborers results in greater efficiency for warehouse facilities.
As AGVs become more sophisticated, they begin to acquire the attributes of intelligent robots. Guiding and maneuvering each AGV and providing the necessary software and control of the AGV requires corresponding sophisticated techniques.
Heretofore, AGV systems have been unreliable. Often these systems caused more problems than they were designed to eliminate. AGV systems have been found to require human intervention, a condition they were to aleviate.
These drawbacks have severely hurt the industry (Ailing robot industry is turning to services, John Holusha, Business Section, New York Times, Page D1, Feb. 14, 1989).
The present invention has combined computerized sub-systems of proven reliability and capability to form an integrated AGV system of advanced design. While it was no simple task to interface all of the various computer sub-systems, once having accomplished this task, the overall AGV system of this invention has shown itself to have versatility and capabilities which are presently unknown in the industry.
DISCUSSION OF RELATED ART
Generally speaking, there are presently two major types of automated guided vehicle system for warehouses:
a) a system featuring a buried wire in the floor of a warehouse, that guides the vehicle through given paths of the warehouse; and
b) a vehicle traveling on a warehouse path that is kept on track by optical (e.g., laser) reflective units positioned above ground along the guide path.
Both of the aforementioned systems have drawbacks that have been found to make the guidance of the vehicles unreliable.
In most of these systems, problems arise at intersections, and where vehicles are caused to make turns or slow down for other vehicles in their path.
Another formidable problem occurs at loading docks and depositing bays, where decisions must be resolved concerning priority status of each vehicle.
U.S. Pat. No. 4,168,760; issued: Sept. 25, 1979, depicts a wire guidance system that makes decisions at vehicular intersections based upon comparison of destination addresses stored at the intersections, thereby reducing the need to store large quantities of data in computer memory.
In U.S. Pat. No. 4,727,492: issued: Feb. 23, 1988, a system is disclosed for guiding a vehicle along a given route or pathway by storing data in the vehicle indicative of the path to be followed. The system also features a fixed target detection system utilizing a scanning laser.
In U.S. Pat. No. 4,791,570, issued: Dec. 13, 1988, a wire guided vehicle system is shown which features a computer that polls the status of each vehicle for the purpose of maintaining proper traffic flow.
In U.S. Pat. No. 4,790,402; issued: Dec. 13, 1988, a laser guided vehicular system is illustrated wherein laser beam reflectors are positioned along the guide path for routing the vehicle. Certain targets are bar coded to keep track of the vehicle position. The system also features reflective microwave sensors for speed and distance control.
U.S. Pat. No. 4,361,202; issued: Nov. 30, 1982, describes a system utilizing a sonic or radar collision avoidance system and a wire guidance technique. Transponders buried in the roadway provide position and speed information.
In the U.S. Pat. No. 4,215,759, issued: Aug. 5, 1980, a vehicle guide path system is featured wherein the vehicle is steered and guided by radio control stations along the pathway.
U.S. Pat. No. 4,322,670; issued: Mar. 30, 1982, teaches a guide wire vehicle tracking system with superimposed signals for negotiating curves.
While all of the above-identified systems function reasonably well, none has been found to be completely reliable.
It would be advantageous to provide an AGV system having a sub-system whereby specific status information could be displayed in human readable form.
It would also be advantageous to provide an AGV system having a diagnostic sub-system that is self contained so that no additional references need be consulted.
It would also be advantageous to provide an AGV system comprised of individualized sub-systems each having computerized control of departmentalized functions of the overall system.
It would also be advantageous for an AGV system which truly does away with human intervention, but which also has the versatility to provide for manual control.
It would be advantageous to provide an AGV with proven reliability and capabilities heretofore unknown.
SUMMARY OF THE INVENTION
The present invention uses a guided wire AGV system that is very accurate and versatile. The system features separate traffic and loading control sub-systems. An on-board computer in each AGV vehicle performs guidance control in conjunction with a overall system host computer for greater versatility. An EPROM in the vehicle computer can be programmed with the particular floor plan of the warehouse. The on-board computer of each vehicle can be interrogated to determine the status of any system, and provide for both manual and stand-alone operation.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when taken in conjunction with the detailed description thereof and in which:
FIG. 1 is a schematic diagram of a typical automatic guided vehicle (AGV) system;
FIG. 2 is a perspective view of the AGV of this invention;
FIG. 3 is an exploded view of the AGV illustrated in FIG. 2;
FIG. 4 is an exploded view of the load-lifting mechanism of the AGV shown in FIG. 3;
FIGS. 4a and 4b depict exploded views of the suspension system for the AGV illustrated in FIG. 2;
FIG. 5a is a plan view of a display and control panel disposed on the right side of the AGV shown in FIG. 2;
FIG. 5b is a plan view of a second control panel disposed on an opposite side of the AGV depicted in FIG. 2;
FIGS. 6a-6d are plan views of the various sides of a hand-held control wand that plugs into the control panel shown in FIG. 5a, which is used to manually control and interrogate the AGV;
FIG. 7 is a schematic block diagram of the communication and control of each individual AGV of the system shown in FIG. 1;
FIGS. 8a-8d, when taken together and arranged as shown in the corresponding interconnection diagram, and hereinafter referred to in the specification as FIG. 8, are schematic block diagram of the computer shown in FIG. 7;
FIG. 9 is a block diagram depicting the functionality of the LAC;
FIG. 10 is a block diagram depicting the functionality of the hyper driver shown in FIG. 1;
FIG. 11 is a block diagram depicting the functionality of a control box (CB) as shown in FIG. 1;
FIG. 12 is a flow chart for one of the functions of the CB depicted in the system of FIGURES;
FIG. 13 is a flow chart for another of the CB functions, specifically the intersection traffic controller;
FIGS. 14a-14f, when taken together and arranged as shown in the corresponding interconnection diagram, and hereinafter referred to in the specification as FIG. 14, are a schematic diagram of a signal conditioning card as depicted in FIG. 8;
FIGS. 15a-15d, when taken together and arranged as shown in the corresponding interconnection diagram, and hereinafter referred to in the specification as FIG. 15, are a block diagram of a guidance control card as depicted in FIG. 8;
FIGS. 16a-16d, when taken together and arranged as shown in the corresponding interconnection diagram, and hereinafter referred to in the specification as FIG. 16, are a block diagram of a digital card as depicted in FIG. 8;
FIGS. 17a-17b, when taken together and arranged as shown in the corresponding interconnection diagram, and hereinafter referred to in the specification as FIG. 17, are a block diagram of a non-volatile memory system in accordance with the present invention; and
FIGS. 18a-18d, when taken together and arranged as shown in the corresponding interconnection diagram, and hereinafter referred to in the specification as FIG. 18, are a block diagram of the traffic manager in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of clarity, like components will have the same numerical designation throughout the FIGURES.
Referring now to FIG. 1, the system of the present invention and a host computer are shown generally at reference numeral 110. A host computer 112, such as a Tandem mainframe computer, is a customer interface to the automatic guidance vehicle system (AGVS) 114 of the present invention.
A local area controller (LAC) 116 provides the interface to host computer 112. LAC 116 is a computer such as that manufactured by the AST Corporation based on a Model No. 80286 microprocessor provided by Intel Corporation.
Connected to LAC 116 is a hyper driver (HD) 117, which is programmed to control and pass communications information among a plurality of control boxes (CBs) 119. Up to eight CBs can be configured in one system. In addition, HD 117 is programmed for passing communications information between LAC 116 and CBs 119.
Connected to hyper driver (HD) 117 is a plurality of CBs 119, each of which is programmed to communicate with and control the movement of one or more AGVs 132. Two CBs are shown in this FIGURE. Communication includes controlling AGV movement at intersections of the guide path and at P & D zone clusters. Traffic control for each CB occurs within a predetermined jurisdiction 150 of the guide path 122. In addition, CBs 119 are programmed to control and maintain the status of a plurality of switch boxes (SBs) 123. HD 117 is also connected to LAC 116.
Connected to CB 119 are:
1) a plurality of SBs 123, each of which is used for controlling discrete devices, as in a P & D stand switch;
2) an inductive communication device 121, used for passing communication information between CB 119 and any one of the AGVs 132; and
3) HD 117.
Each CB 119 controls its OWn discrete guide path 122 including any of the subsystems of the AGV system 114, such as P and D stand clusters 120, SBs 123, intersections 128, homes 125, battery charge area 124, maintenance area 126 and AGVs 132, the totality being referred to as a CB jurisdiction 150. Only one jurisdiction 150 is depicted in the FIGURE.
Connected to SB 123 are up to two P & D stand switches, a warehouse bay door, a light, or any other discrete device that can provide a two bit input to SB 123 and be controlled by a single bit output.
An inductive communication device (ICD) 123 is connected to guide path 122. Communication information is inductively passed through guide path 122 to AGVs 132.
A guide wire communications network 122 is laid out in a facility beneath the surface of the warehouse floor, not shown. At various stations along guide path 122 are areas 124 for recharging the batteries of AGVs 132, areas for storing AGVs between assignments (home or parking position) 125 and areas for performing maintenance 126.
The AGVs of the present invention are programmed to travel to battery charge area 124 when their battery voltage level is less than a predetermined amount and programmed to travel to maintenance area 126 for predetermined preventive maintenance scheduling.
LAC 116 is an intelligent device that is loaded with a program for controlling it. The program is shown in Appendix I.
Along guide wire 122 is an intersection 128 of guide wire paths. It should be understood that a plurality of intersections may occur in any given layout. Traffic control in an intersection 128 is provided by a software program within CB 119.
One or more AGVs 132 operate along guide wire 122 in a manner described hereinbelow. Within AGV 132 is a vehicle control program shown in Appendix II.
Referring to FIG. 2, the automatic guidance vehicle (AGV) 132 of this invention is illustrated. The AGV comprises a rectangular housing 202 containing internal guidance and control mechanisms, which are shown in FIG. 3, and which will be explained in detail hereinafter.
On top 201 of housing 202 is disposed an expandable load-lifting table 204, that is capable of depositing or removing items from P & D stands.
On right side 206 of housing 202 is a display and control panel 208 for manual control and interrogation of the vehicle as will be explained in more detail, hereinafter.
On the front face 210 and rear face 211 of housing 202 are several sensors 203, 205 and 207, respectively, for determining obstructions in the travel path of vehicle. Sensors 203 are infrared light beam proximity sensors that detect a reflected beam from an object at a distance of six feet, and provide a signal to slow the vehicle to half speed.
Sensors 205 are similar to sensors 203 and cause the vehicle to come to a stop when an object is detected at a distance of three feet. Sensors 203 and 205 can be purchased from Opcon, Model Nos. 1355A or 1356A.
A flexible bumper band 215 is disposed at the front and rear of the vehicle, respectively. The flexible bumpers 215 are semi-circular in shape, and are supported by guy-wires 216.
When an object contacts either bumper sufficient to distort its semi-circular shape, sensors 207 detect the displacement and cut power to the drive system. This is achieved by means of reflective spots 218 that are disposed on the inside surface 219 and reflect the sensor beam from each bumper band 215 back to sensors 207. Sensors 207 can be purchased from OPCON, Model 1456A.
The headlights 220 disposed on front and rear surfaces 210 and 211, respectively, act to light the path of travel and also act as warning flashers when an obstacle is detected.
An easily removable panel 213 located on side 206 of housing 202 provides access to a battery pack that powers the vehicle 132. A similar panel is disposed on the other side of the AGV.
Sensor 260 (Opcon Model No. 1356A) mounted on top 201 of housing 202 (FRONT & REAR) sense when a cargo bay or stand is filled.
Sensors 230 (OPCON Models 1155A and 1255A) mounted at the base of bumpers 215 on either side, provide power interrupt signals when an object or foot brushes against right side 206 or its opposite side.
Sensors 250 (Opcon Model No. 1355A) mounted on the side 206 sense when the AGV has entered a cargo bay or stand.
Referring to FIG. 3, the AGV 132 is depicted in greater detail with the various component parts illustrated in exploded view. The AGV 132 is constructed upon a main frame 300 about which all the parts are easily accessible.
Front and rear sides 210 and 211, respectively are fashioned as hinged covers that articulate about hinges 310 and 311, respectively. Hinges 310 and 311 are secured to main frame 300. These hinged covers provide easy access to front and rear wheel assemblies 320 and 321, respectively. The front wheel 325 is a servo driven wheel, and movably powers the vehicle. [Its matching rear wheel 326 is not powered, and its steering mechanism is functionally and electrically independent with respect to front wheel 325.] The wheel 326 is directionally controlled by sprocket gear 327, which turns the idler caster housing 328. The front drive wheel 325 is supported in a SUMITOMO housing, Model No. C0303S, manufactured by Big Joe Manufacturing Co., and is also directionally controlled by a sprocket gear 327. Each sprocket gear 327 is rotated by sprocket chain 329, which is driven by cog 330. The cog 330 is powered by a servo motor 331.
The front wheel 325 is powered by drive motor 332. A tachometer 333 attached to motor 332 measures the number of revolutions, and in this way, the distance the vehicle travels is measured, since the diameter of wheel 325 is known.
The AGV 132 has a balance wheel 340 (only one shown here) on each side. An electromechanical brake 341 attached to wheel 340 causes the vehicle to stop, when the power is cut off.
The AGV 132 is powered by an easily accessible battery pack 342, which is accessible for maintenance purposes through side doors 213 on either side of the vehicle, as aforementioned.
The battery pack 342 is slidably removable from the vehicle by virtue of a deck of rollers 343 upon which the batter pack 342 is supported.
The AGV 132 is internally controlled by a computer 350, which is located behind the display and control panel 208. the computer 350, and its operation, will be described in more detail, hereinafter.
The computer 350 is housed in a slidable draw 351 which is easily accessed by virtue of slide rails 352, which allows the computer 350 to be removed from or repaired within the vehicle housing 202.
The power supplied by the battery pack 342 is distributed to the computer 350 and various drive and steering motors through a power supply module and isolation switches housed in slidable draw 360, having slide rails 361 to provide ease of access, as shown.
Mounted on the top plate 201 of AGV 132 is a hydraulically actuated lift mechanism 370, for pick-up and delivery of items in the warehouse in accordance with the system illustrated in FIG. 1.
The lift mechanism 370 comprises a lift table 371, which is caused to be raised or lowered (arrows 375) for contacting and removing items stored in cargo bays or cargo stands (not shown).
The lift mechanism 370 is shown in more detail in FIG. 4.
The lift mechanism 370 is actuated by a hydraulic cylinder and piston arrangement 410 which receives hydraulic fluid to retract piston rod 411 (arrow 405) through hydraulic line 412. The hydraulic fluid pump and reservoir 322 shown in FIG. 3 are disposed inside the vehicle housing 202.
The key 413 of piston rod 411 is rotatively secured to the lips 414 of the roller mechanism 415. The rollers 416 of roller mechanism 415 are free to rotate about shaft 417, and are caused to roll upwardly (arrow 420) along inclined plane 421 attached to one half of the cross-bars 430, when the piston rod 411 is retracted.
As the rollers 416 roll up the inclined plane 421, the cross-bars 430 are caused to expand (arrows 440), thus causing the lift table 371 to which it is secured, to rise (arrow 450).
When the lift table 371 is to be lowered, the procedure is reversed, and piston rod 411 is hydraulically allowed to return to its expanded rest position. The hydraulic cylinder 409 is rotatively secured to the top plate 201 of the AGV 132 about key 408. Arms 460, 461 and 462 of crossbars 372 of table 371 are rotatively secured at end fingers 480, 481 and 482, respectively.
The other end of bars 460 and 461 have rollers 490 and 491, that are caused to roll within frame 495 when the cross-bar mechanism 430 is actuated. Cross bar 462 is rotatively secured to the frame 495 at end 496.
Frame 495 is bolted to top 201 of the AGV 132 through bolt holes 497.
A reflective beam sensor (Opcon Model No. 1356A) 498 attached to table 371 provides a signal when table 371 is unloaded by reflecting and receiving a beam bounced off reflector 499 mounted at the opposite end of table 371. Absence of the reflected beam indicates a load has been placed on table 371.
The lift table 371 is just one of many mechanisms which can be supported or carried by the AGV 132.
For example, the lift table 371 may be replaced or used in conjunction with a robot arm for grasping, removing or placing items on the AGV 132.
Referring to FIGS. 3, 4a and 4b, a unique suspension system of the AGV 132 will be explained.
The AGV 132 is driven by rotatively powering [front wheel] 325. This arrangement, however, causes a problem, which is uniquely solved by the vehicle suspension system.
The problem as experienced by the vehicle, occurs when the front wheel 325 runs over a lower level surface than is contacted by both side wheels 340 and rear wheel 326.
In this position, the front wheel 325 will immediately lose traction with the floor, because the weight of the vehicle is centered towards the back. The AGV will, therefore, become uncontrollable in a drivable sense.
In order to keep the front wheel 325 in continuous driving contact with the floor, the suspension system of the AGV provides an upward torque upon side wheels 340 via unique suspension linkage 390, which by equal and opposite reaction provides a down force on front wheel 325.
Each side wheel 340, typically shown in greater detail in FIG. 4b, is also provided with anti-sway capabilities by suspension 390, illustrated in greater detail in FIG. 4a.
Both side wheels 340 are each rotatively journalled to pivotable frame 487 via side journal bearings 485 and 486 disposed in the pivotal mounting frame 487, as depicted in the exploded view of FIG. 4b.
Mounting frame 487 is pivotally secured to mainframe 300 by means of bearings 481 which allow flanges 482 of frame 487 to pivot (arrows 400) with respect to main frame 300.
The pivotable frame 487 is pivotably biased toward the floor, and hence, the wheel 340 is also pivotably biased against the floor by a pair of coil springs 489.
The ball jointed rods 500 and 501, respectively secure each side wheel frame 487 to socket 505 of lever arms 503 and 504, respectively of the suspension mechanism illustrated in FIG. 4a.
The ball jointed rods 500 and 501 are each height adjustable by means of turnbuckles 506.
The lever arms 503 and 504 are torsionally coupled to each other, and hence, side wheels 340 are torsionally coupled to each other, by means of the torsion rod 510, that rotatively anchors to frame 30 via flanges 511 and connects to each lever arm 503 and 504 within socket holes 508 and 509, respectively.
Torsionally coupling the wheels 340 in this manner creates an upward force on both wheels 340 when front drive wheel 325 moves over a lower surface.
The torsional coupling also creates an equal and opposite force on the opposite side wheel 340 every time one of the side wheels rolls over a bump or hole in the roadway. This equal and opposite force produces an anti-sway condition that reduces side roll effects.
Referring to FIG. 5a, the control and display panel 208 is shown in greater detail. The control and display panel 208 mounted on the right side of the vehicle features a switch E for changing the AGV 132 from automatic to manual control. A hand-held control wand or manual controller 600, which will be described in greater detail with reference to FIGS. 6a through 6d, is plugged into socket F, when it is desired to control the vehicle manually, or to alternately interrogate the vehicle, as will be described in more detail hereinafter.
A visual indication of the remaining operating time or power of the battery pack 342 (FIG. 3) can be continuously obtained in either automatic or manual modes by reference to electronic indicator gauge G.
Switch A is an interrupt switch for stopping the AGV by means of an interrupt program in the internal computer 350.
The start switch B overrides the interrupt of switch A, and reactivates the vehicle.
Switch C is an ignition switch that supplies power to the AGV via battery pack 342.
Switch D is an emergency switch that cuts off power to the vehicle motor and steering systems, but maintains power to the computer 350.
The display H provides a visual screen for interrogating the vehicle by various program menus, as will be explained hereinafter.
A control panel 208' is disposed on the left side of the AGV, opposite side 206.
The panel 208' has switches A', B' and C', that perform the same function as switches A, B and C on panel 208.
The panel 208' is convenient to stop the vehicle if an operator is on the opposite side of the vehicle.
Referring now to hand-held wand 600 that plugs into socket F of panel 208 (FIG. 5a), it will be observed that FIGS. 6a through 6d depict the four faces of a generally rectangular wand. While a preferred embodiment of the wand switches is herein disclosed, it is to be understood that other switch configurations and corresponding functions can also be used, as is well known in the art of manual controllers.
FIG. 6c depicts an emergency switch BB that interrupts the power to the vehicle. It is a double-throw switch that must be pressed again to restart the AGV.
FIG. 6b depicts a spring loaded deadman switch AA, which must be continuously pressed in order to actuate the other switches on the wand.
FIG. 6d illustrates switches G', H', I' and J' that manually control the speed and direction of the vehicle. Switch G' controls the vehicle by commanding a slow speed to the rear. Switch H' is for a fast rear control. Switch I' is a slow forward command, and switch J' is for fast forward.
Referring to FIG. 6a, switch F' controls the raising of the lift table 371 (FIG. 3).
Likewise, switch E' commands the lift table 371 of the vehicle to descend.
Switch D' sets the brake 341 (FIG. 3) of the vehicle.
Switch K' is for interrogating the AGV via display H (FIG. 5a).
Potentiometer C' is used to walk the user through the displayed menus.
AGV 132 is capable of operating in either of two modes: automatic and manual. Switch E of the display and control panel 208 (FIG. 5a) is used to toggle between automatic and manual mode. In automatic mode, the AGV performs tasks it has been assigned providing an alphanumeric readout of its assignments on its interactive display 208.
AGV 132 receives its assignment from either LAC 116 when the AGV system 114 is configured as an LAC system; or by program menus available through placing AGV 132 in manual mode and using the manual controller 600 (FIG. 6) to access the menus, when the AGV system 114 is configured as a stand alone system (SAS).
When AGVs 114 is configured as an SAS, HD 117 and host computer 112 can be eliminated.
In manual mode the operator has control of AGV 132. The options available to the operator at this point are to drive AGV 132 manually or to enter the off-line diagnostic mode.
Within the drive mode of operation, AGV 132 can operate manually, by means of the manual controller; or semi-automatically, by means of the inductive wire in combination with the manual controller.
Within the diagnostic mode, menus are used in combination with the manual controller to monitor status of AGV 132. For purposes of this description, certain sample menus are disclosed as examples hereinbelow, but other diagnostic menus can also be used, depending upon the specific AGV and facilities configuration, without departing from the scope of the present invention.
The main diagnostic menu is shown as Example 1.0.
EXAMPLE 1.0: MAIN DIAGNOSTIC MENU ##STR1##
When INSTRUCTIONS is selected from the main diagnostic menu by the manual controller, the sub-menu shown as Example 2.1 is displayed.
EXAMPLE 2.1: INSTRUCTIONS
______________________________________HOW TO USE DIAGNOSTICS:______________________________________PUSH THE ENTER BUTTON ON THEOPERATOR INTERFACE (OIM)TO ACTIVATE THE MENUPUSH LIFT AND LOWER TOGETHERTO EXIT THE MENUUSE STEERING POT TO DIAL A MENU______________________________________
When DISPLAY DIGITAL INPUTS is selected from the main diagnostic menu by the manual controller, the sub-menu shown as Example 2.2 is displayed.
EXAMPLE 2.2: DISPLAY DIGITAL INPUTS ##STR2##
When TEST ANALOG INPUTS is selected from the main diagnostic menu by the manual controller, the sub-menu shown as Example 2.3 is displayed.
EXAMPLE 2.3: TEST ANALOG INPUTS ##STR3##
When INTERACTIVE SYSTEM TEST is selected from the main diagnostic menu by the manual controller, the sub-menu shown as Example 2.4 is displayed.
EXAMPLE 2.4: INTERACTIVE SYSTEM TEST ##STR4##
When TEST/ADJUST VOLUME is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu display is shown as Example 2.4.1.
EXAMPLE 2.4.1: TEST/ADJUST VOLUME ##STR5##
When TEST PITCH CONTROL is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.2.
EXAMPLE 2.4.2: TEST PITCH CONTROL ##STR6##
When PPI 1 PORT A TEST is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.3.
EXAMPLE 2.4.3: PPI 1 PORT A TEST ##STR7##
When PPI 1 PORT B TEST is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.4.
EXAMPLE 2.4.4: PPI 1 PORT B TEST ##STR8##
When PPI 2 PORT A TEST is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.5.
EXAMPLE 2.4.5: PPI 2 PORT A TEST ##STR9##
When PPI 2 PORT B TEST is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.6.
EXAMPLE 2.4.6: PPI 2 PORT B TEST ##STR10##
When PPI 2 PORT C TEST is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.7.
EXAMPLE 2.4.7: PPI 2 PORT C TEST ##STR11##
When PPI 3 PORT C TEST is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.8.
EXAMPLE 2.4.8: PPI 3 PORT C TEST ##STR12##
When PPI 5 PORT B TEST is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as EXAMPLE 2.4.9.
EXAMPLE 2.4.9: PPI 5 PORT B TEST ##STR13##
When PPI 5 PORT C TEST is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu display is shown as Example 2.4.10.
EXAMPLE 2.4.10: PPI 5 PORT C TEST ##STR14##
When MONITOR TRAFFIC FREQ. is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.11.
EXAMPLE 2.4.11: MONITOR TRAFFIC FREQ. ##STR15##
When TEST WASPOT is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.12.
EXAMPLE 2.4.12: TEST WASPOT ##STR16##
When TEST WHEEL TACH. is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.13.
EXAMPLE 2.4.13: TEST WHEEL TACH. ##STR17##
When TEST GUIDANCE ASSY. is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.14.
EXAMPLE 2.4.14: TEST GUIDANCE ASSY. ##STR18##
When CALCULATE TRUCK SPEED is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.15.
EXAMPLE 2.4.15: CALCULATE TRUCK SPEED ##STR19##
When CALIBRATE TRUCK OPTICS is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.16.
EXAMPLE 2.4.16: CALIBRATE TRUCK OPTICS ##STR20##
When GRAPH WASPOT RESPONSE is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.17.
EXAMPLE 2.4.17: GRAPH WASPOT RESPONSE ##STR21##
When MONITOR GUIDANCE FREQ. is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.18.
EXAMPLE 2.4.18: MONITOR GUIDANCE FREQ. ##STR22##
When TEST TRAFFIC XMIT. is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu display is shown as Example 2.4.19.
EXAMPLE 2.4.19: TEST TRAFFIC XMIT. ##STR23##
When SNIFF FLOOR CONFIG. is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.20.
EXAMPLE 2.4.20: SNIFF FLOOR CONFIG. ##STR24##
When TEST LIFT/LOWER DECK is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu displayed is shown as Example 2.4.21.
EXAMPLE 2.4.21: TEST LIFT/LOWER DECK ##STR25##
When TEST P&D STAND is selected from the INTERACTIVE SYSTEM TEST sub-menu by the manual controller, the next menu display is shown as Example 2.4.22.
EXAMPLE 2.4.22: TEST P&D STAND ##STR26##
CHOICE 23-CHOICE 60 of the INTERACTIVE SYSTEM TEST sub-menu are not used in the present configuration, but can be replaced by appropriate routines for testing or monitoring different functions.
Referring now to FIG. 7, there is shown a schematic block diagram of the communication and control of an AGV 132 (FIG. 1). At the heart of the AGV system is a computer 350 (FIG. 3) such as a Model PC/XT manufactured by IBM Corp. Computer 350 is self-contained, having a central processing unit (CPU), not shown, as well as internal random access memory and logic as is conventionally found in a commercial personal computer. In fact, the mother board, not shown, of computer 350 is a standard PC/XT computer mother board that can be provided by the aforementioned manufacturer.
Connected to computer 350 are a power supply and associated switches 712 for controlling power distribution to the various portions of the vehicle 132.
Also connected to computer 350 are guidance controllers 714a and 714b for providing guidance to the front and rear wheels 325 and 326, respectively of AGV 132.
Steering controls 716a and 716b are provided to control servo motors, not shown, for the front and rear wheels, respectively.
Also connected to computer 350 by means of a bidirectional line 718 are drivers for control and display panel and for manual controller, shown generally at reference numeral 720. While control and display panel and manual controller drivers 720 are separate devices, they are shown in this FIGURE as one unit for simplicity. The interaction between display panel and manual controller 720 with one another and with computer 350 is generally via the aforementioned menu system.
Safety apparatus, shown generally at reference numeral 722, controls such equipment as bumpers and optics. Certain threshold limits are monitored and controlled by this block 722, as is an emergency power off (EPO) switch D (FIG. 5a) hereinabove described.
Lift table 371 (FIG. 4) is controlled by computer 350 by means of a lift/lower controller 724 connected to computer 350 and adapted to operate pursuant to instructions thereof.
Also connected to computer 350 is a drive controller 726, including a drive servo motor, not shown.
Operating instructions for computer 350 are loaded in a PROM 728, which is replaceable in accordance with the present invention and which is described in further detail hereinbelow.
Computer 350 is also connected by means of a bidirectional bus 730 to a communications controller 732, including ICD 121 (FIG. 1), which is inductively coupled to a buried wire, not shown. Communication controller 732 therefore provides the interface between AGV 132 and local area controller 116.
Peripheral equipment 734, such as printers, keyboards, floppy or hard disk drives, plotters and the like, can be connected to computer 350 with minimal effort, thereby allowing computer 350 to function as a conventional PC/XT with peripheral devices.
Referring now also to FIG. 8, there is shown a schematic block diagram of the computer 350 (FIG. 7) in greater detail.
Each of the blocks shown in FIG. 8 resides on a separate printed circuit board or separate sub-assembly in computer 350 in the preferred embodiment. A signal conditioning block 810 is connected to a guidance control, so-called Butterworth block 812. Also connected to Butterworth block 812 is a sensor array 814 for guidance. Connected to signal conditioning block 810 and Butterworth card 812 are servo interfaces 815a (front) and 815b (rear). Connected to servo interface cards 815 are steering servos for the front 816a and 816b of the vehicle. Also connected to servo interfaces 815 are front wheel angle sensor potentiometers (WASPOT) 818a and 818b, respectively.
Front and rear optics 820a and 820b are provided for safety. Specifically, as mentioned above, the vehicle is slowed when a neutral white object appears within six feet of one of the sensors and the vehicle stops when a neutral white object appears within three feet of another one of the sensors. Power to the front and rear optics 820a and 820b is provided through servo interfaces 815a and 815b, respectively.
A traction amplifier (PMC) 822 is connected both to signal conditioning block 810 and to front servo interface 815a. The output of traction amplifier 822 is applied to front and rear contactors 824a and 824b, respectively, for controlling a motor 826 in a forward or rearward direction, respectively.
Connected to signal conditioning block 810 is an output opto rack which optoelectronically isolates signal conditioning block 810 from any one of the following devices: parking brake, load at P & D, optic power, bumper power, precision stop optic right front power, precision stop optic left front power, right rear, left rear, right front, left front lights and the main contactor, none of which is shown on this FIGURE.
An input opto rack 830 is connected to signal conditioning block 810 and receives input signals from the aforementioned devices (e.g., parking brake). The connection between input opto rack 830 and signal conditioning block 810 prevents mutually exclusive operations from occurring, such as lifting and lowering the lift table 371 (FIG. 4) simultaneously. Connected to input opto rack 830 is a lift/lower contactor 832 which, in turn, is connected to a lift/lower motor 834.
Also connected to signal conditioning block 810 is a horn driver 836 which is connected to a speaker 838. Horn and speaker 836, 838 are capable of generating a signal that is infinitely variable with respect to amplitude and frequency. It should also be understood that a speech synthesizer can replace the horn driver 836, if desired, in a manner that is well known in the art.
Connected to signal conditioning block 810 are front and rear traffic transmitter drivers 840a and 840b, respectively. Traffic transmitter drivers 840a and 840b drive inductive coils 842a and 842b, respectively, which are focused and directed toward the ground loop, not shown. Three frequencies are used as a signal between traffic transmitters 840 and signal conditioning block 810.
Any one frequency or any of certain combinations of two or three frequencies can be used to signal a specific condition. For example, if the first frequency ft 1 , is present (binary 1), then the vehicle 132 is physically located on the floor. If frequencies ft 2 , and ft 3 are present in certain combinations, the vehicle 132 is directed variously to turn left, to turn right, to maintain a straight orientation or to enter an elevator going up or down, respectively. Thus, the presence of frequencies ft 1 , ft 2 and ft 3 may signal an elevator operation, whereas frequencies ft 1 and ft 3 alone signal a right turn operation.
An electronic inductive sensor and interface is shown at reference numeral 844. The inductive sensor is a low powered device containing sensor electronics and an antenna. It contains an inductive power source used to activate an electronic label, not shown, usually disposed beneath the floor of a warehouse. The electronic label, in turn, is incited by the sensor and interface to transmit a signal in response thereto. The entire electronic label/sensor/interface system is available from Namco Controls Co. of Mentor, Ohio and marketed under the trademark SENSORNET I. Connected to the electronic label system 844 is a digital card 846. The input to digital card 846 is an RS232 serial communications bus. Digital card 846 receives input from a variety of sources and interrupts system operation in response thereto. For example, the deadman switch AA (FIG. 6) of manual controller 848 (references numeral 600 in FIG. 6) is input to digital card 846, as is Luke? 854 and safety optics 852. Moreover, a watch dog monitor in signal conditioning block 810 and a bumper bit signal from signal conditioning block 810 is also input to digital block 846, described in greater detail hereinbelow.
A nonvolatile RAM card 850 contains information necessary to restart the system in the event of loss of power. Card 850 also contains the operational program for AGV 132 residing in PROM 728 (FIG. 7) and is also used to convert or interrupt a number of switches that can be operated by manual controller 848, such as fast forward, slow forward, fast reverse, slow reverse and horn.
Front and rear receiver coils 856a and 856b, respectively, receive inductive signals from the receive loop in guide path 122 and are transferred to a daughter board 858. Daughter board 858 generates three bits in response to the receiver signals from received coils 856a and 856b. The bits correspond to the aforementioned frequency binary bits ft 1 , ft 2 and ft 3 .
Referring now to FIG. 9 there is shown a functionality diagram of local area controller 116 (FIG. 1). Host computer 112 is connected to a host interface 910, which performs three functions:
a) processes status inquiries 910,
b) stores/retrieves assignments and reroutes 914, and
c) receives unsolicited system status reports 916 to be transferred, in turn, to host 112.
In providing unsolicited system status reports 916 to host interface 910, the system determines the optimal AGV for a given assignment 918. In processing status inquiries 912, the status of AGVs 132, CBs 119, P & Ds 120 and hyper driver is maintained 920. When an optimal AGV 132 is selected for assignment 918, the identification of the AGV is transferred to HD interface 922 which, in turn, transfers the information to the hyper driver 117. Any status of devices or locations is generated by the hyper driver 117 and transferred through HD interface 922 to block 920.
Referring now to FIG. 10 there is shown a functionality diagram of hyper driver 117. LAC 116 is connected to LAC interface 1010, which receives information from a CB status control block 1012 and AGV lost/location status block 1014, LAC/CB communications block 1016 and P & D status control block 1022. LAC interface 1010 transfers such information to LAC 16.
A control box interface 1020 is provided for communicating with CB status control block 1012, AGV lost/location status block 1014, LAC/CB communications block 1016 and P & D status control block 1022. Connected to CB interface 1020 are one or more CBs 119.
Similarly, a second CB interface block 1024 receives data from a CB x to CB y message manager 1018, the function of which is to communicate between CBs. The CB x to CB y message center is in communication with the AGV loss/location status drop block 1014. The second CB interface 1024 also communicates with one or more CBs 119. The functional channel from block 1010 through blocks 1014, 1018 and 1024 allows an AGV 132 to cross from the jurisdiction 150 one CB 119 to the jurisdiction of another CB.
It can be seen that the function of the hyper driver 117 is to allow communications from LAC 116 through blocks 1010, 1012 and 1020 as well as through blocks 1010, 1016 and 1020 to specific CBs, ultimately reaching predetermined AGVs. Likewise, the status of specific AGVs is returned by means of their respective CBs through the first CB interface 120 and eventually back to LAC 116. Likewise, the status of the P & D stands is relayed to or from LAC 116 and to and from respective CBs 119.
Referring now to FIG. 11, there is shown a functionality diagram for control box (CB) 119 (FIG. 1). Control box 119 controls all vehicles 132 and locations in a given jurisdiction 150 (FIG. 1). Similarly, status from all vehicles 132 and devices in a given jurisdiction 150 is reloaded up through appropriate functionality channels to hyper driver 117. Specifically, functionality channels include hyper driver interfaces 1 and 2, 1112 and 1110, respectively, bay to bay AGV movement control 1114, zone and intersection control 1116, LAC/AGV communications 1118, P & D node communication/control 1120, AGV status control 1122, P & D interface 1126 and AGV interface 1124. Conductive communications 121 are connected to AGV interface 1124.
Referring now to FIG. 12, a flow chart of one of the functions of the control box 119 (FIG. 1) is shown. The software loaded in CB 119 is adapted to provide a number of functions, one of which is traffic management within P & D zone clusters.
When an AGV (vehicle A) approaches a cluster of P & D stands, step 1210, the vehicle reads the code tag buried underground and CB, not shown, determines whether another AGV (vehicle B) is already in the specified cluster, step 1212. If that is the case, CB determines whether vehicle B is merely passing through the cluster on its way to another destination, step 1214.
If vehicle B is not merely passing through, LAC 116 determines whether vehicle B has already pulled in to a P & D stand, step 1216. If vehicle B is not in a P & D stand, vehicle A must wait, step 1218, until that event occurs. Once vehicle B pulls into a P & D stand, step 1216, vehicle A may enter the specified cluster, step 1220.
At any point in the process, when CB 119 determines that it is safe for vehicle A to enter the cluster, the vehicle is instructed to do so, step 1220.
Once in the cluster, CB 119 determines whether vehicle A must perform a pickup or delivery operation, step 1222. The pickup or delivery ensues, step 1224. At this point, vehicle A is free to request permission to leave the P & D stand, step 1212, and the flow of operations continues in the same manner as hereinabove described.
Referring now to FIG. 13, there is shown a flow chart for another function of control box 119 (FIG. 1). CB 119 monitors an intersection, step 1310. If an AGV 132 is in the intersection, step 1312, a stop command is transmitted at all intersection entrances, step 1314. This stop command prevents any other AGV from entering the occupied intersection.
CB 119 determines whether AG 132 has exited the intersection, step 1316. Once the AGV has left the intersection, CB determines whether more than one other AGV is waiting to enter the intersection, step 1318.
If only one or no AGVs are waiting, all intersection code tags are cleared, step 1320, so that the next approaching AGV may enter the intersection without delay. If, however, more than one AGV is waiting to enter the intersection, step 1318, CB chooses a code tag at one intersection to be released, step 1322, thereby permitting only one of the waiting AGVs to enter the intersection while prohibiting all remaining AGVs from doing so.
Monitoring the intersection, step 1310, continues indefinitely.
Referring now to FIG. 14, there is shown the signal conditioning card 810 (FIG. 8) in greater detail. Conventional decode logic is provided at reference numeral 1410. All cards in computer 350 contain the same sort of decode logic. An output port 1412 is connected to failsafe logic 1414. Failsafe logic 1414 is used to prevent mutually exclusive conditions, such as travelling forward and reverse at the same time.
Another output port 1416 has the same logic as output port 1412. An input port 1418 is connected to debounce circuitry 1420. In general, all input ports described herein are similar to input port 1418 and all output ports are similar to output port 1412. Output port 1422, connected to digital/analog converters 1423, results in changing the speed or horn amplitude shown at reference numeral 1424.
As used herein, the designation PPI refers to parallel ports and are numbered consecutively from PPI 1 through PPI 5. The proper operation of such parallel ports is monitored by corresponding selectable items in the aforementioned menus.
Referring now to FIG. 15, there is shown the Butterworth guidance control card 81 (FIG. 8) in greater detail. A microprocessor 1510 such as is manufactured by Motorola corporation as Model no. 68705 contains firmware for guidance control algorithms. In general, guidance control algorithms control movement of AGVs despite unequal loading, anomalies that occur during turns, and other maneuvers and the like.
Microprocessor 1510 communicates with the AGV computer, not shown, by means of standard decode logic 1511. Connected to microprocessor 1510 is a parallel port 1512 which forms the gateway of communications between microprocessor 1510 and AGV computer, not shown. Connected to microprocessor 1510 by means of PPI 1512 are sensors from the guidance system 1514, such as position sensors, phase, center, forward and reverse for front and rear wheels, and steering. Also connected to PPI 1512 is a temperature circuit 1516 to indicate the temperature of the vehicle.
Referring now to FIG. 16, there is shown the digital card 846 (FIG. 8) in greater detail. Level shift 1610 debounces signals that are input thereto and translates all signals to proper voltage levels between 5 volts and ground. The self test circuitry 1612 is used on power up to test all operating systems in the vehicle. A tri-state buffer 1614 connected to self test unit 1612 and input signals at level shift 1610 allows an operator to detect the status of any diagnostics bits that are input to level shift 1610. In other words, tri-state buffer 1614 provides the state of all of the input levels in a logic sense.
Thus, any of the functions that are input to level shift 1610 (e.g., proximity sensor or deadman/enter), are continually monitored and provided at tri-state buffer 1614. When the signal is active, it is designated as a binary 1 and when inactive it is designated binary value is 0. Since the aforementioned process is a real time operation, any monitored anomaly results in the tri-state buffer immediately shifting for the associated bit. When the anomaly is removed, the tri-state buffer immediately resets to a nominal value.
A priority interrupt chip 1616 is connected to tri-state buffer 1614 for interrupting system operation upon sensing an anomaly. A serial port 1618 is used to interface to guidance sensor 844 (FIG. 8). Two additional serial ports 1618a and 1618b are unused in the present embodiment.
Referring now to FIG. 17, there is shown the non-volatile memory card 850 (FIG. 8) in greater detail. A communications bus interface 1710 is provided to pass information to a precision distance shaft and encoder 1712 which is operatively connected to the axle of side wheels of the vehicle 132. Precision distance in encoder 1712 allows for precise distance measurement based on rotation of the axle. While coarse measurements are made from the front and rear wheels, for very precise measurement within fractions of an inch, the precision shaft and encoder 1712 is used. Shaft encoder 1712 allows the unit to act in a rotate and advance mode wherein each of the two side wheels is monitored independently. The effect is to have the AGV positioned very accurately despite vehicle turns.
Also connected to communications bus interface 1710 is an EPROM (reference numeral 728 in FIG. 7) such as is provided by Intel Corp. as Model no. 27C512, having 64K bytes of memory. Eprom 1714 stores operations program instructions, such as that embodied in Appendix II. EPROM 1714 contains algorithms and instructions to perform the following functions:
a) all diagnostics
b) map of floor
c) pathfinding
d) traffic control
e) communications
f) speed control
g) safety functions
h) built in self test
i) power on self test
The aforementioned functions are programmable and, of course, are dependent upon the environment in which the AGV system is to operate. For example, the map of the floor must change with each facility.
Accordingly, an operator can change AGV critical instructions merely by exchanging one EPROM 1714 for another, suitably programmed EPROM. In this way, the AGV can be customized easily for greatest flexibility without the necessity of changing hardware.
Also connected to communications bus interface 1710 is an 8K nonvolatile RAM 1716. RAM 1716 is used to maintain data in the event of power interruption. Such data may consist of previous transactions, in which case the data stored in RAM 1716 can be used much like a flight recorder, and can be analyzed to determine what caused mal functions or power interruptions themselves. The stored data can be used when power is resupplied to the system.
Also connected to communications bus interface 1710 is a display buffer 1718 for driving the electroluminescent display H (FIG. 5a).
Referring now to FIG. 18, there is shown the traffic manager which resides in control box 119 (FIG. 1) and which contains software such as that described hereinabove with respect to FIG. 12. Decode logic is shown generally at reference numeral 1810, and is similar to the decode logic used on other cards hereinabove mentioned. When a computer such as a PC/XT is driving the system, decode logic 1810 is used to interface such computer to the rest of the board.
Microprocessor or CPU 1812, manufactured by Motorola Corp. as Model no. 68HC11 is provided to control traffic. Connected to CPU 1812 is data 1814 for allowing a PC/XT, not shown, to communicate therewith.
Serial communication ports 1816 are connected to microprocessor 1812.
Seventeen traffic output signals are provided at connector 1818 which allow data from microprocessor 1812 to enable an external card, not shown, to excite a receiver loop disposed under the surface of the floor.
Similarly, a twelve-signal traffic input connector 1820 is used to receive a signal from the transmit coil in the AGV. The signal is demodulated by circuitry shown generally at reference numeral 1822. Thus, a tone that is received at connector 1820 is converted to a logic level. If traffic is present, a logical 1 is transferred to microprocessor 1812.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. | An AGV and guidance system for transporting material between at least two pickup and delivery stands. The AGV has a chassis for carrying objects. A computer processor is supported by the chassis for controlling and monitoring AGV operation. An interactive display is connected to the computer processor and mounted on the chassis for displaying status, current assignment and diagnostic information relating to AGV operation. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a Continuation in Part (CIP) Application of a co-pending application Ser. No. 13/289,918 filed on Nov. 4, 2011 by a common inventor of this application. Application Ser. No. 13/289,918 is a Divisional application and claims the Priority Date of another application Ser. No. 12/606,290 filed on Oct. 27, 2009 now issued into U.S. Pat. No. 8,076,183. The Disclosures made in the patent application Ser. Nos. 13/289,918 and 12/606,290 are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a semiconductor power device and preparation method thereof. Particularly, this invention aims at providing a power device with a bottom source electrode and preparation method thereof.
DESCRIPTION OF THE RELATED ART
[0003] Power consumption of power devices is commonly very high. In the application of DC-DC power converter devices, some metal electrodes of the devices are usually exposed from plastic packaging material coating a semiconductor chip for improving the electrical connection and heat dissipation performance of the devices. For example, as shown in FIG. 1 , US patent application publication US2003/0132531A1 discloses a semiconductor packaging structure 24 with a bottom electrode of a semiconductor chip exposed and used for supporting surface mounting technology. Here, a power MOSFET 10 is arranged in an interior space of a cup-shaped metal can 12 and a drain electrode at one side of the MOSFET 10 is connected to the bottom of the interior space of the cup-shaped metal can 12 through a layer of conductive epoxy 14 , so that the drain electrode of the MOSFET 10 is electrically connected to an extruding edge 22 of the cup-shaped metal can 12 , while a source electrode 18 and a gate electrode (not shown) located at the other side of the MOSFET 10 become sub-flush with the surface of the extruding edge 22 . Low stress and high adhesion epoxy 16 is provided to fill in gaps in the interior space of the cup-shaped metal can 12 surrounding the MOSFET 10 . The semiconductor packaging structure 24 improves the heat dissipation performance. However, it is expensive to form the cup-shaped metal can 12 in actual production. In addition, both the source electrode and the gate electrode of the MOSFET 10 are fixed in the packaging structure 24 , as a result the contact surface of the gate electrode cannot be adjusted to level with the extruding edge 22 , thus it is hard to match the contact surface of the gate electrode with a pad on a PCB (Printed Circuit Board), which limits the application of the semiconductor packaging structure 24 .
[0004] In addition, the resistance of a substrate in the chip of the power device is usually high, this makes the RDSon of the device correspondingly high; therefore, there is a need to reduce the resistance of the substrate of the chip. In a conventional wafer level chip scale packaging (WLCSP), packaging test is performed and ball placement on a wafer (for ball bonding) is carried out after the processing of all power devices in the whole wafer is completely finished, individual IC (Integrated Circuit) is then singulated with its size being same as the desired original chip.
[0005] Given the above description of related prior arts, therefore, there is a need to manufacture ultra thin chips by WLCSP and to apply these chips in power devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The embodiment of the present invention is described more sufficiently through the drawings. However, the drawings are only used for explaining and illustrating rather than limiting the scope of the invention.
[0007] FIG. 1 is a cross sectional schematic diagram of the semiconductor packaging structure of the prior art.
[0008] FIGS. 2A-2E are structural schematic diagrams of the power devices according to a first embodiment of the present invention.
[0009] FIGS. 3A-3F are schematic diagrams illustrating a process for preparing the primary packaging structure of the power devices of the present invention.
[0010] FIGS. 4A-4C are cross sectional schematic diagrams illustrating a process for preparing the power devices of the present invention.
[0011] FIGS. 5A-5B are cross sectional schematic diagrams illustrating the power devices according to a second embodiment of the present invention.
[0012] FIGS. 6A-6D are structural schematic diagrams illustrating the power devices according to a third embodiment of the present invention.
[0013] FIGS. 7A-7C are structural schematic diagrams illustrating the power devices according to a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] FIG. 2A and FIG. 2B are schematic diagrams showing a top view and a bottom view of the power device 100 A of a first embodiment of the present invention. FIG. 2C and FIG. 2 D- 1 are cross sectional views of the power device 100 A along a plane AA and along a plane BB respectively shown in FIG. 2B . The power device 100 A comprises a lead frame unit including a first base 111 , a second base 112 , a third base 113 and a fourth base 114 (as shown in FIG. 2B ). The thicknesses of all the bases are basically the same and the bases are arranged on the same plane. The first base 111 preferably has a square shape. The third base 113 and the fourth base 114 are arranged at two opposite sides of the first base 111 respectively and extend along the edges of the first base 111 , and the second base 112 is positioned adjacent to the first base 111 between the third base 113 and the fourth base 114 . In one embodiment, the third base 113 and the fourth base 114 are symmetrical relative to the center of the first base 111 , thus the second base 112 is positioned on a line of symmetry of the third base 113 and the fourth base 114 . Usually, a lead frame strip comprises a plurality of such lead frame units with the bases connected to the lead frame strip through connecting bars (not shown).
[0015] As shown in FIG. 2C and FIG. 2D-1 , the power device 100 A also comprises a primary packaging structure 130 that is a completely packaged structure rather than an unpackaged original chip. The primary packaging structure 130 includes a semiconductor chip 131 that is flipped and attached onto the first base 111 and the second base 112 . Conductive epoxy (such as conductive solder or paste) is used for forming a plurality of balls or bumps 132 a - 1 and 132 b - 1 on the front surface of the primary packaging structure 130 for attaching it onto the second base 112 and the first base 111 respectively. As shown in FIGS. 2 C and 2 D- 1 , the primary packaging structure 130 comprises a semiconductor chip 131 and a top plastic packaging layer 134 covering the front surface of the chip 131 . The front surface of the chip 131 is provided with a plurality of metal pads. The solder bumps 132 a - 1 and 132 b - 1 are placed on the metal pads, which will be described in details later. The top plastic packaging layer 134 of the primary packaging structure 130 are only encapsulated on the side walls of the solder bumps 132 a - 1 and 132 b - 1 . A bottom metal layer 133 is formed at the back surface of the chip 131 .
[0016] The power device 100 A also comprises a bridge-shaped metal clip 150 (also shown in FIG. 2E ) attached to the bottom surface of the flipped primary packaging structure 130 or to the bottom surface of the bottom metal layer 133 of the flipped chip 131 . The bridge-shaped metal clip 150 is also attached to the third base 113 and the fourth base 114 . The bridge-shaped metal clip 150 comprises a top metal portion 151 and side metal portions 153 a and 153 b connected to two opposite sides of the top metal portion 151 . The side metal portions 153 a and 153 b are bent downwards as shown in FIG. 2C . In particular, the side metal portions 153 a and 153 b are bent away from each other, so that the angles formed between the side metal portions 153 a and 153 b and the top metal portion 151 are obtuse angles. In one embodiment, the side metal portions 153 a and 153 b are symmetrically located relative to the center of the top metal portion 151 . In addition, a groove 113 a is formed on the top surface of the third base 113 and a groove 114 a is formed on the top surface of the fourth base 114 . As a result the side metal portion 153 a can be attached and trapped in the groove 113 a , likewise the side metal portion 153 b can be attached and trapped in the groove 114 a . A conductive material 140 , such as a conductive solder or paste, is applied to bond the bottom surface of the top metal portion 151 to the bottom metal layer 133 . The groove 113 a and the groove 114 a can be of many shapes, for example, the grooves 113 a and 114 a can be in V-shape, as shown in FIG. 2C , for convenient engagement with the side metal portions 153 a and 153 b . The side metal portions 153 a and 153 b are respectively attached to the third base 113 and the fourth base 114 through conductive epoxy deposited in the groove 113 a and the groove 113 b.
[0017] Furthermore, the power device 100 A also comprises a plastic packaging body 160 encapsulating the lead frame unit, the primary packaging structure 130 and the bridge-shaped metal clip 150 . As shown in FIG. 2B where the power device 100 A is finally mounted on a PCB with the first base 111 , the second base 112 , the third base 113 and the fourth base 114 serving as electrical contacts directly connected to the pads on the PCB. Here, the respective bottom surfaces of the first base 111 , the second base 112 , the third base 113 and the fourth base 114 should be exposed from the bottom surface of the plastic packaging body 160 . Furthermore, as shown in FIG. 2B , the third base 113 and the fourth base 114 usually include a plurality of pins, for example pins 113 ′ and pins 114 ′. Therefore, the bottom surfaces of the pins 113 ′ and the pins 114 ′ are also exposed from the bottom surface of the plastic packaging body 160 and serving as the electrical contacts of the third base 113 and the fourth base 114 .
[0018] In the embodiment shown in FIGS. 2 C to 2 D- 1 , one or more through holes 152 are formed through the whole thickness of the top metal portion 151 . FIG. 2E shows a top view of the bridge-shaped metal clip 150 including a through hole 152 . The through hole 152 can be of a ‘cross’ shape as shown in FIG. 2E or can be of round, rectangle, polygon or any other suitable shapes. The through hole 152 is used for venting gas during the reflow of the conductive material 140 that attaches the top metal portion 151 to the bottom metal layer 133 . Additionally, any excess of the conductive material 140 deposited to form a conductive layer between the top metal portion 151 and the bottom metal layer 133 can be dredged into the through holes 152 so that the final layer thickness of the conductive material 140 is uniform.
[0019] In another embodiment as shown in FIG. 2D-2 , one or more clip grooves 152 ′ can be formed from a bottom surface of the top metal portion 151 with the bottom of the clip groove 152 ′ ended up inside the top metal portion 151 . The groove 152 ′ may be of many shapes similar to the through holes 152 as described above. Similar to the though hole 152 , the clip groove 152 ′ is used for venting gas during the reflow of the conductive material 140 for attaching the top portion 151 to the bottom metal layer 133 and for holding any excess of the conductive material 140 deposited to form a conductive layer between the top metal portion 151 and the bottom metal layer 133 thus improving the thickness uniformity of the conductive material 140 .
[0020] Another difference between the embodiment of FIG. 2D-1 and that of FIG. 2D-2 is that the top surface of the top metal portion 151 as shown in FIG. 2D-1 is not exposed from the plastic packaging body 160 whereas the top surface of the top metal sheet 151 as shown in FIG. 2D-2 is exposed from the plastic packaging body 160 . To achieve a structure as shown in FIG. 2D-2 , before depositing a plastic packaging material, such as epoxy resin, to form the plastic packaging body 160 , a resist film (not shown) can be applied to the inner surface of the top chase of the molding tool, which is then brought in contact with and covers the top surface of the top metal portion 151 thus preventing it from coverage by the plastic packaging materials. The plastic packaging body 160 encapsulates the lead frame unit, the primary packaging structure 130 and the side metal portions 153 a and 153 b of the bridge-shaped metal clip 150 . After the plastic packaging material is solidified, the resist film is peeled off from the top surface of the top metal portion 151 , thus the top surface of the top metal portion 151 is now exposed from the top surface of the plastic packaging body 160 . This plastic packaging process is usually completed at a wafer processing level (i.e., this technology is used in WLCSP), which is well known in the art.
[0021] In another embodiment of the invention, recessed portions 154 a and 154 b formed on the top surface of the top metal portion 151 at the corner of the top metal portion 151 are configured to connect the side metal portions 153 a and 153 b thus forming a step structure. FIGS. 2C-2E illustrate the structure of the bridge-shaped metal clip 150 . Typically, the side metal portions 153 a and 153 b are originally formed on the same plane of the top metal portion 151 , then the side metal portions 153 a and 153 b are bent downward by an angle (through a stamping method), so that the angles formed between the side metal portions 153 a and 153 b and the top metal portion 151 are obtuse angles. However, the thus obtained final top metal portion 151 is not a flat plane and the edges of the top surface of the top metal portion 151 at the corner of the top metal portion 151 and the side metal portions 153 a 153 b do not form a straight line. Therefore, the recessed portions 154 a and 154 b at the corner of the top metal portion 151 and the side metal portions 153 a 153 b can beneficially buffer and stop the tension influences of the side metal portions 153 a and 153 b on the top metal portion 151 during the stamping step with the thus obtained top metal portion 151 free of deformation, in which case lines 151 a - 1 and 151 a - 2 at the two sides of the top surface of the top metal portion 151 are now straight lines and the top surface of the top metal portion 151 is now a flat rectangular plane.
[0022] FIGS. 3A-3F illustrate a method for preparing the primary packaging structure 130 . A wafer 1310 (shown in FIG. 3C ) usually includes numerous semiconductor chips 131 (shown in FIG. 3A ) formed at the top surface of the wafer and spaced-apart by scribe lines (not shown), which is well known in the art. The front surface of the chip 131 includes numerous metal pads 132 , such as aluminum-silicon pads, which serve as the electrodes of the chip or the terminals for off-chip signal transmission. In a preferred embodiment, the chip 131 is a vertical power metal oxide semiconductor field effect transistor (MOSFET). The metal pads 132 include metal pads 132 b forming the first electrode (such as a source electrode) of the chip 131 and a metal pad 132 a forming the second electrode (such as a gate electrode) of the chip 131 , while the drain electrode area of the chip 131 is formed at the back surface of the chip 131 (not shown). Firstly, numerous solder bumps are formed on the metal pads 132 by ball placement or plating and the likes. As shown in FIG. 3B , a solder bump 132 a - 1 is formed on the metal pad 132 a and a solder bumps 132 b - 1 are formed on the metal pads 132 b . As the area of the metal pad 132 b forming the source electrode is usually larger than that of the metal pad 132 a forming the gate electrode, the size of the solder bumps 132 b - 1 is also larger than that of the solder bumps 132 a - 1 to carry large currents. Alternatively, numerous solder balls of smaller size than the solder bump 132 b - 1 can be placed on the metal pad 132 b (not shown) and are closer to each other, so that the solder balls can be merged into one piece after being heated, softened and melted to form the solder bump 132 b - 1 of a larger size. As shown in FIG. 3C , a plastic packaging layer 1340 is formed on the front surface of the wafer 1310 covering all the solder bumps 132 a - 1 and 132 b - 1 . Then the plastic packaging layer 1340 is ground until the solder bumps 132 a - 1 and 132 b - 1 are exposed through the plastic packaging layer 1340 . As shown in FIG. 3D , the top surfaces of the solder bumps 132 a - 1 and 132 b - 1 and the top surface of the plastic packaging layer 1340 are co-planar. The plastic packaging layer 1340 physically supports the wafer 1310 . Therefore, when the wafer 1310 is ground and thinned, the wafer 1310 is not prone to crackage. This means that highly desirable ultra-thin chips with reduced substrate resistance can be made. As shown in FIG. 3E , after the back surface of the wafer 1310 is ground and thinned, impurity ions can be heavily doped into the back surface of the thinned wafer 1310 (optionally), and then a metal layer 1330 can be deposited onto the back surface of the thinned wafer 1310 forming the drain electrode at the back surface of the chip. The wafer 1310 , the plastic packaging layer 1340 and the metal layer 1330 (as shown in FIG. 3E ) are then cut apart to form individual primary packaging structures 130 (as shown in FIG. 3F ), each of which includes a single chip 131 and a top plastic packaging layer 134 covering the front surface of the chip 131 . The top plastic packaging layer 134 only covers the side walls of the solder bumps 132 a - 1 and 132 b - 1 with the top surface of the solder bumps 132 a - 1 and 132 b - 1 exposed through the top plastic packaging layer 134 and is co-planar with the top surface of the top plastic packaging layer 134 . In this step, the metal layer 1330 is also cut apart into numerous bottom metal layers 133 , each of which covers the back surface of a chip 131 and is contact with the drain area at the back surface of the chip 131 forming the third electrode (such as the drain electrode) of the chip 131 .
[0023] As shown in FIG. 2D-1 , the solder bump 132 b - 1 , formed on the metal pad 132 b forming the first electrode of the chip, is attached to the top surface of the first base 111 . As shown in FIG. 2C , the solder bump 132 a - 1 , formed on the metal pad 132 a forming the second electrode of the chip, is attached to the top surface of the second base 112 . As shown in FIG. 2B , the surface area of the first base 111 forming the source electrode is usually larger than the surface area of the second base 112 forming the gate electrode. Therefore, the exposed area of the bottom surface of the first base 111 is larger than the exposed area of the bottom surface of the second base 112 , which also performs the function of heat dissipation. The third base 113 and the fourth base 114 are electrically connected to the drain electrode of the chip 131 through the bridge-shaped metal clip 150 .
[0024] FIGS. 4A-4C illustrate a method for preparing the power device 100 A shown in FIG. 2D-1 along the line BB of FIG. 2B . However, the preparation of the power device 100 A shown in FIG. 2C along the line AA of FIG. 2B is also described but not shown in FIGS. 4A-4C . In FIG. 4A , a lead frame unit is provided firstly. The lead frame unit includes the first base 111 , the second base 112 , the third base 113 and the fourth base 114 , all of which are separated from each other, with the third base 113 and the fourth base 114 respectively arranged at the two opposite sides of the first base 111 as described above. The primary packaging structure 130 is then attached on the first base 111 and the second base 112 of the lead frame unit by a conductive epoxy. In this step, the plurality of solder bumps 132 b - 1 and 132 a - 1 (see FIG. 3F ) formed on the front surface of the primary packaging structure 130 are respectively attached to the first base 111 and the second base 112 by a conducting material, such as the conducting material 120 b shown in FIG. 4A . In FIG. 4B , the bridge-shaped metal clip 150 is mounted atop the primary packaging structure 130 . The bridge-shaped metal clip 150 comprises the top metal portion 151 and the side metal portions 153 a and 153 b connected to two opposite sides of the top metal portion 151 and bent downwards. In this step, the top metal portion 151 is directly attached to the primary packaging structure 130 . The side metal portions 153 a and 153 b are respectively aligned and positioned in the groove 113 a at the top surface of the third base 113 and the groove 114 a at the top surface of the fourth base 114 . Conductive epoxy is deposited in the groove 113 a and the groove 114 a for attaching the side metal portions 153 a and 153 b of the bridge-shaped metal sheet 150 to the third base 113 and the fourth base 114 respectively. As such, the bridge-shaped metal clip 150 is precisely located in the groove 113 a and the groove 114 a . A bottom metal layer 133 at the back surface of the primary packaging structure 130 is connected to the bottom surface of the top metal portion 151 through the conductive material 140 . In FIG. 4C , the plastic packaging material is deposited to form the plastic packaging body 160 encapsulating the lead frame unit, the primary packaging structure 130 and the bridge-shaped metal clip 150 . The bottom surfaces of the first base 111 , the second base 112 , the third base 113 and the fourth base 114 of the lead frame unit are exposed from the bottom surface of the plastic packaging body 160 , while the top surface of the top metal portion 151 can be selected whether to be exposed from the top surface of the plastic packaging body 160 or not. In FIG. 4C , the top metal portion 151 is covered by the plastic packaging body 160 and the through hole 152 in the top metal portion 151 is filled with plastic packaging material.
[0025] FIGS. 5A-5B illustrate a structure of a power device 100 B according to another embodiment of the invention. The structure of power device 100 B is mostly similar as the structure of power device 100 A excepting the structure of the bridge-shaped metal clip 150 . As shown in these figures, the top metal portion 151 does not include a through hole. Instead it includes pluralities of dimples 155 formed on the bottom surface of the top metal portion 151 . The dimples 155 extrude from the bottom surface of the top metal portion 15 land are located between the bottom metal layer 133 and the bottom surface of the top metal portion 151 after the bridge-shaped metal clip 150 is mounted on the primary packaging structure 130 . With the dimples formed between the bottom metal layer 133 and the bottom surface of the top metal portion 151 , the thickness of the conducting material 140 is uniform. As shown in FIG. 5B , the top surface of the top metal portion 151 of the power device 100 B is not exposed from the plastic packaging body 160 . Alternatively, the top surface of the top metal portion 151 can be exposed from the top surface of the plastic packaging body 160 (not shown).
[0026] FIGS. 6A-6D illustrate a power device 100 C of another embodiment of the invention with the structure and the position of a second base of the lead frame unit different from that in the power devices 100 A and 100 B. FIGS. 6B and 6C are cross sectional schematic diagrams along the dotted lines AA and BB in FIG. 6A respectively. As shown in FIGS. 6A and 6B , the second base 212 includes a base extension 212 a and an external pin 212 b connected to the base extension 212 a . The thickness of the base extension 212 a is thinner than the thickness of the first base 111 and thus the base extension 212 a is encapsulated inside the plastic packaging body 160 . Only the bottom surface of the external pin 212 b is exposed from the bottom surface of the plastic packaging body 160 .
[0027] As shown in FIG. 6A , the length of the fourth base 214 is shorter than the length of the third base 113 and the external pin 212 b is arranged on the same side as the fourth base 214 . Particularly the external pin 212 b and a plurality of pins 214 ′ in the fourth base 214 are arranged on the same straight line. The base extension 212 a extends under the primary packaging structure 130 until the solder bump 132 a - 1 on the front surface of the primary packaging structure 130 superimposed on the base extension 212 a . As such, the conducting material 120 a is deposited for attaching the solder bumps 132 a - 1 on the top surface of the base extension 212 a . As shown in FIGS. 6B-6C , the top surface of the base extension 212 a and the top surface of the first base 111 are arranged on the same plane substantially, so that the primary packaging structure 130 is easily mounted on the first base 111 and the base extension 212 a of the second base 212 . The thickness of the base extension 212 a is thinner than the thickness of the first base 111 so that the extension base 212 a is encapsulated inside the plastic packaging body 160 to avoid any negative effect on subsequent SMI technology. The external pin 212 b and the fourth base 214 are arranged on the same straight line, therefore, to avoid a short circuit between the external pin 212 b and the bridge-shaped metal clip 150 , as shown in FIG. 6D , the bridge-shaped metal clip 150 includes a shorter side metal portion 153 ′ b for connecting to the fourth base 214 without connecting to the external pin 212 b of the second base 212 . Particularly, the width D 1 of the side metal portion 153 ′ b is smaller than the width D 2 of the top metal portion 151 , while the width of the side metal sheet 153 a is the same as the width D 2 of the top metal portion 151 . In the power device 100 C, the top surface of the top metal portion 151 is covered by the plastic packaging body 160 .
[0028] FIGS. 7A-7C illustrate a power device 100 D of another embodiment of the invention. The power device 100 D is similar to the power device 100 C, excepting that the top surface of the top metal portion 151 is exposed from the plastic packaging body 160 . FIG. 7C is a top view of the power device 100 D showing the top metal portion 151 is exposed from the plastic packaging body 160 , which is also used to improve the heat dissipation of the power device.
[0029] The above detailed descriptions are provided to illustrate specific embodiments of the present invention and are not intended to be limiting. Numerous modifications and variations within the scope of the present invention are possible. The present invention is defined by the appended claims. | A power semiconductor package has an ultra thin chip with front side molding to reduce substrate resistance; a lead frame unit with grooves located on both side leads provides precise positioning for connecting numerous bridge-shaped metal clips to the front side of the side leads. The bridge-shaped metal clips are provided with bridge structure and half or fully etched through holes for relieving superfluous solder during manufacturing process. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2008-018452, filed on Jan. 30, 2008, the entire content of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] One embodiment of the present invention relates to an information processing apparatus.
[0004] 2. Description of the Related Art
[0005] There is proposed an information processing apparatus in which a plurality of display units can be detachably joined to one another. An example of such apparatus is disclosed in JP-A-10-063195.
[0006] The information processing apparatus has a main unit that performs processing for displaying contents, and a cover unit that is attached to the main unit by a hinge. A plurality of display units are housed in the cover unit. In a state where the display units are housed in the cover unit, one of the display units is connected to a connector of the main unit, and displays contents under the control of the main unit. The display units are configured to be detachable from the cover unit to be connected to one another to form a single large display device that is attached to the cover unit, which is connected to the connector of the main unit, thereby displaying contents of a large display area under the control of the main unit. Each of the display units are configured that the respective display units may display contents different from one another.
[0007] In thus configured information processing apparatus, however, the main unit displays contents while the content substance (for example, the size of the contents) is changed in accordance with a display format (the display size of the display units or the display device), and the display format cannot be changed in accordance with the content substance.
SUMMARY
[0008] According to one aspect of the present invention, there is provided an information processing apparatus including: a main unit having a flat boxed shape; a first display device that displays contents; a connecting portion that is configured to detachably attach and fix the main unit to another apparatus; a connection interface that communicates with the another apparatus; and a controller that operates to: determine whether the main unit is fixed to the another apparatus by the connecting portion in a manner covering a second display device that is provided in the another apparatus and that the main unit is positioned in a facing state where the first display device faces a user; control, when determined that the main unit covers the second display device of the another apparatus and that the main unit is positioned in the facing state, the another apparatus through the connection interface; and control the first display device to display given contents.
[0009] According to another aspect of the present invention, there is provided an information processing apparatus including: a main unit having a flat boxed shape; a first display device that displays contents; a connecting portion that is configured to detachably attach and fix the main unit to another apparatus; a connection interface that communicates with the another apparatus; a first indicator that indicates a display state of the first display device; and a controller that operates to: determine whether the main unit is fixed to the another apparatus by the connecting portion in a manner covering a second display device that is provided in the another apparatus and that the main unit is positioned in a facing state where the first display device faces a user; control, when determined that the main unit covers the second display device of the another apparatus and that the main unit is positioned in the facing state, the another apparatus through the connection interface; and control the first display device to display given contents.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] A general configuration that implements the various feature of the invention will be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention.
[0011] FIG. 1 is a schematic perspective view showing an appearance of an information processing apparatus according to an embodiment of the present invention.
[0012] FIG. 2 is a block view showing a configuration of the information processing apparatus according to the embodiment.
[0013] FIGS. 3A to 3C are schematic perspective views respectively showing connection states for connecting the information processing apparatuses according to the embodiment.
[0014] FIGS. 4A to 4C are schematic perspective views showing the configuration of the information processing apparatus of the embodiment.
[0015] FIGS. 5A and 5B are views showing the information processing apparatuses according to the embodiment.
[0016] FIG. 6 is a flowchart showing the operation of the information processing apparatus according to the embodiment.
[0017] FIGS. 7A and 7B are views showing the operations of the information processing apparatuses according to the embodiment of the invention.
[0018] FIG. 8 is a flowchart showing the operation of the information processing apparatus according to the embodiment.
[0019] FIGS. 9A and 9B are views showing the operations of the information processing apparatuses according to the embodiment.
[0020] FIG. 10 is a flowchart showing the operation of the information processing apparatus according to the embodiment.
DETAILED DESCRIPTION
[0021] Hereinafter, an embodiment of an information processing apparatus according to the invention will be described in detail with reference to the accompanying drawings.
[0022] FIG. 1 is a schematic perspective view showing an appearance of the information processing apparatus according to the embodiment.
[0023] The information processing apparatus 1 has a flat-box shaped main unit that houses electronic components, such as a processor (CPU) and a storage device (i.e. an HDD), and a power source such as a rechargeable battery. The information processing apparatus 1 includes: a display device 20 , which is configured by, e.g., an LCD panel, that displays characters and images on both faces of the main unit; a transparent touchscreen 21 that is overlapped on the display device 20 ; a sensor 22 that is configured by a camera and a gravity sensor; LEDs 23 a to 23 d that are disposed on the four side faces of the main unit (two side faces are not shown in FIG. 1 ); and connection mechanism 24 a to 24 d that are disposed in the four corners of the main unit, respectively, and through which other information processing apparatuses are to be attached to the main unit.
[0024] The sensor 22 is configured by, for example, a gravity sensor that detects the posture of the information processing apparatus 1 . The sensor 22 may also include other sensors, such as a CCD camera, an IR sensor, or an ultrasonic sensor to detect the line of sight of the user or the presence of the user. In accordance with results of the detections by the plural sensors, which face of the information processing apparatus 1 and which area of the face are viewed by the user are detected. The sensor 22 is disposed on the both faces of the information processing apparatus 1 , respectively.
[0025] Pairs of the LEDs 23 a to 23 d are respectively disposed on the side faces. In the LEDs 23 a to 23 d , those which are on the side where the display device is turned on are lit on, whereby the user is informed of the display state of the display device. For example, when the LEDs 23 a and 23 c , shown in FIG. 1 , are lit on, they indicate that the display device 20 is in the display state. When the LEDs 23 b and 23 d are lit on, they indicate that another display device which is disposed on the rear face of the display device 20 , which is not shown in FIG. 1 , is in the display state.
[0026] FIG. 2 is a block view showing a block diagram of the information processing apparatus 1 according to the embodiment.
[0027] The information processing apparatus 1 is provided with: a connection interface 10 A which communicates with other information processing apparatuses having the same configuration; a controller 10 which controls operations of other components of the information processing apparatus 1 . and which controls or is controlled by controllers of the other information processing apparatuses via the connection interface 10 A; an image processor 11 which processes image information, and which displays the information on the display device 20 ; an input device interface 12 which outputs commands that are input through the touchscreen 21 , as an operation signal to the controller 10 ; a sensor controller 13 which analyzes information that is input into the sensor 22 , and which outputs a result of the analysis as a sensor signal; and an LED controller 14 which controls the light on/off of the LEDs 23 (LEDs 23 a to 23 d ).
[0028] The information processing apparatus 1 is further provided with: a memory 15 which temporary stores information to assist processes for various components; a storage 16 which stores information in a readable/writable manner, and which is configured by an HDD; a communication interface 17 which performs wireless communication in accordance with a standard such as a wireless LAN via an antenna 17 A; and an audio processor 18 which processes audio information, and which applies an audio input/output control on a speaker 18 A and amicrophone 18 B. These components are connected to one another through a bus 19 .
[0029] The connection interface 10 A performs wireless communication in accordance with a standard such as Bluetooth®. Alternatively, a wired connection may be performed.
[0030] FIGS. 3A to 3C are schematic perspective views respectively showing manners of connecting information processing apparatuses according to the embodiment of the invention.
[0031] Information processing apparatuses 1 A to 1 D which have the same configuration as the information processing apparatus 1 are contacted and attached to one another by the respective connection mechanism as shown in FIGS. 3A to 3C . As shown in FIG. 3A , for example, the information processing apparatuses 1 A to 1 D are attached so as to be stacked with one another. The attached state of the information processing apparatuses 1 A to 1 D can be changed from the state shown in FIG. 3A to that shown in FIG. 3B in a manner similar to opening of a book. As shown in FIG. 3C , the information processing apparatuses 1 A to 1 D can be attached to one another so as to be arranged on the same plane to form a single large display device.
[0032] FIGS. 4A to 4C are schematic perspective views showing the configuration of the information processing apparatus 1 according to the embodiment.
[0033] As shown in FIG. 4A , the connecting portion 24 (connection mechanism 24 a to 24 d ) of the information processing apparatus 1 are disposed in the four corners of the information processing apparatus 1 , respectively, and, for example, have a spherical cavity portion 240 , and a spherical magnet 241 which is disposed in the cavity portion 240 .
[0034] In the case where, as shown in FIG. 4B , side faces of the information processing apparatuses 1 A and 1 B are attached to each other, the magnets 241 A, 241 B of the connection mechanism 24 A, 24 B are attracted to each other by the magnetic force, thereby maintaining the attached state. The magnets 241 A, 241 B are positioned so as to be closest to each other in the respective cavity portions 240 A, 240 B.
[0035] In the case where, as shown in FIG. 4C , the display faces of the information processing apparatuses 1 A, 1 B are attached to each other, the magnets 241 A, 241 B of the connection mechanism 24 A, 24 B are attracted to each other by the magnetic force, thereby maintaining the attached state.
[0036] Hereinafter, the operation of the information processing apparatuses in the embodiment will be described with reference to the drawings.
[0037] FIGS. 5A and 5B are views showing the information processing apparatuses in the embodiment of the invention.
[0038] The information processing apparatuses 1 A to 1 D communicate with one another via the respective connection interfaces 10 A, to know their relative positions, for example, a state where the apparatuses are attached so as to be stacked with one another as shown in FIG. 5A .
[0039] Next, the information processing apparatuses which are positioned outmost, for example, the information processing apparatuses 1 A, 1 D in FIG. 5A detect the postures of the main units and the line of sight of the user, by using the respective sensors 24 A, 22 D to analyze which one of the information processing apparatuses is viewed and disposed to be operated by the user.
[0040] First, the information processing apparatuses 1 A, 1 D cause the sensors 24 A, 22 D, for example, the gravity sensors to operate, thereby detecting their postures. In the case where the gravity sensors determine that the information processing apparatuses 1 A, 1 D are in a near horizontal state, for example, the possibility that the information processing apparatus 1 A which is positioned in the upper side is viewed by the user is high. Therefore, the sensor 22 A recognizes, for example, the face of the user from an image which is obtained by using a CCD camera, so that the display device which is viewed by the user is identified.
[0041] In the case where the user lies down and holds the information processing apparatuses upside down, for example, the is sensor 22 A of the information processing apparatus 1 A does not detect the user, and the sensor 22 D of the information processing apparatus 1 D which is positioned in the lower side with respect to the direction of gravity detects that the apparatus 1 D is viewed by the user. Alternatively, an IR sensor may be used in place of the CCD camera to detect IR rays emitted from the user. Also in the alternative, the user can be similarly detected. In the case where an ultrasonic sensor is used, the distance to the user is detected.
[0042] In a state where the user holds the information processing apparatuses 1 A to 1 D in hand, contact positions between the touchscreens 21 and the hand(s) of the user may be analyzed to identify the display device which is viewed by the user. Alternatively, the display device with which the user is first in contact may be identified as the display device which is viewed by the user.
[0043] In the case where the information processing apparatuses 1 A to 1 D are not in contact with the user and are placed on a desk or the like, a brighter direction is detected by using an illumination sensor or the like, and the display device which is viewed by the user is identified.
[0044] When, as a result of the above-described operations of the sensors 22 , it is determined that the display device 20 A of the information processing apparatus 1 A is viewed by the user, the operations of the information processing apparatuses 1 A to 1 D are controlled while the information processing apparatus 1 A is set as a master, and the other the information processing apparatuses 1 B to 1 D are set as slaves as shown in FIG. 5B . The information processing apparatus 1 A displays a main screen 200 which is preset by the user, and an operation screen 201 which function as an index of an operation performed by using the touchscreen 21 A, on the display device 20 A, and causes a main-screen indicating LED 230 to light on so as to inform the user of the display state of the display device 20 A.
[0045] FIG. 6 is a flowchart showing the operation of the information processing apparatus of the embodiment of the invention. The plural information processing apparatuses 1 A to 1 D operate in a similar manner. In the following description, therefore, the operation of the information processing apparatus 1 A will be described as an example.
[0046] First, the information processing apparatus 1 A communicates with the other information processing apparatuses 1 B to 1 D via the connection interface 10 A (S 10 ), and obtains the respective overlapping positions (S 11 ).
[0047] When determined that the information processing apparatus 1 A is positioned outmost (S 12 : Yes), the sensor 22 A is operated to analyze the posture of the main unit and the line of sight of the user (S 13 ). If a result of the analysis shows that the main unit is on the surface side with respect to the user (S 14 : Yes), the main unit is set as a master (S 15 ).
[0048] The information processing apparatus 1 A which is set as a master displays the main screen 200 on the display device 20 A (S 16 ), and also the operation screen 201 , and sets the operation screen as an operation surface (S 17 ). Any operation on the touchscreens of the information processing apparatuses 1 B to 1 D is invalidated.
[0049] When determined in step S 12 that the information processing apparatus 1 A is not positioned outmost (S 12 : No), or when the apparatus is positioned outmost, it is determined in step S 14 that the main unit is not on the surface side with respect to the user (S 14 : No), the main unit is set as a slave, and operates in accordance with instructions of one of the other information processing apparatuses which is set as a master.
[0050] FIGS. 7A and 7B are views showing the operations of the information processing apparatuses in the embodiment of the invention.
[0051] In the state where the information processing apparatuses 1 A to 1 D are attached so as to be stacked with one another, the information processing apparatus 1 A can display a content screen 202 showing a photograph, a video picture, or the like on the display device 20 A as shown in FIG. 7A . In the case where the resolution of the photograph or the video picture is larger than that of the display device 20 A, the information processing apparatus 1 A displays a display switchover button 202 a for displaying the contents on a larger display screen.
[0052] When, in the touchscreen 21 A, the area corresponding to the display switchover button 202 a is contacted with the finger or the like, the information processing apparatus 1 A which is a master transmits information of the contents to, for example, the information processing apparatuses 1 B and 1 C which are slaves. When the information processing apparatuses 1 B and 1 C complete image processing of the received content information, the apparatuses cause indicating LEDs 230 a , 230 b to light on, thereby instructing the user to open the information processing apparatuses 1 B and 1 C.
[0053] When the information processing apparatuses 1 B and 1 C are opened by the user to attain the state shown in FIG. 7B , the information processing apparatuses 1 B and 1 C display the image of the contents on the respective display devices 20 B, 20 C. The display devices 20 B, 20 C cooperate with each other as one adequate content screen 203 , so that the contents are displayed at the adequate resolution on the adequate content screen 203 . When contents of a larger resolution are to be displayed, another adequate content screen 203 is configured by using all the display devices of the information processing apparatuses 1 A to 1 D, and then the contents are displayed.
[0054] FIG. 8 is a flowchart showing the operation of the information processing apparatus of the embodiment of the invention.
[0055] First, when the information processing apparatus 1 A is instructed by the user to display contents, the content screen 202 is displayed on the display device 20 A (S 20 ). Next, the information processing apparatus 1 A determines whether the resolution of the contents is larger than the maximum displayable resolution of the display device 20 A or not. If the resolution of the contents is larger than that of the display device 20 A (S 21 : Yes), the display switchover button 202 a is displayed on the display device 20 A (S 22 ).
[0056] Next, when the touchscreen 21 A corresponding to the display switchover button 202 a is operated (S 23 : Yes), the information processing apparatus 1 A transmits data of contents for switching the display to plural ones of the other information processing apparatuses. When the preparation for display is completed in the other plural information processing apparatuses, for example, the information processing apparatuses 1 B and 1 C, the indicating LEDs 230 a , 230 b which correspond to the display devices of the apparatuses are lit on (S 24 ).
[0057] Next, when the user opens the designated screen (S 25 : Yes), the display devices 20 B, 20 C which are the designated screen are set as the adequate content screen 203 , and the contents are displayed on the screen (S 26 ).
[0058] FIGS. 9A and 9B are views showing the operations of the information processing apparatuses in the embodiment of the invention.
[0059] In the state where the information processing apparatuses 1 A to 1 D are attached so as to be stacked with one another, the information processing apparatus 1 A can display an application selection screen 204 for selecting an application which is to be activated, on the display device 20 A as shown in FIG. 9A .
[0060] When, in the touchscreen 21 A, the area corresponding to a desired application is contacted with the finger or the like, the information processing apparatus 1 A which is the master activates the application. In the case where it is set so that plural screens are displayed for an application, the apparatus transmits information of the application to the information processing apparatuses 1 B and 1 C which are slaves. When the information processing apparatuses 1 B, 1 C complete image processing of the received application information, the apparatuses cause indicating LEDs 230 c , 230 d to light on, thereby instructing the user to open the information processing apparatuses 1 B and 1 C.
[0061] When the information processing apparatuses 1 B and 1 C are opened by the user to attain the state shown in FIG. 9B , the information processing apparatuses 1 B, 1 C display images of an application screen 205 and a keyboard screen 206 on the display devices 20 B, 20 C, respectively. In the case where an application which requires a further display device(s) is to be activated, an image of the application is displayed with further using the display device(s) of the information processing apparatus 1 A and/or 1 D.
[0062] FIG. 10 is a flowchart showing the operation of the information processing apparatus of the embodiment of the invention.
[0063] First, when the information processing apparatus 1 A is instructed in the application selection screen 204 by the user to activate an application (S 30 ), the controller activates the application stored in the storage.
[0064] Next, the information processing apparatus 1 A checks the details of the application to be activated. If it is determined that the application uses plural screens (S 31 : Yes), the information processing apparatus 1 A transmits data of the application for switching the display to plural ones of the other information processing apparatuses. When the preparation for activation is completed in the other plural information processing apparatuses, for example, the information processing apparatuses 1 B and 1 C, the indicating LEDs 230 c , 230 d which correspond to the display devices on which the application is to be displayed are lit on (S 32 ).
[0065] Next, when, after the user opens the designated screen (S 33 : Yes), the information processing apparatus 1 A determines that the application requires a keyboard (S 34 : Yes), the keyboard screen 206 is displayed on the information processing apparatus 1 C (S 35 ), and the application is activated in the information processing apparatus 1 B to display the application screen 205 (S 36 ).
[0066] In the case where the application does not require a keyboard (S 34 : No), the application is activated in plural information processing apparatuses to display the application screen 205 (S 38 ). In the case where the application does not use plural screens, the application is activated in the information processing apparatus 1 A (S 37 ).
[0067] According to the above-described embodiment, the information processing apparatus is configured to be able to know the attachment state with respect to the other apparatuses, and displays appropriate contents, for example contents which are set by the user, on the display device that faces the user. Therefore, the display format can be changed in conjunction with the content substance.
[0068] In the case where contents which require a display area larger than the display device of one information processing apparatus are to be processed, the information processing apparatus controls the other information processing apparatuses to display the contents while combining the display devices of the other apparatuses with each other, and indicates the display devices which currently perform the display operation, by lighting on the corresponding instructing portions. Therefore, the display format can be changed in conjunction with the content substance.
[0069] When the remaining power of an internal battery is is low, the information processing apparatus may transfer the mater role to one of the other information processing apparatuses, and switch to the sleep state. When the information processing apparatus positioned in the outside is replaced with another information processing apparatus, the apparatus may transfer the master role to the other information processing apparatus which is newly positioned in the outside, or may not transfer the master role and may control the display of the other apparatus which is positioned in the outside, and which is a slave.
[0070] The information processing apparatus which is the master may be indicated by an LED. The indicator may be configured by a small display device in place of the LEDs, or by a device which indicates the display state by means of sound or vibration.
[0071] When information is processed, the information processing apparatus may cause the controllers of the other information processing apparatuses to perform distributed processing. | An information processing apparatus includes: a main unit having a flat boxed shape; a first display device that displays contents; a connecting portion that is configured to detachably attach and fix the main unit to another apparatus; a connection interface that communicates with the another apparatus; and a controller that operates to: determine whether the main unit is fixed to the another apparatus by the connecting portion in a manner covering a second display device that is provided in the another apparatus and that the main unit is positioned in a facing state where the first display device faces a user; control, when determined that the main unit covers the second display device of the another apparatus and that the main unit is positioned in the facing state, the another apparatus through the connection interface; and control the first display device to display given contents. | 6 |
This is a division of application Ser. No. 842,854 filed Mar. 24, 1986, which is a continuation of Ser. No. 459,999 filed Jan. 21, 1983, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to thermally responsive trigger devices suitable for use in liquid metal (conveniently identified as sodium) cooled systems such as sodium-cooled fast reactors where a trigger may typically be required at temperatures up to 700° C. to release neutron absorber units.
"Hot" magnetic triggers are known. Such devices rely upon the fact that all magnetic materials have a Curie point which is a temperature at which the material becomes de-gaussed and ceases to function magnetically. The attainment of the Curie point can, for example, allow the release of a component which had previously been magnetically held or retained. For such triggers to be acceptable a suitable magnetic material has to be selected to give the trigger function at the correct temperature and at the same time the selected material must be acceptable in the context of its use, and not deteriorate or introduce risks. Such devices are not adjustable and they also operate under stress.
Fusible links are also known but these can give rise to problems similar to those referred to above in relation to magnetic triggers.
Bellows compression devices are also known (see for example GB-PS 1,580,322) in which an expansible material such as sodium-potassium alloy contained in a helical tube, is connected with a reservoir column outside a bellows to compress the bellows with temperature rise and the bellows then operates a trigger via linkages. Such devices include a significant number of co-related parts and hence there must be a modest probability of failure of the parts themselves or at the inter connection between the parts. Repair or replacement of failed parts in a nuclear reactor can be very difficult and costly.
FEATURES AND ASPECTS OF THE INVENTION
The present invention continues with the bellow concept but improves it in that it is arranged for the bellows to be closed (that is it does not have any openings into connecting tubes or bulbs), the bellows has a filling of liquid metal, and the bellows is disposed to act as a trigger device in the vicinity of its free end. The bellows and trigger are then located at the actual location at which temperature is to be sensed.
With this improvement presented it is possible to incorporate it into a nuclear fast reactor in a very advantageous way.
In known fast reactor shut-down arrangements a neutron absorber rod is suspended above the reactor core and is arranged to be released to fall into a receiving channel in the core on receipt of an emergency signal. However, both the core support structure and the absorbing carrying structure can distort and substantial tolerances have to be provided to ensure that the absorber rod will enter its receiving channel and pass into that channel despite distortion.
In this context the present invention takes the already known sub-assembly form of construction of fast reactor cores and the already known devices called "demountable sub-assembly vehicles" used in such cores for conducting irradiation experiments. These vehicles are self-contained and designed for easy removal and insertion into the core. The fact that they are self-contained allows the avoidance or reduction of problems of distortions in and deflections between components of a large integrated structure. The fact that they are easily removable and replaceable allows a high standard of testing and performance to be maintained.
The trigger device of the present invention accordingly finds use in a demountable sub-assembly vehicle having therein a fuel unit, a triggerable absorber unit and coolant inlet and outlet arranged so that coolant in flow between inlet and outlet passes first over the fuel unit and then over a temperature responsive trigger in the absorber unit, which trigger includes said device to trigger the absorber unit to fall when a threshold temperature is reached.
DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to an accompanying drawing, in which:
FIG. 1 shows diagrammatically in elevation in subassembly vehicle incorporating a trigger device according to the invention;
FIG. 2 shows diagrammatically in plan the trigger device in the vehicle of FIG. 1;
FIG. 3 shows in elevation, a cam arrangement which is a part of the trigger device of FIG. 2;
FIG. 4 shows in elevation the support of an absorber unit;
FIG. 5 shows diagrammatically in plan the relative disposition of fuel units, absorber units and coolant units;
FIG. 6 shows an elevation on the line VI-VI of FIG. 5;
FIG. 7 shows another trigger device according to the invention in sectional elevation;
FIG. 8 shows an element of the device of FIG. 7 in a perspective view;
FIG. 9 shows another element of the device of FIG. 7 in perspective view; and
FIG. 10 shows in diagrammatic plan view the device of FIG. 7 used to control the release of control elements in a fast reactor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a removable sub-assembly vehicle 10 having lifting lugs 10a and orientation devices 10b, has two fuel units 11 (only one being shown but see also FIGS. 5 and 6) and two triggerable absorber units 12 (only one being shown). Coolant enters the vehicle at inlet 13, sweeps over the fuelunits 11 and diverts over sodium filled bellows 14 (which are associated with the units 12) and discharges at an outlet 15. The units 12 are suspended above dash pots 16. The fissile region of the fuel units 11 is represented by a hatched portion 11a and the absorber region of the absorber units 12 is represented by a hatched portion 12a which is above the region represented by 11a. Coolant flow is indicated by arrows 17. A by-pass coolant flow is represented by arrows 18. This is substantially smaller than the flow represented by arrows 17 and serves to avoid stagnation around the absorber units 12 and also serves to cool the absorber units 12.
A triggering mechanism, described in more detail with reference to FIG. 2 below, is identified by the numeral 19.
In FIG. 2 there is shown the vehicle 10 which supports a fixed hexagonal shaped plate 20. The plate 20 supports, in its turn, a pair of separately movable rotary wing-shaped plates 21. The plates 21 each have a projectionor lip 22 which latches below a rim 23 of absorber units 12. The plates 21 have upstands 24 secured to them and these define cam slots (as mentioned below with FIG. 3). A cam rod 25 is shown between each pair of upstands 24and this engages with a push rod 26 penetrating apertures 27 in the plate 21.
For FIG. 3 there is shown the bellows 14, which has its free end attached to the push rod 26, and the cam rod 25 engaging a cam slot 28 in the plate24 which is, in turn, secured to a wing-shaped plate 21. The push rod 26 isshown passing through the plate 20.
In FIG. 4 a projection 22 on one of the wing-shaped plates 21 is shown latched below the rim 23 of an absorber unit 12.
In FIG. 5 the sub-assembly vehicle is shown in plan. This comprises two fuel units 11, two bellows 14 associated with triggerable absorber units and two coolant outlet apertures 50. A partition 51 is also provided. Coolant rises vertically in fuel units 11 and, on discharge at the top of the units, the coolant seeks the outlets 50 by sweeping over the bellows 14 of the absorber units. The coolant flow is indicated by arrows 17. The absorber units 12 lie below the outlets 50.
The coolant flow pattern of FIG. 5 is shown in elevation to FIG. 6.
The functioning of the apparatus above described can be considered with FIG. 6 to hand. For normal operation (eg below 600° C.) sodium heated by a fuel unit 11 flows over a sodium filled bellows 14 as indicated by arrows 17. The flowing sodium heats the sodium in the bellowsand causes the bellows to expand. This causes the cam pin 25 to enter the inclined part of cam slot 28. For normal operation FIG. 6 represents the stable operating condition.
If the coolant flow 17 becomes overheated the bellows expand further. This drives the pin 25 further along the slot 28. This causes plate 21 to move and the projection 22 comes clear of the rim 23, (FIG. 4) and the absorberunit 12 then falls freely into the vehicle 10 and reduces the reactivity ofthe fuel unit 11 to set a stable safe condition. These events could typically take place when coolant temperature reaches 700° C.
The sodium-filled bellows which is typically 100 mm long, is capable of providing a 2.5 mm deflection for each 100° C. temperature change with a force of 1000 newtons.
The unit described above can be re-cocked on removal from its position in the reactor core either by removal to the edge of the core or by removal from the reactor to a shielded manipulation facility.
The sub-assembly vehicle above described provides a self-contained unit comprising a control rod, fuel heat source, and control rod trigger fully independent of any external activation and substantially free of distortion problems. In general it will find use as a secondary shut-down device and will provide safety back-up in the event of failure or mobilityof primary devices to cope with faults such as loss of coolant pumping. Thesubassembly vehicle is adaptable in that it can be given a large number of locations in a reactor core and it could accordingly be given alternative positions as burn-up of a core causes reactivity to change. The vehicle isalso adaptable in that the fuel to absorber ratio in any one unit can be preselected. For example, it is possible to have any whole number ratio, in a six compartment unit, between 1:5 and 5:1.
It is also important to note that the bellows 14 operates unstressed and hence is not subjected to stress recycling risks as the reactor changes temperature.
In FIG. 7 there is shown a bellows 70 having a sodium filling 71. The bellows has a top (fixed) end closure 72 and a bottom (free) end closure 73. The closure 72 is held in one part of a structural frame 74 by a screw75 and the closure 73 is constrained laterally but free to move axially in a cup 76. The cup is supported on a spring trigger 77 (FIG. 8) and it has a stem 78 movable in a guide aperture 79 in another part of the structuralframe 74.
In FIG. 8 the spring trigger 77 is shown having two divergent curved wall parts 80 and a curved base 81 with a hole 82 to accommodate the stem 78 ofthe cup 76.
The upper edges of the trigger 77 can support control elements 83 by engaging under lips 84 on the rods. This is illustrated in FIG. 1.
In FIG. 9 the cup 76 is shown in perspective view. The cup has flats 85 to accommodate movement of the wall parts 80 of the trigger.
In FIG. 10 another sub-assembly vehicle 90 is shown . The vehicle 90 consists of a hollow body part 91 in which there are located six units 92.These may be either control units (like elements 83) or fuel units 93, or voids, the combination being selectable. In FIG. 10 four of the units are control units and two are fuel units 93. The control units 83 are latched on the trigger 77 and are supported at a higher level than the fuel units and are, in this way, above the reactor core.
In operation, the bellows 10 is situated at a location so as to be responsive to sodium coolant which has flowed upwardly over the fuel units93 (such flow is indicated by arrows 94). As the coolant temperature rises with the change from zero power in the reactor to operating power so the temperature of the bellows rises and the bellows expands axially. This expansion is unconstrained as the end closure 73 moves freely into the cup16. Should the temperature of the bellows now rise further (because, for example, there has been an unplanned restraint in the coolant flow) then the closure 73 of the bellows acts on the base of the cup 76 and depressesthe cup. At the same time the curved base 81 of the trigger is depressed and this causes the curved wall parts 80 to take up a less divergent orientation until the upper edges of the curved wall parts leave the lips 84 of the control units 83 and the units are free to fall by gravity into the reactor core.
The device described above can be designed to use readily available and relatively inexpensive materials compatible with the hostile environment in which the operation has to be performed and of well-tried performance, namely stainless steel and sodium. The temperature at which the trigger releases can be made adjustable by only relatively simple mechanical operations such as inserting a shallower or deeper cup. The trigger is recockable by the simple operation of raising a released control unit 83 until it relatches on the upper edge of the trigger 77.
The device described above also has the merit that, apart from the trigger 77, it operates unstressed except at the point of operation and even at that point the stress is very low. | A thermally responsive trigger device comprises a closed bellows (14) having a filling of liquid metal and acting on a trigger (19) responsive to the free end of the bellows. The bellows and trigger are located at a temperature measuring location which is the coolant flow outlet (15) from a demountable sub-assembly vehicle (10) having a fuel unit (11) and a triggerable absorber unit (12). The outlet flowing coolant sweeps over the bellows (14) and once the expansion of the bellows exceeds a threshold a pin (26) and cam (28) at the free end of the bellows causes a plate (21) to move to release the absorber unit (12). | 8 |
The present invention relates to the compound of formula (I):
and to the pharmaceutical composition comprising it. This compound is preferably the levogyratory compound (Ia). This compound can be used as an anti-cancer ingredient. The invention also relates to a process for preparing the compound (I) or (Ia) and also to some of the intermediates in said process.
Technical Problem
A number of cancer treatment strategies are aimed at inhibiting the Aurora-type kinases, particularly Aurora A and B, which are involved in the regulation of mitosis; in this regard, see Nature Reviews 2004, 4, 927-936 ; Cancer Res. 2002, 94, 1320 ; Oncogene 2002, 21, 6175 ; Mol. Cell. Biol. 2009, 29(4), 1059-1071 ; Expert Opin. Ther. Patents 2005, 15(9), 1169-1182 ; Clin. Cancer Res. 2008, 14(6), 1639.
Some Aurora inhibitor compounds (for example, MLN-8237 from Millennium, AZD-1152 from Astra-Zeneca or SNS-314 from Sunesis) are presently under evaluation in clinical trials. MLN-8237 is selective for Aurora A while AZD-1152 is selective for Aurora B. Since both kinases, Aurora A and B, are deregulated in cancer, inhibiting both Aurora A and B provides an advantage relative to selective inhibition of one kinase or the other. Moreover, multikinase compounds are in existence, such as the compound AT-9283 from Astex, which inhibit a number of kinases, including Aurora A and B. For this type of compound it is difficult to predict that the inhibition of the Aurora kinases might actually be exploited clinically, since the inhibition of kinases other than Aurora A and B is likely to give rise to side effects. One technical problem the invention intends to solve is therefore that of developing a compound which is a potent and selective inhibitor of Aurora A and B.
The cyclic nucleotide phosphodiesterase enzyme PDE3 plays a major part in the signalling mediated by the cyclic nucleotides cAMP and cGMP that takes place in the myocytes of the smooth cardiac and vascular muscles. The inhibition of PDE3 by small molecules has an inotropic and vasodilatory action, which may prove to be useful on a short-term basis for the treatment of certain cardiomyopathies in which defects in cardiac contraction are a feature. It has been shown, however, that the long-term use of these molecules increases mortality among this type of patient. Furthermore, the use of PDE3 inhibitors in patients who do not present this type of pathology, such as patients affected by cancer, may give rise to unwanted effects on cardiac rhythm. It is therefore important, in the context of an anti-cancer therapy, not to inhibit PDE3. In this regard, see Exp. Opin. Invest. drugs 2002, 11, 1529-1536 “Inhibitors of PDE3 as adjunct therapy for dilated cardiomyopathy”; Eur. Heart J. supplements 2002, 4(supplement D), D43-D49 “What is wrong with positive inotropic drugs? Lessons from basic science and clinical trials”. Another technical problem the invention intends to solve is that the Aurora A and B inhibitor compound shall not inhibit the enzyme PDE3.
It is also important that the anti-cancer ingredient presents a metabolic stability (see section 10.2.2 of “Chimie pharmaceutique” G. L. Patrick, De Boeck, published 2003, ISBN=2-7445-0154-9). The reason is that the inadequacy of the pharmacokinetics of pharmaceutical compounds is one of the primary reasons for failure in their development (Curr. Pharm. 2005, 11, 3545 “Why drugs fail—a study on side effects in new chemical entities”). Moreover, the metabolism is often a major determinant of clearance, of drug interactions, of intra-individual variability in pharmacokinetics, and of clinical efficacy and toxicity ( Curr. Drug Metab. 2004, 5(5), 443-462 “Human hepatocytes in primary culture: the choice to investigate drug metabolism in man”). Another technical problem the invention intends to solve is that the Aurora A and B inhibitor compound shall exhibit high chemical and metabolic stability.
PRIOR ART
Bioorg. Med. Chem. Lett. 2002, 12, 1481-1484 describes in table II the compound 6A, which has a different tricyclic structure.
WO 01/36422 describes compounds having a different tricyclic structure.
WO 2004/005323 describes the compound E5A29 of formula (a):
as an EPO receptor having a different tricyclic structure. Furthermore, the compound does not include a phenyl ring substituted by the group —O-benzimidazolyl at the top of the tricyclic ring system.
WO 2005/016245 describes anti-cancer compounds having a different tricyclic structure, of formula (b):
in which R 4 may represent a substituted phenyl group. Substitution by the —O-benzimidazolyl group is neither described nor suggested.
WO 2007/012972 and EP 1746097 describe anti-cancer compounds of formula (c)
and, in one embodiment, of the formula (c′):
R 2 represents a substituted aryl or heteroaryl group. X represents N or CR 7 , R 5 and R 6 may both represent H or CH 3 . No example in WO 2007/012972 contains the group
which characterizes the compound of formula (I). Moreover, among the compounds resolved. WO 2007/012972 teaches that it is dextrogyratory compounds which are the most active on Aurora A or B (cf. ex. 119 and 120 in the table on page 147).
WO 02/062795 describes compounds of formula (d):
in which R 4 and R 5 may optionally form a 5- or 6-membered ring.
BRIEF DESCRIPTION OF THE INVENTION
The invention relates to the compound of formula (I):
more particularly in its levogyratory form (Ia), particularly that exhibiting the optical rotation [α] D =−38.6±0.7 at a concentration of 0.698 mg/ml in methanol. The compound may exist in the form of a base or an addition salt with an acid, particularly a pharmaceutically acceptable acid. This compound is a selective inhibitor of Aurora A and B kinases. It can be used as an anti-cancer ingredient.
The invention also relates to a pharmaceutical composition comprising the compound and at least one pharmaceutically acceptable excipient, and to the medicament comprising the compound.
The invention also relates to the process for preparing the compound, comprising:
reacting together the three compounds below, PG denoting a protective group for the NH function of the benzimidazole
to give the compound:
deprotecting the NH function of benzimidazole, to give the compound of formula (I); where appropriate, isolating the levogyratory compound.
The reaction between the three compounds is carried out in an alcohol at reflux, particularly 1-butanol. The following intermediates also form part of the invention:
PG may be, for example, the group
DESCRIPTION OF THE INVENTION
The invention relates to the compound of formula (I):
This compound may exist in a racemic form or in the form of the two levogyratory (Ia) and dextrogyratory (Ib) enantiomers. The levogyratory compound (Ia) has a selective inhibitory activity on Aurora A and B kinases which is much greater than that of the dextrogyratory enantiomer (Ib). The levogyratory compound (Ia) also has an anti-proliferative activity which is greater than that of the dextrogyratory enantiomer (Ib) (see Table 1).
The three compounds (I), (Ia) and (Ib) may exist in the form of a base or an addition salt of an acid. The salt is advantageously prepared with a pharmaceutically acceptable acid (see P. Stahl, C. Wermuth; Handbook of Pharmaceutical Salts; Wiley Ed. ISBN-13: 978-3906390260, ISBN-10: 3906390268), although the salt of any other type of acid, which may be used, for example, for a purification or isolation step, also forms part of the invention.
The compounds (I) and (Ia) may be used as anti-cancer ingredients or for preparing a medicament for treating a cancer. The cancer is more particularly a cancer in which Aurora A and/or B kinase(s) are/is involved.
The compounds (I), (Ia) and (Ib) are obtained according to Scheme I below:
step 1: the NH function of a 2-halo-benzimidazole (Hal=Br or Cl) is protected using a protective group PG, to give A1. PG-X represents a reagent which introduces the protective group PG. PG may be, more particularly, dihydropyran
and, in that case. PG-X represents 3,4-dihydro-2H-pyran
step 2: A1 is reacted with 3-formyl-phenol in the presence of a base producing the corresponding phenolate ion, to give B1. The base may be an alkali metal hydride, such as NaH, for example. The reaction is carried out in a polar aprotic solvent such as DMF;
step 3: B1, 3-amino-2-ethoxycarbonylpyrrole and 1,3-cyclohexanedione are reacted with one another, for example in an alcohol (e.g. 1-butanol) at reflux, to give C1;
step 4: the NH function of C1 is deprotected, to give the compound (I). The deprotection conditions are dependent on the nature of PG. For example, where PG represents dihydropyran, a strong acid is used;
step 5: using, for example, a chiral chromatography, the two enantiomers (Ia) and (Ib) are isolated.
For each of steps 1-5, reference may be made to the specific conditions described in example 1.
EXAMPLES
Analytical Methods
Method LC/MS-A
The products for analysis are separated on an Acquity Beh C18 HPLC column, 1.7 μm 2.1×50 mm (Waters) thermostated at 70° C. and eluted at a flow rate of 1 ml/min with a gradient from acetonitrile containing 0.1% formic acid (solvent B) into water containing 0.1% formic acid (solvent A); elution programmeme: isocratic stage at 5% of solvent B for 0.15 min, gradient from 5% to 100% of solvent B in 3.15 min then return to the initial conditions over 0.1 min. The products are detected by an Acquity PDA diode-array UV/vis detector (Waters, wavelength range scanned: 192-400 nm), a Sedex 85 light scattering detector (Sedere, nebulizing gas: nitrogen, nebulizing temperature: 32° C., nebulizing pressure 3.8 bar) and an Acquity SQD mass spectrometer (Waters, operating in positive and negative mode, mass range scanned: 80 to 800 amu).
Method LC/MS-B
The spectra were obtained on a Waters HPLC-SQD instrument in positive and/or negative electrospray ionization mode (ES+/−), under the following liquid chromatography conditions:
column: ACQUITY BEH C18 1.7 μm, 2.1×50 mm; T column : 50° C.; flow rate: 1 ml/min;
solvents: A: H 2 O (0.1% formic acid); B: CH 3 CN (0.1% formic acid); gradient (2 min): 5% to 50% B in 0.8 min; 1.2 min: 100% B; 1.85 min 100% B; 1.95 min 5% B.
1 H NMR
The spectra are recorded on a Bruker spectrometer, the product being dissolved in DMSO-d6. The chemical shifts δ are expressed in ppm.
IR
The infrared spectrum is recorded on a Nicolet Nexus spectrometer, on a KBr disc, with a resolution of 2 cm −1 .
Measurement of the Optical Rotation
The optical rotations were recorded on a Perkin-Elmer 341 polarimeter.
Elemental Analysis
The elemental analyses were made on a Thermo EA1108 analyser.
Measurement of the Activity on Aurora A and B
The capacity to inhibit the kinase activity of the enzyme is estimated by measuring the residual kinase activity of the enzyme in the presence of different concentrations of the test compound (generally from 0.17 to 10 000 nM). A dose-response curve is produced, which allows an IC 50 (50% inhibitory concentration) to be determined. The kinase activity is measured by a radioactive assay of the amount of radioactive phosphate ( 33 P) incorporated into a fragment of the protein NuMA (Nuclear Mitotic Apparatus protein) after 30 minutes of incubation at 37° C. The test compound is first dissolved at different concentrations in dimethyl sulphoxide (DMS (J). Reaction takes place in the wells of a FlashPlate microtiter plate (Nickel Chelate FlashPlate-96, PerkinElmer). Each well (100 μl) contains 10 nM Aurora A, 500 nM NuMA, 1 μM ATP and 0.2 μCi ATP-γ-33P in a buffer of 50 mM Tris-HCl, pH=7.5; 10 mM MgCl 2 ; 50 mM NaCl, 1 mM dithiothreitol. The final percentage of DMSO is 3%. After homogenization by stirring, the plate is incubated at 37° C. for 30 minutes. The contents of the wells are then removed and the wells are washed with PBS buffer. The radioactivity is than measured using a TRILUX 1450 Microbeta counter (WALLAC). In each plate, there are eight control wells: four positive controls (maximum kinase activity), for which measurement is made in the presence of enzyme and substrate and in the absence of compound of the invention, and four negative controls (background) for which measurement is made in the absence of enzyme, substrate and test compound. The measurements are given in Table I.
Aurora A
The recombinant human enzyme Aurora A used is expressed in entire form with a poly-Histidine tag in N-terminal position and is produced in E. coli . A fragment (amino acids 1701-2115) of the human protein NuMA, with a poly-Histidine tag in C-terminal position, is expressed in recombinant form in E. coli.
Aurora B/Incenp
The entire human enzyme Aurora B is coexpressed with a fragment of the human protein Incenp (aa 821-918) in a baculovirus system and is expressed in insect cells. Aurora B has a poly-Histidine tag in N-terminal position, while the Incenp fragment possesses a Glutathione-S-Transferase (GST) tag in N-terminal position. The two proteins form a complex which is called Aurora B/Incenp. A fragment (aa1701-2115) of the human protein NuMA with a poly-Histidine tag in C-terminal position is expressed in recombinant form in E. coli . This fragment is used as substrate.
Measurement of the Cell Proliferation
Cells (tumour cell line HeLa—ref.: ATCC CCL-2 and HCT116 ref.: ATCC CCL-247) are contacted with the test compound for 96 hours, with 14 C-thymidine added during the last 24 hours. The cell proliferation is estimated by the amount of 14 C-thymidine incorporated in the cells.
The test compound is dissolved to form a stock solution at 10 mM in DMSO, and this stock solution is used to produce a range of serial dilutions, generally from 10 000 μM to 0.3 μM, these serial dilutions being themselves diluted 1/50 in the cell culture medium (20× solution) which will be used for 1/20 dilution in the cell culture plates. The final concentrations of the test compound will generally be between 10 000 and 0.3 nM.
D0: the cells are seeded in 96-well Cytostar plates in 180 μL of culture medium. The plates are then placed in an incubator at 37° C., 5% CO 2 for four hours. The test products are then added in a volume of 10 μL per well, starting from a 20× solution. This solution contains 2% of DMSO in the culture medium. The final concentration of DMSO is therefore 0.1%. The plates are then placed in an incubator at 37° C./5% CO 2 for 72 hours.
D3: after 72 hours, 10 μL per well of 14 C-thymidine at 10 μCi/mL in the culture medium are added. The plates are then placed in an incubator at 37° C., 5% CO 2 for 24 hours.
D4: The incorporation of 14 C thymidine is measured on a Micro-Beta radioactivity counter (Perkin-Elmer) after this 24-hour, “pulse” period. The total time of treatment of the cells with the test product is 96 hours.
The percentage inhibitions IC50 are calculated in Excel using the following formula:
I % Inhibition = 100 * ( 1 - ( X - Blank CC - Blank ) )
X=Measurement for the Sample
CC=Cell Control
Blank=Measurement in the wells without cells
IC 50 is calculated using the XLfit software (IDBS. UK) with the aid of formula 205, with the parameter D (Hill number) locked to a value of 1. The results are given in Table I.
Evaluation of the Effect of the Compounds of the Invention on the Activity of the Enzyme PDE3
The effect of the compounds of the invention on the activity of the enzyme PDE3 was evaluated by the company CEREP (Le bois I'Evêque, 86600 Celle I'Evescault, France; http://www.cerep.fr) in accordance with its standard protocol (see Bender, A. T., Beavo, J. A. Pharmacol Rev. 2006, 58, 488-520: the enzyme PDE3A in recombinant form is expressed in Sf9 cells, the substrate is cAMP and the residual AMPc is measured by HTRF. The reference inhibitor in the test is milrinone, whose IC 50 is 270 nM. The residual activity % are related to the control without inhibitor). The results are expressed either as the concentration which induces inhibition by 50% (IC 50 ) or as a percentage inhibition measured at a set concentration of the compound. The results are given in Table I.
Measurement of the Chemical Stability of the Compounds
The chemical stability of the compounds was measured in various media: 0.05 N hydrochloric acid in a 50/50 (v/v) water/acetonitrile mixture; 0.05 N sodium hydroxide in a 50/50 (v/v) water/acetonitrile mixture; sodium phosphate buffer, 25 mM, pH=7.4, in a 50/50 (v/v) water/acetonitrile mixture; sodium phosphate buffer 25 mM, pH=7.4, in a 50/50 (v/v) water/acetonitrile mixture containing 1% (w/v) of benzylamine hydrochloride; sodium phosphate buffer, 25 mM, pH=7.4 in a 50/50 (v/v) water/acetonitrile mixture containing 1% (v/v) of 2-mercaptoethanol. The compounds are diluted in the media under study at a final concentration of 100 μM, by dilution of a 10 mM stock solution in DMSO. The solutions are stored at 20° C. for a total time of 48 hours, and the concentration of the compounds under study is measured over time (t=0, 1, 6, 12, 24 and 48 hours) by HPLC. HPLC analysis is carried out with an Agilent system 1100 instrument equipped with a diode array detector on a Luna 018 column, 30×4.6 mm, 3 μm (Phenomenex) which is eluted with a gradient from acetonitrile (solvent B) into water containing 0.5% (v/v) of formic acid (solvent A) at a flow rate of 1.5 ml/min and a temperature of 25° C. The elution programme consists of a gradient from 10 to 90% solvent B in 5 minutes, followed by an isocratic stage of one minute at 90% of solvent B, and return to the initial conditions over one minute. The concentration of the products under study is estimated from the height and area of the characteristic peak of the product under study on a chromatogram at the maximum wavelength of each product. The area and the height measured at each time of sampling are related to the area and height obtained for the sample at time 0. When degradation is observed, a half-life is measured from the resulting time-concentration curve. The results are given in Table II.
Evaluation of the Metabolism in the Presence of Microsomal Preparations of Human and Murine Livers.
Whereas microsome preparations remain important in determining the metabolic stability of a pharmaceutical compound, primary hepatocyte culture allows a more detailed evaluation of its intrinsic clearance, and better vitro-vivo correlations suggest hepatic clearance in humans.
The compounds of the invention (5 μM) are incubated at physiological temperature over human and murine microsomal liver fractions (1 mg/ml of proteins), diluted in a phosphate buffer, in the presence of bovine serum albumin (1 mg/ml BSA), and the reduced form of nicotinamide adenine dinucleotide phosphate (1 mM NADPH). To terminate incubation, four volumes of acetonitrile containing corticosterone as internal standard (IS) are added. The samples are centrifuged and the supernatants are analysed by liquid chromatography/tandem mass spectrometry coupling (LC/MS-MS). The LC/MS-MS analysis is performed on a QTRAP API4000 mass spectrometer (Sciex) equipped with an 1100 series chromatography system (Agilent) and a Pal CTC automatic injector. The data are acquired and analysed using Analyst 1.4.1 software. The samples are separated on a 3 μm C18 Polaris column, eluted at a flow rate of 0.7 ml/min with a gradient from acetonitrile (solvent B) into water containing 0.1% formic acid (solvent A). The elution programme is composed of the gradient from 20 to 90% of solvent B in 2 minutes, an isocratic stage at 90% of solvent B, for 0.9 minute, and a return to the initial conditions in 0.1 minute. The area of the chromatographic peaks for the compound and for the internal standard are integrated using the Analyst-Classic algorithm. The metabolic stability of the products of the invention is estimated by comparing the integration ratios (ion currents of the compounds/ion current IS) measured after 0 minute (t0) and 20 minutes (t20) of incubation. The metabolic stability is then expressed as a percentage disappearance in accordance with the following formula:
Metabolism %=(ratio of peaks at t 0−ratio of peaks at t 20)/ratio of peaks at t 0
The results are given in Table III.
Evaluation of the Clearance in the Presence of Human Hepatocytes.
The compounds of the invention (0.5 or 5 μM) are incubated for 24 hours in 48-well plates covered with collagen in the presence of fresh or cryopreserved human hepatocytes (˜200 000 cells/well) obtained from specific donors, in an incubator at a physiological temperature. The incubations are carried out with a culture medium (HAM F12-William E). At various times (0; 0.5; 1; 2; 4; 6; 8 and 24 hours), 100 μl are sampled from each well, and the kinetics are halted by addition of 700 μl of a 70/30 (v/v) acetonitrile/water mixture containing corticosterone as internal standard (IS). The cells are then dissociated and the intracellular and extracellular media are mixed and stored in frozen form at −20° C. prior to their analysis. Following thawing, the samples are centrifuged at 300 g for 20 minutes and the supernatants are analysed by liquid chromatography/tandem mass spectrometry coupling (LC/MS-MS). The LC/MS-MS analysis is performed on a QTRAP API4000 mass spectrometer (Sciex) equipped with an 1100 series chromatography system (Agilent) and a Pal CTC automatic injector. The data are acquired and analysed using Analyst 1.4.1 software. The samples are separated on a 3 μm C18 Polaris column, eluted at a flow rate of 0.7 ml/min with a gradient from acetonitrile (solvent B) into water containing 0.1% formic acid (solvent A). The elution programme is composed of the gradient from 20 to 90% of solvent B in 2 minutes, an isocratic stage at 90% of solvent B, for 0.9 minute, and a return to the initial conditions in 0.1 minute. The concentration of the products of the invention is measured by integrating the ion current of the characteristic ions of the products, relative to the internal standard (IS). The compound/IS ratios obtained are related to calibration standards of known concentrations, thereby allowing the concentration of the products of the invention to be ascertained. The intrinsic clearance (expressed in ml.h −1 .10 −6 cells) is then determined from the kinetic profiles (concentration/time), using the WinNonLin software (5.0). The results are given in Table IV.
Example 1
Preparation of ethyl 8-oxo-9-[3-(1H-benzimidazol-2-yloxy)phenyl]-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate (I)
A1. 2-Chloro-1-(tetrahydro-pyran-2-yl)-1H-benzimidazole (CAS No. 208398-29-2)
A 10 l reactor is charged, under argon and with stirring, with 2.5 l of THF, 180 g of 2-chlorobenzimidazole (1.18 mol) and 325 ml of 3,4-dihydro-2H-pyran (6.56 mol, 3 eq.). The reactor is heated until dissolution occurs (temperature of the mixture: 40° C.). Then 6.3 g of para-toluenesulphonic acid (0.033 mol, 0.028 eq.) are introduced. The temperature is held at between 49 and 52° C. for 2.5 h. Cooling takes place at 12° C. and 7.65 g of sodium methoxide (0.142 mol, 0.12 eq.) are added, with stirring maintained for a total time of 15 min. The temperature is then taken to 18° C., 5 l of n-heptane are added, and the whole mixture is filtered on 300 g of Clarcel FLO-M, the retentate being washed with 5 l of n-heptane. The filtrate is concentrated to dryness under reduced pressure to give 292.6 g of 2-chloro-1-(tetrahydro-pyran-2-yl)-1H-benzimidazole in the form of a slightly yellow oil (quantitative yield). 1 H NMR (400 MHz, DMSO-d6): 1.42 to 2.01 (m, 5H); 2.21 to 2.34 (m, 1H); 3.69 to 3.78 (m, 1H); 4.12 (d, J=11.4 Hz, 1H); 5.72 (dd, J=2.4 and 11.2 Hz, 1H); 7.22 to 7.34 (m, 2H); 7.82 (d. J=72 Hz, 1H); 7.78 (d, J=7.2 Hz, 1H).
B1: 3-[1-(Tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]benzaldehyde
Two 2 l three-necked round-bottomed flasks, each equipped with a condenser, a thermometer and a stirrer shaft, are charged under argon with N,N-dimethylformamide (0.4 l per flask), and 3-hydroxybenzaldehyde (68.5 g, flask 1; 64.2 g, flask 2; 1.08 mol). Sodium hydride (60% dispersion in mineral oil) is then added in portions (flask 1: 26 g; flask 2: 24 g; 1.25 mol, 1.2 eq.), the maximum temperature during the addition being 32° C. 2-chloro-1-(tetrahydro-pyran-2-yl)-1H-benzimidazole (A1), purity estimated at 85%) is then introduced (flask 1: 151 g in 0.5 l of N,N-dimethylformamide; flask 2: 142 g in 0.5 l of N,N-dimethylformamide; 1.05 mol, 0.97 eq.). The mixture is than heated at reflux (temperature 140° C., temperature rise time 40 min) and the reflux is maintained for 1 h. Heating is then stopped and the mixture is allowed to cool over 1.5 h. The contents of the two flasks are combined. The combined mixture is mixed slowly into 5 l of ice-water. The aqueous phase obtained is then extracted with 4×2.5 l of ethyl acetate (AcOEt). The organic phases are then combined, washed with 3 l of water and then with 2 l of saturated NaCl solution, and finally dried by addition of MgSO 4 overnight. The organic phase obtained is then filtered on a glass frit (porosity 4) and concentrated to dryness under reduced pressure to give 385 g of a brown oil (LC/MS-A, tr (retention time)=1.86 min, MS positive mode: m/z=323.16).
A fraction of 158 g of the crude product obtained above is dissolved hot in 1.5 l of an n-heptane/AcOEt mixture (8/2 by volume), combined with 500 g of silica (70-30 mesh), and the mixture is stirred for 45 min. The resulting suspension is filtered on Celite, and washed with 3 l of an n-heptane/AcOEt mixture (8/2 by volume). The organic phase obtained is concentrated to dryness under reduced pressure. The residue is resuspended in 200 ml of isopropyl ether by mechanical stirring and ultrasound treatment, and then filtered on a glass frit (porosity 3). The resulting solid is washed with 2×40 ml of isopropyl ether and dried under reduced pressure at 40° C. for 16 h to give 68 g of solid. A similar treatment applied to the remainder of the crude product produces 87.8 g of solid. The solids obtained are combined and homogenized to give 155.8 g of 3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]benzaldehyde in the form of pale beige crystals (LC/MS-A, tr=1.87 min, MS positive mode m/z=323.13). MS (LC/MS-B): tr=1.00 min; [M+H] + : m/z 323; 1 H NMR (400 MHz, DMSO-d6): 1.54 to 1.82 (m, 1H); 1.63 to 1.84 (m, 2H); 1.92 to 2.03 (m, 2H); 2.30 to 2.42 (m, 1H); 3.70 to 3.79 (m, 1H); 410 (d, J=11.5 Hz, 1H); 5.74 (dd, J=2.1 and 11.1 Hz, 1H); 7.13 to 7.22 (m, 2H); 7.43 (d, J=7.3 Hz, 1H); 7.65 (d, J=7.3 Hz, 1H); 7.73 (t, J=7.8 Hz, 1H); 7.78 to 7.83 (m, 1H); 7.87 (d, J=7.8 Hz, 1H); 7.96 (s, 1H); 10.05 (s, 1H).
Washing of the silica phases used above with 2 l of an n-heptane/AcOEt mixture (1/1 by volume) produces 67 g of product following concentration to dryness under reduced pressure. This product is taken up in 2 l of an n-heptane/AcOEt mixture (9/1 by volume), combined with 285 g of silica (70-30 mesh), stirred and treated with ultrasound for 1 h. The suspension is then filtered on Celite and the solid phase is washed with 2 l of an n-heptane/AcOEt mixture (9/1 by volume). The filtrate is concentrated to dryness under reduced pressure and the residue is triturated in 400 ml of an n-heptane/ethanol mixture (95/5 by volume), filtered on a glass frit (porosity 3) and dried under reduced pressure to give 35 g of 3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]benzaldehyde in the form of pale beige crystals (LC/MS-A, tr=1.93 min, MS positive mode m/z=323.16).
C1: Ethyl 8-oxo-9-{3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]phenyl}-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate
A 2 l conical flask is charged, with magnetic stirring, with 50 g of 3-amino-2-ethoxycarbonylpyrrole hydrochloride and 0.204 l of 2N sodium hydroxide solution. The mixture is stirred for 15 minutes at ambient temperature (AT), and then extracted with 3×0.3 l of dichloromethane. The organic phases are combined, dried over MgSO 4 and concentrated to dryness under reduced pressure. The residue is triturated with n-pentane, filtered and dried under reduced pressure to a constant weight, to give 36.4 g of 3-amino-2-ethoxycarbonylpyrrole in the form of a brown solid.
A 2 l three-necked round-bottomed flask equipped with a stirrer shaft, a thermometer and a condenser is charged with 1.2 l of 1-butanol, 145 g of 3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]benzaldehyde (0.405 mol, B1), 62.4 g of 3-amino-2-ethoxycarbonylpyrrole (1 eq., 0.405 mol), 46.8 g of 1,3-cyclohexanedione in 97% form (1 eq., 0.405 mol) and 70.5 ml of N,N-diisopropylethylamine (1 eq.) and the mixture is taken to reflux (temperature rise time 55 min, reflux maintained for 30 min, temperature 114° C.) The mixture is then cooled to AT and concentrated to dryness under reduced pressure to give 290 g of a brown oil containing ethyl 8-oxo-9-{3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]phenyl}-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate (LC/MS-A, tr=1.96 min. MS positive mode m/z=553.33). A similar operation carried out with 35 g of 3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]-benzaldehyde (0.098 mol, example B1) produces 72 g of a brown oil containing ethyl 8-oxo-9-{3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]phenyl}-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate (LC/MS-A, tr=1.96 min. MS positive mode m/z=553.35).
D1: Ethyl 8-oxo-9-[3-(1H-benzimidazol-2-yloxy)phenyl]-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate (compound I)
A 2 l round-bottomed flask is charged with 224 g of the brown oil containing ethyl 8-oxo-9-{3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]phenyl}-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate (example 1.3), 0.7 l of ethanol and 0.243 l of 2N hydrochloric acid. The mixture is stirred at AT for 16 h and then filtered on a glass frit (porosity 4). The filtrate is concentrated to dryness under reduced pressure and the residue is triturated with 0.5 l of isopropyl ether. The solid obtained is dried under reduced pressure at a constant weight to give 253 g of a brown solid containing ethyl 8-oxo-9-[3-(1H-benzimidazol-2-yloxy)phenyl]-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate (LC/MS-A, tr=1.46 min. MS positive mode m/z=469.29). A similar operation carried out with 54 g of the brown oil containing ethyl 8-oxo-9-{3-[1-(tetrahydro-pyran-2-yl)-1H-benzimidazol-2-yloxy]phenyl}-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate (C1) produces 60 g of a brown solid containing ethyl 8-oxo-9-[3-(1H-benzimidazol-2-yloxy)phenyl]-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate (LC/MS-A, tr=1.48 min. MS positive mode m/z=469.29).
An aliquot fraction of 0.8 g of the product obtained may be purified by chromatography on a 50 g silica cartridge (10-90 μm) (Biotage SNAP, KP-Sil) eluted with an isocratic stage of dichloromethane of 20 min, then a gradient from 0 to 1% by volume of isopropanol in dichloromethane over 1 h, and, finally, an isocratic stage of dichloromethane/isopropanol (99/1 by volume) of 20 min. The fractions containing the expected product are combined to give 0.21 g of a yellow solid. The products of two similar chromatographic separations carried out on the same scale are crystallized from acetonitrile to give a total of 0.16 g of ethyl 8-oxo-9-[3-(1H-benzimidazol-2-yloxy)phenyl]-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate in the form of beige crystals (LC/MS-A, tr=1.61 min. MS positive mode m/z=469.28). 1 H NMR (400 MHz, DMSO-d6): 1.29 (t, J=7.0 Hz, 3H); 1.80 to 1.97 (m, 2H); 2.19 to 2.27 (m, 2H); 2.55 to 2.69 (m, 1H); 2.81 (dt, J=4.8 and 17.2 Hz, 1H); 4.26 (q, J=7.0 Hz, 2H); 5.11 (s, 1H); 6.73 (d, J=3.3 Hz, 1H); 7.02 to 7.16 (m, 5H); 7.25 (t, J=7.9 Hz, 1H); 7.31 to 7.38 (m, 2H); 8.34 (s, 1H); 11.33 (broad s, 1H); 12.26 (broad s, 1H). Elemental analysis: C=68.72%; H=5.10%; N=11.82%; H 2 O=0.38%.
Example 2
Levogyratory/enantiomer (Ia) of ethyl 8-oxo-9-[3-(1H-benzimidazol-2-yloxy)phenyl]-4,5,6,7,8,9-hexahydro-2H-pyrrole[3,4-b]quinoline-3-carboxylate
The levogyratory enantiomer is purified from the crude product of example D1 on a Welk-01RR chiral column, 10 μM, 80×350 mm (Regis. USA) eluted with an n-heptane/dichloromethane/ethanol/triethylamine mixture (50/47.5/2.5/0.1 by volume). The elution of the products is detected by UV spectroscopy at 265 nm. Amounts of 10 g of the crude product described in example D1 are injected in each operation. Under these conditions, the peak corresponding to the levogyratory enantiomer is eluted with a tr of between 50 and 80 min. The fractions of purified levogyratory enantiomer corresponding to the operations needed to purify 310 g of the crude product described in example D1, are combined, homogenized and concentrated to dryness under reduced pressure to give 50 g of a beige solid. Mass spectrum (LC/MS-B): tr=0.77 min; [M+H]+: m/z 469; [M−H]−: m/z 467. 1 H NMR (400 MHz, DMSO-d6): 1.29 (t, J=7.1 Hz, 3H); 1.79 to 1.97 (m, 2H); 2.19 to 2.27 (m, 2H); 2.55 to 2.66 (m, 1H); 2.81 (dt, J=4.9 and 17.1 Hz, 1H); 4.26 (q, J=7.1 Hz, 2H); 5.12 (s, 1H); 6.73 (d, J=3.4 Hz, 1H); 7.02 to 7.16 (m, 5H); 7.25 (t, J=8.3 Hz, 1H); 7.29 to 7.41 (m, 2H); 8.32 (s, 1H); 11.31 (broad s, 1H); 12.26 (broad s, 1H). IR: principal bands: 1678; 1578; 1525; 1442; 1188; 1043 and 743 cm −1 . Optical rotation: [α] D =−38.6±0.7 at c=0.698 mg/ml in methanol. Elemental analysis: C=68.18%; H=5.92%; N=11.22%; H 2 O=1.25%.
Example 3
Dextrogyratory enantiomer (Ib) of ethyl 8-oxo-9-[3-(1H-benzimidazol-2-yloxy)phenyl]-4,5,6,7,8,9-hexahydro-2H-pyrrolo[3,4-b]quinoline-3-carboxylate
The dextrogyratory enantiomer is obtained by purification of the purified product from example D1 by chromatography on a Welk-01SS chiral column, 10 μM, 60×350 mm (Regis, USA) eluted with an n-heptane/ethanol mixture (7/3 then 6/4 by volume). The elution of the products is detected by UV spectroscopy. The fractions of the dextrogyratory enantiomer are combined, homogenized and concentrated to dryness under reduced pressure to give 1.9 g of a yellow powder. MS (LC/MS-B): tr=0.77 min; [M+H]+: m/z=469.2; [M−H]−: m/z=467.2. Optical rotation: [α] D =+53.1±1.1 at c=3.6 mg/ml in methanol.
Examples 4-13
the compounds of examples 4-11 were prepared according to the teaching of WO 2007/012972 (see process of claim 26). The tricyclic dihydropyridine products of formula (II) may be prepared according to Scheme II:
A mixture of one equivalent of pyrazole (X═N) or of pyrrole-2-carboxylate (X═COOEt), one equivalent of aldehyde R—CHO and one equivalent of diketone derivative (Y═CH 2 , CMe 2 , N-Boc) is heated at reflux in an alcohol such as ethanol or 1-butanol for a period of between ½ h and several h. The mixture is then cooled to ambient temperature. The desired products are isolated by filtration or else the solvent is evaporated to dryness. If necessary, the crude product is purified by chromatography on silica gel or else by high-performance preparative liquid chromatography (HPLC).
When Y represents N-Boc, the products may be deprotected using a solution of trifluoroacetic acid in dichloromethane (50/50) or else a solution of hydrochloric acid in dioxane (Scheme III):
The aldehydes of general formula (III), that are used in the preparation of the compound 4 (R═H), may be obtained according to Scheme IV. R denotes one (n=1) or more substituents (n from 2 to 4) on the benzimidazole nucleus, which are selected from the following: H, F, Cl, Br, OH, SH, CF 3 , OCF 3 , OCH 3 , SCF 3 , SCH 3 , OCHF 2 , OCH 2 F, SCH 2 F, (C 1 -C 6 )alkyl, O-allyl, phenyl optionally substituted by one or more halogen atoms.
step 1; the aldehyde function of 3-iodo-benzaldehyde is protected using an alcohol protective group and more particularly a diol protective group (ethylene glycol for example) in the presence of an acid such as para-toluenesulphonic acid in an inert solvent such as toluene and at a temperature of between 20° C. and the boiling temperature of the reaction mixture;
step 2: the intermediate formed is reacted with a product of formula (IV) in the presence of a palladium complex such as bis(dibenzylideneacetone)palladium, a phosphine derivative such as bis[(2-diphenylphosphino)phenyl]ether and a base such as sodium tert-butoxide, in an inert solvent such as toluene and at a temperature of between 20° C. and the boiling temperature of the reaction mixture;
step 3: the aldehyde function is deprotected in the presence of an aqueous acid solution such as hydrochloric acid, optionally in a solvent such as acetone and at a temperature of between 20° C. and the boiling temperature of the reaction mixture.
Table I compares the Aurora A and B inhibition activities, the anti-proliferative activities on the lines HeLa and HCT116, the PDE3 inhibition activity and the metabolism. It is found that compound (I) or (Ia) exhibits a high level of inhibition of Aurora A and B kinases and also very good activity on the lines HeLa and HCT116.
TABLE I
IC50
Aurora
IC50
IC50
IC50
IC50
Human
Mouse
B/Incenp
Aurora A
HeLa
HCT116
PDE3
microsome
microsome
Example
Compound
[nM]
[nM]
[nM]
[nM]
[nM]
[%]
[%]
1-inventive
(I)
4
6
205
nd
78% inhibition at 1000 nM
37%
31%
2-Inventive
Levogyratory compound (Ia)
1
1
67
20
4000
32%
50%
3-
Dextrogyratory compound
900
3800
>10000
nd
nd
nd
nd
comparative
(Ib)
4- comparative
6
72
9 664
nd
nd
77%
67%
5- comparative
6
23
9 633
nd
nd
nd
nd
6- comparative
13
109
>10000
nd
nd
nd
nd
7- comparative
4
3
430
nd
nd
65%
96%
8- comparative
21
102
6 863
nd
nd
80%
84%
9- comparative
8
15
9 462
nd
nd
nd
nd
10- comparative
9
22
6 692
nd
nd
nd
nd
11- comparative
107
1755
>10000
nd
nd
nd
nd
12- comparative
3
4
16
1
68
75%
81%
13- comparative
10
11
20
nd
93% inhibition at 1000 nM
53%
74%
nd: not determined
TABLE II
HCl 0.05N
NaOH
Phosphate buffer 25 mM
Phosphate buffer 25 mM
Phosphate buffer
50/50 water/
0.05N 50/50
pH = 7.4 50/50
pH = 7.4 + 1% benzylamine
25 mM pH = 7.4 + 1% 2-
Compound
acetonitrile
water/acetonitrile
water/acetonitrile
50/50 water/acetonitrile
mercaptoethanol 50/50 water/acetonitrile
Compound 12
stable
stable
stable
stable
unstable (half life t 1/2 = 2.06 h)
(comparative)
Compound 2
stable
stable
stable
stable
stable
(levogyratory
compound (Ia))
TABLE III
Metabolism measured
in the presence
Metabolism
of human microsomal
measured in the presence
Example
fraction
of murine microsomal fraction
Compound 12
75%
81%
(comparative)
Compound 2
32%
50%
(levogyratory
compound (Ia))
TABLE IV
Intrinsic clearance measured in the presence of human
Example
hepatocytes (in ml · h −1 · 10 −6 cells)
Compound 12
0.29 (average of 3 determinations obtained with 3
(comparative)
different preparations of hepatocytes)
Compound 2
0.121 (average of 5 determinations obtained with 5
(levogyratory
different preparations of hepatocytes)
compound (Ia)) | The invention relates to a compound of formula (I), more specifically in the levorotatory form (1a) thereof, in particular the form having a rotatory power [α]D=−38.6+0.7 at a concentration of 0.698 mg/ml in methanol. The compound may be in the form of a base or an acid addition salt, in particular a pharmaceutically acceptable acid. The compound is a selective Aurora A and B kinase inhibitor and can be used as an anticancer drug. | 2 |
FIELD OF THE INVENTION
[0001] The field of the invention in one aspect comprises a thermal interface structure made up of a thermal interface material (“TIM”) on an interposer that controls the area of contact of the TIM to a substrate.
BACKGROUND OF THE INVENTION
[0002] The so-called “silicon revolution” brought about the development of faster and larger computers beginning in the early 1960's with predictions of rapid growth because of the increasing numbers of transistors packed into integrated circuits with estimates they would double every two years. Since 1975, however, they doubled about every 18 months.
[0003] An active period of innovation in the 1970's followed in the areas of circuit design, chip architecture, design aids, processes, tools, testing, manufacturing architecture, and manufacturing discipline. The combination of these disciplines brought about the VLSI era and the ability to mass-produce chips with 100,000 transistors per chip at the end of the 1980's, succeeding the large scale Integration (“LSI”) era of the 1970's with only 1,000 transistors per chip. (Carre, H. et al. “Semiconductor Manufacturing Technology at IBM”, IBM J. RES. DEVELOP ., VOL 26, no. 5, September 1982). Mescia et al. also describe the industrial scale manufacture of these VLSI devices. (Mescia, N. C. et al. “Plant Automation in a Structured Distributed System Environment,” IBM J. RES. DEVELOP ., VOL. 26, no. 4, July 1982).
[0004] The release of IBM's Power6™ chip in 2007, noted “miniaturization has allowed chipmakers to make chips faster by cramming more transistors on a single slice of silicon, to the point where high-end processors have hundreds of millions of transistors. But the process also tends to make chips run hotter, and engineers have been trying to figure out how to keep shrinking chips down while avoiding them frying their own circuitry.” (http://www.nytimes.com/reuters/technology/tech-ibm-power.html?pagewanted=print (Feb. 7, 2006))
[0005] Technology scaling of semiconductor devices to 90 nm and below has provided many benefits in the field of microelectronics, but has introduced new considerations as well. While smaller chip geometries result in higher levels of on-chip integration and performance, higher current and power densities, increased leakage currents, and low-k dielectrics with poorer heat conductivity occur that present new challenges to package and heat dissipation designs.
[0006] CMOS power density is increasing. Recently the industry has seen it rise from 100 W/sq cm to 200 W/sq cm, beyond that of bipolar technology in the early 1990's. This increase in power density also increases the operating temperature of the device which materially interfered with proper operation of the device. The industry addressed this increase in operating temperature by securing the device to a heat exchange structure or material (i.e., heat spreader), but different coefficients of expansion of the heat spreader and the device caused structural and consequently further operating problems in the device. The difficulty was resolved for the most part by placing a TIM between the two that not only joined them in a heat exchange relation but also provided sufficient flexibility that enabled a link between the surfaces that substantially compensated for their different coefficients of expansions and substantially minimized any stress or strain placed on the device in the heat exchange process. The TIM material typically would sit underneath “contact patches,” helping to thermally bridge the gap between the device being cooled and the “contact patch.”
[0007] New generation servers employ more vendor technology that usually requires some level of custom integration to realize reliable performance. “VTM is one such technology used for power control in servers developed today. The VTM requires a TIM to effectively transfer heat from an array of VTMs to a common heat spreader. Inherent in manufacturing a VTM printed circuit board (PCB) assembly is rework. Thus, the common heat spreader must be easily separable from the VTM array in order to remove and replace a failed module. The heat spreader removal process must not damage any good modules.
[0008] The VTM has fragile solder connections that can only tolerate a compressive limit of about 15 psi and about 7 psi of tensile stress. TIMs that separate at tensile stress less than 7 psi either lack compliance to accommodate the bondline tolerances as in the case of thermal pads; or, in the case of accommodating bondline tolerances, for example greases or low cross link density gels, lack positional stability and pump out due to thermal mechanical movement between the common heat spreader and large PCB with the array of modules. Curable paste, adhesive TIMs that accommodate bondline tolerances and which are mechanically stable will require tensile forces greater than 7 psi to separate and thus will damage good components.
[0009] The application requirements for thermal interface materials therefore can include both assembly (compressive) and disassembly (tensile) force requirements. As noted above, the VTM module has a compressive limit of about 15 psi and tensile limit of about 7 psi. These requirements have limited the selection of thermal interface materials in the past to only one candidate, Chomerics T636, however, the present invention allows the use of many other commercial TIM's as well as newly formulated TIM's.
[0010] The present invention proposes a method for controlling TIM force for disassembly which would meet this and all other application requirements.
RELATED ART
[0011] Schuette et al., U.S. Pat. No. 7,738,252; Furman, et al., U.S. Pat. No. 7,694,719; Gruendler et al., U.S. Pat. No. 7,688,592; Thompson et al., U.S. Pat. No. 7,646,608; Mok et al., U.S. Pat. No. 7,002,247; Solbrekken et al., U.S. Pat. No. 6,523,608; Edwards et al., U.S. Pat. No. 6,275,381; Lee et al. U.S. Pat. No. 6,050,832; Deeney, U.S. Pat. No. 5,783,862; Rhoades et al., U.S. Pat. No. 4,151,547; Hill et al. United States Patent Application Publication 2010/0321895; Pang TIM Selection Criteria for Silicon Validation Environment; 26th IEEE SEMI-THERM Symposium 2010, pp. 107 et seq. all show heat transfer devices for dissipating heat from a heat generating body.
SUMMARY OF THE INVENTION
[0012] The present invention provides structures, articles of manufacture and processes that address these needs to not only provide advantages over the related art, but also to substantially obviate one or more of the foregoing and other limitations and disadvantages of the related art by providing a thermal interface structure made up of a TIM on an interposer that controls the area of the contact surface of the TIM on a surface from which or to which heat is to be transferred.
[0013] Not only do the written description, claims, and abstract of the disclosure set forth various features, objectives, and advantages of the invention and how they may be realized and obtained, but these features, objectives, and advantages will also become apparent by practicing the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings are not necessarily drawn to scale but nonetheless set out the invention, and are included to illustrate various embodiments of the invention, and together with this specification also serve to explain the principles of the invention. These drawings comprise various Figures that illustrate, inter alia structures and methods for adjusting the bonding strength of adhesives such as TIMs to substrates.
[0015] FIG. 1 Illustrates an aspect of the present invention comprising a side elevation in cross-section of a perforated interposer coated with an adhesive on one side where the adhesive extends through the openings toward the other side of the interposer.
[0016] FIG. 2 Illustrates an aspect of the present invention comprising a plan view of a perforated interposer.
[0017] FIG. 3 illustrates an aspect of the present invention comprising a side elevation in cross-section of a perforated interposer coated with an adhesive on one side, the adhesive also extending through the perforations toward the other side of the interposer. Substrates are placed on either side of the interposer where the adhesive on one side of the interposer substantially contacts the entire face of one of the substrates, and the adhesive projecting through the perforations contacts limited areas on the other of the substrates.
DETAILED DESCRIPTION OF THE INVENTION
[0018] To achieve the foregoing and other advantages, and in accordance with the purpose of this invention as embodied and broadly described herein, the following detailed description comprises disclosed examples of the invention that can be embodied in various forms.
[0019] The specific processes, compounds, compositions, and structural details set out herein not only comprise a basis for the claims and a basis for teaching one skilled in the art how to employ the present invention in any novel and useful way, but also provide a description of how to make and use this invention. The written description, claims, abstract of the disclosure, and the drawings that follow set forth various features, objectives, and advantages of the invention and how they may be realized and obtained. These features, objectives, and advantages will also become apparent by practicing the invention.
[0020] The invention comprises, inter alia, a process for reducing the area of contact between a thermal interface material and a module which is to be cooled. The disassembly force of a thermal adhesive is equal to the adhesive force per unit area (e.g. pounds/square inch) times the total area of contact (square inches). This invention allows control over the disassembly force to protect fragile components from damage due to separation forces. This invention provides the ability to accommodate large bondline tolerances on the order of about +/−0.5 mm or more and which are mechanically stable when using curable paste adhesive TIMs having reduced bond area.
[0021] Reducing the bond area is accomplished by using an adhesive such as a TIM known in the art, and in one embodiment, a curable or cured TIM, in combination with an interposer sheet or film, e.g., a thermally conductive interposer sheet. The interposer has holes or perforations that allow a layer of the thermal paste adhesive positioned on and above one face of the interposer to continuously bond to a heat spreader above the interposer both in areas above the perforations and in areas adjacent the perforations. The layer of the thermal paste adhesive is also made to extend through the perforations to the surface of a component (e.g., PCB) beneath the interposer to bond the heat spreader to the component as well. However, in the web area (non-perforated area) of the interposer, the thermal paste adhesive is blocked from contacting a portion of the component beneath the interposer to which it would normally bond in the absence of the interposer.
[0022] By reducing the bond area of the curable TIM below the interposer, the tensile stress to separate the heat spreader from the array of components on the PCB is lowered and controlled to below the fragility limit of the component. We therefore enable a low thermal resistance of the interposer contacting a surface by coating the interposer with the TIM, and in one embodiment an elastomeric TIM that is fully cured or curable in situ and has low or no tack. We illustrate this TIM as element 16 in FIG. 1 .
[0023] Although the interposer side with the TIM coating may be placed in dry contact with either the electrical device component or heat spreader surface, in the Figures, we show the interposer side with the TIM coating placed in dry contact with the heat spreader surface. Because the TIM coating is soft and compliant, the mating force used to join the heat spreader with the components will promote good thermal contact between the TIM coating and the surface to which it is mated.
[0024] FIGS. 1 and 2 show a thin (0.003 inches) interposer, e.g., copper foil ( 12 , 22 respectively) coated with a 0.003 inch thick layer of high performance curable TIM ( 16 ) that is preapplied to a first side of the interposer either as a curable paste and cured in place or, already cured thermal polymer pad with a tacky surface for adhering to the interposer.
[0025] The TIM coated interposer 12 , 22 is cut to the size of a typical VTM, about 22 to about 32.5 mm. Five holes, ( 14 , 24 ), about 9 mm in diameter, are punched in the interposer 12 , 22 , i.e., we coat the 0.003 thick copper foil, 0.003 with a high performance curable paste TIM and then add the five, 9 mm diameter holes. The surface of the interposer foil ( 12 , 22 ) that is coated with TIM 16 , is placed in direct contact with a VTM substrate surface. The preapplied TIM, 16 , is fully cured and has low adhesion, that can range from substantially no adhesion to less than two psi in tension. We then dispense, as normal, a curable paste TIM thermal adhesive, 17 on the second side of the copper foil interposer ( 12 , 22 ).
[0026] In another embodiment, we coat an interposer or metal foil ( 12 , 22 ) with a TIM ( 16 ). The TIM can be either a thermal pad that has an adhesive on one side that allows it to stick to the interposer; or, it can be an adhesive paste TIM that can be applied by stencil and screen printing and then cured. In either case, (thermal pad or curable paste), the resulting structure is the interposer (metal foil) with a continuous coating of TIM. Next, holes are punched in the two layer structure. The total area of the holes is the area over which a second curable TIM, 17 , will bond. After the holes are punched, the two layer structure is placed on a component for example the VTM. The TIM layer, 16 , is placed on the component. TIM layer, 16 , has very low adhesion to the VTM because it is already completely cured. But, it is allowed that TIM layer, 16 , can have some tack, enough so that it does not move when placed on the VTM. Next, the second TIM, 17 , a paste and curable material is dispensed over the two layer structure that is in place on the VTM.
[0027] The second TIM, 17 , only contacts the VTM in the area where there are perforations or holes in the two layer structure and this is the controlled bond area that will, by design, allow tensile separation forces less that 7 psi being applied over the entire area of the VTM. After the second TIM, 17 , is dispensed, the heat spreader is mated. The second TIM, 17 , is a paste and therefore can accommodate a large range of bond lines with large tolerances that result from a PCB with many varieties of components that are interfaced to a common heat spreader.
[0028] Lastly, the heat spreader, ( 38 in FIG. 3 ) is mated with force over a period of time to the VTM substrate surface below. In this example, adhesion is developed to the VTM substrate surface over only 44% of its area (area of holes or perforations 14 , 24 ) and the corresponding tensile stresses to separate the heat spreader are reduced by 56% as this is the area that is blocked by the interposer 12 , 22 . The reduction of the area of adhesive to one of the substrates compared to the area of the adhesive on the other substrate is substantially proportional to the reduction of adhesive strength to the substrate with the lesser amount of adhesive
[0029] FIG. 3 comprises an illustration of substrates 38 and 40 bonded to an interposer 32 having perforations 34 . A high performance curable paste TIM thermal adhesive 36 extends over the top of interposer 32 to adhesively bond interposer 32 to substrate 38 . Adhesive 36 also extends downward through perforations 34 and adhesively bonds to substrate 40 in adhesive areas on substrate 40 that substantiality conform to the dimensions of perforations 34 where these adhesive areas are adjacent to substantially adhesive free areas on substrate 40 . Either one of substrates 38 and 40 may comprise a heat spreader and the other an electrical device such as a PCB, e.g., a VTM.
[0030] Interposer 12 , 22 , and 32 comprises a foil from about 0.001 inch to about 0.005 inches in thickness and can be made of any material known in the art, but especially heat conductive materials such as metals, e.g., copper, silver, gold, aluminum, titanium, tungsten and the like and alloys thereof, or carbon fibers or carbon nanotube sheets or combinations thereof, including multilayer devices that include any combination of these materials.
[0031] The adhesive includes high performance curable paste or cured TIM thermal adhesives known in the art or any other TIM material, such as greases, gels, phase change materials and the like, all of which are described by A. Gowda, et al., Solid State Technology , “Choosing the Right Thermal Interface Material,” Volume 14, Issue 3, 2005. The present invention allows for the selection of a TIM adhesive from the many commercially available TIM adhesives since the bond strength of these adhesives to fragile substrates is now adjustable by employing the interposer of the invention.
[0032] A second embodiment is to use a thin thermal pad with low to no tack and place it on the VTM surface. Next, we dispense the second TIM, 17 , on top of the thermal pad and then mate the heat spreader. The very low adhesion of the thin thermal pad will allow easy separation. The use of the second TIM, 17 , a curable paste adhesive, accommodates large ranges and tolerances in bond lines that cannot be accommodated by thermal pads. While this is a much simpler solution, the benefit of the first embodiment is that by personalizing the perforations in the two layer structure, these can be located over hot spot areas and therefore a very high performance TIM can be used in the these areas and have direct contact to hot spots.
[0033] Throughout this specification, and abstract of the disclosure, the inventors have set out equivalents, of various materials as well as combinations of elements, materials, compounds, compositions, conditions, processes, structures and the like, and even though set out individually, also include combinations of these equivalents such as the two component, three component, or four component combinations, or more as well as combinations of such equivalent elements, materials, compositions conditions, processes, structures and the like in any ratios or in any manner.
[0034] Additionally, the various numerical ranges describing the invention as set forth throughout the specification also includes any combination of the lower ends of the ranges with the higher ends of the ranges, and any single numerical value, or any single numerical value that will reduce the scope of the lower limits of the range or the scope of the higher limits of the range, and also includes ranges falling within any of these ranges.
[0035] The terms “about,” “substantial,” or “substantially” as applied to any claim or any parameters herein, such as a numerical value, including values used to describe numerical ranges, means slight variations in the parameter or the meaning ordinarily ascribed to these terms by a person with ordinary skill in the art. In another embodiment, the terms “about,” “substantial,” or “substantially,” when employed to define numerical parameter include, e.g., a variation up to five per-cent, ten per-cent, or 15 per-cent, or somewhat higher. Applicants intend that terms used in the as filed or amended written description and claims of this application that are in the plural or singular shall also be construed to include both the singular and plural respectively when construing the scope of the present invention.
[0036] All scientific journal articles and other articles, including internet sites, as well as issued and pending patents that this written description or applicants' Invention Disclosure Statements mention, including the references cited in such scientific journal articles and other articles, including Internet sites, and such patents, are incorporated herein by reference in their entirety and for the purpose cited in this written description and for all other disclosures contained in such scientific journal articles and other articles, including internet sites as well as patents and the references cited therein, as all or any one may bear on or apply in whole or in part, not only to the foregoing written description, but also the following claims, and abstract of the disclosure.
[0037] Although we describe the invention by reference to some embodiments, other embodiments defined by the doctrine of equivalents are intended to be included as falling within the broad scope and spirit of the foregoing written description, and the following claims, abstract of the disclosure, and drawings. | A method comprises applying an adhesive to a first substrate and a second substrate to secure the first substrate to the second substrate. The adhesive extends in a plane on one side of an interposer that also extends in the plane, and is contiguous with the adhesive. The interposer comprises openings to enable flow of adhesive through the openings to form adhesive bond areas on one of the substrates where the areas substantially conform to the openings and lie adjacent to adhesive free areas. The adhesive substantially covers the other of the substrates so that the bond areas produce regions of reduced adhesive strength to the one substrate compared to the bond strength of the adhesive to the other substrate. Adjusting opening sizes adjusts area bond strengths. One substrate may comprise a VTM, the other a heat spreader, and the adhesive, a TIM. An article of manufacture comprises the substrate-adhesive-interposer-adhesive-substrate layers. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national phase entry under 35 U.S.C. §371 of International Patent Application PCT/GB2015/051965, filed Jul. 7, 2015, designating the United States of America and published in English as International Patent Publication WO 2016/012748 A1 on Jan. 28, 2016, which claims the benefit under Article 8 of the Patent Cooperation Treaty to Great Britain Patent Application Serial No. 1413112.2, filed Jul. 24, 2014, the contents of each of which are incorporated herein in their entirety by this reference.
TECHNICAL FIELD
[0002] This application relates to a system of growing vegetables and an apparatus for use in this system. The system finds particular use where the available area for growing is limited, and especially on a rooftop of a building.
BACKGROUND
[0003] Given an increasing need to produce more food crops from a decreasing area of available land, and also to use as little fossil fuel-derived energy as possible in that production, many different techniques have been developed that improve yield per m 2 with minimal energy input. Additionally, techniques have been developed enabling previously unusable areas to support crops.
[0004] For example, particularly in urban environments, roofs of buildings are increasingly being used to grow crops. Where the rooftop is capable of supporting the weight, conventional greenhouses can be erected. Alternatively, containers or raised beds are located on a strong flat roof and growing is carried out in a manner used in conventional rural market gardens.
[0005] In attempting to utilize roof space and for an enterprise to be run commercially, one problem that needs to be addressed is that of tending and harvesting the crop. Many supermarkets have rooftop areas available. In a recent calculation, there were 2160 supermarkets, each having in excess of 5000 m 2 available. The use of this area could be exploited by utilizing modern polytunnel structures with a potential capacity of such a supermarket to grow crops with a value of £3 million per year. The process would benefit from directing the heat and carbon dioxide from boiler flue gases into the polytunnels, thereby improving conditions for growth.
[0006] However, simply utilizing polytunnels as part of a commercial rooftop farming enterprise retains the problem of land-based enterprises in that access is still required for farming machinery and for the workforce. The need for access removes a relatively large area from availability for cultivation. Additionally, when working in a rooftop environment, safety measures need to be undertaken to minimize the risk of falling from the rooftop, particularly of personnel, but also of equipment and materials. Moreover, the use of polytunnels is not suitable where the rooftop is pitched and is not a horizontal flat roof
[0007] One solution to the access problem uses hydroponics to deliver water and nutrients to the plants. There are two basic variants of hydroponics. In the first variant, individual pots containing plants are linked to an array of pipes that delivers what is required by the plant for growth. Due to the time required to set the pipework up, this variant is more advantageous for plant crops with a long growing period such as tomatoes. However, because of the need for access, not just to the crop but also to the pipework, a relatively large access area is still required. The second variant, which is often used for crops with a short growth cycle, such as salad leaf crops, utilizes polystyrene trays that float in tanks holding nutrient-enriched water. The tanks are usually relatively long, with the trays floating adjacent to each other from a first end when the plants are young, to a second end where the plants are grown and can be harvested. The nature of this second variant restricts growing crops to a single layer.
[0008] This disclosure seeks to address the above problems by providing a system for growing crops suitable for use on a rooftop, which improves space utilization and also safety of personnel. The system is also suitable for use in conjunction with sloping roofs.
BRIEF SUMMARY
[0009] According to a first aspect of the disclosure, there is provided an apparatus for use in growing a plant crop, the apparatus comprising:
a structure enclosing a volume in which a crop can be maintained in a controlled environment during the growth of a crop, the structure housing two endless belts in spaced-apart parallel relationship and mounted for synchronous motion about a closed path, a trough to removably retain a nutrient solution for a crop, suspension means to enable a container holding a crop to be suspended between and move with the belts, the paths of the belts being such as to at least partially immerse the container in nutrient solution and feed a crop at least once during a complete belt circuit.
[0015] The apparatus enables a crop to be grown within a relatively small volume, with minimal input from an operative.
[0016] Optionally, the suspension means includes a framework to hold one or more containers, which enables the crops to be removed, together with the container for further transportation, and for a new crop to be added relatively easily to pass through the apparatus. In addition, the suspension means includes a bar or axle attached to and extending between the belts to provide a secure support.
[0017] Conveniently, each belt is mounted to a drive sprocket, with the path of each belt being conveniently defined by a plurality of idler cogs, which additionally provide support to the belts. Further, the drive sprockets are conveniently located within the structure. The drive belts are preferably chains.
[0018] The apparatus preferably includes sensors, such as temperature or humidity sensors, these sensors being connected to a display enabling an operative to control the environment within the structure. Optionally, the sensors are linked to a processing means and a control means to enable the environment within the structure to be automatically controlled.
[0019] Optionally, one or more cameras are located within the structure to provide a visual image and/or record of the growth of the plants.
[0020] Preferably, one or more lasers are mounted within the structure to enable growth control of plant materials within the structure and reduce the requirement for herbicides during the growth of a crop.
[0021] The apparatus preferably includes a pump to respectively fill and empty the trough.
[0022] Preferably, the floor of the structure consists of a building roof that can enable crops to be grown close to a point of sale in an urban environment.
[0023] According to a second aspect of the disclosure, there is provided a method of growing plants, the method comprising the steps of:
(i) placing a plant into a container; (ii) freely suspending the container between two endless belts, the belts being arranged in spaced-apart parallel relationship and mounted for synchronized motion about a closed path, (iii) adding a nutrient solution to a trough, (iv) the path of the belts being such as to at least partially immerse the container and the plant through a nutrient solution in the trough to feed and water the plant and then to remove the container and plant from a nutrient solution and trough, (v) the path being confined within a space having a controlled environment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The disclosure is now described with reference to the accompanying drawings that show by way of example only, one embodiment of a farming system. In the drawings:
[0030] FIG. 1 is a diagrammatic illustration of a building including a rooftop farming system in accordance with the disclosure;
[0031] FIG. 2 is a side view of the building and system of FIG. 1 ;
[0032] FIG. 3 is a diagrammatic illustration, not to scale, of trays and a nutrient trough; and
[0033] FIG. 4 illustrates a tray suspended between drive chains.
DETAILED DESCRIPTION
[0034] Referring to FIGS. 1 and 2 , these illustrate a modular system located on the rooftop of a building. The building rooftop is of design that is common for modern warehouses and also supermarkets, especially those constructed as part of a purpose-built industrial retail park. In such buildings, a basic steel frame is erected and cold-rolled steel purlins bolted thereto. The purlins are then covered with the insulated steel profile sheets. Larger buildings can be put together with several low-pitched bays.
[0035] The modules erected on the roof 11 of the building 10 can be installed to suit the frame of the building 10 and with minimal disturbance of the frame either during or subsequent to construction. In addition, it is intended that the weight of a module be borne, where possible, by the building frame. A basic module, generally referenced 12 , therefore, comprises a steel framework having walls and a roof made of a plastics material. The plastics material is known in the art and is already widely used for the construction of conventional polytunnels. Moreover, the plastics material is available as a roll, approximately two meters in width and the modules can be constructed using the known Keder method. In this method, the framework of the module is erected, and includes regularly spaced arches across which the plastics material is attached to form a roof of the module. A roof can, therefore, be constructed from several strips of plastics material going across the width of the module or, alternatively, a single length of plastics material running the length of the module.
[0036] Within the module, an almost completely automated process enables the growing plant to be monitored, watered and fed, and harvested. Additionally, means are optionally included to control weeds and pests.
[0037] Within the internal volume of the module generally referenced 12 , and defined by the building roof 11 , module walls 13 a , 13 b and module roof 14 a , 14 b is maintained a controlled environment in which the crop is grown. A pair of parallel endless drive belts, or as herein exemplified, chains, approximately two meters apart, only one of which chains 15 is shown in FIG. 1 for convenience, are utilized to transport plants through the module 12 . The chain 15 is driven by a main drive cog 16 and the path of the chain is effectively determined by the idler sprockets 17 . The drive cog 16 is driven by a motor located where shown in FIG. 1 . At spaced intervals along the chain 15 , bars or axles 18 (see FIG. 4 ) extend between and are fixed at either end to the chain 15 . In an alternative embodiment, not illustrated, a cable or chain can replace the bar or axle.
[0038] In use, containers 19 in which plants are retained are suspended by cables 19 a from the axles 18 . In an advantageous embodiment, not illustrated, the containers 19 are held in a common framework, enabling a container 19 to be removed, the crop harvested, a new crop planted in the container 19 and the container 19 then put back into a framework. In order to reduce costs therefor, it is envisaged that the framework is so sized as to accept an integer number, especially three, industry standard-sized containers. Such containers are available in a wide variety of shapes and sizes and can themselves carry smaller trays or pots. By using industry standard containers, the costs are kept to a minimum. In particular, certain trays are available that hold potted plants, such that the potted plants do not fall over and that fit into Danish trolleys, used within a supermarket or horticultural outlet. Although normally single use, trays can be reused with this disclosure, which again reduces costs.
[0039] It will be noted, therefore, that as the main drive cog 16 turns, the chain 15 and the containers 19 suspended therefrom are transported around the module 12 and the plants, therefore, are moved from one region of the module 12 to another. At defined points along this course, the light conditions, humidity, etc., can be monitored, and feeding and weed and pest control can be undertaken. The trays can be provided with RF tags or Bar/QR codes, which can be read by sensors at various points, for example, as a tray approaches a watering trough or a transfer point (see below).
[0040] One advantage of the disclosure described herein over prior art systems is that of being able to be installed on roofs of different shapes and dimensions, without needing to manufacture elements specifically for that roof or plant crop. The configuration of the path of the chain 15 is determined by the idler sprockets 17 and, therefore, these can be positioned to suit the general roof shape and any other installations that may be present on the roof 11 .
[0041] The above system enables a much simplified watering and feeding regime to be implemented. Unlike prior art systems that require a large number of pipes and branches to water individual plant-containing pots or that require the pots to be located on a capillary matting, the present system can comprise a single watering point consisting of a trough 20 . The trough 20 can be filled with water and any nutrient solution 21 for the particular plant and its stage of growth. The trough can be filled either by hand or by utilizing a pump. As the plant is moved along its path by the chain 15 , the plant is dipped into the trough 20 , thereby watering and/or feeding the plants. Should the particular plant require it, the movement of the chain 15 can be paused to ensure thorough watering.
[0042] Once the watering and/or feeding is completed for that container, the trough 20 can be emptied, again optionally by means of a pump, ready to receive fresh water and nutrients 21 . As the containers move on, any excess water dripping from the plants runs back into the trough 20 and can be reused. An advantage of this method of watering is that as the water drains from the plant, air is sucked into the soil, enhancing the soil's ability to support growth.
[0043] In order to monitor the progress of the plants, sensors are installed at points within the module 12 and also cameras so that the visual status of the plants can be observed. In FIG. 1 , a number of detectors is shown. First, a temperature indicator is shown at 22 and, second, a humidity indicator at 23 . It should be appreciated that the detectors can be positioned elsewhere within the system as best determined on setting the system up. Conveniently, sensors can be located in the region of the trough 20 . The sensors can, in particular, include a barcode reader, camera or laser. The sensors are conveniently linked to a central processing and control unit, which will be programmed to take the actions necessary to keep the values of various properties such as temperature within a preset range. Alternatively, the unit can simply provide read outs when it is required that the values be maintained manually.
[0044] The use of sensors not only allows for conditions to be controlled but also to provide information to retailers that they can use as a marketing tool within that business.
[0045] First, the data can be accumulated and can be used to enable the grower to build a knowledge base to aid in their understanding of how to manage conditions within the modules to ensure best growth.
[0046] Additionally, the data can be used to show customers, either through labels on the goods or through screens throughout the store, the provenance of the goods. A further use for the data would be as part of a smartphone app to enable customers/consumers to receive direct camera feeds to determine when a crop is ready. Also, crops at different stages of development can be harvested and brought down for educational purposes to show students in the building below.
[0047] Finally, the images from the cameras can be used to give a time-lapsed film showing growth of a plant.
[0048] The information from the cameras can also be linked to a processor that is linked to a laser. The laser can be mounted at a convenient point within a module in line of sight of the trays/containers and because all the plants within a module pass that point, all the plants should at some time come within the line of sight of the lasers. The laser can then be used, under the control of a processor, for example, to remove weeds or to trim unwanted roots, stems or leaves or perhaps to thin out plants in a tray. The requirement to use herbicide is, therefore, reduced.
[0049] Where space allows, modules can be located side by side along a roof and, assuming temperature requirements between adjacent modules allow it, share a common dividing wall. Depending on the crops being grown, adjacent modules can either share a watering trough or be provided with their own individual trough. In the former situation, coordination between chain movement and delivery of a crop to the common trough can be carried out to minimize the frequency of filling and emptying a trough, particularly where the same solutions are used for both crops. The use of individual troughs would, of course, remove the requirement for that level of coordination and would also enable the growing conditions for each crop to be individually optimized.
[0050] When using a plurality of modules, there is an increased need to maximize the growing space available and also to enable the system to remain predominantly automated. To achieve this and to enable as high a density of plant growth as possible, a number of access points to a module is reduced to the minimum possible. Moreover, produce from each module is brought to a single access point, from where it can be removed from the roof to, for example, the supermarket floor. For convenience, an access point can be in the region of trough 20 . This facilitates the process of watering, weeding, pruning, etc., as these actions can first be monitored visually in a control area, and second, take place while the plants are stationary. In order to minimize the requirement for physical labor to be used to move produce, robotics and CNC machining techniques can be utilized to lift plant trays/containers from frames and to place them on a transport frame. The transport frame is then carried by means of a pair of chains that give a route across the roof to the access point. By suitable routing, a growing area of several thousand square meters can be accessed from a very small area, perhaps no larger than a lift shaft.
[0051] Again, the use of a single access area provides a great deal of flexibility in respect of where the access area can be located within the building or whether even on the outside of the building. As long as the layout allows for an adequate corridor for the transport frame, the positioning of the access area to the ground floor can be anywhere on the corridor. Of course, where a system is installed at ground level, or on a rooftop on which human access is not restricted, then a crawler frame may not be required. | An apparatus for use in growing a plant crop, the apparatus comprising a structure enclosing a volume in which a crop can be maintained in a controlled environment during the growth of a crop, the structure housing two endless belts in spaced-apart parallel relationship and mounted for synchronous motion about a closed path, a trough to removably retain a nutrient solution for a crop, suspension means to enable a container holding a crop to be suspended between and move with the belts, the paths of the belts being such as to at least partially immerse the container in nutrient solution and feed a crop at least once on a complete belt circuit. | 0 |
This is a divisional of application Ser. No. 275,208, filed June 19, 1981 now U.S. Pat. No. 4,414,895 issued Nov. 15, 1983.
BACKGROUND OF THE INVENTION
This invention relates generally to a printing press, and more particularly, to a method and apparatus for converting letterpress and dilithographic printing presses to wet and dry offset printing.
As a result of greatly increasing operating costs and advances in print quality, the newspaper industry has been abandoning letterpress and dilitho printing in favor of offset printing. Until recently, newspaper publishers have had little option in this change but to abandon their letterpress and dilitho printing presses as they abandoned letterpress and dilitho printing. As a result, the expense of new offset printing presses has stood as an obstacle to the adoption of offset printing, thereby depriving the public and industry of offset printing advantages.
Attention has focused on the conversion of letterpress and dilitho presses to offset printing. Advances have been made, but present conversion methods and equipment have required extensive reconstruction of presses, including the scrapping of many press cylinders. Present methods and equipment also fail to achieve high operating efficiency, maintainability, simplicity, dependability and the highest quality printing. An example of a present method and apparatus is provided by U.S. Pat. No. 4,250,809, issued Feb. 17, 1981. In this example, conversion requires the replacement of the plate cylinders and impression cylinders of the press, and the inclusion of a massive auxiliary frame and bulky replacement cylinders. The conversion also requires integration of gear drives for the replacement cylinders into the existing gear train, with a resultant increase in the load on the drive. Conversion take extensive time, and involves great expense.
SUMMARY OF THE INVENTION
A primary object of the invention is to provide a method and apparatus for converting existing printing presses to offset printing, with no scrapping of press cylinders and without extensive reconstruction, in a minimum of time and expense.
Another primary object is to provide a converted, offset press with high operating efficiency, maintainability, simplicity, dependability and the highest quality offset printing.
These and others are the objects of the invention, which has several principal aspects. In one aspect, the invention is an apparatus for converting an existing web fed printing press into a web fed offset printing press, where the existing press has a main frame with two main side frame members and an existing cross brace member mounted to the two main side frame members, a spaced pair of existing plate cylinders and a spaced pair of existing impression cylinders all mounted on the main frame. The apparatus comprises an auxiliary frame, two auxiliary impression cylinders, means for adapting the existing impression cylinders, and means for moving the auxiliary cylinders into impression contact.
The auxiliary frame is mounted to the main frame through the use of existing mounting means on the main frame. The auxiliary frame includes an auxiliary cross brace member. This member defines a web slot, and is mounted to the two main side frame members in place of the existing cross brace member. Two auxiliary side frame members are mounted to the auxiliary cross brace member and the main side frame members. The two auxiliary impression cylinders are rotatably mounted on the auxiliary side frame members adjacent the existing impression cylinders and are friction driven by the web. The adapting means adapts the existing impression cylinders to offset blanket cylinders, and the plate cylinders to offset plate cylinders. The means for moving the auxiliary cylinders moves the auxiliary cylinders into offset impression contact with the blanket cylinders.
The apparatus defines a web path through the web slot. The path extends to one of the auxiliary impression cylinders, and around the one auxiliary impression cylinder between the one auxiliary impression cylinder and one of the blanket cylinders. The path continues to the other of the auxiliary impression cylinders, and around the other auxiliary impression cylinder between the other auxiliary impression cylinder and the other blanket cylinder.
With this apparatus, the press is operable for offset printing.
As should be apparent, conversion of a press to offset printing according to the invention involves minimal reconstruction of the press. The existing plate and impression cylinders are retained, in converted form. The auxiliary frame is mounted on the main frame through existing mounting means on the main frame. The auxiliary cross brace member is a direct replacement of the existing cross brace member. The auxiliary impression cylinders are friction driven, without need of gear drives requiring integration into the existing gear train.
As a result, conversion occurs with minimal time and expense. The converted press retains the dependability of the existing cylinders, and has no additional, complex equipment requiring intensive maintenance. The converted press has high efficiency, maintainability, simplicity, dependability and high quality offset printing.
The other principal aspects, objects and advantages of the invention are too numerous to be summarized here. As a result, all this information is provided in the Detailed Description, which follows.
BRIEF DESCRIPTION OF THE DRAWING
The preferred embodiment of this invention is described in the following Description in relation to the accompanying drawing. This drawing consists of 7 figures. The figures are briefly described as follows;
FIG. 1 FIG. 1 is a schematic view of a printing press prior to conversion to offset printing through use of the preferred embodiment;
FIG. 2 FIG. 2 is a schematic view of the press of FIG. 1 after conversion;
FIG. 3 FIG. 3 is a partial, pictorial, perspective view of the converted press of FIG. 2;
FIG. 4 FIG. 4 is a partial, elevation view of the converted press, with the cylinders removed, taken along line 4--4 of FIG. 3;
FIG. 5 FIG. 5 is a partial side elevation view of the converted press;
FIG. 6 FIG. 6 is a partially cross-sectioned, detail view taken of area 6 in FIG. 5; and
FIG. 7 FIG. 7 is a view of the impression cylinder control of the converted press.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a letterpress printing press 10, before conversion to offset printing, includes a main frame 12. A pair of horizontally spaced, letterpress plate cylinders 14 are mounted on the frame 12, between the spaced, main side frame members 16 (one is shown). The side frame members 16 are joined by a cross brace member 18, and the cylinders 14 are end mounted for rotation about central axes, between the side frame members 16. Two horizontally spaced, impression cylinders 20 are also end mounted on the frame 12 for rotation. The impression cylinders 20 are located inward and upward of the plate cylinders 14. The impression cylinders 20 make letterpress impression contact with the plate cylinders 14, to impress print upon a web 22. The press 10 has a web path extending through the nip between one of the plate cylinders 14 and one of the impression cylinders 20, and around the one cylinder 20. The web path continues around the other cylinder 20, and between the other cylinder 20 and other cylinder 14. With this path, the web 22 is printed once on each surface, as for black-on-white newsprint. Other web paths may be defined, for other print, such as two color, single surface print. The press 10 may also include other cylinders, as in the color hump, double color hump and color deck configurations.
Referring to FIG. 2, the press 10, after conversion according to the invention, retains the main frame 12 and the cylinders 14, 20. The existing cross brace member 18 is replaced by an auxiliary cross brace member 24, which defines a web slot 26. The cylinders 14 are modified, by shims, to accept offset printing plates, and the letterpress blankets on the impression cylinders 20 are replaced by offset blankets, to convert the cylinders 20 to offset blanket cylinders. Auxiliary side frame members 28 (one is shown) are mounted on the auxiliary cross member 24 and the main side frame members 16, within the main side frame member 16. Two new, auxiliary impression cylinders 30 are end mounted for rotation between the auxiliary side frame members 28, along with a compensating roller 32 and pipe roller 34. The impression cylinders 30 are mounted upward and inward of the blanket cylinders 20, one adjacent each blanket cylinder 20. As will be explained, means is provided for moving the auxiliary impression cylinders 30 into offset impression contact with the blanket cylinders 20. The rollers 32, 34 are mounted upward of the cylinders 30, midway therebetween.
A new web path 36 is defined. The path 36 extends through the web slot 26 to the pipe roller 34. The path continues around the pipe roller 34 and to one of the impression cylinders 30. The path continues around the one cylinder 30, between the one cylinder and one of the blanket cylinders 20. The web then travels to and about the compensating roller 32, and to and about the other impression cylinder 30, between the other cylinder and the other blanket cylinder 20. Ink is transferred from the offset plate cylinders 14, to the blanket cylinders 20, thereby to the web. Thus, the web is offset printed, once on each surface. Other web paths may be defined, as shown by phantom path 36' in FIG. 2.
Referring now to FIG. 3, the auxiliary cross brace member 24 and auxiliary side frame members 28 form an auxiliary frame within the main frame 12. The cross brace member 24 is a direct replacement of the existing members 28. The member 24 is mounted to the frame 12 by mounting means, such as bolts 38, which held the members 28. The web slot 26 is defined between two spaced beams of the member 24, which are formed for rigidity. The member 24 performs the same support tasks as the member 18, and also acts to support the auxiliary side frame members 28. The members 28 are bolted to the member 24, and also to the main side frame members 16. Existing frame openings are used for mounting to the main side frame members 16, as by bolts 40 or the like.
The auxiliary side frame members 28 are shaped to accomodate the cylinders 20, while supporting the cylinders 30 and cylinder throw-off/impression mechanisms 42 (one is shown). The members 28 have narrow, lower portions extending upward from integral, actuator mounting castings adjacent the brace member 24. The lower portions are positioned between the cylinders 20. Atop the lower portions, the members 28 widen horizontally into impression cylinder mounting portions. Two horizontally spaced, two-part pillow blocks 44 are mounted on the impression cylinder mounting portions. The pillow blocks 44 support the cylinders 30. Each cylinder 30 is end mounted to pillow blocks 44, with interposed roller bearings for rotation of the cylinders 30 in relation to the blocks 44 and thereby the frame 12.
Continuing with FIG. 3, auxiliary side frame mounting brackets 46 (one is shown) are mounted to the auxiliary and main side frame members 28, 16. The brackets 46 are L-shaped, with horizontal foot portions and upwardly extending roller mounting portions. The foots are atop the members 16, outward of the members 28. A lip of each member 28 is bolted to the mounting portion of each bracket 46. The brackets 46 support the rollers 32, 34. As shown in FIG. 5, adjustment mechanisms 50 are included on the brackets 46 for adjustable mounting of the roller 32. Adjustment in the vertical direction, exemplified by arrow 48, is provided for coordination or timing of the printing of the two cylinders 20.
The impression cylinders 30, and throwoff/impression mechanisms 42, are constructed to throw the impression cylinders 30 both on and off. As shown in FIG. 6, each impression cylinder 30 includes a central shaft 52 and an independent cylinder surface member 54. The member 54 is concentrically mounted on a central portion 56 of the shaft 52, for rotation about the shaft 52. The member 54 provides the impression surface of the cylinder 30. When the cylinder 30 is on impression, the cylinder surface is friction driven by the web. Two end portions 58 (one is shown) are integrally formed into the shaft 52, on opposite ends of the central portion 56. The end portions 58 are eccentric to the central portion 56. As shown in FIG. 4, the centerlines 60 of the end portions 58 are offset from the centerlines 62 of the central portions 56. As a result, rotation of the shaft 52 rotates the impression cylinder surface into and out of impression contact with the corresponding blanket cylinder 20.
Advantage is taken of the eccentricity by the throwoff/impression mechanisms 42. As shown best in FIG. 4, each mechanism 42 includes an actuator arm 66 keyed to one of the end portions 58 of a shaft 52. The arm 66 is linked to an actuator 68, which includes a telescopic rod 70 for driving the arm 66. The linear position of the rod 70 controls the rotational position of the arm 66, the shaft 52 and thereby the impression cylinder surface. In one position of the rod 70 the cylinder 30 is thrown on impression, and in the other positions, the cylinder 30 is off impression. The cylinder 30 is on impression in the position shown in FIG. 4. A mechanical stop 72 with a stop plate 74 affixed to the auxiliary side frame member 28 sets the "on impression" position of the mechanism.
Each cylinder 30 includes but one throw-off/impression mechanism 42. For one cylinder 30, the corresponding mechanism 42 is adjacent one auxiliary side frame member 28. For the other cylinder 30, the corresponding mechanism is adjacent the other member 28. The allocation of one mechanism 42 per cylinder 30 is a synergistic effect of the cylinder construction. The shaft 52 is a dead shaft in the sense that it does not rotate with the cylinder surface as the web passes the cylinder 30. The shaft 52 is so constructed and mounted that parallelism of the cylinders 20, 30, once set, is essentially constant. Rotation of the shaft 32 does not disturb the parallelism, and thus, one mechanism 42 is possible per shaft 52. The use of one mechanism per shaft, besides eliminating hardware, eliminates any skewing of the shaft due to lack of precise co-ordination between two or more mechanisms.
Referring again to FIG. 6, mounting of the member 54 to the shaft 52 is provided by pairs 76 (one is shown) of bearings 78. The bearings 78 are tapered roller bearings internally mounted between the central shaft portion 56 and the memeber 54, in a recess of the member 54. The pairs 76 are adjacent each end portion 58. A bearing retainer 80 is mounted to the end of the member 54 adjacent each pair 76, to retain the pairs 76 and pre-load the bearings 78. Location of the bearings 78 as described substantially eliminates bending stress in the cylinder 30, and the centrally faint printing which is the result of such stress.
Bearers 82 (one is shown in FIG. 6) for the cylinders 30 are located on the shaft central portion 56 adjacent each retainer 80. Each bearer 82 is a cylindrical metal ring. The bearer 82 is shrunk fit about bearings 84 for independent rotation about the shaft 52. The bearer 82 has an outer diameter reduced from the diameter of the member 54.
Bearer plates 86, shown in FIGS. 3 and 5, are located on the cylinders 20 in alignment with the blanket slots 88 of the cylinders 20. The bearer plates 86 are curved, and bridge the slots 88. The bearers 82 and plates 86 are co-operatively sized and located. The amount by which the outer diameters of the bearers 82 is reduced is equal to twice the amount by which the bearer plates 86 extend radially beyond the adjacent blankets on the cylinders 20. This amount is about equal to twice the radial thickness of the bearer plates 86. The bearers 82 and plates 86 are axially aligned and the bearers and plates contact on rotation of the cylinders 20, 30, to provide smooth movement of the impression cylinder surfaces across the slots 88. Bouncing of the cylinders 30 over the slots 88 is eliminated, improving print uniformity.
The bearer bearings 84 and other bearings 78 are lubricated by a lubrication circuit 85. The circuit 85 includes an axial channel 87 in the shaft 52, transverse openings 89 at the bearings, and circumferential grooves 91 in the shaft 52 at the bearings. Lubricant injected in the channel 87 spreads through the circuit 85 to the bearings 78, 84.
The throw-off impression mechanisms 42 are part of an automatic control mechanism for the cylinders 20 generally designated 92 in FIG. 7. Each actuator 68 is a pressure actuated, telescoping member having a piston cylinder 94. A piston (not shown) is movably mounted in the cylinder 94. The piston is connected to the rod 70. Two piston cylinder inlets 96, 98 open into the cylinder 94 on opposite sides, or faces, of the piston. The introduction of a pressurized fluid to the inlet 96 drives the piston, piston rod 70 and thereby the corresponding impression cylinder 30 to the position in which the impression cylinder 30 is on impression. The introduction of a pressurized fluid to the other inlet 98 drives the piston, piston rod 70 and thereby the impression cylinder 30 to the position in which the impression cylinder 30 is off impression. This second position is the position of FIG 7.
Fluid lines create a fluid circuit between the cylinders 94, a reservoir 104 and a solenoid valve 110. Fluid lines 100 connect the inlets 96 to a first reservoir inlet 102. Fluid lines 106 connect the inlets 98 to an outlet 108 of the solenoid valve 110. A second outlet 112 of the solenoid valve 110 is connected by a fluid line 114 to a second reservoir inlet 116 of the reservoir 104. The valve 110 is supplied with pressurized gas, such as air, by a supply line 118 through filters 120.
The reservoir 104 includes a reservoir piston (not shown). The reservoir inlets 102, 116 are located on opposite sides of the reservoir piston. Between the reservoir piston and the pistons of cylinders 94, through lines 100 and inlets 96, 102, a substantially incompressible fluid such as hydraulic oil is provided.
The oil is driven to and from the reservoir 104 and cylinders 94 by the supplied air. In one state of operation of the valve 110, pressurized air is supplied to the line 114 and the lines 106 are vented. The air supply at reservoir inlet 116 drives the reservoir piston toward the inlet 102, forcing oil to the cylinders 94. The oil retracts the rods 70, moving the impression cylinders 30 to the on impression position and maintaining them there so long as the valve 110 remains in the one operating state. In a second state, the valve 110 vents the line 114 and supplies the lines 106. The air supply at piston cylinder inlets 98 drives the oil to the reservoir 104. Adjustable flow restrictors 120 control flow in the lines 106, to control the release of air from the piston cylinders 94.
The solenoid valve 110 is wired to control circuitry (not shown). The valve 110 switches on command between the operating states. As most preferred, the valve 110 is wired with a web break detector, to throw-off the cylinders 30 in the event of a web break.
As now apparent, the substantially incompressible fluid (oil) holds the cylinders 30 on impression, while a gas (air) throws the cylinders 30 off impression. This construction reduces bounce of the cylinders 30 and improves print quality, while providing rapid throw-off of the cylinders 30. | An apparatus and method converts an existing printing press to offset printing. An auxiliary frame and two auxiliary impression cylinders are mounted to the press and existing cylinders are adapted for offset printing. A new web path is defined to the cylinders, through an auxiliary cross brace member. The shafts of auxiliary cylinders are eccentrically mounted dead shafts. The cylinder surface is friction driven by the web. Bearers smooth the movement of the cylinders across the blanket slots. The auxiliary cylinders are maintained on impression by an incompressible fluid for uniform impression and thrown off rapidly by a pressurized gas. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a temperature measurement apparatus in which the temperature of a medium such as air is measured by detecting a change with temperature in its acoustic wave propagation speed.
Heretofore, there have been disclosed such devices according to prior art, in which, an output signal of a carrier wave generator is frequency-modulated by means of a low frequency variable-frequency generator to provide a modulated wave for exciting an ultrasonic vibrator, thus causing an ultrasonic wave of about 40 KHz as shown in a waveform of FIG. 9A to be sent therefrom intermittently; the ultrasonic wave is received by a receiver and amplified to obtain a signal as shown in FIG. 9B. The amplified signal is passed through a frequency discriminator to obtain a modulating wave. The modulating wave thus obtained is compared with respect to its phase so as for its modulation frequency to be varied so that the distance between the acoustic transmitter and the receiver is an integral multiple of the wavelength of the modulating wave and so that the established frequency indicates the propagation speed and thus the temperature of the medium between the transmitter and the receiver.
However, in these prior art devices, a time duration for building up a signal as shown at B - 1 in FIG. 9B, is necessary between the time when the receiver receives the carrier wave and that when an output waveform having a fixed level is established. As a result, when not only the medium to be measured but also the whole measurement circuit are subject to a considerable change of temperature, for example, a waveform shown as C - 1 in FIG. 9C which is received and amplified in the receiver at a temperature of To will be evidently shifted as shown as the waveform C - 2 in FIG. 9C as the temperature is varied to increase the amplification factor of the amplifier. Thus, a phase difference or time difference t is caused due to a change in the performance of the measurement circuit, that is, a problem that a true change in the acoustic wave propagation speed cannot be detected precisely is raised.
SUMMARY OF THE INVENTION
The present invention is intended to eliminate the above-mentioned problem. In the first aspect of the present invention, an acoustic transmitting means and a receiving means sends and receives, respectively, a carrier wave in the form of an ultrasonic wave continuously at all times whereby an output waveform always having a fixed level can be provided independently of the environmental temperature and thus the change in the acoustic wave propagation speed can be detected always with stability and accuracy for measuring the temperature of the medium to be measured.
The second aspect of the present invention has a sensor circuit which is provided with a transmitting and receiving means for sending and receiving constantly a carrier wave as an ultrasonic wave, and an operation circuit which determines the temperature of the medium to be measured by the phase difference between the sent and received signals, whereby a pulse signal having a frequency of twice the excitation frequency of the ultrasonic vibrator is supplied from the operation circuit through signal lines to the sensor circuit where the pulse signal is frequency-divided through a factor of 1/2 to form an excitation signal, so that the sensor circuit and the operation circuit can be disposed at a distance from each other and the temperature of the medium to be measured can be determined always with stability and accuracy.
Further, in the third aspect of the present invention, a phase difference detecting signal from the sensor circuit is high-frequency modulated in the operation circuit and the modulated pulses are counted successively for every definite time interval, whereby the mean value over the definite intervals is displayed. Thus, the temperature of the medium to be measured can be displayed with stability at a remote distance.
Since, in the first aspect, there are provided an acoustic transmitting means which continuously sends an ultrasonic wave, a receiving means which receives the carrier wave from the transmitting means through a medium to be measured, and a determination circuit which detects through the corresponding pulse width the phase difference at a predetermined time between the series of signals sent from the transmitting means and those received by the receiving means and determines by the detected pulse width the temperature of the medium to be measured, and the transmitting means and the receiving means sends and receives, respectively, the carrier wave constantly without interruption; the receiving means can constantly provide an output waveform having a fixed level independently of the environmental temperature and thus the change in the acoustic wave propagation speed can be detected with stability and accuracy so as to measure the temperature of the medium to be measured. Further, if there is provided a temperature determination circuit as the above-mentioned determination circuit in which a phase difference detecting signal corresponding to the phase difference is high-frequency modulated and the number of the modulated pulses is counted for determining the temperature of the medium to be measured, the pulse width corresponding to the phase difference detecting signal can be detected reliably and the accuracy of detecting the pulse width can be varied easily by a simple adjustment.
In the second aspect, there are provided a sensor circuit and an operation circuit; the sensor circuit having a signal forming circuit which receives a pulse signal from a first signal line and forms an excitation signal having a frequency obtained by frequency-dividing by a factor 1/2 the pulse signal for exciting the ultrasonic vibrator and a predetermined synchronizing signal, a transmitting means which can perform constantly the transmitting operation with the excitation signal, a receiving means which receives the carrier wave from the transmitting means through the medium to be measured, and a phase difference detecting and processing circuit which detects by means of the synchronizing signal the phase difference, with respect to the corresponding pulse width, between a series of the excitation signals and a series of the signals received by the receiving means; and the operation circuit having a high frequency generator which sends the pulse signal of a predetermined frequency through the first signal line, and a determination and processing circuit which determines the temperature of the medium to be measured by means of the phase difference detecting signal provided from the sensor circuit through the second signal line. Thus, since the pulse signal having a frequency equal to twice the excitation frequency of the ultrasonic vibrator is sent from the operation circuit to the sensor circuit, the sensor circuit can be supplied with constant electric power having an ON-OFF ratio of one to one independently of disturbances, for example, in the distributed capacity of the first signal line, even if the sensor circuit and the operation circuit are at a distance from each other; that is, the signal forming circuit in the sensor circuit performs its operation constantly with stability and reliability and the carrier wave can be constantly sent and received just as in the first aspect so that the phase difference between the series of the sent signals and the series of the received signals can be detected. As a result, the temperature of the medium to be measured can be measured with stability and reliability even at a remote distance.
Further, in the third aspect, there are provided, in addition to the sensor circuit described with reference to the second aspect, a high frequency generator which supplies the pulse signal having a predetermined frequency through the first signal line to the sensor circuit, a modulation circuit which high-frequency modulates by means of the signal from the high frequency generator the phase difference detecting signal obtained from the sensor circuit through the second signal line, a temperature determination and processing circuit which counts successively the modulated pulses from the modulation circuit for every definite time interval and determines by means of the counted value the temperature of the medium to be measured, and an operation display circuit including a display means which display digitally in a predetermined temperature unit the determination signal from the temperature determination and processing circuit; whereby the mean value of the temperature over a definite time interval can be displayed. Thus, the temperature of the medium to be measured can be constantly displayed with stability even at a remote distance.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrated embodiments of a temperature measurement apparatus according to the present invention and the prior art device, in which:
FIG. 1 is a block diagram showing the general constitution of an embodiment of the invention,
FIGS. 2A, 2B and 2C comprise an entire electrical circuit diagram showing the detailed electrical connection in the block diagram of FIG. 1,
FIGS. 3 to 8 show signal waveforms at some portions in the circuit diagram and are helpful to illustrate the operation of the apparatus according to the present invention, and
FIG. 9 shows signal waveforms illustrating the operation of prior art devices.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now, the present invention will be described with respect to an embodiment shown in the drawings. In FIG. 1, which is a block diagram showing the general constitution, a block 100 is an operation display circuit and a block 120 is a sensor circuit, both of which are supplied with electric power from an electric power source 10 through power lines 11 and 12 and are connected with each other through signal lines 13 and 14 for sending and receiving signals. In the operation display circuit 100, numeral 101 is a high frequency generator, numeral 102 is a reference circuit which divides the oscillation frequency to derive a frequency (hereinafter referred to as reference frequency) equal to twice the excitation frequency for the sensor circuit 120, numeral 103 is a modulation circuit which modulates the high frequency oscillation frequency by means of a phase difference signal from the sensor circuit 120, numeral 104 is an accumulation circuit which accumulates the modulated pulse signal, numeral 105 is a time signal circuit which supplies a signal every definite time interval, numeral 106 is a logic circuit which supplies a memory signal and a reset signal in response to the time signal, numeral 107 is a counter signal which counts the number of the pulses accumulated in the accumulation circuit 104, numeral 108 is a switch circuit which switches the number of the accumulated pulses depending on whether the temperature of medium air is positive or negative, numeral 109 is a discrimination circuit which discriminates whether the temperature of medium air is positive or negative, and numeral 110 is a display circuit which displays the temperature of medium air.
Next, in the sensor circuit 120, numeral 121 is a synchronization circuit which divides the reference frequency from the operation display circuit 100 by a factor of φ to provide the excitation frequency for the ultrasonic vibrator and further provides a synchronizing signal for detecting the phase difference between the signals sent from a transmitter 123 and those received by a receiver 124, both being continuously sending and receiving the excitation frequency, numeral 122 is a phase difference detecting circuit which detects the phase difference between the signals sent to the transmitter 123 and the signals provided by the receiver 124.
Next, the details of the above-described constitution and its operation will be described with reference to FIG. 2 which is an entire electrical circuit diagram of the apparatus according to the present invention. In FIG. 2, the high frequency generator 101 is a known oscillation circuit using a crystal oscillator and includes a crystal oscillator 203, capacitors 201 and 202, resistors 204, 205, 206 and 207, gates 208 and 209, and an inverting and amplifying inverter gate 210. This oscillation pulse signal is frequency-divided by a factor of 1/100 through the reference circuit 102, which includes decode counters 211 and 212, an inverter gas 213 and a transistor 214, so that a reference signal waveform which is obtained by inverting the waveform (300) in FIG. 3 appears at a terminal 14'. In this embodiment, two IC SN7490s manufactured by TEXAS INSTRUMENTS (hereinafter referred to as TI), USA are cascade connected as the decode counters 211 and 212 for providing the 1/100 frequency-divided signal. This reference signal reaches a terminal 14" of the sensor circuit 120 where the reference signal is shaped by an inverter gate 21 at the output of which a signal as shown by (300) in FIG. 3 appears. This reference signal 300 reaches the input of the synchronization circuit 121 including a frequency-dividing circuit (SN 7493 manufactured by TI) and a 1/2 frequency-divided signal shown by (301) in FIG. 3 and a 1/8 frequency-divided signal shown by (302) in FIG. 3 are provided over lines 131 and 141, respectively. The signal 301 is supplied to the transmitter 123 where the signal 30 is passed through a power amplifier having three inverter gates 26 connected in parallel to excite an ultrasonic vibrator of a transmitting means 27, so that an ultrasonic wave shown by (303) in FIG. 3 is continuously radiated from the transmitting means 27. The transmitting means 27 and a corresponding receiving means 28 are both known ones conventionally used for sending and receiving ultrasonic waves, respectively. The reason why the reference signal is frequency-divided by a factor of 1/2 to form the excitation frequency is that, even if, for example, the locations of the operation display circuit 100 and the sensor circuit 120 are at a distant from each other and each period (Ta in FIG. 3 (300)) of the signal waveform reaching the terminal 14" of the sensor circuit 120 is caused by the distributed capacity or the like of the signal line 14 connecting these portions to have an ON-OFF ratio different from one to one, each period (Tb in FIG. 3 (301)) of the 1/2 frequency-divided output signal has an ON-OFF ratio of one to one so that the transmitting means 27 can provide constantly a definite electric power. This is a manner of processing in the case that, as described above, the signal line 14 is long (for example, several meters) and, of course, it is not necessarily required that, in the case the signal line 14 is short and its distributed capacity is small, the processing of 1/2 frequency-division is made in the sensor circuit 120.
The ultrasonic wave which is constantly sent from the transmitting means 27 is received by the receiving means 28, whose output provides constantly a signal, shown by (310) in FIG. 3, corresponding to the received ultrasonic wave. The signal 310 is supplied to the inversion input and the non-inversion input of a comparator 29, whose output provides a waveform, shown by (311) in FIG. 3, which is similar to but different in phase from that of the carrier wave 301. Then, the continuous wave signal (310) from the receiving means 28 is made to oscillate with the zero voltage centered, whereby the comparator 29 provides the pulse signal waveform 311 which varies in dependence on the change in polarity of the input signal 310. Thus, even if the comparator 29 has a temperature drift, its output is never influenced by the drift.
Thus, the carrier wave 301 and the received waveform 311 reach the clock terminals CP of j-k flip-flop 22 and 23 of the phase difference detecting circuit 122. Since the clear terminals of the j-k flip-flop 22 and 23 have been supplied with the inverted waveform of the synchronizing signal shown in FIG. 3 (302), a signal shown by (312) in FIG. 3 appears every time interval To at the output Q of the flip-flop 22 while a signal shown by 313 in FIG. 3 appears every time interval To at the output Q of the flip-flop 23. These signals 312 and 313 reach the inputs of a NAND gate 24. As a result, a signal having a phase difference T 1 , shown by (314) in FIG. 3, appears every time interval To at the output of the NAND gate 24.
Now, this phase difference will be described with reference to FIG. 4. In FIG. 4, if a transmitting means 401 and a receiving means 402 are spaced from each other by a definite length l and a signal which was sent by the transmitting means 401 at the time Ao on the carrier wave 411, the time interval t from the time Ao to the time A 1 is given by t=l/v (where, v is the speed of sound). Since n pulses (n=0, 1, 2, - - - ) are sent from the transmitting means 401 during this time interval t, the pulse signal or the series of pulses have a phase difference of T=(l/v)-n·T b (where, T b is the period of the pulse signal) between the receiving means 402 and the transmitting means 401. From the above-mentioned relation, it is evident that the phase difference T varies with the speed of sound v, that is, the temperature of air.
Further, as is evident from the above-described formula of the phase difference T, the phase difference T depends considerably also on the distance l, in particular, increases with the increasing distance l and thus the accuracy of detection is also increased. However, on the other hand, when the distance l is increased, the variation in the detected phase difference T caused by the variation in the temperature distribution or the like due to the air flow between the transmitting and receiving means is increased, and thus the temperature of air cannot possibly be detected when a variation in the air flow is significant at the measurement point. Thus, the distance l must be suitably determined by taking into consideration the degree of variation in the temperature distribution of the object to be measured and by taking into consideration the period of the carrier wave. Some experimental results in this embodiment show that the distance l is suitably 24 to 30 mm for the carrier wave of 40 kHz. In general, if the values of the distance l satisfy the equation; l=n·T b +T (where, T is the phase difference, T b is the period of the synchronizing signal, and n=0, 1, 2, . . . ), then these values may be used.
Now, the phase difference detecting signal is supplied from the terminal 13" of the sensor circuit 120 through the signal line 13 to the terminal 13' of the operation display circuit 100. Thus, a phase difference detecting signal shown by (501) in FIG. 5 appears at the output of an inverter gas 221 of the modulation circuit 103. This signal shown by (501) in FIG. 5 is the same as that shown by (314) in FIG. 3 with the time scale magnified. A NAND gate 223 which modulates a high frequency signal 502 from the reference circuit 102 with this signal 501 provides at its output a modulated pulse signal 503 with the T 1 interval superposed with high frequency pulses. Thus, it is evident that, if the phase difference T 1 is varied by the variation in the temperature of air, the number of the high frequency pulses present in the T 1 interval is correspondingly varied. Then, as the frequency of the high frequency signal 502 is increased, the number of the high frequency pulses is increased thus causing the accuracy of detecting the phase difference T 1 to be increased. The output signal 501 of the inverter gate 221 is also supplied to the signal circuit 105, which counts the pulse signal 501 by 2 m (by 2 12 in this example) to form a time signal of a definite time. The signals 2 m-3 , 2 m-2 , 2 m-1 and 2 m are shown by (601), (602), (603) and (604) in FIG. 6.
Each of these signals is supplied to the logic circuit 106 including an inverter gates 251 and 252 and NAND gates 253 and 254, in which, a memory signal shown by (605) in FIG. 6 and a reset signal shown by (606) in FIG. 6 appear at the outputs of the NAND gate 253 and the NAND gate 254, respectively. The signal 604 is supplied to one input of a NOR gate 271 of the switch circuit, while the other input receives the output signal 607 of the accumulation circuit 104 which has accumulated the modulated pulse signal by 2 m-1 pulses. Thus, a signal shown by (608) in FIG. 6 appears at the output of the NOR gate 271. It is evident that the number of pulses present in the interval T 2 in (608) of FIG. 6 is equal to the means value of the number of pulses present in the interval T 1 of the modulated pulse signal 503 averaged over the time interval t 1 (t 1 =To×2 m ). This modulated pulse signal 503 is accumulated in the accumulation circuit 104 during the time interval t 1 determined by the time signal circuit 105 so that the mean value of the phase difference over the time interval t 1 is derived.
The reset signal 606 which is the output signal of the NAND gate 254 causes a D type flip-flop 283 in the discrimination circuit 109 to be at the initial state, so that its outputs Q and Q become "0" and "1", respectively, and as these signals Q and Q reach the inputs of the NAND gates 272 and 273 of the switch circuit 108, respectively, the gate of the NAND gate 272 is closed while the gate of the NAND gate 273 is opened. Thus, a signal shown by (701) in FIG. 7 appears at the output of the NAND gate 273. This signal 701 reaches the COUNT DOWN terminal of an up-down counter 261 such as DECADE UP/DOWN COUNTERS (TI 74192, USA) in the counter circuit 107. The BORROW terminal of the up-down counter 261 provides one pulse every time ten pulses have reached the COUNT DOWN terminal. The output signal of the BORROW terminal is supplied to the COUNT DOWN terminal of the next stage up-down counter 262, so that the up-down counter 261 represents "the first order" while the up-down counter 262 represents "the second order". The same is valid also when the COUNT UP terminals are supplied with signals for up-counting.
Now, assume that the data inputs A, B, C and D of the counter 261 are all "0" and the data inputs A, B and C of the counter 262 are "0" while the data input D of the counter 262 is "1". Thus, when the data inputs are set to be "80", the outputs varies to be 79→78→77→ . . . as pulses reach the COUNT DOWN terminal of the counter 261. When the reset signal 606 shown in FIG. 7 reaches the LOAD terminals of the counters 261 and 262; at the time B 1 , the outputs Q A , Q B , Q C and Q D of the counter 261 all provide "0" signals and the outputs Q A , Q B and Q C of the counter 262 provide "0" signals while the data output Q D of the counter 262 provides "1" signal. The output signal 701 of the NAND gate 273 reaches the COUNT DOWN terminal of the counter to cause the outputs Q A , Q B , Q C and Q D of the counter 261 to change as shown by (702), (703), (704) and (705) in FIG. 7, while the signal 706 appearing at the BORROW terminal of the counter 261 causes the outputs Q A , Q B , Q C and Q D of the counter 262 to change as shown by (707), (708), (709) and (710) in FIG. 7.
Now, assuming that fifty-five pulses are present in the interval T 2 ; the outputs Q A , Q B , Q C and Q D of the counter 261 are "1", "0", "1" and "0", respectively, and the outputs Q A , Q B , Q C and Q D of the counter 262 are "0", "1", "0" and "0", respectively, so that the entire output represents 80-55=25 during the time interval between B 2 and B 3 . These output signals reach the inputs of light-emitting diode display means 291 and 292 (YOKOGAWAHEWLETT-PACKARD 7300) which represent, respectively, "the first order" and "the second order" in the display circuit 110.
Since these display means 291 and 292 have been supplied at their ENABLE terminals with the memory signals 605 shown by (605) in FIG. 7, these display means 291 and 292 light the light-emitting diodes in response to the input code signals in the case of the memory signal 605 being "0" for displaying and further memorize the state. Thus, the display means 291 displays the figure "5" while the display means 292 displays the figure "2", so that the temperature of air as a medium to be measured is displayed to be 25° C. When the time B 4 in FIG. 7 is reached, the counters 261 and 262 are set to be in the initial state so that the same operation as described above may be made and thus a display corresponding to the outputs of the counters 261 and 262 may be made. Assuming, for example, that the temperature of air as a medium to be measured is increased thus causing the time interval T 1 in the phase difference detecting signal 314 shown in FIG. 3 to be narrowed so that the number of pulses present in the interval T 2 in FIG. 7 becomes twenty-five; the outputs Q A , Q B , Q C and Q D of the counter 261 are "1", "0", "1" and "0", respectively, and the outputs of the counter 262 are "1", "0", "1" and "0", respectively, so that the entire output represents 80-25=55 during the time interval between B 2 and B 3 just as the abovedescribed operation. Thus, the display means 291 and 292 both display the figures "5", which means that the temperature of air is 55° C.
Next, assume that the temperature of air as a medium to be measured is decreased to reach a negative value in the centigrade unit (°C.). Then, it is evident from the hereinbefore-described formula T=l/v-n·T b that the interval T 1 in the phase difference detecting signal 314 shown in FIG. 3 is widened. Assume further that the modulated signal is accumulated so that the number of pulses present in the interval T 3 (the same as the interval T 2 in FIG. 7) of the output signal of the NOR gate 271 shown by (608) in FIG. 8 is ninety-nine. The manner shown in FIG. 8 is just the same as described above, in which, starting from the time C 1 , the output signal 801 of the NAND gate 273 reaches the COUNT DOWN terminal of the counter 261 and the outputs of the counters 261 and 262 change as shown by (803), (804), (805), (806), (807), (811), (812), (813) and (814) in FIG. 8.
In this case; at the time C 2 when eighty pulses have reached the COUNT DOWN terminal of the counter 261, the outputs of the counters 261 and 262 are all "0" becouse of the relation 80-80=0 and a signal shown by (815) in FIG. 8 appears at the BORROW terminal of the counter 262 for displaying "the second order". This signal 815 and the output sigaal 807 of the BORROW terminal of the counter 261 for displaying "the first order" are supplied to a NOR gate 281 of the discrimination circuit 109, at the output of which appears a signal 820 rising to "1" at the time C 2 . Since this signal 820 is supplied to the clock terminal of a D type flip-flop 283; at the time C 2 , the output Q of the D type flip-flop 283 becomes "1" while the output Q becomes "0". Thus, the gate of the NAND gate 272 in the switch circuit 108 is opened while that of the NAND gate 273 is closed. As a result, a pulse signal shown by (802) in FIG. 8 appears at the output of the NAND gate 272. Since this signal 802 is supplied to the COUNT UP terminal of the counter 261; after the time C 2 , the outputs of the counters 261 and 262 provide signals with their pulses increasing in response to the number of input pulses. During the time interval between the time C 3 and the time C 4 , the outputs Q A , Q B , Q C and Q D of the counter 261 are "1", "0", "0" and "1", respectively, and the outputs Q A , Q B , Q C and Q D of the counter 262 are "1", "0", "0" and "0", respectively, so that the display means 291 for displaying " the first order" displays "9" while the display means 292 for displaying "the second order" displays "1", in preparation for entirely displaying the result 80-99=-19.
Further, since the signal 821 from the output Q of the D type flip-flop 283 which has become "1" at the time C 2 is supplied to the D terminal of the next step D type flip-flop 284, whose clock terminal is supplied with a signal obtained by inverting through an inverter gate 282 the memory signal 605 as the output of a NAND gate 253; a signal 822 which rises to "1" at the time C 3 appears at the output Q of the D type flip-flop 284. This signal 822 is inverted through an inverter gate 285 to reach a display means 293 at its terminal which causes the display means 293 to display the minus sign, so as to make the display means 293 display the minus sign. Thus, the figures with minus symbol "-19" are displayed in the display circuit 110, which means that the temperature of air as a medium to be measured is -19° C.
Although, in the above-described embodiment, the measurement operation is made by means of the phase differenct T 1 (FIG. 3, 314) between the signals of the transmitting means and the receiving means, the same measurement may be made by means of the pulse width To which is obtained by subtracting the phase difference T 1 from the period of the synchronizing signal. In this case, the pulse width To is widened, contrary to the above-described embodiment, as the temperature is increased. Thus, by reversing the operation of up-counting and down-counting in the up-down counters 261 and 262 to set respective data inputs, the same performance as that in the above-described example can be evidently obtained. Further, although, in the above-described embodiment, the oscillation frequency is 1/100 frequency-divided to form the reference signal as shown in FIG. 2, the factor of frequency-division is not limited to the above-described value but determined by the excitation frequency of the ultrasonic vibrator.
In the above-described embodiment, in order to make display with stability, the modulated pulses from the modulation circuit 103 are accumulated by the accumulation circuit 104, the mean value of the number of the modulated pulses over a predetermined time interval is calculated by the time signal circuit 105, and this signal is supplied to the counter circuit 107 to drive the display circuit 110 for displaying the mean value. However, the modulated pulses may be supplied directly to the counter circuit 107 to be accumulated, without performing the averaging operation.
In the above-described embodiment, the output of the counter circuit 107 is supplied to the display circuit 110 for digital display. However, a movable coil type ampere meter or the like instead of this display circuit 110 may be employed for analogue display.
Further, although, in the above-described embodiment, the output of the counter circuit 107 is used for display, the output may be supplied, other than for display, to another electronic control device serving as a temperature sensor. In this case, when the frequency of the high frequency pulses which are to be supplied to the NAND gate 503 in the modulation circuit is set to be higher, the temperature can be detected with higher accuracy. Thus, by suitably matching the frequency setting of high frequency pulses with the rapid detection responsibility, the use of such temperature sensor makes possible the rapid electronic control to the temperature change.
Still further, although, in the above-described embodiment, the temperature of air as a medium to be measured is measured; of course, the medium is not limited to air but may be any other material which permits ultrasonic wave to propagate therethrough, for example, various kinds of gases such as oxygen, nitrogen, helium or the like, some kinds of liquid such as water, oil or the like, and even some kinds of solid such as iron, wood or the like. However, in these cases, the parameters such as the distance between the transmitting means and the receiving means, the excitation frequency, or the constants of the determination circuit must be adjusted in view of different conditions of acoustic wave propagation for different mediums. | An apparatus for measuring the temperature of a medium such as air or the like by the use of a change in the propagation speed of an ultrasonic sound wave depending on the temperature change of the medium. An acoustic transmitter transmits a carrier as an ultrasonic sound wave continuously through the medium to a receiver by exciting an ultrasonic wave vibrator with a series of pulses which constitute the carrier. The received ultrasonic wave when amplified exhibits a series of pulses having a constant signal level irrespective of a change in the amplification factor of the amplifier in the receiver. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation application under 35 U.S.C. §120 based upon co-pending U.S. patent application Ser. No. 14/750,055 filed on Jun. 25, 2015, which claims priority to U.S. patent application Ser. No. 14/330,070 filed on Jul. 16, 2014, which claims priority to U.S. provisional application 61/847,653 filed on Jul. 18, 2013. Additionally, this present application claims the benefit of priority of co-pending U.S. patent application Ser. No. 14/750,055 filed on Jun. 25, 2015. The entire disclosure of the prior application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an overhead door backup spring system for use in connection with providing an emergency spring counterweight for overhead doors upon failure of a main spring counterweight.
[0004] 2. Description of the Prior Art
[0005] Overhead door backup spring systems are desirable for allowing a user to still operate an overhead door, such as a garage door, even when the main spring counterweight has failed. The majority of overhead doors include multiple door panel sections that are hinged together and which travel along parallel side tracks or rails from a closed vertical position to an open horizontal position. These overhead doors normal utilize a torsion spring connected to a shaft which supplies the force to counter balance the door during the opening operation. The spring has a life cycle and will break or fail when reached.
[0006] When the spring fails, the user will call a garage door technician to make a house-call to replace the broken spring. Many users are not able to manually lift the full weight of the garage door because the spring is not providing the counter lifting force. In some cases, the user's vehicle is in the garage, which is now trapped and thus the technician would be required to make an emergency house-call. The emergency house-call can cost the user an increased rate over planned service calls.
[0007] Known garage door auxiliary spring systems specifically use a second spring that is connected to the shaft and which provides a lifting force for the door during only a portion of the travel path.
[0008] While the above-described devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not describe an overhead door backup spring system that allows providing an emergency spring counterweight for overhead doors upon failure of a main spring counterweight
[0009] Therefore, a need exists for a new and improved overhead door spring system that uses an extra spring providing an emergency spring counterweight for overhead doors upon failure of a main spring counterweight. In this regard, the present invention substantially fulfills this need. In this respect, the overhead door backup spring system according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of providing an emergency spring counterweight for overhead doors upon failure of a main spring counterweight.
SUMMARY OF THE INVENTION
[0010] In view of the foregoing disadvantages inherent in the known types of garage door auxiliary spring systems now present in the prior art, the present invention provides an improved overhead door backup spring system, and overcomes the above-mentioned disadvantages and drawbacks of the prior art. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved overhead door backup spring system and method which has all the advantages of the prior art mentioned heretofore and many novel features that result in an overhead door backup spring system which is not anticipated, rendered obvious, suggested, or even implied by the prior art, either alone or in any combination thereof.
[0011] To attain this, the present invention essentially comprises an activation unit for operating upon failure of a spring. The activation unit has a plunger including an extension. The extension is operably associated with a portion of the spring. The plunger is configured to be operable upon failure of the spring
[0012] The plunger can be rotatably and slidably received in a plunger sleeve which surrounds the plunger. The extension can be a plunger pin extending out from the plunger, with the plunger pin slidably received in a sleeve slot defined in the plunger sleeve. The activation unit can further include a plunger spring that biases the plunger away from the spring.
[0013] The plunger of the activation unit can further being engageable with an engagement unit of an overhead door backup spring system upon failure of the spring. The engagement unit can be engageable with an auxiliary spring engagement unit in an engaged position upon operation of the activation unit upon failure of the spring. The engagement unit can be operably associated with an auxiliary spring, with the engagement unit being configured to transfer torque from the auxiliary spring to a shaft of an overhead door in the engaged position.
[0014] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.
[0015] The activation unit may also include an activation spring attached to an activation bar extending from the spring. The activation spring has a spring force less than a torque of the spring to move the activation bar upon failure of the spring.
[0016] There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims attached.
[0017] Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. In this respect, before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
[0018] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0019] It is therefore an object of the present invention to provide a new and improved activation unit that has all of the advantages of the prior art garage door auxiliary spring systems and none of the disadvantages.
[0020] It is another object of the present invention to provide a new and improved activation unit that may be easily and efficiently manufactured and marketed.
[0021] An even further object of the present invention is to provide a new and improved activation unit that has a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such activation unit economically available to the buying public.
[0022] Still another object of the present invention is to provide a new activation unit that provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
[0023] Lastly, it is an object of the present invention to provide a new and improved method of using an activation unit. The method can include the steps of moving a portion of a spring upon failure of the spring. Then engaging the portion of the spring with an extension of a plunger. Then moving the plunger upon engagement with the portion of the spring.
[0024] These together with other objects of the invention, along with the various features of novelty that 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 the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] 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:
[0026] FIG. 1 is a top elevational view of an embodiment of the overhead door backup spring system constructed in accordance with the principles of the present invention and fitting to an existing overhead door spring and shaft assembly, with the phantom lines depicting environmental structure and forming no part of the claimed invention.
[0027] FIG. 2 is a top perspective view of the overhead door backup spring system of the present invention.
[0028] FIG. 3 is a cross-section view of the activation linkage and the backup spring engaging assembly of the overhead door backup spring system in the non-engaged position taken along line 3 - 3 of FIG. 1 .
[0029] FIG. 4 is a cross-section view of the activation linkage and the backup spring engaging assembly of the overhead door backup spring system in the engaged position.
[0030] FIG. 5 is a cross-section view of the activation linkage and the backup spring engaging assembly of the overhead door backup spring system in the non-engaged position taken along line 5 - 5 of FIG. 3 .
[0031] FIG. 6 is a cross-section view of the activation linkage and the backup spring engaging assembly of the overhead door backup spring system in the engaged position.
[0032] FIG. 7 is a side perspective view of the safety spring assembly of the overhead door backup spring system in the non-engaged position.
[0033] FIG. 8 is a side perspective view of the safety spring assembly of the overhead door backup spring system in the engaged position.
[0034] FIG. 9 is a top perspective view of an alternate embodiment of the overhead door backup spring system of the present invention.
[0035] FIG. 10 is a side perspective view of the activation linkage and the backup spring engaging assembly of the alternate embodiment overhead door backup spring system of FIG. 9 .
[0036] FIG. 11 is a side perspective view of an alternate embodiment of the overhead door backup spring system of the present invention.
[0037] FIG. 12 is a cross-sectional view of the activation linkage of the alternate embodiment overhead door backup spring system in the non-engaged position taken along line 12 - 12 of FIG. 11 .
[0038] FIG. 13 is a cross-sectional view of the activation linkage of the alternate embodiment overhead door backup spring system of FIG. 11 in the engaged position.
[0039] FIG. 14 is a top perspective view of an alternate embodiment overhead door backup spring system of the present invention.
[0040] FIG. 15 is a front perspective view of the alternate embodiment overhead door backup spring system with the control assembly removed for clarity and the plunger sleeve being transparent so as to view the interior of the activation unit.
[0041] FIG. 16 is a perspective view of the activation unit of the alternate embodiment overhead door backup spring system of the present invention.
[0042] FIG. 17 is a cut-away perspective view of the activation unit of the alternate embodiment overhead door backup spring system of the present invention.
[0043] FIG. 18 is a front perspective view of the control assembly of the alternate embodiment overhead door backup spring system of the present invention.
[0044] FIG. 19 is a front perspective view of the control assembly of the alternate embodiment overhead door backup spring system of the present invention.
[0045] FIG. 20 is a rear perspective view of the control assembly of the alternate embodiment overhead door backup spring system of the present invention.
[0046] FIG. 21 is a top perspective view of the engagement assembly of the alternate embodiment overhead door backup spring system of the present invention with a transparent plunger sleeve and a transparent pillow block.
[0047] FIG. 22 is a cross-sectional view of the activation unit and engagement assembly in the non-engaged position.
[0048] FIG. 23 is a cross-sectional view of the activation unit and engagement assembly in the engaged position
[0049] FIG. 24 is a front perspective view of the alternate embodiment overhead door backup spring system of the present invention.
[0050] FIG. 25 is a front side view of the alternate embodiment overhead door backup spring system of the present invention.
[0051] FIG. 26 is a top elevational view of the alternate embodiment overhead door backup spring system of the present invention.
[0052] The same reference numerals refer to the same parts throughout the various figures.
DETAILED DESCRIPTION OF THE INVENTION
[0053] Referring now to the drawings, and particularly to FIGS. 1-26 , an embodiment of the overhead door backup spring system of the present invention is shown and generally designated by the reference numeral 10 .
[0054] In FIGS. 1 and 2 , a new and improved overhead door backup spring system 10 of the present invention for providing an emergency spring counterweight for overhead doors upon failure of a main spring counterweight is illustrated and will be described. More particularly, the backup spring system 10 can be retrofitted to an existing overhead door spring and shaft assembly 2 . It can be appreciated that the present invention can be integrated in new overhead door spring and shaft assemblies. Standard overhead door spring and shaft assemblies 2 are secured to a wall or beam 3 , and include a shaft 5 connected to bearings 4 at its ends, and a main spring 6 connected to the shaft 5 and a main spring bracket 7 . The main spring 6 provides torque to the shaft 5 which provides a lifting force to an overhead door (not shown).
[0055] When the main spring 6 fails, the door is always in the closed position and/or will remain in the closed position. The user would be required to manually lift the entire weight of the door, and in cases where the user is not able to lift the door and the user's vehicle in the garage, then the user would require an emergency service call from a technician. The emergency service call can be very expensive, even double a standard service call rate.
[0056] The backup spring system 10 includes an auxiliary spring 12 , a control assembly 22 and an engagement assembly 50 . The auxiliary spring 12 is held in a coiled state by the control assembly 22 , thereby storing potential energy or torque and releasing such upon activation of a line 24 by the user. The control assembly 22 simultaneously releases the torque energy of the auxiliary spring 12 and transfers it to the engagement assembly 50 , which then transfer it to the shaft 5 .
[0057] The auxiliary spring 12 , can be but not limited to, a coil spring fitted over the shaft 5 so that the shaft is received in the auxiliary spring 12 . The auxiliary spring 12 is attached to a mounting bracket 16 via a coupler 14 at a first end, which secures the first end of the auxiliary spring 12 to the mounting bracket 16 and prevents the auxiliary spring 12 from rotating. A second end of the auxiliary spring 12 includes a fitting 18 having a plurality of extensions or spring posts 20 extending radially outwardly therefrom. The second end of the auxiliary spring 12 and fitting 18 are configured to be rotatable about the shaft 5 .
[0058] Regarding FIGS. 2-6 the control assembly 22 can be fitted to a mount 28 which is attached to the beam 3 or can be attached directly to the beam 3 . The line 24 activates the control assembly 22 and can run over a pulley 26 , thereby allowing the line 24 to be positioned remote from the control assembly 22 . The control assembly 22 includes a lever 30 pivotably mounted to the mount 28 via a pivot pin or hinge 32 .
[0059] The hinge 32 is located between free ends of the lever 30 , with the line 24 coupled at one end and an engagement rod 40 coupled to an opposite end, as best illustrated in FIGS. 3 and 4 . A retaining rod 34 is coupled to the lever 30 between the hinge 32 and the engagement rod 40 . The retaining rod 34 passes through at least two linear bearings 36 fitted to the mount 28 . The linear bearings 36 hold the torque of the auxiliary spring 12 in a pre-wound state, thus creating the potential energy or torque required to rotate the shaft 5 upon activation. The retaining rod 34 extends out past the linear bearings 36 so as to protrude between the spring posts 20 and thus engage with one of the spring posts 20 to hold the auxiliary spring 12 in the pre-wound state.
[0060] The control assembly 22 additionally includes a fork 42 that is pivotably coupled to the mount 28 via a fork hinge 44 , and is configured so that the shaft 5 passes between forks thereof. A fork stop 46 extends away from the mount 28 adjacent the fork 42 so as to limit the travel of the fork 42 away from the engagement assembly 50 . The engagement rod 40 is additionally coupled to a fork extension 43 spaced away from and connected to the fork 42 . The engagement rod 40 transfers rotational movement of the lever 30 to pivotal movement of the fork 42 .
[0061] The engagement assembly 50 features a central bore configured to receive the shaft 5 therethrough, and includes a disk 52 , a pillow block 56 and an engagement disk 64 . The disk 52 and engagement disk 64 are slidable on the shaft 5 , and at least two sliding rods 54 . The disk 52 includes a surface configured to contact the fork 42 . The sliding rods 54 extend away from the disk 52 , through the pillow block 56 by traveling on a bearing race, and are coupled to the engagement disk 64 .
[0062] The pillow block 56 features a cutout 58 that has a threaded bore therethrough for receiving a set screw 60 . The set screw 60 is configured to engage with the shaft 5 and retain the pillow block 56 to the shaft 5 while preventing the pillow block 56 to rotate about the shaft 5 . The pillow block 56 additionally includes a linear bearing 62 fitted to a recess in the pillow block 56 and to the engagement disk 64 , and is configured to slide on the shaft 5 .
[0063] The engagement disk 64 includes a plurality of engagement posts 66 extending away from the engagement disk 64 toward the fitting 18 , wherein the engagement posts 66 are parallel with the shaft 5 . The engagement posts 66 are configured to engage with the spring posts 20 , upon movement of the disk 52 produced by the fork 42 .
[0064] Regarding FIGS. 3 and 5 , the lever 30 , fork 42 , disk 52 and engagement disk 64 are in a non-engaged position. In the non-engaged position, the retaining rod 34 is between the spring posts 20 and in contact with at least one of the spring posts 20 . The fork 42 is not engaged with the disk 52 , so the disk 52 and the engagement disk 64 are positioned away from the auxiliary spring 12 , thus the engagement posts 66 are not located between the spring posts 20 . The linear bearings 36 hold the retaining rod 34 in place, preventing the retaining rod 34 from moving upward or downward by the resulting torque from the pre-wound auxiliary spring 12 .
[0065] Regarding FIGS. 4 and 6 , the user would pull on the line 24 , thereby pivoting the lever 30 about the hinge 32 and thus pulling the retaining rod 34 and the engagement rod 40 in a direction opposite that of the line 24 . The lever 30 pulls the retaining rod 34 out of engagement with the spring posts 20 . Simultaneously, the engagement rod 40 pulls the fork 42 toward the disk 52 and pushes the disk 52 towards the fitting 18 . The sliding movement of the disk 52 slides the sliding rods 54 through the pillow block 56 and pushes the engagement disk 64 towards the fitting 18 . The sliding movement of the engagement disk 64 pushes the engagement posts 66 between the spring posts 20 . This simultaneous disengagement of the retaining rod 34 and engagement of the engagement posts 66 allows the auxiliary spring 12 to freely rotate, and thus transfers the torque of the auxiliary spring 12 to the pillow block 56 via the sliding rods 54 received therethrough, and then to the shaft 5 so as to assist in lifting the door coupled to the shaft 5 .
[0066] Regarding FIGS. 7 and 8 , the backup spring system 10 can also include a safety assembly for the line 24 , so as to prevent the line 24 from being activated when the main spring 6 is not broken. The safety assembly can be associated with the main spring bracket 7 or an additional main spring bracket 70 . The bracket 70 features a first bore 72 , and a second bore 74 in communication with the first bore 72 . The line 24 passes through the first and second bores 72 , 74 and includes a washer 25 . The washer 25 is sized larger than the second bore 74 so as to prevent the washer 25 from passing therethrough when the user pulls on the line 24 , as best illustrated in FIG. 7 . The first bore 72 is configured to allow the washer 25 to pass therethrough.
[0067] A shoulder bolt 76 is connected to the main spring 6 , and passes through the second bore 74 . A safety spring 78 is connected to and pulls on the shoulder bolt 76 ; however the torque of a non-broken main spring 6 overcomes the pull of the safety spring 78 .
[0068] In operation, when the main spring 6 fails, the safety spring 78 pulls the shoulder bolt 76 from one end of the second bore 74 toward the other end. The shoulder bolt 76 contacts the washer 25 and pushes it away from the second bore 74 and toward the first bore 72 , as best illustrated in FIG. 8 . Once the washer 25 is adjacent the first bore 72 , then the user can pull the line 24 and the washer 25 will then pass freely through the first bore 72 .
[0069] Regarding FIGS. 9 and 10 , an alternate embodiment backup spring system 80 is described. The backup spring system 80 includes the auxiliary spring 12 , a fork 42 ′ activated by the line 24 , and an engagement assembly. The main spring 6 is connected to the shaft 5 and a mounting bracket 82 . A first engagement fitting 84 is rigidly connected to the shaft 5 , and it includes a plurality of extensions 86 extending toward the auxiliary spring 12 parallel with the shaft 5 .
[0070] The auxiliary spring 12 is secured at one end so as not to rotate, and includes a pillow block 96 at an opposite end adjacent the first engagement fitting 84 . The fork 42 ′ is pivotably connected to the wall or mount 28 via a hinge 44 ′, and is activated by the line 24 via a fork extension 43 ′. The fork 42 ′ is configured so that the auxiliary spring 12 passes through the forks, so as to make contact with the pillow block 96 .
[0071] The engagement assembly includes a pillow block 96 which slides along the shaft 5 passing therethrough and is coupled to a disk 98 . A bore 100 is defined through the center of the disk 98 and features multiple notches 102 . A geometric stop block 104 is rigidly fitted to the shaft 5 , and positioned so that its corners are received in the notches 102 . The stop block 104 retains the auxiliary spring 12 in a pre-wound state.
[0072] A plurality of bearings or rollers 106 connected to the disk 98 contact the stop block 104 and allows the pillow block 96 and disk 98 to slide freely over the stop block 104 when acted upon by the fork 42 ′.
[0073] Multiple sliding posts 108 connect the disk 98 to a second engagement fitting 110 which includes a plurality of extensions 112 extending toward the first engagement fitting 84 parallel with the shaft 5 . The extensions 112 of the second engagement fitting 110 are configured to mesh with the extensions 86 of the first engagement fitting 84 when moved into an engagement position by the fork 42 ′.
[0074] When the fork 42 ′ is pivoted by the line 24 , it pushes the pillow block 96 , the disk 98 and the second engagement fitting 110 toward the first engagement fitting 84 . The disk 98 travels over and past the stop block 104 so that the stop block 104 is received in a hollow interior of the pillow block 96 , thereby allow the pillow block 96 to freely rotate around stop block 104 . The extensions 112 of the second engagement fitting 110 engage with the extensions 86 of the first engagement fitting 84 , thereby transferring the torque of the pre-wound auxiliary spring 12 to the shaft 5 .
[0075] Regarding FIG. 11 , an alternate embodiment backup spring system 120 is described. The backup spring system 120 includes the auxiliary spring 12 , a control lever 130 , a fork 42 ″ and an engagement assembly. The auxiliary spring 12 is held in a coiled state by the control lever 130 , thereby storing potential energy or torque and releasing such upon activation of the line 24 by the user. The control lever 130 and the fork 42 ″ simultaneously release the torque energy of the auxiliary spring 12 and transfer it to the engagement assembly, which then transfer it to the shaft 5 .
[0076] The auxiliary spring 12 is attached to a mounting bracket via a coupler at a first end, which secures the first end of the auxiliary spring 12 to the mounting bracket and prevents the auxiliary spring 12 from rotating. A second end of the auxiliary spring 12 includes the fitting 18 featuring the spring posts 20 extending radially outwardly therefrom. The second end of the auxiliary spring 12 and fitting 18 are configured to be rotatable about the shaft 5 .
[0077] The control lever 130 and a control bracket 122 can be fitted to the mount 28 which is attached to the beam 3 or directly to the beam 3 . The line 24 passes through a first bore 124 defined through the control bracket 122 and is coupled to the control lever 130 and the fork 42 ″. The fork is pivotably connected to the mount 28 via a hinge 44 ″, and the control lever 130 is pivotably mounted to the mount 28 via a pivot pin or hinge 132 , as best illustrated in FIGS. 12 and 13 . The fork 42 ″ is moved upon activation of the line 24 and is configured so that the shaft 5 passes between forks.
[0078] The hinge 132 is located between free ends of the control lever 130 , with the line 24 coupled at one end and a retaining rod 34 ′ coupled to an opposite end. The retaining rod 34 ′ passes through a second bore 126 defined through the control bracket 122 . The second bore 126 hold the torque of the auxiliary spring 12 in a pre-wound state, thus creating the potential energy or torque required to rotate the shaft 5 upon activation. The retaining rod 34 ′ extends out past the control bracket 122 so as to protrude between the spring posts 20 and thus engage with one of the spring posts 20 to hold the auxiliary spring 12 in the pre-wound state.
[0079] The engagement assembly includes a pillow block 96 ′ which slides along a stop block 104 ′ that is rigidly attached to the shaft 5 . An engagement disk 64 ′ is fitted to the pillow block. A bore 100 ′ is defined through the center of the engagement disk 64 ′ and is configured to receive the shaft 5 therethrough. The stop block 104 ′ is rigidly fitted to the shaft 5 , and is configured to retain the pillow block 96 ′ and transfer any rotational movement to the shaft 5 . The pillow block 56 ′ is slidable on the stop block 104 ′, and has a surface configured to contact the fork 42 ″.
[0080] The engagement disk 64 ′ includes a plurality of engagement posts 66 ′ extending away from the engagement disk 64 ′ toward the fitting 18 , wherein the engagement posts 66 ′ are parallel with the shaft 5 . The engagement posts 66 ′ are configured to engage with the spring posts 20 , upon movement of the engagement disk 64 ′ produced by the fork 42 ″.
[0081] Regarding FIG. 12 , the control lever 130 , the fork 42 ″, and engagement disk 64 ′ are in a non-engaged position. In the non-engaged position, the retaining rod 34 ′ is between the spring posts 20 and in contact with at least one of the spring posts 20 . The fork 42 ″ is not engaged with the disk 52 , so the disk 52 and the engagement disk 64 are positioned away from the auxiliary spring 12 , thus the engagement posts 66 ′ are not located between the spring posts 20 . The second bore 126 holds the retaining rod 34 ′ in place, preventing the retaining rod 34 ′ from moving upward or downward by the resulting torque from the pre-wound auxiliary spring 12 .
[0082] The control lever 130 may include a line slot 136 and a rod slot 134 which allow for rotational movement of the control lever 130 with lateral movement of the line 24 and retaining rod 34 ′.
[0083] Regarding FIG. 13 , the user would pull on the line 24 , thereby pivoting the control lever 130 about the hinge 132 and thus pulling the retaining rod 34 ′ in a direction opposite that of the line 24 . The control lever 130 pulls the retaining rod 34 ′ out of engagement with the spring posts 20 . Simultaneously, the line 24 pulls the fork 42 ″ toward the pillow block 96 ′, which pushes the pillow block 96 ′ and engagement disk 64 ′ towards the fitting 18 . This simultaneous disengagement of the retaining rod 34 ′ and engagement of the engagement posts 66 ′ allows the auxiliary spring 12 to freely rotate, and thus transfers the torque of the auxiliary spring 12 to the pillow block 96 ′ via the stop block 104 ′, and then to the shaft 5 so as to assist in lifting the door coupled to the shaft 5 .
[0084] In FIGS. 14-26 , an alternate embodiment of the overhead door backup spring system of the present invention is shown and generally designated by the reference numeral 200 .
[0085] The alternate overhead door backup spring system 200 of the present invention for providing an emergency spring counterweight for overhead doors upon failure of a main spring counterweight is illustrated and will be described. More particularly, the backup spring system 200 can be retrofitted to an existing overhead door spring and shaft assembly. It can be appreciated that the backup spring system 200 can be integrated in new overhead door spring and shaft assemblies.
[0086] Regarding FIG. 14 , the backup spring system 200 includes an auxiliary spring 12 , an activation unit 220 , a control assembly 240 , an engagement assembly 280 , and an auxiliary spring engagement assembly 300 . The auxiliary spring 12 is held in a coiled state by the control assembly 240 , thereby storing potential energy or torque and releasing such upon activation of by the backup spring system 200 automatically upon failure of the main spring 6 . The activation unit 220 automatically activates the control assembly 240 which simultaneously releases the torque energy of the auxiliary spring 12 and transfers it to the engagement assembly 280 , which then transfer it to the shaft 5 .
[0087] The auxiliary spring 12 , can be but not limited to, a coil spring fitted over the shaft 5 so that the shaft is received in the auxiliary spring 12 . The auxiliary spring 12 is attached to a mounting bracket 208 , and a spring pin 204 and bracket slot 205 arrangements which prevents the main spring 6 from rotating until failure. While the auxiliary spring 12 is retained in a torqued or tensioned position by the control assembly 240 and engagement assembly 280 .
[0088] Referencing FIGS. 14-17 , the activation unit 220 includes an activation bar 210 coupled to the main spring 6 , so as to rotate about the shaft 5 upon failure of the main spring 6 . The torque of the main spring 6 keeps the activation bar 210 in the non-engagement position and is retained by a side edge of a slot defined in the bracket 208 . An activation spring 211 is attached to the bracket 208 and to the activation bar 210 to provide a pulling force that counteracts the torque of the main spring 6 , as best illustrated in FIG. 16 . The pulling force of the activation spring 211 is less than the torque of the main spring 6 . Upon failure of the main spring 6 its torque is reduced below the pulling force of the activation spring 211 . The activation spring 211 is now able to pull the activation bar 210 into the engaged position.
[0089] A release member or bar 212 is attached to and able to move with the activation bar 212 upon failure of the main spring 6 . The release member 212 can include a bore configured to receive the activation bar 212 therethrough, or a bracket attachable to the activation bar 212 . The release member 212 is operated by the activation bar 210 so as to rotate or move along a pin 214 by way of a slot 213 defined through the release member 212 .
[0090] A linkage can be used to operate the control assembly 240 . The linkage can include a stop 216 is fitted to a control shaft or line 218 , and is biased by a stop spring 217 located to produce a force on the control shaft 218 . In the non-engagement position, the release member 212 prevents the stop 216 from moving, thus retaining the control shaft 218 in position. When the release member 212 is operated by the activation bar 210 , the slot 213 is aligned with the stop 216 thereby allowed the spring 217 to move the control shaft 218 .
[0091] A plunger sleeve 222 extends from the bracket 208 , opposite the main spring 6 , and is secured to the bracket 208 or to the shaft 5 by a bearing 206 . The plunger sleeve 222 includes a J-shaped or L-shaped slot 224 , as best illustrated in FIG. 17 .
[0092] A plunger 226 is slidably received in the plunger sleeve 222 , and is biased away from the bracket 208 by a plunger spring 230 . The plunger 226 includes a plunger pin 228 extending through the slot 224 and which is in operable location with the activation bar 210 . The plunger 226 can also include a recess configured to receive a first end of the plunger spring 230 , while a second of the plunger spring 230 abuts the bearing 206 or bracket 208 . The activation bar 210 can have a forked end so as to receive a section or the plunger pin 228 .
[0093] The shape of the slot 224 prevents the plunger 226 from moving away from the bracket 208 in a non-engaged position because a wall or edge of the slot 224 contacts the plunger pin 228 in a direction substantially perpendicular to the sliding movement of the plunger 226 produced by the plunger spring 230 . Once the plunger pin 228 is rotated by the activation bar 210 upon failure of the main spring 6 to an engaged position where the plunger pin 228 is free to travel down the slot 224 thereby allowing the plunger 226 to move away from the bracket 208 .
[0094] Referencing FIGS. 18-20 , the control assembly 240 includes first and second plate assemblies in a spaced relationship with each other. The first plate assembly includes a pair of first plates 244 mounted to a wall or mount 242 via a plurality of fasteners 248 . The first plates 244 are spaced apart from each other via spacers 249 located about the fasteners 248 , thus created a gap between the first plates 244 . The first plates 244 define corresponding J-shaped or L-shaped plate slots 246 that are aligned with each other. The plate slots 246 include a first section parallel with a longitudinal axis of the control shaft 218 , and a second section that is perpendicular to the longitudinal axis of the control shaft 218 .
[0095] A control shaft block 250 is fitted to an end of the control shaft 218 , and is slidably or moveably received in the gap between the first plates 244 . The control shaft black 250 can be located so as to slidably rest upon at least one of the spacers 249 , thereby providing support for the control shaft block 250 .
[0096] The second plate assembly includes a pair of second plates 262 mounted to the wall or mount 242 via a plurality of fasteners 263 . The second plates 262 are spaced apart from each other via spacers 249 located about the fasteners 263 , thus created a gap between the second plates 262 . The second plates 262 can also define corresponding J-shaped or L-shaped plate slots so that first plates can be used to produce the second plates 262 . Each of the second plates 262 includes facing detents or bumps 264 .
[0097] A control bar 252 is slidably received in the gaps of the first and second plates 244 , 262 . The control bar 252 includes a post 254 that is received in the plate slots 246 , and an engagement block 256 located between the first and second plate assemblies. The engagement block 256 defines a bore 258 configured to receive the control bar 252 , and a set screw configured to secure the engagement block 256 to the control bar 252 in an adjustable position.
[0098] The section of the control bar 252 located between the second plates 262 is positioned so as to be adjacent with and below the detents 264 , thereby creating a pivot point while allowing the control bar 252 to slide there along.
[0099] A control bar spring 260 is connected to a spacer or pin 265 located near a top of the second plates 262 , and to the control bar 252 at a location between adjacent or near the first plates 244 or the engagement block 256 , as best illustrated in FIGS. 18 and 19 . The control bar spring 260 produces an upward force on the control bar 252 .
[0100] The control shaft block 250 is operable coupled to an end section of the control bar 252 so as to slide or move the control bar 252 upon movement of the control shaft 218 . When the control bar 252 moves, the post 254 slides along the first section of the plate slots 246 prevents the control bar 252 from moving upward until it is aligned with the second section of the plate slots 246 . At this position, the control bar spring 260 pulls on the control bar 252 thereby pivoting it against the detents 264 and lifting the post 254 up the second section of the plate slots 246 .
[0101] An engagement lever assembly is pivotably connected to the second plates 262 via a pair of lever members 266 which are spaced apart from each other so as to receive the second plates 262 therebetween. A first end of the lever members 266 are pivotably fitted to at least one of the second plate fasteners 268 located near a lower corner of the second plates 262 . A second end of the lever members 266 extend past the second plates 262 . A first lever bar 270 extends from the second end of the lever members 266 and includes a linkage end.
[0102] A second lever bar 272 includes a linkage end connected to the linkage end of the first lever bar 270 so as to extend the second lever bar 272 away from the first lever bar 270 at an angle different from the first lever bar 270 . The first lever bar 270 can be rotatably connected to the lever members 266 , and/or the second lever bar 272 can be pivotably connected to the first lever bar 270 . The first lever bar 270 can be biased by a spring so as to rotate the second lever bar 272 in a predetermined direction.
[0103] Referencing FIGS. 21-23 , the engagement assembly 280 features a central bore configured to receive the shaft 5 therethrough, and includes an engagement disk 282 , a pillow block 290 and the auxiliary spring engagement assembly 300 .
[0104] The engagement disk 282 includes a plurality of engagement posts 284 extending away from the engagement disk 282 toward the pillow block 290 , wherein the engagement posts 284 are parallel with the shaft 5 . Each of the engagement posts 284 includes an annular recess 288 located at predetermined distance on the posts 284 , and a tapered free end 286 . The free end 286 features a base having a diameter larger than a diameter of it respective post 284 to create a ledge, and a tapering tip.
[0105] The engagement disk 282 also includes a surface configured to rotatably contact the plunger 226 , and is configured to slide along the shaft 5 when operated by movement of the plunger 226 . The engagement disk 282 can slide along the shaft 5 by way of a linear or thrust bearing. It can be appreciated that the engagement disk 282 and/or the plunger 226 and/or the plunger sleeve 222 can include a magnet (not shown) to assist retaining the engagement disk 282 in the non-engaged position.
[0106] The pillow block 290 is located between the engagement disk 282 and the free end 286 of the engagement posts 284 , and is retained therebetween by the ledge of the free end 286 . The pillow block 290 features a cutout or keyway 298 that has a threaded bore therethrough for receiving a set screw 299 . The set screw 299 is configured to engage with the shaft 5 and retain the pillow block 290 to the shaft 5 while preventing the pillow block 290 from rotating about the shaft 5 . The keyway 298 allows the position of the pillow block 290 on the shaft 5 to be adjusted.
[0107] The pillow block 290 includes a plurality of longitudinal bores 292 , and a plurality of retention balls 294 each being moveably located in bores defined in the pillow block 290 . The bores associated the retention balls 294 are in communication with one of the longitudinal bores 292 , and it can be appreciated that these bores are defined from the interior or exterior of the pillow block 290 . The longitudinal bores 292 are each configured to slidably receive at least one of the engagement posts 284 therethrough from the non-engaged position to the engaged position. Each of the retention balls 294 includes a spring for biasing the ball 294 toward the engagement post 284 . When the annular recess 288 of the engagement post 284 is aligned with a corresponding ball 294 , the ball is received in the recess 288 to retain the engagement post 284 in a predetermined position.
[0108] The auxiliary spring engagement assembly 300 is located at an end of the auxiliary spring 12 , and includes a cylindrical extension 302 , a plurality of spring posts 304 extending radially outward from the cylindrical extension 302 , and a spring post disk 308 located between the spring posts 304 and an end of the backup spring 12 . The auxiliary spring engagement assembly 300 is rotatably supported about the shaft 5 by a bearing. The cylindrical extension 302 has a diameter that allows it to be received between the free ends 286 of the engagement posts 284 .
[0109] Each of the spring posts 304 include a notch 306 configured to receive at least one of the ledges created by the free end 286 of the engagement post 284 , when the engagement posts 284 are in the engaged position. The notches 306 retain engagement between the engagement posts 284 and the spring posts 304 while preventing the engagement posts 284 from retracting back to the non-engaged position until desired by the user. The spring posts 304 have a length allowing at least one of them to contact and abut against the engagement block 256 , thereby retaining the auxiliary spring 12 in a pre-wound stated. The auxiliary spring 12 is allowed to transfer its torque to the engagement posts 284 when in the engaged position because the engagement block 256 is moved out of contact with the spring post 304 .
[0110] The spring post disk 308 is slidable along the cylindrical extension 30 , and has a diameter allowing contact with free end of the second lever bar 272 . The spring post disk 308 is pushed toward the spring posts 304 by the biased force of the second lever bar 272 . The spring post disk 308 has a surface configured to be contacted by the tip of the free end 286 of the engagement posts 284 in the engaged position. The biasing force of the second lever bar 272 against the spring post disk 308 keeps the free ends 286 of the engagement posts 284 from advancing into the engaged position until desired.
[0111] In operation, as best illustrated in FIGS. 24-26 , the alternate embodiment backup spring system 200 is initially in the non-engaged position where the activation unit 220 is not activated and the plunger 226 is retracted, the control bar 252 is not pivoted and the post 254 is in the first section of the plate slots 246 , the engagement block 256 is in contact with at least one of the spring posts 304 , and the engagement posts 284 are not engaged with the spring posts 304 .
[0112] In this non-engaged position, the torque of the pre-wound auxiliary spring 12 is retained as potential energy by the engagement block 256 in contact with at least one of the spring posts 304 . The main spring 6 and shaft 5 are allowed to rotated and operate normally because the activation bar 210 abuts the edge of the slot in the bracket 208 by the torque of the main spring 6 . The spring post disk 308 is urged toward the spring posts 304 by the second lever bar 272 to prevent accidental engagement of the engagement posts 284 with the spring posts 304 .
[0113] Upon failure of the main spring 6 , the main spring torque is reduced below the pulling force of the activation spring 211 , which automatically pulls or rotates the activation bar 210 . The activation bar 212 consequently pushes the plunger pin 228 into the plunger sleeve slot 224 allowing the plunger spring 230 to push the plunger 226 against the engagement disk 282 . Simultaneously, the activation bar 212 moves the release member 212 that releases the stop 216 and allows the stop spring 217 to move the control shaft 218 .
[0114] The force of the plunger 226 pushes the engagement disk 282 and thus pushes the engagement posts 284 toward an opened space between the spring posts 304 . The free ends 286 of the engagement posts 284 will contact the spring post disk 308 and push it away, thus allowing the free ends 286 to engage with the notches 306 of the spring posts 304 .
[0115] Movement of the control shaft 218 moves the control shaft block 250 which moves the control bar 252 . The movement of the control bar 252 simultaneously moves the post 254 into the second section of the plate slots 246 allowing the control bar spring 260 to pivot the control bar 252 against the detents 264 , and move the engagement block 256 out of engagement with the spring post 304 .
[0116] With the engagement block 256 out of engagement with the spring post 304 , and the engagement posts 284 engaged with the spring posts 304 , the alternate embodiment backup spring system 200 is now in the engaged position. In the engaged position, the potential energy of the pre-wound auxiliary spring 12 is now transferred to the engagement posts 284 and thus to the pillow block 290 , which transfers it to the shaft 5 , thereby allowing the overhead door to operate until the main spring 6 is repaired or replaced.
[0117] While embodiments of the overhead door backup spring system have been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. And although providing an emergency spring counterweight for overhead doors upon failure of a main spring counterweight have been described, it should be appreciated that the overhead door backup spring system herein described is also suitable for any sliding element or closure which uses a spring for counter force or assisting force.
[0118] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | The present invention essentially comprises an activation unit of an overhead door backup spring system operable upon failure of a spring, and method of using an activation unit. The activation unit has a rotating and sliding plunger that is operated upon failure of a spring. The activation unit can be used with an engagement unit that is engageable with an auxiliary spring to transfer torque from the auxiliary spring to an overhead door shaft. A plunger sleeve supports and guides the plunger by way of a sleeve slot that receives a plunger pin extending from the plunger. A plunger spring biases the plunger, while the sleeve slot retains the plunger in a biased state until activation by a portion of the spring upon failure of the spring. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates in general to a high-speed photographic device of the type having a spark-discharge flashlamp unit provided with a plurality of discrete spark gaps, means for sequentially activating respective spark gaps with a time delay of one spark discharge, a projecting optical system and a deflecting optical system cooperating, respectively, with the flashlight unit to take a succession of separate images of the path of movement of an object and reproduce the images side-by-side upon an image plane according to ignition points of respective spark gaps.
In particular the invention relates to a method of and a device for adjusting operational conditions of such high-speed photographic devices.
High-speed photography serves for investigating very fast processes or extremely short paths of movement. The correspondingly short exposure times and high illumination intensities required for taking high-speed photographic pictures can be obtained by means of spark discharges.
One known device of this type is the retarded-action spark system according to Cranz-Schardin. This device includes a spark-discharge flashlamp unit with a plurality of series-arranged spark gaps and a circuit for feeding and controlling the latter. In taking photographic pictures of a momentary process, the spark gaps are ignited in short time intervals, one after the other, to produce a succession of spark flashes. The flashes of individual spark gaps are spatially separated by means of a projecting and deflecting optical system on a photographic plate (or a film) of a receiving camera. As a result, the photographic plate records a succession of images arranged side-by-side of an object, illustrating the movement of the same in fast succession of time points corresponding to the ignition points of individual spark gaps.
A "Cranz-Schardin camera", described in a publication of the firm Impulsphysik GmbH of Hamburg, Germany, entitled "Automatische High Speed Photographie, Schnelle Bewegungsablaufe elektronisch-photographisch analysiert", pages 14 and 15, is designed with a projecting and deflecting optical system including a spherical mirror which focuses the flashlight of individual spark gaps through the object on a corresponding schlieren diaphragm. In the direction of light rays behind respective schlieren diaphgrams, an adjusting prism is arranged for receiving light from each spark gap. By adjusting the prism, it is possible to select the location on the photographic plate of the receiving camera on which the corresponding image is recorded. By adjusting the individual prisms different images are distributed on the photographic plate in such a manner as to prevent overlap, and the resulting arrangement permits the recognition of the time succession of the movement of the object with the best clarity. In a conventional method for adjusting the position of the adjusting prism, incandescent lamps are employed. The incandescent lamps together with spark gaps are arranged on a carrier of a precision slide in such a manner that, for the adjusting operation, the lamps are displaceable to the points at which the spark gaps are situated in the picture-taking position. The adjusting prisms and the remaining parts of the projecting and deflecting optical systems can thus be adjusted by means of the continuous light from the incandescent lamps. In order that the filaments of the incandescent lamps may be accurately placed in the position corresponding to that of the spark gaps during picture taking, an extremely accurate arrangement of the incandescent lamps on the optical slide bench was necessary, and the guiding accuracy of the slide required corresponding precision. The employed optical bench therefore was very expensive, and the installation of the incandescent lamps on the slide was also extremely costly. Moreover, this prior-art method and device did not permit an accurate adjustment because of the differences of the light sources, that is, due to different light intensities of the incandescent lamps and spark gaps. In the course of technical development, light-conductive glass fibers were employed for achieving the desired accuracy of the adjustment. The fibers were illuminated at one end by a lamp and the other end was installed on the optical slide bench instead of the incandescent lamps. A slider with slot-shaped diaphragms was arranged so as to cover the other ends of the glass fibers, to provide strip-shaped light sources corresponding to the configuration of respective sparks. In spite of the fact that this arrangement made it possible to achieve a more accurate adjustment, primarily of the schlieren diaphragm, even this arrangement was expensive and its installation and adjustment extremely time-consuming.
SUMMARY OF THE INVENTION
It is therefore a general object of the present invention to overcome the aforementioned disadvantages.
More particularly, it is an object of the invention to provide an adjusting device for the high-speed photography of the above described kind, by means of which the above described adjustment can be made with simple means and with great precision.
Another object of this invention is to provide an adjusting method resulting in improved quality of pictures by means of the spark-discharge flash unit.
In keeping with these objects, and others which will become apparent hereafter, one feature of the invention resides in a method of adjusting the high-speed photographic devices of the aforedescribed type in which the set of spark gaps is activated at an increased repetition rate, resulting in a reproduction of a flicker-free test image on the image plane, and then adjusting the test image to the desired quality.
The device for adjusting the operation of the high-speed photographic device of the aforedescribed kind includes a pulse generator by means of which the individual spark gaps are ignited at the increased repetition rate, so that the flicker-free image of the object is projected on the image plane.
The novel features which are considered characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a device for high-speed photography for obtaining retarded or slow-motion action by sparks according to Cranz-Schardin;
FIG. 2 is a sectional plan view of a spark-discharge flashlamp unit of FIG. 2, illustrating a spark gap; and
FIG. 3 is a schematic block circuit diagram of a spark-discharge flashlamp unit according to FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The device illustrated in the Figures includes a spark-discharge flashlamp unit 1 with eight spark gaps 11-18 and a power supply and control circuit 2 (FIG. 3) for activating the spark gaps, a projecting and deflecting optical system 3, and a receiving camera 4. The optical system 3 includes a spherical hollow mirror 5, arranged for focusing spark light flashes transmitted by the individual spark gaps 11-18 on the photographed object 6 and through a deflection prism 7 on the individual schlieren diaphragms 8 assigned to respective spark gaps. In FIG. 1, dashed lines 20 illustrate the light rays emitted by the spark-discharge flash of light emitted by the lowermost spark gap 18 which is directed through the uppermost schlieren diaphragm 8. By means of eight adjusting prisms 21-28 the spark-discharge light, upon passing through the assigned schlieren diaphragm 8, is deflected in the receiving camera 4, of which only objective 9 and image plane 10 are illustrated in FIG. 1. During the adjustment process, a frosted or ground glass plate is arranged in the image plane 10, whereas during the picture-taking operation there is provided a photographic plate. The deflection prism 7, the schlieren diaphragm 8 and the adjusting prisms 21-28 are mounted in a non-illustrated attachment head which can be secured to the receiving camera 4.
Referring now to FIG. 2, it will be seen that the spark gaps 11-18, of which only one is visible in FIG. 2, are arranged one above the other at a distance of about 9 mm in a common pressure-resistant housing 30 behind a light-permeable disk 31. The housing is filled up with a gas mixture containing more than 50% by volume of rare gases, for example 20% by volume N 2 and 80% by volume of Ar, or 40% by volume N 2 and 60% by volume of Kr. The pressure of the gas mixture is increased such that the breakdown field strength for igniting the spark discharge corresponds approximately to that in air under atmospheric pressure. By using the gas mixture consisting predominantly of noble gases and being under overpressure, a high light intensity and a relatively long duration of the spark discharge of the flash unit is achieved, and these features facilitate the below-described adjusting process of the arrangement. Preferably, hydrogen or helium is admixed also in the gas mixture, for example about 20% by volume. As a preferred composition for the gas mixture thus consists of 20% by volume of H 2 or He and 80% by volume of Ar or 20% by volume N 2 , 20% H 2 or He, and 60% by volume Kr. It has proved that the gas mixture due to the admixing or hydrogen or helium obtains a high thermal conductivity. The increased thermal conductivity prevents excessive overheating of the spark gaps during the below-described adjusting process according to this invention.
The spark gaps are the so-called three-electrode spark gaps, that is, each spark gaps has two master electrodes 32 and 33 between which the spark discharge takes place and an ignition electrode 34 for igniting the discharge. The diameter of the two main or master electrodes 32 and 33 is about 2 mm and the clearance, that is, the length of the spark gap, is also 2 mm. This relatively thick construction of the main electrodes 32 and 33 is also essential for the successful adjusting process according to this invention, in which each spark gap is ignited at a repetition frequency of 100 cycles per second. At this frequency, the tips of thinner electrodes would glow because of the insufficient heat conduction.
The power supply and control circuit 2 illustrated schematically in FIG. 3 includes a high-voltage power source 36 which supplies adjustable feed voltage of 2.5 to 4.5 kilovolts to ceramic capacitors 37 which are connected parallel to respective spark gaps 11-18. The ignition currents for the ignition electrodes 34 are initiated by non-illustrated thyristors. The control electrodes of the total of eight thyristors are connected to the outputs of assigned transistor AND-gates of a shift register 38. The two inputs of the AND-gates are connected to one storing cell of the shift register and to a clock pulse input of the latter.
The shift register 38 is connected to a pulse generator 41 which is switched off by a releasing pulse or by actuating a switch on its input B to initiate a photographic picture of an object moving at high speed. The impulse generator 41 starts a frequency divider 42 which divides the basic frequency of 40 megahertz of a quartz-controlled oscillator 43 in a ratio of 4:1. The pulse generator 41 also sets a flip-flop 44 which interrogates two stores 45 and 46. The stores 45 and 46 store respectively a value of a starting delay time and a clock pulse delay time selected by setting switches 47 and 48. Furthermore, as mentioned before, the pulse generator 41 controls the first flip-flop storing cell of the shift register 38. The values of the starting delay time and of the clock pulse delay time are applied to a programmable downwards counter 49. In particular, the read-in of the starting delay time is initiated by the pulse generator 41 and the read-in of the clock pulse delay time is released by a flip-flop 50 at the moment when the counter 49, which counts downwardly in synchronism with the frequency of 10 megahertz delivered by the frequency divider 42, reaches zero value. Simultaneously with reading-in the clock pulse delay time in the downward counter 49, a clock pulse is delivered from flip-flop 50 to the clock pulse input of the shift register 38. By means of the first clock pulse which is generated after runoff of the starting delay time, the transistor AND-gate of register 38, which is connected to the first storing stage of the latter, becomes conductive and the corresponding thyristor delivers the ignition current for the ignition electrode 34 of the first spark gap 11. Simultaneously, the first storage cell is disabled and the second storing cell is enabled. After the expiration of the clock pulse delay time, the second spark gap 12 is ignited in the above-described manner. In the same manner, the remaining spark gaps become activated. The individual spark gaps 11-18 thus produce a succession of spark discharges, whereby the time interval between the discharges corresponds to the clock pulse delay time preselected by the switch 48. After the ignition of the last spark gap 18, all storing cells in the register 38 are disabled, so that no ignition of the spark gaps can occur. By actuating a switch at the input C of the impulse generator 41, the flip-flop stage 44 is reset and stores 45, 46 as well as the counter 49 are brought into their starting states.
For adjusting the aforedescribed device, the circuit 2 includes a 100-cycles-per-second oscillator 52 which during the period required for adjustment is activated by a non-illustrated switch at its input A and starts activation of all spark gaps at the repetition rate of 100 Hz. The 100-Hz oscillator 52 is thus connected to both inputs of transistor AND-gates of the shift register 38, and consequently during the adjusting process all spark gaps are simultaneously ignited at a repetition rate of 100 cycles. In a modification, it is also possible to connect oscillator 52 through the shift register 38 and to the switching units for the clock pulse generation in similar manner as the clock pulse generator 41, so that spark gaps 11-18 be momentarily ignited one after the other at the repetition rate of 100 Hz.
The setting and adjustment of the device for the high-speed photography is made as follows:
The spark-discharge flash unit 1, mirror 5 and the receiving camera 4 with the attachment head 3 are installed such that the eight sparks generated in spark gaps 11-18 are sharply reproduced at a scale of 1:1 in the schlieren diaphragms 8. For this purpose, the mirror 5 must be arranged at a distance corresponding to double the focal length from the spark gaps and schlieren diaphragm 8. As soon as the three components are arranged approximately in this spatial relationship, the oscillator 52 is switched on for completing an accurate adjustment. The mirror 5 is first rotated so that the spark discharges generated in the spark gaps at the repetition rate of 100 Hz are reflected into themselves or are formed with images which are staggered laterally about several millimeters. The scale of 1:1 of the reproduced images is accurately obtained when the spacing between the spark gaps and the spacing between the images of the sparks correspond accurately to each other. Thereupon mirror 5 is turned and the attachment head on camera 4 is adjusted such that the eight sparks are sharply reproduced in the planes of schlieren diaphragm 8. In doing so, the schlieren diaphragms 8 are first adjusted so that the spark-discharge flash light can pass through the diaphragms without obstruction. Thereupon are adjusted the prisms 21-28 by means of the ground glass disk 10 inserted during the adjusting process into the image plane 10 of camera 4. Each of the spark gaps 11-18 when ignited at the repetition rate of oscillator 52 produces on the ground glass disk 10 a light spot which is continuously visible by the observer. The adjusting prisms 21-28 now can be set so that the light spots of individual spark gaps 11-18 do not overlap and permit a clear recognition of the time succession at which the spark gaps during the photographic picture taking are consecutively ignited. It is of advantage for the adjusting operation when the bellows of the camera are removed, and in order to make the light spots clearly visible a white paper is placed before the ground glass plate. Finally, for taking schlieren pictures, the schlieren diaphragms 8 are adjusted so that the direct image of the sparks is substantially covered. The adjustment of the device for taking photographic pictures is now complete, and oscillator 52 is switched off. The taking of photographic pictures is released by switching on the clock pulse generator 41.
The repetition rate of oscillator 52 can be also smaller than 100 cycles, but it should always be selected such that a continuously visible, substantially flicker-free image of the spark discharges be reproduced on the image plane. This can be achieved for example even at a frequency of 16 cycles, but the brightness of individual images is not very high. At a frequency of 50 cycles it is possible to obtain very bright individual images yielding a flicker-free impression which is agreeable for observation.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a specific example of a device for a high-speed photography, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A high-speed photographic device including a spark-discharge flash light unit according to Cranz-Schardin slow-motion camera having an optical projecting and deflecting system for reproducing individual consecutively ignited spark discharges on an image plane is to be adjusted for optimum operation.
The device for adjusting the optical system includes a pulse generator connected to ignition control means for the spark gaps and operating at a repetition rate to ignite simultaneously the spark gaps so as to produce a flicker-free test image of all spark discharges on the image plane. | 6 |
FIELD OF THE INVENTION
[0001] The invention relates to a transfer device for pushing a projectile into the barrel of a weapon along a transfer trough that is located behind the barrel at least during the transfer and positioned substantially parallel to the barrel, the transfer device having an elongate power transmission element that during the transfer of the projectile moves at least along part of its length substantially parallel to the transfer trough toward the barrel of the weapon, and at least one transfer element that under the influence of the moving power transmission element pushes the projectile from behind toward the barrel of the weapon.
BACKGROUND OF THE INVENTION
[0002] In various medium-heavy or heavy weapons or cannons and mortars, transferring the projectile to the barrel of the weapon is difficult. Especially handling heavy projectiles manually is both slow and dangerous. The aim is more and more to use semi-automatic or automatic operation, in which the projectiles are stored in different cartridges and moved from the cartridges with separate transfer equipment to the orifice of the barrel of the weapon, from where they are then transferred mechanically by pushing with a transfer device into the barrel. Devices of this type are known from U.S. Pat. No. 4,481,862, for instance.
[0003] During firing, the barrel of a weapon usually moves backward due to recoil, and this matter needs to be taken into consideration when designing the transfer equipment, its position and operation. Further, the breech mechanism, with which the back end of the barrel is closed during firing, requires its own space, and transfer devices need to be able to transfer the projectile at one go sufficiently far into the cartridge housing.
[0004] There are also risks involved in handling projectiles and, therefore, a projectile must not be rattled or subjected to very sudden accelerations.
BRIEF DESCRIPTION OF THE INVENTION
[0005] It is an object of the present invention to provide a transfer device with which the transfer of a projectile, after it is brought behind the barrel of a weapon in a coaxial position with the barrel, is efficient and smooth and takes place with a substantially even movement without sudden stops or accelerations during the transfer movement.
[0006] The transfer device of the invention is characterised in that it has two turning wheels at a distance from each other, that the power transmission element is a flexible element forming a closed loop and mounted to run around the turning wheels, that it has two transfer elements mounted to push a projectile in consecutive steps toward the barrel of a weapon, that the power transmission element has two connecting elements at a distance from each other, which alternately engage to move first the first transfer element and then the second transfer element, that the first transfer element is always in a position in which it extends behind the projectile and moves it first a part of the way, while the second transfer element is in a position in which it is at the side of the projectile and disengaged from the power transmission element, that when the first transfer element is in the predefined position, the second transfer element engages the power transmission element and turns behind the projectile, that after this the first transfer element decelerates and the second transfer element continues to push the projectile into the barrel of the weapon after the pushing movement of the first transfer element ends.
[0007] An essential idea of the invention is that to achieve a sufficient transfer distance, the projectile is moved by two transfer elements operated with an endless power transmission element so that the first transfer element moves the projectile a part of the way and the second transfer element pushes the projectile the rest of the transfer distance. A further essential idea of the invention is that the transfer elements engage to push the projectile so that the second transfer element starts to push the projectile from behind before the first transfer element stops moving the projectile, in which case the change of transfer element does not substantially cause any stops or decelerations or accelerations for the projectile during the transfer movement.
[0008] The invention provides the advantage that the projectile is moved from its initial position to the barrel of the weapon substantially evenly and smoothly, and the transfer equipment can also be made reasonably short with respect to the required transfer distance. A further advantage of the invention is that it is relatively simple to implement and very reliable to operate.
BRIEF DESCRIPTION OF THE FIGURES
[0009] The invention is described in more detail in the attached drawings, in which FIGS. 1 a to 1 d are schematic views of the barrel of a weapon, a transfer device, and a projectile before it is transferred to the barrel of the weapon, the transfer steps of the projectile and, correspondingly, the projectile after it is in place in the barrel of the weapon,
[0010] FIGS. 2 a and 2 b are schematic views of the transfer device and the position of the transfer elements in the loading situation of FIGS. 1 a to 1 d , as seen from behind the projectile, and
[0011] FIGS. 3 a to 3 b are schematic views of a second embodiment of the transfer device of the invention before the projectile is transferred into the barrel of the weapon, and, correspondingly, the projectile after it is in place in the barrel of the weapon.
DETAILED DESCRIPTION OF THE INVENTION
[0012] FIG. 1 a is a partly cross-sectional schematic view of the end of a barrel 1 of a weapon, where the breech mechanism is. Weapons of this type may be either cannons or mortars of different calibre. By way of example, grooves are marked at the furthest end of the barrel 1 to show the position of a housing 1 a of the breech block (not shown) relative to the barrel 1 . Several different breech mechanisms and types are used in different weapons. It is not necessary to describe them separately herein, because they are known per se to a person skilled in the art and not essential per se for this invention. Around the barrel 1 , several weapons have a cradle 1 b , and the barrel 1 can move in a manner known per se in its longitudinal direction backward due to recoil from firing, and return by means of separate known returning devices (not shown) back to its firing position. Further, FIG. 1 a shows a transfer trough 2 with a transfer-ready projectile 3 resting on it. The projectile 3 is substantially coaxial with the barrel of the weapon so that when it is moved along the transfer trough 2 , it goes straight into the barrel. It further has a transfer device 4 with which the projectile is transferred by pushing it from behind in a manner described later in FIGS. 1 b to 1 d . FIGS. 1 b to 1 d show schematically how the projectile 3 is moved with the transfer device 4 into the barrel 1 of the weapon. In the situation of FIG. 1 a , the projectile 3 is moved to or set on the transfer trough 2 to wait for transfer into the barrel 1 of the weapon. The transfer device 4 has turning wheels 5 and 6 , i.e. in this embodiment chain wheels, at a distance from each other, and an endless power transmission element 7 , in this embodiment a chain, is arranged to run around them. A first transfer element 8 is connected to the power transmission element 7 . The transfer element 8 is an elongate element that has at one end, i.e. in the case of FIG. 1 a in the leftmost end, a slot-like connection part 8 a and at the opposite end a pin-like pulling part 8 b extending behind the back part of the projectile. The power transmission element 7 has a connection element 9 that extends to the slot of the slot-like part 8 a and is, by way of example, a pin transverse to the longitudinal direction of the power transmission element 7 . As the power transmission element moves during the transfer of the projectile 3 in direction A, it simultaneously pulls the first transfer element 8 with it, and consequently the transfer element 8 acts on the back part of the projectile 3 with the pulling part 8 b and moves the projectile toward the barrel 1 of the weapon.
[0013] The transfer device 4 further has a second transfer element 10 with a slot-like connection part 10 a at one end, i.e. in the solution of FIGS. 1 a to 1 d , the rightmost end. The second transfer element 10 is connected to the connection part 10 a to turn around the longitudinal axis of the transfer element 10 so that, when the projectile 3 is in the position of FIG. 1 a , it is turned away from the path of the projectile 3 , in the case of FIG. 1 a , it is turned above it. The position and location of the second transfer element 10 relative to the projectile 3 may be different depending on what position the transfer device 4 is relative to the projectile 3 . In the figures, the transfer device 4 is, by way of example, shown above the projectile only for illustrative reasons, and it may be located above or below the projectile or at its side at different points.
[0014] A second connection element 11 is connected to the power transmission element 7 , in this case, it is by way of example a pin transverse to the longitudinal direction of the power transmission element 7 and, when the power transmission element moves in the direction of arrow A, it initially moves in the opposite direction with the power transmission element 7 and, when turning around the turning wheel 6 , it settles into the slot of the connection part 10 a and then starts to move the second transfer element 10 to the direction of arrow A.
[0015] FIG. 1 b shows a situation, in which the projectile 3 has been moved toward the barrel 1 of the weapon part of the way. In this situation, the first transfer element 8 still moves with the power transmission element 7 at the same speed and pushes the projectile toward the barrel 1 . The second transfer element 10 has correspondingly turned behind the back part of the projectile 3 and also moves at the same speed with the power transmission element 7 . Now the speed of the first transfer element 8 begins to slow, because the movement speed component of the power transmission element 7 in the direction of arrow A begins to decrease as the power transmission element turns upward along the circumference of the turning wheel 5 . At the same time as the transfer element 8 begins to fall behind the projectile, the second transfer element 10 moves at the same speed with the power transmission element 7 and continues to push the projectile 3 toward the barrel 1 of the weapon without any substantial speed change, deceleration or acceleration in the movement of the projectile when the transfer element changes, and the connection from the action of the first transfer element to the action of the second transfer element is smooth.
[0016] In the situation of FIG. 1 c , the first transfer element 8 has already fallen behind and nearly stopped, while the second transfer element 10 has continued to push the projectile 3 forward.
[0017] In the situation of FIG. 1 d , the projectile 3 is in the barrel 1 of the weapon on the other side of the housing 1 a , when the second transfer element 10 extends over the housing 1 a and recoil movement measurement of the barrel 1 to the inside of the barrel. The first transfer element waits in the position shown in FIG. 1 d that the power transmission element 7 is engaged to move in the opposite direction to the direction of arrow A. The power transmission element 7 then first pulls the second transfer element 10 backward. During the return movement, when the transfer elements 8 and 10 and power transmission element 7 are in a situation corresponding to FIG. 1 c , the connection element 9 , i.e. pin, turns with the power transmission element around the turning wheel 5 to the slot of the slot-like connection part 8 a and begins to move the first transfer element 8 backward, i.e. to the right in FIGS. 1 a to 1 d . As the second transfer element 10 comes to the position corresponding to FIG. 1 b during the return movement, a separate guide mechanism turns the second transfer element 10 away from the projectile 3 to the position shown in FIG. 1 a.
[0018] In an embodiment of the invention according to FIGS. 1 a to 1 d , the transfer device 4 can be installed in a fixed position relative to the weapon, in which case the recoil movement of the barrel of the weapon must be taken into consideration when determining the relative positions of the transfer device 4 and barrel 1 of the weapon.
[0019] FIG. 2 a is a view of the transfer device and projectile in a situation corresponding to FIG. 1 a , as seen from behind the projectile. As
[0020] FIG. 2 a shows, the second transfer element 10 is turned above the projectile 3 , and the pulling part 8 a of the first transfer element 8 extends behind the projectile 3 so that it can push the projectile 3 . FIG. 2 b , in turn, is a view of situations according to FIGS. 1 b to 1 d , as seen from behind the projectile. They show how the second transfer element 10 is turned downward so that it coincides with the back part of the projectile 3 and can push the projectile 3 forward. FIGS. 2 a and 2 b also schematically show a motor 12 that turns the turning wheel 6 and thus moves the power transmission element 7 . The motor can be any suitable motor, such as a hydraulic, pneumatic, or electric motor depending on the application.
[0021] FIGS. 3 a and 3 b are schematic views of another embodiment of the transfer device of the invention. The starting point in this embodiment is that the transfer device 4 is separately turned or moved in transverse direction to the barrel 1 into the projectile transfer position, when the projectile is transferred to the barrel of the weapon, and, correspondingly, after the transfer, it is moved away from behind the barrel of the weapon. The recoil movement of the barrel then need not be taken into account, and the length of the transfer device 4 and its transfer elements can be dimensioned differently so that the total length becomes smaller than in the embodiment shown in FIGS. 1 a to 1 d . In this embodiment, the components of the transfer device 4 are the same and, thus, they are also numbered the same. The only visible difference is that the length of the power transmission element 7 , and thus also the distance between the turning wheels 5 and 6 , for instance chain wheels or cogwheels, is smaller than in the previous embodiment. Correspondingly, the first transfer element 8 is significantly shorter than in the previous embodiment. Otherwise the operation of this embodiment corresponds fully to the embodiment shown in FIGS. 1 a to 1 d . Different turning mechanism of this type, linear transfer mechanisms, such as rails and other sliding structures, are known per se, and their application in this situation is apparent in accordance with the embodiment.
[0022] The turning of the second transfer element 10 in the initial position, i.e. the situation shown in FIG. 1 a and 3 a , respectively, away from the projectile 3 can be implemented in different ways. At its simplest, it can be done in such a manner that only the second transfer element is pivoted to turn around the longitudinal axis, and the transferring of the projectile from the side to the transfer trough 2 pushes the second transfer element aside. A result of this is, of course, that the second transfer element 10 drags along the side of the projectile 3 during the first transfer step, but this is not significant. Another alternative is that the second transfer element 10 is during its return movement directed by force to turn aside with different pin surfaces or other protruding guide surfaces or guides, for instance. Correspondingly, the turning of the second transfer element away from the pushing position is prevented during the transfer of the projectile for the reliability of the transfer movement and for safety's sake. This can be implemented for instance by using a guiding groove along the entire travel distance of the second transfer element, in which the transverse section of the turning part runs during the entire movement. The groove can then be made curved at the turning wheel 6 side end so that it forces the second transfer element to turn aside from the pushing position. Guides and mechanisms of this type are generally used in the art and obvious to a person skilled in the art and, therefore, need not be described in more detail herein. Instead of a chain, the power transmission element can be a wire or cogged belt, and instead of the chain wheels, cogged band pulleys, grooved pulleys or corresponding components can be used. | A transfer device for pushing a projectile ( 3 ) into the barrel of a weapon in the direction of the barrel ( 1 ) of the weapon along a transfer trough ( 2 ). The transfer device has two turning wheels ( 5, 6 ), a flexible power transmission element ( 7 ) forming a closed loop, and two transfer elements ( 8, 10 ) mounted to push the projectile ( 3 ) in consecutive steps towards the barrel ( 1 ) of the weapon. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to valves for fitting to pressurized receptacles.
BACKGROUND OF THE INVENTION
[0002] French patent application FR-A-2 680 161 describes a valve for a pressurized receptacle that includes a shutter member constituted by a ball. The ball is intended to close an orifice through which the dispensing fluid passes whenever the receptacle is not in a normal position of use, and in which case actuating the valve might lead, for example, to propellant gas being lost. In the event of an attempt to use the device in the wrong position, the pressure downstream from the shutter member tends towards atmospheric pressure because of the communication with the outside that is established through the valve rod when the valve is actuated. The ball is then liable to remain pressed against its seat, even if the receptacle is turned back into the normal position of use, because the pressure inside the receptacle is greater than the pressure downstream from the shutter member.
[0003] In order to prevent the shutter member remaining for too long a time in its closing position, even after the receptacle has been put back in its normal position of use, a leak is provided for between the inside of the valve body downstream from the shutter member and the inside of the receptacle by means of a micro-orifice passing through the valve body.
[0004] Making such a micro-orifice turns out to be relatively difficult and complicates manufacture of the valve.
[0005] In addition, the valve has a gasket which is liable to become swollen in contact with the fluid contained in the receptacle, and swelling of this gasket tends to disturb the passage of propellant gas through the micro-orifice, thereby further complicating manufacture of the valve.
[0006] One object of the present invention is thus to provide a valve which makes it possible to avoid the shutter member being held in its closing position even after the receptacle has been turned over into a normal position of use, and that is relatively simple to implement while also being reliable.
SUMMARY OF THE INVENTION
[0007] This and other objects have now been realized by the invention of a valve for use in a pressurized receptacle containing a fluid to be dispensed therefrom with at least one propellant gas, the valve comprising a housing having an axis, an inner wall, and including an orifice for dispensing the fluid, a shutter member disposed in the housing, the shutter member movable along the axis under the action of gravity between a closed position in which the shutter member substantially closes the orifice when the valve is in a predetermined orientation and a dispensing position in which the shutter member releases the orifice, and an absorber disposed downstream from the shutter member relative to the direction of flow of the fluid, the absorber adapted to absorb the at least one propellant gas contained within the fluid and for releasing at least a portion of the at least one propellant gas upon a decrease in pressure in the area adjacent to the absorber. Preferably, the absorber comprises porous material.
[0008] In accordance with one embodiment of the valve of the present invention, the absorber comprises a material capable of absorbing the at least one propellant gas.
[0009] In accordance with another embodiment of the valve of the present invention, the absorber comprises polyamide fibers, preferably nylon fibers. In another embodiment, the absorber comprises a separate sintered member. In yet another embodiment, the absorber comprises silicone.
[0010] In accordance with another embodiment of the valve of the present invention, the housing comprises a valve body, and the valve includes a chamber in fluid communication with the valve body by means of the orifice, wherein the absorber is disposed in the chamber. Preferably, the absorber is affixed to the valve body.
[0011] In accordance with another embodiment of the valve of the present invention, the valve includes a valve rod, wherein the absorber is affixed to the valve rod. Preferably, the valve rod includes a first end, and the absorber is affixed to the first end of the valve rod.
[0012] In accordance with another embodiment of the valve of the present invention, the housing comprises a valve body, and the shutter member is disposed in the valve body.
[0013] In accordance with another embodiment of the valve of the present invention, the valve includes a dip tube affixed to the valve body, the shutter member being disposed in the dip tube.
[0014] In a preferred embodiment of the valve of the present invention, the shutter member comprises a ball.
[0015] In accordance with one embodiment of the valve of the present invention, the predetermined orientation comprises a head-down position for the valve, and the position for normal use of the valve comprises a head-up position for the valve. In another embodiment, however, the predetermined orientation comprises a head-up position for the valve and the position for normal use of the valve comprises a head-down position for the valve.
[0016] In accordance with another embodiment of the valve of the present invention, the valve includes actuation means for actuating the valve, the actuation means being actuated by being depressed. In another embodiment, the actuation means being actuated by being rocked.
[0017] In accordance with the present invention, a dispensing device has been discovered for dispensing a fluid comprising a pressurized receptacle containing the fluid and a valve as defined hereinabove.
[0018] In one embodiment, the present invention provides a valve for a pressured receptacle, the valve comprising:
[0019] an orifice configured to pass a fluid to be dispensed;
[0020] a shutter member movable under the action of gravity between a closing position taken when the valve has a predetermined orientation, in which closing position the shutter member substantially closes the orifice, and a dispensing position in which the shutter member releases the orifice; and
[0021] an absorber situated downstream from the shutter member relative to the direction of fluid flow, suitable for absorbing at least a propellant gas contained in the fluid and for releasing at least part of the propellant gas when the pressure in the vicinity of the absorber becomes low enough.
[0022] The shutter member is particularly configured in such a manner that the quantity of propellant gas that is released enables the pressure difference that exists across opposite sides of the shutter member to be reduced sufficiently for the shutter member to be able to leave its closing position in the event of the shutter member remaining in its closing position while no longer being held in its closing position by gravity.
[0023] The shutter member can leave its closing position on its own under gravity and/or under the action of movements of the receptacle.
[0024] The absorber may be made of a material and/or of a physical structure that are selected as a function of the nature of the substance(s) contained in the receptacle, in particular the nature of the propellant gas and the quantity of gas that is to be released by desorption, taking into account, for example, the configuration of the valve and the volume that the gas released by desorption is to occupy, the weight of the shutter member, the pressure that exists inside the receptacle, the shape of the shutter member, and the shape of its seat.
[0025] The absorber may comprise a porous material. The absorber may also comprise a material whose chemical nature enables it to absorb the propellant gas contained in the fluid. The absorber may be configured, for example, so as to be capable of absorbing a propellant gas selected from the group constituted by: alkanes, in particular butane, isopropane, and isobutane; fluorine-containing compounds, in particular difluoroethane 152 a , and tetrafluoroethane 134 a ; and dimethyl ether, this list not being limiting.
[0026] The absorber may comprise fibers of polyamide, e.g. of nylon.
[0027] The absorber may comprise a cellular material, for example a foam or a sintered piece, in particular a sintered piece having high porosity with pores of a size that may lie, for example, in the range from about 5 microns (μm) up to about 20 μm.
[0028] The sintered piece may be constituted, for example, by a piece of sintered high density polyethylene, polypropylene, or polyvinylidene fluoride (PVDF).
[0029] The absorber may also comprise a silicone, in particular when the propellant gas is butane, isobutane, difluoroethane 152 a , tetrafluoroethane 134 a , dimethyl ether, or a mixture of at least two such compounds, because of the affinity that exists between silicone and the propellant gas.
[0030] The valve may comprise a valve body defining a chamber with which the above-mentioned orifice communicates, the chamber being situated downstream from the shutter member, and the absorber being disposed in the chamber. By way of example, the absorber may be fixed to the valve body. In a variant, or additionally, the absorber may be fixed to the valve rod. In particular, the absorber may be fixed to one end of the valve rod.
[0031] The shutter member may be disposed in a housing in the valve body. In a variant, the shutter member may be disposed in a dip tube fixed to the valve body.
[0032] The shutter member may comprise a ball, in particular a glass ball or a stainless steel ball.
[0033] The above-mentioned predetermined position which the shutter member occupies in its closing position may correspond to an attempt at using the valve in a head-down position. In that case, the receptacle is normally used in a head-up position in order to dispense the fluid contained inside. A dip tube may be fixed to the valve body.
[0034] The predetermined position in question may also correspond to an attempt at using the valve in a head-up position. In this case, the receptacle is normally used head-down. The valve need not have a dip tube.
[0035] The valve may be configured so as to be actuated by being depressed or rocked, for example.
[0036] The present invention also provides a device for packaging and dispensing a fluid, the device comprising:
[0037] a receptacle containing the fluid to be dispensed under pressure; an
[0038] a valve as defined above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The present invention can be better understood on reading the following description of non-limiting embodiments thereof, and on examining the accompanying drawings, in which:
[0040] [0040]FIG. 1 is a side, elevational, partially sectional and fragmentary view of a pressurized receptacle fitted with a valve in accordance with one embodiment of the present invention;
[0041] [0041]FIG. 2 is a side, elevational, partially sectional, fragmentary view of the receptacle shown in FIG. 1 in a head-down position;
[0042] [0042]FIG. 3 is a side, elevational, partially sectional, fragmentary view of a valve in accordance with one embodiment of the present invention;
[0043] [0043]FIG. 4 is a side, elevational, partially sectional, fragmentary view of another valve in accordance with the present invention;
[0044] [0044]FIG. 5 is a side, elevational, partially sectional, fragmentary view of another valve in accordance with the present invention; and
[0045] [0045]FIG. 6 is a side, elevational, partially sectional, fragmentary view of another valve in accordance with the present invention.
DETAILED DESCRIPTION
[0046] [0046]FIG. 1 shows a valve 1 in accordance with the present invention mounted on a pressurized receptacle R.
[0047] The receptacle R contains a fluid P for spraying under the pressure of a propellant gas G such as isobutane, difluoroethane 152 a , tetrafluoroethane 134 a , or dimethyl ether, for example.
[0048] In its top portion, the receptacle R has an opening 2 with a cup 3 crimped thereon in a conventional manner. The valve 1 is crimped in a central housing 9 of the cup 3 .
[0049] The valve 1 presents a valve body 4 defining a chamber 7 in which a valve rod 5 having a longitudinal axis X is engaged and suitable for moving inside the chamber 7 between a valve-closed position and an open position.
[0050] At its end emerging from the valve body 4 , the valve rod 5 is provided with a pushbutton 6 , as can be seen in FIG. 2. The pushbutton 6 has an internal channel 8 which may optionally be fitted with one or more swirling channel nozzles, for example, depending on the type of aerosol that is desired and on the nature of the fluid that is to be sprayed, for example.
[0051] A sealing washer 10 is interposed between the valve body 4 and the cup 3 .
[0052] The valve rod 5 can slide inside the valve body 4 along the axis X in a leaktight manner in contact with the washer 10 .
[0053] A dispensing channel 12 is formed inside the valve rod 5 . This channel opens out at one end into the inside channel 8 of the pushbutton 6 , and at its other end into a side surface of the valve rod 5 by means of a radial orifice 14 .
[0054] In the valve-closed position, as shown in FIG. 1, the orifice 14 is closed by the washer 10 .
[0055] In order to dispense the fluid P, the valve rod 5 in the example described is depressed into the valve body 4 so that the orifice 14 opens out below the washer 10 into the chamber 7 . The fluid P can then flow into the dispensing channel 12 .
[0056] The valve 1 has a helical spring 22 urging the valve rod 5 towards its closed position, as shown in FIG. 1, whenever it is released by the user.
[0057] The bottom portion of the valve rod 5 comprises a cylindrical portion 23 of axis X that is used for guiding the spring 22 .
[0058] The bottom end of the valve body 4 carries a spigot 15 having a dip tube 16 fixed thereon. The spigot 15 opens out through an orifice 21 of circular section into the dip tube.
[0059] The dip tube 16 is closed at its bottom end by an end wall 17 and a ball 30 is retained inside the dip tube.
[0060] A side opening 20 is made in the dip tube 16 close to its end wall 17 , the opening 20 opening out into the space situated immediately above the ball 30 when the ball is resting on the end wall 17 .
[0061] The ball 30 is free to move inside the dip tube 16 under the action of gravity.
[0062] When the receptacle R is in its normal position of use, the ball 30 rests on the bottom wall 17 of the dip tube 16 , as shown in FIG. 1.
[0063] The orifice 21 is closed by the ball 30 when the receptacle R is turned upside-down, in an attempt to dispense the fluid P while the receptacle is in a head-down position, as shown in FIG. 2.
[0064] In this position, when the user presses on the pushbutton 6 , the propellant gas G is prevented from traveling through the orifice 21 and the pressure inside the chamber 7 can become equal to atmospheric pressure through the dispensing channel 12 .
[0065] In order to ensure that the ball 30 does not remain blocked in its position closing the orifice 21 under the effect of the pressure difference across the ball, an absorber 32 is disposed inside the chamber 7 , with this absorber 32 being fixed to the cylindrical portion 23 of the valve rod 5 in the example described.
[0066] In the example shown, the absorber 32 is made of a porous material having high porosity suitable for absorbing propellant gas G in the liquid state, and possibly also some of the fluid P.
[0067] By desorbing the propellant gas G, the absorber 32 serves to increase the pressure that exists inside the chamber 7 after the valve rod 5 has been returned to the closed position, and consequently this enables the pressure difference between the upstream and downstream sides of the ball 30 to be reduced.
[0068] The absorber 32 is configured so that the volume of gas that is released by desorption is sufficient to enable the ball 30 to leave the orifice 21 under gravity and/or under the action of movements imparted to the receptacle while it is being handled by the user.
[0069] In the example described above, the absorber 32 is fixed to the valve rod 5 .
[0070] In a variant, as shown in FIG. 3, the absorber 32 may be fixed to the valve body 4 .
[0071] Specifically, the absorber 32 may be in the form of a ring disposed around the spring 22 and bearing against a shoulder of the valve body 4 .
[0072] It would not go beyond the ambit of the present invention if, instead of putting the shutter member in a dip tube, a housing were to be provided in the valve body for receiving the shutter member.
[0073] By way of example, FIG. 4 shows a valve 40 that differs from the valve 1 described above by the fact that the valve body 4 comprises not only its chamber 7 , but also a housing 42 at its bottom end in which the ball 30 is disposed.
[0074] This housing 42 communicates with the chamber 7 by means of an orifice 44 and it also communicates with the inside of the receptacle by means of a lateral spigot 46 having a dip tube 47 fixed thereon, which dip tube may be open at its bottom end.
[0075] When the receptacle is turned upside-down in an attempt to use it in a head-down position, the ball 30 closes the orifice 44 .
[0076] The absorber 32 acts as described above.
[0077] In the examples described above, the valve is normally used in a head-up position.
[0078] It would not go beyond the ambit of the present invention for the valve to be configured for head-down use.
[0079] By way of example, FIG. 5 shows a valve 50 for normal use in a head-down position, the chamber 7 communicating by means of a channel 53 with a housing 51 containing the ball 30 . The channel opens out into the housing 51 by means of an orifice 55 situated at the bottom end of the housing 51 .
[0080] In an attempt to use the receptacle in a head-up position, as shown in FIG. 5, the ball 53 closes the orifice 55 , thereby preventing the fluid P and the propellant gas G contained in the receptacle from penetrating into the chamber 7 . The absorber 32 acts as before.
[0081] When the receptacle R is placed in a head-down position, the ball 30 disengages the orifice 55 , and the fluid P can travel into the chamber 7 in order to be dispensed.
[0082] In the examples described above, the shutter member 30 can move freely within the space that contains it.
[0083] It would not go beyond the ambit of the present invention for means to be provided that serve to retard displacement of the shutter member between its dispensing and closing positions.
[0084] By way of example, FIG. 6 shows a valve 60 comprising a valve body 4 having a spigot 62 at its bottom end suitable for engaging a dip tube 47 , as shown.
[0085] The spigot 62 defines a housing 66 which communicates with the chamber 7 by means of an orifice 65 .
[0086] A ball 30 is present in the housing 66 to close the orifice 65 when the receptacle is not in its normal position of use.
[0087] The housing 66 is closed at its bottom end by an endpiece 68 provided with an orifice 69 for passing the fluid.
[0088] A threaded hollow rod 63 is placed inside the housing 66 . This rod 63 has an inside channel 70 serving to feed the orifice 65 with the fluid that has penetrated through the orifice 69 .
[0089] The rod 63 has a thread 72 which co-operates with the wall of the spigot 62 to define a helical path along which the ball 30 travels under the action of gravity when the receptacle is turned upside-down, thereby enabling the ball to reach its position in which it closes the orifice 65 .
[0090] When the receptacle is head-up, as shown in FIG. 6, the ball 30 does not run any risk of being thrown against the orifice 65 due to movement of the receptacle, thereby interrupting dispensing, because this is prevented by the presence of the threaded hollow rod 63 .
[0091] The present invention is not limited to the embodiments descried above.
[0092] In particular, the valve body could be made to have yet other shapes.
[0093] The valve may be configured to enable dispensing to take place when the valve rod is pivoted instead of being depressed.
[0094] Throughout the description, including in the claims, the term “comprises a” should be understood as being synonymous with “comprises at least one” unless specified to the contrary.
[0095] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | Valves for use in a pressurized receptacle are disclosed including a housing and an orifice in the housing for dispensing a fluid, a shutter disposed in the housing and movable along the axis of the housing under the action of gravity between a closed position in which the shutter substantially closes the orifice when the valve is in a predetermined orientation and a dispensing position in which the shutter releases the orifice, and an absorber disposed downstream from the shutter relative to the direction of flow of the fluid, the absorber adapted to absorb a propellant gas contained within the fluid and for releasing propellant gas upon a decreasing pressure in the area adjacent to the absorber. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is claims priority to U.S. Provisional Application Ser. No. 60/291,215 of Fei Mao, filed on May 15, 2001 and entitled “Biosensor Membranes Composed of Polyvinylpyridines”, which is incorporated herein in its entirety by this reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to an analyte-flux-limiting membrane. More particularly, the invention relates to such a membrane composed of polymers containing heterocyclic nitrogens. The membrane is a useful component in biosensors, and more particularly, in biosensors that can be implanted in a living body.
BACKGROUND OF THE INVENTION
[0003] Enzyme-based biosensors are devices in which an analyte-concentration-dependent biochemical reaction signal is converted into a measurable physical signal, such as an optical or electrical signal. Such biosensors are widely used in the detection of analytes in clinical, environmental, agricultural and biotechnological applications. Analytes that can be measured in clinical assays of fluids of the human body include, for example, glucose, lactate, cholesterol, bilirubin and amino acids. The detection of analytes in biological fluids, such as blood, is important in the diagnosis and the monitoring of many diseases.
[0004] Biosensors that detect analytes via electrical signals, such as current (amperometric biosensors) or charge (coulometric biosensors), are of special interest because electron transfer is involved in the biochemical reactions of many important bioanalytes. For example, the reaction of glucose with glucose oxidase involves electron transfer from glucose to the enzyme to produce gluconolactone and reduced enzyme. In an example of an amperometric glucose biosensor, glucose is oxidized by oxygen in the body fluid via a glucose oxidase-catalyzed reaction that generates gluconolactone and hydrogen peroxide, whereupon the hydrogen peroxide is electrooxidized and correlated to the concentration of glucose in the body fluid. (Thomé-Duret, V., et al., Anal. Chem. 68, 3822 (1996); and U.S. Pat. No. 5,882,494 of Van Antwerp.) In another example of an amperometric glucose biosensor, the electrooxidation of glucose to gluconolactone is mediated by a polymeric redox mediator that electrically “wires” the reaction center of the enzyme to an electrode. (Csöregi, E., et al., Anal. Chem. 66, 3131 (1994); Csöregi, E., et al., Anal. Chem. 67, 1240 (1995); Schmidtke, D. W., et al., Anal. Chem. 68, 2845 (1996); Schmidtke, D. W., et al., Anal. Chem. 70, 2149 (1998); and Schmidtke, D. W., et al., Proc. Natl. Acad. Sci. U.S.A. 95, 294 (1998).)
[0005] Amperometric biosensors typically employ two or three electrodes, including at least one measuring or working electrode and one reference electrode. In two-electrode systems, the reference electrode also serves as a counter-electrode. In three-electrode systems, the third electrode is a counter-electrode. The measuring or working electrode is composed of a non-corroding carbon or a metal conductor and is connected to the reference electrode via a circuit, such as a potentiostat.
[0006] Some biosensors are designed for implantation in a living animal body, such as a mammalian or a human body, merely by way of example. In an implantable amperometric biosensor, the working electrode is typically constructed of a sensing layer, which is in direct contact with the conductive material of the electrode, and a diffusion-limiting membrane layer on top of the sensing layer. The sensing layer typically consists of an enzyme, an enzyme stabilizer such as bovine serum albumin (BSA), and a crosslinker that crosslinks the sensing layer components. Alternatively, the sensing layer consists of an enzyme, a polymeric mediator, and a crosslinker that crosslinks the sensing layer components, as in the above-mentioned “wired-enzyme” biosensor.
[0007] In an implantable amperometric glucose sensor, the membrane is often beneficial or necessary for regulating or limiting the flux of glucose to the sensing layer. By way of explanation, in a glucose sensor without a membrane, the flux of glucose to the sensing layer increases linearly with the concentration of glucose. When all of the glucose arriving at the sensing layer is consumed, the measured output signal is linearly proportional to the flux of glucose and thus to the concentration of glucose. However, when the glucose consumption is limited by the kinetics of chemical or electrochemical activities in the sensing layer, the measured output signal is no longer controlled by the flux of glucose and is no longer linearly proportional to the flux or concentration of glucose. In this case, only a fraction of the glucose arriving at the sensing layer is consumed before the sensor becomes saturated, whereupon the measured signal stops increasing, or increases only slightly, with the concentration of glucose. In a glucose sensor equipped with a diffusion-limiting membrane, on the other hand, the membrane reduces the flux of glucose to the sensing layer such that the sensor does not become saturated and can therefor operate effectively within a much wider range of glucose concentration.
[0008] More particularly, in these membrane-equipped glucose sensors, the glucose consumption rate is controlled by the diffusion or flux of glucose through the membrane rather than by the kinetics of the sensing layer. The flux of glucose through the membrane is defined by the permeability of the membrane to glucose, which is usually constant, and by the concentration of glucose in the solution or biofluid being monitored. When all of the glucose arriving at the sensing layer is consumed, the flux of glucose through the membrane to the sensing layer varies linearly with the concentration of glucose in the solution, and determines the measured conversion rate or signal output such that it is also linearly proportional to the concentration of glucose concentration in the solution. Although not necessary, a linear relationship between the output signal and the concentration of glucose in the solution is ideal for the calibration of an implantable sensor.
[0009] Implantable amperometric glucose sensors based on the electrooxidation of hydrogen peroxide, as described above, require excess oxygen reactant to ensure that the sensor output is only controlled by the concentration of glucose in the body fluid or tissue being monitored. That is, the sensor is designed to be unaffected by the oxygen typically present in body fluid or tissue. In body tissue in which the glucose sensor is typically implanted, the concentration of oxygen can be very low, such as from about 0.02 mM to about 0.2 mM, while the concentration of glucose can be as high as about 30 mM or more. Without a glucose-diffusion-limiting membrane, the sensor would become saturated very quickly at very low glucose concentrations. The sensor thus benefits from having a sufficiently oxygen-permeable membrane that restricts glucose flux to the sensing layer, such that the so-called “oxygen-deficiency problem,” a condition in which there is insufficient oxygen for adequate sensing to take place, is minimized or eliminated.
[0010] In implantable amperometric glucose sensors that employ wired-enzyme electrodes, as described above, there is no oxygen-deficiency problem because oxygen is not a necessary reactant. Nonetheless, these sensors require glucose-diffusion-limiting membranes because typically, for glucose sensors that lack such membranes, the current output reaches a maximum level around or below a glucose concentration of 10 mM, which is well below 30 mM, the high end of clinically relevant glucose concentration.
[0011] A diffusion-limiting membrane is also of benefit in a biosensor that employs a wired-enzyme electrode, as the membrane significantly reduces chemical and biochemical reactivity in the sensing layer and thus reduces the production of radical species that can damage the enzyme. The diffusion-limiting membrane may also act as a mechanical protector that prevents the sensor components from leaching out of the sensor layer and reduces motion-associated noise.
[0012] There have been various attempts to develop a glucose-diffusion-limiting membrane that is mechanically strong, biocompatible, and easily manufactured. For example, a laminated microporous membrane with mechanical holes has been described (U.S. Pat. No. 4,759,828 of Young et al.) and membranes formed from polyurethane are also known (Shaw, G. W., et al., Biosensors and Bioelectronics 6, 401 (1991); Bindra, D. S., et al., Anal. Chem. 63, 1692 (1991); Shichiri, M., et al., Horm. Metab. Res., Suppl. Ser. 20, 17 (1988)). Supposedly, glucose diffuses through the mechanical holes or cracks in these various membranes. Further by way of example, a heterogeneous membrane with discrete hydrophobic and hydrophilic regions (U.S. Pat. No. 4,484,987 of Gough) and homogenous membranes with both hydrophobic and hydrophilic functionalities (U.S. Pat. Nos. 5,284,140 and 5,322,063 of Allen et al.) have been described. However, all of these known membranes are difficult to manufacture and have inadequate physical properties.
[0013] An improved membrane formed from a complex mixture of a diisocyanate, a diol, a diamine and a silicone polymer has been described in U.S. Pat. Nos. 5,777,060 (Van Antwerp), 5,786,439 (Van Antwerp et al.) and 5,882,494 (Van Antwerp). As described therein, the membrane material is simultaneously polymerized and crosslinked in a flask; the resulting polymeric material is dissolved in a strong organic solvent, such as tetrahydroforan (THF); and the resulting solution is applied onto the sensing layer to form the membrane. Unfortunately, a very strong organic solvent, such as THF, can denature the enzyme in the sensing layer and also dissolve conductive ink materials as well as any plastic materials that may be part of the sensor. Further, since the polymerization and crosslinking reactions are completed in the reaction flask, no further bond-making reactions occur when the solution is applied to the sensing layer to form the membrane. As a result, the adhesion between the membrane layer and sensing layer may not be adequate.
[0014] In the published Patent Cooperation Treaty (PCT) Application bearing International Publication No. WO 01/57241 A2, Kelly and Schiffer describe a method for making a glucose-diffusion-limiting membrane by photolytically polymerizing small hydrophilic monomers. The sensitivities of the glucose sensors employing such membranes are widely scattered, however, indicating a lack of control in the membrane-making process. Further, as the polymerization involves very small molecules, it is quite possible that small, soluble molecules remain after polymerization, which may leach out of the sensor. Thus, glucose sensors employing such glucose-diffusion-limiting membranes may not be suitable for implantation in a living body.
SUMMARY OF THE INVENTION
[0015] The present invention is directed to membranes composed of crosslinked polymers containing heterocyclic nitrogen groups, particularly polymers of polyvinylpyridine and polyvinylimidazole, and to electrochemical sensors equipped with such membranes. The membranes are useful in limiting the flux of an analyte to a working electrode in an electrochemical sensor so that the sensor is linearly responsive over a large range of analyte concentrations and is easily calibrated. Electrochemical sensors equipped with membranes of the present invention demonstrate considerable sensitivity and stability, and a large signal-to-noise ratio, in a variety of conditions.
[0016] According to one aspect of the invention, the membrane is formed by crosslinking in situ a polymer, modified with a zwitterionic moiety, a non-pyridine copolymer component, and optionally another moiety that is either hydrophilic or hydrophobic, and/or has other desirable properties, in an alcohol-buffer solution. The modified polymer is made from a precursor polymer containing heterocyclic nitrogen groups. Preferably, the precursor polymer is polyvinylpyridine or polyvinylimidazole. When used in an electrochemical sensor, the membrane limits the flux of an analyte reaching a sensing layer of the sensor, such as an enzyme-containing sensing layer of a “wired enzyme” electrode, and further protects the sensing layer. These qualities of the membrane significantly extend the linear detection range and the stability of the sensor.
[0017] In the membrane formation process, the non-pyridine copolymer component generally enhances the solubility of the polymer and may provide further desirable physical or chemical properties to the polymer or the resulting membrane. Optionally, hydrophilic or hydrophobic modifiers may be used to “fine-tune” the permeability of the resulting membrane to an analyte of interest. Optional hydrophilic modifiers, such as poly(ethylene glycol), hydroxyl or polyhydroxyl modifiers, may be used to enhance the biocompatibility of the polymer or the resulting membrane. In the formation of a membrane of the present invention, the zwitterionic moiety of the polymer is believed to provide an additional layer of crosslinking, via intermolecular electrostatic bonds, beyond the basic crosslinking generally attributed to covalent bonds, and is thus believed to strengthen the membrane.
[0018] Another aspect of the invention concerns the preparation of a substantially homogeneous, analyte-diffusion-limiting membrane that may be used in a biosensor, such as an implantable amperometric biosensor. The membrane is formed in situ by applying an alcohol-buffer solution of a crosslinker and a modified polymer over an enzyme-containing sensing layer and allowing the solution to cure for one to two days. The crosslinker-polymer solution may be applied to the sensing layer by placing a droplet or droplets of the solution on the sensor, by dipping the sensor into the solution, or the like. Generally, the thickness of the membrane is controlled by the concentration of the solution, by the number of droplets of the solution applied, by the number of times the sensor is dipped in the solution, or by any combination of the these factors. Amperometric glucose sensors equipped with diffusion-limiting membranes of the present invention demonstrate excellent stability and fast and linear responsivity to glucose concentration over a large glucose concentration range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is an illustration of a typical structure of a section of an analyte-diffusion-limiting membrane, according to the present invention.
[0020] FIG. 2A is a schematic, side-view illustration of a portion of a two-electrode glucose sensor having a working electrode, a combined counter/reference electrode, and a dip-coated membrane that encapsulates both electrodes, according to the present invention. FIGS. 2B and 2C are schematic top- and bottom-view illustrations, respectively, of the portion of the glucose sensor of FIG. 2A . Herein, FIGS. 2A , 2 B and 2 C may be collectively referred to as FIG. 2 .
[0021] FIG. 3 is a graph of current versus glucose concentration for sensors having glucose-diffusion-limiting membranes, according to the present invention, and for sensors lacking such membranes, based on average values.
[0022] FIG. 4 is a graph of current output versus time at fixed glucose concentration for a sensor having a glucose-diffusion-limiting membrane, according to the present invention, and for a sensor lacking such a membrane.
[0023] FIG. 5 is a graph of current output versus time at different levels of glucose concentration for sensors having glucose-diffusion-limiting membranes, according to the present invention, based on average values.
[0024] FIG. 6 is a graph of current output versus time at different levels of glucose concentration, with and without stirring, for a sensor having a glucose-diffusion-limiting membrane, according to the present invention, and for a sensor lacking such a membrane.
[0025] FIG. 7A is a graph of current output versus glucose concentration for four separately prepared batches of sensors having glucose-diffusion-limiting membranes, according to the present invention, based on average values. FIGS. 7B-7E are graphs of current output versus glucose concentration for individual sensors in each of the four above-referenced batches of sensors having glucose-diffusion-limiting membranes, respectively, according to the present invention. Herein, FIGS. 7A , 7 B, 7 C, 7 D and 7 E may be collectively referred to as FIG. 7 .
DESCRIPTION OF THE INVENTION
[0026] When used herein, the terms in quotation marks are defined as set forth below.
[0027] The term “alkyl” includes linear or branched, saturated aliphatic hydrocarbons. Examples of alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl and the like. Unless otherwise noted, the term “alkyl” includes both alkyl and cycloalkyl groups.
[0028] The term “alkoxy” describes an alkyl group joined to the remainder of the structure by an oxygen atom. Examples of alkoxy groups include methoxy, ethoxy, n-propoxy, isopropoxy, butoxy, tert-butoxy, and the like. In addition, unless otherwise noted, the term ‘alkoxy’ includes both alkoxy and cycloalkoxy groups.
[0029] The term “alkenyl” describes an unsaturated, linear or branched aliphatic hydrocarbon having at least one carbon-carbon double bond. Examples of alkenyl groups include ethenyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-methyl-1-propenyl, and the like.
[0030] A “reactive group” is a functional group of a molecule that is capable of reacting with another compound to couple at least a portion of that other compound to the molecule. Reactive groups include carboxy, activated ester, sulfonyl halide, sulfonate ester, isocyanate, isothiocyanate, epoxide, aziridine, halide, aldehyde, ketone, amine, acrylamide, thiol, acyl azide, acyl halide, hydrazine, hydroxylamine, alkyl halide, imidazole, pyridine, phenol, alkyl sulfonate, halotriazine, imido ester, maleimide, hydrazide, hydroxy, and photo-reactive azido aryl groups. Activated esters, as understood in the art, generally include esters of succinimidyl, benzotriazolyl, or aryl substituted by electron-withdrawing groups such as sulfo, nitro, cyano, or halo groups; or carboxylic acids activated by carbodiimides.
[0031] A “substituted” functional group (e.g., substituted alkyl, alkenyl, or alkoxy group) includes at least one substituent selected from the following: halogen, alkoxy, mercapto, aryl, alkoxycarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, —OH, —NH2, alkylamino, dialkylamino, trialkylammonium, alkanoylamino, arylcarboxamido, hydrazino, alkylthio, alkenyl, and reactive groups.
[0032] A “crosslinker” is a molecule that contains at least two reactive groups capable of linking at least two molecules together, or linking at least two portions of the same molecule together. Linking of at least two molecules is called intermolecular crosslinking, while linking of at least two portions of the same molecule is called intramolecular crosslinking. A crosslinker having more than two reactive groups may be capable of both intermolecular and intramolecular crosslinkings at the same time.
[0033] The term “precursor polymer” refers to the starting polymer before the various modifier groups are attached to form a modified polymer.
[0034] The term “heterocyclic nitrogen group” refers to a cyclic structure containing a sp 2 hybridized nitrogen in a ring of the structure.
[0035] The term “polyvinylpyridine” refers to poly(4-vinylpyridine), poly(3-vinylpyridine), or poly(2-vinylpyridine), as well as any copolymer of vinylpyridine and a second or a third copolymer component.
[0036] The term “polyvinylimidazole” refers to poly(1-vinylimidazole), poly(2-vinylimidazole), or poly(4-vinylimidazole).
[0037] A “membrane solution” is a solution that contains all necessary components for crosslinking and forming the membrane, including a modified polymer containing heterocyclic nitrogen groups, a crosslinker and a buffer or an alcohol-buffer mixed solvent.
[0038] A “biological fluid” or “biofluid” is any body fluid or body fluid derivative in which the analyte can be measured, for example, blood, interstitial fluid, plasma, dermal fluid, sweat, and tears.
[0039] An “electrochemical sensor” is a device configured to detect the presence of or measure the concentration or amount of an analyte in a sample via electrochemical oxidation or reduction reactions. Typically, these reactions can be transduced to an electrical signal that can be correlated to an amount or concentration of analyte.
[0040] A “redox mediator” is an electron-transfer agent for carrying electrons between an analyte, an analyte-reduced or analyte-oxidized enzyme, and an electrode, either directly, or via one or more additional electron-transfer agents. A redox mediator that includes a polymeric backbone may also be referred to as a “redox polymer”.
[0041] The term “reference electrode” includes both a) reference electrodes and b) reference electrodes that also function as counter electrodes (i.e., counter/reference electrodes), unless otherwise indicated.
[0042] The term “counter electrode” includes both a) counter electrodes and b) counter electrodes that also function as reference electrodes (i.e., counter/reference electrodes), unless otherwise indicated.
[0043] In general, membrane of the present invention is formed by crosslinking a modified polymer containing heterocyclic nitrogen groups in an alcohol-buffer mixed solvent and allowing the membrane solution to cure over time. The polymer comprises poly(heterocyclic nitrogen-containing constituent) as a portion of its backbone and additional elements, including a zwitterionic moiety, a hydrophobic moiety, and optionally, a biocompatible moiety. The resulting membrane is capable of limiting the flux of an analyte from one space, such as a space associated with a biofluid, to another space, such as space associated with an enzyme-containing sensing layer. An amperometric glucose sensor constructed of a wired-enzyme sensing layer and a glucose-diffusion-limiting layer of the present invention is very stable and has a large linear detection range.
Heterocyclic-Nitrogen Containing Polymers
[0044] The polymer of the present invention has the following general formula, Formula 1a:
[0000]
[0000] wherein the horizontal line represents a polymer backbone; A is an alkyl group substituted with a water soluble group, preferably a negatively charged group, such as sulfonate, phosphate, or carboxylatc, and more preferably, a strong acid group such as sulfonate, so that the quaternized heterocyclic nitrogen to which it is attached is zwitterionic; D is a copolymer component of the polymer, as further described below; each of n, l, and p is independently an average number of an associated polymer unit or polymer units shown in the closest parentheses to the left; and q is a number of a polymer unit or polymer units shown in the brackets.
[0045] The heterocyclic nitrogen groups of Formula 1a include, but are not limited to, pyridine, imidazole, oxazole, thiazole, pyrazole, or any derivative thereof. Preferably, the heterocyclic nitrogen groups are independently vinylpyridine, such as 2-, 3-, or 4-vinylpyridine, or vinylimidazole, such as 1-, 2-, or 4-vinylimidazole. More preferably, the heterocyclic nitrogen groups are independently 4-vinylpyridine, such that the more preferable polymer is a derivative of poly(4-vinylpyridine). An example of such a poly(4-vinylpyridine) of the present invention has the following general formula, Formula 1b:
[0000]
[0000] wherein A, D, n, l, p and q are as described above in relation to Formula 1a.
[0046] While the polymer of the present invention has the general Formula 1a or Formula 1b above, it should be noted that when A is a strong acid, such as a stronger acid than carboxylic acid, the D component is optional, such that p may equal zero. Such a polymer of the present invention has the following general formula, Formula 1c:
[0000]
[0000] wherein A is a strong acid and the heterocyclic nitrogen groups, n, l and q are all as described above. Sulfonate and fluorinated carboxylic acid are examples of suitably strong acids. It is believed that when A is a sufficiently strong acid, the heterocyclic nitrogen to which it is attached becomes zwitterionic and thus capable of forming intermolecular electrostatic bonds with the crosslinker during membrane formation. It is believed that these intermolecular electrostatic bonds provide another level of crosslinking, beyond the covalent bonds typical of crosslinking, and thus make the resulting membrane stronger. As a result, when A is a suitably strong acid, the D component, which is often a strengthening component such as styrene, may be omitted from the polymers of Formulas 1a and 1b above. When A is a weaker acid, such that the heterocyclic nitrogen is not zwitterionic or capable of forming intermolecular electrostatic bonds, the polymer of the present invention does include D, as shown in Formulas 1a and 1b above.
[0047] Examples of A include, but are not limited to, sulfopropyl, sulfobutyl, carboxypropyl, and carboxypentyl. In one embodiment of the invention, group A has the formula -L-G, where L is a C2-C12 linear or branched alkyl linker optionally and independently substituted with an aryl, alkoxy, alkenyl, alkynyl, —F, —Cl, —OH, aldehyde, ketone, ester, or amide group, and G is a negatively charged carboxy or sulfonate group. The alkyl portion of the substituents of L have 1-6 carbons and are preferably an aryl, —OH or amide group.
[0048] A can be attached to the heterocyclic nitrogen group via quaternization with an alkylating agent that contains a suitable linker L and a negatively charged group G, or a precursor group that can be converted to a negatively charged group G at a later stage. Examples of suitable alkylating agents include, but are not limited to, 2-bromoethanesulfonate, propanesultone, butanesultone, bromoacetic acid, 4-bromobutyric acid and 6-bromohexanoic acid. Examples of alkylating agents containing a precursor group include, but are not limited to, ethyl bromoacetate and methyl 6-bromohexanoate. The ethyl and methyl ester groups of these precursors can be readily converted to a negatively charged carboxy group by standard hydrolysis.
[0049] Alternatively, A can be attached to the heterocyclic nitrogen group by quaternizing the nitrogen with an alkylating agent that contains an additional reactive group, and subsequently coupling, via standard methods, this additional reactive group to another molecule that contains a negatively charged group G and a reactive group. Typically, one of the reactive groups is an electrophile and the other reactive group is a nucleophile. Selected examples of reactive groups and the linkages formed from their interactions are shown in Table 1.
[0000] TABLE 1 Examples of Reactive Groups and Resulting Linkages First Reactive Group Second Reactive Group Resulting Linkage Activated ester* Amine Amide Acrylamide Thiol Thioether Acyl azide Amine Amide Acyl halide Amine Amide Carboxylic acid Amine Amide Aldehyde or ketone Hydrazine Hydrazone Aldehyde or ketone Hydroxyamine Oxime Alkyl halide Amine Alkylamine Alkyl halide Carboxylic acid Ester Alkyl halide Imidazole Imidazolium Alkyl halide Pyridine Pyridinium Alkyl halide Alcohol/phenol Ether Alkyl halide Thiol Thioether Alkyl sulfonate Thiol Thioether Alkyl sulfonate Pyridine Pyridinium Alkyl sulfonate Imidazole Imidazolium Alkyl sulfonate Alcohol/phenol Ether Anhydride Alcohol/phenol Ester Anhydride Amine Amide Aziridine Thiol Thioether Aziridine Amine Alkylamine Aziridine Pyridine Pyridinium Epoxide Thiol Thioether Epoxide Amine Alkylamine Epoxide Pyridine Pyridinium Halotriazine Amine Aminotriazine Halotriazine Alcohol Triazinyl ether Imido ester Amine Amidine Isocyanate Amine Urea Isocyanate Alcohol Urethane Isothiocyanate Amine Thiourea Maleimide Thiol Thioether Sulfonyl halide Amine Sulfonamide *Activated esters, as understood in the art, generally include esters of succinimidyl, benzotriazolyl, or aryl substituted by electron-withdrawing groups such as sulfo, nitro, cyano, or halo; or carboxylic acids activated by carbodiimides.
By way of example, A may be attached to the heterocyclic nitrogen groups of the polymer by quatemizing the heterocyclic nitrogens with 6-bromohexanoic acid and subsequently coupling the carboxy group to the amine group of 3-amino-1-propanesulfonic acid in the presence of a carbodiimide coupling agent.
[0050] D is a component of a poly(heterocyclic nitrogen-co-D) polymer of Formula 1a or 1b. Examples of D include, but are not limited to, phenylalkyl, alkoxystyrene, hydroxyalkyl, alkoxyalkyl, alkoxycarbonylalkyl, and a molecule containing a poly(ethylene glycol) or polyhydroxyl group. Some poly(heterocyclic nitrogen-co-D) polymers suitable starting materials for the present invention are commercially available. For example, poly(2-vinylpyridine-co-styrene), poly(4-vinylpyridine-co-styrene) and poly(4-vinylpyridine-co-butyl methacrylate) are available from Aldrich Chemical Company, Inc. Other poly(heterocyclic nitrogen-co-D) polymers can be readily synthesized by anyone skilled in the art of polymer chemistry using well-known methods. Preferably, D is a styrene or a C1-C18 alkyl methacrylate component of a polyvinylpyridine-poly-D, such as (4-vinylpyrine-co-styrene) or poly(4-vinylpyridine-co-butyl methacrylate), more preferably, the former. D may contribute to various desirable properties of the membrane including, but not limited to, hydrophobicity, hydrophilicity, solubility, biocompatibility, elasticity and strength. D may be selected to optimize or “fine-tune” a membrane made from the polymer in terms of its permeability to an analyte and its non-permeability to an undesirable, interfering component, for example.
[0051] The letters n, l, and p designate, respectively, an average number of each copolymer component in each polymer unit. The letter q is one for a block copolymer or a number greater than one for a copolymer with a number of repeating polymer units. By way of example, the q value for a polymer of the present invention may be > about 950, where n, l and p are 1, 8 and 1, respectively. The letter q is thus related to the overall molecular weight of the polymer. Preferably, the average molecular weight of the polymer is above about 50,000, more preferably above about 200,000, most preferably above about 1,000,000.
[0052] The polymer of the present invention may comprise a further, optional copolymer, as shown in the following general formula, Formula 2a:
[0000]
[0000] wherein the polymer backbone, A, D, n, l, p and q are as described above in relation to Formulas 1a-1c; m is an average number of an associated polymer unit or polymer units shown in the closest parentheses to the left; and B is a modifier. When the heterocyclic nitrogen groups are 4-substituted pyridine, as is preferred, the polymer of the present invention is derivative of poly(4-vinylpyridine) and has the general formula, Formula 2b, set forth below.
[0000]
[0000] Further, when A is a suitably strong acid, as described above, the D copolymer is optional, in which case the polymer of the present invention has the general formula, Formula 2c:
[0000]
[0053] In any of Formulas 2a-2c, B is a modifier group that may add any desired chemical, physical or biological properties to the membrane. Such desired properties include analyte selectivity, hydrophobicity, hydrophilicity, elasticity, and biocompatibility. Examples of modifiers include the following: negatively charged molecules that may minimize entrance of negatively charged, interfering chemicals into the membrane; hydrophobic hydrocarbon molecules that may increase adhesion between the membrane and sensor substrate material; hydrophilic hydroxyl or polyhydroxy molecules that may help hydrate and add biocompatibility to the membrane; silicon polymers that may add elasticity and other properties to the membrane; and poly(ethylene glycol) constituents that are known to increase biocompatibility of biomaterials (Bergstrom, K., et al., J. Biomed. Mat. Res. 26, 779 (1992)). Further examples of B include, but are not limited to, a metal chelator, such as a calcium chelator, and other biocompatible materials. A poly(ethylene glycol) suitable for biocompatibility modification of the membrane generally has a molecular weight of from about 100 to about 20,000, preferably, from about 500 to about 10,000, and more preferably, from about 1,000 to about 8,000.
[0054] The modifier B can be attached to the heterocyclic nitrogens of the polymer directly or indirectly. In direct attachment, the heterocyclic nitrogen groups may be reacted with a modifier containing an alkylating group. Suitable alkylating groups include, but are not limited to, alkyl halide, epoxide, aziridine, and sulfonate esters. In indirect attachment, the heterocyclic nigrogens of the polymer may be quaternized with an alkylating agent having an additional reactive group, and then attached to a molecule having a desired property and a suitable reactive group.
[0055] As described above, the B-containing copolymer is optional in the membrane of the present invention, such that when m of Formula 2a-2c is zero, the membrane has the general formula of Formula 1a-1c, respectively. The relative amounts of the four copolymer components, the heterocyclic nitrogen group containing A, the optional heterocyclic nitrogen group containing B, the heterocyclic nitrogen group, and D, may be expressed as percentages, as follows: [n/(n+m+l+p)]×100%, [m/(n+m+l+p)]×100%, [l/(n+m+l+p)]×100%, and [p/(n+m+l+p)]×100%, respectively. Suitable percentages are 1-25%, 0-15% (when the B-containing heterocyclic nitrogen group is optional) or 1-15%, 20-90%, and 0-50% (when D is optional) or 1-50%, respectively, and preferable percentages are 5-20%, 0-10% (when the B-containing heterocyclic nitrogen group is optional) or 1-10%, 60-90%, and 5-20%, respectively.
[0056] Specific examples of suitable polymers have the general formulas, Formulas 3-6, shown below.
[0000]
Examples of Syntheses of Polyvinylpyridine Polymers
[0057] Examples showing the syntheses of various polyvinylpyridine polymers according to the present invention are provided below. Numerical figures provided are approximate.
EXAMPLE 1
Synthesis of a Polymer of Formula 3
[0058] By way of illustration, an example of the synthesis of a polymer of Formula 3 above, is now provided. A solution of poly(4-vinylpyridine-co-styrene) (˜10% styrene content) (20 g, Aldrich) in 100 mL of dimethyl formamide (DMF) at 90° C. was stirred and 6-bromohexanoic acid (3.7 g) in 15-20 mL of DMF was added. The resulting solution was stirred at 90° C. for 24 hours and then poured into 1.5 L of ether, whereupon the solvent was decanted. The remaining, gummy solid was dissolved in MeOH (150-200 mL) and suction-filtered through a medium-pore, fritted funnel to remove any undissolved solid. The filtrate was added slowly to rapidly stirred ether (1.5 L) in a beaker. The resulting precipitate was collected by suction filtration and dried at 50° C. under high vacuum for 2 days. The polymer had the following parameters: [n/(n+l+)]×100%≈10%; [l/(n+l+p)]×100%≈80%; and [p/(n+l+p)]×100%≈10%.
EXAMPLE 2
Synthesis of a Polymer of Formula 5
[0059] By way of illustration, an example of the synthesis of a polymer of Formula 5 above, is now provided. A solution of poly(4-vinylpyridine-co-styrene) (˜10% styrene) (20 g, Aldrich) in 100 mL of anhydrous DMF at 90° C. was stirred, methanesulfonic acid (˜80 mg) was added, and then 2 g of methoxy-PEG-epoxide (molecular weight 5,000) (Shearwater Polymers, Inc.) in 15-20 mL of anhydrous DMF was added. The solution was stirred at 90° C. for 24 hours and 1,3-Propane sultone (2.32 g) in 10 mL of anhydrous DMF was added. The resulting solution was continuously stirred at 90° for 24 hours, and then cooled to room temperature and poured into 800 mL of ether. The solvent was decanted and the remaining precipitate was dissolved in hot MeOH (˜200 mL), suction-filtered, precipitated again from 1 L of ether, and then dried at 50° C. under high vacuum for 48 hours. The resulting polymer has the following parameters: [n/(n+m+l+p)]×100%≈10%; [m/(n+m+l+p)]×100%≈10%; [l/(n+m+l+p)]×100%≈70%; and [p/(n+m+l+p)]×100%≈10%.
Example 3
Synthesis of a Polymer having a Polyhydroxy Modifier B
[0060] By way of illustration, an example of the synthesis of a polymer having a polyhydroxy modifier B, as schematically illustrated below, is now provided. Various polyhydroxy compounds are known for having biocompatibility properties. (U.S. Pat. No. 6,011,077.) The synthesis below illustrates how a modifier group having a desired property may be attached to the polymer backbone via a linker.
[0000]
[0000] 1,3-propane sultone (0.58 g, 4.8 mmoles) and 6-bromohexanoic acid (1.85 g, 9.5 mmoles) are added to a solution of poly(4-vinylpyridine-co-styrene) (˜10% styrene) (10g) dissolved in 60 mL of anhydrous DMF. The resulting solution is stirred at 90° C. for 24 hours and then cooled to room temperature. O—(N-succinimidyl)-N,N,N′,N′-tetramethyl-uronium tetrafluoroborate (TSTU) (2.86 g, 9.5 mmoles) and N,N-diisopropylethylamine (1.65 mL, 9.5 mmoles) are then added in succession to the solution. After the solution is stirred for 5 hours, N-methyl-D-glucamine (2.4 g, 12.4 mmoles) is added and the resulting solution is stirred at room temperature for 24 hours. The solution is poured into 500 ml of ether and the precipitate is collected by suction filtration. The collected precipitate is then dissolved in MeOH/H 2 O and the resulting solution is subjected to ultra membrane filtration using the same MeOH/H 2 O solvent to remove small molecules. The dialyzed solution is evaporated to dryness to give a polymer with the following parameters: [n/(n+m+l+p)]×100%≈10%; [m/(n+m+l+p)]×100%≈10%; [l/(n+m+l+p)]×100%≈70%; and [p/(n+m+l+p)]×100%≈10%.
Crosslinkers
[0061] Crosslinkers of the present invention are molecules having at least two reactive groups, such as bi-, tri-, or tetra-functional groups, capable of reacting with the heterocyclic nitrogen groups, pyridine groups, or other reactive groups contained on A, B or D of the polymer. Preferably, the reactive groups of the crosslinkers are slow-reacting alkylating groups that can quaternize the heterocyclic nitrogen groups, such as pyridine groups, of the polymer. Suitable alkylating groups include, but are not limited to, derivatives of poly(ethylene glycol) or poly(propylene glycol), epoxide (glycidyl group), aziridine, alkyl halide, and sulfonate esters. Alkylating groups of the crosslinkers are preferably glycidyl groups. Preferably, glycidyl crosslinkers have a molecular weight of from about 200 to about 2,000 and are water soluble or soluble in a water-miscible solvent, such as an alcohol. Examples of suitable crosslinkers include, but are not limited to, poly(ethylene glycol) diglycidyl ether with a molecular weight of about 200 to about 600, and N,N-diglycidyl-4-glycidyloxyaniline.
[0062] It is desirable to have a slow crosslinking reaction during the dispensing of membrane solution so that the membrane coating solution has a reasonable pot-life for large-scale manufacture. A fast crosslinking reaction results in a coating solution of rapidly changing viscosity, which renders coating difficult. Ideally, the crosslinking reaction is slow during the dispensing of the membrane solution, and accelerated during the curing of the membrane at ambient temperature, or at an elevated temperature where possible.
Membrane Formation and Sensor Fabrication
[0063] An example of a process for producing a membrane of the present invention is now described. In this example, the polymer of the present invention and a suitable crosslinker are dissolved in a buffer-containing solvent, typically a buffer-alcohol mixed solvent, to produce a membrane solution. Preferably, the buffer has a pH of about 7.5 to about 9.5 and the alcohol is ethanol. More preferably, the buffer is a 10 mM (2-(4-(2-hydroxyethyl)-1-piperazine)ethanesulfonate) (HEPES) buffer (pH 8) and the ethanol to buffer volume ratio is from about 95 to 5 to about 0 to 100. A minimum amount of buffer is necessary for the crosslinking chemistry, especially if an epoxide or aziridine crosslinker is used. The amount of solvent needed to dissolve the polymer and the crosslinker may vary depending on the nature of the polymer and the crosslinker. For example, a higher percentage of alcohol may be required to dissolve a relatively hydrophobic polymer and/or crosslinker.
[0064] The ratio of polymer to cross-linker is important to the nature of the final membrane. By way of example, if an inadequate amount of crosslinker or an extremely large excess of crosslinker is used, crosslinking is insufficient and the membrane is weak. Further, if a more than adequate amount of crosslinker is used, the membrane is overly crosslinked such that membrane is too brittle and/or impedes analyte diffusion. Thus, there is an optimal ratio of a given polymer to a given crosslinker that should be used to prepare a desirable or useful membrane. By way of example, the optimal polymer to crosslinker ratio by weight is typically from about 4:1 to about 32:1 for a polymer of any of Formulas 3-6 above and a poly(ethylene glycol) diglycidyl ether crosslinker, having a molecular weight of about 200 to about 400. Most preferably, this range is from about 8:1 to about 16:1. Further by way of example, the optimal polymer to crosslinker ratio by weight is typically about 16:1 for a polymer of Formula 4 above, wherein [n/(n+l+p)]×100%≈10%, [l/(n+l+p)]×100%≈80%, and [p/(n+l+p)]×100%≈10%, or for a polymer of Formula 5 above, wherein [n/(n+m+l+p)]×100%≈10%, [m/(n+m+l+p)]×100%≈10%, [l/(n+m+l+p)]×100%≈70%, [p/(n+m+l+p)]×100%≈10%, and r≈110, and a poly(ethylene glycol) diglycidyl ether crosslinker having a molecular weight of about 200.
[0065] The membrane solution can be coated over a variety of biosensors that may benefit from having a membrane disposed over the enzyme-containing sensing layer. Examples of such biosensors include, but are not limited to, glucose sensors and lactate sensors. (See U.S. Pat. No. 6,134,461 to Heller et al., which is incorporated herein in its entirety by this reference.) The coating process may comprise any commonly used technique, such as spin-coating, dip-coating, or dispensing droplets of the membrane solution over the sensing layers, and the like, followed by curing under ambient conditions typically for 1 to 2 days. The particular details of the coating process (such as dip duration, dip frequency, number of dips, or the like) may vary depending on the nature (i.e., viscosity, concentration, composition, or the like) of the polymer, the crosslinker, the membrane solution, the solvent, and the buffer, for example. Conventional equipment may be used for the coating process, such as a DSG D1L-160 dip-coating or casting system of NIMA Technology in the United Kingdom.
Example of Sensor Fabrication
[0066] Sensor fabrication typically consists of depositing an enzyme-containing sensing layer over a working electrode and casting the diffusion-limiting membrane layer over the sensing layer, and optionally, but preferably, also over the counter and reference electrodes. The procedure below concerns the fabrication of a two-electrode sensor, such as that depicted in FIGS. 2A-2C . Sensors having other configurations such as a three-electrode design can be prepared using similar methods.
[0067] A particular example of sensor fabrication, wherein the numerical figures are approximate, is now provided. A sensing layer solution was prepared from a 7.5 mM HEPES solution (0.5 μL, pH 8), containing 1.7 μg of the polymeric osmium mediator compound L, as disclosed in Published Patent Cooperation Treaty (PCT) Application, International Publication No. WO 01/36660 A2, which is incorporated herein in its entirety by this reference; 2.1 μg of glucose oxidase (Toyobo); and 1.3 μg of poly(ethylene glycol) diglycidyl ether (molecular weight 400). Compound L is shown below.
[0000]
[0000] The sensing layer solution was deposited over carbon-ink working electrodes and cured at room temperature for two days to produce a number of sensors. A membrane solution was prepared by mixing 4 volumes of a polymer of Formula 4 above, dissolved at 64 mg/mL in 80% EtOH/20% HEPES buffer (10 mM, pH 8), and one volume of poly(ethylene glycol) diglycidyl ether (molecular weight 200), dissolved at 4 mg/mL in 80% EtOH/20% HEPES buffer (10 mM, pH 8). The above-described sensors were dipped three times into the membrane solution, at about 5 seconds per dipping, with about a 10-minute time interval between consecutive dippings. The sensors were then cured at room temperature and normal humidity for 24 hours.
[0068] An approximate chemical structure of a section of a typical membrane prepared according to the present invention is shown in FIG. 1 . Such a membrane may be employed in a variety of sensors, such as the two- or three-electrode sensors described previously herein. By way of example, the membrane may be used in a two-electrode amperometric glucose sensor, as shown in FIG. 2A-2C (collectively FIG. 2 ) and described below.
[0069] The amperometric glucose sensor 10 of FIG. 2 comprises a substrate 12 disposed between a working electrode 14 that is typically carbon-based, and a Ag/AgCl counter/reference electrode 16 . A sensor or sensing layer 18 is disposed on the working electrode. A membrane or membrane layer 20 encapsulates the entire glucose sensor 10 , including the Ag/AgCl counter/reference electrode.
[0070] The sensing layer 18 of the glucose sensor 10 consists of crosslinked glucose oxidase and a low potential polymeric osmium complex mediator, as disclosed in the above-mentioned Published PCT Application, International Publication No. WO 01/36660 A2. The enzyme- and mediator-containing formulation that can be used in the sensing layer, and methods for applying them to an electrode system, are known in the art, for example, from U.S. Pat. No. 6,134,461. According to the present invention, the membrane overcoat was formed by thrice dipping the sensor into a membrane solution comprising 4 mg/mL poly(ethylene glycol) diglycidyl ether (molecular weight of about 200) and 64 mg/mL of a polymer of Formula 4 above, wherein [n/(n+l+p)]×100%≈10%; [l/(n+l+p)]×100%≈80%; and [p/(n+l+p)]×100%≈10%, and curing the thrice-dipped sensor at ambient temperature and normal humidity for at least 24 hours, such as for about 1 to 2 days. The q value for such a membrane overcoat may be ≧ about 950, where n, l and p are 1, 8 and 1, respectively.
Membrane Surface Modification
[0071] Polymers of the present invention have a large number of heterocyclic nitrogen groups, such as pyridine groups, only a few percent of which are used in crosslinking during membrane formation. The membrane thus has an excess of these groups present both within the membrane matrix and on the membrane surface. Optionally, the membrane can be further modified by placing another layer of material over the heterocyclic-nitrogen-group-rich or pyridine-rich membrane surface. For example, the membrane surface may be modified by adding a layer of poly(ethylene glycol) for enhanced biocompatibility. In general, modification may consist of coating the membrane surface with a modifying solution, such as a solution comprising desired molecules having an alkylating reactive group, and then washing the coating solution with a suitable solvent to remove excess molecules. This modification should result in a monolayer of desired molecules.
[0072] The membrane 20 of the glucose sensor 10 shown in FIG. 2 may be modified in the manner described above.
EXPERIMENTAL EXAMPLES
[0073] Examples of experiments that demonstrate the properties and/or the efficacy of sensors having diffusion-limiting membranes according to the present invention are provided below. Numerical figures provided are approximate.
Calibration Experiment
[0074] In a first example, a calibration experiment was conducted in which fifteen sensors lacking membranes were tested simultaneously (Set 1), and separately, eight sensors having diffusion-limiting membranes according to the present invention were tested simultaneously (Set 2), all at 37° C. In Set 2, the membranes were prepared from polymers of Formula 4 above and poly(ethylene glycol) diglycidyl ether (PEGDGE) crosslinkers, having a molecular weight of about 200. In the calibration experiment for each of Set 1 and Set 2, the sensors were placed in a PBS-buffered solution (pH 7) and the output current of each of the sensors was measured as the glucose concentration was increased. The measured output currents (μA for Set 1; nA for Set 2) were then averaged for each of Set 1 and Set 2 and plotted against glucose concentration (mM), as shown in the calibration graph of FIG. 3 .
[0075] As shown, the calibration curve for the Set 1 sensors lacking membranes is approximately linear over a very small range of glucose concentrations, from zero to about 3 mM, or 5 mM at most. This result indicates that the membrane-free sensors are insufficiently sensitive to glucose concentration change at elevated glucose concentrations such as 10 mM, which is well below the high end of clinically relevant glucose concentration at about 30 mM. By contrast, the calibration curve for the Set 2 sensors having diffusion-limiting membranes according to the present invention is substantially linear over a relatively large range of glucose concentrations, for example, from zero to about 30 mM, as demonstrated by the best-fit line (y=1.2502x+1.1951; R 2 ≈0.997) also shown in FIG. 3 . This result demonstrates the considerable sensitivity of the membrane-equipped membranes to glucose concentration, at low, medium, and high glucose concentrations, and of particular relevance, at the high end of clinically relevant glucose concentration at about 30 mM.
Stability Experiment
[0076] In a second example, a stability experiment was conducted in which a sensor lacking a membrane and a sensor having a diffusion-limiting membrane according to the present invention were tested, simultaneously, at 37° C. The membrane-equipped sensor had a membrane prepared from the same polymer and the same crosslinker as those of the sensors of Set 2 described above in the calibration experiment. In this stability experiment, each of the sensors was placed in a PBS-buffered solution (pH 7) having a fixed glucose concentration of 30 mM, and the output current of each of the sensors was measured. The measured output currents (μA for the membrane-less sensor; nA for the membrane-equipped sensor) were plotted against time (hour), as shown in the stability graph of FIG. 4 .
[0077] As shown, the stability curve for the membrane-less sensor decays rapidly over time, at a decay rate of about 4.69% μA per hour. This result indicates a lack of stability in the membrane-less sensor. By contrast, the stability curve for the membrane-equipped sensor according to the present invention shows relative constancy over time, or no appreciable decay over time, the decay rate being only about 0.06% nA per hour. This result demonstrates the considerable stability and reliability of the membrane-equipped sensors of the present invention. That is, at a glucose concentration of 30 mM, while the membrane-less sensor lost sensitivity at a rate of almost 5% per hour over a period of about 20 hours, the membrane-equipped sensor according to the present invention showed virtually no loss of sensitivity over the same period.
Responsivity Experiment
[0078] Ideally, the membrane of an electrochemical sensor should not impede communication between the sensing layer of the sensor and fluid or biofluid containing the analyte of interest. That is, the membrane should respond rapidly to changes in analyte concentration.
[0079] In a third example, a responsivity experiment was conducted in which eight sensors having diffusion-limiting membranes according to the present invention were tested simultaneously (Set 3), all at 37° C. The sensors of Set 3 had membranes prepared from the same polymers and the same crosslinkers as those of the sensors of Set 2 described in the calibration experiment above. In this responsivity experiment, the eight sensors were placed in a PBS-buffered solution (pH 7), the glucose concentration of which was increased in a step-wise manner over time, as illustrated by the glucose concentrations shown in FIG. 5 , and the output current of each of the sensors was measured. The measured output currents (nA) were then averaged for Set 3 and plotted against time (real time, hour:minute:second), as shown in the responsivity graph of FIG. 5 .
[0080] The responsivity curve for the Set 3 sensors having diffusion-limiting membranes according to the present invention has discrete steps that mimic the step-wise increases in glucose concentration in a rapid fashion. As shown, the output current jumps rapidly from one plateau to the next after the glucose concentration is increased. This result demonstrates the considerable responsivity of the membrane-equipped sensors of the present invention. The responsivity of these membrane-equipped electrochemical sensors makes them ideal for analyte sensing, such as glucose sensing.
Motion-Sensitivity Experiment
[0081] Ideally, the membrane of an electrochemical sensor should be unaffected by motion or movement of fluid or biofluid containing the analyte of interest. This is particularly important for a sensor that is implanted in a body, such as a human body, as body movement may cause motion-associated noise and may well be quite frequent.
[0082] In this fourth example, a motion-sensitivity experiment was conducted in which a sensor A lacking a membrane was tested, and separately, a sensor B having a diffusion-limiting membrane according to the present invention was tested, all at 37° C. Sensor B had a membrane prepared from the same polymer and the same crosslinker as those of the sensors of Set 2 described in the calibration experiment above. In this experiment, for each of test, the sensor was placed in a beaker containing a PBS-buffered solution (pH 7) and a magnetic stirrer. The glucose concentration of the solution was increased in a step-wise manner over time, in much the same manner as described in the responsivity experiment above, as indicated by the various mM labels in FIG. 6 . The stirrer was activated during each step-wise increase in the glucose concentration and deactivated some time thereafter, as illustrated by the “stir on” and “stir off” labels shown in FIG. 6 . This activation and deactivation of the stirrer was repeated in a cyclical manner at several levels of glucose concentration and the output current of each of the sensors was measured throughout the experiment. The measured output currents (μA for sensor A; nA for sensor B) were plotted against time (minute), as shown in the motion-sensitivity graph of FIG. 6 .
[0083] As shown, the output current for the membrane-less sensor A is greatly affected by the stir versus no stir conditions over the glucose concentration range used in the experiment. By contrast, the output current for sensor B, having diffusion-limiting membranes according to the present invention, is virtually unaffected by the stir versus no stir conditions up to a glucose concentration of about 10 mM, and only slightly affected by these conditions at a glucose concentration of about 15 mM. This result demonstrates the considerable stability of the membrane-equipped sensors of the present invention in both stirred and non-stirred environments. The stability of these membrane-equipped electrochemical sensors in an environment of fluid movement makes them ideal for analyte sensing within a moving body.
Sensor Reproducibility Experiment
[0084] Dip-coating, or casting, of membranes is typically carried out using dipping machines, such as a DSG D1L-160 of NIMA Technology of the United Kingdom. Reproducible' casting of membranes has been considered quite difficult to achieve. (Chen, T., et al., In Situ Assembled Mass - Transport Controlling Micromembranes and Their Application in Implanted Amperometric Glucose Sensors, Anal. Chem., Vol. 72, No. 16, Pp. 3757-3763 (2000).) Surprisingly, sensors of the present invention can be made quite reproducibly, as demonstrated in the experiment now described.
[0085] Four batches of sensors (Batches 1-4) were prepared separately according to the present invention, by dipping the sensors in membrane solution three times using casting equipment and allowing them to cure. In each of the four batches, the membrane solutions were prepared from the polymer of Formula 4 and poly(ethylene glycol) digycidyl ether (PEDGE) crosslinker having a molecular weight of about 200 (as in Set 2 and other Sets described above) using the same procedure. The membrane solutions for Batches 1 and 2 were prepared separately from each other, and from the membrane solution used for Batches 3 and 4. The membrane solution for Batches 3 and 4 was the same, although the Batch 3 and Batch 4 sensors were dip-coated at different times using different casting equipment. That is, Batches 1, 2 and 3 were dip-coated using a non-commercial, built system and Batch 4 was dip-coated using the above-referenced DSG D1L-160 system.
[0086] Calibration tests were conducted on each batch of sensors at 37° C. For each batch, the sensors were placed in PBS-buffered solution (pH 7) and the output current (nA) of each of the sensors was measured as the glucose concentration (mM) was increased. For each sensor in each of the four batches, a calibration curve based on a plot of the current output versus glucose concentration was prepared as shown in FIG. 7B (Batch 1: 5 sensors), FIG. 7C (Batch 2: 8 sensors), FIG. 7D (Batch 3: 4 sensors) and FIG. 7E (Batch 4: 4 sensors). The average slopes of the calibration curves for each batch were the following:
Batch 1: Average Slope=1.10 nA/mM (CV=5%); Batch 2: Average Slope=1.27 nA/mM (CV=10%); Batch 3: Average Slope=1.15 nA/mM (CV=5%); and Batch 4: Average Slope=1.14 nA/mM (CV=7%).
Further, for each batch, the current output for the sensors in the batch was averaged and plotted against glucose concentration, as shown in FIG. 7A . The average slope for Batches 1-4 was 1.17 nA/mM (CV=7.2%).
[0091] The slopes of the curves within each batch and from batch-to-batch are very tightly grouped, showing considerably little variation. The results demonstrate that sensors prepared according to the present invention give quite reproducible results, both within a batch and from batch-to-batch.
[0092] The foregoing examples demonstrate many of the advantages of the membranes of the present invention and the sensors employing such membranes. Particular advantages of sensors employing the membranes of the present invention include sensitivity, stability, responsivity, motion-compatibility, ease of calibration, and ease and reproducibility of manufacture.
[0093] Various aspects and features of the present invention have been explained or described in relation to beliefs or theories, although it will be understood that the invention is not bound to any particular belief or theory. Various modifications, processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the specification. Although the various aspects and features of the present invention have been described with respect to various embodiments and specific examples herein, it will be understood that the invention is entitled to protection within the full scope of the appended claims. | Novel membranes comprising various polymers containing heterocyclic nitrogen groups are described. These membranes are usefully employed in electrochemical sensors, such as amperometric biosensors. More particularly, these membranes effectively regulate a flux of analyte to a measurement electrode in an electrochemical sensor, thereby improving the functioning of the electrochemical sensor over a significant range of analyte concentrations. Electrochemical sensors equipped with such membranes are also described. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to tissue holder structure, and more particularly pertains to a new and improved spare tissue holder assembly wherein the same is arranged for accommodating a tissue roll in adjacency to a tissue roll dispenser.
2. Description of the Prior Art
The use of tissue roll dispensers of various types is utilized throughout the prior art and exemplified in the U.S. Pat. Nos. 4,826,063; 4,373,682; and 4,634,067. Accommodating various storage of tissue rolls is exemplified in the U.S. Pat. No. 4,098,469.
The instant invention attempts to overcome deficiencies of the prior art by providing for a spare tissue holder assembly arranged for use in conjunction with a conventional roll dispenser and in combination thereto to provide for ease of storage and retrofit of the spare tissue holder assembly relative to an associated tissue roll dispenser and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of tissue holder structure now present in the prior art, the present invention provides a spare tissue holder assembly wherein the same utilizes a spring-biased clamp structure to secure a tissue roll therebetween for storage thereof. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved spare tissue holder assembly which has all the advantages of the prior art tissue holder structure and none of the disadvantages.
To attain this, the present invention provides a tissue holder arranged to secure a roll of tissue in a stored configuration in adjacency relative to a conventional tissue roll dispenser, with the spare tissue holder having a base and a plurality of arcuate finger members mounted to the base to secure a tissue roll therebetween.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved spare tissue holder assembly which has all the advantages of the prior art tissue holder structure and none of the disadvantages.
It is another object of the present invention to provide a new and improved spare tissue holder assembly which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved spare tissue holder assembly which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved spare tissue holder assembly which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such spare tissue holder assemblies economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved spare tissue holder assembly which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with 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 the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
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:
FIG. 1 is an isometric illustration of the instant invention.
FIG. 2 is an orthographic rear view of the spare tissue holder assembly of the invention.
FIG. 3 is an orthographic side view, taken along the lines 3--3 of FIG. 2 in the direction indicated by the arrows.
FIG. 4 is an orthographic side view, partially in section, of a modified tissue holder assembly of the invention.
FIG. 5 is an orthographic view, taken along the lines 5--5 of FIG. 4 in the direction indicated by the arrows.
FIG. 6 is an orthographic side view of a further modified aspect of the invention.
FIG. 7 is an orthographic view of section 7 as set forth in FIG. 6.
FIG. 8 is an orthographic view of the invention in an assembled configuration, as set forth in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 7 thereof, a new and improved spare tissue holder assembly embodying the principles and concepts of the present invention and generally designated by the reference numerals 10 and 10a will be described.
More specifically, the spare tissue holder assembly 10 of the instant invention essentially comprises operative association with a tissue roll dispenser 32 having support arms 33 mounting a roll axle 34 to secure a first tissue roll T(1) for selective dispensing of the tissue roll T(1).
To provide for ease of access to and the presentation of a spare tissue roll T(2), a base plate 11 includes respective first and second arcuate fingers 12 and 13 fixedly mounted to the base plate, with the arcuate fingers 12 and 13 defining a cylindrical cavity therebetween having an access gap 16 directed between the first and second arcuate fingers 12 and 13 defined between respective first and second frontal linear edges 14 and 15 respectively of the first and second arcuate fingers 12 and 13. Base plate fastener openings 17 may be provided, as illustrated in FIG. 2, to utilize conventional fasteners to secure the holder assembly 10 to the vertical wall surface in adjacency to the tissue roll duspenser 32.
The invention as indicated in the FIG. 4 by the numeral 10a includes a modified base plate 11a having a base plate rear wall 18, including a base plate cavity 19 directed into the base plate extending from the rear wall. A mounting plate 20 is provided for assemblage to the base plate, with the mounting plate 20 including a mounting plate front wall having a plurality of mounting plate front wall projections 26 received within base plate cavity bores 25 intersecting the base plate cavity 19. The bores 25 are spaced apart a predetermined spacing substantially equal to a predetermined spacing of the projections 26. An adhesive layer 23 is mounted to the mounting plate rear wall 22 accessed by a peel-away flexible web 24, whereupon removal of the web permits selective positioning of the mounting plate 20 onto the vertical wall surface in adjacency relative to the tissue roll dispenser 32. A ferromagnetic liner 27 is mounted coextensively along a floor of the base plate cavity 19 and directed into the bores 25 cooperative with the ferrous metallic mounting plate 20 and the projections 26.
The invention as indicated in the FIGS. 6-8 includes a bore floor 29 of each bore 25 having a membrane film 30 overlying an adhesive fluid 31. Each of the projections 26 includes a pointed forward end 28, whereupon manual projection of the base plate 18 effects projection of each pointed forward end 28 to rupture each associated membrane film 30 to direct the adhesive fluid 31 to permanently secure the mounting plate to the base plate 11a for permanent assemblage. Otherwise, individuals may selectively remove the assembly 10a for storage until use for quests and the like that have access as required to the second tissue roll T(2).
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A tissue holder arranged to secure a roll of tissue in a stored configuration in adjacency relative to a conventional tissue roll dispenser is provided, with the spare tissue holder having a base and a plurality of arcuate finger members mounted to the base to secure a tissue roll therebetween. | 0 |
FIELD OF THE INVENTION
The present invention generally relates to cylindrical grinding apparatuses and processes and, more particularly, to a holder for holding workpieces during a cylindrical grinding process and a holding method for such a process.
DESCRIPTION OF RELATED ART
Usually, optical elements such as camera lenses and spectacles are in used in cylindrical form. However, original optical workpieces (i.e. lens blanks) are most easily manufactured in the form of a square. Therefore, these original optical workpieces have to be cylindrically ground before use.
A typical example of a contemporary cylindrical grinding apparatus is a centering apparatus. The centering apparatus typically includes a pair of holders for holding the original workpiece, where each holder has a hollow chamber communicating with a surface of the holder. The holder can hold the workpiece on its surface by using an air pump evacuating the hollow chamber, and a grinding wheel is then used to cylindrically grind the workpiece. However, the centering apparatus can only cylindrically grind one workpiece at a time.
FIGS. 7-8 show an apparatus for cylindrically grinding more than one workpiece at a time. The apparatus includes a first holding tool 12 and a second holding tool 14 . The first holding tool 12 defines a holding groove 122 , and the second holding tool 14 defines a semicircular groove 142 . The holding groove 122 and the semicircular groove 142 are both for securing the workpieces 16 in the holding tools 12 , 14 . In use, firstly, a plurality of workpieces 16 are placed in the holding groove 122 of the first holding tool 12 . Secondly, the workpieces 16 are bonded together using an adhesive. Thirdly, a grinding wheel is used to grind a portion of the workpieces 16 projecting out of the holding groove 122 into a semicircular shape. Fourthly, the semicircular portion 162 of the workpieces 16 is transferred to the semicircular groove 142 of the second holding tool 14 . Fifthly, the other portion of the workpieces 16 is also ground into a semicircular shape using the grinding wheel. The final result being that the workpieces 16 are ground to a cylindrical shape.
When transferring the workpieces 16 from the first holding tool 12 to the second holding tool 14 , the adhesive should be dissolved so that the workpieces 16 can be taken out of the first holding tool 12 . However, the workpieces 16 will not be held compactly in the second holding tool 14 and may become disarrayed whilst the adhesive is being dissolved.
Therefore, an apparatus and a process for cylindrically grinding workpieces which can easily and compactly transfer the workpieces is desired.
SUMMARY OF THE INVENTION
In one aspect, an apparatus for cylindrically grinding workpieces includes a first holding tool for positioning pre-grinding workpieces and a second holding tool for positioning partially ground workpieces (i.e. workpieces which have been ground on one side only). The first holding tool defines a first groove for containing the pre-grinding workpieces to be partially ground and the second bonding defines a second groove for containing the partially ground workpieces. A first resisting member and a first back plate detachably connect with at least one first holding member, and thus making up the first holding tool. A second resisting member and a second back plate detachably connect at least one second holding member, and thus make up the second holing tool.
In another aspect, a process for grinding workpieces can be used wherein a plurality of pre-grinding workpieces are positioned in a first groove of a first holding tool with a first portion of the pre-grinding workpieces projecting out of the first groove. The first portion of the pre-grinding workpieces is partially ground into a first predetermined shape. A second holding tool is provided, the second holding tool defining a second groove. The first holding tool is detached, whilst the second holding tool is then placed on the partially ground workpieces with the first portion in the second groove. The parts of the second holding tool are fastened. The second holding tool is then reversed, whilst a second portion of the workpieces projects out of the second groove, this second portion is then ground into a second predetermined shape thus completing the grinding process.
Other advantages and novel features will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the apparatus can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present apparatus. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a schematic view of a first holding tool of an apparatus for cylindrically grinding workpieces in accordance with a first preferred embodiment;
FIG. 2 is a schematic view of a second holding tool of the apparatus for cylindrically grinding workpieces in accordance with the first preferred embodiment;
FIG. 3 is a schematic view of a step of the process for cylindrically grinding workpieces using the apparatus of FIG. 1 ;
FIG. 4 is a schematic view of another step subsequent to the step in FIG. 3 ;
FIG. 5 is a schematic view of a further step subsequent to the step in FIG. 4 ;
FIG. 6 is a schematic view of a first holding tool of an apparatus for cylindrically grinding workpieces in accordance with a second preferred embodiment;
FIG. 7 is a schematic view of a first holding tool of a typical apparatus for cylindrically grinding workpieces; and
FIG. 8 is a schematic view of a second holding tool of the apparatus in FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1-2 , an apparatus for cylindrically grinding workpieces 40 according to a first preferred embodiment, includes a first holding tool 100 , a second holding tool 200 , and a grinding wheel 300 . The holding tools 100 , 200 are configured for holding workpieces 40 .
The first holding tool 100 includes two first holding members 22 , a first back plate 24 , two first resisting members 26 , and two first fixing members 28 .
Each first holding member 22 is rectangular in shape, and has two opposite side surfaces 222 , and a working surface 224 between the side surfaces 222 . Each first holding member 22 defines a through-hole 225 extending through the side surfaces 222 . The working surface 224 defines a first groove 226 for containing pre-grinding workpieces 40 . The pre-grinding workpieces 40 can be optical elements having a non-cylindrical shape. In this preferred embodiment, the workpieces 40 are substantially square-shaped. Therefore, the first groove 226 is configured to have a V-shaped cross section along a traverse direction, for compliantly receiving the pre-grinding workpieces 40 therein. The pre-grinding workpieces 40 are partially ground on the first groove 226 and centers of the workpieces 40 are higher than the working surface 224 , thus the grinding wheel 300 cannot touch the working surface 224 when the grinding wheel 300 grinds the workpieces 40 . Understandably, the cross section along a traverse direction of the first groove 226 may be of other shape depending on the shape of the pre-grinding workpieces 40 .
The first back plate 24 , which is substantially rectangular shaped, defines two spaced bores 242 . The bores 242 correspond to the through-holes 225 of the first holding members 22 . The first back plate 24 has a top surface 243 paralleling the axes of the bores 242 . Two protruding columns 244 are formed on the top surface 243 . A cross-section along a traverse direction of the protruding column 244 is semicircular shape, and a radius of the protruding column is same as that of the finished product, corresponding to the shape of the first groove 226 . Each protruding column 244 has an end surface 246 which is used to resist the workpieces 40 . The end surface 246 is flat enough to avoid harming the workpieces 40 .
The first resisting members 26 include a base plate 262 , and a column 264 extending from one surface of the base plate 262 . A diameter and a length of the column 264 are similar to those of the through-hole 225 of the first holding member 22 . A screw hole 269 is defined at the end of the column 264 . The screw hole 269 is coaxial to the column 264 . The cross section shape along a traverse direction of protruding column 266 is the same as the protruding column 244 of the first back plate 24 . The extension direction of the protruding column 266 is the same as that of the column 264 . Each protruding column 266 has a end surface 268 which is used to resist the workpieces 40 .
The fixing member 28 , includes a head portion 282 , a screw portion 284 , and a connecting portion 286 . The connecting portion 286 connects the head portion 282 and the screw portion 284 . A diameter of the head portion 282 is larger than that of the connecting portion 286 , thus the diameter of the connecting portion 286 is larger than that of the screw portion 284 .
The configuration of the second holding tool 200 is almost the same as that of the first holding tool 100 . The second holding tool 200 includes two second holding members 32 , a second back plate 34 , two second resisting members 36 , and two second fixing members 38 . The back plate 34 includes two protruding columns 342 having an end surface 344 . Each resisting member 36 includes a protruding column 362 having an end surface 364 . Compared with the first holding tool 100 , the second holding tool 200 has some differences, which are as follows: each holding member 32 defines a second groove 322 having a semicircular shaped cross section along a traverse direction; A radius of the second groove 322 is same as the finished product.
In assembling the first holding tool 100 , the first holding members 22 are joined together with the first grooves 226 facing upward. The protruding columns 266 face upward, and each column 264 is inserted through the through-holes 225 . The first back plate 24 abuts against the side surfaces 222 of the first holding members 22 . Finally, each first fixing member 28 is inserted through the bores 242 and the screw portion 284 is screwed into the screw holes 269 of the columns 264 .
The process of assembling the second holding tool 200 is the same as that of the first holding tool 100 .
Referring to FIGS. 3-5 , an exemplary process for cylindrically grinding workpieces 40 includes the steps of:
(1) A stack of workpieces 40 (i.e. pre-grinding workpieces) are placed in the first groove 226 of the first holding tool 100 . The first fixing members 28 are screwed down and the pre-grinding workpieces 40 are clamped by the protruding columns 244 , 266 . A first portion 42 of the pre-grinding workpieces 40 projects out of the first grooves 226 .
(2) The first portion 42 of the pre-grinding workpieces 40 is partially ground to a semicircular shape.
(3) The first fixing members 28 of the first holding tool 100 are released so that the first back plate 24 and the first resisting members 26 are detached from the first holding tool 100 . The second holding tool 200 is placed on the partially ground workpieces 40 with the first portion 41 in the second groove 322 . The second fixing members 38 are screwed down and the partially ground workpieces 40 are clamped.
(4) The holding tool 200 is reversed and a second portion 44 of the partially ground workpieces 40 projects out of the second grooves 322 .
(5) The second portion 42 of the workpieces 40 is ground to a semicircular shape. Thus a plurality of cylindrical workpieces 40 are obtained.
It is believed that the cross section along a traverse direction of the first grooves 226 can be of other shape, for example, a square groove can be defined under the original first groove 226 . The first grooves 226 and the second grooves 322 may extend to the end surfaces of the holding members 22 , 32 .
It is believed that the number of the holding members 22 , 32 can be changed and the number of the corresponding resisting members 26 , 36 can be changed accordingly; the first resisting members 26 of the first holding tool 100 can be integrally formed and the second resisting members 36 of the second holding tool 200 can also be integrally formed.
The process can easily and compactly transfer workpieces 40 from the first grooves 226 to the second groove 322 using the resisting members 26 , 36 and the back plate 24 , 34 which can promote the working efficiency of the cylindrical process. Also the process does not use adhesive, and thus does not require water or other solvents to dissolve the adhesive, so the workpieces 40 can avoid becoming disarrayed.
Referring to FIG. 6 , an apparatus for cylindrically grinding workpieces according to a second preferred embodiment includes a first holding tool 100 and a second holding tool 200 . The first holding tool 100 includes one holding member 62 , two back plates 64 , two resisting members 66 , and two fixing members 68 . The holding member 62 defines two through-holes 622 and two grooves 624 with a V-shaped cross section along a traverse direction. Each back plate 64 defines a bore. The second holding tool is same as the first holding tool 100 except for the cross section shape along a traverse direction of the grooves 624 being semicircular.
It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the examples here before described merely being preferred or exemplary embodiments of the invention. | An apparatus for cylindrically grinding workpieces includes a first holding tool ( 100 ) for positioning pre-grinding workpieces ( 40 ) and a second holding tool ( 200 ) for positioning partially ground workpieces (i.e. workpieces which have been ground on one side only). The first holding tool ( 100 ) defines a first groove ( 226 ) for containing the pre-grinding workpieces to be partially ground and the second bonding defines a second groove ( 322 ) for containing the partially ground workpieces. At least one first resisting member ( 26 ) and at least one first back plate ( 24 ) detachably connect with the at least one first holding member ( 22 ), and thus making up the first holing tool ( 100 ). At least one second resisting member ( 36 ) and a at least one second back plate ( 34 ) detachably connect at least one second holding member ( 36 ), and thus making up the second holding tool ( 100 ). The present invention also provides a process for cylindrically grinding workpieces. | 1 |
BACKGROUND
[0001] The present invention relates generally to a golf ball made of recyclable materials.
[0002] The game of golf is an increasingly popular sport at both amateur and professional levels. A wide range of technologies related to the manufacture and design of golf balls are known in the art. Such technologies have resulted in golf balls with a variety of play characteristics. For example, some golf balls have a better flight performance than other golf balls. Some golf balls have a good feel when hit with a golf club. While materials have advanced to increase the performance of golf balls, the materials are not always easy to recycle. Thus, to help manage costs and reduce damage to the environment, it would be advantageous to make a golf ball made of recyclable materials.
SUMMARY
[0003] Generally, the present disclosure relates to a recyclable golf ball. The structure of the disclosed golf ball and/or the materials used to make the golf ball may enhance the ability to recycle the golf ball. As a result, the disclosed golf ball may decrease waste and the costs associated with acquiring and/or processing new materials.
[0004] In one aspect, the disclosure provides a golf ball that may have a first layer having a first melting point and a second layer enclosing the first layer. The second layer may have a second melting point that is at least 50 degrees Celsius different from the first melting point. The golf ball may include a third layer disposed between the first layer and the second layer. The third layer may have a third melting point that is at least 10 degrees Celsius different from the first melting point and the second melting point. The golf ball may include a fourth layer disposed between the second layer and the third layer. The fourth layer may have a fourth melting point that is at least 10 degrees Celsius different from the first melting point, the second melting point, and the third melting point. The first layer may be a core layer and the second layer may be a cover layer. The golf ball may include a third layer that is a core layer made of a thermoset. The golf ball may include a first intermediate layer disposed between the first layer and the second layer. The first intermediate layer may have a thickness ranging from about 1 μm to about 1 mm. The first intermediate layer may have a third melting point that is 10 degrees Celsius different from the first melting point and the second melting point.
[0005] In one aspect, the disclosure provides a golf ball that may have a first layer and a second layer surrounding the first layer. The golf ball may have a first intermediate layer disposed between the first layer and the second layer. The first intermediate layer may have a thickness ranging from about 1 μm to about 1 mm and the first intermediate layer may be made of at least one of epoxy adhesives, acrylic adhesives, urethane adhesives, ethylene vinyl acetate adhesives, and rubber adhesives. The first intermediate layer may have a thickness ranging from about 1 μm to about 0.6 mm. The golf ball may have a third layer surrounding the second layer and a second intermediate layer disposed between the second layer and the third layer.
[0006] In one aspect, the disclosure provides a golf ball that may have a first layer and a second layer enclosing the first layer. One of the first layer and the second layer may include magnetic additive. A third layer may be disposed between the first layer and the second layer. The third layer may include magnetic additive. One of the first layer and the second layer may include at least about 2 vol % to about 20 vol % less magnetic additive than the third layer. One of the first layer and the second layer may include of at least about 5 vol % to about 15 vol % of magnetic additive and the third layer may include about 7 vol % to about 35 vol % of magnetic additive. The type of magnetic additive added to one of the first layer and the second layer may be a ferrite magnetic powder. The first layer may be a thermoset containing magnetic additive. The first layer may be a thermoplastic containing magnetic additive. The second layer may be a thermoplastic containing magnetic additive.
[0007] Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
[0009] FIG. 1 is a golf ball according to an exemplary embodiment;
[0010] FIG. 2 is a golf ball according to an exemplary embodiment;
[0011] FIG. 3 is a golf ball according to an exemplary embodiment; and
[0012] FIG. 4 is an outer view of the golf ball shown in FIG. 3 .
DETAILED DESCRIPTION
[0013] Generally, the present disclosure relates to a recyclable golf ball. In this disclosure, the terms “used golf ball” and “new golf ball” are used to distinguish between a golf ball that is to be recycled and a golf ball that is made from recycled materials. Accordingly, “used golf ball” means a golf ball that is to be recycled. The term “used golf ball” can include golf balls that have literally been used in a golf game and golf balls that have not literally been used. “New golf ball” refers to a golf ball made from materials recycled from the “used golf ball.”
[0014] FIG. 1 shows an exemplary embodiment of a golf ball 100 . Golf ball 100 may include an inner core layer 110 , an outer core layer 120 , a mantle (inner cover) layer 130 , and an outer cover layer 140 . While the exemplary embodiment of golf ball 100 has been described and illustrated as having four layers, other embodiments may include any number of layers. For example, in some embodiments, golf ball 100 may be a one-piece, two-piece, three-piece, or five-piece ball. In some embodiments, golf ball 100 may include more than five layers. The number of layers may be selected based on a variety of factors. For example, the number of layers may be selected based on the type of materials used to make the golf ball and/or the size of the golf ball.
[0015] The type of materials used to make the layers of the golf ball may be selected based on a variety of factors. For example, the type of materials used to make the layers of the golf ball may be selected based on the properties of the material and/or the processes used to form the layers. Exemplary materials are discussed below with respect to the individual layers of the exemplary embodiment. In some embodiments, one or more layers may be made from different materials. In some embodiments, one or more layers may be made from the same materials.
[0016] In some embodiments, the materials used to make the layers of the golf ball may be selected to aid in recycling the golf ball. In such embodiments, the materials may be selected to aid in separating and identifying the materials before reusing the materials. This way the materials may be stored separately before using and/or the proper proportions of the materials may be measured out for reusing. For example, in an embodiment in which a used golf ball is made of material A and material B, the used golf ball may be pulverized into particles so that the materials may be reused to make new golf balls. Pulverizing the used golf ball may result in particles of material A and material B to become intermixed. If only material A, and not material B, is to be used in a layer of a new golf ball, it may be helpful to be able to separate material A from material B. Similarly, if material A and material B are to be used in a certain proportion in a layer of a new golf ball, it may be helpful to be able to distinguish between material A and material B. Separating and identifying materials may be helpful in recycling golf balls made of any number of materials and during any type of recycling process. For example, separating and identifying materials may be helpful in recycling golf balls made of four different types of materials.
[0017] In some embodiments, the density and/or specific gravity of the materials used to make golf ball 100 may be used to separate the materials during recycling. Specific gravity is the ratio of the density of a substance compared to the density of fresh water at 4° C. (39° F.). At this temperature the density of water is at its greatest value and equals 1 g/cm 3 . Since specific gravity is a ratio, specific gravity is dimensionless. An object will float in water if its density is less than the density of water and sink if its density is greater than the density of water. Thus, an object with specific gravity less than 1 will float in water and an object with a specific gravity greater than 1 will sink in water. The same principle may be applied to other types of liquids. For example, if the ratio of the density of an object to the density of a liquid is less than 1, the object will float in that particular liquid. In some cases, the density of an object may cause the object to become suspended at a certain level within the liquid. The ratio of the density of the object to the density of the liquid may dictate the level to which the object is suspended in that particular liquid. These principles may be used to separate materials having different densities. For example, in some embodiments, golf ball 100 made from materials having different densities. For recycling, golf ball 100 may be pulverized into particles. Then, the particles may be added to a liquid having a certain known density. The liquid and/or the materials may be selected based on their densities. In other words, the materials and/or liquid may be selected based on the levels the particles will float to within the liquid. This way, the particles can be separated based on the level to which the particles float in the liquid. In some embodiments, the temperature of the liquid may be changed to alter the density of the liquid, thereby altering the level to which the particles float. Similarly, the type of liquid may be changed to alter the density of the liquid. For example, in some embodiments, salt may be added to water to change the density of the water.
[0018] In an embodiment in which golf ball 100 is made from materials having different densities, inner core layer 110 , outer core layer 120 , mantle layer 130 , and outer cover layer 140 may be each made from a single type of material or a composition including multiple materials. For example, inner core layer 110 may be made from HPF 2000, produced by E. I. DuPont de Nemours and Company. HPF 2000 has a density of 0.96 g/cm 3 . Outer core layer 120 may be made from TAIPOL™ BR0150, which is the trade name of a rubber produced by Taiwan Synthetic Rubber Corp. The density of outer core layer 120 may be from about 1.05 g/cm 3 to about 1.35 g/cm 3 . Mantle layer 130 may be made from Neothane 6303D, which is the trade name of a thermoplastic polyurethane produced by Dongsung Highchem Co. LTD. Cover layer 140 may be made from PTMEG. “PTMEG” is polytetramethylene ether glycol, commercially available from Invista under the trade name of Terathane® 2000. The density of mantle layer 130 or outer cover layer 140 may range from about 1.1 g/cm 3 to about 1.35 g/cm 3 . Pulverizing golf ball 100 of this embodiment into particles and putting the particles in water having a temperature of 4° C. (39° F.) may result in the materials of each layer floating to a different level in the water. The particles may be removed from the water level by level to keep like particles together. For example, particles of HPF 2000 may have the lowest density and may, therefore, float to the top of the water. These particles may be removed first to reveal the next level of particles, which may include the particles having the second lowest density. Then, the particles having the second lowest density may be removed to reveal the next level of particles. In this manner, the particles may be separated into levels and removed level by to level to keep like particles together.
[0019] In some embodiments, the melting point of the materials used to make golf ball 100 may be used to separate the materials during recycling. This way, the materials of golf ball 100 may be melted one at a time. In such an embodiment, golf ball 100 may be made from materials having different melting points such that, as the temperature of golf ball 100 is raised, more materials may begin to melt. In this manner, the layers may be melted one by one and molten material may be separated from solid material. The materials may be selected based on the melting temperatures of the materials. The melting temperatures may be used to control which material melts. The materials used to make the golf ball may include any suitable material generally known to be used in golf balls. In some embodiments, the materials may include thermoplastics. For example, the materials may include high melt thermoplastics, such as polyetheramides and/or polyetheresters. In some embodiments, the materials may include PEBAX (a polyetheramide produced by Elf-Atochem), HYTREL (a polyetherester produced by DuPont), ESTANE (a thermoplastic urethane either ether or ester urethane produced by Lubrizol, Inc.), or any other material disclosed in Comeau et al., U.S. patent publication number 2009/0280928, entitled Golf Ball with Heat Resistant Layer, published on Nov. 12, 2009, the entirety of which is hereby incorporated by reference. In some embodiments, the materials may include resins, such as SURLYN, produced by E. I. DuPont de Nemours and Company. In some embodiments, the materials may include a highly neutralized acid polymer, such as HPF 1000 or AD 1035, both produced by E. I. DuPont de Nemours and Company.
[0020] In some embodiments, the different materials used to make the golf ball may each have a melting temperature that is at least 10 degrees Celsius different from the melting temperatures of the other materials. For example, in some embodiments, a first material of the golf ball may include HPF 2000, produced by E. I. Dupont de Nemours and Company. HPF 2000 has a melting temperature of about 73 degrees Celsius. A second material of the golf ball may include SURLYN 8528, produced by E. I. DuPont de Nemours and Company. SURLYN 8528 has a melting temperature of about 93 degrees Celsius. In such embodiments, when the temperature of the golf ball is raised to 75 degrees Celsius, the first material may melt and the second material may remain solid.
[0021] In some embodiments, golf ball 100 may be pulverized into particles before melting the materials. In such an embodiment, the materials may be selected based on the melting temperature of the materials. For example, outer cover layer 140 may have the highest melting temperature. Mantle layer 130 may have the lowest melting temperature. Outer core layer 120 may have the second highest melting temperature. Inner core layer 110 may have the second lowest melting temperature. As discussed above, the melting points of the materials may be sufficiently disparate for the melting of the materials to occur at different temperatures. This way, the particles of golf ball 100 may be heated to the certain temperatures to control which materials melt. For example, the particles may be heated to a temperature that is the same or higher than the lowest melting point of the materials and lower than the second lowest melting point of the materials. This heating may cause the particles of the materials having the lowest melting point to melt without causing the particles of the other materials to melt. The melted material may be strained out from the solid particles.
[0022] In some embodiments, the temperature of the particles may be progressively raised to melt different types of materials. For example, after melting the particles having the lowest melting point, the particles may be heated to a temperature that is the same or higher than the second lowest melting point of the materials and lower than the second highest melting point of the materials. In some embodiments, less than all of the materials may be melted. For example, only one or two materials may be melted and strained from the solid particles. Then, the solid particles may be separated in another way and/or prepared for another type of processing. For example, the solid particles leftover after melting may be separated by their densities in the manner described above. Any of the techniques used to separate materials may be combined with each other. The materials of the particles not intended to be melted may include materials simply having melting points that are higher than the melting points of the materials intended to be melted. As another option, the materials of the particles not intended to be melted may be materials not conducive to melting, such as thermosets. The materials intended to be melted may include thermoplastics.
[0023] In some embodiments, the materials used to make the layers of golf ball 100 may be selected such that the melting points of the layers correspond with the order in which the layers are to be melted. For example, in some embodiments, the melting temperatures of the layers may become progressively higher from outer cover layer 140 to inner core layer 110 . This way, golf ball 100 may be melted without being pulverized first. Outer cover layer 140 may have the lowest melting temperature. Mantle layer 130 may have the second lowest melting temperature. Outer core layer 120 may have the second highest melting temperature. Inner core layer 110 may have the highest melting temperature. This embodiment may be recycled by melting each layer from the outside in. For example, the temperature of the golf ball 100 may be raised to a temperature that is the same or higher than the melting point of outer cover layer 140 and lower than the melting point of the other layers of golf ball 100 . This temperature may cause outer cover layer 140 to melt without causing the other layers of golf ball 100 to melt. In the same manner that outer cover layer 140 is melted and removed from underlying layers, mantle layer 130 , and outer core layer 120 may be melted and removed from underlying layers. With all of the layers surrounding inner core layer 110 being separately melted and collected, inner core layer 110 may be melted and collected.
[0024] In some embodiments, less than all of the layers may be melted. In such embodiments, the melting point of the layers not intended to be melted may be sufficiently high to prevent such layers from melting during processing. For example, inner core layer 110 may have a melting point that is higher than all of the other layers. After all of the other layers are melted and removed from inner core layer 110 , inner core layer 110 may be left whole or may be prepared for another type of processing. For example, inner core layer 110 may be pulverized to prepare the material of inner core layer 110 to be mixed with particles of other materials. In some embodiments, the layers not intended to be melted may be made of a thermoset or other type of material that may not be conducive to melting. Accordingly, the materials of these layers may be separated from each other by another manner. For example, these layers may be ground away from the other layers. In another example, these layers may be pulverized and separated by their densities in the manner discussed above. In another example, outer cover layer 140 may be the only layer removed through melting. In such an example, the materials of the other layers may have a higher melting point than that of outer cover layer 110 such that the other layers do not melt when outer cover layer 110 is melted. However, the melting points of the other layers may be the same or different from each other since the other layers may not be melted.
[0025] In some embodiments, the materials used to make the layers of golf ball 100 may be selected based on the magnetic susceptibility of the materials. For example, in some embodiments, the material used to make a first layer of golf ball 100 may be magnetically susceptible and the material used to make a second layer be magnetically non-susceptible. Magnetic additives may be mixed with materials to make the materials magnetically susceptible. For example, the layers of golf ball 100 may be made of thermoplastics and/or thermosets containing a magnetic additive. The magnetic additive may include any suitable magnetic additive. For example, in some embodiments, the magnetic additive may include a ferrite magnetic powder, such as barium ferrite powder, strontium ferrite powder, and/or AlNiCo powder. In some embodiments, the magnetic additive may include iron oxides, such as hematite and magnetite. In some embodiments, a material of the golf ball may include from about 5 vol % to about 80 vol % magnetic additive.
[0026] In some embodiments, during recycling, golf ball 100 may be pulverized into particles and separated by applying a magnetic field to the particles. Materials with different amounts of magnetic additive may have different levels of attraction toward magnetic fields. For example, materials including 5 vol % magnetic additive may be less attracted to a magnetic field than materials including 10 vol % magnetic additive. Following this principle, a weak magnetic field may be used to separate material particles having the highest amount of magnetic additive from the other material particles. In some embodiments, each layer may have a different amount of magnetic additive. For example, outer cover layer 140 may include about 5 vol % to about 15 vol % magnetic additive. Mantle layer 130 may include about 20 vol % to about 35 vol % magnetic additive. Outer core layer 120 may include about 40 vol % to about 55 vol % magnetic additive. Inner core layer 110 may include 0% magnetic additive.
[0027] FIG. 2 shows an exemplary embodiment of a golf ball 200 . Golf ball 200 may include an inner core layer 210 , an outer core layer 220 , a mantle layer 238 , and an outer cover layer 240 . While the exemplary embodiment of golf ball 200 has been described and illustrated as having three layers, other embodiments may include any number of layers. For example, in some embodiments, golf ball 200 may be a one-piece, two-piece, four-piece, or five-piece ball. In some embodiments, golf ball 200 may include more than five layers. The number of layers may be selected based on a variety of factors. For example, the number of layers may be selected based on the type of materials used to make the golf ball and/or the size of the golf ball.
[0028] Golf ball 200 may include an intermediate layer 216 between inner core layer 210 and outer core layer 220 . Similarly, golf ball 200 may include an intermediate layer 236 between outer core layer 220 and mantle layer 238 . In some embodiments, intermediate layer 216 and intermediate layer 236 may be made of the same types of materials. In some embodiments, intermediate layer 216 and intermediate layer 236 may be made of different types of materials. In some embodiments, intermediate layer 216 and/or intermediate layer 236 may act as primers and/or adhesives. For example, in some embodiments, intermediate layer 216 and/or intermediate layer 236 may include epoxy adhesives, acrylic adhesives, urethane adhesives, ethylene vinyl acetate adhesives, and/or rubber adhesives. Intermediate layer 216 and/or intermediate layer 236 may be made of materials that aid in separation between inner core layer 210 , outer core layer 220 , and mantle layer 238 . For example, in some embodiments, intermediate layer 216 and/or intermediate layer 236 may be made of materials having lower melting points than the other layers. Such materials may be softened and/or melted to help separate inner core layer 210 , outer core layer 220 , and cover layer 240 from each other.
[0029] In some embodiments, golf ball 200 may be pulverized into particles. Then, to aid in separating the different materials, the particles may be heated to a temperature that is the melting point of intermediate layer 216 and/or intermediate layer 236 . The materials of intermediate layer 216 and intermediate layer 236 soften and/or melt, releasing particles of mantle layer 238 from particles of outer core layer 220 and releasing particles of outer core layer 220 from particles of inner core layer 210 . The melted material may be strained from the solid particles.
[0030] In some embodiments, inner core layer 210 may have a diameter ranging from about 19 mm to about 32 mm. In some embodiments, inner core layer 210 may have a diameter ranging from about 20 mm to about 30 mm. In some embodiments, inner core layer 210 may have a diameter ranging from about 21 mm to about 28 mm. In some embodiments, outer core layer 220 may have a thickness ranging from about 5 mm to about 11 mm. For example, outer core layer 220 may have a thickness of about 7 mm. In some embodiments, outer core layer 220 may have a thickness ranging from about 8 mm to about 15 mm. For example, in some embodiments, outer core layer 220 may have a thickness of about 11 mm.
[0031] In some embodiments, outer cover layer 240 and/or mantle layer 238 of golf ball 200 may have a thickness ranging from about 0.5 mm to about 2 mm. For example, outer cover layer 240 and/or mantle layer 238 may have a thickness of about 1 mm. In some embodiments, outer cover layer 240 and/or mantle layer 238 may have a thickness ranging from about 1 mm to about 1.5 mm. For example, in some embodiments, outer cover layer 240 and/or mantle layer 238 may have a thickness of about 1.2 mm.
[0032] In some embodiments, intermediate layer 216 and/or intermediate layer 236 may be substantially thinner than the other layers of golf ball 200 . For example, in some embodiments, intermediate layer 216 and/or intermediate layer 236 may be less than or equal to 1 mm. In some embodiments, intermediate layer 216 and/or intermediate layer 236 may range from about 1 μm to about 0.70 mm. In some embodiments, intermediate layer 216 and/or intermediate layer 236 may range from about 0.01 mm to about 0.4 mm.
[0033] In some embodiments, golf ball 200 may have an intermediate layer between each layer. For example, in some embodiments, golf ball 200 may include an intermediate layer between mantle layer 238 and outer cover layer 240 . In some embodiments, golf ball 200 may have an intermediate layer between less than all of the layers. For example, golf ball 200 may include intermediate layer 216 and not intermediate layer 236 . In another example, golf ball may include intermediate layer 236 and not intermediate layer 216 . The number of intermediate layers may be selected based on a variety of factors. For example, the number of intermediate layers may be selected based on the process used to recycle golf ball 200 .
[0034] In some embodiments, intermediate layer 216 and/or intermediate layer 236 may be made of materials that are dissolvable in certain solvents. Accordingly, in such embodiments, golf ball 200 may be pulverized into particles. Then, to aid in separating the different materials, the particles may be placed in a solvent. The materials of intermediate layer 216 and intermediate layer 236 may be dissolved, releasing particles of mantle layer 238 from particles of outer core layer 220 and releasing particles of outer core layer 220 from particles of inner core layer 210 . For example, in some embodiments, dissolvable materials may include thermoplastic polyurethane elastomers, thermoplastic polyamide elastomers, thermoplastic polyester elastomers, and ethylene propylene diene monomer (EPDM) rubbers. In some embodiments, solvents used to dissolve the dissolvable materials may include tetrahydrofuran, methyl isobutyl ketone, dimethylformamide, dimethyl sulfoxide, methylpyrrolidone, toluene, acetone, chloroform, and ethyl acetate.
[0035] FIGS. 3 and 4 show an exemplary embodiment of a golf ball 300 . FIG. 3 shows a cross-sectional view of golf ball 300 and FIG. 4 shows the outside of golf ball 300 . In some embodiments, golf ball 300 may include a core layer 310 and a cover layer 340 . In other embodiments, golf ball 300 may include multiple core layers and/or multiple cover layers. For example, golf ball 300 may include an inner core layer, an outer core layer, an inner cover layer, and an outer cover layer. In some embodiments, an outer cover layer with dimples may be formed around golf ball 300 .
[0036] As shown in FIG. 3 , in some embodiments, golf ball 300 may be made through a sandwich molding process. During the sandwich molding process, concentric nozzles may be used to simultaneously inject multiple layers of a golf ball. For example, concentric nozzles may include an outer nozzle 342 surrounding an inner nozzle 344 . In embodiments including more layers, more concentric nozzles may be used. FIG. 3 shows golf ball 300 after golf ball 300 has been formed. The concentric nozzles are shown to illustrate how the materials flow from the concentric nozzles to form a pattern including a plume 348 within golf ball 300 . A first material may be dispensed from outer nozzle 342 and a second material may be dispensed from inner nozzle 344 . In some embodiments, a first material may include a core material and the second material may include a cover material. In some embodiments, the first material and the second material may include thermosets. As shown in FIGS. 3 and 4 , the simultaneous injection of the first material and the second material may create plume 348 of the second material. The first material may flow around plume 348 and into the center of the mold. The second material may continue to flow from outer nozzle 342 and plume 348 to the walls of the mold to form outer cover layer 340 . Plume 348 may solidify as a distinct region of the second material that is surrounded by the first material. As shown in FIG. 3 , plume 348 may have a fan-shaped cross-section. As shown in FIG. 4 , core layer 310 may be exposed through cover layer 340 at region 346 . Region 346 may include a thinned region of cover layer 340 that is radially spaced from plume 348 . Region 346 may be sufficiently thin for cover layer 340 to be visible from the outside of golf ball 300 . In some embodiments, a border between cover layer 340 and core layer 310 may be substantially more uneven, or ragged, in a first portion of golf ball 300 near plume 348 . The border may become smoother and more even in a second portion of golf ball 300 that is located opposite plume 348 .
[0037] Golf ball 100 , golf ball 200 , and golf ball 300 may be made by any suitable process. For example, in some embodiments, injection molding and/or compression molding may be used to make any of the golf ball layers. The process of making the golf ball may be selected based on a variety of factors. For example, the process of making the golf ball may be selected based on the type of materials used and/or the number of layers included.
[0038] While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims. | A recyclable golf ball is disclosed. The structure of the disclosed golf ball and/or the materials used to make the golf ball may enhance the ability to recycle the golf ball. As a result, the disclosed golf ball may decrease waste and the costs associated with acquiring and/or processing new materials. The golf ball may be made of materials that make it easier to separate the materials in a used golf ball for recycling. The golf ball may be made of materials having different densities. The golf ball may be made of materials having different melting points. The golf ball may be made of materials mixed with a magnetic additive. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a cap for a beverage container and more particularly, to a drink mix dispensing apparatus adapted to store and controllably release selected drink mix ingredients from a plurality of compartments in order to combine with the out flow of the beverage as it is poured out.
2. Description of Related Art
Pre-mixed flavored or fortified drink beverages are commonly available and sold in grocery and convenience stores. Drink beverages are composed primarily of water. Beverage container caps are well known to prevent the contents of a beverage container from escaping. In addition to pre-mixed flavored or fortified beverages, concentrated mixes are available for preparing flavored or fortified beverages. These mixes are commonly in the form of powder or concentrated syrup.
To prepare a flavored or fortified beverage from concentrated syrup or powder, a large container such as a pitcher is commonly filled with water and the powder or syrup is mixed with the water in the container. A large container is commonly used to prepare multiple servings of the beverage so that the effort required to prepare the beverage is conserved. The prepared beverage is then poured into a glass or other drinking container and consumed.
To prepare a flavored drink, a flavored liquid syrup or powder must first be mixed with water in a container. The contents of the container are poured out and the flavored drink is consumed. To create a different-flavored drink, the same steps must be repeated with a different-flavored mix. A different flavored drink can be mixed in a separate container or can be mixed in the same container after the previously mixed drink has been consumed. The above method of preparing one flavored beverage after another is time consuming and requires the user to use a container, then re-use the container only after its contents have been emptied.
When a consumer wishes to purchase different flavored drinks, whether it is different flavored sodas, i.e. cherry soda or orange soda, or different flavored non-carbonated drinks, he or she must purchase each desired flavor. This proves to be quite costly. In families where there is a diversity of drink favorites, it becomes extremely costly to purchase drinks or sodas to please every family member.
In today's health conscious world, herbal and vitamin supplements are in vogue. Many of these supplements are water-soluble and dissolve easily in water, juice or tea. However, it would be cumbersome to add a supplement to a container of water, juice or tea, empty the bottle of its contents, consume the mixture and then re-fill the container again with water, juice or tea so a different supplement can be added.
What is needed is a drink mix bottle cap dispenser that can be easily attached to a liquid-holding container, and which contains compartments, each housing a different flavored syrup, liquid and/or powder, or a different vitamin and/or herbal supplement, where the user can simply select a flavor or supplement and tip the bottle over so the flavored mix or supplement from the selected container mixes with the liquid to instantly form a flavored drink or soda, or a vitamin-fortified drink. If any contents are remaining in the container, the process can be repeated for a different selection, or the cap can be easily and quickly removed, the beverage replenished, the compartments refilled with drink mixes, or a new cap reattached and the process repeated. A virtually unlimited number of flavored drinks or herbal-fortified beverages can be produced thereby eliminating the need to purchase different flavored beverages.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a beverage cap adapted to be removeably secured to the open end of a liquid-holding container that stores a plurality of concentrated mixes in separate compartments within the cap, which are selectively dispensed and combined with the outflow of the liquid stored in the container thereby producing a variety of liquid-concentrated mix combinations.
In the preferred embodiment, the liquid within the container is a drinkable beverage, such as water or carbonated water, and the concentrated mixes are different flavored liquid or powdered mixes, or different herbal or vitamin supplements. In an alternate embodiment, the mixes could each be a different type of oil.
A cap dispenser for use with a beverage container, which separately stores concentrated beverage mixes that are selectively released and combined with the outflow of the drinkable liquid contained in the beverage container. The resealable cap stores concentrated beverage mixes which are selectively dispensed within the outflow of the beverage container when the liquid is being poured out so that different flavored or vitamin fortified drinks are produced. The resealable cap includes a base, a selector disc and a head assembly.
The base is substantially cylindrical in shape with a top end, a bottom end, an inside surface and an outside surface. The bottom end is open and the inside surface is tapered in diameter from the bottom end to the top end so that at the bottom end the inside surface is substantially the diameter of the base and towards the top end the diameter is reduced so that a bottle aperture is formed. The inside surface of the bottle aperture is sized to accommodate the mouth of a conventional beverage container and is adapted with bottle threads to engage the mouth of a conventional beverage container. The threaded mouth of a conventional bottle is inserted into the bottom end of the base and is rotated upon engaging the bottle threads of the flow aperture until fully engaged and sealed.
Within the base are a plurality separate compartments which hold concentrated mixes. Each compartment is tapered in shape to conform to the tapered shape of the inside surface of the base.
A circular selector platform is disposed upon the base. The selector platform is adapted with six pairs of radially disposed alignment dimples and inner and outer circular ring channels. The inner circular ring channel surrounds the bottle aperture. The outer ring channel is positioned so that it separates pairs of alignment dimples. Compartment apertures are positioned within three pairs of alignment dimples so that compartment apertures alternate in occurrence within alignment dimple pairs. Each pair of compartment apertures open into a corresponding compartment.
A selector disk rotatably engages the selector platform. The selector disk is adapted with six pairs of radially disposed raised alignment flanges which are equally spaced apart along the bottom surface of the disk so that they may properly engage corresponding dimples located on the selector platform. Each pair of alignment flanges corresponds with a pair of alignment dimples so that when the selector disk engages the selector platform the corresponding alignment flanges engage the corresponding alignment dimples. The bottom surface of the selector disk is also adapted with a pair of raised circular ring tracks. The ring tracks are positioned so that when the selector disk engages the selector platform the corresponding tracks of the selector disk engage the corresponding channels of the selector platform.
The selector disc includes apertures, which allow access to the drink fluid of the attached bottle and the concentrated drink mixes contained within the compartments. A hollow flow spout extends from the top of the selector disc towards the outside perimeter of the selector disc. A mix spout extends from the top of the selector disc and is connected to the lower portion of the flow spout thereby allowing the selected drink mix to combine with the drink beverage. A vacuum spout extends from the top of the selector disc in the opposite direction of the flow spout to allow for unimpeded flow of the combined liquid and concentrated mix.
A head assembly holds the selector disk in engagement with the selector platform of the base. The head assembly is formed by a substantially cylindrical body and a top. The top of the head assembly is adapted in shape to receive the selector disc so that the flow spout is exposed through a pour aperture. When the head assembly fully engages the base, the raised ring tracks of the selector disc engage the cooperating ring channels of the selector platform and corresponding alignment flanges engage of the selector disc engage alignment dimples of the selector platform.
In use, the head assembly and selector disc enclosed therein are rotated in relation to the base. While rotating, the head assembly snaps into six unique positions that are created when the alignment dimples of the selector platform and the raised flanges of the selector disc engage. Each position is unique and is identified by indicator markings on the outside of the base and which are revealed through one or more windows in the head assembly as the head assembly is rotated into different positions.
Each position causes the alignment of apertures within the selector disc with respect to the selector platform to change. A closed position causes all apertures to be closed and sealed so that neither the bottle's liquid contents or the concentrated mixes can escape.
To pour out the contents of the attached container, the head assembly is rotated to one of the five positions that do not completely seal the container. The container is then simply tipped over so that gravity causes the bottle contents to flow out through the bottle aperture of the base through the flow spout. When a drink blended with a concentrated mix is desired the head assembly is rotated so that the aperture within the selector disc opens into the compartment containing the desired drink mix and as the container is tipped over the desired drink mix contained in the corresponding compartment are allowed to combine with and flow out along with the bottle contents. The concentrated mix is blended with the bottle contents within the outflow so that a flavored or fortified drink is formed as the container's contents are being poured out. To prepare a different-flavored drink, the head assembly is simply rotated so that the compartment containing the desired concentrated mix is selected and the contents of the container is blended with the concentrated mix as it is being poured out.
Another position can be selected to release the bottle's liquid contents, i.e. plain water or carbonated water, tea or juice, without releasing any of the drink mixes, thereby releasing only the bottle's contents, i.e. water, tea or juice.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a top exploded perspective view of the drink mix dispensing apparatus of the present invention.
FIG. 2 is a bottom exploded perspective view of the drink mix dispensing apparatus of the present invention.
FIG. 3 is a side view showing the drink mix dispensing apparatus in use.
FIG. 4 is a front view showing the drink mix dispensing apparatus of the present invention affixed to a conventional beverage container.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, an exploded view of the drink mix dispensing apparatus of the present invention is illustrated. The invention includes a base assembly 100 , a selector disc 200 and a head assembly 300 which together form a dispensing cap 10 used to seal a conventional beverage container 20 which contains a liquid drink as seen in FIGS. 3 and 4. Container 20 can be off-the-shelf two-liter bottles, 500 ml bottles and other bottles or cans offered for sale containing soda, juice, water, carbonated water and other beverages. In the preferred embodiment, container 20 is a conventional water or soda bottle with a threaded spout.
Base 100 is substantially cylindrical in shape with a closed top end 102 , an open bottom end 104 , a tapered inside surface 106 and an outside surface 108 as shown in FIGS. 1 and 2. Bottom end 104 is open and inside surface 106 is tapered in diameter from bottom end 104 to top end 102 so that at bottom end 104 , inside surface 106 is substantially the diameter of base 100 and towards top end 102 the diameter of inside surface 106 is reduced so that a bottle receiving aperture 110 is formed. Bottle receiving aperture 110 is sized to accommodate the mouth of a conventional beverage container 20 . Inside surface 106 is adapted in size to accommodate the top portion of container 20 . Inside surface 106 at bottle aperture 110 includes bottle threads 112 to engage corresponding threads on the mouth of conventional beverage container 20 .
In use, the threaded mouth of container 20 is inserted into bottom end 104 of base 100 and is rotated upon bottle threads 112 until fully engaged and sealed within bottle aperture 110 as seen in FIGS. 3 and 4. Top end 102 is substantially flat forming a circular selector platform 120 .
In FIG. 2, embedded within base 100 are three compartments 130 , 132 and 134 , which hold concentrated mixes (preferably liquid). Each compartment 130 , 132 and 134 is tapered in shape to conform to the tapered shape of inside surface 106 .
In the preferred embodiment, three mix-holding compartments 130 , 132 and 134 , each containing a different flavored liquid drink mix or a different vitamin or herbal supplement, are embedded within base 100 . The concentrated drink mix combines with a liquid flowing out of the container to form a mixed liquid, preferably a drinkable mixed beverage. It is, however, within the scope of the invention to include either a greater or a fewer number of compartments, and for each compartment to house powdered or granular drink mixes, herbal or vitamin supplements, or various types of oils, each of which, when dispensed, combines with the liquid contents of the container as it exits the container.
Circular selector platform 120 is disposed upon and is an integral part of base 100 . In the preferred embodiment, platform 120 is adapted with three pairs of spaced apart radially disposed alignment dimples 122 . Each pair of alignment dimples is comprised of a mix dimple 122 a and a vacuum dimple 122 b . Each mix dimple 122 a is positioned radially around bottle aperture 110 creating an interior circle. Each vacuum dimple 122 b is positioned adjacent and just outside a corresponding mix dimple 122 a . Each vacuum dimple 122 b is positioned radially along an outer circle, said outer circle encircling the inner circle formed by mix dimples 122 a . Both inner circle of mix dimples 122 a and the concentric outer circle of vacuum dimples 122 b , encircle bottle aperture 110 .
Circular selector platform 120 is also adapted with inner and outer circular ring channels 124 a and 124 b . Inner ring channel 124 a surrounds bottle aperture 110 . Outer ring channel 124 b is positioned so that it separates each mix dimple 122 a from its corresponding vacuum dimple 122 b.
Along with the alignment dimples 122 , and also disposed on the upper face of base 100 , are three pairs of compartment apertures 126 . Each pair of compartment apertures 126 is comprised of a mix compartment aperture 126 a and a vacuum compartment aperture 126 b . Compartment apertures 126 alternate in occurrence within pairs of alignment dimples 122 . Each pair of compartment apertures 126 open into a corresponding compartment 130 , 132 or 134 . Six alignment divots 123 are positioned radially between mix dimples 122 a and mix compartment apertures 126 a.
Although both mix compartment apertures and vacuum compartment apertures open into a corresponding compartment, drink mix only flows out of mix compartment aperture, as can be seen more clearly in FIG. 3 . Due to gravity, the drink mix contents (indicated by the arrows) flow out of compartment 132 through mix compartment aperture 126 a as seen in FIG. 3 . Vacuum compartment aperture 126 b allows air to flow freely, facilitating the dispensing and flow of drink mix through mix compartment aperture 126 a into mix spout 246 .
Selector disc 200 is a substantially flat, circular disk having a top surface 200 a and a bottom surface 200 b . Selector disc 200 and selector platform 120 are substantially the same diameter. Selector disc 200 rotatably engages selector platform 120 . Selector disc 200 is adapted with six pairs of radially disposed circular raised alignment flanges 210 which are equally spaced apart along bottom surface 200 b . Each pair of raised alignment flanges 210 is comprised of a mix flange 210 a and a vacuum flange 210 b which are sized to properly engage mix dimples 122 a and vacuum dimples 122 b respectively. Each pair of alignment flanges 210 corresponds with a pair of alignment dimples 122 so that when selector disk 200 engages selector platform 120 , corresponding alignment flanges 210 engage corresponding alignment dimples 122 .
Additionally, selector disc 200 is adapted with a biased alignment finger 125 which projects from the bottom surface 200 b of disk 200 . Alignment finger 125 engages an alignment divot 123 located on base 100 , when corresponding alignment flanges 210 properly engage corresponding alignment dimples 122 . Bottom surface 200 b is adapted with raised inner and outer ring tracks 220 a and 220 b which correspond in position with the inner and outer ring channels 124 a and 124 b so that when selector disk 200 engages selector platform 120 , corresponding inner ring track 220 a engages inner ring channel 124 a and corresponding outer ring track 220 b engages ring channel 124 b thereby providing an additional sealing mechanism of disc 200 upon base 100 .
Selector disc 200 provides apertures which allow access to the drink fluid contained in the attached bottle 20 and the concentrated mixes contained within compartments 130 , 132 and 134 . Referring to FIG. 2, a mix selector aperture 236 and a vacuum selector aperture 238 are positioned between a pair of alignment flanges 210 . One mix selector aperture 236 is positioned between one mix flange 210 a and one vacuum selector aperture 238 is positioned between a corresponding vacuum flange 210 b . Mix selector aperture 236 allows the out flow of the selected mix from its compartment via mix spout 246 when a selector aperture 236 is aligned directly over a compartment aperture 126 . This is accomplished by simply rotating the head assembly 300 , which in turn, rotates disk 200 upon base 100 . Vacuum selector aperture 238 allows for the transfer of air and the unimpeded flow of liquid mix through mix spout 246 .
A bottle flow aperture 232 is disposed within inner ring track 220 a . A bottle vacuum aperture 234 is located inside inner ring track 220 a substantially adjacent to inner ring track 220 a and substantially opposite bottle flow aperture 232 . Three vacuum stopper dimples 235 are disposed inside inner ring track 220 a so that bottle vacuum aperture 234 and vacuum stopper dimples 235 form a circle around the center of selector disc 200 .
A hollow flow spout 242 is disposed upon the top surface 200 a of selector disc 200 covering bottle flow aperture 232 . Flow spout 242 extends from the top of selector disc 200 towards the outer perimeter of selector disc 200 opposite mix and vacuum selector apertures 236 and 238 . Mix spout 246 is connected to the top surface 200 a of selector disc 200 covering mix selector aperture 236 . Mix spout 246 is connected at one end to top surface 200 a of selector disc 200 and at the opposite end to flow spout 242 . A vacuum spout 244 is connected to the top 200 a of selector disc 200 covering bottle vacuum aperture 234 and extends towards the outer perimeter of selector disc 200 in substantially the opposite direction of flow spout 242 . Vacuum spout 244 does not reach the outer edge of selector disc 200 .
Vacuum spout 244 allows for the flow of liquids through and out of flow spout 242 . Vacuum spout 244 is bent towards the back of disk 200 away from and in the opposite direction of flow spout 242 so that when bottle 20 is tipped in pouring position, liquid does not flow inadvertently out of vacuum spout 244 instead of flow spout 242 .
A head assembly 300 holds selector disk 200 in engagement with the selector platform portion 120 of base 100 . Head assembly 300 is formed by a hollow substantially cylindrical body 310 , top end 312 and is open at its opposite end. The interior of head assembly 300 is adapted in shape to receive selector disc 200 so that flow spout 242 extends through a pour aperture 314 . The diameter of body 310 is substantially equivalent to the diameter of base 100 at bottom end 104 . The upper portion of outside surface 108 of base 100 is reduced in diameter forming collar 150 . Body 310 is adapted with periodically occurring raised rotator flanges 316 located along the inside surface of body 310 substantially adjacent to the open end of body 310 as seen in FIG. 2 . Alternatively, rotator flanges 316 can be a continuous raised ring along the inner circumference of the open lower end of body 310 . The outer circumference of collar 150 is adapted with a rotator channel 152 which is adapted to receive rotator flanges 316 . Head assembly 300 engages collar 150 so that body 310 overlaps collar 150 and rotator flanges 316 engage rotator channel 152 . The engagement of rotator flanges 316 and rotator channels 152 lock head assembly 300 onto base 100 while allowing it to rotate in either direction in relation to base 100 . When head assembly 300 engages base 100 , selector disc 200 fully engages selector platform 120 so that inner and outer raised ring tracks 220 a and 220 b engage cooperating inner and outer ring channels 124 a and 125 b.
Head assembly 300 is rotatable in relation to base 100 so that one of a plurality of positions may be selected. In the preferred embodiment, six selections are available: three drink mix selections; two selections to allow only the contents of the beverage container 20 and not any drink mixes to flow, and one selection to prevent any liquid or drink mix from exiting. Selector disk 200 rotates along with head assembly 300 . Selector disk 200 is held in alignment with head assembly 300 by four protrusions 320 which extend from top 312 and are received by grooves 250 in selector disc 200 . While rotating, head assembly 300 snaps into six unique positions which are created when alignment dimples 122 engage raised alignment flanges 210 and alignment finger 125 engages alignment divot 123 . Each unique position may be identified by indicator markings 154 located along collar 150 which are revealed by an indicator window 322 within body 310 as shown in FIG. 4 .
Each discrete position causes mix selector aperture 236 and vacuum selector aperture 238 to be positioned over either a pair of (closed) alignment dimples 122 or (open) compartment apertures 126 . Alignment over the dimples 122 causes all apertures to be closed and sealed so that the concentrated mixes cannot escape from the compartments 130 , 132 , and 134 . In one or more of the alignment positions, not only do mix selector aperture 236 and vacuum selector aperture 238 cover closed dimples 122 preventing egress of the drink mix from the compartment, but flow stopper 127 also covers bottle flow aperture 232 thereby preventing liquid from exiting container 20 .
Therefore, in the closed position, bottle flow aperture 232 and bottle vacuum aperture 234 are closed by a biased flow stopper 127 and vacuum stopper 128 , respectively, which extend from selector platform 120 within bottle aperture 110 . In the closed position, compartment apertures 126 are sealed by engagement with alignment flanges 210 , which do not contain apertures. In the closed position, mix and vacuum selector apertures 236 and 238 are sealed by engagement with dimples 122 , which do not contain apertures. When not in a closed position, vacuum stopper 128 may engage vacuum stopper dimples 235 .
To pour out only the contents of the attached bottle, without any drink mixes, head assembly 300 is rotated to one of the positions where bottle flow aperture 232 and vacuum aperture 234 are not blocked by flow stopper 127 and vacuum stopper 128 . Bottle 20 is simply tipped over horizontally so that gravity causes the bottle contents to flow out the bottle mouth through bottle aperture 110 , bottle flow aperture 232 and out flow spout 242 as seen in FIG. 3 . When a drink blended with a drink mix is desired, mix selector aperture 236 and vacuum selector aperture 238 are aligned over one of the three pairs of compartment apertures 126 which open into compartments 130 , 132 or 134 . As bottle 20 is tipped over, the concentrated drink mix contained in the corresponding compartment 130 , 132 or 134 is allowed to flow out into the mix spout 246 and combine with the out-flowing liquid from the bottle in flow spout 242 , as seen in FIG. 3 . The concentrated mix is blended with the bottle contents within flow spout 242 so that a flavored or fortified drink is produced as the bottle contents are poured out.
Each of the six functional positions including the closed position may be marked so that the desired position is easily located by placing indicator markings 154 along collar 150 which are correspondingly revealed through window 322 as head assembly 300 is rotated so that the function of each position is easily identified. For example, indicator markings 154 could be “1”, “2”, and “3”, each representing a different compartment containing a different drink mix; “w”, representing water only (or whatever the liquid is within container 20 ), without the release of a drink mix; and “x” representing no exit of either the liquid within the container or a drink mix, i.e. a “sealed” selection.
Head assembly 300 , selector disc 200 and base 100 may be constructed of any resilient waterproof material such as plastic or resin.
In an alternate embodiment, head assembly 300 and selector disk 200 are one integral component.
The instant invention has been shown and described in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to persons skilled in the art. | A cap dispenser for use with a liquid-holding container that separately stores concentrated mixes within one or more compartments. The mixes are selectively released within the outflow of the liquid contained by the liquid-holding container. By rotating the head assembly of the dispenser, the user can select which concentrated mix, if any, is to be released. The head assembly also offers a sealed position that seals the liquid within the container and the concentrated mixes within their respective storage compartments. The concentrated mixes are selectively dispensed into the outflow of the liquid from the container when the liquid is being poured out so that a mixed liquid, or flavored or fortified a drink is produced. | 1 |
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